Sinnar LPG Bottling Plant is an Ultra Modern Bottling Plant, the first plant in India with an Electronic Carousel. It is entrusted with the task of receipt and storage of bulk LPG, bottling of LPG in cylinders and the dispatch of these cylinders to the distributors. It operates in two shifts. The plant is located in MIDC area and gets its power from MSEB (Maharashtara State Electricity Board).Like any other industry and installation this plant also incurs some operational costs. Saving on these operational costs adds on to our profit. Of these operational costs, electricity is a major component of it and every plant tries its level best in order to curtail this cost to a minimum extent . Various power saving equipments and modes are applied in order to do so. Same is the case for as our project says to , to optimize the electricity costs.
We , as a group analyzed and studied the various processes of power usage , their significance, their consumption, their hour of usage etc. As per our observation, we were able to chalk up a pattern of electricity consumption in the 7 day study and the reasons that could have prompted it to happen. Also the extensive study of the conveyor belt was carried out as we collectively thought that it could play a major part in our study to conserve electricity.
Analysis of pattern of power consumption
For the purpose of understanding the pattern of power consumption in the plant, electricity usage has been analysed for the period of 18 August 2008 to 22 August 2008, i.e. for a week from Monday to Friday. The energy usage has been divided into 3 parts, from 7 a.m. to 3p.m. which covers the Ist shift in the plant, from 3p.m. to 11p.m. which covers the IInd shift in the plant and from 11p.m. to 7a.m. which is the period during which the plant is not in operation and only the lighting consumes electricity. The data has been obtained from the meter readings available in the MCC room and is as shown below:
DayDateIst shiftIInd shiftNightTotal
It was observed from the data that generally the power consumed during the Ist shift was greater than the power consumed during the IInd shift. This observation was contrary to that which was expected. During the IInd shift along with the processes running in the Ist shift, illumination is also required and thus it was expected that the power consumption in the IInd shift would be greater. It was also observed that there was a sudden variation in the power consumption pattern during the two shifts on Thursday. This may be due to erroneous meter reading by the operator during the meter reading at 3p.m. or the operator might have taken the reading due for 3p.m. at a later time. Another observation was that the consumption during night on Friday was much more as compared to other days. This is due to the reason that the next meter reading was taken on Sunday at 7 a.m. On Saturday the plant runs on DG Set however there must have been some period of time during Saturday when electricity from MSEB must have been used. It was thought that greater energy consumption during the Ist shift might have been due to larger number of filling operations during the Ist shift than in the IInd shift. So, the following filling pattern was obtained from the filling shed: Ist shiftIInd shift
14 kg. cylinders19 kg. cylindersTotal kgs. filled14 kg. cylinders19 kg. cylindersTotal kgs. filled carouselmanualcarousel manualcarouselmanualcarousel manual 832504500126765745400243110463.8
It was also observed that the period of time LPG compressor used for unloading bulk LPG at...