Detail Energy Audit Report-Draft-Pradeep Rice Mill

Draft
Comprehensive Energy Audit Report
DULIELLA TEA
FACTORYPRADEEP RICE MILL
NeluwaSaliyapura
Comment [l1]: Deleted
PreparedforPrepared for
Comment [NPEJ2]: Delete
INSTITUTE OF POST HARVESTING
Formatted: Font: (Default) Calibri, 11 pt, Sm

caps
and
Formatted: Font: (Default) Helvetica
By
for Sustainable Tomorrow
ISB
Industrial Services Bureau (ISB)
Comprehensive Energy Audit - Draft Report

FactoryPradeep Rice Mill
Duliella
Tea
JUNE FEBRUARY 20143
ABBREVIATIONS
CEB
hr
ISB
SLSEA
PADGO
kg
V
kVA
kVAr
kW
kWh
MT
GL
SEEC
SDC
SLPGC
HWG
E
T
H
M
L
I
ST
LT
nos.
M
Ceylon Electricity Board

Hours
Industrial Services Bureau
Sri Lanka Sustainable Energy Authority
Portfolio Approach to Distributed Generation Opportunities
Kilograms
Voltage
Apparent power
Reactive power
Active power
Kilowatt hours
Made Tea
Green Leaf
Specific Electrical Energy Consumption
Specific Diesel Consumption
Specific LP Gas Consumption
Hot Water Generator
Electrical
Thermal
High
Medium
Low
Immediate (less than 6 months)
Short Term (less than 1 year)
Long Term (less than 3 years)
Numbers
Million
Industrial Services Bureau (ISB) - Kurunegala, Sri Lanka
II

Duliella
Tea
III

Duliella
Tea
ACKNOWLEDGEMENT
Industrial Services Bureau (ISB) wishes to express its gratitude to International Finance
CorporationInstitute of Post Harvest Technologies (IFCIPHT) and Sri Lanka Sustainable Energy
Authority (SLSEA) for giving itus an opportunity to conduct a comprehensive Energy Audit in
Duliella Tea Factory in NeluwaPradeep Rice Mill - Saliyapura.
Also, ISB would like to take this opportunity to thank Mr. D.P.C Swarnasiri Additional Director,
Research & Technology Transfer- IPHT Mr. N. JayasooriyaMahesh Dissanayake, Associate
Operations Officer Mechanical Engineer IFCIPHT, Mr M. M. R. Pathmasiri, Director Energy
Management -SLSEA and Mr V. Ekanayake, Professional Engineer-SLSEA for their support in
organizing the energy audit. Our heartfelt gratitude to MrW.Jinadasa-Chairman, MrM. D.
Premachandra-ManagerManager, and the all staff of DuliellaTea FactoryPradeep Rice Mill for
their assistance and cooperation extended to the Consultants of ISB during the Energy Audit
carried out at their premises.
Our sincere appreciation also goes to the Consultants who took a great effort in completing the
assignment within the stipulated time frame. Though their names are not specifically mentioned
here,wehere, we would also wish to thank all those who have helped us in numerous ways to
carry out this Energy Audit successfully.
ISB hopes that this report will help the management team of Duliella Tea FactoryPradeep Rice
Mill to have a greater awareness on the energy situation of the factory and to work towards
Energy Conservation & Management by implementing the recommendations of this report.
Industrial Services Bureau (ISB)

141, Kandy Road
Kurunegala, Sri Lanka
Tel
: 0094 37 22 237 21 ~ 3
Fax : 0094 37 22 23562
Email: info@isb.lk
Web : www.isb.lk
IV

Duliella
Tea
EXECUTIVE SUMMERY
This report is an outcome of the energy audit conducted at Duliella tea factory from .To .
June 2013 covering both electrical and thermal energy use with the intention of improving the
energy efficiency and reducing the energy demand.
In general, DuliellaTea Factory maintains a fairly satisfactorylevel of energy efficiency. They
have already implemented various energy efficiency measures such as introducing a capacitor
bank for Power Factor Correction and utilizing daylight in the trough area, utilizing gravity flow
for water supply,etc. However, energy efficiency could be further improved by implementing the
recommendations made in this report.
Adscriptionabout the present situation of energy usage and the observations made by the audit
team along with the recommendation for energy reduction and current baseline for energy
consumption are also indicated in this report.
DuliellaTeaFactory is a medium scale,low grown factory with orthodox tea manufacturing
process producing 2,000 -2,500kg of made tea per day. The factory is equipped with 14 troughs
for withering process, 7 rollers, 2 dryers and 3colour sorters for the production.
The Factorymeetsitselectricityneedsfrom the national grid via a 100 kVA transformer while
thermal energy needs from firewood bought rom outside suppliers. Diesel is used for
standbygeneratorof185 kVA capacity. Monthly average electricity bill of thefactoryamounts to
LKR400,000.00 and average monthly cost of firewood for the hot air generatorsamountstoLKR.
356,000.00.
Ithasfound that DuliellaTea Factory has a great potential forimproving the efficiency of energy
utilization. The estimated saving by implementing the energy efficiency improving measures
identified by the energy auditshall bearound30% which is approximately equivalent to a
financial saving of LKR 2.3 million per annum.The investments required towards these
improvements would be approximately xxx with a pay back period of xxx.
This could be further improved by high investments projects such as introducing bio mass
steam boiler system, Net Metering solar power system, etc. In such a case the investments
required would be around xxx, the savings would be around xxx per annum with a pay
back period of xxx.
ISB recommends that the low cost measures listed in this report with obvious savings be
immediately implemented.
Summary of recommended energy conservation measures, annual energy savings and cost savings are
given in the table below;
Comment [S3]: All costs in US $ also for

international audience
Comment [l4]: Done

Duliella
Tea
VI
Recommended
Energy Efficiency
Measure
Anticipated
Energy
Saving
Anticipated Annual
Financial Saving
(LKR)
Estimated Cost of
Implementation
(LKR)
Simple
Payback Period
in Years
Section
Comment [S5]: One coulumn for USD too
Comment [l6]: Included in USD
21,240 kWh
276,120.00
Nil
Immediate
R2. Introduce VSD controllers to troughs. The

factory could give the priority to trough no 1, 5,
6 9, 10 & 12 which are operated for longer
duration after reaching the withering condition
and rest after words.
24,108 kWh
313,000.00
1.2 M
2.5
R3. Load the troughs depending on their electrical Loading frequency should be 14, 11, 6, 1, 12, 2, 3, 10, 13, 9, 4.
efficiency as the hot air temperature is reaching
most of the troughs without any interruption.
R4. Introduce 2 kW high efficient (80% or higher)
motors (HEMs) for the process for future
replacements with light weight fans and a proper
overloading breaker system.
31,400 kWh
440,000.00
2.1 M
R5. Replace the oversize motors with 5 kW high

efficient motors (HEMs) which are with more
than 85% efficiency in future replacements along
with a proper overload breaker system.
22,600 kWh
317,000.00
1.6 M
5.1
R6. Introduce soft starters for the rollers to minimize

the sudden peaks during batch operation.
240 kVA
138,000.00
175,000.00
1.3
ROLLING
SECTION
R1. Operate troughs at their maximum carrying

capacities as per TRI norm which is 900 kg.
Therefore, one trough can be taken off from
operation under normal circumstances.
WITHERING SECTION
ELECTRICAL
R7. Introduce steam radiator system for the each

trough and avoid utilizing the main fan for
withering process.
22,764 kWh
318,600.00
1M
3.1
R8. Introduce7.5 kW high efficient (80% or higher)

motors (HEMs) for the process for future
replacements
4,552 kWh
63,700.00
250,000
3.9
R9. The norm is to run the compressors at the lowest

pressure to match the system need. Any
additional increase in 1 bar will increase energy
consumption around 8%. So operate the
compressors at 4-7 bar range.
5,672 kWh
79,410.00
Nil
immediate
R10. Connect the two tanks of Meiji compressors to

the Hansi compressor and operate the all colour
sorter with it while keeping the Meiji
compressors standby.
5,190 kWh
72,600.00
Nil
immediate
R11. OR
7,600 kWh
106,400.00
700,000.00
DRYER
SECTION
Duliella Tea Factory
SIFTING SECTION
Introduce a screw compressor with 1500 liters/

minute coupled with an air dryer and an air
receiver and operate at 4-6 bar range.
This will contribute to reduce the sudden peaks in the maximum demand
R13. Introduce separate breakers for key sections This is contributing to work towards
along with electricity meters and connect to the energy saving in future
sub breakers and record the sectional power
consumption daily.
LKR 350,000
MAIN PANEL
R12. Increasing the awareness of the employees on

the maximum demand variation.
VIII
R14. Introduce a automatic synchronous change over

for the generator
240 kVA
264,000.00
400,000.00
1.5
R15. Introduce a 50 kW net metered solar power

system for the premises.
72,000 kWh
100,800.00
10 M
100,000.00
5 months
SUB-TOTAL
MAIN
PANEL
2.40 M
THERMAL
R16. Implement
W
a firewood shed for the day stock
Repair the roof
74,589 kg
298,359.00
DRYER SECTION
a FIFO system and educate the feeding

R17. Introduce
W
team to maintain
R18. Store
W the split firewood under the shed for at
least 3 weeks before feeding to the dryer
R19. Introduce
W
a moisture meter to the firewood yard
and feed firewood with at least 25% moisture.
R20. Introduce a multi fuel bio mass boiler and along

with a steam radiator system where rice husk,
saw dust, firewood and etc which could be
utilized for thermal energy generation.
570,000 kg
1.5 M
SUB-TOTAL
1.53 M
GRAND TOTAL
3.93 M
6M
IX
Comment [S7]: Seems incomplete

Comment [l8]: Accepted and Completed
Comment [S9]: At least?

Comment [l10]: Less than 25%
The tables below compare thepresent situation and the specific energy consumption figures with industrial
benchmarks;
Parameter
Present Consumption /
Situation
Potential Savings
Percentage
Savings
Electrical Energy
kWh
402,000
137,000
32%
kVA
1,061
480
45%
1.15 M
74,000 kg
6.4%
1.15 M
640,000 kg
55%
Thermal Energy
Firewood
(without
Biomass Boiler)
Firewood
(with
Biomass Boiler)
Parameter
Specific Electrical Energy

Consumption (SEEC)
Specific Thermal Energy
Consumption (STEC)
Consumption (STEC)
Specific Firewood
Consumption (SFWC)
Specific CO2 Emission
(SCO2E)
Factory Baseline
SLSEA Baseline
SWITCH-Asia
Baseline for Low
Grown
0.71
0.63
0.69
kWh/ kg of MT
kWh/ kg of MT
kWh/ kg of MT
7.04
8.05
kWh/ kg of MT
kWh/ kg of MT
25.33
kJ/ kg of MT
2.036
1.78
2.44
kg / kg of MT
kg/ kg of MT
kg / kg of MT
0.0069
Ton/ kg of MT
Content
ABBREVIATIONS ........................................................................................................................ II
ACKNOWLEDGEMENT ............................................................................................................. III
EXECUTIVE SUMMERY ............................................................................................................IV
CHAPTER 1:
INTRODUCTION AND BACKGROUND .................................................... 1
1.1
Background ....................................................................................................................... 1
1.2
Objective ........................................................................................................................... 1
1.3
Methodology Adopted for the Comprehensive Energy Audit .......................................... 1
1.4
General Details of the Factory .......................................................................................... 2
1.5
Energy Supply and Utilization ........................................................................................ 43
1.6
Instruments Used ............................................................................................................. 87
1.6.1
Energy Audit Team ..................................................................................................... 98
CHAPTER 2:
2.1
BREIF DESCRIPTION OF MAJOR ENERGY CONSUMING AREAS

109
Electrical Energy System .............................................................................................. 109
2.1.1
Demand profile and power quality ............................................................................ 119
2.1.2
Line Current Variation............................................................................................. 1310
2.1.3
Line Voltage Variation ............................................................................................ 1411
2.2
Thermal Energy System .............................................................................................. 1412
2.3
Main Energy Utilities .................................................................................................. 1512
2.3.1
Withering Section .................................................................................................... 1613
2.3.2
Rolling Section ........................................................................................................ 1714
2.3.3
Drying section.......................................................................................................... 1815
2.3.4
Sifting Section ......................................................................................................... 1816
2.3.5
Generator ................................................................................................................. 1917
CHAPTER 3:
ANALYSIS OF MAJOR ENERGY CONSUMING AREAS ................. 2018
XI
3.1
Electrical...................................................................................................................... 2018
3.1.1
3.1.2
Rolling Section ........................................................................................................ 2220
3.1.3
Dryer Section ........................................................................................................... 2321
3.1.4
Sifting Section ......................................................................................................... 2422
3.1.5
Main Panel ............................................................................................................... 2624
3.2
Thermal ....................................................................................................................... 2927
3.2.1
3.2.2
Drying Section ......................................................................................................... 3028
3.2.3
Generator ................................................................................................................. 3432
CHAPTER 4:
CONCLUSIONS AND RECOMMENDATIONS ................................... 3735
4.1
Recommendations ....................................................................................................... 3735
4.2
Conclusions ................................................................................................................. 4038
XII
List of Tables
Table 1: Baseline Comparison ......................................................................................................... 4
Table 2: List of Measuring Instruments Used during the Comprehensive Audit .......................... 87
Table 3: Details of the Withering Section.................................................................................. 1614
Table 4: Details of the Rolling Section ...................................................................................... 1715
Table 5: Details of the Air Heaters ............................................................................................ 1815
Table 6: Details of the Dryers .................................................................................................... 1816
Table 7: Details of the Colour Sorters ....................................................................................... 1916
Table 8: Power Consumption Analysis for the Withering Section ............................................ 2018
Table 9: Observation & Recommendation for Withering Section ............................................. 2119
Table 10: Power Consumption Analysis for Rolling Section .................................................... 2220
Table 11: Observation & Recommendation for Rolling Section ............................................... 2321
Table 12: Power Consumption Analysis for Dryer Section ....................................................... 2321
Table 13: Observation & Recommendation for Dryer Section ................................................. 2422
Table 14: Power Consumption Analysis for Sifting Room ....................................................... 2422
Table 15: Operational Condition Analysis of Colour Sorters .................................................... 2523
Table 16: Observation & Recommendation for Sifting Section ................................................ 2624
Table 17: Observation & Recommendation for Main Panel ..................................................... 2826
Table 18: CFM Details of the Withering Troughs ..................................................................... 2927
Table 19: Flue Gas Analysis for the Air Heater ........................................................................ 3028
Table 20: Energy Dissipation of the Hot Air Generator ............................................................ 3129
Table 21: Energy Dissipation of Dryer 1 ................................................................................... 3331
Table 22: Saving Percentages According to the Moisture Content of Firewood ...................... 3331
Table 23: Observation & Recommendation for Drying Section ............................................... 3331
Table 24: Results of the Flue Gas Analysis of Generator .......................................................... 3634
Table 25: Observation & Recommendation for Generator ........................................................ 3634
XIII
List of Graphs & Figures

Graph 1: Monthly Variation of the Baseline of Firewood and Electrical Energy Consumption ... 65
Graph 2: Energy Share of Duliella Tea Factory ............................................................................ 76
Graph 3: Energy Cost Share of Duliella Tea Factory .................................................................... 76
Graph 4: Monthly Variation of Energy Resources Vs Production (Made Tea) ............................ 87
Graph 5: Maximum Demand Variation ....................................................................................... 119
Graph 6: Variation of the Power Factor ..................................................................................... 1210
Graph 7: Line Current Variation of the Main Panel .................................................................. 1311
Graph 8: Line Voltage Variation ............................................................................................... 1411
Graph 9: Firewood Consumption Variation for an Operation Day ........................................... 1412
Graph 10: Electrical Energy Balance for a Day Operation........................................................ 1513
Graph 11: Firewood Utilization for a Day Operation ................................................................ 1613
Graph 12: Load Variation during a Day Operation ................................................................... 2725
Graph 13: Voltage Variation of the National Grid Due to Poor Power Quality ........................ 2725
Graph 14: Firewood Consumption Variation for a Day ............................................................ 3028
Figure 1: Shanky diagram of the Air Heater 1 ........................................................................... 3129
Figure 2: Shanky diagram of the Dryer 1 .................................................................................. 3230
Graph 15: Line Current Variation of the Generator................................................................... 3533
Graph 16: Line Voltage Variation of the Generator .................................................................. 3533
XIV
Comprehensive Energy Audit- Draft Report
CHAPTER 1:
1.1
INTRODUCTION AND BACKGROUND
Background
The tea sectorrice industry in Sri Lanka has always been a vital component of its economy. Rice
is the staple food of the inhabitants of Sri Lanka. Paddy crops are cultivated as a wetland
crop in all the districts. The total land devoted for paddy is estimated to be about 708,000
Hectares at present. There are two cultivation seasons namely; Maha and Yala which are
synonymous with two monsoons. Maha Season falls during North-east monsoon from
September to March in the following year. Yala season is effective during the period from
May to end of August. When the crop is sown and harvested during above periods, the
particular season is defined. However, the whole area devoted for paddy is not being
cultivated due to number of reasons such as shortage of water during the seasons,
prevailing unsettle conditions on the ground, etc.
Sri LankaAnuradhapura District is the world's thirdfourth largest producer of black tearice and
the industry is one of the country's districts main sources of foreign exchangeincome and a
significant source of income for employees, with tea accounting for 2% of the GDP of the
country with 2 million employed directly and indirectly comprising 10% of the Sri Lankan
population. There are about 700 tea factories in operation in the country.The tea industry is one
of the energy intensive food processing sectors consuming both electrical and thermal energy.
The sources of thermal energy are xxxxAccording to the statistics of Sri Lanka Sustainable
Energy Authority (SLSEA), the tea industry ranks 8 in terms of electrical energy use and is
responsible for 5.23% of the electricity consumption of the entire industrial sector in Sri Lanka.
Electricity is used to run machinery and thermal energy is used to reduce the moisture content of
green leaves from 70% 80% down to 3%.
1.2
Objective
The main objectives of the comprehensive Energy Audit are is to determine the current baselines
namely amount of electrical and thermal energy utilized, where they are being used and to find
out the most viable and practical ways of reducing the energy consumption and associated cost.
Any reduction in the energy consumption would also translate into lesser green house gas
emissions, reducing the carbon footprint of the factory operations. The report provides
suggestions to improve the energy efficiency and to overcome shortcomings associated with
energy utilities. Furthermore, this report intends to improve the awareness of managers &
technical staff of Duliella Tea FactoryPradeep Rice Mill on the importance of Energy
Management for the enhancement of the productivity.
1.3
Methodology Adopted for the Comprehensive Energy Audit
Step 1 - Document Review for Past Energy Data

During the walkthrough audit and subsequent kick off meeting with the factory personnel, the audit
team obtained an idea on the average energy consumption and costs involved. Records were reviewed
Comment [S11]: Is it only 2 %??

Comment [l12]: Extract from the TOR
Formatted: Font color: Red
Formatted: Font: 12 pt, Font color: Red
Comment [NPEJ13]: complete
Comment [l14]: Included
Formatted: Font: 12 pt, Font color: Red
to collect past data related to energy consumption as well as cost information for a period of past 12
months. The factory baseline energy consumption was established from past data to compare with the
country baselines.
Step 2 -Facility Inspection, Energy Monitoring and Evaluation
The major energy consuming units and processes were further investigated and field measurements
were taken to obtain operating parameters.
Step 3 - Identify/Evaluate Feasible Energy Conservation Mechanisms

A list of major energy conservation mechanisms along with key observations were developed for all
major energy consuming systems (i.e., withering, rolling, drying, lighting, siftingsoaking, drying,
milling, polishing, etc). Based upon a final review of all information and data gathered, and also
based on the operational requirements obtained from the factory personnel, a finalized list of energy
conservation measures was developed.
Step 4 Preparation of the Energy Report
The findings and recommendations are summarized in this energy audit report. The report includes a
description of the factory, itsits operation, a discussion of all major energy consuming systems, a
description of all recommended energy conservation mechanisms with their specific energy impact,
implementation costs, benefits and payback periods.
Step 5 Presenting the Audit Findings to Factory Personnel
The findings of the energy audit will be presented to factory personnel (especially to the energy
conservation team). All observations, current issues, recommendations and cost saving opportunities
together with contact details of prospective equipment and technology suppliers will be presented.
Step 6-Submition of Final Report
After receiving the comments/ feedbacks fromreviewing the draft report by ISB IFCconsultants, the
draft report will be revised and the final report will be submitted to IPHT.
1.4
General Details of the Factory
Company Name
Group
Address
Duliella Tea FactoryPradeep Agro Mart Rice

Mills Holdings (Pvt) Ltd
Andaradeniya Estate Pvt Ltd
District
Kosmilla, NeluwaSaliya Mawatha,

Anuradhapura.
Province
GalleAnuradhapura
Southern ProvinceNorth Central Province
Formatted: Font: 12 pt, Highlight
Contact Person
Mr. M.D. Premachandra
Designation
Manager
Contacts
Tel : 09125-5635003226065
09171-56350039684227
Fax Mob1 :
Formatted: Line spacing: single
Mob2 : 077-22936977915955
Year of establishment
19802013
Factory Classification
Elevation Technology : Low Grown Semi

Automated
Type of tea rice manufacture :Orthodoxparboiled

Rice
Factory Capacity
20,000 2,500 kg Made TeaRice per day
Key Machineries Available
Troughs
Dryer
- 141 nos.
Rollers
Boiler
- 17 nos.
Dryers
Polisher
- 2 1 nos.
Colour SortersDe Stoner

Husker
- 3 1 nos.
- 2 nos
Paddy Cleaner - 1 nos

Whitener
- 3 nos
Bran Separator - 2 nos
Approximate
Distance
ColomboEmployee Details
Colour Sorter
- 1 nos
Silky Polisher
- 1 nos
Grader
- 2 nos
Separator
- 1 nos
Formatted Table
from 220 kmDirectors -04

Managers- 06
Skill Workers- 50
Approximate Distance from Colombo
1.5
150 km
Energy Supply and Utilization
The energy recourses utilized in DuliellaTea FactoryPradeep rice mill are Electricity and Paddy
Husk, Firewood and Diesel. Firewood Paddy Husk is for drying and withering parboiling
processes and Diesel electricity is utilized for the standby generatormachinery.
Electricity to the factory is from the national grid via a dedicated transformer with 100 kVA
capacity under the Industrial Tariff 2 (I-2). A 185kVAcapacity standby generatorisinstalled for
emergency power requirement. There are 14 3 troughswhiteners, 7 1 rollers Huskerand3 , 1
compressors Polisher and a for colour sorters with compressor consuming the major part of
electricity.
Average maximum demand and the electricity consumption for the past 12months were 88 kVA
and 33,513 kWh respectively corresponding to the average monthly production of 46,960 kg of
Made Teaparboiled rice.The average firewood paddy husk consumption is 95,600 kilograms.
Thermal energy, which is generated from the burning of firewoodpaddy husk, is utilized for two
dryers of 270 kg/hr and 140 kg/hr capacitiesy. The hot airsteam generated is also utilized for
withering parboilig processes. 140 kg/hr air heater is kept as a standby unit for the drying
process. The hot air generatordryer operates almost 20 hours per day batch for both drying and
withering processes. Hot airSteam is supplied for withering parboiling process in order to
maintain the desired temperature difference between the dry and wet bulb temperatures and to
improve the withering process.

Comment [S15]: Per annum? Per month? Seem

the number mentioned in the below paragraph is
higher.
Comment [l16]: Per month
Comment [S17]: What is mix fire wood?
Mix firewoodPaddy Husk is used with the average moisture content of above 3510% for feeding
into the hot air generatorsteam boiler. The average monthly Paddy Huskfirewood consumption
for drying and withering parboiling process is around 105,000 kg. The Average purchasing price
of firewood is LKR. 950.00 per yard, whichisapproximately 293 kg.Paddy husk is available free
as a byproduct of the rice processing.
Table 1: Baseline Comparison
Comment [l18]: Changed to firewood. This is

local term for firewood with rubber firewood and
jungle firewood composition. The term was remov
from the report.

Parameter
Factory Baseline
SLSEA Baseline
SWITCH-Asia
Baseline for Low
Grown
Specific Electrical Energy

Consumption (SEEC)
0.71
0.63
0.69
kWh/ kg of MT
kWh/ kg of MT
kWh/ kg of MT
7.04
8.05

Consumption (STEC)
kWh/ kg of MT
kWh/ kg of MT

Consumption (STEC)
25.33
CHAPTER 2:
CHAPTER 3:
Formatted: Font: 12 pt, Font color: Accent 3

Highlight
kJ/ kg of MT
Specific Firewood
Consumption (SFWC)
Specific CO2 Emission
(SCO2E)
2.036
1.78
2.44
kg / kg of MT
kg/ kg of MT
kg / kg of MT
0.0069
CHAPTER 4:
CHAPTER 5:
Formatted: Highlight
Ton/kg of MT
Note: In two different contexts and occasions, Sri Lanka Sustainable Energy Authority (SLSEA) and SWITCHAsia Project established industry wide specific energy consumptions for the tea industry and the figures indicated
above are the industry average values based on two different samples of tea factories.
Table 1 compares the specific energy consumption of Duliella tea factoryPradeep Rice Mill with
that of two national level baselines. Though the specific electricity consumption of the Duliella
tea factory is slightly over the industry average as per the two sources indicated,still there is room
for further improvements, which will be described under the observation and recommendation
section. In case of thermal energy (firewood), there appears to be a higher potential for saving.
Formatted: Font: 12 pt, Not Bold, Highlight
The specific energy consumption for a tea manufacturing facilityrice milling facility is an
indicator giving of the energy consumption per for a unit of production which in this case is 1 kg
of Made Teaparboiled rice. The fluctuation of energy consumption with respect to production is
clearly highlighted in specific energy consumption figures.
Comment [S19]: Ok good.
You should recommend which baseline is relevan

more for this factory and what their targets should
be. This must be part of the exercise.
Comment [l20]: Better to take SWITCH basel

as it focused to low grown tea manufacturing
Formatted: Font: 12 pt
Comment [S21]: ?
Comment [l22]: removed
3.00
0.80
2.50
0.70
0.60
2.00
0.50
1.50
0.40
0.30
1.00
0.20
SFWC ( kg/kg of MT)
SEEC (kWh/ kg of MT)
0.90
0.50
0.10
-
Month
Specific firewood consumption variation
Specific electrical Energy Variation
Graph 1: Monthly Variation of Specific Firewood and Electrical Energy Consumption

The specific electrical energy consumption varies between 0.6 and 0.8 kWh per 1 kg of made tea
during the year 2012/2013. The highest figure wasin September and August 2012, and that
was0.80kWh per 1 kg of made tea. Therefore, the baseline for specific electrical energy
consumption for Duliella Tea Factory is 0.71 kWh per 1 kg of made tea.
The specific firewood consumption of Duliella tea factor varies between 1.2 and 2.84 kg per 1 kg
of made tea during the year 2012/2013. The highest value was in December 2012 and from
December 2012 to April 2013 specific firewood consumption was more than 2.3 kg per 1 kg of
made tea. This is mainly due to the increase of rainfall in those months, which contributes to
increased moisture in firewood xxxx . Since paddy husk is freely available in the factory, the
consumption was not recorded in the past. But the average specific paddy husk consumption per
1000kg of parboiled rice is xxxxx as per the analysis conducted by the ISB consultants.

The relationship between production and the electrical energy consumption is given by the
equation; Y = 0.303X + 19,283wherein; Y=electrical energy consumption in kWh & X=Made
Tea productionParboiled Rice in kg.

The relationship between production and the specific firewood consumption is given by the
equation; Y = 3.121X 50,967wherein; Y= firewood consumption in kg& X=Made Tea
production in kg.
Electrical Energy
11%
Thermal Energy
89%
Formatted: Font: Bold, Highlight
Graph 22: Energy Share of Duliella Tea Factory
Graph 2 explains the Energy Share of Duliella Tea Factory. Thermal energy is utilized in a
dominant way and it is 89%. This is a common situationin most of the Sri Lankan tea
factories.The thermal energy load for thefactoryis shared by firewood and diesel for the stand-by
generator. The Graph 3represents the resourcewise energy cost share for the factory and the
electricity is the major cost element (53%), followed by firewood which is 30%. Diesel shares
17% of the energy cost. This relatively high shareis mainly due to the frequent power
interruptions in the national electricity supply in the area where the factory is located.
Diesel
17%
Firewood
30%
Electricity
53%
Graph 33: Energy Cost Share of Duliella Tea Factory

60,000
160,000
140,000
50,000
120,000
40,000
100,000
30,000
80,000
60,000
20,000
Firewood (kg)
Electrical Energy (kWh) | Made Tea (kg)
40,000
10,000
20,000
Firewood Consumption (kg)
Month
Electrical Energy Consumption (kWh)
Made Tea (kg)

Graph 4: Monthly Variation of Energy Resources Vs Production (Made Tea)
According to Graph 4, the electrical energy utilization pattern is closely co related to the
production up to May 2012 from April 2013. The firewood consumption during the high rainy
season from December 2012 to January 2013 is very high which could be attributed to wet
firewood but it has a linear relationship during the rest of the period.
5.1
Comment [S23]: This can come as an annex .

Not here
Instruments Used
Comment [l24]: Included in the annex
Table 2: List of Measuring Instruments Used during the Comprehensive Audit

Instrument
Measuring Parameters
Flue Gas Analyzer
O2, CO, Combustion efficiency, CO2, NOx, SO2,NO, Excess

air, ambient temperature, Flue gas temperature
Type : Kane May

Make: UK
Data Loggers
Type : DENT Pro
Current, kW, Power factor, Voltage, kVAr, kVA, harmonics

(maximum, minimum, average, instantaneous, or all parameters
logging)
Make: USA
Thermometer K
Temperature (C /F)
Model: S 506
Make : India
Thermometer IR
Temperature (C /F)
Type: Hioke
Make:Japan
Rh logger
Type :Testo
Relative humidity, Temperature (C/F) (maximum, minimum,

instantaneous, logging)
Make: Germany
Power meter
Type : HIOKI
Current, kW, Power factor, Voltage, kVAr, kVA, frequency

(instantaneous)
Make: Japan
Portable data logger
(Energy monitoring socket)
Make: UK
Single phase Current, Voltage, kW and kWh
Wind meter
Wind velocity, flow rate
Make: India
Velo meter
Air Flow
Make: Germany
Lux Meter
Lux level/ illumination level
5.1.1 Energy Audit Team

Comment [S25]: Can come in annex
5.1.1
Formatted: Normal,Normal LIP, No bullets o

numbering
1. Eng. GaminiSenanayake
Team Leader
2.1.Eng. LoshanPalayangoda
- ISB Contact PointSenior Consultant
3.2.Eng. ChanakaMahawatta
- Consultant
4. Eng. ChamilaWickramasingheThilanka Alwis
Comment [l26]: Included in the Annex
- Tranee Consultant
3.
4. Sachindra Weerasooriya
- UG Trainee
5. Mohommed Ziham
- UG Trainee
5.6.NalakaWeerasekara
Technical Officer
7. JagathBandara
- Technical Officer
Formatted: Indent: Left: 0.5", No bullets o

numbering
6.
CHAPTER 6:
BREIF DESCRIPTION OF MAJOR ENERGY
CONSUMING AREAS
6.1
Electrical Energy System
The CEB meters electricity consumption at the main panel. However, there is no facility to meter
the power consumption of individual processes or equipment ( sub metering facility). . Also, the
self generated electricity using Diesel Generator setsis not metered. Ascribed to these situations,
it is thus difficult to evaluate the energy consumption pattern with respect to the production
output in each process. Monitoring and reviewing of energy consumption in each process is one
of the key elements in efficient energy management system and it is strongly recommended to
install individual energy meters for major energy consuming areas such as witheringPolishing,
rollingWhitening, sifting, drying and colourcolor sorters.
The main panel along with key electrical energy consuming components was measured with the
power loggers. Electrical power demands of the main panel werewas logged separately along
with other important parameters like kW, kVA, PF, I, V, etc. via electrical power loggers for a
period of 24 hrs at Duliella Tea FactoryPradeeep Rice Mill. Measurements were taken from
0611th- JuneFebruary-20134, 1613:1500 pm to 0712-JuneFebruary-20134, 162:15.
pm.SSpecially, the troughs, rollers, compressors and dryersall machinery were closely monitored
for individual power consumption using portable data analyzing instrument.
10
Comment [S27]: This is not good. The audit

team should look at the diesel consumption as wel
as the efficiency Kwh per litre of Diesel.
Comment [l28]: This is by the factory NOT b

the Audit team
Formatted: Font: 12 pt, Superscript
6.1.1 Demand profile and power quality

Graph 6 describes the behavior of the maximum demand of the main panel. Factorys peak
demand occur around 09.00 hrswhen operation of all major production units (withering, rolling
and dryingPolishers, Huskers, Whitener) takes place simultaneously and contribution from the
outside line. The maximum demand of 12275 kVA was registered on the day where the recording
was done.
140
120
kW/kVA
100
80
60
40
Time
kW
16:15
15:30
14:45
14:00
13:15
12:30
11:45
11:00
9:30
10:15
8:45
8:00
7:15
6:30
5:45
5:00
4:15
3:30
2:45
2:00
1:15
0:30
23:45
23:00
22:15
21:30
20:45
20:00
19:15
18:30
17:45
17:00
16:15
20
kVA
Graph 64: Maximum Demand Variation 11/02/2014 13.00 12/02/2014 12.15

30
Formatted: Normal,Normal LIP
kW/kVA
25
20
15
10
5
13:00:00
13:45:00
14:30:00
15:15:00
16:00:00
16:45:00
17:30:00
18:15:00
19:00:00
19:45:00
20:30:00
21:15:00
22:00:00
22:45:00
23:30:00
0:15:00
1:00:00
1:45:00
2:30:00
3:15:00
4:00:00
4:45:00
5:30:00
6:15:00
7:00:00
7:45:00
8:30:00
9:15:00
10:00:00
10:45:00
11:30:00
12:15:00
kW
kVA
Graph 6: Maximum Demand Variation 12/02/2014 16.00 13/02/2014 15.15
11

Formatted: Font: Not Bold
200
180
160
140
120
100
80
60
40
20
0
16:00:00
16:45:00
17:30:00
18:15:00
19:00:00
19:45:00
20:30:00
21:15:00
22:00:00
22:45:00
23:30:00
0:15:00
1:00:00
1:45:00
2:30:00
3:15:00
4:00:00
4:45:00
5:30:00
6:15:00
7:00:00
7:45:00
8:30:00
9:15:00
10:00:00
10:45:00
11:30:00
12:15:00
13:00:00
13:45:00
14:30:00
15:15:00
kW/kVA
kW
kVA
The peak points occurred from 7:30 hr to 14:00 hr is due to the rolling process as it is done in
batch wise in 20 minutes intervals. The peak occurred around 01:00 hrdue to the loading of all
the troughs along with the compressors of the colour sorters.
1.2
1
PF
0.8
0.6
0.4
Time
16:15
15:30
14:45
14:00
13:15
12:30
11:45
11:00
9:30
10:15
8:45
8:00
7:15
6:30
5:45
5:00
4:15
3:30
2:45
2:00
1:15
0:30
23:45
23:00
22:15
21:30
20:45
20:00
19:15
18:30
17:45
17:00
16:15
0.2
PF
Graph 45: Variation of the Power Factor

12
Graph 7 depicts the power factor variation of the main panel for the measured 24 hour duration.
The power factor varied from 0.67 to 0.99.The average power factor was 0.96whichis
anacceptablelevel. The minimum power factor was 0.67 and it occurred at 12:30 hrs. As this did
not occur during the factory peak time, it has no impact on the maximum demand.
6.1.2 Line Current Variation

The line current variation is useful to find out the imbalances in threephases.According to the
Graph 8,there is no significant imbalance of line currents. The imbalance doe not exceeds 5%
which is the desired limit.
140
120
100
A
80
60
40
Time
CH 01 (A)
CH 02 (A)
16:15
15:30
14:45
14:00
13:15
12:30
11:45
11:00
9:30
10:15
8:45
8:00
7:15
6:30
5:45
5:00
4:15
3:30
2:45
2:00
1:15
0:30
23:45
23:00
22:15
21:30
20:45
20:00
19:15
18:30
17:45
17:00
16:15
20
CH 03 (A)
Graph 56: Line Current Variation of the Main Panel
13
6.1.3 Line Voltage Variation

The line voltage variation is an indicator to identify the power quality supplied by the national
grid. Graph 9 explains the behavior of the voltage of the main panel respectively. The variation in
the line voltage is exceeding the accepted limit of 5%.
245
240
235
230
V
225
220
215
CH 01 (V)
Time
16:15
15:30
14:45
14:00
13:15
12:30
11:45
11:00
9:30
CH 02 (V)
10:15
8:45
8:00
7:15
6:30
5:45
5:00
4:15
3:30
2:45
2:00
1:15
0:30
23:45
23:00
22:15
21:30
20:45
20:00
19:15
18:30
17:45
16:15
205
17:00
210
CH 03 (V)
Graph 67: Line Voltage Variation
6.2
Thermal Energy System
Firewood is used to generate thermal energy required for the dryer operation. The factory does not have a
mechanism to record the firewood consumption.Therefore, the audit team had to make hourly measurements during
the testing period. The firewood was measured in yards and at an accuracy of 0.5, thus the reading could contain an
error of +/- 0.5 yards. Introducing of a
weighing scale to the Heater room will be an added advantage to the factory to have a true
picture of daily firewood consumption. The total firewood consumption for the 24 hours from
06-June-2013 16:30 hrs to 07-June-2013 16:30 hrswas 4,149.5 kg which is slightly higher than
the daily average taken from the monthly records of 3,825 kg. This could be attributed to high
consumption in rainy days.
450
400
350
kW/kVA
300
250
200
14
Industrial
150 Services Bureau (ISB) - Kurunegala, Sri Lanka
100
50
0
Time
Firewood (kg)
Comment [S29]: Then this should be suggeste

as a recommendation. Some one should know at
least on a monthly basis how much they are
consuming
Comment [l30]: Included under the
Recommendations
Comment [S31]: Suggest this as a
recommendation. Not here .
Comment [l32]: Included under the
Recommendations
6.3
Main Energy Users
The energy utilization of main sections likes of withering, rolling, sifting, drying and colour
sorters at Duliella tea factory is described below;
Graph 10 depicts the electrical energy balance of Duliella tea factory for a day operation
considering all the sections contributing for electricity consumption. The main electrical energy
consuming area is the withering process with 36% share, followed by Colour sorters andsifting
with18% each. Dryer & heatershare is 14% and the share of rollers is 13% for the rollers. The
impact of the illumination system is very low for Duliella tea factory.
Graph 11 expresses the firewood utilization for the withering and the drying processes and as
expected the drying process consumes more than 70%.
Rolling
13%
Whithering
36%
Sifting
18%
Lighting
1%
Compressors &
Colour Sorters
18%
Dryer & Heater

14%
Graph 89: Electrical Energy Balance for a Day Operation
15
Whithering
27%
Drying
73%
Graph 910: Firewood Utilization for a Day Operation
6.3.1 Withering Section

Withering is used to remove free as well as embeddedwater of green tea leaves and allows a very
slight amount of oxidation. This is the major electricity consuming section, whichis in operation
for more than 14 hours every day.
Table 3: Details of the Withering Troughs

Machine
Size
(feet)
Rated
Power
(hp)
Rated Power
of
blower(kW)
Speed
(RPM)
No of
Blades
in the
Blower
Capacity
(kg)
Trough No 1
60' x 6'
5.50
4.10
960
795
Trough No 2
60' x 6'
5.50
4.10
960
795
Trough No 3
60' x 6'
5.50
4.10
960
795
Trough No 4
60' x 6'
5.50
4.10
960
795
Trough No 5
60' x 6'
3.50
2.61
960
795
Trough No 6
60' x 6'
5.50
4.10
960
795
Trough No 7
60' x 6'
5.50
4.10
960
795
Trough No 8
60' x 6'
3.50
2.61
960
795
Trough No 9
60' x 6'
5.50
4.10
960
795
60' x 6'
3.50
2.61
960
795
Trough No 10
16
Trough No 11
60' x 6'
7.50
5.60
960
Trough No 12
60' x 6'
5.50
4.10
960
Trough No 13
60' x 6'
5.50
4.10
960
60' x 6'
5.50
4.10
960
73.00
54.46
Trough No 14
Total Rated
Power
795
900
900
950
6.3.2 Rolling Section

The rolling section is with 7 rollers and two are with double action and the rest are with fixed bed
single action. As per the literature, the rolling action also causes some of the sap, essential oils,
and juices inside the leaves to ooze out, which further enhance the taste of the tea. The rolling
section operates an average of 7 hours per day from 7:30 am to 2:00 pm.
Table 4: Details of the Rolling Section

Size
(inches)
Loading
Capacity (kg)
Motor
Capacity (hp)
47
220
15
47
220
15
CCC
47
11% 3rddhools
15
2nd
CCC
47
15% 1stdhools
15
05
2nd
Browns
47
15% 1stdhools
14 (Old Motor)
06
3rd
CCC
34
20% 2nddhools
10
07
3rd
CCC
40
20% 2nddhools
14 (Old Motor)
Roller No
Rolling Step
Brand
01
1st
02
1st
SIROCCO
Double Action
SIROCCO
Double Action
03
4th
04
17
6.3.3 Drying section

The drying section consists of the air heater which generates hot air from firewood and the dryer
uses hot air to dry the fermented tea. The dried or fired tea is usually has less than 3% moisture
level. The dryer is also used for the transferring of hot air for the withering process to expedite
the process. Dyer No 1 is for regular use while Dryer No 2 is either kept as a stand-by or used
during high crop season. Thus the main fan (Induced Draft Fan) of Dryer No 1 is in operation for
nearly 22 hours per day.
Table 5: Details of the Air Heaters

Identificatio
nNo
Average fuel
Consumption
(per hour)
Make
(Air Heater)
Motor Capacity (hp)

Main fan 15hp
Comment [S33]: Include in Kgs too
01
Browns
1 Yards
Other
3hp
Comment [l34]: Included in kgs
Main fan15 hp
02
Sirocco
1 Yards
Others3 hp
Table 6: Details of the Dryers
Dryer No
Brand
No of
Stages
01
Browns
Size (ft)& Type

5
Fired Tea
Output (kg)
Motor
Capacity (hp)
270
1.5
140
1.5
Belt Conveyer
5
02
Sirocco
3
Belt Conveyer
6.3.4 SiftingSection
Grading & sorting operations are done in the sifting section in which tea particles of the bulk are
separated into various grades of different sizes and forms conforming to trade requirements. In
other words, it basically converts the bulk into finished products. The process of sorting has two
objectives (i) to enhance the value (ii) to impart quality. The siftingis the only section operating
round the clock.
The sifting consists of two main operations namely the coloursorting and grading. The three
colour sorters are fitted with 35 hpmotors while the shifters are fitted with nearly 25 hp motors.
18
Identification
No
Table 7: Details of the Colour Sorters

Comment [S35]:
Compressor Details
Make
Type
01
Senvac
C8000wm
02
Super
shizyok
e
NS 40
03
Nanta
7000 D
camera
Operating
Pressure
Comment [l36]: Compressor is with the colou

sorter. So taken both together.
Type
Motor
Capacity (hp)
Set
Pressure
3 bar
Reciprocating
10
Pressure
gauge is not
working
2.2 bar
Reciprocating
10
9-10 bar
3 bar
Reciprocating
15
6-9.5 bar
6.3.5 Generator
Generator is used for emergency power generation. The generator at Duliella tea factory is being
operated at least 100 hrs per month due to the frequent power interruptions in the area. This is
comparatively high due to long lead period of restoring the power by the CEB.
The generator was tested and the load test was carried out to find out the performance. The
specific power generation KWh/ litre of Diesel is found to be xxxx.
19
CHAPTER 7:
ANALYSIS OF MAJOR ENERGY CONSUMING AREAS
The main sections identified under Chapter 2 are and analyzed under this section to make
recommendations for further improvements. Sections taken in to account are troughs, rollers,
colour sorters (compressors) and dryers, which were closely monitored for individual energy
consumption.
7.1
Electrical

According to the Table 8, some trough motors have a lowerloading factor. Thus, Trough no. 4, 3,
2, 9, 10 & 13consumes high energy compared the trough fans of similar capacity in Duliella tea
factory. This is mainly due to utilization of rewound motors and lack of preventive maintenance
related to motor bearings. Except trough no 12,13 &14, all other troughs are loaded below the
nominal TRI standard quantity of 900 kg for a trough with 60 X 6.The main reason for under
loading is theinability of the hot air duct to supply hot air for troughs that are away from the
dryer.In addition, troughs are running at fixed speed right throughout the withering process.
Trough no 1, 5, 6 9,10 & 12were kept running more than four hours even after reaching the
required wither of green leaves.
Table 8: Power Consumption Analysis for the Withering Section
Trough
No
Size
(feet)
Rated
Power (hp)
Rated
Power
(kW)
Actual
Power
(kW)
Loading
Factor
No of
Blades
Capacity
(kg)
Unloading
Time
60' x 6'
5.50
4.10
3.55
87%
795
9.55am
60' x 6'
5.50
4.10
3.66
89%
795
9.10am
60' x 6'
5.50
4.10
3.68
90%
795
8.35am
60' x 6'
5.50
4.10
4.72
115%
795
7.30am
60' x 6'
3.50
2.61
Under Repair
795
13.45pm
60' x 6'
5.50
4.10
3.47
85%
795
13.10pm
60' x 6'
5.50
4.10
2.31
56%
795
Not
loaded
60' x 6'
3.50
2.61
1.75
67%
795
Not
loaded
60' x 6'
5.50
4.10
3.86
94%
795
11.05am
10
60' x 6'
3.50
2.61
2.39
92%
795
11.50am
11
60' x 6'
7.50
5.60
4.72
84%
795
8.15am
60' x 6'
5.50
4.10
3.66
89%
900
12.35am
12
20
13
60' x 6'
5.50
4.10
3.84
93%
900
7.00am
14
60' x 6'
5.50
4.10
3.27
80%
950
10.30am
73.00
54.46
Total
Rated
Power
Table 9: Observation & Recommendation for Withering Section

Observation
Recommendation with Investment & Payback
OB1. The factory uses different spreading R1. Operate troughs at their maximum carrying
densities in troughs, without considering

its carrying capacity.
capacities as per TRI norm which is 900 kg.

Therefore, one trough can be taken off from
operation under normal circumstances.
Expected Energy saving : 21,240 kWh
Expected Annual Saving: LKR 276,120.00
Estimated Investment : Nil
SPP
: Immediate
Comment [S37]: A trial of the same should be

done with the plant. IF not working this
recommendation should be through through.
Comment [l38]: This standard can be achieved

the low grown sector.
OB2. Fixed speed motors are employedfor R2. Introduce VSD controllers to troughs. The
withering troughs. Priority can be given

to motors of trough no 1, 5, 6, 9, 10 &
12 are running unlit unloading to keep
the leaf condition although it has
withered five hours ago.
factory could give the priority to trough no 1,

5, 6 9, 10 & 12 which are operated for longer
duration after reaching the withering
condition and rest after words.
Estimated Investment : LKR 1.2 M
SPP
: 2.5 Years
OB3. Sequence of troughs loadingis based on R3. Load the troughs depending on their
the proximity to hot air supply but not
electrical efficiency as the hot air
based on their efficiency levels.
temperature is reaching most of the troughs
without any interruption.
Loading frequency should be 14, 11, 6, 1,
12, 2, 3, 10, 13, 9, 4.
OB4. Conventional induction motors are
utilized in the section. Conventional R4. Introduce 2 kW high efficient (80% or
higher) motors (HEMs) for the process for
motors are usually with low efficiency
future replacements with light weight fans
level (70% or less).
and a proper overloading breaker system.
Expected Energy saving :31,400 kWh
SPP
: 5 Years
xx
Comment [S39]: There should be a section

called back up calculations where all calculations
explained in detail eg for this how you arrive at
24108 kwh per annum saving
Comment [l40]: Supporting calculations are
provided in the Annex
Comment [S41]: Its seems to me that some m

explanation of the recommendations needs to be
made, The above way of summarizing the
recommendations in table form is good but may b
we can have an explanation section which explain
all the details associated with the observation and
recommendations May be 2 pages.
Comment [l42]: Explained and literature is
included in the Annex
21
7.1.2 Rolling Section

Motors which arerated at20 hp in the rolling sectionare below 6 hp during operation. Therefore,
the average loading factor is around 30%. Thus, thesemotors operate at very low efficiency
levels. Therefore, it is better to make a trial with a 10hp motor to check its capability of rollers to
withstand the startup and loading conditionsof rolling. Roller no 07wasdrawing a higher current
as it is a rewound motor which is more than 25 years old.As rolling is a batch operation, motors
have to be switch on and switch off around every 20 minutes. This has resulted in creating peaks
in the power demand pattern of Duliella Tea Factory.
Table 10: Power Consumption Analysis for Rolling Section
Roller
No
Rolling
Step
Size
(inches)
Motor
Capacity
(hp)
Motor
Capacity
(kW)
Actual
Loading
(kW)
Loading
Factor
01
1st
47
15
11.19
2.47
22%
02
1st
47
15
11.19
1.14
10%
03
4th
47
15
11.19
2.14
19%
04
2nd
47
15
11.19
1.86
17%
2nd
05
06
3rd
14
47
(Very Old
Motor)
10.44
1.95
19%
34
10
7.46
2.31
31%
10.44
4.12
39%
3rd
07
14
40
(Very Old
Motor)
22
Table 11: Observation & Recommendation for Rolling Section

Observation
OB5. Averageloading factor of the motors in R5. Replace the oversize motors with 5 kW high
section is less than 30%.
efficient motors (HEMs) which are with
more than 85% efficiency in future
replacements along with a proper overload
breaker system.
Estimated Investment :LKR 1.6 M
SPP
:5.1 Years
OB6. Rolling is a batch type operation and R6. Introduce soft starters for the rollers to
rollers are switch-on and switch-off at

around 20 minutes for loading and
unloading.
minimize the sudden peaks during batch

operation.
Expected Energy saving : 240 kVA
Estimated Investment : LKR 175,000.00
SPP
:1.3 Years
7.1.3 Dryer Section

Only Dryer No 1 is used while Dryer No 2 is kept stand-by or to utilized during the high crop
season. ID fans of both dryersare running below 50% of the rated load.
Table 12: Power Consumption Analysis for Dryer Section

Machine
Dryer 01
Rated Power
(hp)
Rated Power
(kW)
Actual
power (kW)
Loading Factor
1.492
0.68
46%
Heater FD Fan
3.73
0.47
36%
Heater ID Fan
20
14.92
44%
1.492
Heater ID Fan
20
14.92
5.42
Could not
measure
5.17
Heater FD Fan
3.73
0.57
13%
Fiber Met
0.746
0.14
35%
Middle ton sifter 1
0.746
0.11
15%
Dryer 02
36%
23
Comment [S43]: Give some more detail and

explanation.
Also for each recommendation have a separate ba

up calculation which covers, in detail how you hav
arrived at the energy saving figures.
included in the Annex.
Table 13: Observation & Recommendation for Dryer Section

Observation
OB7. The dryer main fan is in operation for R7. Introduce a steam radiator system (coupled
additional 14 hours to supply hot air to

troughs.
with the proposed bio mass boiler in

recommendation R22) for each trough and
avoid utilizing the main fan for withering
process.
Estimated Investment : LKR 1 M
SPP
: 3.1 Years
OB8. Conventional induction motors are R8. Introduce7.5 kW high efficient (80% or
utilized in the section. Conventional
higher) motors (HEMs) for the process for
motors are usually with low efficiency
future replacements
level (70% or less).
Estimated Investment : LKR 250,000
SPP
: 3.9 Years
7.1.4 Sifting Section

The sifting room is operated for 24 hours and almost right throughoutthe year except for few
days. Therefore, this is one of the key sections responsible for 16% of electricity consumption.
The Compressors of colour sorter are responsible for more than 60% of the total consumption.
According to Table 11, except Compressor-Hansin and five-tray shifter, all the motors are
running below 50% of the rated load.
Table 14: Power Consumption Analysis for Sifting Room

Machine
Rated Power
(hp)
Rated Power
(kW)
Actual Power
(kW)
Loading
Factor
Middleton Sift 2
1.50
1.12
0.18
12%
Middleton Sift 3
1.00
0.75
0.05
5%
Fiber Met 2
3.00
2.24
0.46
15%
5 trays sifter
2.00
1.49
1.17
59%
Conveyer to 5 trays sifter
1.00
0.75
0.25
25%
Machine Sifter 1
1.00
0.75
0.12
12%
Machine Sifter 2
1.00
0.75
0.26
26%
Machine Sifter 3
1.50
1.12
0.31
20%
Machine Sifter 4
N/A
N/A
0.19
N/A
24
Machine Sifter 5
1.00
0.75
0.06
6%
Machine Sifter 6
1.50
1.12
0.21
14%
Winnower No 1 Fan
N/A
N/A
0.02
N/A
Winnower No 1
Conveyer
Winnower No 2 Fan
N/A
N/A
3.83
N/A
N/A
N/A
3.00
N/A
Winnower No 2
Conveyer
Exhaust Fan
N/A
N/A
0.01
N/A
N/A
N/A
1.42
N/A
Colour Sorter
N/A
N/A
3.35
N/A
Compressor-Meiji
10.00
7.46
4.88
49%
Compressor-Meiji
10.00
7.46
4.70
46%
Colour Sorter Super

Shizuoka
Compressor-Hansin
N/A
N/A
0.99
N/A
15.00
11.19
14.23
95%
Colour Sorter
N/A
N/A
0.20
N/A
Air Dryer
N/A
N/A
0.86
N/A
Wood Splitter
3.00
2.24
0.41
14%
Total Power Demand
52.50
39.17
37.84
Identification
No
Table 15: Operational Condition Analysis of Colour Sorters

Compressor Details
Make
Operating
Pressure
Type
Motor
Capacity
(hp)
Set
Pressure
Range
Load & Unload

Duration
Load 10s (14%)
10
Pressure
gauge is
not
working
10
9-10 bar
Reciprocating
01
Senvac
3 bar
(Meiji)
Super
02
03
shizyok
e
Nanta
Load 15s (22%)
Reciprocating
2.2 bar
3 bar
Unload- 61s (86%)
(Meiji)
Unload- 54s (78%)
Reciprocating
with auto
cutoff at
unload
(Hansin)
Load 31s (11%)
15
6-9.5 bar
Unload- 263s (89%)
25
Table 16: Observation & Recommendation for Sifting Section

Observation
OB9. The compressors are set at 9-10 bar R9. The norm is to run the compressors at the
operating range while the colour sorters

operate at 2-3 bar range.
lowest pressure to match the system need.

Any additional increase in 1 bar will increase
energy consumption around 8%. So operate
the compressors at 4-7 bar range.
Estimated Investment :Nil
SPP
:immediate
OB10. The colour sorters are running with R1. Connect the two tanks of Meiji compressors
three separate reciprocating compressors
to the Hansi compressor and operate the all
and their loading time is less than 25%.
colour sorter with it while keeping the Meiji
compressors standby.
SPP
:immediate
R10. OR
Introduce a screw compressor with 1500
liters/ minute coupled with an air dryer and
an air receiver and operate at 4-6 bar range.
Estimated Investment :LKR 700,000.00
SPP
:6 Years
7.1.5 Main Panel

As per the Graph No 12, factory has sudden electricity peaks (as indicated in the Graph). The
peaks could be attributed to followings;
1.
2.
3.
4.
Sudden on and off of heavy motors due to operational changes in the process
Frequent power interruptions of the national supply
Workshop operations during the process peak time
Poor power quality (high fluctuations in the supply voltage) from the National grid supply
26
Comment [S45]: I think a better language wou

be
Reduce the pressure settings of xx, yy and zz
reciprocating type compressors from the current
settings of xxx to yyy.
Comment [l46]: Changed
Comment [S47]: Receiver?

Comment [l48]: Changed to Receiver tank
140
120
kW/kVA
100
80
60
40
Time
kW
16:15
15:30
14:45
14:00
13:15
12:30
11:45
11:00
9:30
10:15
8:45
8:00
7:15
6:30
5:45
5:00
4:15
3:30
2:45
2:00
1:15
0:30
23:45
23:00
22:15
21:30
20:45
20:00
19:15
18:30
17:45
17:00
16:15
20
kVA
Graph 1011: Load Variation during a Day Operation
As indicated in Graph 13, the grid supply has a large variation. This variation is exceeding the
5% of allowable limit. The indicated area has a variation above 10%. This is due to the factory
location which is at the extreme end of the supply line.
245
240
235
230
V
225
220
215
Time
CH 01 (V)
CH 02 (V)
16:15
15:30
14:45
14:00
13:15
12:30
11:45
11:00
10:15
9:30
8:45
8:00
7:15
6:30
5:45
5:00
4:15
3:30
2:45
2:00
1:15
0:30
23:45
23:00
22:15
21:30
20:45
20:00
19:15
18:30
17:45
17:00
205
16:15
210
CH 03 (V)
Graph 1112: Voltage Variation of the National Grid Due to Poor Power Quality
27
Table 17: Observation & Recommendation for Main Panel

Observation
OB11. Sudden peak load due to rapid on and R11. Enhance the awareness of employees on
off of high capacity motors.
the maximum demand variation.
This will contribute to reduce the sudden
peaks in the maximum demand. For an
example turning all the machineries at
once after a power interruption.
Comment [S49]: Could you not suggest some

schedules as to how they should do this ? or have
training ?
OB12. The panel does not have sub metering R12. Introduce separate breakers for key
facilities.
sections along with electricity meters and
connect to the sub breakers and record the
sectional power consumption daily.
Estimated Investment :LKR 350,000
This is contributing to work towards
energy saving in future
OB13. Absence of automatic synchronous R13. Introduce a automatic synchronous
change over for the generator and CEB
change over for the generator
supply. Thus sudden maximum demand
Expected Energy saving :240 kVA
increase in the during the power
Expected Annual Saving: LKR264,000.00
interruptions.
SPP
:1.5 Years
R14. Introduce a 50 kW net metered solar
OB14. 20m x 20m roof space is available in
power system for the premises.
the factory premises
Expected Energy generation: 72,000 kWh
Expected Annual Saving:LKR100,800.00
Estimated Investment:LKR10 M
SPP
: 9 Years
Comment [S53]: Needs further explanation as

how the change over would work and how it woul
act during power interruptions as compared to the
current situations.
Comment [S51]: How ? needs further
explanations
Comment [S54]: Very less explanation. This

should be dealt with under a separate section calle
onsite renewable energy ( or something similar) .
Details on technology, PV specifications, inverter
specifications and probably a block diagram / sing
line diagram needs to be provided.
One also has to make sure that the roof is structura

stable to hold the system and that for a particular
orientation of the solar PV system, what would be
effect of shadows etc due to trees and other object
For an investment of 10 M LKR dedicating just 2
3 sentences is not sufficient at all
28
7.2
Thermal

Table 18: CFM Details of the Withering Troughs
Trough
No
Total
CFM (closed
hot air
damper)
Hot Air
Temperat
ure (C)
Hot Air
rH (%)
CFM (after
opening the
Hot Air
damper)
Hot air
CFM
26,000
47.3
32.9
16,000
10,000
20,000
50.4
28.6
12,500
7,500
24,000
50.9
28.1
12,000
16,000
46.2
33.6
11,500
32,000
40.8
44.9
23,000
9,000
43,500
50.1
28.9
31,000
12,500
27,500
39.1
48.6
23,000
4,500
10
28,000
39.8
49.1
24,500
3,500
11
24,000
41.9
43.4
23,000
12
25,000
44.5
36.1
12,000
13
23,500
48.6
29.6
22,000
1,500
14
30,000
49.9
29.3
21,000
9,000
Remarks
12,000
Motor
Vibrating
is
4,500
Motor
Vibrating
is
7
8
1,000
Motor is
Vibrating
13,000
Motor is
Vibrating
According the above table explains the air flow variation of the troughs in Duliella tea factory.
The reason for hot air temperature variation is the distance from the dryer. More the distance
away from dryerindicates lesser the hot air temperature. It is advisable to have at least 30% hot
air flow to enhance the withering cycle.
29
7.2.2 Drying Section

Dryer systemincludes two key components; the hot air generator and the tea dryer. Dryer systems
are being utilized for drying of wet dhools up to 3% moisture level. Dryer systems are gaining
the heat from firewood at an average consumption rate of 1.6 yards (468.8 kg). The hot air
generator and the 20 hp electric blower are there to circulate hot air to the dryer. The analysis
was done focusing the Dryer No 1 which is normally used.
450
400
350
kW/kVA
300
250
200
Withering Process
150
100
50
0
Time
Firewood (kg)
Graph 1213: Firewood Consumption Variation for a Day

Table 19: Flue Gas Analysis for the Air Heater
Parameter
Level
Ambient Temperature
32.7 C
Flue Gas Temperature
217.4 C
Combustion Efficiency
79.9 %
Net Temperature difference

Oxygen in Flue gas
Excess Air
184.7 C
12.2
141 %
CO2 in Flue gas
7.9 ppm
NO in Flue gas
44 ppm
NO2 in Flue gas
0 ppm
Nox in Flue gas
44 ppm
SO2 in Flue gas
79 ppm
30
Combustion Loss
20.1 %
Dry Flue Gas Loss
15.6 %
Wet Flue Gas Loss
2.1 %
CO loss
2.4 %
The shankey diagrams of energy dissipation in the air heater 1 and the dryer are as follows.
Heat
Input
5,625.6
MJ
Heat loss
through flue gas
100%
1,130.7 MJ
Body losses
20.1%
46.4 MJ
0.8%
Heat used for hot

air generation
4,448.4 MJ
79.1%
Figure 1: Shanky diagram of the Air Heater 1
Table 20: Energy Dissipation of the Hot Air Generator

Description
Heater Specification
31
Heat Input
5,625.6 MJ (100%)
Heat used for hot air generation
4,448.4 MJ (79.1%)
Heat loss through flue gas
1,130.7 MJ (20.1%)
Body losses
46.4 MJ (0.8%)
Thermal Efficiency
79.1 %
The overall thermal efficiency of the hot air generator is 79% which is superlative for an air
heater. But, the efficiency is drastically varied with the quality of the firewood fed and the
behaviors of the dryer operator during feeding of firewood.
Heat
Input
Heat Loss
through exhaust
air
4,448.4
MJ
Dryer body loss
100%
194.3 MJ
4.4 %
Heat carrying
with made tea
1,780 MJ
40%
126.5 MJ
2.8 %
Heat used for drying /
firing of wet dhools
2,348.1 MJ
52.8 %
Figure 2: Shanky diagram of the Dryer 1
32
Table 21: Energy Dissipation of Dryer 1

Description
Dryer Specifications
Heat Input
4,448.4 MJ
Heat Used for drying / firing of wet dhools
2,348.1 MJ
Heat loss through exhaust air
1,780MJ
Heat taken by the made tea
126.5 MJ
Body losses
194.3 MJ
Thermal efficiency
52.8%
Overall Thermal efficiency of the drying Process
41.7 %
The overall system efficiency of the drying process is 41.7%. It is usual that these systems have
very low thermal efficiency compared to the steam boiler and radiator system. According
moisture analysis of the firewood utilized at Duliella tea factory,the average moisture content
was 40%. This is understandable as the factory is located near the Sinhaja forest of the wet zone.
Table 22: Saving Percentages According to the Moisture Content of Firewood
Moisture content (%)
Saving Potential (%)
40
Current Level
35
1.8
30
4.3
25
6.3
20
8.0
Table 23: Observation & Recommendation for Drying Section

Observation
33
OB15. Absence of a firewood shed for the day

stock.
OB16. The main firewood shed is with a
leaking roof.
OB17. Absence of a First in and First out
(FIFO) system in the firewood shed.
OB18. The firewood is splited just before
feeding.
OB19. Average moisture content of firewood
is 38%.
R15. Construct a firewood shed for the day

stock
R16. Repair the roof
R17. Introduce a FIFO system and educate the
feeding team
R18. Store the split firewood under the shed
for at least 3 weeks before feeding to the
dryer
R19. Introduce a moisture meter to the
firewood yard and feed firewood with at
least 25% moisture.
Expected firewoodsaving :74,589 kg
SPP
:5 Months
OB20. The overall efficiency of the dryer R20. Introduce a multi fuel bio mass
system is very low.
boileralong with a steam radiator system
OB21. Frequent variation of the hot air
where rice husk, saw dust, firewood,etc. can
temperature of the dyer.
be used for thermal energy generation.
OB22. Smoke contamination of made tea
Expected firewood saving :570,000 kg
which leads to poor quality and hence
Expected Annual Saving: 1.5 M
lower prices at the tea auction.
Estimated Investment :LKR 6 M
OB23. Absence of a steady firewood supply to
SPP
:4 Years
the factory.
OB24. Current dryer output is 220-250 kg/hr R21. Introduce a high efficient fluidized bed
and the dryer is operated for 10 hours
dryer coupled to a bio mass boiler system.
per day
Capacitycould be in the range of 350 kg/hr to
550 kg/hr and hence the dryer operating time
could be reduced to 6 hours.
SPP
:8 Years
Comment [S56]: Is there some waste heat stre

that can be looped into the shed which can really
reduce moisture further?
Comment [l57]: Explanations are included
Comment [S58]: This is to be proposed to the

factory immediately on a training program and
probably a trial to be done
Comment [S60]: Vendor details tobe given in

the report
Comment [l61]: Vender details included in
Annex
Comment [S63]: This needs a detailed write u

Please correspond with the supplier and give detai
some specifications
Comment [l64]: Included a detail description
along with literature in the Annex with relevant
suppliers.
Comment [S62]: How to eliminate smoke

contamination with the existing system itself has a
be thought about
Comment [S65]: There would be a cost for the

fuels May be that is less than firewood. But thes
cannot be treated as zero cost inputs.
Comment [l66]: Usually theses fuel could
compensate 50% of firewood so, the firewood
consumption will get reduced.
7.2.3 Generator
The generator is utilized for stand-by power generation.Fuel consumption of the generator was
measured for 2 hours. The generator was fully loaded from 11:15am to 11:30am. During the
testing period, the generator has produced 59.83 kWh consuming 30 liters of diesel. This means
the generator is only producing 2.32 kWh per liter of diesel, which is below the industry average.
According to graph 16 the voltage has a very minor variation at full load means the power quality
is at the acceptable limits.
34
Comment [S67]: Very very low.

Comment [l68]: Yes. Generator is a very old
one.
140
120
100
A
80
60
40
20
0
10:15:00
10:30:00
10:45:00
CH 01 (A)
Time
11:00:00
CH 02 (A)
11:15:00
CH 03 (A)
Graph 1314: Line Current Variation of the Generator
300
250
200
150
100
50
0
10:15:00
10:30:00
Time
10:45:00
CH 01 (V)
11:00:00
11:15:00
CH 02 (V)
11:30:00
CH 03 (V)
Graph 1415: Line Voltage Variation of the Generator
35
Table 24: Results of the Flue Gas Analysis of Generator

Parameter
Level
Ambient Temperature
32.7 C
Flue Gas Temperature
442.8 C
Combustion Efficiency
61.9 %
Net Temperature difference
411.1 C
Oxygen in Flue gas
11.2 %
CO2 in Flue gas
6.9 ppm
CO in Flue gas
150 ppm
Table 25: Observation & Recommendation for Generator

Observation
OB25. Generator is only producing 2.32 kWh
R22. Check the generator condition under the

guidance of an expert or the supplier and try
to reach the consumption level of 3.2~3.5
kWh per liter of diesel.
per liter of diesel which is below

industry average
Comment [S69]: Values near to 4 I think are

available in India- Could you look at these figures
little more?
Comment [l70]: Yes. For a generator. It is dou

with this one
36
CHAPTER 8:
8.1
CONCLUSIONS AND RECOMMENDATIONS
Recommendations
8.1.1 Electricity
The summary of the recommendations are as follows.
Section
Recommendations for Electrical Energy Reduction

R1. Operate troughs at their maximum carrying capacities as per TRI norm which is 900
TROUGH SECTION
kg. Therefore, one trough can be taken off from operation under normal
circumstances.
Estimated Investment : Nil
SPP
: Immediate
R2. Introduce VSD controllers to troughs.The factory could give the priority to trough
no 1, 5, 6 9, 10 & 12which are operated for longer durationafter reaching the
withering condition and rest after words.
SPP
: 2.5 Years
R3. Load the troughs depending on their electrical efficiency as the hot air temperature
is reaching most of the troughs without any interruption.
Loading frequency should be 14, 11, 6, 1, 12, 2, 3, 10, 13, 9, 4.
ROLLING
SECTION
R4. Introduce 2 kW high efficient (80% or higher) motors (HEMs) for the process for
future replacements with light weight fans.
SPP
: 5 Years
R5. Replace the oversize motors with 5 kW high efficient motors (HEMs) which are
with more than 85% efficiency in future replacements along with a proper overload
breaker system.
Estimated Investment :LKR 1.6 M
SPP
:5.1 Years
37
SIFTING ROOM
DRYER SECTION
R6. Introduce soft starters for the rollers to minimize the sudden peaks during batch
operation.
Expected Energy saving : 241 kVA
SPP
:1.3 Years
R7. Introduce steam radiator system for the each trough and avoid utilizing the main fan
for withering process.
SPP
: 3.1 Years
R8. Introduce7.5 kW high efficient (80% or higher) motors (HEMs) for the process for
future replacements
Estimated Investment : LKR 250,000
SPP
: 3.9 Years
R9. The norm is to run the compressors at the lowest pressure to match the system need.
Any additional increase in 1 bar will increase energy consumption around 8%. So
operate the compressors at 4-7 bar range.
SPP
:immediate
R10. Connect the two tanks of Meiji compressors to the Hansi compressor and
operate the all colour sorter with it while keeping the Meiji compressors standby.
SPP
:immediate
R11. OR
Introduce a screw compressor with 1500 liters/ minute coupled withan air dryer and
an air receiver and operate at 4-6 bar range.
SPP
:6 Years
38
Section
Recommendations for Electrical Energy Reduction
MAIN PANEL
R12. Increasing the awareness of the employees on the maximum demand variation.
This will contribute to reduce the sudden peaks in the maximum demand
R13. Introduce separate breakers for key sections along with electricity meters and
connect to the sub breakers and record the sectional power consumption daily.
Estimated Investment :LKR 350,000
This is contributing to work towards energy saving in future
R14. Introduce a automatic synchronous change over for the generator
Expected Energy saving :240 kVA
SPP
:1.5 Years
R15. Introduce a 50 kW net metered solar power system for the premises.
Expected Energy generation: 72,000 kWh
Expected Annual Saving:LKR100,800.00
Estimated Investment:LKR10 M
SPP
: 9 Years
8.1.2 Thermal
DRYER SECTION
Section
Recommendations for Thermal Energy Reduction

R16. Implement a firewood shed for the day stock
R17. Repair the roof
R18. Introduce a FIFO system and educate the feeding team to maintain
R19. Store the split firewood under the shed for at least 3 weeks before feeding to the
dryer
R20. Introduce a moisture meter to the firewood yard and feed firewood with at least
25% moisture.
Expected firewood saving : 74,589 kg
SPP
: 5months
R21. Introduce a multi fuel bio mass boiler and along with a steam radiator system
where rice husk, saw dust, firewood and etc which could be utilize for thermal
energy generation.
Expected firewood saving :570,000 kg
Expected Annual Saving: 1.5 M
SPP
:4 Years
R22. Introduce a high efficient fluidized bed dryer with for the process couple to the
bio mass boiler system. Capacity could be in the range of 350 kg/hr to 550 kg/hr and
39
reduce the dryer duration to 6 hours.

SPP
:8Years
GENERATOR
Section
8.2
Recommendations for Thermal Energy Reduction
R23. Check the generator condition via an expert and carry out their recommendations
to match the generation at least to 3.2~3.5 kWh per liter of diesel range.
Conclusions
According to the energy audit, there is a possibility to reduce electrical energy consumption of
the factory by approximately 137,000 kWh per annum (32% of current annual consumption),
amounting to LKR 2.4 million and the 480 kVA (40%), amounting to LKR 50,000.00. Most of
these recommendations can be implemented with no cost and with a short payback time. The
estimated reduction in firewood consumption alone is approximately 74,000 kg per annum with
no cost and low cost options while it will increase to 640,000 kilograms with the long term
project of introducing the bio mass boiler.
An energy management system with Separate meters should be installed in all intermediate
stages of production so that it would be possible to calculate the daily electricity consumption of
each process. These recordings in turn would be important to calculate specific energy
consumptions on a daily basis. The specific energy consumptions with high fluctuation needed to
be attended to.
It is recommended to appoint an Energy Manager to carryout and facilitate successful energy
management programmes within the factory premises.
Enhancement of awareness on energy conservation and management among the factory workers
and staff are also recommended.
40
Comment [S71]: Would they have to surrende

this demand to the utility to get the money? Im no
clear
Comment [l72]: Projected financial Saving by

reducing 480 kVA.
Comment [S73]: We should give some more

details as to which all sections they should start w
and how they should proceed.
Comment [l74]: Included in the
recommendations and literature and suppliers are
Annexed
ISB
for Sustainable Tomorrow
Industrial Services Bureau

141, Kandy Road, Kurunegala, Sri Lanka
Tel : 0094 37 22 237 21 ~ 3, Fax : 0094 37 22 23562
Email: info@isb.lk , Web : www.isb.lk
The Industrial Services Bureau (ISB), which is a statutory body under the Provincial Council of North
Western Province, was established in 1990 to assist industries in the province. Among various services it
provides, Energy Management and Conservation is an important activity commenced in 1991 after
identifying the real need of such services to industry. ISB is a registered Energy Service Company
(ESCO) at Sri Lanka Sustainable Energy Authority (SLSEA) to provide energy services to industries all
over the Island to increase their profitability through better management of energy usage.ISB is the only
41
semi-government body to win awards for the Best Energy Services Company in two consecutive years
of 2010 and 2011 at National Energy Efficiency Award competition organized by SLSEA.
42

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Draft

Comprehensive Energy Audit Report

Comment [NPEJ2]: Delete

INSTITUTE OF POST HARVESTING

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for Sustainable Tomorrow

Industrial Services Bureau (ISB)

Comprehensive Energy Audit - Draft Report

JUNE FEBRUARY 20143

Ceylon Electricity Board

Industrial Services Bureau (ISB) - Kurunegala, Sri Lanka

Comprehensive Energy Audit - Draft Report

Industrial Services Bureau (ISB) - Kurunegala, Sri Lanka

Comprehensive Energy Audit - Draft Report

Industrial Services Bureau (ISB)

Industrial Services Bureau (ISB) - Kurunegala, Sri Lanka

Comprehensive Energy Audit - Draft Report

Industrial Services Bureau (ISB) - Kurunegala, Sri Lanka

Comment [S3]: All costs in US $ also for

Comprehensive Energy Audit - Draft Report

Industrial Services Bureau (ISB) - Kurunegala, Sri Lanka

R2. Introduce VSD controllers to troughs. The

R5. Replace the oversize motors with 5 kW high

R6. Introduce soft starters for the rollers to minimize

R1. Operate troughs at their maximum carrying

R7. Introduce steam radiator system for the each

R8. Introduce7.5 kW high efficient (80% or higher)

R9. The norm is to run the compressors at the lowest

R10. Connect the two tanks of Meiji compressors to

Duliella Tea Factory

Comprehensive Energy Audit - Draft Report

Introduce a screw compressor with 1500 liters/

Industrial Services Bureau (ISB) - Kurunegala, Sri Lanka

R12. Increasing the awareness of the employees on

Duliella Tea Factory

R14. Introduce a automatic synchronous change over

R15. Introduce a 50 kW net metered solar power

Comprehensive Energy Audit - Draft Report

a FIFO system and educate the feeding

R20. Introduce a multi fuel bio mass boiler and along

Industrial Services Bureau (ISB) - Kurunegala, Sri Lanka

Comment [S7]: Seems incomplete

Comment [S9]: At least?

Comprehensive Energy Audit - Draft Report

Duliella Tea Factory

Specific Electrical Energy

Industrial Services Bureau (ISB) - Kurunegala, Sri Lanka

Comprehensive Energy Audit - Draft Report

Duliella Tea Factory

INTRODUCTION AND BACKGROUND .................................................... 1

Methodology Adopted for the Comprehensive Energy Audit .......................................... 1

General Details of the Factory .......................................................................................... 2

Energy Supply and Utilization ........................................................................................ 43

Instruments Used ............................................................................................................. 87

Energy Audit Team ..................................................................................................... 98

BREIF DESCRIPTION OF MAJOR ENERGY CONSUMING AREAS

Electrical Energy System .............................................................................................. 109

Demand profile and power quality ............................................................................ 119

Line Current Variation............................................................................................. 1310

Line Voltage Variation ............................................................................................ 1411

Thermal Energy System .............................................................................................. 1412

Main Energy Utilities .................................................................................................. 1512

Withering Section .................................................................................................... 1613