Energy audit at two plants of Times of India, Sahibabad

Bennett, Coleman & Company Ltd. (BCCL) is the largest media company in India. It is best known as the publisher of the English daily newspaper, The Times of India (TOI). The Times Group/BCCL presses have always been a frontrunner in introducing the latest printing technology in India. BCCL has a number of newspaper printing presses in different zones/states in the country. This project was conceptualized when BCCL's newspaper printing press at Sahibabad initiated activities to implement International Organization for Standardization (ISO) schemes for continual improvement in energy utilization.

TERI was awarded the project for conducting an energy audit of select energy intensive areas and equipment at the plants in Sahibabad. The audit was carried out with an objective of studying the level of energy consumption pattern and identifying energy saving possibilities in various sections of the printing press.

Checking of air leakage
Arresting air leakages in air compressor line joints
The study focused at TOI Presses at Plot 13 and Plot 15/1 in specific areas including transformers, power factor and harmonics in electrical system, electric motors (>20 HP), pumps, fan and blowers, air compressors, refrigeration and air-conditioning systems, diesel generating sets, cooling towers, and lighting systems.

TERI team visited the presses between January-June 2009 to undertake extensive measurements at peak/normal load condition and for collection of data. A mutually consultative process was adopted where extensive discussions were held with plant personnel to identify potential areas for improving energy efficiency and minimizing energy consumption. Three types of measures were identified: short term measures (recommendations with investment ? Rs. 10,000); medium term measures (recommendations with investment ? Rs 1, 00,000); and long term measures (recommendations with investment > Rs 1, 00,000).

Increase in Pages Printed per kWh
Results after implementing the energy conservation
measures in the printing press
Based on the analysis and the onsite measurements using TERI's instruments/data taken from the plants control panel, suitable energy saving measures by way of better operational practices, adopting energy efficient devices and modifications in the existing system were identified. In their post-audit assessment, Times of India estimated that the energy savings potential identified by TERI were to the tune of 9 million INR. At the time of assessment, the unit had achieved savings of up to 5.6 million INR after implementing the post-audit recommendations presented by TERI. The energy audit study and subsequent implementation of recommendations led to a successful addition in the 'Pages Printed per kWh'.
Sealing of air exit points
As a result of the project sizeable savings that required short-term measures were identified. The payback period of investments required for energy saving was in the range of 1-3 years. Monetary savings were generated as the measures were implemented by the technical team and management at the printing presses. The recommendations were substantiated with a cost-benefit analysis to help in prioritizing the implementation of economic measures, wherever applicable.

The project serves as an example for similar energy audit studies and energy saving measures in the numerous other printing presses under BCCL.

Sponsor: Bennett, Coleman & Co. Limited
Duration: 6.5 months
Key Stakeholder / Beneficiaries: Bennett, Coleman & Company Ltd. (BCCL), technical personnel, and plant management at TOI Plant 13 and Plant 15/1.
Objectives
  • To carry out a detailed energy performance evaluation of major equipment and auxiliaries of the individual press with a view to identify thrust areas for energy conservation.
  • To quantify the extent of energy savings that can be achieved.
  • To recommend various technically sound and economically viable measures to improve the end-use energy efficiency.
Major Achievements of the project
  • The study undertaken by TERI identified considerable energy saving potential in different sections of the printing press setup.
  • In their post-audit assessment, Times of India estimated that the energy savings potential identified by TERI were to the tune of 9 million INR.
  • At the time of assessment, the unit had achieved savings of up to 5.6 million INR after implementing the post-audit recommendations presented by TERI.
  • The energy audit study and subsequent implementation of recommendations led to a successful reduction in the 'kWh per Page Printed'.
Variable Frequency Drive technology used to interconnect air compressor lines
Air compressor lines were interconnected to use Variable Frequency Drive (VFD) technology optimally
Posted on: 24 July 2012  |   Project status: Completed