Final Trail Report case study industry

FINAL REPORT ON FUEL SAVINGS

Trials conducted by
Team of PSE

Industrial Case Study

21/04/2023
PageSol Enterprises LLP

PageSol Enterprises LLP LLP Identification Number: AAS-8523

Reg. Address: B-902, Plumeria Garden Estate, OMICRON - III, Greater Noida, U.P. – 201310
Email: sales@pse.net.in Phone: +91 9384000192,93,95,96,97 Web: http://www.pse.net.in
 Final Trail Report case study industry

Table of Contents
1. Executive Summary
2. Fuel Treatments
3. Fuel Optimization
4. Data Compilations
5. Comparison & Charts
6. Estimation of fuel Savings

PageSol Enterprises LLP LLP Identification Number: AAS-8523

Reg. Address: B-902, Plumeria Garden Estate, OMICRON - III, Greater Noida, U.P. – 201310
Email: sales@pse.net.in Phone: +91 9384000192,93,95,96,97 Web: http://www.pse.net.in
 Final Trail Report case study industry

Executive Summary

We were asked to conduct trails on 1st December 2022 on SKO and HSD bullets. We
started our trails from 3rd December 2022 and started optimization from mid of
December. We kept a close observation on plant operation, fuel consumption and
actual consultations in main tank, please find below our findings for the month of
January, February & March 2023
We have seen a savings of 17.2k liters of SKO as per data generated and shown in
tables in the month of January.

We have seen a savings of 8.9k liters of SKO as per data generated and shown in
tables in the month of February.

We have seen a savings of 17.4k liters of SKO as per data generated and shown in
tables in the month of March.

Currently as per yesterday calculations we are seeing a savings of 16.8% or saved 8.4K
liters of SKO in the month of April.

Aggregated saving of 15.31%

PageSol Enterprises LLP LLP Identification Number: AAS-8523

Reg. Address: B-902, Plumeria Garden Estate, OMICRON - III, Greater Noida, U.P. – 201310
Email: sales@pse.net.in Phone: +91 9384000192,93,95,96,97 Web: http://www.pse.net.in
 Final Trail Report case study industry

Fuel Treatments

1. Our team visited the company on 1st of December 2022 for survey and a survey
was conducted on areas where treatment had to be conducted.
2. Total 5 DG sets were identified with tank capacity of:
1. Two 1650 KVA 1200 L Capacity
2. One 320 KVA 380 L Capacity
3. Two 500 KVA 480 L Capacity

Tank Treatments (HSD) 02/12/2022

1. Main tank 20K L was treated

2. Sub tank 1200 L was treated
3. Unit II powerhouse DG with 3 metal barrels, 1 plastic barrel were treated
4. Yanmar DG1 sub tank of 600 L was treated
5. Yanmar DG2 sub tank 550 L was treated
6. Machine Shop I DG with 450 L and 2 barrels with 400 L were treated
7. Machine Shop I DG 320 KVA with 350 L was treated
8. INV plant sub tank of 420 L was treated

Tank Treatments (SKO) 03/12/2022

There are 2 SKO tanks with Main tank capacity of 20K L and 1500 L overhead tank.
The main tank 20k L was treated, we were not able to treat the 1500 L sub tank as
there was no access for it.

Total M1BOOSTER used for above treatment: 634 ml

M1BOOSTER used for treatment for rest of the month: 1536 ml
Total M1BOOSTER used for the month of December 2022: 634 + 1536 = 2170 ml

PageSol Enterprises LLP LLP Identification Number: AAS-8523

Reg. Address: B-902, Plumeria Garden Estate, OMICRON - III, Greater Noida, U.P. – 201310
Email: sales@pse.net.in Phone: +91 9384000192,93,95,96,97 Web: http://www.pse.net.in
 Final Trail Report case study industry

Optimization

It was observed from trial, after treating SKO fuel with M1BOOSTER and checked for
change in fuel characteristics, there was no significant change in fuel economy. From
the operation it was observed that the fuel controller is not an automatic with
respect to burner temperature changes. The present set up of settings of fuel control
rate is not for an automatic adjustment. It was felt, there is a need to optimize fuel
control system for getting benefits of M1BOOSTER. Our team with the help of the
organization team started valuating the plants to do necessary optimization on
boilers, ladles, burners and sand dryers.

It took us some time to evaluate and identify where maintenance work was needed
so that the burner or sand dryer can run on an optimal level. We also had to wait for
untreated fuel in pipes or tanks which were beyond treatment could be replenished.

21 December 2022
1. G & H burner was optimized from 5.5 fuel flow to 4.5 and were calibrated to
work in optimal level
2. SKO boiler was optimized by reducing fuel flow valve by 15%

24 December 2022

1. Unit 1 one ladle preheater was optimized from 7.5 to 6 cm fuel flow and was
calibrated to work in optimal level
2. INV plant one ladle preheater was optimized from 7.5 to 5.5 cm fuel flow and
was calibrated to work in optimal level

PageSol Enterprises LLP LLP Identification Number: AAS-8523

Reg. Address: B-902, Plumeria Garden Estate, OMICRON - III, Greater Noida, U.P. – 201310
Email: sales@pse.net.in Phone: +91 9384000192,93,95,96,97 Web: http://www.pse.net.in
 Final Trail Report case study industry

27 December 2022
1. Sand dryer was optimized from 4 to 3.5 cm flue flow and two trails were
conducted to calibrate and it was working on optimal level

30 December 2022
1. One ladle preheater was calibrated and optimized from 7.5 to 6 cm fuel flow

4 January 2023
1. Four ladle preheaters were calibrated and optimized from 7.5 to 6 cm fuel flow

PageSol Enterprises LLP LLP Identification Number: AAS-8523

Reg. Address: B-902, Plumeria Garden Estate, OMICRON - III, Greater Noida, U.P. – 201310
Email: sales@pse.net.in Phone: +91 9384000192,93,95,96,97 Web: http://www.pse.net.in
 Final Trail Report case study industry

Table 1
Fuel Consumption Plant Vs Fuel Consumption Tank Data
December 2022

Date Tank as per plant Tank Actual Consumption plant Tank Consumption
03-12-2022 2722 4786 3259 4762
04-12-2022 11463 12024 0 125
05-12-2022 11463 11899 3164 2892
06-12-2022 8299 9007 4211 3648
07-12-2022 4088 5359 3539 3538
08-12-2022 549 1821 4261 3809
09-12-2022 8288 10012 3478 4537
10-12-2022 4810 5475 2604 1576
11-12-2022 2206 3899 756 2389
12-12-2022 1450 13510 2200 0
13-12-2022 11250 13510 3665 1566
14-12-2022 7585 11944 4374 6022
15-12-2022 15211 17922 4020 4535
16-12-2022 11191 13387 4071 4255
17-12-2022 7120 9132 3610 3720
18-12-2022 15510 17412 279 317
19-12-2022 15231 17095 4168 3708
20-12-2022 11063 13387 4282 3249
21-12-2022 6781 10138 3676 4311
22-12-2022 3105 5827 4156 3612
23-12-2022 -1051 2215 4269 3699
24-12-2022 6680 10516 3139 4095
25-12-2022 3541 6421 767 712
26-12-2022 2774 5709 2700 2950
27-12-2022 74 2759 3757 4243
28-12-2022 8317 10516 3473 3854
29-12-2022 4844 6662 3383 4196
30-12-2022 1461 2466 3887 3924
31-12-2022 9574 10542 1908 3272

Total consumption as per plant: 99090 L

Total consumption as per tank: 101626 L

PageSol Enterprises LLP LLP Identification Number: AAS-8523

Reg. Address: B-902, Plumeria Garden Estate, OMICRON - III, Greater Noida, U.P. – 201310
Email: sales@pse.net.in Phone: +91 9384000192,93,95,96,97 Web: http://www.pse.net.in
 Final Trail Report case study industry

Results and discussion

It was informed that the fuel inventory is estimated from the plant operation and stock in
the main fuel tanks. Referred to the previous months the fuel data, the plant
consumption Vs tank fuel data was closely matching with a small deviation.

Chart 1

DECEMBER TANK DATA

20000

15000

10000

5000

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

-5000

Tank as per plant Tank Actual

Chart-1 indicates that the fuel opening stock of plant and tank. It can be clearly seen
that both plant and tank data are nearly similar without any fuel savings even though
the fuel is treated with M1BOOSTER in the main fuel tanks. It was observed that the tank
fuel increased as compared to plant due to decrease in density of fuel delivered without
adjusting fuel flow for changes in fuel characteristics.

PageSol Enterprises LLP LLP Identification Number: AAS-8523

Reg. Address: B-902, Plumeria Garden Estate, OMICRON - III, Greater Noida, U.P. – 201310
Email: sales@pse.net.in Phone: +91 9384000192,93,95,96,97 Web: http://www.pse.net.in
 Final Trail Report case study industry

Table 2
Fuel Consumption Plant Vs Fuel Consumption Tank Data
January 2023
Date Tank as per plant Tank Actual Consumption as per plant Tank Consumption Actuals
31-12-2022 9574 10642 3030 3372
02-01-2023 6544 7270 1805 898
03-01-2023 6544 18022 3572 3663
04-01-2023 16739 14359 4171 3465
05-01-2023 13167 10894 5259 3868
06-01-2023 8996 7026 3364 3127
07-01-2023 3737 3899 1755 1716
08-01-2023 373 2183
09-01-2023 -1382 13997 2013 2600
10-01-2023 10618 11397 4046 3264
11-01-2023 8605 8133 4079 3601
12-01-2023 4559 16332 5318 3482
13-01-2023 12480 12523 5230 4390
14-01-2023 7162 8133 1652 1591
15-01-2023 1932 6542 0 0
16-01-2023 280 6542 0 0
17-01-2023 -360 6542 2991 2643
18-01-2023 -360 3899 3538 3152
19-01-2023 -3351 12647 4529 4080
20-01-2023 5111 8567 4194 4007
21-01-2023 582 4560 3839 3418
22-01-2023 -3612 13142 0 0
23-01-2023 4549 12771 4173 3764
24-01-2023 4549 9007 4360 3879
25-01-2023 376 5128 3964 4110
26-01-2023 -4079 13018 423 495
27-01-2023 4584 12523 4292 3767
28-01-2023 4161 8756 4456 3857
29-01-2023 -131 4899 2485 1839
30-01-2023 -4587 3060 3396 3412
31-01-2023 -7072 11648 4640 4009

Total consumption as per plant: 95042 L

Total consumption as per tank: 77830 L

PageSol Enterprises LLP LLP Identification Number: AAS-8523

Reg. Address: B-902, Plumeria Garden Estate, OMICRON - III, Greater Noida, U.P. – 201310
Email: sales@pse.net.in Phone: +91 9384000192,93,95,96,97 Web: http://www.pse.net.in
 Final Trail Report case study industry

Chart 2

Chart 2 indicates the fuel opening stock of plant Vs tank for the month of January
2023 after optimizing SKO burners, ladle and preheaters. It can be clearly seen that
both plant and tank data show a deviation and the gap increases as the month has
progressed. That is the opening stock in the fuel tank showed fuel savings. Requested
to report plant data as per non treating of fuel for estimating the fuel economy.

PageSol Enterprises LLP LLP Identification Number: AAS-8523

Reg. Address: B-902, Plumeria Garden Estate, OMICRON - III, Greater Noida, U.P. – 201310
Email: sales@pse.net.in Phone: +91 9384000192,93,95,96,97 Web: http://www.pse.net.in
 Final Trail Report case study industry

Table 3
Fuel Consumption Plant Vs Fuel Consumption Tank Data
February 2023
Consumption as Tank Consumption
Date Tank as per plant Tank Actual per plant Actuals
2441 2300
01-02-2023 1532 7639 2499 3196
02-02-2023 11033 16443 3294 3301
03-02-2023 7739 13142 3621 3633
04-02-2023 4118 9509 2461 2967
05-02-2023 1657 6542 789 597
06-02-2023 868 5945 3122 2757
07-02-2023 9746 15188 3635 3917
08-02-2023 6111 11271 4618 3878
09-02-2023 1493 7393 4584 4088
10-02-2023 8909 15305 4400 4285
11-02-2023 4509 11020 4698 3258
12-02-2023
13-02-2023 -189 7762 3493 2990
14-02-2023 8318 16772 3838 4249
15-02-2023 4480 12523 4056 4016
16-02-2023 424 8507 4375 4512
17-02-2023 8049 15995 3628 3597
18-02-2023 4421 12398 4364 4141
19-02-2023
20-02-2023 57 8257 4340 4500
21-02-2023 7717 15757 4760 3984
22-02-2023 2957 11773 4261 4380
23-02-2023 -1304 7393 4224 4634
24-02-2023 -5528 2759 4545 5502
25-02-2023 1927 9257 4303 3430
26-02-2023 -2376 5827 2328 1379
27-02-2023 -4704 4448 3912 3801
28-02-2023 3384 12647 4265 2383

Total consumption as per plant: 118817 L

Total consumption as per tank: 109917 L

PageSol Enterprises LLP LLP Identification Number: AAS-8523

Reg. Address: B-902, Plumeria Garden Estate, OMICRON - III, Greater Noida, U.P. – 201310
Email: sales@pse.net.in Phone: +91 9384000192,93,95,96,97 Web: http://www.pse.net.in
 Final Trail Report case study industry

Chart 3

Chart 3 indicates the fuel opening stock of plant Vs tank for the month of February
2023. It can be clearly seen that both plant and tank data show a deviation and the
gap increases as the month has progressed. That is the opening stock in the fuel tank
showed fuel savings.

February there was some data issue from the organization as around 11 days in
February the difference between plant consumption vs tank consumption was in
negative, which is logically or practically not possible. The difference between the two
either should be 0 or in positive only it can’t be negative. Still in February we have
achieved around 8%.

PageSol Enterprises LLP LLP Identification Number: AAS-8523

Reg. Address: B-902, Plumeria Garden Estate, OMICRON - III, Greater Noida, U.P. – 201310
Email: sales@pse.net.in Phone: +91 9384000192,93,95,96,97 Web: http://www.pse.net.in
 Final Trail Report case study industry

Table 4
Fuel Consumption Plant Vs Fuel Consumption Tank Data
March 2023
Date Tank as per plant Tank Actual Cons as per plant Tank Cons actuals
28-02-2023 12647 2335 2335
01-03-2023 1367 8382 4214 3137
02-03-2023 9003 17095 3313 3463
03-03-2023 5690 13632 4105 3872
04-03-2023 1585 9760 4427 4517
05-03-2023 -2842 5243 540 571
06-03-2023 -3382 4672 4624 3975
07-03-2023 3944 12647 4539 3891
08-03-2023 -595 8756 4684 4048
09-03-2023 -5279 4672 4774 4189
10-03-2023 1862 12398 4468 4265
11-03-2023 -2606 8133 4016 2774
12-03-2023 -6622
13-03-2023 -6622 5359 3549 3233
14-03-2023 1579 13876 4520 4116
15-03-2023 -2941 9760 4899 4198
16-03-2023 4010 17412 4654 3780
17-03-2023 -644 13632 4530 3872
18-03-2023 -5174 9760 5362 4763
19-03-2023 1239 16772 1996 1235
20-03-2023 -757 15537 3340 3139
21-03-2023 -4097 12398 4497 3642
22-03-2023 -8594 8756 4808 4084
23-03-2023 -13402 4672 4759 4553
24-03-2023 -6386 11899 4469 3642
25-03-2023 -10855 8257 4920 4140
26-03-2023 -15775 4117 2565 1477
27-03-2023 -18340 2640 2820 2640
28-03-2023 -21160 0 4761 3545
29-03-2023 -14021 10012 4279 3710
30-03-2023 -18300 6302 4016 3445
31-03-2023 -10456 14717 2483 1822

Total consumption as per plant: 137978 L

Total consumption as per tank: 120785 L

PageSol Enterprises LLP LLP Identification Number: AAS-8523

Reg. Address: B-902, Plumeria Garden Estate, OMICRON - III, Greater Noida, U.P. – 201310
Email: sales@pse.net.in Phone: +91 9384000192,93,95,96,97 Web: http://www.pse.net.in
 Final Trail Report case study industry

Chart 4

Chart 4 indicates the fuel opening stock of plant Vs tank for the month of March 2023.
It can be clearly seen that both plant and tank data show huge deviation and the gap
increases as the month has progressed. That is the opening stock in the fuel tank
showed fuel savings.

PageSol Enterprises LLP LLP Identification Number: AAS-8523

Reg. Address: B-902, Plumeria Garden Estate, OMICRON - III, Greater Noida, U.P. – 201310
Email: sales@pse.net.in Phone: +91 9384000192,93,95,96,97 Web: http://www.pse.net.in
 Final Trail Report case study industry

Table 5
Fuel Consumption Plant Vs Fuel Consumption Tank Data
April 2023

Tank
as per Tank Consumption Tank Consumption
Date plant Actual as per plant Actuals Load Fuel Saved
31-03-2023 12807 12895 621
01-04-2023 12186 12274 2005 1254 751
02-04-2023 10181 12274
03-04-2023 10181 11020 3019 2513 506
04-04-2023 7162 8507 3780 3547 11703 233
05-04-2023 15085 16663 3935 3398 537
06-04-2023 11150 13265 4631 4133 498
07-04-2023 6519 9132 4228 3540 688
08-04-2023 2291 5592 4254 3761 11923 493
09-04-2023 9960 13754 1480 1480 0
10-04-2023 8480 12274 4035 3518 517
11-04-2023 4445 8756 4093 3164 929
12-04-2023 352 5592 3630 3126 11772 504
13-04-2023 8494 14238 4211 3722 489
14-04-2023 4283 10516 0
15-04-2023 4283 10516 1620 1127 493
16-04-2023 2663 9389 279 257 22
17-04-2023 2384 9132 4563 3602 11777 961
18-04-2023 9598 17307 4035 3553 482
19-04-2023 5563 13754 4231 3868 363

Total consumption as per plant: 58029 L

Total consumption as per tank: 50184 L

PageSol Enterprises LLP LLP Identification Number: AAS-8523

Reg. Address: B-902, Plumeria Garden Estate, OMICRON - III, Greater Noida, U.P. – 201310
Email: sales@pse.net.in Phone: +91 9384000192,93,95,96,97 Web: http://www.pse.net.in
 Final Trail Report case study industry

Fuel savings report summary

Month Jan 2023 Feb 2023 Mar 2023 Total
Fuel
consumption 85935 103985 106073 310705
in Lt
Fuel Cost 80,77,890 97,74,590 1,13,53,790 2,92,06,270
in Rs.
Fuel 17212 8900 17464 43,576
saving in
Ltrs
Cost
saving in
Rs. 16,17,928 8,36,600 16,41,616 40,96,144
(Rs.94/Itr
approx.)

% Saving 20% 8% 16.46 14.82

April we are saving of 8466 Liters and around 16.8% if we take a average of four months
An average of 15.31% of fuel was saved during the past three months

PageSol Enterprises LLP LLP Identification Number: AAS-8523

Reg. Address: B-902, Plumeria Garden Estate, OMICRON - III, Greater Noida, U.P. – 201310
Email: sales@pse.net.in Phone: +91 9384000192,93,95,96,97 Web: http://www.pse.net.in
 Final Trail Report case study industry

Thank You

PageSol Enterprises LLP LLP Identification Number: AAS-8523

Reg. Address: B-902, Plumeria Garden Estate, OMICRON - III, Greater Noida, U.P. – 201310
Email: sales@pse.net.in Phone: +91 9384000192,93,95,96,97 Web: http://www.pse.net.in