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UseoftrolleyLoca&on: AgroEngineeringWorks,Butwal-12,RupandehiProcess: Fabrica&on
BeforeOperatorsusedtothrowworkitemsitemsonthefloora7erdrilling,grindingandothermachiningopera;ons.Anotherpersonhadaddi;onallycollectthoseitemsforthenextprocess.
ACerWorkitemsa7erdrilling,grindingandothermachiningopera;onsarenowdirectlyplacedontrolley(wheelbarrow).Thisistheneasilytakentonextprocessstep.
Costs/benefitsCost:NPR70,000Annualmanpowersaving:150man-daysSavings:NPR120,000Payback:7months
Contact: [email protected]@seednepal.org
Disclaimer: This document has been produced with the financial assistance of the European Union. The contents of this document are the sole responsibility of TERI and can under no circumstances be regarded as reflec@ng the posi@on of the European Union.
SwitchoffWeldingMachineswhennotinuseLoca&on: OshinPowerServicePvt.Ltd.,Butwal,RupandehiProcess: Fabrica&on
BeforeThreeweldingmachinesontheshopfloorwereinopera9on.Theseweregenerallynotturnedoffwhennotinproduc9one.g.duringlunchbreak,orinbetweenjobs.Stand-bypower(loss)wasmeasuredtobe1.2kW
A@erAFerawarenesssessionforshopfloorteam;weldingoperatorsareawareoflossfromidlerunningweldingmachinesandtheworkshopsupervisornowswitchesoffthepowerlinetoworkshopduringlunchbreaktostopidlerunningofweldingmachines
Costs/benefitsCost:Nocost Annualelectricitysavings:540kWhAnnualsavings:NPR5,400 Payback:Immediate
Contact: [email protected]@seednepal.org
Disclaimer: This document has been produced with the financial assistance of the European Union. The contents of this document are the sole responsibility of TERI and can under no circumstances be regarded as reflec@ng the posi@on of the European Union.
Energy Savings by insulating the curing tank
Location: Pioneer Electrocables, Biratnagar, Nepal
Process: Electrical Cable Manufacturing
Before
Two curing tanks with 16 kW electric heaters in each tanks are installed for curing of electrical cables. The tanks were not insulated and operation time was 6 hours consuming 192 kWh per batch.
After
Both tanks were insulated with glass wool and protected with metal cladding due to which operation time is reduced to 4 hours now consuming only 128 kWh per batch.
Costs/benefits
Cost: NPR 30,000 Annual savings: NPR 102,400
Payback: 3.5 months (160 batches/yr * 64 kWh/batch = 10240 kWh/yr)
Contact: Dr M Balakrishnan [email protected] Mr Amar B Manandhar [email protected]
Disclaimer: This document has been produced with the financial assistance of the European Union. The contents of this document are the sole responsibility of TERI and can under no circumstances be regarded as reflecting the position of the European Union.
Improvedworkingcondi0ons-be4erillumina0onLoca&on: PioneerElectrocables,Biratnagar,NepalProcess: ElectricalCableManufacturing
BeforeLightswereplacedhighinceilingprovidinglowerillumina0onatworkingarea.
A<erHeightofsomelightsisreducedbysimplysuspendingthesefromchains.Halvingtheheightincreasesillumina1onby41mes!Over0me,remaininglightswillbeloweredtoprovideworkplaceillumina0on.
Costs/benefitsCost:NillAnnualsavings:Be4erworkingcondi0on,
increaseproduc0vityPayback:Immediate
Contact: DrMBalakrishnanmalini@metabuild-southasia.orgMrAmarBManandharamar@metabuild-southasia.org
Disclaimer: This document has been produced with the financial assistance of the European Union. The contents of this document are the sole responsibility of TERI and can under no circumstances be regarded as reflec@ng the posi@on of the European Union.
Installa(onoftranslucentsheets
Loca&on: OshinPowerServicePvt.Ltd.,Butwal,RupandehiProcess: Ligh&ng
BeforeNaturallightwasnotfullyu(lisedattheworkplace.Someareaswereilluminatedbyusingfluorescentlampseveninday(me.
A?erIndustryhasinstalledtwotranslucentsheetsontheroof.Theworkplaceiswellilluminatedbynaturallightandnowthereisnoneedtousethreefluorescentlampsduringtheday.
Costs/benefitsCost:NPR2,200 Annualelectricitysaving346kWhAnnualsavings:NPR3,460 Payback:8months
Contact: [email protected]@seednepal.org
Disclaimer: This document has been produced with the financial assistance of the European Union. The contents of this document are the sole responsibility of TERI and can under no circumstances be regarded as reflec@ng the posi@on of the European Union.
RepairofCapacitorBankLoca&on: AgroEngineeringWorks,Butwal,RupandehiProcess: PowerFactorImprovement
BeforeOutofthenineinstalledcapacitors(of15kVArra;ngeach)incapacitorbank,fourwerenotfunc;oning;onewasdamaged,twowerehavingproblemwithcontactorandthefourthonewasmalfunc;oning.Therecordedpowerfactorwasonly0.88
ABerOnecapacitorisrepaired,connectorsoftwocapacitorsarerepaired,MCBforconnec;onofoncecapacitorisrepairedandonecapacitorisreplaced.Averagepowerfactorisimprovedto0.99
Costs/benefitsCost:NPR10,000 Demandreduc;on:10.5kVA/monthAnnualsavings:NPR31,500 Payback:4months
Contact: [email protected]@seednepal.org
Disclaimer: This document has been produced with the financial assistance of the European Union. The contents of this document are the sole responsibility of TERI and can under no circumstances be regarded as reflec@ng the posi@on of the European Union.
PowerFactorImprovementLoca1on: InterTechPvt.Ltd.,Butwal-12,RupandehiProcess: Fabrica1onandGalvanizing
Before Grid supply to the industry had poor power factor. The recorded average power factor was 0.48
AFerThecompanyhasinstalledanAutoma3cPowerFactorController(APFC)of98kVArra3nginlinewiththemainpanel.Nowthecompanyismaintainingpowerfactorof0.99
Costs/benefitsCostforAPFCinstalla3on:NPR150,000Reduc3onofdemandcharge:31kVA/monthAnnualsaving:NPR93,000/year Payback:1.7years
Contact: [email protected]@seednepal.org
Disclaimer: This document has been produced with the financial assistance of the European Union. The contents of this document are the sole responsibility of TERI and can under no circumstances be regarded as reflec@ng the posi@on of the European Union.
Improvementininsula0onofsteampipelinesLoca&on: HulasWireIndustries,Biratnagar,NepalProcess: Surfacetreatment
BeforeInsula0oninthesteampipelineswasdamagedleadingtoheatlossandhigherfuelconsump0on.Thesurfacetemperatureofsteampipewas55°Ccontribu0ngtoheatlossofaround16,000kCal/hr.Addi0onally,processtankwithfluxsolu0oncouldnotaGaindesiredtemperature(couldreachonlyaround66°C)fromsuppliedsteam.
A>erThepipelineisinsulatedwithglasswoolandcoveredwithjutesacktoreducesteampipetemperatureto35°Candcorrespondingheatlossreducedtoaround6,000kCal/hr.Withlesseropera0ng0me,85°Ctemperatureoffluxsolu0onisnowaGained.
Costs/benefitsCost:NPR30,000Annualsavings:NPR209,000Payback:1.7months (5264litresofFOi.e.,~3%)
Contact: DrMBalakrishnanmalini@metabuild-southasia.orgMrAmarBManandharamar@metabuild-southasia.org
Disclaimer: This document has been produced with the financial assistance of the European Union. The contents of this document are the sole responsibility of TERI and can under no circumstances be regarded as reflec@ng the posi@on of the European Union.
Fuel Savings by reducing the Furnace opening
Location: Pashupati Iron & Steel, Biratnagar, Nepal
Process: Rerolling Mill
Before
The company is using furnace oil (FO) fired furnace to heat the billet before rerolling it to make TMT bars. The opening of the feeding door in the furnace was 15 cm contributing to 1,056 kCal of heat loss per hour
After
The height of door is lowered by 7.5 cm by manually setting the door hangers to minimize heat loss
Costs/benefits
Cost: Nil Annual savings: NPR 21,440
Payback: Immediate (536 kg of Furnace oil)
Contact: Dr M Balakrishnan [email protected] Mr Amar B Manandhar [email protected]
Disclaimer: This document has been produced with the financial assistance of the European Union. The contents of this document are the sole responsibility of TERI and can under no circumstances be regarded as reflecting the position of the European Union.
