Energy Management System (EnMS)

Implementation Training
Webinar 3 Report

Energy Conservation Opportunities List and Measurement Plan

Candidate Plant Name: Dipped Products PLC

Team Name : Energy Meters
Team Members : Gamani Jayanath , Iresh Lakmal, Upendra
Arjeewani, Wasuda Abeyrathna, Udula
Prasanna, T A Thushara

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 No and Low Cost Opportunities
SEU Description Electri Fuel Saving Cost Verification Payba
cal (kWh) Savin Method ck
Saving g (R) perio
(kWh) d
Bio Fire wood stores are not well organized. and there is
no method implemented to feed the woods with low
Mass moisture level
Boiler LKR Onsite Less than
It is recommended organised the fire wood stores with
- 2,058kg/day 21,609/d inspection for three
partitions. firewood can use First come first serve
ay implementation months
basis. (it will help to reduce moisture content and
improve efficiency).
Boiler efficiency will be increased by boiler inspection

2
 No and Low Cost Opportunities
SEU Description Electrical Fuel Cost Verificati Payb
Saving Saving Savin on ack
(kWh) (kWh) g (R) Method perio
d
Dryers Set time for the washing and drying 5,880+ Onsite Less
can be reduced by providing 11,340= inspection than
2160kg/
specifications through R & D and 5%, 420kWh
day
LKR Product three
reducing safe margined times can be 17,220/d Spec months
saved huge electricity . ay

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 No and Low Cost Opportunities
SEU Description Electrical Fuel Cost Verifica Payback
Saving Saving Saving tion period
(kWh) (kWh) (R) Metho
d
Lighting Awareness raising through visual aids, Less than three
months
notices, briefings and etc
Plant is working 24 hours and lights
are switch on 24 hours to provide lux.
lights are fixed in high elevation (close 10%, Onsite
Less than three
months
to the roof). - LKR 891/day
31.832kWh/day
It is recommended to provide lighting
to the source by reducing its elevation
Improve daylight condition by fixing
transparent roofing

4
 No and Low Cost Opportunities
SEU Description Electrical Fuel Cost Saving Verific Payback
Saving Saving (R) ation period
(kWh) (kWh) Metho
d
Steam Fixing the steam leaks of
Distribution pipelines
line Onsite
Repair damage -
The steam generation will be
reduced by 3%. This calculation is verificati
Less than 3
Insulation not yet done on
months
Oven Repair damage
Insulation of oven walls
to avoid heat loss

5
 Opportunities Requiring Investment
SEU Description Electrical Fuel Cost Verification Payback
Saving Saving Saving Method period
(kWh) (kWh) (R)/day
AC Use wastage heat energy for air conditioning
Still calculating 5 years +
according to absorption chiller technology
AC Ensure AC’s capacity matches the room it is
If there is a
placed in. Since an AC with a lower capacity
significant
than the capacity required for the room, will
decrease In
not be able to cool the room to the set
the electricity
temperature and the compressor(AC) will
bill.
always be running to cool which leads to an
unnecessary energy loss
AC Carry out gas tests and amphere tests for
If there is a
the AC’s at least once a month. So that any
decrease In
problems in the AC capacitors, refrigerants
the electricity
would not lead to inefficient running which
bill.
once again leads to energy losses.

Feasibility Analysis will done from third party to assess economic and
technical feasibility for this models
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 Opportunities Requiring Investment
SEU Description Electrica Fuel Cost Verification Payback
l Saving Saving Saving Method period
(kWh) (kWh) (R)/day
• Introduce inverters to
reduce the flow
Plant J,K,L,B,C,F 2950 145,990 18
Oven Motors • Need to measure the kwh LKR/day months
efficiency of each
blower.

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 Opportunities Requiring Investment
SEU Description Electrica Fuel Cost Verification Payback
l Saving Saving Saving Method period
(kWh) (kWh) (R)/day
Tube lights In some buildings such as the
workshop, 4-6 lights turn on If there is a
from the same switch, all these decrease In the
lights are unnecessary. Alocating 30 1035 electricity bill.
more switches for these lights
would save more energy.
Flashlights Motion Sensors are fixed so that
it lights up when someone If there is a
comes closeby and stays off decrease In the
when no one is there. Currently, electricity bill.
they are always kept on so there
Is a significant energy loss.

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 Opportunities Requiring Investment
SEU Description Electri Fuel Cost Verificati Payback
cal Saving Saving on period
Saving (kWh) (R)/day Method
(kWh)
Compressor Reduce the system pressure as per
the requirement of the
machines/process through Pressure
booster. 300kWh 2 Months
8550 LKR
Install separate small capacity
compressor/s for the plants which
needs low system pressure/.
Hire a Compressor Expert for
further improvement of the
compressed air system

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 Opportunities Summary
Low Cost High Cost Total
SEU

Electrical Thermal Electrical Thermal Electrical Thermal

Bio Mass Boiler
Dryer
Lighting

Steam Distribution line

Oven
AC
Tube lights 30
Plant J,K,L,B,C,F Oven
Motors 2950
Flashlights
Compressor 300
Total

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 Completed / Implemented Opportunities
SEU Description Electrical Fuel Cost Saving Verification Payback
Saving Saving (R) Method period
(kWh)

GL chiller GL Chiller operation stop during 14,500

peak hours 420 3 months
/month

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 Completed / Implemented Opportunities
SEU Description Electrical Fuel Cost Saving Verification Payback
Saving Saving (R) Method period
(kWh)

Plant E-2
Use inverters to reduce the
Oven Motors frequency of the motors and If there is no
test if the quality of the gloves negative effect
are unaffected or not. If there 22576/ on the
is no significant affect in the 590 month production of
18 months
production process, we can go the gloves, this
for an inverter solution which solution is valid
would save more energy

12
 Completed / Implemented Opportunities
SEU Description Electrical Fuel Cost Saving Verification Payback
Saving Saving (R) Method period
(kWh)

Compressor • Leak track system

introduced and minimized
leaks.
• Pressure booster was 300 2 Months
8550/month
used to reduce the system
pressure for units which
had an increased
pressure.

13
 Completed / Implemented Opportunities
SEU Description Electrical Fuel Saving Cost Saving Verification Payback
Saving (R) Method period
(kWh)
Plant J,K and GL Chl operate
Reduce fire using steam generated from
wood the Boiler no 3 or 4. both are
consumptio firewood fired boilers.
Firewood consumption are
n/pair saved by utilizing the steam
user points 389.4
• Waste heat recovery
3,115,350 4months
system introduced. Tons/Year (3.1M)
• Steam tap monitored
weekly.
• Condensate line size
changed.
• Used PRV used at areas
of low pressure

14
 Completed / Implemented Opportunities
SEU Description Electrical Fuel Saving Cost Saving Verification Payback
Saving (R) Method period
(kWh)

Plant E Leach tank with high flowrate

of the plant E heated from
leach water thermal line earlier and
heat from consumed more energy to
waste heat water heat.
651Kg/day 250,000 LKR/ 12 Months
Waste heat from the thermal month
heater stack used to heat
this tanks and now this
completely operate from
waste heat

15
 Completed / Implemented Opportunities
SEU Description Electrical Fuel Saving Cost Saving Verification Payback
Saving (R) Method period
(kWh)
Hot water
systems Centralized hot water
system with waste heat 1,896,790 17 months
recovery

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Existing Sub-Meters Sections
P/E TSP (CFG) 15 sub
CHL01 meters
EFFLUENT

NEW HEATER

OVER HEAD

PADDLE STIRRER

NL HEATER

PLANT C

P/C & P/F Dryers

PLANT E2

PLANT E

PLANT F

CHL02

LAB

PLANT G

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 Measurement Plan
Section
P/E TSP (CFG) Daily measuring and
monitoring methods are
CHL01
EFFLUENT
NEW HEATER already implemented
covering all the SEU at
OVER HEAD
PADDLE STIRRER
NL HEATER
PLANT C the facility.
P/C & P/F Dryers
PLANT E2
PLANT E
PLANT F
CHL02
LAB
PLANT G

18
 Existing Relevant Variables and EnPI
SEU Relevant EnPI and Energy Use
Variables
Bio Mass Boiler Moisture content of Ton/Year
the Bio mass

Type of Bio mass

900KWh
Oven motors Frequency of motor

Dryer
Dry Oven

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Thank you

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