Page 13 - Arebian

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f) It is recommended to check for the option of installation of VFD’s to the above loads to
serve both purposes i.e. Energy Saving as well as Maintaining PF close to 1.00.

g) ROI Estimations can be done once the Energy Meters are installed on all above
equipments. However, ROI will be within 18 Months and there would be substantial
savings.
h) As per the measurements in the plant, average running load of the plant is App. 850
KW.
i) Pie chart shows that the utilities i.e. Chillers, Boilers, Compressors & AHU’s
contributes to 60% of the total power consumption followed by the ceruti machines
(App. 25%) Refer Figure-1. Out of the base line consumption monitoring , we have
done detailed analysis of energy saving opportunities, efficiencies of above utility
equipments.

j) Compressor
1. Compressors consume app. 85 KW (App. 10% of total energy of plant) which is
significant area of energy use. Cost of compressed air in the plant is App. 37 AED Per
Hour.
2. Its observed that for compressor no AC 5 and AC 7, volumetric efficiency are 79.08
%,75.68 % respectively. We can raise this eff. upto 80 -85 % practically by means of
proper overhauling of compressor, healthy condition of suction filter, proper lubrication

of rotary parts and arresting leakages through the system.
3. Design Specific Energy Consumption of the compressors is 0.17 KW/CFM where as
measured SEC was above 2.60 KW/ CFM which is a huge deviation over the time. This
means that the compressors are consuming 35% more energy than the design or
operational / ambient inefficiencies are deducted at 10%, still the consumption is very
high. This may be because of Improper Design, Very high operating pressures, Improper
maintenance with respect to energy & also lack of monitoring system.
4. Another opportunity is to reduce the unloading hours, both compressors together have
22700 Unloading Hours which is a shear wastage of energy of app. 636,735 KWH units
or equivalent to 241,959 AED in the tenure of operation.
5. Therefore, this is necessary to monitor the Energy as well as loading /unloading hours of

the compressors daily/ shift wise and efforts should be put to reduce the same to the
minimum with the target of 10% per month. This has no cost but energy saving
opportunity of App. 15000 KWH per month.
6. Actual % leakage test could not be conducted, but we have observed significant
leakages which might be in the tune of 15-20% & thus compared to present leakages
inside of the plant would save approximate 10-15 Kw of the present generated air.