# Where does energy go in a plastic pipe unit in Ramnagar?

Canonical: https://senseible.earth/answers/ramnagar-pipe-unit-energy-share

Into the extrusion line, run on grid electricity. TERI's profile of the Ramnagar plastics cluster puts its 20 pipe and fitting units at 1,755 of the cluster's 2,860 toe a year, over 60%. Power comes from PUVVNL, with diesel in DG sets through frequent power cuts.

## Inside the line

- Barrel heaters: often ON-OFF controlled and poorly insulated, one of the largest users.
- Extruder screw motor, usually at constant speed through a gearbox.
- Vacuum sizing tank and cooling stages.
- Caterpillar haul-off and the cutter on a limit switch.
- Air compressors and process cooling.

## Fuels besides the grid

Across the cluster, high speed diesel runs DG sets during power failures, and used engine oil and LPG are also burned. Electricity is about 84% of the cluster's energy.

## How the bill is built

Most units take supply from PUVVNL under tariff HV-2, a two-part tariff billed on maximum demand and kVAh. TERI found power factor at the main incomer between 0.95 and 0.97; automatic power factor correction cuts kVAh billed for the same work.

## What to fix first

- Radiant barrel heater bands: 20 to 30% of heating energy.
- VFD on the extruder motor: up to 20%.
- Air leaks, often above 20%, brought to about 5%.
- Replace motors rewound three or more times with IE3 motors.

## An average pipe unit (estimate)

- 1,755 toe across 20 units = 87.75 toe per unit a year.
- If 84% is electricity, as for the cluster: 73.7 toe, about 857,700 kWh at the profile's 11,636 kWh per toe.
- 857,700 kWh x 0.675 kg CO2 (CEA, FY 2025-26) = about 579 tCO2 a year from grid power.

Averages from a 2016 cluster profile; your own bills give the real figure.

## What Senseible does here

Senseible reads PUVVNL bills, using the printed kWh on kVAh bills, and DG diesel invoices into monthly CO2 for your unit, so you can see whether a heater or drive change moved it.

- [Your MSME carbon number](https://senseible.earth/msme-carbon-number)
- [Ramnagar plastics cluster: energy and CO2](https://senseible.earth/answers/ramnagar-plastic-cluster-energy-co2)

Sources: [TERI and SAMEEEKSHA, Cluster profile: Ramnagar plastic industries](https://sameeeksha.org/pdf/clusterprofile/Ramnagar-Plastic-Industries-Uttar-Pradesh.pdf), [CEA CO2 Baseline Database for the Indian power sector, version 22.0](https://cea.nic.in/cdm-co2-baseline-view?mappingId=234&lang=en)

Last reviewed 2026-11-03.