SUMMARY OF ENERGY AUDIT:-

1) LIGHITHG SYSTEM: TOTAL LIGHY OF THE MILL = 2544 PCS

a) LED TUBE LIGHT (18W) =850 PCS

b) T-5 TUBE LIGHT (28W+4W) =675 PCS

c) T-8 TUBE LIGHT (36W+4W) = 1019 PCS

If conventional T-8 tube light is replaced by T-5 or LED Tube light then the energy will be saved as below ----

For T-5: saved energy = (40-32) = 8watt /tube light

= (8 x 1019) watt /hour for 1019 nos. Tube light

= (8 x 1019 x 10) watt/day = 81.52 unit / day

= (81.52 x 30) unit /month = Rs. (81.52 x 30 x 7.7) / month

=Rs. 18,831 /month

For LED Tube light: saved energy = (40-18) = 22watt /tube light

= (22 x 1019) watt /hour for 1019 nos. Tube light

= (22 x 1019 x 10) watt/day = 224.18 unit / day

= (224.18 x 30) unit /month = Rs. (224.18 x 30 x 7.7) / month

=Rs. 51785 /month.

2) POWER FACTOR STUDY: Electric bill based on NON-TOD meter and the average P.F. of whole day is
maintained in between 98.2% to 98.8%.

But for new Tariff rate we are getting 4% rebate which is less than the maximum rebate. Maximum rebate is 5%
for power factor above 99%. So, we are losing 1% rebate each month.

From study it has been observed that at peak load time P.F. goes down to 96.8% to 97.2%. But over all P.F.
remain above 98%. This can be controlled and can avail maximum benefit by introducing A.P.F.C. (Automatic
power factor controller).

By installing APFC panel instrument we can save Rs. 1 lac (approx) per month.

3) COMPRESSED AIR SYSTEM: minimizing by arresting air leakage from different joint, valves, etc we are able
to reduce the operating hours of the compressors and the total energy consumption of compressor.

Previously three number compressor run for supplying compressed air (50 hp IR compressor + 50 hp IR
compressor +40 hp screw compressor= 140 hp).
Now, only two compressor run alternately one number 70HP screw compressor or 50HP IR compressor and
one number 40HP screw compressor i.e. total 110 HP / 90 HP.

Then the energy saved = 320 units / day = 9600 units / month

= Rs. (9600 x 7.7) = Rs. 73920 / month.

4) ENERGY SAVER FOR LIGHTING BUSABR: As the Schneider suggested ENERGY SAVER FOR LIGHTING BASBAR for
Bally Jute mill, we are using this type of energy saver from last eight years. We have two numbers Energy saver

busbar system (100 KVA + 100 KVA).

5) EARTHING PROTECTION SYSTEM: We are already installed 6 nos. new EARTH PIT at different location for
safety purpose. Now we are planning to install another new 4 nos. earth pit. All installation is carried by in-
house.

6) REPLACEING CONVENTIONAL S.F.U. (SWITCH FUSE UNIT) BY MCB: We are already started replacing old fuse
type main switch by MCB at Drawing section. MCB prevent short circuit fire at drawing machine almost 70%
and thus save the fire maintenance cost of that drawing machine.

7) INSULATION RESISTANCE TEST OF DIFFERENT CABLE IN DIFFERENT LOCATION (TOTAL TEST CARRIED OUT
ONLY WHEN MILL WAS SHUTDOWN i.e. HOLIDAY BY MAGGER 1000 VOLT)

SL. LOCATION SIZE OF TYPE OF CABLE INSULATION RESISTANCE IN

NO CABLE MOHM
.

01 MAIN POWER HOUSE TO A- 120 SQ. XLPE COPPER, 180 (P-P)

BLOCK MM. X 3 11KV
178 (P-P)
CORE
181 (P-P)

169 (P-E)

176 (P-E)

176 (P-E)

02 MAIN P/H TO SACKING 185 SQ. PAPER 120 (P-P)

PLATEFORM EAST SIDE MM. X 3 INSULATED LEAD
112 (P-P)
BUSBAR ½ CORE COVER CABLE
(PILC) , COPPER , 116 ( P-P)
1.1 KV
108 (P-N)

112 (P-N)

112 (P-N)

116 (P-E)
 108 (P-E)

110 (P-E)

112 (E-N)

03 MAIN P/H TO SACKING 400 SQ. XLPE , ALUMIUM, 198 (P-P)

PLATEFORM NORTH SIDE MM X 3 1.1 KV
BUSBAR ½ CORE 188 (P-P)

188 (P-P)

198 (P-N)

200 (P-N)

200 (P-N)

200 (P-E)

200 (P-E)

192 (P-E)

200 (N-E)

04 MAIN P/H TO 4 NO. 185 SQ. PILC , COPPER , 098 (P-P)

PLATEFORM NORTH SIDE MM X 3 1.1 KV
100 (P-P)
BUSBAR ½ CORE
100 (P-P)

110 (P-N)

099 (P-N)

108 (P-N)

097 (P-E)

100 (P-E)

100 (P-E)

100 (E-N)

05 MAIN P/H TO EAST SIDE 240 SQ. PILC , COPPER , 150 (P-P)
BUSBAR OF 4 NO. PLATEFORM MM X 3 1.1 KV
½ CORE 138 (P-P)

140 (P-P)

150 (P-N)

150 (P-N)

150 (P-N)

136 (E-N)
 140 (E-N)

140 (E-N)

06 A-BLOCK P/H TO B-BLOCKE 400 SQ XLPE 200 (P-P)

MAIN BUSBAR MM X 3 ALUMINIUM, 1.1
200 (P-P)
½ CORE KV
190 (P-P)

200 (P-N)

200 (P-N)

198 (P-N)

200 (N-E)

200 (N-E)

200 (N-E)

07 A-BLOCK P/H TO 16 NO. 400 SQ XLPE 180 (P-P)

GODOWN MM X 3 ALUMINIUM, 1.1
180 (P-P)
½ CORE KV
180 (P-P)

150 (P-N)

170 (P-N)

170 (P-N)

180 (E-N)

180 (E-N)

180 (E-N)

08 A-BLOCK P/H TO 15 NO. 150 SQ XLPE 88 (P-P)

GODOWN MM X 3 ALUMINIUM, 1.1
86 (P-P)
½ CORE KV
90 (P-P)

92 (P-N)

90 (P-N)

92 (P-N)

94 (P-E)

88 (P-E)

90 (P-E)

90 (E-N)
 09 MAIN P/H TO BOILAR MAIN 50 SQ. XLPE 120 (P-P)
SWITCH MM X 3 ALUMINIUM, 1.1
½ CORE KV 120 (P-P)

120 (P-P)

110 (P-N)

120 (P-N)

120 (P-N)

NOTE: ONE NUMBER OLD CABLE IS FOUND UNDER SIZED. EXSISTING OLD PLC ARMOURED COPPER CABEL IS 70 SQ
MM X 3 CORE AND ITS CURRENT CAPACITY IS 145 AMP AND IT CARRIES 190 -210 AMP CURRENT. SO THERE IS HUGE
HEAT LOSS (BECAUSE THE GENERATED HEAT LOSS INCREASE WITH THE SQURE TIMES OF CURRENT).

NOW, THIS UNDER SIZED CABLE WILL BE REPLACED BY A NEW OVER SIZE CABLE (XLPE ARMOURED ALUMINIUM CABLE
240 SQ MM X 3 CORE) IN HOLIDAY TO REDUCE AND MINIMIZE HEAT LOSSES (i.e. LINE TRANSMISSION LOSS) AND
IMPROVE LOAD END VOLTAGE. THUS BY CHANGING OVER SIZE CABLE WE WILL SAVE THE LINE LOSS ENERGY.

8) SOME OF ENERGY AUDIT DATA AS GIVEN BELOW:

A) BOILER-1 (OLD):

SL M/C NAME HP/KW VOLT LOAD P.F. LOAD (KW) % LOAD REMARKS
NO CURRENT
(AMPS)

01 ID FAN 35 HP 408V 38.9 A 0.79 21.71 83.14%

FD FAN-1 5 HP 409V 6.5 A 0.81 3.72 99.7%

FD FAN 2 3 HP 408V 4.0A 0.77 2.176 97.22%

B) NEW WORKSHOP:

SL M/C NAME HP/KW VOLT LOAD P.F. LOAD (KW) % LOAD REMARKS
NO CURRENT
(AMPS)
01 NEW WORKSHOP 406V 45 A 0.86 27.21

C) JUTE SPREADER MACHINE:

SL M/C NAME HP/KW VOLT LOAD P.F. LOAD (KW) % LOAD REMARKS

NO CURRENT
(AMPS)

01 SPREADER-2 10 HP + 410V 13.5 A 0.76 7.28 62.97%

5 HP +
0.5 HP

02 SPREADER-3 10 HP + 410V 12.4A 0.82 7.22 62.45%

5 HP +
0.5 HP

03 SPREADER-4 10 HP + 410V 14.4A 0.67 6.851 59.26%

5 HP +
0.5 HP

04 SPREADER-5 10 HP + 410V 10A 0.84 5.965 51.60%

5 HP +
0.5 HP

05 SPREADER-6 10 HP + 410V 10.2A 0.79 5.722 49.49%

5 HP +
0.5 HP

06 SPREADER-7 10 HP + 410V 12.6 0.74 6.621 57.27%

5 HP +
0.5 HP

07 SPREADER-8 10 HP + 410V 10.7 0.81 6.154 53.23%

5 HP +
0.5 HP
08 SPREADER-9 10 HP + 410V 10.2A 0.78 5.649 48.86%
5 HP +
0.5 HP

09 SPREADER-10 10 HP + 410V 14.6A 0.71 7.361 63.67%

5 HP +
0.5 HP

D) FINISHER CARD MACHINE:

SL MACHENE NAME HP/KW VOLT LOAD P.F. LOAD (KW) % LOAD REMARKS
NO CURRENT
(AMPS)

01 F/CARD-1 10HP 402V 12.2A 0.72 6.11 81.90%

02 F/CARD-2 10HP 404V 10.6A 0.78 5.78 77.47%

03 F/CARD-3 10HP 402V 12.8A 0.67 5.971 80.04%

04 F/CARD-8 15HP 398V 9.8A 0.64 4.32 38.60%

05 F/CARD-9 15HP 401V 17.6A 0.74 9.05 80.87%

06 F/CARD-10 15HP 398V 14.8A 0.69 7.039 62.90%

07 F/CARD-22 15HP 396V 9.8A 0.68 4.57 40.84%

08 F/CARD-23 15HP 399V -- -- -- -- M/C STOP

09 F/CARD-24 10HP 401V 11.6A 0.75 6.042 80.99%

10 F/CARD-27 15HP 401 9.6A 0.74 4.933 44.08%

NOTE: QUITE NORMAL EFFICIENCY OF F/CARD MOTOR. IT HAS BEEN OBSERVED FROM STUDY TIME THAT AFTER
‘’AKHRA” THE FINISHER CARD MACHINE’S LOAD CURRENT REDUCED 0.8-1 AMP i.e. 0.4 – 0.5 KW.

E) BREAKER CARD MACHINE:

SL MACHINE MANE HP/KW VOLT LOAD P.F. LOAD (KW) % LOAD REMARKS
NO CURRENT
(AMPS)
01 B/CARD-6 15HP 400V 16.5A 0.74 8.46 KW 75.60%

02 B/CARD-7 15HP 399V 12.6A 0.76 6.617 KW 59.13%

03 B/CARD-8 15HP 396V 15.2A 0.68 7.089 KW 63.35%

04 B/CARD-14 20HP 396V 14.8A 0.72 7.308 KW 48.98%

NOTE: IT HAS BEEN OBSERVED FROM STUDY TIME THAT WHEN B/CARD M/C STARTS IT DRAW 70-80 AMPS CURRENT
AND STAY ABOUT 20-26 SEC WHICH CAUSE THE FREQUENT BURNT OF THE MOTOR AND THIS ALSO EFFECT ON
MAXIMUM DEMAND. BUT AFTER FULL RUNNING OF THE MACHINE IT CAME DOWN NORMAL CURRENT 14 AMPS TO
17 AMPS.

THE STARTING TORQUE CURRENT CAN BE REDUCED BY INTRODUCING CENTRIFUGAL CLUTCH PULLEY SYSTEM.

F) FIRST DRAWING MACHINE:

SL MACHINE NAME HP/KW VOLT LOAD P.F. LOAD (KW) % LOAD REMARKS
NO CURRENT
(AMPS)

01 1ST DRG-01 5 HP 406V 5.2A 0.85 3.108 83.32%

02 1ST DRG-02 5 HP 404V 408A 0.81 2.72 72.92%

03 1ST DRG-03 3HP 404V 3.45A 0.78 1.88 84.00%

04 1ST DRG-04 5HP 408V 4.8A 0.79 2.679 71.82%

05 1ST DRG-05 5HP 405V 5.2A 0.68 2.480 66.48%

06 1ST DRG-06 5HP 405V 4.78A 0.82 2.749 73.69%

07 1ST DRG-07 5HP 406V 5.69A 0.79 3.161 84.74%

08 1ST DRG-08 5HP 406V 5.26A 0.80 2.959 79.32%

09 1ST DRG-09 5HP 406V 4.98A 0.78 2.731 73.21%

10 1ST DRG-10 7.5HP 405V 6.18A 0.71 3.077 54.99%

11 1ST DRG-11 3HP 406V 3.83A 0.76 2.046 91.42%

12 1ST DRG-12 5HP 405V 5.46A 0.68 2.604 69.81%

13 1ST DRG-13 3HP 405V 2.83A 0.81 1.608 71.84%

14 1ST DRG-14 3HP 405V 3.46A 0.76 1.844 82.395%

NOTE: IT IS OBSERVED THAT A LITTLE BIT UNIT/HOUR ENERGY WILL BE SAVED BY PROPER LUBRICATION ON PROPER
POINTS OF MACHINE PARTS.

G) SECOND DRAWING MACHINE:

SL MACHINE NAME HP/KW VOLT LOAD P.F. LOAD (KW) % LOAD REMARKS
NO CURRENT
(AMPS)

01 2ND DRG-1D 5HP 406V 5.89A 0.80 3.313 88.82%

02 2ND DRG-2D 5HP 408V 5.65A 0.72 2.874 77.05%

03 2ND DRG-01 5HP 406V 6.05A 0.69 2.935 78.68%

04 2ND DRG-02 5HP 406V 5.43A 0.76 2.901 77.77%

05 2ND DRG-03 5HP 406V 5.80A 0.72 2.936 78.71%

06 2ND DRG-04 5HP 408V 6.26A 0.69 3.052 81.82%

07 2ND DRG-05 5HP 406V 5.75A 0.72 2.911 78.04%

08 2ND DRG-06 5HP 406V 5.73A 0.78 3.142 84.23%

09 2ND DRG-07 5HP 404V 5.26A 0.81 2.981 79.91%

10 2ND DRG-08 5HP 405V 6.50A 0.76 3.465 92.89%

11 2ND DRG-09 5HP 406V 5.98A 0.69 2.901 77.77%

12 2ND DRG-10 5HP 406V 6.20A 0.76 3.313 88.82%

13 2ND DRG-11 5HP 406V 5.65A 0.72 2.860 76.67%

14 2ND DRG-12 5HP 402V 5.80A 0.78 3.149 84.42%

15 2ND DRG-14 5HP 406V 5.63A 0.82 3.246 87.02%

16 2ND DRG-15 5HP 402V 6.10A 0.71 3.015 80.83%

NOTE: IT IS OBSERVED FROM STUDY TIME THAT NEAR ABOUT 0.6 – 0.8 AMPS CURRENT REDUCED (i.e. APPROX 0.3 –
0.4 UNITS/HOUR ENERGY SAVED) BY PROPER TENSION OF DELIVERY PRESSING ROLLER AND PROPER LUBRICATION ON
PROPER POINTS OF MACHINE PARTS.

H) FINISHER DRAWING / 3RD DRAWING MACHINE:

SL MACHINE NAME HP/KW VOLT LOAD P.F. LOAD (KW) % LOAD REMARKS
NO CURRENT
(AMPS)

01 F/DRG -01 5HP 404V 6.54A 0.69 3.157 84.63%

02 F/DRG -02 5HP 406V 6.20A 0.78 3.40 91.15%

03 F/DRG -03 5HP 406V 5.78A 0.78 3.170 84.98%

04 F/DRG -04 5HP 404V 5.46A 0.82 3.132 83.96%

05 F/DRG -05 5HP 403V 6.10A 0.72 3.065 82.17%

06 F/DRG -06 5HP 405V 5.98A 0.76 3.187 85.44%

07 F/DRG -07 5HP 405V 5.76A 0.80 3.232 86.64%

08 F/DRG -08 5HP 405V 6.06A 0.76 3.230 86.59%

09 F/DRG -09 5HP 406V 6.20A 0.76 3.313 88.82%

10 F/DRG -10 5HP 406V 5.75A 0.81 3.275 87.80%

11 F/DRG -11 5HP 409V 6.54A 0.76 3.520 94.30%

12 F/DRG -12 7 ½ HP 408V 6.68A 0.81 3.823 68.32%

13 F/DRG -13 5HP 408V 5.72A 0.76 3.071 82.33%

14 F/DRG -14 5HP 407V 5.45A 0.81 3.111 83.40%

15 F/DRG -15 5HP 406V 5.98A 0.76 3.195 85.65%

16 F/DRG -16 5HP 406V 6.12A 0.69 2.969 79.59%

17 F/DRG -17 7 ½ HP 406V 6.65A 0.68 3.179 56.81%

18 F/DRG -18 5HP 406V 6.02A 0.76 3.217 86.24%

19 F/DRG -19 5HP 406V 5.79A 0.72 2.931 78.58%

20 F/DRG -21 5HP 408V 5.92A 0.78 3.263 87.47%

21 F/DRG -22 5HP 406V 6.16A 0.76 3.292 88.25%

22 F/DRG -23 5HP 406V 6.10A 0.81 3.474 93.13%

NOTE: IT IS OBSERVED FROM STUDY TIME THAT NEAR ABOUT 0.6 – 0.8 AMPS CURRENT REDUCED (i.e. APPROX 0.3 –
0.4 UNITS/HOUR ENERGY SAVED) BY PROPER TENSION OF DELIVERY PRESSING ROLLER AND PROPER LUBRICATION ON
PROPER POINTS OF MACHINE PARTS.

I) CORESIDE FIRST DRAWING:

SL MACHINE NAME HP/KW VOLT LOAD P.F. LOAD (KW) % LOAD REMARKS
NO CURRENT
(AMPS)

01 C/S 1ST DRG-1 5HP 400V 5.26A 0.78 2.842 76.19%

02 C/S 1ST DRG-2 5HP 403V 5.05A 0.86 3.031 81.26%

03 C/S 1ST DRG-3 7 ½ HP 400V 6.98A 0.76 3.675 65.68%

04 C/S 1ST DRG-4 (12 10 HP 398V 7.62A 0.76 3.992 53.51%

HEAD)

NOTE: IT IS OBSERVED FROM STUDY TIME THAT NEAR ABOUT 0.6 – 0.8 AMPS CURRENT REDUCED (i.e. APPROX 0.3 –
0.4 UNITS/HOUR ENERGY SAVED) BY PROPER TENSION OF DELIVERY PRESSING ROLLER AND PROPER LUBRICATION ON
PROPER POINTS OF MACHINE PARTS.

J) CORE SIDE FINISHER DRAWING MACHINE:

SL MACHINE NAME HP/KW VOLT LOAD P.F. LOAD (KW) % LOAD REMARKAS
NO CURRENT
(AMPS)
01 C/S FIN DRG-01 5HP 398V 5.26A 0.78 2.828 75.81%

02 C/S FIN DRG -02 5HP 402V 5.75A 0.81 3.242 86.91%

03 C/S FIN DRG -03 5HP 401V 6.00A 0.82 3.417 91.60%

04 C/S FIN DRG -04 5HP 398V 5.45A 0.76 2.855 76.54%

05 C/S FIN DRG -05 5HP 404V 5.50A 0.80 3.078 82.52%

NOTE: IT IS OBSERVED FROM STUDY TIME THAT NEAR ABOUT 0.6 – 0.8 AMPS CURRENT REDUCED (i.e. APPROX 0.3 –
0.4 UNITS/HOUR ENERGY SAVED) BY PROPER TENSION OF DELIVERY PRESSING ROLLER AND PROPER LUBRICATION ON
PROPER POINTS OF MACHINE PARTS.