ENERGY EFFICIENCY CONSULTING

ABOUT SERVICE

Our customized energy management solutions combine process and operational improvements with proven benefits. Our experts can help your organization reduce energy costs along with significant business advantage.

Due to high and volatile energy prices, uncertain supply, increasing environmental regulations and public concern over climate change have created great pressure on energy-intensive industries to treat energy management as a strategic issue.

Our team has extensive experience in energy-intensive industries to help organizations integrate energy management into your business strategy and processes, delivering significant, sustainable results. Our energy management solutions help lead to substantial reductions in operational costs and improve operational excellence, profitability, and competitive advantage.

This Service of Universal Engineering Arm is conceptualized keeping in view over all demand across industries for saving ENERGY.

We aim at Energy saving by targeting 5 focus areas, Water, Compressed Air, Steam, Time and Electricity/Power. We understand overall process flow and identify activities which result into saving one of the five sources of energy identified above.

SCOPE OF WORK

  • Collection of present data of consumption.(Audit survey can be arranged on request in absence of availability of data.)
  • Evaluation & Analysis of Data.
  • Energy conservation options to be arrived.
  • Techno-commercial comparison of proposed options.
  • Designing of finalized proposal.
  • ssuing work order for the scheme. Periodic checking for the work progress.
  • Report Submission on Saving derived.

CASE STUDY

Here are some of the steps we have taken at various client locations to attain desired Energy savings output. These steps are indicative and not all inclusive in nature. Actions as well as results would vary from case to case depending on the exiting situation at each location.

These are Steps taken to SAVE:

  • WATER
  • AIR (Compressed Air)
  • STEAM
  • TIME
  • ELECTRICITY / POWER

Water

  • Avoid continuous pumping for water supply unless necessity. Supply water through over head tanks,which can supply with constant head & reduce wear& tear of valves & maintenance.
  • Excess pressure : Heavy waste from leakages & higher consumption then standard from Norms
  • Reduction in water saving in : ground water power requirement, treatment cost reduction in soft-RO- DM, Pumping cost reduction & Before discharge influent water treatment cost.
  • Process cooling tower : Decrease process cooling time, increase m/c available increase productivity.
  • Result: REDUCTION IN CONSUMPTION BY 30% i.e. 10,000 m3 to 7000 m3.
  • Cost Reduction in Bore water generation, Treatment to suit to process requirement, Pumping cost to supply in dept.(Load on pump & working Hr.),ETP Load & it's treatment.
  • ETP Treatment cost reduction: By Use of by product of chemical plant for colour reduction & dosing location.
  • Treatment cost Before modification : Rs. 12 /- per m3 and post modification : Rs. 6/- per m3

AIR (Compressed)

  • Changing of oil free screw compressors of lower range by calculating total requirement of unit & set
    new Centrifugal air compressor & reduce electrical Power consumption:
    Screw compressor : 0.21 kwh/cfm
    Centrifugal compressor: 0.15 kwh/cfm
    Difference : 0.05 kwh/cfm
    Requirement : 55000 cfm
  • Regular monitoring & action on leakages in department.
  • Measuring air consumption on each machine periodically & set right requirement. Reduction in consumption @ 8.5%.
  • Designing of pipe line & changing size on consumption & pressure requirement base.
  • To avoid pressure drop, installed Air receiver near major user point. Reduction in stoppages & value loss by reducing damage.
  • Added air receiver & PRV Station as per the adequate requirement of pressure for cleaning in department.

Steam

  • Condensate collection & return to Boiler feed water tank. Increase temp. from 45 Deg C to 90 Deg C. Save DOC Consumption by 3%.
  • Insulation audit for steam piping & repairing done.
  • Hot water collection & send back to process department for initial heating in Yarn Dyeing process. Reduction in steam requirement by 5.5%
  • Process cooling tower : Decrease process cooling time, increase m/c available increase productivity.
  • Result: Total saving in steam requirement by 12.5%

Time

  • Cooling water : Process cooling water Temp. Reduction by 10 to 15 Deg. C. Instead of using direct water from storage tank, used through the cooling tower. Cooling cycle time reduction 12.5%. Increase in production capacity. Because of this system reduction in ETP Load.
  • Installing over head water supply tank, reduction in feeling time. Water is available at constant pressure & continuous. Reduction in utilization of pumping hrs.

Electricity / Power

  • H-Plant : Aero dynamically balanced FRP fan. Increase in CFM & Reduction in Power consumption @ 10-15%.
  • Change Star connection to Delta , where the load on the motor was less than 60%.
  • Installing A C Inverters on variable speed drive. On screw/centrifugal compressors, cooling towers fan, pumps, ID / FD Fans on Steam Boiler etc.
  • P F Improvement : by installing Auto Power Factor Controlling Panel. APFC
  • Replacing Low efficiency motors by replacing EEF 1 or EEF 2 motors
  • Proper maintenance of bearings by measuring vibration & temp. periodically & replaced by spare motors.
  • Result: Observed saving 12% after program. i.e. 18 mw from 21 mw