Techno economic (TE) analysis of ENCON measures and energy efficient opportunities for the machinery in the engineering workshop

The energy audit is one of the tool is used to evaluate the energy performance of the equipment used in the industries. ENCON (energy conservation measures) is outcome of the energy audit, by implementing the ENCON the quantative amount of energy can be saved. In this research paper, energy performance analysis of carriage repair shop (CRS) was taken for study. The CRS is basically a engineering workshop which is taking care of maintenance of railway coaches, maintenance activities carried out in the Engineering workshop includes welding, wheel lathe operation, grinding of wheels, testing the healthiness of the battery, etc. The energy audit was carried out with energy audit equipment’s like power analyzer, lux meter, thermohygrometer, ultrasonic flow meter and tachometer on energy intensive equipment’s like Hydraulic press, lathe machine, air compressor system, shop floor lighting system and administrative building in Engineering Workshop. The potential energy saving option was identified i.e. ENCON from the outcome of the energy audit and techno-economic analysis of each energy saving measures was done in this paper. Using mathematical calculation each energy saving option was validated. ENCON measures in this paper is classified in to 4 types, (i) DSM (Demand Side Management), (ii) compensating the reactive power requirement in the system, (iii) replacing the existing absolute control system with energy efficient control system i.e. the on/off control system can be replaced with VFD (Variable Frequency Drives) and (iv) addressing the air leakage in the pneumatic pipe lines. In this paper, total potential energy saving identified in the engineering workshop under study is 1,25,650 units/kWh and in terms of cost is Rs. 11, 64,231. Reduction in Carbon Foot for the proposed energy saving was evaluated and it is about 105 MT (Metric Tonne).