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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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CONTENTS
SECTIONS

DESCRIPTION

PAGE NO.

Summary of Findings

1.0

Power scenario at the Rice mill

2.0

Power Requirement with CPP

3.0

Power distribution & PF improvement

4.0

Compressed Air at Color sorting machine

8
10
5.0

Electrical safety audit & precaution

6.0

General maintenance & Prevention of break downs

11
12

Annexure I-II

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SUMARY OF FINDINGS
Ref no.

Action Suggested

1.0
2.0

Power scenario of rice mill operation is

illustrated
Power requirement with envisaged CPP

3.0
4.0
5.0
6.0

Recurring
Budgetary
Saving/year
Investment
Rs.
Rs.
Details are specifically illustrated

Page
No

Details are specifically illustrated

Power distribution & PF improvement

167000

52500

Reduction of Air pressure from 7.0

Kg/cmto 5.0 kg./cm
Interconnecting Present Earthing system

60200

nil

10

Initiate cleaning schedule for Electrical

Equipment

Total

Specific suggestions are made to

improve safety of electrical
system.
Specific measures are made to
minimize break downs.
Rs.2,27,200/year Rs. 52,500

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CONSULTANTS

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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
i.Arua ketel
ii.Arua section
iii.Old mill with
Dryers
iv. New mill with
dryers
v.color sorting with
air compressor
vi Boiler
vii.Other Misc
(Lighting, Packing
etc)
Total Load

Connected HP
22.5
172.5
222+27

Connected-KW
16.785
128.68
165.612+20

116.5+20

86.909+15

40

30

30
47

22
35

697.50 HP

519.986 KW

Remarks
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

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
i.New line with dryers
ii. Old line with

Running loadKW
90
135

Running LoadKVA
96
143.9

Remarks
i.Total actual running load with
two lines ( parboiling

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dryers
iii.Colour sorting m/c
with Compressor
iv Boiler section
v. Other misc load
Total load
Proposed load with
Arua section& ketel
Total Plant running
load

30

33

10
35
300 KW
110

10.70
37
320.06 KVA
120

410 KW

440 say 450KVA

Operation was found to the

order of 300KW.
ii. Power was found to the
order of 0.94-0.96.

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.
ii.
iii.
iv.
v.
vi.

Running load of entire Rice mill

= 410 KW
Running power demand of entire rice mill =450 KVA
Considering 10% misc loadd, the power requirement would be =460 Kw or 515 KVA
( 410+50 Kw)
Maximum power demand with starting kick load=645 KVA say 650 KVA
( 515x1.25 )
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
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.
b.
c.
d.

Sanctioned power demand = 200 KVA

Running power demand
=384-480 KVA
Power Factor
= 93-94%
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
Power
0.55factor
0.61

Main
I/C
panel
line.-2
0.0.490.60

Polishing
Motor-1
30HP

Polishing
Motor-2
30HP

Polishing
Motor-3
30HP

Polishing
Motor-4
30HP

Silky
50HP

Dryers.
No.1

0.74

0.46

0.35

0.63

0.82

0.65

Equipments Dryers
No2

Air
Blowers

Power
factor

0.0.600.75

0.700.77

Air
Boiler
Comp.
panel
18.5 Kw
0.55-0.87 063-.071

LT Trs
O/G

Remarks

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:
Particular Line-1
PDB
Capacitor 20
-Kvar

Line-2
PDB
20

Line-3
PDB
20

Dryer
PDB-1
7.5

Dryer
PDB-2
7.5

Boiler
PDB
5

Sortex
PDB
10

Other
PDB
10

Total
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 NM/minute capacity to generate
compressed air at 7 kg/cm. 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/cm. 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
Phase-I

Present air generation

Cut off prs.
Restart prs
7.2 kg/cm
5.5kg/cm

Proposed air pressure

Cut off prs.
Restart prs.
6 kg/cm
5.5 kg/cm

Reccurring
saving/year
Rs 36000

Phasr-II

7.2 kg/cm

5 kg/cm

Rs 61250

5.5kg/cm

4.5 kg/cm

4.2 ANTICIPATED BENEFIT

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CONSULTANTS

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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
should be reduce to 6 kg/cm and later on the air pressure setting should be restricted to 5 kg/cm
only.
4.3 RECOMMENDATION
It is strongly recommended to reduce the operating pressure of sorting air compressor from 7
kg /cm to5 Kg/ cm 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
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carried out once in 3 years.The organization may approach some local agency to carry out above
said inspection & measurement.
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
Peak season

Frequency of cleaning should be once in 15-20 days month

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
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CONSULTANTS

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V . S. RAI

V S RAI ASSOCIATES-ENERGY MANAGEMENT

CONSULTANTS