Energy Performance Contract
United Phosphorus Limited (UPL) is 11th largest agrochemical company in the world. M/s. Aditya Energy Services, Ahmedabad was assigned a Technical Audit of Chillers system & Co-gen Power plant (48.5 MW) in the year 2018-19 through a " SAVE & SHARE" contract. The CW/CHW networks studies were carried out using Hydraulic pipe-network simulation Models prepared using EPANET software tool. The coal based co-gen power plant of 48.5 MW comprising of CFBC and AFBC boilers was studied using Heat & Mass Balance Diagram (HMBD) technique. The study successfully pin-pointed various energy conservation and efficiency improvement measures (ECM’s) tent amounting to annualized savings of more than INR 15 million at Unit 5, Jhagadia alone with attractive pay-back of less than one year. The total energy savings identified and mutually agreed across UPL group companies (Unit 0,1,2 & 5) exceeded INR 25 million. View PDF
Performance Assessment & Validation
Abellon Co-gen Ltd – a group company of Abellon CleanEnergy Ltd, awarded an assignment to Aditya Energy Services, Ahmedabad for the determination of “operational vis a vis design” performance of its Co-gen power plant situated at A’bad-Bawala highway, in 2019-20. The project covered study of co-gen power plant (Triveni make) of 4 MW capacity along with 12 TPH & 16 TPH boilers of Thermax and its auxiliaries through HMBD (Heat & Mass Balance Diagram) approach and following steps: • Energy Balance made to derive the efficiency figures for Steam turbine and Power generator. • Theoretical model prepared for the three cases for which HMBD of OEM was shared. • Actual data from log sheet is placed in the model for comparison of theoretical power generation v/s actual power generation based on the sample analysis of the data. The study revealed substantial derating of Steam turbine capacity @7.88 % and the maximum power that can be generated can not exceed 3.92 MW. View PDF
Asian Paints Limited is one of the top 10 decorative coatings companies in the world. M/s. Aditya Energy Services, Ahmedabad was assigned a detailed Energy Audits of two of their manufacturing facilities - Industrial Coatings Limited, Sarigam and Asian Paints Ltd, Taloja, in the year 2019-20. The energy assessment covered all the energy consuming areas through exhaustive data collection and analysis, measurements of various operating parameters and detailed performance evaluation of the electrical distribution network including Transformers, PCCs/MCCs, Lightings and Utilities comprising of Pumping systems, Air compressors, Cooling towers etc. as well as process equipment viz. reactors, mixers etc. Value added studies viz. power quality (harmonics) and Thermography of the electrical systems were also carried out under the study. The study has successfully pin-pointined various energy conservation and efficiency improvement measures tantamount to more than 9% & 7% of the present energy bills of Sarigam and Taloja, respectively. View PDF View
Resins and Plastics Ltd. (RPL) is one of India's leading Synthetic Resin manufacturers of Alkyd Resins, Epoxy Resins, Foundry Resins, Ketonic Resins, and Phenolic Resins some of which are import substitutes. M/s. Aditya Energy Services, Ahmedabad was assigned a comprehensive Energy Audit in the year 2019-20. The energy assessment covered all the energy consuming areas through exhaustive data collection and analysis, measurements of various operating parameters and detailed performance evaluation of the electrical distribution network including Transformers, PCCs/MCCs, Lightings and Utilities comprising of Pumping systems, Air compressors, Cooling towers, Thermic fluid heaters etc. as well as process equipment viz. reactors, condensers, mixers etc. Through a stematic & meticulous approach the study was successful in pin-pointing various energy conservation and efficiency improvement measures tantamount to more than 11% of the present energy bill. View PDF
A Pilot Study On Developing Energy Management Program In Kuwait Oil Company (KOC)
Kuwait Oil Compony (KOC) awarded the assignment and was jointly executed by NAPESCO (India) and GSH ES in the year 2016-17. Mr. Prakash Vankani then Director, (Energy), GSH ES successfully lead the project. Being a Lead Auditor ISO 50001 (EnMS), he also imparted Energy Auditor training to the core team members / focal points of KOC. The activities and tasks performed, keeping the main objective of evolution of Energy Baselines & ISO 50001 (EnMS) Facilitation for select pilot sites of Kuwait Oil Company, were: Imparting Energy Management Program Awareness Session to Core Energy Team. Site visit for understanding possible energy interventions in select pilot sites (Gathering Center, Booster Station, Effluent Water Disposal Plant and Buildings). Energy Review through Baseline Performance Establishment, Identification of Significant Energy Use Equipment / Processes, Variables affecting Significant Energy Users, Evolution of Energy Performance Indicators (EnPIs) in line with ISO 50001 guidelines. Conduct of EnMS / Internal Audit training for core team members / focal points and Evolution of Energy Policy suitable to KOC operations. Submission of Energy Management Report based on the outcomes of the pilot study. Close out presentation on Energy Management Program to KOC top management.
Energy Efficiency Pilot implementation in SME Cluster – Ankleshwar chemical industry cluster, Gujarat.
The World Bank awarded this unique project to Dalkia Energy Services in the year 2010. Mr. Prakash Vankani the then Business Head (WR), Dalkia lead the team for Ankleshwar cluster. World Bank objectives: To systematically support the development of large number of EE investment proposals under the programmatic approach to aggregate demand for EE investment in SME industrial clusters and to create a sustainable mechanism for identifying, preparing and financing these proposals at the local level. Project Brief: Pilot technical assistance in 2 clusters – Faridabad & Ankleshwar to understand current barriers in implementing energy efficiency measures in SME sector and to mobilize initial capacity and interest for the follow-up operations. Activities Performed: Potential Assessment studies in 4 units in Ankleshwar cluster followed by detailed investment grade studies in 2 units. Arranging seminar, provide project specific financial analysis to unit’s chartered accountant for incorporating the same in the unit’s overall financial status. Provide any and all input to ensure accuracy of EE project related cost-benefit analysis. Develop a “vendor identification document” for key select EE measures which are identified during pre-assessment and subsequent DPR preparation stage. The pilot successfully lead to the scale up across many industrial clusture across India by World Bank.
Energy Efficiency Assessment at Dubai International Airport (DIA)
Dubai International Airport awarded in the year 2011/12 and was jointly executed by MAF Dalkia (Dubai) and DESL, India in the span of 6 months. Mr. Prakash Vankani then Business Head, DESL lead the DESL energy team. Activities and tasks performed were: Energy analysis of the existing Terminals, Concourses, Chiller Plants and ancillary facilities in Dubai International Airport. The energy study and analysis to include a breakout of all energy conservation measures identified and estimated costs, energy and operational savings, and life-cycle cost benefits. To develop estimates for specific and total energy consumption specific and total GHG emissions potential energy savings in specific and total energy terms potential reduction in energy related GHG emissions incremental costs of achieving the potential for energy saving and/ or GHG emissions reductions. All activities involving implementation of the above starting from process mapping, base line establishment, identification of energy efficiency measures, designing PMV protocol, project implementation and post implementation PMV. The exhaustive study was successful in pin-pointing towards electrical savings of 11.83 % which in monetary tems worked out to 29.25 million AED and 22.6% water savings equivalent to 13 million AED per annum.
PAT (Perform,Achieve and Trade) Mandatory Energy Audit
Gujarat State Fertilizers & Chemicals Limited (GSFC) was the first industrial complex in the country set up in joint sector in 1962. The company, during the course of time, has ventured into the foray of industrial chemicals segment namely Caprolactam, Nylon 6, Melamine and also Argon gas recovered from purge gas. The MEA assignment was awarded in the year 2017 and Prakash Vankani, Accredited EA of BEE and the then Director (Energy), GSH ES, lead the team. The study was based on methodology specified in the Bureau of Energy Efficiency (Manner and Intervals of Time for Conduct of Energy Audit) Regulations, 2010”. Following tasks and activities were performed: Conducting field study and related data analysis on utilities & processes to establish operating energy efficiencies. Identification of Energy Efficiency / Conservation Projects and Techno-commercial feasibility assessment of identified options and prioritizing viable projects on the basis of financial indicators. Vendor identification, interaction and obtaining quotes for identified energy abatement options. Preparation & Submission of Detailed Energy Audit (DEA) Report as per PAT guidelines and requirements. The exercise was successful in pin-pointing towards energy savings opportunities in Electrical and Thermal Energy. Adoption of 23 Energy Conservation Measures (ECMs) tent amounted to 38.61 million INR / y of overall monetary savings with an very attractive pay-back of mere 5 months.
ITC Limited, PSPD (Energy Training)
ITC, PSPD, Bhadrachalam invited Aditya Energy Services (AES), Ahmedabad to conduct a online Energy Training for their officers participating from amongst all the ITC’s manufacturing sites including; Bhadrachalam (Telangana), Tribeni (Kolkata) , Kovai (TN) etc. The training covered most relevant and useful topics pertaining to the Paper & Pulp sector including; General aspects of EC/EE and approaches; Energy Policies and Regulators role viz. BEE’s PAT scheme, MEA as per EC Act 2001 and utilities namely; Pumping System,Compressed air system, Fan & Blower System, Refrigeration – Compression chillers & VAM etc. Sharing of best practices and demonstration of innovative tools/approaches viz. hydraulic network modelling, HMBD for co-gen power plants, Chiller performance tool (Cool-pack) etc. and their usefulness as an integrated approach for holistic energy assessment was provided to the participants. The active participation of the audience made the training more interesting, useful and as they later shared, the exposure and deliberations on the innovative tools/approaches were The Key Take Away too…. View PDF
United Phosphorous Limited, Jhagadia (Third Party Inspection)
M/s. Aditya Energy Services (AES), Ahmedabad was assigned a Third Party Performance Testing of a new Vapor Absorption Machine (VAM – 670 TR) by UPL Limited, Unit: 5, Jhagadia, in the year 2018-19 at Thermax Test Bed, Pune. United Phosphorus Limited (UPL) is the 5th largest agrochemical company in the world. The unit has dedicated chiller systems (Brine - 1418 TR/water - 2500 TR/VAM - 1900 TR) for different plants manufacturing pesticides intermediates and technical products. Vapor Absorption Machines (VAM) are the major consumers of steam. The uniqueness of this very special task was to check, verify and confirm the design vis a vis actual performance of Triple Effect Vapor Absorption Machine (VAM) at the test bed of the OEM (Thermax, Pune) using our own calibrated instruments while following prescribed testing guidelines. The exercise fully justified the decision of UPL of the need for such third party intervention and their independent assessment of performance for new VAM procurements. The gaps were identified, documented and agreed by the OEM - Transpek. View PDF