SAVINGS THROUGH VFD’s SAVINGS THROUGH COMPRESSORS & CHILLING PLANT SAVINGS BY REPLACING DYNO DRIVES MOTORS WITH INDUCTION MOTORS & SPEED CONTROL WITH VFD’s. SAVINGS THROUGH ENERGY EFFICIENT MOTORS SAVINGS THROUGH ENERGY EFFICIENT PUMPS SAVINGS THROUGH TUBE WELL RUN HRS & REPLACING INEFFICIENT WATER PUMPS SAVINGS THROUGH OPTIMIZATION OF EQUIPMENTS

1. ENERGY CONSERVATION INITIATIVES (TEAM Unit– Shree Gopal)
ENERGY CONSERVATION INITIATIVES IMPLEMENTED

2. ENERGY SAVING IDEAS IMPLEMENTED
SAVINGS THROUGH
VFD’s

3. ENERGY SAVING IDEAS IMPLEMENTED
S. No. Description Gain Photo
1. Installation of VFD at 37 KW Power saving of 11 KW
Hydra treated pump PM-5,7.
Power reduced from 33 to 22
KW.
2. Installation of VFD at 67KW Power saving of 9 KW
water supply pump to PM-5,7.
Power reduced from 50 to 41
KW.
3. Installation of VFD at 55KW Power saving of 16 KW
Specialty back water tank
pump supplying to pulp mill.
Power reduced from 40 to 24
KW.
Sheet Total=36kWh

4. ENERGY SAVING IDEAS IMPLEMENTED
S. No. Description Gain Photo
4. Installed VFD for 55KW Vat Power saving = 9 kWh
Dilution Pump of BSW-1 in
pulp Mill and started at 45HZ.
Power reduced from 33 to 24
KW.
5. Installed VFD at 45KW Cooling Power saving = 18 kWh
Tower pump of PM-7 and
started at 42HZ. Power
reduced from 40 to 22 KW.
6. Installation of VFD at 67KW Power saving = 11 kWh
Fan pump PM-7. Power
reduced from 33 to 22 KW.
Sheet Total=38kWh

5. ENERGY SAVING IDEAS IMPLEMENTED
S. No. Description Gain Photo
7. Installed VFD at 11KW B/L Power saving of 3KW
supply pump. Power reduced
from 9 to 6 KW.
8. Installed VFD at 45KW Couch Power saving=14 KW
Pit Pump PM-4 , Average
power consumption got
reduced from 25KW to 11KW.
9. Installed VFD at 45KW stock Power saving=6KW
chest pump pulp mill. Power
reduced from 30-24=6KW.
10. Provided VFD at 75KW Decker Power saving of 12 KW
MC pump in pulp mill.
Power reduced from 60 to 48
KW.
Sheet Total=35kWh

6. ENERGY SAVING IDEAS IMPLEMENTED
S. No. Description Gain Photo
11. Provided VFD at 30KW 10m3 Power saving of 8KW
FRP tank back water pump
motor. Power reduced from 21
kWh to 13 kWh.
12. Provided VFD at 22KW Clear Power saving of 9 KW
water pump at PM-4. Power
reduced from 19kWh to
10kWh.
13. Provided VFD at 15KW Cloudy Power saving of 5KW
water pump at PM-4. Power
reduced from 10kWh to 5kWh.
Sheet Total=22 kWh

7. ENERGY SAVING IDEAS IMPLEMENTED
S. No. Description Gain Photo
14. Provided VFD at 75KW B-6 Power saving of 12KW
effect pump soda recovery
evaporator house. Power
reduced from 52kWh to
40kWh.
Sheet Total=12 kWh
TOTAL SAVING THRO’ VFD’s
143 KW

8. ENERGY SAVING IDEAS IMPLEMENTED
SAVINGS THROUGH
COMPRESSORS & CHILLING PLANT

9. ENERGY SAVING IDEAS IMPLEMENTED
S. No. Description Gain Photo
1. Two 1000CFM & one 500CFM Power saving of 72 kWh
compressors were running for
PM-5, 7&Pulp mill. Over
hauled these compressor,
replaced air header PM-7,
plugged air leakages at various
locations in plant. With this
one extra running 500 CFM
compressor has been stopped.
Power reduced from 367 to
295KW.
2. Over hauled all three 500CFM Power saving of 50 kWh
compressor of Soda recovery.
Plugged air leakages at various
locations in plant. With this
one 500 CFM 90KW
compressor has been stopped.
Power reduced from 142 KW
to 92 KW.
Sheet Total=122kWh

10. ENERGY SAVING IDEAS IMPLEMENTED
S.
Description Gain Photo
No.
3. Installed Elgi compressor 5 HP for sludge Power saving of
filter soda recovery separately. Where 5Kg 18kWh
pressure was required, where as for other
areas of soda recovery 3Kg pressure was
required. This has reduced working
pressure of one compressors of 90KW.
Power reduced from 92 to 74 KW.
4. Old inefficient chilling unit replaced with Power saving of
energy efficient chilling unit at PM-7 and 18 KW
by changing its location just below
machine calendars for reducing losses in
line bends and line length. Power reduced
from 34 to 16 KW
Sheet Total= 36 kWh
TOTAL SAVING THRO’ COMPRESSORS
& CHILLING PLANT
158 KW

11. ENERGY SAVING IDEAS IMPLEMENTED
SAVINGS BY REPLACING DYNO DRIVES MOTORS
WITH
INDUCTION MOTORS & SPEED CONTROL WITH VFD’s.

12. ENERGY SAVING IDEAS IMPLEMENTED
S.
No Description Gain Photo
.
1. Replaced 20 Nos. variable speed inefficient Power saving
dyno drive motors with energy efficient =30 KW
normal induction motors by controlling its
speed with VFD at following locations:-
(a) 6 No Silo Screw extractors of chipper
house 7.5KW each power saving 12KW
(b) 5 No. Wire shaker motors of 3.7KW of all
5 paper machines Power saving 7.5 KW
(c) 6 No. Rectifier rolls motors 2.2KW each
of PM-4, 5 & 7 power saving 3 KW
(d) 3 No Maloney filters motors 11KW each
of Soda recovery, PM-4 & PM-5 power
saving 7.5 KW
TOTAL SAVING BY REPLACING
DYNO DRIVE MOTORS
30 KW

13. ENERGY SAVING IDEAS IMPLEMENTED
SAVINGS THROUGH
ENERGY EFFICIENT MOTORS

14. ENERGY SAVING IDEAS IMPLEMENTED
No. Description Gain Photo
1 Replaced A class open type inefficient Power saving of
motors with F class energy efficient motors 26KW
at 17 locations mill wide after
reconsidering their actual power
requirement of equipment.
2. Replaced Broke Refiner open type A class Power saving of
motor 65KW 1000 RPM with F class 37 KW 20KW
750RPM after taking trial with VFD of PM
4. Power reduced from 42kWh to 22kWh.
Sheet Total= 46 kWh
TOTAL SAVING THRO’ ENERGY EFFICIENT
MOTORS
46 KW

15. ENERGY SAVING IDEAS IMPLEMENTED
LIST OF MOTORS REPLACED WITH NEW ENERGY EFFICIENT MOTORS IN FY_-2010-11
No. EQUIPMENT NAME RATING SAVING NO. EQUIPMENT NAME RATING SAVING
THICK BLACK LIQ TANK AGIT
1 10 CAUSTIC PUMP OLD EVAP.HOUSE 0.7
S/R 22 1.2 7.5
BLEACHED STOCK CHEST
2 11 PULP TRANSFER PUMP PM-4
PUMP 11 0.8 55 2.5
MIXING CHEST -1 AGITATOR PM-
3 STOCK CHEST-5 AGIT PM-4 12
22 1 4. 22 1.2
4 STUFF PUMP-1 PM-2 13 SMALL W.L.PUMP-1 DOOR PLANT
15 0.6 7.5 0.5
SERVICE PUMP NO.2 PUMP LIME TANK-1 AGIT. CHEMICAL
5 14
HOUSE 75 3.5 HOUSE 7.5 0.75
LIME TANK-2 AGIT.CHEMICAL
6 B.W.PUMP-2 PM-1 15
22 1 HOUSE 7.5 0.75
7 STUFF PUMP PM-1 16 REFINER PM-2
18.5 1 63.75 3.5
8 PULPER NO.1 PM-2 17 COMPRESSOR SODA RECOVERY
37 1.5 90 4
TOTAL 26
9 PULPER NO.2 PM-2
37 1.5

16. ENERGY SAVING IDEAS IMPLEMENTED
SAVINGS THROUGH
ENERGY EFFICIENT PUMPS

17. ENERGY SAVING IDEAS IMPLEMENTED
S.
Description Gain Photo
No.
1. Replaced inefficient 67KW pump of water Power saving = 18
supply to PM-5,7 with energy efficient kWh
pump & with new lines. Also started VFD
in close loop by providing pressure control
switch with setting of 2.1Kg pressure.
Power reduced from 50 to 32KW
2. Replaced inefficient 75KW water supply Power
pump of PM-1,2 with energy efficient saving=9KW
pump and started in close loop with
pressure of 1.5Kg. Power reduced from 50
to 41KW
3. Replaced inefficient pump of 110KW Blow Power saving of
tank stock pump pulp mill with new 10KW
efficient one Power reduced from 80 to 70
KW.
Sheet Total= 37 kWh

18. ENERGY SAVING IDEAS IMPLEMENTED
S. No. Description Gain Photo
4. Replaced inefficient 55KW Power saving of 10 KW
pump of Bleached stock chest
PM-4 with energy efficient
pump. Average power
consumption got reduced from
34KW to 24KW.
5. Replaced inefficient 30KW Power saving of 5 KW
pump of back water PM-4 with
energy efficient pump. Power
reduced from 22 to 17KW.
Sheet Total= 15 kWh
TOTAL SAVING THRO’ ENERGY EFFICIENT
PUMPS
52 KW

19. ENERGY SAVING IDEAS IMPLEMENTED
SAVINGS THROUGH
TUBE WELL RUN HRS & REPLACING INEFFICIENT WATER PUMPS

20. ENERGY SAVING IDEAS IMPLEMENTED
S. No. Description Gain Photo
1. Unit SGU was meeting its Power saving 93 KW BEFORE
water demand thro’ installed
19 No. bore wells (130M3/Ton
of Paper) by running 16 bore
wells continuously. Through
various actions on water
conservation & by replacing
inefficient vertical 45KW bore
wells with 37KW submersible
water pumps at new locations AFTER
with increased water flow, we
are now meeting our water
demand by running 13 bore
wells only.
1) Water conservation
actions.
2) Waste water management.
3) Utilization of treated
effluent
Sheet Total=93kWh

21. ENERGY SAVING IDEAS IMPLEMENTED
FOLLOWING INITIATIVES WERE TAKEN FOR WATER CONSERVATION MILL WIDE
1 Re-use of pope reel & 6 Re-use of vacuum pump 11 Push button type taps
compressor cooling water. water by passing thro’ provided in bath rooms &
cooling tower. toilets of mills.
2 Re-use of barometric 7 Re-use of machine back 12 Re-use of treated effluent in
condenser water Clo2 in water for pulp dilution. jet condenser chemical
pulp mill. house.
3 Use of disc save all clear 8 Wood log washing with 13 Installed level controllers in
water on wire showers PM-4. treated effluent water. pumps to avoid overflow.
4 Re-use of treated effluent for 9 Ash quenching with treated 14 Thickener shower of PM-1,2
gardening in mills & colony. effluent water. replaced with new showers.
5 Re-use of D1 filtrate on E/O 10 Use of Macstar packing in TOTAL POWER SAVING = 93kWh
screw conveyor for pulp pump glands for reduction WATER CONS.100M3/TON PAPER
dilution. in water consumption.
TOTAL SAVING THRO’ TUBE WELL RUN HRS
& REPLACING INEFFICIENT WATER PUMPS
93 KW

22. ENERGY SAVING IDEAS IMPLEMENTED
SAVINGS THROUGH
OPTIMIZATION OF EQUIPMENTS

23. ENERGY SAVING IDEAS IMPLEMENTED
S. No. Description Gain Photo
1. Filtrate tank pump made shut at PM- Power saving 5 KW
1,2 by transferring back water by
gravity with modification in pipe line.
2. Speed reduction of Pressure Screen Power saving 19KW
PM-4 by changing motor pulley.
3. Started KVM-600 Vacuum pump PM- Power saving 36KW
4 and stopped KVM-900 Vacuum
pump. Consumption reduced from
110kWh to 74kWh.
4. Decreased run time of two Foam Power saving 2 KW
breakers in NPM of running 6KW
each. These were running for 30 min
and shut for 30min. Now these are
running for 30min & shut for 1 Hr.
Saving 4 HrsX6X2KW
Sheet Total = 62 kWh

24. ENERGY SAVING IDEAS IMPLEMENTED
S. No. Description Gain Photo
5. Replaced suction fan of Power saving=1KW
secondary conveyor of Sheeter
no.2 BCP from 2.2KW to
0.55KW and has saved 1KW.
OLD NEW
6. Optimized speed of white Power saving of 5 KW
liquor supply pump after
taking trial with VFD &
replaced pulley of motor
accordingly.
Sheet Total=6 kWh
TOTAL POWER SAVING BY OPTIMIZING
EQUIPMENTS
68 KW

25. ENERGY SAVING IDEAS IMPLEMENTED
SAVINGS THROUGH STOPPING EQUIPMENT
AFTER
OPTIMIZATION OF OTHERS RUNNING

26. ENERGY SAVING IDEAS IMPLEMENTED
S. No. Description Gain Photo
1. Connected water lines of high Power saving of 21 KW
pressure pump PM-7 with PM-
5 high pressure pump &
stopped PM-7 H.P.Pump .
PM-5 H.P.Pump running for
PM-5 only= 25 KW
PM-7 H.P.Pump= 22 KW
PM-5 H.P.Pump running for
PM-5 & 7 M/C = 26 KW
2. Installed new 132 KW KVM Power saving of 15 KW
900 Vacuum pump at PM-7
resulted to shut of two
inefficient 90 KW vacuum
pumps consuming 65KW each.
Power saved 15 KW.
3. Shut one1000KVA transformer Power saving of 4 KW
of finishing house running at
30% load by shifting its load to
other under loaded
transformer at PM-4. Power
saving 4 KW.
Sheet Total=40kWh

27. ENERGY SAVING IDEAS IMPLEMENTED
S. No. Description Gain Photo
4. Stopped one paper rewinder Power saving of 25KW
no.1 of PM-4 which was
consuming average 25KW
power by optimizing
production at other three
rewinders.
5. Stopped trim nozzle pump at Power saving of 4KW
PM-2 by connecting line with
H. P. Oscillating shower PM-1.
With this common operation
saved 4 KW.
6. Three 250KW refiners were Power saving of 148KW
running for common
operation of PM-1, 2 (178KW +
190 KW + 200 KW). Stopped
DDR 2 (20”) 250KW refiner
permanently which was
consuming 190 KW power, by
optimizing refining on other
two 250KW refiners. Net
power saving 148KW.
Sheet Total=177 kWh

28. ENERGY SAVING IDEAS IMPLEMENTED
S. No. Description Gain Photo
7. Two refiners 250 & 110KW Power saving=40KW
were running for PM-7
(158KW + 90 KW). Stopped
110KW refiner permanently by
increasing refining on 250KW
refiner. Net power saving
achieved = 40KW.
Sheet Total=40kWh
TOTAL POWER SAVING BY STOPPING EQUIPMENT
AFTER OPTIMIZATION OF
OTHERS RUNNING
257 KW

29. ENERGY SAVING IDEAS IMPLEMENTED
SAVINGS THROUGH AUTO CONTROL
OF
EQUIPMENTS INSTEAD OF MANUAL CONTROLS

30. ENERGY SAVING IDEAS IMPLEMENTED
FOLLOWING VFD’s OF PULP MILL HAS BEEN STARTED IN CLOSE LOOP IN DCS TO SAVE POWER
S.
Description Gain Photo
No.
1. CD tower launder dilution pump Power saving of 1.3 KW
pulp mill 30KW.Saving= 26.3-25 =
1.3KW
2. EO tower dilution pump pulp mill Power saving of 1.7 KW
37KW.Saving=26-24.3= 1.7KW.
3. EO tower stock pump pulp mill Power saving of 1.3 KW
37KW.Saving=15-13.7=1.3KW
4. EO washer Vat dilution pump pulp Power saving of 2.7 KW
mill. Saving=25-22.3= 2.7KW
5. D2 tower launder dilution pump Power saving of 5.0 KW
pulp mill. Saving=27-22= 5.0KW.
6. P4 warm water BHR area pulp mill Power saving of 1.7 KW
30KW. Saving=16-14.3= 1.7KW.
7. D1 launder dilution pump P.Mill Power saving of 1.3 KW
45KW. Saving=30.7-29.4= 1.3KW.
Sheet Total=15kWh

31. ENERGY SAVING IDEAS IMPLEMENTED
S. No. Description Gain Photo
8. Started VFD of P.Mill fresh Power saving of 6.0 KW
water supply pump in close
loop of pressure.
Saving=62-56= 6KW.
9. Provided emergency stop for Power saving of 2.0 KW
stopping cooling fan PM-7
rewinder DC motor when not
in use. Saving=2-0= 2 KW.
10. Modified control circuit of Power saving=6 KW
warm water pump P.Mill &
hooked up with level from
DCS. Saving = 18-12=6 KW.
Sheet Total=14kWh

32. ENERGY SAVING IDEAS IMPLEMENTED
TOTAL SAVING THRO’
AUTO CONTROL OF EQUIPMENTS
INSTEAD OF MANUAL CONTROLS
29 KW

33. ENERGY SAVING IDEAS IMPLEMENTED
SAVINGS THROUGH
VOLTAGE & FREQUENCY OPTIMIZATION

34. ENERGY SAVING IDEAS IMPLEMENTED
S. No. Description Gain Photo
1. Earlier many motors in plant were open type Power
‘A’ class having voltage rating 425-440V. But saving of
now maximum motors are replaced with ‘F’ 150 KW
class rating having voltage level 415V and will
give maximum efficiency at 415V. Reduced
voltage from 11KV to 10.7KV & 6.6 to 6.4 KV
and frequency from 49.9 HZ to 49.3 HZ of both
sources 11KV TG & 6.6KV BTH turbines. Also
adjusted transformer tap changer switches at
few locations as per required voltage. Power
saving 90 + 60 = 150 KW.
Sheet Total=150 kWh
TOTAL SAVING THRO’
VOLTAGE & FREQUENCY OPTIMIZATION
150 KW

35. ENERGY SAVING IDEAS IMPLEMENTED
SAVINGS THROUGH
LIGHTING & OTHERS

36. ENERGY SAVING IDEAS IMPLEMENTED
S. No. Description Gain Photo
1. Provided MCB for putting of all Power saving of 5 KW
lights of pulp mill, PM-5,7
mech. workshop, drive rooms,
electrical centers &
transformer rooms. etc. Total
10KW load will be saved for 12
Hrs. Net Saving=5KW
2. Provided MCB in cable gallery Power saving of 2.0 KW
& HT switchboard of pulp mill.
2KW will remain shut for
24Hrs.Net saving = 2KW
3. Replaced 120 chokes of Power saving of 2.0 KW
fluorescent tubes with
electronic chokes. Power
saving 2KW
BEFORE
AFTER
Sheet Total=9 kWh

37. ENERGY SAVING IDEAS IMPLEMENTED
S. No. Description Gain Photo
4. Interacted with workmen of Power saving of 3.0 KW
various departments mill wide
after identification and
marking lights to be put off
when not required in day
time. Power saving = 6 KW for
12 Hrs. Net power saving =
3KW.
5. Restructured street light Power saving of 2.0 KW
circuits in mills near canteen
PM-1, mechanical workshop
pulp mill & chipper house
area. Saving = 2KW
6. 1000 Watt Halogen lights for Power saving=4 KW
Load Break Switches removed
after installation of OCBs at
four transformers. Saving = 4
KW.
Sheet Total = 9 kWh

38. ENERGY SAVING IDEAS IMPLEMENTED
S. No. Description Gain Photo
7. Provide 20 MCBs for main Power saving of 1.0KW
power supply at the doors of
offices, halls, So that complete
power can be switched off
while moving out. Power
saving = 1KW
8. Transparent fiber sheets on Power saving of 6.0KW
roof sheds at Pulp godown,
New syn. Sheeter area, new
dispatch section, stores etc.
Power saving 12KW for 12 Hrs.
Net power saving = 6KW
Sheet Total=7 kWh
TOTAL SAVING THRO’
LIGHTING & OTHERS
25 KW

39. TOTAL SAVING WITH ENERGY SAVING IDEAS IMPLEMENTED
SR. SAVING
SAVING THROUGH
NO. IN kWh
1. VFD’s 143
2. Compressors & Chilling plant. 158
3. Replacing Dyno Drive motors with induction motors &
30
speed control with VFD’s
4. Energy efficient motors. 46
5. Energy efficient pumps. 52
6. Tube wells run hrs reduced thro’ water saving & by
93
replacing inefficient water pumps mill wide.
7. Optimization of equipments 68
8. Stopping equipment after optimization of others running. 257
9. Auto control of equipments instead of manual controls. 29
10. Voltage & Frequency optimization 150
11. Lighting & Others. 25
TOTAL = 1051 kWh