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OF Conducted By (EASTERN REGION) 2, Gariahat Road South, Dhakuria Kolkata – 700 068 Ph: 033 – 2414 5092, 2414 5088, 2414 5094; Telefax: 033 – 2414 5091 e-mail: [email protected] Website: http://www.pcra.org December’2012

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OF

Conducted By

(EASTERN REGION)

2, Gariahat Road South, Dhakuria Kolkata – 700 068

Ph: 033 – 2414 5092, 2414 5088, 2414 5094; Telefax: 033 – 2414 5091 e-mail: [email protected]

Website: http://www.pcra.org

December’2012

Report on Energy Audit of OIL installation at GCS-2, Moran, Assam, India

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Energy Audit by PCRA, Eastern Region Page 2 of 27

Report on Energy Audit of OIL installation at GCS-2, Moran, Assam, India

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Energy Audit by PCRA, Eastern Region Page 3 of 27

ACKNOWLEDGEMENT

Petroleum Conservation Research Association, Eastern Region (PCRA, ER),

appreciates the interest, participation and collaboration by the management &

engineers of the Oil India Limited (OIL) in carrying out Energy Audit at “Gas

Compressor Station-2(GCS –2), Moran”.

Our special thanks to the Installation Manager and his team of Engineers,

Supervisors and technicians attached to GCS-2 at Moran, who extended their

proactive co-operation and courtesy to the energy audit team during the audit.

T h e E n e r g y A u d i t T e a m :

Sl.

No. From OIL From PCRA

1. Mr. J. Bhowmik, Chief Engg. Drilling / Asset, Moran Sri D. Dutta, CEM

2. Mr. Dilip Kalita ,Installation Manager, GCS-2 Sri A.K.Mallick, CEA

3 Mr. R. Mandal, Chief Engr(Tech. Audit)

4 Mr. Jishu Shyam, Sr. Engineer, (P-Gas)

5 Mr. Kishore Deka (Sr.Technical Auditor)

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Energy Audit by PCRA, Eastern Region Page 4 of 27

INDEX

Chapter

No.

Title

Page

1.0 Executive Summary

5

2.0 Introduction

6

3.0 Existing Energy System

9

4.0 Study of Air Compressor

13

5.0 Study of Gas Compressor System 17

6.0 Study of Illumination 21

Annexure – I List of Energy Efficient Equip. Suppliers 24

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Energy Audit by PCRA, Eastern Region Page 5 of 27

1.0 EXECUTIVE SUMMARY

Table-1.1 Major Findings and Estimated Savings

Recommendations (Short /

Medium Term)

Savings per Annum Estimated

Investment

Simple

Payback

period

KWh Rs. Rs. Years

1. Maintain separate Air

Compressors with

separate air receivers at

14kg/cm2 and 5 kg/cm2

pressure level

46712 2.12 Lakhs Nominal Immediate

2. Arresting line Leak and

running 20 HP

compressors in place of

40 HP compressors.

82519 3.75 Lakhs To be

estimated

3. Replace 36 watt FTL

with 28 watt energy

efficient T5 lamps

5339 0.24 Lakhs 0.21 Lakhs 10.5

Months

Total 134570 6.11 Lakhs 0.21 Lakhs

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Energy Audit by PCRA, Eastern Region Page 6 of 27

2.0 INTRODUCTION

2.1 IMPORTANCE OF ENERGY CONSERVATION & ITS BACKGROUND

Energy is one of the most coveted inputs in the development of any society. With the

accelerated growth of the economy the demand for energy is increasing exponentially. On the

supply side the stock of the conventional energy resources like fossil fuel are limited and

rapidly depleting. India gradually becoming dependent on external sources of energy thereby a

considerable part of the GDP is exhausted for procurement of energy.

One of the easier available options for survival is energy conservation through energy

efficiency improvement; thereby reduction of energy consumption and cost thereof through

strategic energy management concept and mechanism.

Energy conservation is a worldwide objective. The energy policy of the Government of India

also calls for conservation of energy. With the enactment of ‘Energy Conservation Act-2001’,

amongst others has emphasized upon the power of the appropriate Govt. to enforce efficient

use of energy and its conservation.

The management of OIL has adopted the energy system study and implements solutions

thereof with the objective to optimal utilization and output of available energy consuming

systems and to conserve energy.

In view of energy efficiency improvement and cost reduction program for long-term business

solution the management of OIL sought the services of PCRA for energy system study on Gas

Compressors, air compressors and Lighting systems at their plant (GCS-2)at Moran in Assam.

PCRA has studied the energy systems of the plants accordingly with the help of OIL

representatives. During the study, the energy audit team has mapped present status of

electrical power and energy systems at the plant premises, identified, major energy loss areas

etc. The study has identified potential scope for improvement and energy efficiency

improvement in major energy consuming systems. It also recommends cost effective and fast

pay back solutions for energy cost control.

2.2 COMPANY PROFILE

The story of Oil India Limited (OIL) traces and symbolizes the development and growth of the

Indian petroleum industry. From the discovery of crude oil in the far east of India at Digboi,

Assam in 1889 to its present status as a fully integrated upstream petroleum company, OIL has

come far, crossing many milestones.

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Energy Audit by PCRA, Eastern Region Page 7 of 27

On February 18, 1959, Oil India Private Limited was incorporated to expand and develop the

newly discovered oil fields of Naharkatiya and Moran in the Indian North East. In 1961, it

became a joint venture company between the Indian Government and Burmah Oil Company

Limited, UK.

In 1981, OIL became a wholly-owned Government of India enterprise. Today, OIL is a premier

Indian National Oil Company engaged in the business of exploration, development and

production of crude oil and natural gas, transportation of crude oil and production of LPG. OIL

also provides various E&P related services and holds 26% equity in Numaligarh Refinery

Limited.

The Authorized share capital of the Company is Rs. 2000 Crores. The Issued, Subscribed and

Paid share capital of the company is Rs. 601.14 Crores. At present, The Government of India,

the Promoter of the Company is holding 78.43% of the total Issued & Paid-up Capital of the

Company. The balance 21.57% of the Equity capital is held by others.

OIL has over 1 lakh sq km of PEL/ML areas for its exploration and production activities; most of

it is in the Indian North East, which accounts for its entire crude oil production and majority of

gas production. Rajasthan is the other producing area of OIL, contributing 10 per cent of its

total gas production.

Additionally, OIL’s exploration activities are spread over onshore areas of KG Basin, Mahanadi

Basin, Cauvery Basin, Andaman Basin and Gujarat-Kutch Basin etc. OIL also has participating

interest in NELP exploration blocks in Mahanadi Offshore, Mumbai Deepwater, Krishna

Godavari Deepwater, etc. as well as various overseas projects in Libya, Gabon, Iran, Yemen,

Nigeria, Sudan and Venezuela.

In a recent CRISIL-India Today survey, OIL was adjudged as one of the five best major PSUs and

one of three best energy sector PSUs in the country.

Table-2.1 GENERAL DETAILS OF THE COMPLEX

2.3 ENERGY AUDIT STUDY:

a) SCOPE OF THE STUDY

• To study Electrical system and transformers

• To study Electrical Motors

• To study Gas Compressors.

Name of the Complex Gas Compressor Station, OIL, Moran

Address Moran, Assam

Contact Person Mr. Dilip Kalita-Installation Manager

Tel 9435004588

Type of Ownership Central PSU

Contract Demand Self-Generation by Moran Gas Turbine

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Energy Audit by PCRA, Eastern Region Page 8 of 27

• To study air compressor system.

• To study lighting system & illumination level at various work places & suggest for improvement.

b) METHODOLOGY

The study was concentrated on the above areas to find out energy conservation options. Discussion

was held with the concerned personnel regarding the system familiarization and the operation of the

specific equipment. Trial and field measurement by portable instrument were conducted in selective

areas. Related data also collected from estate department for further analysis. Cost benefit analysis

was carried out in some energy conservation options.

c) INSTRUMENTS USED

1. Three phase power analyzer

2. Single phase power analyzer

3. Non-contact thermometer

4. Lux meter

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Energy Audit by PCRA, Eastern Region Page 9 of 27

3.0 EXISTING ENERGY SYSTEM:

The source of Energy for GCS-2 is as follows:

1) Electrical energy for GCS -2 from Gas based Captive Power Plant at Moran.

2) Fuel gas for engine driven gas compressor - fuel gas taken from the main suction line

through LP header coming from OCS and MP header from OCS.

3.1 MAJOR EQUIPMENT LIST:

Low Pressure Gas Booster Compressors

a) LPB 1 Make: IR(I) Compressor / NGEF Motor

Capacity: 2802 Standard Cubic mtrs/hr

b) LPB 2 Make : IR(I) Compressor / NGEF Motor

Capacity: 2802 Standard Cubic mtrs/hr

c) LPB 3 Make : IR(I) Compressor / Waukesha L7042 (Engine)

Capacity: 5614 Standard Cubic mtrs/hr

d) LPB 4 Make : IR(I) Compressor / Waukesha L7042 (Engine)

Capacity: 5614 Standard Cubic mtrs /hr

e) LPB 5 Make : Worthington Compressor / Caterpillar (Engine)

Capacity: 2700 Standard Cubic mtrs /hr

f) LPB 6 Make : Atlas Copco Compressor / Waukesha engine L7042

Capacity: 5400 Standard Cubic mtrs /hr

g) LPB 7 Make: Atlas Copco Compressor / Waukesha engine L7042

Capacity: 5300 Standard Cubic mtrs/hr

Gas Lifter Compressors

a) GL 1 Make: Ingersoll Rand Compressor / NGEF Motor

Capacity: 3368 Standard Cubic mtrs/hr

b) GL 2 Make: Ingersoll Rand Compressor / NGEF Motor

Capacity: 3368 Standard Cubic mtrs/hr

c) GL 3 Make: Worthington Compressor / Caterpillar G 399 Engine

Capacity: 3200 Standard Cubic mtrs/hr

d) GL 4 Make: BPCL Compressor / Waukesha engine L 5108

Capacity: 3200 Standard Cubic mtrs / hr

e) GL 5 Make: Atlas Copco Compressor / Caterpillar G 399 Engine

Capacity: 3200 Standard Cubic mtrs / hr

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Energy Audit by PCRA, Eastern Region Page 10 of 27

f) GL 6 Make: Atlas Copco Compressor / Caterpillar G 399 Engine

Capacity: 3200 Standard Cubic mtrs / hr

g) GL 7 Make : Atlas Copco Compressor / Waukesha L 5108 Engine

Capacity: 3200 Standard Cubic mtrs / hr

3.2 ELECTRICAL MOTOR DETAILS:

SL. NO L.T. LOADS K.W.

1 AIR COMPRESSOR MOTOR NO -1 30

2 AIR COMPRESSOR MOTOR NO -2 30

3 AIR COMPRESSOR MOTOR NO -3 30

4 AIR COMPRESSOR MOTOR NO -5 15

5 AIR COMPRESSOR MOTOR NO -6 30

6 AUX. WATER PUMP-1 MOTOR 5

7 AUX. WATER PUMP-2 MOTOR 5

8 AUX. WATER PUMP-3 MOTOR 5

9 AUX. WATER PUMP-4 MOTOR 5

10 AUX. WATER PUMP-5 MOTOR 5

11 ETHYLENE GLYCOL PUMP MOTOR 10

12 LIGHTING LOAD 18.2

LOAD IN K.W. 188.2

SL. NO H.T. LOADS K.W.

1

LOW PRESSURE GAS BOOSTER NO -1 & 2 (MAIN

MOTOR) 670

2 GAS LIFTER NO -1 & 2 (MAIN MOTOR) 670

LOAD IN K.W. 1528.2

3.3 THE POWER SYSTEM:

The source of power supply for GCS-2 is from Moran (Gas Turbine) Power Generating Station

(generated at 11 kV) for 3.3 KV HT supply to the 4 nos. of Motor driven Gas Compressors (2 nos. Gas

Lifters & 2 nos. Low Pressure Boosters) and 2 nos. Transformers, out of which one is kept standby.

The 11 KV to 3.3 KV Transformers Details are as below:

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Energy Audit by PCRA, Eastern Region Page 11 of 27

Transformer No: 1

Make: Crompton and Parkinson

Capacity: 2000 KVA

Voltage Range: 11000/3300 V

Ampere Range: 104.9 / 349.9

Impedance: 5.66 %

Mfg: 1960

Transformer: 2 (Standby)

Make: Bharat Bijlee

Capacity: 2000 KVA

Voltage Range: 11000/3300 V

Ampere Range: 105 / 350

Impedance: 5.9 %

Mfg: 1993

Another one transformer is present to cater the need for the LT load of 433 Volt. The detail of the

transformer is as below:

Transformer-3:

Make: Not Available

Capacity: 500 KVA

Voltage Range: 11000/433 V

Ampere Range: 26.2 / 666.7

Impedance: 4.68 %

Mfg: 2003

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Energy Audit by PCRA, Eastern Region Page 12 of 27

Fig. 1, shows percentage share of electrical power consumption by major equipment at the OIL’s-GCS-2

plant:

Observation :

� It is observed that the major portion of the electrical power is consumed by the HT motors.

� Monitoring of electrical power consumed by the plant is not practiced at present. Energy

monitoring and targeting is primarily a management technique that uses energy information as

the basis to eliminate wastage, reduce and control current level of energy usage and improve

the existing operating procedures.

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Energy Audit by PCRA, Eastern Region Page 13 of 27

4.0 STUDY OF AIR COMPRESSOR

4.1 AIR COMPRESSOR DETAILS

The compressed air system of GCS-2, Moran has five reciprocating type air compressors. Four nos. are

of 30 kW and the other one is of 15 kW capacities.

Table-4.1 Specification of Air Compressors

Air Comp. No.

1

Air Comp. No.

2

Air Comp. No.

3

Air Comp. No.

4

Air Comp. No.

5

MAKE Kirloskar Kirloskar Ingersoll Rand Ingersoll Rand Ingersoll Rand

MODEL 2HY2ST 2HY2ST 2HYST 15T2 15T2

CAPACITY

2.83 M

3/HR 2.83 M

3/HR 2.83 M

3/HR 4.8 M

3/HR 4.8 M

3/HR

Motor

Rating, kW 30 30 15 30 30

Discharge

pressure in

kg/cm2

14 14 14 14.8 14.8

Air compressors are connected to common receivers. Air is supplied at 14 kg/ cm2 for cranking

operation of the gas engines of gas compressors during start-up. Air @ 6 kg/cm2 is required for the

pneumatic control of the gas engine valves & circuit.

Pneumatic air taken from the air receiver passes through a pressure reducing device and air dryer and

supplied to pneumatic systems @ 6 kg/cm2

at the gas compressor panel only as the pneumatic control

valves in the unit are controlled by the NG after reducing the pressure.

Air Pressure of around 12 kg/cm2 is only required at the time of start-up of the gas engines and once

the engines are started then maintaining 14 kg/cm2 header pressure is not required. Continuous air

pressure is only required for the pneumatic control valves & circuit of the gas engines and that too at 6

kg/cm2 pressure.

In present condition the air is maintained from 14 kg/cm2 at any point of time. The unloading of the air

compressor is set at 14kg/cm2 and the loading set is at 10 kg/cm

2. But, in eight hours of our stay in the

air receiver area, it never got unloaded and it was told to us that the compressor always runs without

unloading. This means the line leak is almost 90%, approx 10% air is being used in the compressor

panel.

Hence in the above condition it is clear that although the air pressure requirement of 14 kg/cm2 is only

required during starting of the Gas engines but still the pressure is maintained at 14 kg/cm2 throughout

the day in order to start any engine when sudden requirement is there.

The performance of the Air Compressors (FAD Test) could not be carried out as the compressors could

not be isolated due to operational inconvenience.

It should be noted that more power is required to compress air at higher pressure compared to lower

pressure i.e, energy required to compress air from 6 to 14 kg/cm2 is much higher compared to

pressurizing air from 3 to 6 kg/cm2.

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Energy Audit by PCRA, Eastern Region Page 14 of 27

Power Consumption Data:

Air Compressor-4 (Load Power)

Line Voltage Current

Power

Factor Power

Total

V1, Volt 238.1 I1 Amp 39.02 Pf1 0.830 P1, kW 7.711 Pt, kW 23.04

V2, Volt 239.2 I2 Amp 38.88 Pf2 0.82 P2, kW 7.626 Qt, kVAr 15.88

V3, Volt 237.9 I3 Amp 39.47 Pf3 0.82 P3, kW 7.700 St, kVA 27.98

Freq., Hz 50.0 Avg Pf = 0.823

Air Compressor-4 (UnLoad Power)

Line Voltage Current

Power

Factor Power

Total

V1, Volt 239.6 I1 Amp 25.11 Pf1 0.640 P1, kW 3.850 Pt, kW 11.25

V2, Volt 240.7 I2 Amp 25.18 Pf2 0.62 P2, kW 3.758 Qt, kVAr 14.11

V3, Volt 239.7 I3 Amp 24.89 Pf3 0.61 P3, kW 3.639 St, kVA 18.04

Freq., Hz 50.0 Avg Pf = 0.623

Air Compressor-5 (UnLoad Power)

Line Voltage Current

Power

Factor Power

Total

V1, Volt 240.1 I1 Amp 27.61 Pf1 0.670 P1, kW 4.442 Pt, kW 13.15

V2, Volt 240.6 I2 Amp 27.31 Pf2 0.67 P2, kW 4.402 Qt, kVAr 14.70

V3, Volt 241.4 I3 Amp 27.03 Pf3 0.66 P3, kW 4.307 St, kVA 19.73

Freq., Hz 50.0 Avg Pf = 0.667

Air Compressor-5 (Load Power)

Line Voltage Current

Power

Factor Power

Total

V1, Volt 240.1 I1 Amp 37.13 Pf1 0.800 P1, kW 7.132 Pt, kW 21.33

V2, Volt 240.6 I2 Amp 37.35 Pf2 0.8 P2, kW 7.189 Qt, kVAr 16.18

V3, Volt 240.1 I3 Amp 36.96 Pf3 0.79 P3, kW 7.011 St, kVA 26.78

Freq., Hz 50.0 Avg Pf = 0.797

Air Compressor-2 (Load Power)-40 HP

Line Voltage Current

Power

Factor Power

Total

V1, Volt 239.1 I1 Amp 42.49 Pf1 0.640 P1, kW 6.502 Pt, kW 19.19

V2, Volt 239.2 I2 Amp 40.98 Pf2 0.64 P2, kW 6.274 Qt, kVAr 23.04

V3, Volt 238.3 I3 Amp 42.04 Pf3 0.64 P3, kW 6.412 St, kVA 29.98

Freq., Hz 50.0 Avg Pf = 0.640

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Energy Audit by PCRA, Eastern Region Page 15 of 27

Air Compressor-3 (Load Power)-20 HP

Line Voltage Current

Power

Factor Power

Total

V1, Volt 240.5 I1 Amp 22.56 Pf1 0.760 P1, kW 4.124 Pt, kW 11.91

V2, Volt 240.6 I2 Amp 21.61 Pf2 0.75 P2, kW 3.900 Qt, kVAr 10.29

V3, Volt 238.0 I3 Amp 21.47 Pf3 0.76 P3, kW 3.883 St, kVA 15.74

Freq., Hz 50.0 Avg Pf = 0.757

RECOMMENDATIONS:

At GCS, compressed air is used for two purposes:

1. To start Gas compressor engines (pressure requirement 14 kg/cm2).

2. To drive pneumatic instruments (pressure requirement 6 kg/cm2).

Pressure requirement for both the works are different as mentioned above.

1. It is recommended to maintain different air receivers for 14 kg/cm2 and 6 kg/cm2 line pressure.

Also one of the compressors should be dedicated to 14 kg/cm2 and the other one for 6 kg/cm2

line so that total running time of both the air compressors would reduce in a day.

To have redundancy in operation of the air compressors, one bypass line can be connected

from both the air receivers with a valve in-between so that whenever one compressor is under

shutdown then the other compressor can be compensated.

With a rough estimate min. of 25% of energy can be saved with this kind of arrangement.

Power

Consumption,

Kw

Running

Hour per

day

Energy

Consumption

per day, kWh

Energy

Consumption

per year, kWh

25% Energy

Saving, kWh

If AIR

COMP. 4

is run

23.04 24 552.96 201830 50457.6

If AIR

COMP. 5

is run

21.33 24 511.92 186850.8 46712.7

Investment for this recommendation = NIL (as existing pipeline and knock out drums can be

used)

Monetary value of energy saved per annum with Comp-4 @ Rs. 4.55 per kWh = 50457.6 x 4.55

= Rs. 2.29 Lacs

Monetary value of energy saved per annum with Comp-5 @ Rs. 4.55 per kWh = 46712.7 x 4.55

= Rs. 2.12 Lacs

Investment: Yet to be estimated for checking the very old embedded lines and carry out

segregation job.

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Energy Audit by PCRA, Eastern Region Page 16 of 27

Simple Payback period = To be estimated on the basis of the cost for line excavation and

replacement.

2. It is advised to arrange to carry out leak test at the air line flanges, instrument air reducing

points and copper tubing connectors. This will allow the use of 20 HP compressor to run and

cutoff.

Savings: Power savings in one year= (21.33 - 11.91)x 8760hrs = 82519.2 Kw = Rs. 375462

Investment: Nil and Payback is immediate.

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Energy Audit by PCRA, Eastern Region Page 17 of 27

5.0 STUDY OF GAS COMPRESSORS

5.1 FUEL CONSUMPTION BY INDIVIDUAL EQUIPMENT:

Compressor

No

Gas

Compressed

(SCMD)

Power

Consumption

(KwH)

Equivalent Natural

Gas Consumption

(SCUM/HR)

Remarks

1 LPB 1 41500 256 114.61

2 LPB 2 41500 238 106.6

3 LPB 3

Stand By

4 LPB 4

Stand By

5 LPB 5

Stand By

6 LPB 6 83000 183.5

7 LPB 7 83000 183.5

8 GL 1

S/D

9 GL 2 50000 288 128.9

10 GL 3 50000 135.9

11 GL 4

Stand By

12 GL 5

Stand By

13 GL 6

Stand By

14 GL 7 50000 133.2

Note: The equivalent gas consumption for motor is based on the gas consumed to generate power

at Moran Gas based Power Plant.

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Energy Audit by PCRA, Eastern Region Page 18 of 27

5.2 ACTUAL FUEL CONSUMPTION OF GAS COMPRESSORS W.R.T. DESIGN

Gas Compressor

Number

Natural Gas

Consumption

(SCUM/HR)

Design Gas

consumption at 60%

load

LPB 6 183.5 119.8

LPB 7 183.5 119.8

GL 3 135.9 83.21

GL 7 133.2 102.9

5.3 GAS PRODUCTION AT OCS-Moran

MONTHWISE GAS PRODUCTION

LP Gas Production (KCM) HP Gas Production

(KCM)

JUNE,12 2,767.05 2027

JULY,12 2,686.60 2382.5

AUGUST,12 3,207.09 2275.38

SEPTEMBER,12 2,010.07 2306.692

OCTOBER,12 2,607.78 2356.7

NOVEMBER,12 2,503.81 2265.2

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Energy Audit by PCRA, Eastern Region Page 19 of 27

5.4 REPLACEMENT OF MOTOR DRIVEN COMPRESSORS WITH GAS ENGINE DRIVEN TO CONSERVE

POWER

It was informed to us by OIL personnel that though presently there is surplus power

avaliable at Moran Power Station but in future due to commissioning of new motors

replacing Crude Driven Engines in the Crude oil pumping Station, the power may not be

available for running gas engines in the Gas compression station.

Therefore, following calculation is given to calculate the cost of replacement of

Compressor Motors with New Gas engines.

By matching the RPM of the Gas compressors and BHP of the present Electric Motors, it is

found that Waukesha Dresser F 3521GL is suitable for replacing motors of GL-1,GL-2,LPB-1

and LPB-2.

As per the data sheet the compressor is having Compression Ration of 10.5:1, RPM of 1000

and BHP of 615.

The fuel consumption at full load is 110.6 m3/hr. as the load curve the fuel consuption at

60% load as per design will be 98 m3/hr

Cost of purchasing the Gas Engine is $1,65000 = 1,65000 X 55= Rs. 90075000/-

The cost of running one Gas engine is 98 X 24X365 = 858480 X Rs.8.83 (Cost of NG) = Rs.

7580383.00

Present average equivalent power consumption of running one motor is 260.7 kwh

Cost of running of one motor is 260.7 X 24 X365 X Rs.4.55 = Rs. 10390980/-

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Energy Audit by PCRA, Eastern Region Page 20 of 27

Savings per year = Rs. 2810597

Payback= 90075000/2810597 = 32 years.

Therefore, it is economically not feasible to replace the motors with gas engines but in

case of non avaliability of power, gas engines can be procured.

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Energy Audit by PCRA, Eastern Region Page 21 of 27

6.0 ILLUMINATION SYSTEM

6.1 SUMMARY OF LUMINAIRES

No of Fittings available in the Plant:

GAS COMPRESSION UNIT-2 AREA WISE LIGHTING DETAILS

SL. No LOCATION 36W

T/LIGHT

400W

HPMV

100W

BULB

160W

MLL

400 W

HPSV/MH

1 SECURITY ROOM 8 6

2 ENGINE / GAS COMPRESSOR AREA 6 3 16 15

3 PUMP HOUSE 8

4 GENERATOR HOUSE

5 CHEMICAL HOUSE

6 MATERIAL HOUSE 6

7 CONTROL ROOM

8 EMERGENCY HOUSE 0 6

9 FIRE HOUSE 0 5

10 STREET/AREA LIGHT

15

11 INSTALLTION MANAGER ROOM 4

12 OFFICE ROOM 6

13 SUPERVISOR ROOM 3

14 PUMPING AREA

15 AIR COMPRESSOR HOUSE 12 6

TOTAL NUMBER OF TOTAL LIGHTS 53 3 34 20

15

WATTAGE WITH CHOKE 2756 2538 3400 3200 6345

TOTAL KW LOAD INCLUDING CHOKE 18.2

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Energy Audit by PCRA, Eastern Region Page 22 of 27

The average lux levels in different areas are shown below:

LOCATION LUX LEVEL RECOMMENDED

LUX COMMENTS

SECURITY ROOM 22 50 NEEDS IMPROVEMENT

ROAD TO RIGHT SIDE OF GATE 7 10-20 NEEDS IMPROVEMENT

IN FRONT OF MAINT GODOWN 1 10-20 NEEDS IMPROVEMENT

GAS COMPRESSOR SHED 18 100-150 NEEDS IMPROVEMENT

CONDENSATE RECOVERY

PLANT 0 50-70 NEEDS IMPROVEMENT

ROAD AT THE UNIT 3 10-20 NEEDS IMPROVEMENT

ROAD OF AIR COMPRESSOR 1 10-20 NEEDS IMPROVEMENT

AIR COMPRESSOR HOUSE 11 100-150 NEEDS IMPROVEMENT

SWITCH ROOM IN FRONT OF

COMPR SHED 25 100-150 NEEDS IMPROVEMENT

6.2 RECOMMENDATIONS AND PAYBACK ANALYSIS:

1. Replace all the conventional 36 watt FTL tube light with energy efficient T5 (28 watt).

2. To replace all 160W MLL lights with 150 W MH lights in the shed, this will improve the lights in the

shed which is presently very poor with respect to OISD standard.

Table- 6.3 ANNUAL ENERGY SAVING OPTIONS

Present

System

Proposed

System

Total

No. of

Item

Daily

Working

Hours

Annual

Working

Day

Present

Annual

Consumption

(kWh)

Expected

Annual

Consumption

(kWh)

Annual

Savings

(kWh)

FTL of 36

watt with

choke of 12

watt

T5 light of

29 watt 53 12 365 12071 6732 5339

Investment for T5 lights = 53 Nos. x Rs. 400/- = Rs.21,200/-

Annual Monetary Savings = 5339 x 4.55 = Rs. 24292/- (Rate of Electricity = Rs.4.55/kWh)

Simple Payback Period = 21200 / 24292 = 10.5 Months

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Energy Audit by PCRA, Eastern Region Page 23 of 27

Energy conservation opportunity in lighting :

� Installation of electronic ballast for fluorescent lamps

� Switching off lighting whenever not needed

� Installation of automatic lighting controls

� Installation of lighting voltage controllers

� Regular maintenance and cleaning of lamps

� Use of localized lighting close to working areas where appropriate

List of References :

1) BEE guide book on Energy Efficiency on Electrical Utilities

2) Handbook on energy conservation -by PCRA

.

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Energy Audit by PCRA, Eastern Region Page 24 of 27

Annexure-I

Energy Efficient Equipment Suppliers

Product/ Equipment Contact Details

AC Drives Rockers Control System,

SCO 819, 2nd Floor, NAC, Manimajra, Chandigarh 160101

Ph: 0172 – 2730900, 5071627

AC Drives Allen Bradley India Ltd

C-11, Industrial Area, Site-IV, Sahibabad, Ghaziabad 201 010

AC Drives Asea Brown Boveri Ltd.

Guru Nanak Foundation Building, 15-16, Qutab Institutional Area,

Saheed Jeet Singh Sansanwal Marg, New Delhi - 110 067

AC Drives Crompton Greaves Ltd.

Machine 3 Division, A-6/2, MIDC Area, Ahmednagar 414 111.

Automation, Panel Meters Conzerv System

44P Electronic City Phase –II, East Hosur Road, Bangalore –

560100

Ph: 080-51189700 www.conzerv.com

Automation, Panel Meters Selec controls Pvt Ltd

E – 121, Ansa Industrial Estate, Saki Vihar Road, Mumbai 400072

Ph: 022-28471882, 28476443 www.selecindia.com

Building Automation, sensors,

twilight switches

Electro Art

Plot No K-11, MIDC Area, Ambad, Nashik –422010,

Ph: 0253-5603954, 2380918 www.electronicswitchesindia.com

Burners WESMAN ENGINEERING (P) LTD.

503-504 Eros Apartments, 56 Nehru Place, New Delhi 110019

Tel: +91 (11) 26431723 Fax: +91 (11) 26434577

Burners, Furnace Recuperators,

Hot air generators, Heating &

Pumping unit, Laddle preheating

ENCON

12/3, Mathura Road, Faridabad-121003

Phone: 0129 -25275454 Fax: 0129 –25279070

www.encon.co.in

Capacitors Asian Electronics Ltd.

Plot 68, MIDC, Satpur, Nasik, Nashik - 422 007

Capacitors Shreem Capacitors Pvt. Ltd.

7/39, Vikram Vihar, Lajpat Nagar-IV, New Delhi - 110 024

Capacitors and APFC Panels Matrix Controls & Engineers Pvt Ltd

Rajeev Batra 9811624440, [email protected]

E- 725 DSIDC, Industrial Complex, Narela, GT Road, Delhi – 110040

Ph: 01127786945 / 46 / 47

www.matrixcapacitor.com

Capacitors and APFC Panels Standard Capacitors

B-70/43, DSIDC Complex, Lawrence road Industrial Area, Delhi –

110035

Ph: 011 –27181490, 27151027

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Energy Audit by PCRA, Eastern Region Page 25 of 27

Product/ Equipment Contact Details

www.standardcapacitors.com

Capacitors and APFC Panels Saif Electronics

174, Hira Building, 1st

Floor, Carnac Road,

Opposite Police Commissioner office , Mumbai – 400002

Ph : 022 – 22064626 , 22086613

www.saifel.com

Compressed Air Piping Legris India Pvt Ltd.

Legris House, 99 Pace city –1, sector 37, Gurgaon- 122001

Ph : 9958297093 , 9811054826

www.transair.legris.com

DG Synchronization, Automation

and Capacitors

SGS Industrial Controls & Solutions Pvt Ltd

Floor-II, Madanpur Khadar, Sarita Vihar, New Delhi.

Ph 011 – 29942516, 41402992

Eco-ventilators Nu Plast pipes & profiles

SCF – 124, sector 17 Market, Faridabad – 121002

Ph : 0129 – 6546217 , 4070023

Electrical measurement

Instruments

Riken Instrumentation Ltd

369, Industrial Area, Phase –II, Panchkula, Haryana

Ph : 0172 – 2591651, 2592028 ,

www.rikeninstrumenatation.com

Energy Management & Control

Systems

Manaco Energy Solutions (P) Ltd.

A-6, Shanti Apts.,21 & 22, 1st Cross St, TTK Road, Alwarpet,

Chennai-18 , 044-42316164,

www.mesco.co.in

Energy Saving Products Gautam Enterprises

205, Vinay Indl. Est., Chicholi Bunder Link Road, Malad (West),

Mumbai - 64, India

Tel: (91-22) 2875 04 22, Fax: (91-22) 2873 6985

www.gautament.com

Energy Saving products Techmark Engineers & Consultants.

K-1/28 Ground Floor, Chittaranjan Park New Delhi-110019

Telephone: 91-011-26238349

Fax : 91-011-51603925

Flue Gas Analyzers / Oxygen

Analyzer

Nevco Engineers Pvt. Ltd.,

90A (2nd Floor), Amritpuri B, Main Road, East of Kailash,

Opp. Iskcon Temple, New Delhi – 110 065

Telephone No 26226328, 26213009; Fax: 26285202

www.nevco.co.in

Flue Gas Analyzers / Oxygen

Analyzer

ACE Instruments & Controls

1, Biradari, Above Kashi Dairy, M.G. Road,

Ghatkopar (W), Bombay – 400 086

Tel.: 5125153, 5122762

Flue Gas Analyzers / Oxygen Testo India Pvt Ltd

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Energy Audit by PCRA, Eastern Region Page 26 of 27

Product/ Equipment Contact Details

Analyzer Pune 020 – 25665085,

www.testo.com

FRP Blades and cooling tower

accessories

Eneertech Engineers

SCO 144 – 145, Sector 34A, Chandigarh

Ph : 0172 – 5018077, 9876022225

HVAC related instruments

Thermocouples, pipe fittings,

pressure gauges

Waaree , 36 Damji shamji Industrial Complex

Off Mahakali caves road, Andheri East Mumbai 400093

022 –66963030 26874778

www.waaree.com

Infrared Temperature Meters (600

°C to 1800 °C)

Toshniwal Industries Pvt. Ltd.

Industrial Area, Mahukupura, AJMER - 305 002,

Ph 91145 269 5171, 91145 269 5205

[email protected] www.tipl.com

Infrared Temperature Meters (upto

1500 °C)

KUSAM MECO, G-17 , Bharat Industrial Area ,

T.J. Road, Sewree Mumbai 400015,

Ph : 022 – 24156638, 24124540

www.kusam-meco.co.in

Insulations Lloyd Insulation (India) Ltd.

P.B. No. 4321, Kalkaji Industrial Area,

Punj Sons Premises, New Delhi – 110 019

Ph: 26430746-7 Fax: 26478601/26467259

Insulations Himal Supply (India) Ltd

168 , Rajagarden, New Delhi – 110015

Ph : 011-25438602 , 25448602

www.himalsupply.com

LED lighting Synergy Solar (P) ltd

SCO 133, sector 28D, Chandigarh

Ph 0172-6451133

www.synergysolars.com

Lighting Systems Philips India Ltd

Regional office-North, 9th floor Ashoka Estate, 24,

Barakhamba Road New Delhi – 110 001

Telephone No.: 3353280, 3317442, Fax No.: 3314332

Lighting Systems Crompton Greaves Ltd.

Lighting Business Group, 405, Concorde, RC Dutt Road,

Baroda – 390 007

Lighting Systems OSRAM India Ltd. Signature Towers,

11th Floor, Tower B, South City-I, Gurgaon 122001, Haryana

Tel: 0124- 6526175, 6526178, 6526185

Fax: 0124- 6526184

Lighting Systems Asian Electronics

Surya Place, First Floor, K-185/1, Sarai Julena,

New Friends Colony, New Delhi – 110 025

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Energy Audit by PCRA, Eastern Region Page 27 of 27

Product/ Equipment Contact Details

Lighting Systems Asian Electronics

Surya Place, First Floor, K-185/1, Sarai Julena,

New Friends Colony, New Delhi – 110 025

Lighting Systems Philips India Limited , Technopolis Knowledge Park,

Nelco Complex, Mahakali Caves Road, Chakala,

Andheri (East), Mumbai 400 093.

Tel : 022 56912000

Lighting Systems Surya Roshni Ltd.

Padma Tower-I, Rajendra Palace, New Delhi 110 006.

Lighting Systems Wipro Limited

Sco 196-197, Sector 34-A, Chandigarh - 160 022

Lighting Systems OSRAM India Ltd. Signature Towers,

11th Floor, Tower B, South City-I, Gurgaon 122001, Haryana

Tel: 0124- 6526175, 6526178, 6526185

Fax: 0124- 6526184

Lighting Voltage Control Systems Jindal Electric & Machinery Corporation

C-57, Focal Point, Ludhiana – 141010

Ph : 2670250 , 2676890 ,

www.jindalelectric.com

Lighting Voltage Control Systems ES Electronics (India) Pvt. Ltd.

Plot No.82, KIADB Industrial Area,

Bommasandra – Jigani Link Road, Jigani Hobli,

Anekal Taluk, Bangalore District – 562 106

Telefax: +91 - 8110 – 414547 / 414548,

414549 / 414550

E-mail ID: [email protected]

Website: www.energysaversindia.com

Soft starters Amtech Electronics (India) Ltd

E-6, GIDC Electronics Zone, Ghandinagar – 382028 , Gujarat

Ph : 079 –23289101-3,

www.amtechelectronics.com

Thermocouples and Heaters Beeco Electronics

450 –A, Industrial Area, Phase-II, Chandigarh 160002,

Ph : 0172 – 5083350, 5073750 ,

www.beecoelectronics.com

Thermocouples and temperature

gauges & sensors

Radix Microsystem , 1005, Hemkunt House, 6, Rajendra Place

New Delhi,

Ph : 011-25786350, 09312600075 ,

www.radix.co.in

Note: - The suppliers mentioned above are not the only ones or the best in the market. The plant may

contact other suppliers for competitive rates/ specifications.