This document summarizes the findings of an energy and safety audit conducted at Sonthalia Rice Mill in 2012-13. It identifies several areas for improvement, including installing capacitors to improve power factor, reducing compressed air pressure, improving the electrical earthing system, and establishing preventative maintenance for electrical equipment. Implementing all recommendations could save the mill over Rs. 2.27 lakh annually while requiring a one-time investment of Rs. 52,500 for capacitors.

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ENERGY & SAFETY AUDIT
FOR THE YEAR 2012-13
For
SONTHALIA RICE MILL
S-3/36,37 SEC-A, ZONE-B
MANCHESWAR INDUSTRIAL ESTATE
BHUBANESHWAR-10
22nd. July -2012
AUDITED BY
V S RAI ASSOCIATES
ENERGY MANAGEMENT CONSULTANTS
TIRUPATI APARTMENT, FLAT-1D
BD-205/206, KAMALPARK
KOLKATA-700101
V S RAI ASSOCIATES-ENERGY MANAGEMENT CONSULTANTS

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C O N T E N T S
SECTIONS DESCRIPTION PAGE NO.
Summary of Findings 3
1.0 Power scenario at the Rice mill 4
2.0 Power Requirement with CPP 7
3.0 Power distribution & PF improvement
8
4.0 Compressed Air at Color sorting machine
10
5.0 Electrical safety audit & precaution
11
6.0 General maintenance & Prevention of break downs 12
Annexure I-II
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SUMARY OF FINDINGS
Ref no. Action Suggested Recurring
Saving/year
Rs.
Budgetary
Investment
Rs.
Page
No
1.0 Power scenario of rice mill operation is
illustrated
Details are specifically illustrated 4
2.0 Power requirement with envisaged CPP Details are specifically illustrated 7
3.0 Power distribution & PF improvement 167000 52500 8
4.0 Reduction of Air pressure from 7.0
Kg/cm²to 5.0 kg./cm²
60200 nil 10
5.0 Interconnecting Present Earthing system Specific suggestions are made to
improve safety of electrical
system.
11
6.0 Initiate cleaning schedule for Electrical
Equipment
Specific measures are made to
minimize break downs.
12
Total Rs.2,27,200/year Rs. 52,500
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1.0 POWER SCENARIO AT THE MILL
1.1 BACKGROUND
i. Sonthalia Rice Mill (SRM),Paribasudevpur , Khurda Orissa) is rice mills equipped with 3
parallal production lines of 3Ton/hour capacity each.Two production lines are equipped with
parboiling process while other line is of Arua section. The total power consumption of the plant
is about 11,40,000 kwh/annum which amount to Rs.75.00 Lac/annum. SRM purchase power
from Orissa power supply & distribution company Limited on 11KV power line to cater power
requirement of the mill besides it has also installed 100 KVA DG set to manage power
requirement of critical equipment only during non availability of purchase power.
Further SRM is also facing regular power interruption problems besides very poor quality of
power supply w.r.t low voltage. To overcome low voltage problem, the management has also
installed 500KVA automatic voltage stabilizer. However many times, the said stabilizer is not
able to boost power voltage for the efficient operation of Electric motors & their controls. The
matter of very poor quality of power supply coupled with power interruption is one the key
concern before management to main productivity. The management is contemplating to go for its
own captive power plant to sort out recurring power problems for their steady growth with
higher productivity.
ii. Power Demand & consumption Profile.
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iii. Total Connected Electrical load of Entire Rice Mill
Sections Connected HP Connected-KW Remarks
i.Arua ketel 22.5 16.785 i.Total actual running load with
two lines ( parboiling
Operation) was found to the
order of 300KW with running
Power demand of 320KVA
ii Powqer factor was observed
to the order of 0.94-0.96
ii.Arua section 172.5 128.68
iii.Old mill with
Dryers
222+27 165.612+20
iv. New mill with
dryers
116.5+20 86.909+15
v.color sorting with
air compressor
40 30
vi Boiler 30 22
vii.Other Misc
47 35
(Lighting, Packing
etc)
Total Load 697.50 HP 519.986 KW
iv. Total Running Power Requirement
Power measurement exercise was conducted to ascertain actual power requirement of rice mill
with two line operation. Details are out lined below:
Sections Running load-
KW
Running Load-
KVA
Remarks
i.New line with dryers 90 96 i.Total actual running load with
ii. Old line with 135 143.9 two lines ( parboiling
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dryers Operation was found to the
order of 300KW.
ii. Power was found to the
order of 0.94-0.96.
iii.Colour sorting m/c
with Compressor
30 33
iv Boiler section 10 10.70
v. Other misc load 35 37
Total load 300 KW 320.06 KVA
Proposed load with
110 120
Arua section& ketel
Total Plant running
load
410 KW 440 say 450KVA
v. Projected Power Requirement with 3 lines operation:
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2.0 POWER REQUIREMENT WITH PROPODSED CPP
In case SRM, plan for CPP ( Captive Power Plant ), the requirement would be as follows
a. The power requirement with 3 lines operation =460Kw
b. Power demand requirement with 3 lines operation = 515 KVA
c. Proposed rating of CPP would be = 590KW
2.1 SELECTION CIRITERIA OF CPP
i. Running load of entire Rice mill = 410 KW
ii. Running power demand of entire rice mill =450 KVA
iii. Considering 10% misc loadd, the power requirement would be =460 Kw or 515 KVA
( 410+50 Kw)
iv. Maximum power demand with starting kick load=645 KVA say 650 KVA
( 515x1.25 )
v. Therefore if mill wants to go for a Captive power plant to cater power requirement
with all three line operation ,the power requirement would be = 590 KW or 650KVA
KVA
vi. The selection of captive power should be such that it can supply power to the
order of 590 KW
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3.0 POWER DISTRIBUTION & POWER FACTOR (PF) IMPROVEMENT
3.1 STATUS REVIEW
Sonthalia Rice Mill (SRM) purchase power from Orissa power supply & distribution company
Limited at 11 KV power line & with help of 500KVA transformer (11/0.433KV), the available
power is distributed to various sections of mills. Power requirement at the mill is tabulated
below:
a. Sanctioned power demand = 200 KVA
b. Running power demand =384-480 KVA
c. Power Factor = 93-94%
d. Power consumption/month = 90,000-108700 Kwh
e. Power cost bill/month = Rs.6.50-7.0 Lac
The PF is an index for the effective utilization of available power. The plant has already installed
1no.x200 &1x100 KVAR APFC ( Automatic power factor controllers to improve the power
factor. However the location of the above said APFC is across main distribution board (Adjacent
to 500 KVA LT voltage stabilizer) which does not effectively utilized to optimize power loss at
various key load centers. Further APFC does not correct the low level power factor hence
necessity was felt to install additional capacitors at load centre to optimize line loss &
improvement of motor performances.
3.2 PF Mapping
PF mapping was carried out to ascertain PF at load centers at Line No.1&2 power distribution
panels, dryers power distribution panel, Sortec panel, Boiler panels, & others. Details are
summarized below:
Equipments Main
I/C
panel
line.-1
Main
I/C
panel
line.-2
Polishing
Motor-1
30HP
Polishing
Motor-2
30HP
Polishing
Motor-3
30HP
Polishing
Motor-4
30HP
Silky
50HP
Dryers.
No.1
Power
factor
0.55-
0.61
0.0.49-
0.60
0.74 0.46 0.35 0.63 0.82 0.65
Equipments Dryers
No2
Air
Blowers
Air
Comp.
18.5 Kw
Boiler
panel
LT Trs
O/G
Remarks
Power
factor
0.70-
0.77
0.0.60-
0.75
0.55-0.87 063-.071 0.90-.94 PF At load centrs is very poor
& call for improvement to
optimize power loss
In view of above, the need of PF improvement was felt at following locations:
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a. Installation of Capacitors across transformer.
b. Installation of Capacitors across key lad centers.
3.2.1 CAPACITOR ACROSS TRANSFORMER
In view of above a necessity was felt to connect separate additional capacitor across 500 KVA
transformer besides separate capacitors should be connected on the key loads centers.
Typical connection for proposed capacitors
Details of capacitor, SFU & HRC fuses are out lined below which are to be connected on
secondary side of transformer preferably across LT out going ACB. These capacitors should
remain in circuit even on off or holidays or on part load.
a. Capacitor for 500KVA Trs = 25 KVAR
b. Rating of SFU =63 Amp.
c. HRC fuse rating = 63 amp.
Total investment for item no a, b & c would be around Rs.12500
3.2.2 ADDITIONAL CAPACITOR ACROSS KEY LOAD CENTRE
In view of low power factor across key load centers it is strongly felt to install additional
capacitors to improve PF up to 95% and above. Details are summarized below:
Particula
Line-1
Line-2
Line-3
Dryer
Dryer
Boiler
Sortex
Other
Total
r
PDB
PDB
PDB
PDB-1
PDB-2
PDB
PDB
PDB
Capacitor
-Kvar
20 20 20 7.5 7.5 5 10 10 100
Kvar
Capacitors requirement would be =3 nos.x20KVAR,2nos.x10KVAR, 2 nos.x7.5 KVAR &1
no.x5 KVAR rating. These capacitor bank would be installed with proper SFU &HRC fuses for
effective control & operation.
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3.3 ANTICIPATED BENEFITS
The likely reduction of maximum power demand and reduction of power distribution loss would
be of Rs 167,700/annum against the budgetary investment of Rs 52,500.
3.4 RECOMMENDATION
It is strongly recommended to install 25 Kvar static capacitor delta connected at LT side of 500
KVA transformer, preferably across LT ACB (adjacent to transformer) out going feeder. The
envisaged capacitor would be connected through SFU and HRC fuses and would remain on
always on irrespective of mill operation.
It is also strongly recommended to install 100 KVAR additional capacitor across power
distribution board as indicated above to optimize power loss and improvement of electric motors
efficiency.
4.0 COMPRESSED AIR AT COLOUR SORTING MACHINE
4.1 STATUS REVIEW
Plant has installed Elegi make air compressor of 2.97 NM³/minute capacity to generate
compressed air at 7 kg/cm². The plant has installed Delair make air dryer to supply instrument air
for colour sorting machine. Plant has also installed air receiver to supply steady air pressure for
the proper functioning of sorting machine.
The observation of sorting machine operation indicate that the pneumatic air pressure at machine
was found to the order of 2.6 kg/cm². In view of machine requirement it is our considered
observation to reduce the air pressure of compressor for the comfortable and effective operation
of sorting machine.
The reduction of the said air pressure would reduce the power consumption besides the stress of
compressor would be significantly reduced. The said reduction of air pressure would be adopted
in two phases which are out lined below:
Activities Present air generation
Cut off prs. Restart prs
Proposed air pressure
Cut off prs. Restart prs.
Reccurring
saving/year
Phase-I 7.2 kg/cm² 5.5kg/cm² 6 kg/cm² 5.5 kg/cm² Rs 36000
Phasr-II 7.2 kg/cm² 5.5kg/cm² 5 kg/cm² 4.5 kg/cm² Rs 61250
4.2 ANTICIPATED BENEFIT
The likely power cost saving with the reduce air pressure generation would be Rs 60,200/annum
without any investment. However it is suggested that initially the present air pressure generation
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should be reduce to 6 kg/cm² and later on the air pressure setting should be restricted to 5 kg/cm²
only.
4.3 RECOMMENDATION
It is strongly recommended to reduce the operating pressure of sorting air compressor from 7
kg /cm² to5 Kg/ cm² in two phases to optimize power consumption without any investment.
5.0 ELECTRICAL SAFETY AUDIT & PRECAUTIONS
5.1 STATUS REVIEW
Electric Safety Audit is an organized effort to identify various problems and evolve specific
safety measures at measurable cost & time. Electrical safety audit also provides an effective tool
to the management to identify, implement & sustain safety measures.
Electrical Earthing : The main function is to protect electrical equipment from insulation fault
(a "short circuit") or a very high current flows, which will trigger an over – current relay to
isolate the power circuit. It also avoid the risk of electrical shock to personnel working with
machines.
Sonthalia Rice mill has installed separate earthing system for every power distribution panels
located in each lines & other areas. .The said earthing is connected to two separate earthing pits
adjacent to building for grounding earthing wires. However since last many years no assessment
is made to ascertain the effectiveness of earthing strips..
5.2 OBSERVATION & ANALYSIS
a.. No physical inspections or regular cares are carried out to ascertain the effectiveness of
earthing system.
b.Earthing pits are rarely inspected by plant personnel and no measurement of earth resistance
are being carried out since last many years.
5.3 ACTION SUGGESTED
It is our considered recommendation that all parallel earthings of various sections/locations are
to be inter connected immediately so as to improve the effectiveness of installed earthing system.
The said interconnection should be carried out with 1 inch Aluminum or MS flats. This would
augment present earthing system and improve overall protection.
It is our considered suggestion that regular monitoring & inspection of earthing pits is essential
at least once in 3years. The frequency of Earth resistance & Voltage measurement should be
carried out once in 3 years.The organization may approach some local agency to carry out above
said inspection & measurement.
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6.0 GENERAL MAINTENACE & PREVENTION OF BREAK-DOWNS
6.1 STATUS REVIEW
The organization is equipped with number of electrical mototors, Distribution Board/panels *&
motor starters. To cater the power requirement of entire mill.Presently as and when equipment
fails, electrician is called for the necessary repair and maintenance. This is a time consuming and
SAS type maintenance repair arrangement and call for review.
It has been observed during audit period that most of the distribution boards/panels are filled
with fine dirt & dust particles which seeped through joints and gaskets of panel board, switches
and starters. The said dirt and dust deposits are injurious to the health of the electrical system and
accelerate faults. Further electric motors are muscles of production & are taken them granted
because they usually perform so well. But when a motor fails, entire machine and some time
system goes down. Break downs are quite frequent & causes significant production loss.
6.2 ACTION SUGGESTED
In view of above, a strong possibility was exlored to initiate a preventive care for electrical
equipment to enhance the reliability and minimize the outage of plant machinery.
a.It is our considered suggestion that management should initiate preventive care (maintenance)
with help of a semi skilled workers which would be supplied with air blower, pliers and a set of
spanner to clean all the distribution panel, motor starter and electric motors with following
regular frequency :
Normal season Frequency of cleaning should be once in 15-20 days month
Peak season Frequency of cleaning should be once in 7-8 days
B .Electric motors fitted with grease nipple must be lubricated with grease gun at least once in
six months.
c. Gear Box/Radicon Gear box: The lubricant of Gear box must be topped to maintain minimum
level on regular basis.
c. Cleaning o f suction air filters of Air compressor must be done at -least once in a month
to main good performance.
Place: Kolkata
Date: 26.07.2012
For V SRAI ASSOCIATES-ENERGY MANEGEMENT CONSULTANTS
V . S. RAI
V S RAI ASSOCIATES-ENERGY MANAGEMENT CONSULTANTS