Presentation by Mr Rakesh Surana, Energy Coordinator, Chamber of Industry, Morang, Biratnagar, Nepal.

1. Chamber Of Industries, Morang
Establishment : 1967 A.D
ISO 9001:2001 Certified

2. INTRODUCTION
Chamber of Industries Morang (CIM) is one of the leading chamber in Eastern
Region. It was established in 2024 B.S. (1967 A.D) by one of the well-known
Industrialist of Nepal with the aim of promoting Industries, develop national and
International trade and commerce to achieve quality objectives, make necessary co-
ordination with government and among Industrial sector. Chamber of Industries
Morang plays a key role in promoting different activities like
training, Workshop, Energy Conservation Program, Industrial trade
fair, Seminar, Talk Programs and corporate social responsibilities.

3.  Mission
Develop national and international business, coordinate and regulate different activities establishing
cooperation among the industries of the region.
 Vision
Depicting proper industrial sector and encouraging industrialists and business personalities towards
nation economic development.
 Objective
To promote member industries, develop national and international trade & commerce, to achieve
quality objectives, make necessary co-ordination among industrial sectors.
1. To co-ordinate among organizations and federations.
2. To protect industrial rights for mutual helps among national, international and local authorities.
3. To analyze and suggest annual policies, rules, plans for related member industries.
4. To participate actively in any conflict among industries and labor problem.
5. To organize regional, national & International seminar, talk program & workshop.
6. To open branch offices in all over Nepal if required for the protection of industries.
7. To flow information to the associated members and secretariat.

4. ENERGY AUDIT
An energy audit is an examination of an energy consuming
equipment/system to ensure that energy is being used
efficiently.
(Or)
“Energy Audit” means the verification, monitoring and
analysis of the use of energy including submission of technical
report containing recommendation for improving energy
efficiency with cost benefit analysis and an action plan to
reduce energy consumption.

5. Purposes of Energy Audit:
1. Find realistic energy saving.
2. Environmental protection.
3. National Energy supply/demand balance.
4. Occupational safety and health
5. Promoting energy efficiency and conservation.
6. Create important information, new ideas.
7. Define cost effective project.
8. Prepare action plans.
9. Develop staff training programs.
10.Aspiration of the improvement to corporate image by promoting energy
efficiency and conservation

6.  Objective
Energy audit is an effective energy management tools. By identifying and
implementing the means to achieve energy efficiency & conservation, not
only can save energy but also equipment/system life can be extended. All
these means saving money.
Based on the principle of “The less energy is consumed, the less fossil fuels will
be burnt” so companies will generate relatively less pollutants and by-
products. Therefore, all concerning these will contribute to conserve the
environment and to enhance sustainable development.
Environmental Protection
Energy Audit = Saving Money +
Sustainable Development

7. Classification Of Energy Conservation Measures
Based on energy audit and analysis of the plant, a number of potential energy
saving projects can be identified. These may be classified into three
categories.
 No cost/Low cost – High return
 Medium cost- Medium return
 High cost- High return
Normally the low cost - high return projects receive priority. Other projects
have to be analyzed, engineered and budgeted for implementation in a
phased manner.

8. Energy Audit In Few Industries within Morang and Sunsari Industrial
Corridor
Plant Energy
 Electrical – 567 KWh/ Ton of paper
 Thermal- 1 Ton of rice husk/ ton of paper

Observation (Thermal)
 Heat loss from uninsulated boiler, digester and steam pipe
 Waste water- 47, 000 liter per hour
 Steam leakage- digester, resin cooker vessels

9. After Energy Audit
Low cost high return (Thermal)
Particulars Before After
Surface Temperature (0 C) 180 50
Ambient Temperature (0 C) 30 30
Heat Loss (Kcal/yr) 269,325,000 22,572,000
Heat saved per year ( kCal) 46,753,000
Rice husk saved (tons/year) 78
Cost savings (Rs./year) 391,671
Total cost of insulation for 3 digesters (Rs.) 684,000
Simple payback period (years) 1.75

10. Observation (Electrical)
 11kv supply
 1000 KVA contract demand
 1750 KVA transformer
 0.73 PF
 Flat belt drive in paper machine
Recommendation
 Improve power factor from 0.73 to 0.95
 Replace flat belt drive to VFDs
 Lightening

11. Power factor Management
Existing maximum demand Kva 628.82
Maximum Load 459.04
Measured powered factor 0.73
Improved power factor 0.96
KVAr required 110
KVA saving per month (NRs) 15066
Cost saving per month (NRs) 34,651.80
Cost saving per year (NRs) 415,821.60
Investment of 60 KVAr capacitor bank (NRs) 63,000.0
Simple pay back period 0.15 year (55 days)

12. VFD Application
ID FD
Rated power (KW) 56.25 37.5
Measured power (Kw) 14.5 12
Approx. power consumption(Kw) in
presence os sand in fluidized bed
37 30
Energy consumed after implementation of
VFD (KW)
25.9 21
Energy saving (KW) 11.1 9
Energy saving (KW)
Working Hr-16, Number of days -300
53280(A) 43200(B)
Saving (NRs)
Average per unit cost is Rs- 5.8
309,024.0 250,560.0
Total A+B 559584
Investment 600,000.0 400,000.0
Total Investment 1,000,000.0
Pay back period 1.78 yrs

13. Lightning Consideration
Amount saved = 3kw ×12 hrs × 5.8 × 300
= Nrs 62,640.0 per annum
Note: Just few example of saving is mention here.

14. Hulas Wire Industries Pvt. Ltd.
Morang District, Biratnagar, Nepal
Observation at TMT high pressure pump
 Water pump with rated capacity =110kW
 Power measured by clamp meter = 89.5kW
 Pressure required to produce 12mm TMT rod (P) = 6kg/sq.cm
 Pressure required to produce 8mm TMT rod (P) = 10kg/sq.cm
 Flow required for process = 12 liter/ sec
 Excess flow pumped by motor = 50%
Recommendation
 Installation of VFD for high pressure pump

15. VFD Application
Power measured by clamp meter 89.5kW
Power required for present flow with VFD
installation
12kW
Electrical Power saving 77.5kW
Annual Electrical saving @ working 10 hr per day 279,000kwh
Saving (NRs) @ Nrs 7 per unit 1,953,000
Investment required for VFD (Nrs) 600,000
Payback period 4 month

16. Observation at Combustion control in TMT Pusher furnace
 Oxygen content in flue gas was about 8 to 10% before recuperator resulting
in dry flue gas loss about 17.53%
 During idle condition, 02 content in flue gas was about 14%
 Recommendation
 Reducing 02 percentage in flue gas down to 4% by controlling combustion
blower damper
Heat loss in dry flue gas 11.36%
Reduction in % heat loss 6.2%
Reduction in oil consumption (liter/hour) 35.35
Amount of furnace oil saving annually (KL) 127
Annual Saving (Nrs) 5,726,812
Investment in VFD and O indicator (Nrs) 500,000
Payback period 1 month

17. Benefit of Energy Cell
 Morang & Sunsari Industrial load is about 45 MW, when energy conservation
and audit was conducted it was found about 10% energy was saved. It
can result in financial capital, environmental quality. Economic security and
national security.
 It will help to promote the concept and fundamentals of energy
conservation so that Industries in this region as well as in Nepal can
become more competitive.
 To provide creative input into product and service innovation.
 Present and Explain energy efficiency program to all sector of economy.
 To promote energy awareness in Eastern region with coordination with sister
organization.

18. How Energy Cell will serve to Industries
1. Data collection and Analysis.
 Comparison with standard /Industrial best, average.
 Production data for industrial plants to find out operation improvement
opportunities.
2. Site Investigation
 Discuss operation with site personnel, often they will know the energy use
problems.
 Install energy monitoring where required to assess opportunities and to
identify energy waste.
3. Cost and Benefit Analysis when conducting
 Feasibility study on energy saving projects cost and benefit analysis are
essential

19. Cont.…
4. Preparation of concise report.
5. Staff training
 Through Energy audit, staff are educated and trained.
6. Presentation of the result to management.
7. Action plan for project Implementation.
8. Follow up monitoring to prove result.
 Typical annual saving from project with payback period between 0-2 year.
 Improved knowledge of process operation leads to reduce energy waste.
 Increased awareness of energy cost leads to more management focus on
energy use and improved energy conservation.

20. Conclusion
Energy audits, either walk-through or detailed energy audits, are essential for
all sectors of the economy (including residential/tertiary sector
buildings, School, College, Hotel, Hospital as well as industrial sector and
transport companies) to promote a better understanding of the current status
of end-use energy efficiency.
The audits, which are usually coordinated by engineering or facility
departments, will not only create awareness among those who are
functionally involved in the management of energy but also justify the
necessity for the implementation of energy efficiency activities.

21. And now last but not the least on behalf of Chamber of
Industry, Morang I would like to express my gratitude to FNCCI
and GIZ Nepal in supporting and promoting energy efficiency
in industries enterprises, with capacity building in Energy Audit
as an area of focus.
RAKESH SURANA – Energy Co-Ordinator
THANK YOU