Web

www.teriin.org
The Energy and Resources Institute
Southern Regional Centre Tel. 2535 6590 (5 lines)
Darbari Seth Block 4th Main, 2nd Cross, E-mail terisrc@teri.res.in
Head Office .

Habitat Place, Lodhi Road Domlur II Stage Fax 2535 6589

New Delhi – 110 003 India + 91
Bangalore (0)
Post Box No. 7117
Tel. 2468 2100 or 5150 80
4900 Bangalore – 560 071
E- mailbox@teri.res.in
mail
Fax 2468 2144 or 2468 2145 tsenthil@teri.res.in
India + 91
Delhi T Senthil Kumar
(0) 11 Fellow & Area Convenor
Industrial Energy Group 12May 2015
Other Regional centres within India

North–Eastern Regional
Centre Mr S Raja Sekaran
Guwahati J K Tyre
Tel (361) 234 5395 or 234
4363
Chennai plant
E- terine@sify.com Mobile :08754440032
mail
Fax (361) 234 5395 Dear Mr.Raja Sekaran,

Eastern Regional Centre Sub: Comprehensive Energy Audit of J K Tyre

Kolkatta
Tel. (33) 2283 0549 to 51
E-mail: This is further to the filled in questionnaire received, and based on our
terierc@teri.re.in experience, we are pleased to submit our proposal for carrying out a
comprehensive energy audit of your Chennai Plant.
Western Regional Centre
Panaji, Goa We would be happy to carry out a comprehensive energy audit of your
Tel (832) 245 6053 or 245 plants in the complex to identify energy saving potential. The data and
6064 information provided has given us a broad view of the major electrical
E- terigoa@goatelecom.co energy consuming equipments and the energy system to enable us to
mail m
work out and submit a proposal for comprehensive energy audit.
Fax (832) 245 6053
The energy audit we have proposed is targeted at identifying
T E R I North America economically viable, cost effective energy saving opportunities in the
T E R I worldwide

Centreville, Virginia various sections of the plant, and for assisting the plant management in
Tel. (+1 571) 5221580 implementing the recommended energy saving measures, to actually
E-mail: teri@igc.org realize the benefit of cost reduction.
Fax (+1 571) 522 1581
The energy audit would involve an in-depth study of all the major energy
T E R I Europe consuming equipment / stages of manufacture as given in the scope of
London work. The study would focus on improving energy usage efficiency and
Tel (+44 20) 7747 6212 identifying energy saving opportunities at various equipment and
E- ritukumar@aol.com processes. The analyses would include simple payback calculations
mail where investments are required to be made to implement
Fax (+44 20) 7839 6174 recommendations, to establish their economic viability. It is our
experience that significant savings are possible to achieve without any
T E R I South-East Asia need for large expenditure or investment.
Kuala Lumpur, Malaysia
Tel. (+603) 7782 5718 We have a highly qualified and experienced multi-disciplinary group of
E-mail nimtech@tm.net.my consulting engineers, who have undergone intensive training in advanced
Fax (+603) 7783 5719 energy audit techniques. The audit study would use various portable
instruments we have, and would involve carrying out various
T E R I Japan
measurements and analysis covering major energy consuming
Tokyo equipment, to realistically assess losses and potential for energy savings
Tel. (+81 3) 3519 8979 …2
E-mail teri@iges.or.jp
Fax (+81 3) 3519 8978
 :: 2 ::

During the audit, there would be continuous interaction between the audit team and plant personnel to allow
for possible concurrent implementation and to ensure that the suggestions made are realistic, practical and
implementable. There will be frequent/weekly presentations by the study team on interim findings and
recommendations, so that the management could initiate implementation action without waiting for
submission of final report.

The time frame to complete the energy audit along with the report preparation is given below. We plan to
assign a team of about 4 consulting engineers, as necessary to complete the study within the time frame.
The team would be supported by other supervising / resource professionals on periodic basis.

We expect that plant study including field measurement and analysis will take about a 6-8 days and equal
amount of time for preparation of final report.

The total charges will be Rs. 7.50 lakhs (Rupees Seven lakh and fifty thousand only) + Service Tax
extra as applicable. In addition, the company has to pay or arrange Air travel / 2 AC train fare expenses
between Bangalore - Chennai –Bangalore, boarding & lodging, local travel for the professionals involved
during the field study.

We should be in a position to take up the audit from the month of July as we are pre occupied with other
committed activities.

The payment terms plant wise would be:

50% after completion of field visit;

50% on submission of report.

It would be very useful, if some engineers from the plant are also associated with team to assist, co-ordinate
and to provide necessary data.

Please let us know, if you need any further information regarding the proposal.

Hope the above offer is in line to release the work order from your end.

Thanking you,

Yours sincerely,

T Senthil Kumar

Encl: Detailed Proposal

 T E R I - SRC
4th Main, Domlur II Stage,
Bangalore – 560 071 (India)

CONTENTS

SECTION NO. CONTENTS

1.0 INTRODUCTION

2.0 SCOPE OF ENERGY AUDIT STUDY

3.0 INSTRUMENTS

4.0 OUR APPROACH

5.0 CONCLUSION
Proposal for “Comprehensive Energy Audit of J K
Tyres”

Submitted to

J K Tyres
Chennai

By The Energy and Resources Institute

Proposal No. P15IB007

May 12th 2015
1.0 INTRODUCTION

We are pleased to present this proposal to, J K Tyres Chennai plant for carrying out a detailed
energy audit.

The main objective of this proposal is to identify the energy conservation opportunities in the
major electrical and thermal energy consuming equipment’s and to suitably suggest in reducing
energy consumption in the different plant.

J K Tyres manufactures tyres for commercial vehicles, passenger cars and for farm vehicles.

The capacity of the Chennai plant is 240 T / day

2.0 SCOPE OF ENERGY AUDIT

The proposed scope of work for providing the services is detailed below:

 Collection of preliminary energy consumption data (wherever possible) and

analyzing the same;

 Conducting comprehensive instrumented Energy Audit of the plant;

 Review of present Energy Monitoring and Management and development of

improved energy management strategy (wherever required);

 Recommendations for improving Energy Efficiency measures highlighting

investment cost and payback analysis;

The technical scope of the plant is given in Annexure –I.

3.0 INSTRUMENTS

We have a wide range of sophisticated instruments, which enable us to carry out scientific energy
audit, which will makes it possible to locate the energy saving potential to a very large extent.

We would like to reiterate that we carry out instrumented energy audits, and to our information
no other energy audit consulting organization in the country possesses the range of instruments
we have.

4.0 OUR APPROACH

 Comprehensive Energy Audits are targeted at saving energy costs through detailed techno-
economic study. Detailed energy audits involve step-by step in-depth study of all energy
using plant utilities/sub-processes/equipment system etc, in the manufacturing line, to assess
and evaluate energy saving potential at each stage. The approach is to study, measure,
analyze and quantify useful and wasteful energy and evolve economically viable practical
energy saving alternatives.

 Quite a few companies for whom we had done comprehensive energy audits have had to
invest very little in relation to the gains derived from implementing the recommended
energy-saving measures. In fact, minimizing energy losses in processes and equipments, use
of energy-saving retrofits and modifications, productive use of waste heat/energy, use of
cheaper energy substitutes, etc. are measures which do not require large investments but can
lead to 10-15 percent savings in energy consumption.
 T E R I - SRC
4th Main, Domlur II Stage,
Bangalore – 560 071 (India)

 We have a highly qualified, experienced, multi-disciplinary core group of consulting

engineers, who have undergone intensive training in advanced energy audit techniques in
India and Germany. We operate in alliance with long and short term German experts under
an Indo-German agreement and have continuous access to international back-up support,
international database and modern technology.

 We have a wide array of latest, sophisticated, portable, diagnostic and measuring instruments
to support our energy audit investigations and analyses. These are used in the audits for
carrying out various data logging, measurements, testing, sensing and analyses, to provide
with a more reliable basis for evaluation of energy saving potential and economic viability.

 Our energy study provides for continuous interaction with plant personnel for concurrent
implementation where possible. The constant interaction ensures that the suggestions made
are realistic, practical and implementable. We have also been involved in actual
implementation of energy saving measures.

 In order to share our experience and provide for close interaction with industry on the
methods and approach in carrying out energy audits and implementation, we regularly carry
out training workshops on `Practical Energy Audit’. Such workshops are also organized as
`In-company Programs’ specifically tailored to each industry. We have also experience in
conducting Energy Management programmes with focus on top management, to sensitize
them on the important features of energy conservation and strategies to achieve energy
efficiency.

 TERI’s range of service, besides energy audit and implementation include, advice on energy
efficient equipment purchase, scrutiny of project reports for new ventures to incorporate
energy efficiency parameters, introducing `energy management’ process in organization,
regular monitoring of energy efficiencies on contract basis, and writing practical manuals on
‘Practical Energy Audit’ specific to each industry to enable it to carry out energy audit in-
house.

 We have so far carried out detailed energy audits and facilitated implementation of energy
saving measures in over 950 plants in wide range of industrial groups. These show that there
is potential for saving energy to the extent of 6-20 percent, a significant part of it achieved
without any need for large investments. We are enclosing herewith few of our client list who
have availed our services.

 Our energy audits are of very high standard and not comparable to those carried out by other
organizations, in terms of technical quality, depth, comprehensiveness and output.

5.0 CONCLUSION:

We would be most happy to work with a prestigious organization like yours, and we are
confident that we could contribute to saving significant energy cost.

We would be most happy to provide any clarifications or any further information you may
require.

We look forward to the opportunity of working with you.

 T E R I - SRC
4th Main, Domlur II Stage,
Bangalore – 560 071 (India)

Annexure -I
SCOPE OF ENERGY AUDIT OF J K Tyres

The energy consumption figures of the plant are given in the table below.

Sl. No Source Units

1 Electricity 125 lakh kWh for ( 2014-15)
2 Coal 80T/day
3 HSD 2500 litres/month

The present production is at the rate of 175 T/ day.

A. Electrical Systems

The Contract demand of the plant is 10 MVA.The plant has installed 4800 kVAr of capacitors and
maintains a PF of 0.993.

Plant receives power supply at 110 kV and stepped down to 11 kV by 2 x 16 MVA transformers. The
plant has 21 distribution transformers for distribution of power supply.

The scope covers the study of Electrical Systems comprising the Electrical Substations, Transformer
loading practices, Power Factor Management, Incoming Voltage Conditions and Distribution losses.

i) Transformer Load Management

The study will cover an in-depth analysis of the loading practices on distribution transformer to
evaluate the operating efficiencies. Such an analysis would result in identification of measures for
achieving optimum loading conditions and minimizing transformation losses.

ii) Power Factor Management

The study of power factor at different bus levels will help in designing and optimal placing of
capacitor banks to reduce the distribution losses and at the same time to improve the power factor
further. Installation of optimal rating of capacitor banks on transformer LT bus will also be evaluated.

iii) Distribution Losses

An in-depth study of the energy losses in the cable system would indicate the measures to be taken
for minimizing the energy losses in the cables and the overall distribution losses (percentage).

iv) Incoming Voltage Conditions

A detailed analysis of incoming voltage conditions would help in arriving at possible measures to
improve the same.

B. Electric Motor & Drives

The study would cover motors (11kW and above) loading conditions on motors, loading analysis,
drive matching by using power analyzer. Operating parameters such as kW, kVA, pf, Voltage, Current,
Frequency will be measured. Based on the above analysis, the following practically implementable
energy conservation recommendations will be made.

• Proper sizing of motor to the load

• Use of energy efficient motors by replacing oversized and efficient motors
• Possibility of operating motors in star mode wherever motors are under loaded
• Reactive power compensation for motors operating at low PF
• Application speed controlling devices
 T E R I - SRC
4th Main, Domlur II Stage,
Bangalore – 560 071 (India)

• Energy efficient transmission

• Application of soft starters

Detailed techno-economics of above measures will be carried out.

C. Fans & Blowers

Plant has different capacity and different application blowers. An in-depth study of these fans &
blowers would be covered for fans of above 11kW rating.

• Evaluation of efficiency of fans and blowers

• Application and matching of drive
• Application of flow control methods in pumping systems, fans and blowers
• Application of retrofit for energy savings

All the above will be studied in detail to arrive at various energy conservation opportunities

D. Pumping system

The study of centrifugal pumping system would cover pumps of 11 kW and above.

• Flow only for water pumps and head measurement of pumps by using sophisticated energy
audit equipments
• Measurement of power parameters (kW, kVA, pf, frequency, current, voltage)
• Evaluation of efficiency of pumps
• Study of user areas of cooling water with respect to present/design requirement of water and
respective heat loads
• Application and matching of drive
• Application of retrofit for energy savings

E. Compressed Air System

The installed capacity of the plant is 7290 CFM. The installed capacity of the compressors are given
below.

Compressor Type & Make FAD Motor Comp. Air pressure

capacity rating kW kg/cm2g
m3/min
Screw &KAESER(4 No’s) 1000 160 KW 8.5 Kg/cm2
Screw &KAESER(4 No’s) 240 55 KW 15 Kg/cm2
Screw &KAESER(1 No) 450 90 KW 12 KG/cm2
Screw &ELGI(2 No) 125 22 KW 14 KG/cm2
Screw &Atlas cap co(2 No) 600 110 KW 8.05 kg/cm2

An in-depth study of compressed air system covering compressed air generation and distribution
would be carried out. The study would cover:

• Free air delivery assessment (output of compressors)

• Estimation of specific energy consumption (kW consumption per cfm)
• Quantification of compressed air leakages (No load test if applicable/ if possible)
• Study of distribution network for Pressure drop, leakages, etc.
• Loading and unloading pattern
 T E R I - SRC
4th Main, Domlur II Stage,
Bangalore – 560 071 (India)

• Compressed air utilisation areas

Detailed analysis of the above will be carried out by using portable instruments to arrive at suitable
recommendations.

F. Boilers & Steam System (Steam Generation, Distribution & Utilisation)

The plant has 2 boilers to meet the steam demand. The steam is used in 4 Roll Calenders, PCR curing
and TBR curing.The rating of boilers present the plant are as given below:

Capacity,
Type & Make Fuel Application Annual Fuel
kCal/h

Thermax 20 TPH Coal Tyre curing 75 T/day

Thermax 10 TPH HSD Stand by

The study would cover:

• Efficiency and various losses evaluation of boiler.

• Study of distribution network for pressure drop, steam trapping, leakages, etc
• Evaluation of Specific steam generation
• Pressure drop in the system
• Insulation aspects including insulation surveys
• Quantification of steam leakage, if any
• Condensate recovery and optimization
• Optimization of steam utilization

Detailed analysis of the above will be carried out by using portable instruments to arrive at possible energy
conservation measures.

G. Refrigeration & Air-Conditioning

The plant has 2 x 300 TR Vapour absorption unit to meet the requirements.

The scope of the study would cover the following :

• Estimation of actual TR generation based on BIS standards

• Measurement of power consumption and estimation of specific steam power i.e, kW/TR for
VAM
• Operational features of compressors such as temperatures, pressure control

• Study of distribution network for

o Temperature drop
o Pressure drop
o Insulation
• Monitoring of operating parameters vis-à-vis desirable parameters in user locations
• AHU motors will be studied for the performance
• User area analysis to arrive at energy conservation measures
• Application potential for various energy saving retrofits

H. Cooling Towers
 T E R I - SRC
4th Main, Domlur II Stage,
Bangalore – 560 071 (India)

The plant has 4 cooling towers.The cooling tower efficiency will directly affect the performance of
plant equipment which leads to higher energy consumption. In view of this a study will be under
taken to analyse the present approach and range of the cooling tower against its designed values.

I. Lighting system

Detailed audit in lighting system normally results in considerable savings. Illumance readings with a
lux meter would act as a basis for comparative purpose. The study would cover measurement of lux
level at work place and at various points of light usage. Application of retrofits such as

• Timer control
• Photocell control for street lighting
• Use of energy efficient lighting

Would be studied in detail