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CVBU Pune 1
By TATA Motors Ltd. CVBU, Pimpri, Pune
CVBU Pune 2
TATA Motors Ltd. CVBU, PUNEEnCon in Compressed Air System
Facilitator
Mr. M B Kulkarni (Sr. General Manager – C,C,E & CQH)
Energy Manager
Presentation by
Kishor G Ghude
Assistant General Manager (CPED & Environment)
2
CVBU Pune 3
Company ProfileSpread of Plant - 568 acres.Production Level - 178696 Eq.Veh
(PUNE Commercial Vehicle)
Total Sales turn over Rs. 38364 Crores
(Incl.Pune, Jamshedpur, Lucknow & Pantanagar)
Total shop Sub-stations - 63 Nos.
Total connected load - 172 Mw.
Contract demand - 55372 KVA.
( Incl. CVBU & PCBU)
CVBU Pune 4
TATA Motors's Manufacturing Process
Vehicle Assembly Line
- Chassis Assembly-
Finished product for
Vehicle Assy.
- Axle Assembly -
Finished product for
Vehicle Assy.
- Cowl Assembly-
Finished product for
Vehicle Assy.
- Engine Assembly-
Finished product for
Vehicle Assy.
-Gear Box Assembly-
Finished product for
Vehicle Assy.
Painting
Vehicle
Assembly
3
CVBU Pune 5
SR. NO Thumbnail Model % IMPROVEMENT SR. NO Thumbnail Model % IMPROVEMENT
12.3%
9.8%
CUM - 22 %
. 19.2%
8.1%
CUM - 27.3%
3709 LP/ LPT
EX 19.8% 7 SPACIO 14.70%
4709 SFC
EX12.0% 8
2515 LPT
(697 TCIC) 15.30%
16.6%
22.0%6 207 DI
5407 SFC
EX
FUEL EFFICIENCY IMPROVEMENT
1 1613 SE/ LPT
21510 LP
ENGINEERING
293
486
0 18 36
67
106 15
8
251
382 40
4 446 464
474
0
350
700
2001
-02
2002
-03
Apr-0
3
May
-03
Jun-
03
Jul-0
3
Aug-
03
Sep-
03
Oct-
03
Nov-
03
Dec-
03
Jan-
04
Feb-
04
Mar
-04
Cum
mul
ative
Win
d Un
its in
Lac
s
Target for Year 2004-05 Wind Power - 500 Lacs Wind Units
Energy Efficient & Eco-friendly Technology
To minimise the adverse impact on Environment
Real Time Power Factor Controller
Pond at Shelu VillagePond at Shelu Village
To improve the life of people by…
Comparison with national and international
Automobile Players.
Safe and energy efficient operations
ENERGY POLICY
CVBU Pune 6
Eliminate wastages of resources by maximising “NO INVESTMENT” projects & emphasize on improved productivity of all operations & processes.
Adopt the faster pace for deployment of all ideas in all areas of business thro’ maximizing involvement of people
Focus on accomplishing investment projects with payback less than 2 years at faster pace & deploy across all TATA Motors plants Jamshedpur, Lucknow & Pantanagar.
At saturated performance level introduce break thro’ improvement
by adopting suitable modern technology through adequate
investment .
Share the best practices & performances with vendors , suppliers , partners & other industries & assist them to reduce their ENERGY INTENSITY …..=> ENERGY KAIZEN
TATA Motors, CVBU Pune: ENCON STRATEGY
4
CVBU Pune 7
Trend of Reduction in Specific Energy Consumption
- Electricity -
559536
561
531
400
500
600
06-07 07-08 08-09 09-10
Sp. Energy Cons.(Kwh/Eq.Veh)
5.01%
Reduction over the
year 2006-07
SUSTAINABILITY
CVBU Pune 8
-Trend of Reduction in Specific Energy Consumption
Fuel -(LDO + FO + Propane)
0.38970.3712
0.3500
0.3091
0.3
0.4
0.5
06-07 07-08 08-09 09-10
SpFuel Consum. (Mkcal/Eq.Veh.)
20.68%
Reduction over the
year 2006-07
SUSTAINABILITY
5
CVBU Pune 9
Year 2000-
2001
2001-
2002
2002-
2003
2003-
2004
2004-
2005
2005-
2006
2006-
2007
2007-
2008
2008-
2009
2009-
2010
Kwh/Eq.Veh. 835 734 698 580 552.8 513.1 502.7 536.3 560.9 531.3
% reduction
over 2000---- 12.1% 16.3% 30.5% 33.8% 38.5% 39.8% 35.7% 32.8% 36.3%
Kwh/Eq.Veh. 1181 937 776 630.0 550.0 475.0 472.0 578.0 551.0
% reduction
over 2000-
01
--- 20.7% 34.3% 46.7% 53.4% 59.8% 60.0% 51.1% 53.3%
Kwh/Eq.
Veh.1175.0 1003.0 905.2 755.9 664.8 657.1 647.0 613.3 625.2 648.5
% reduction
over 2007-
08
--- 14.6% 23.0% 35.7% 43.4% 44.1% 44.9% 47.8% 46.8% 44.8%
Kwh/Veh. --- --- --- --- --- --- --- 439.0 290.0
% reduction
over 2007-
08
--- --- --- --- --- --- --- --- 33.9%
Kwh/Eq.Veh. 832 687 632 594 538 510 488
% reduction --- 17% 24% 28.6% 35.3% 38.7% 41.3%
Kwh/Eq.Veh. 524 511 500 448 395 344
% reduction --- 2.5% 4.6% 14.5% 24.6% 34.4%
Kwh/Eq.Veh. 346 316 290
% reduction --- 8.7% 16.2%
Kwh/Car 754 701 534
% reduction --- 7.0% 29.2%
Kwh/Eq.Veh. 1310 1280 1230 1097 911 825
% reduction ---- 2.3% 6.1% 16.3% 30.5% 37.0%
Kwh/Eq.Veh. 4650 4381 4119 4038 3483 3474
% reduction 5.8% 11.4% 13.2% 25.1% 25.3%
Kwh/Eq.Veh. 3160 3080 3210 2940 2940 2940 2900
% reduction ----- 2.5% -1.6% 7.0% 7.0% 7.0% 8.2%
Kwh/Eq.Veh. 8716 6729 4943 6111 4954 4102 3957 3663
% reduction ----- 23% 43% 29.9% 43.2% 52.9% 54.6% 58.0%
Kwh/Eq.Veh. 2094
% reduction -----
Data Not
Available
Data Not
Available
Data Not
Available
Data Not
Available
Data Not
Available
3TATA Motors Car
Plant Chikhali
12
Volvo Truck
Corporation Banglore,
India
13
4TATA Motors Pant
Nagar
9
5
6
Data Not
Available
Data Not
Available
Data Not
Available
7
8
General Motors
(India) Pvt. Ltd.
(Gujarat)
Data Not
Availablewww.volvo.com
Referenece
www.gm.com
www.bmwgroup.com
Sr.
No
Name of
Automobile Player
10
Mahindra & Mahindra
, Kandiwali Plant
(Maharashtra)
1
. Increased due to addition of New
shops/Activity like J-11/12 New Paint,
Xenon Assy, Panel Van shop, Dicor
Engine Assy shop.
http://www.bee-
india.nic.in/ecaward.php
http://www.bee-
india.nic.in/ecaward.php
http://www.bee-
india.nic.in/ecaward.php
http://www.bee-
india.nic.in/ecaward.php
http://www.bee-
india.nic.in/ecaward.php
11 BMW
TATA Motors Pune
(Excluding Foundry)
TATA Motors Jsr 2
General Motors
Mahindra & Mahindra
, Medak Plant (AP)
Mahindra & Mahindra
, Nashik Plant
(Maharashtra)
Data Not Available
Data Not Available
Data Not Available
Sp
. En
erg
y C
on
sum
pti
on
Tata Daewoo
Commercial Vehicle,
Korea
Ashok Leyland ,
Hosur
Data Not
Available
Data Not Available
Data Not Available
Data
Data Not Available
Data Not Available
Data Not
AvailableData Not Available
##
CVBU Pune 10
578 551
3788
5102
4329
832
2111
4298
4827
3800
1280 1230 1097911
1354
825937 776
630 550
1181
475 472
3268
632687 594 538 510 488
11000
12000
13000
12000
11000
6729
3957
531
8716
6111
4954
41024943
513553581698734835
503536 561
0
1000
2000
3000
4000
5000
6000
2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10
Kw
h / E
q. V
eh
icle
0
4000
8000
12000
Ashok Leyland
M & M
Volvo INDIA.
Volvo China.
Scannia
Volvo Brazil
TATA Motors JSR
TATA Motors CVBU Pune
6
CVBU Pune 11
Roadmap to achieve Benchmark / Global best :-Based on above results of National & International companies, TATA Motors CVBU
plant is “Highly Energy Efficient Automobile company”. As part of continual improvement we would further reinvestigate all our processes to achieve further cost reduction by reducing Energy consumptions at all levels.
To sustain the best achieved level. We are following robust process of assessment of performance vis a vis
comparative information / benchmark from different organisation & standards.
Our emphasis would be:-
1. To optimise the use of Resources while using appropriate and innovative method to reduce the energy consumption in all the areas of operation on the continuous basis through evaluation and improvement.
2. Use of Latest technologies wherever possible.3. Maximize the use of non-conventional Energy resources wherever possible.4. Under climate change initiatives, assessment & abatement measures are being
taken to reduce carbon foot print through resource conservation.
CVBU Pune 12
Tata Motors
Pune
CVBU(Commercial Vehicle
Business Unit)
PCBU(Passenger Car Business Unit)
Production- LCVs,MCVs & HCVs Production – Passenger Cars
Compressor Installed Capacity27500CFM
Compressor Installed Capacity27500CFM
7
CVBU Pune 13
Compressed airManagement
Planning for Selection of
Compressor & Associated equipments
Planning of compressed air
pipeline in Compressor
house & Shop
Operation & Maintenance of the Compressor
installation
Installation of Compressor &
Associated equipments &
pipeline
CVBU Pune 14
TPM (Total Productive
Maintenance)SQDCM
5 - S
ISO 14001
TS 16949Poka Yoke
TBEM (Tata Business Excellence Model)
Six Sigma
Management toolsAdopted & Implemented
8
CVBU Pune 15
CVBU Pune 16
Spread of the TML CVBU - Compressed Air SystemInstalled Capacity of compressor -
27,500CFM
Centrifugal Compressor --
2*5500CFM
4*3000CFM
Screw Compressor --3*1500CFM
Compressed Air Peak Draw-15000CFM
Compressed Air Consumption in Kwh Avg.
40000Kwh/Day
Length of Header Pipe line -- 3.0 KM
Total Pipe length -- 19 KM.
9
CVBU Pune 17
CVBU Pune 18
B) Demand side Management
•Plant level Leakage Test
•Block wise leakage as & when required.
•Machine Compressed Air Leakage Audit.
•Special Type of Nozzles
•New Technology Item -Intermediate controller
C) Procurement Guideline/Check-List for New Compressor.
A) Supply side Management
•Compressor Performance Monitoring System
•Optimization of Pressure & Operation of Compressors.
•Intake Air Performance measures.
•Water Recirculation system - Pump , Cooling Tower etc.
•Compressor Efficiency Measurement
• New Technology Item - EnergAir SX System.
10
CVBU Pune 19
CVBU Pune 20
Energy Saving by introduction of Intermediate Control System(IC Unit) for Compressed Air Network :-
Intermediate Control System:It has electronic controller Continuously monitors the downstream demand. Directs the I/C to increase or decrease flow accordingly to correct the deviation from set point. Peaks demands are met with stored energy instead of additional horse power. Air Pressure Boosters are also provided to meet high pressure demand on critical machines.
Benefits:- Operating pressure is 72PSI (5.06Kg/cm2) instead of 84PSI (5.91Kg/cm2) Constant Air pressure within 1PSI (0.07Kg/cm2) Annual Energy Saving in 14 Lakh KWh. Maintenance cost saving due to less pressure operation. Leakage reduction due to optimum pressure.
Control panel
Auto Bypass
Air OutAir In
Modulating Valves
Specific Compressed Air Energy Consumption in Electricity
( KWh/Eq.veh) I.e. Electricity used for producing one vehicle
79
.06
74
.39
76
.94
72
.11
69
.51
69
.15
66
.19
66
.11
66
.2779
.24
80
.98
83
.33
84
.70
83
.79
84
.70
84
.10
86
.82
25
50
75
100
125
Ap
r-0
2
Ma
y-0
2
Ju
n-0
2
Ju
l-0
2
Au
g-0
2
Sep
-02
Oct
-02
No
v-0
2
Dec
-02
Ja
n-0
3
Feb
-03
Ma
r-0
3
Ap
r-0
3
Ma
y-0
3
Ju
n-0
3
Ju
l-0
3
Au
g-0
3
Cu
mm
. S
pe
cif
ic e
ne
rgy
Co
ns
um
pti
on
(KW
H/E
q.v
eh
.)
Cummulative Specific Energy Consumption (KWh/Eq.veh)
Before installation of I/C system.
<----- (Intermediate Control System) ---->
After installation of I/C system.
<-----(Intermediate Control System)----->
Annual Energy saving in Rs. 56 Lakh ;Annual Energy Saving in KWh 14Lakh ;
Annual CO2 Reduction in 1176 tCO2.Investment in Rs. 72 Lakh
11
CVBU Pune 21
A) SUPPLY SIDE MANAGEMENT
CVBU Pune 22
ENCON CASE STUDIES - 01
12
CVBU Pune 23
Energy Saving by Operating Centrifugal Air Compressors atbase load :-
Before: Earlier Reciprocating and Centrifugal air compressors were connected to the upstream of the Intermediate Controller Unit. In this set-up, each compressor was generating compressed air at 84 psi (5.91Kg/cm2) pressure to cater the final pressure requirement of 72 psi (5.06Kg/cm2) at the end-use point inside the Shops.
Before
CVBU Pune 24
After : The base load of CVBU plant is more than 5500 cfm, for which round the clock running one 3000 cfm centrifugal compressor was essential. The 3000 cfm centrifugal compressor has been now connected directly to the down stream of the Intermediate Controller Unit as shown in the following fig.. Pressure setting of the compressor was reduced from 84 psi to 72 psi, since the same is feeding to the compressed air network directly.
Energy Saving :- Rs 12.00 Lac per annum
After
Annual Energy saving in Rs. 12 Lakh ;Annual Energy Saving in KWh 2.67Lakh ;
Annual CO2 Reduction in 224 tCO2.Investment about Nil
Energy Saving by Operating Centrifugal Air Compressors atbase load :-
13
CVBU Pune 25
CVBU Pune 26
ENCON CASE STUDIES - 01
14
CVBU Pune 27
Energy Saving by Modification in Cooling Water recirculation System.:-
Before: Earlier, there was common water recirculation system for D-block compressors and E block.
Before
(Common water
recirculation
System)
CVBU Pune 28
Energy Saving by Modification in Cooling Water recirculation System.:-After: Separated water recirculation systems for D-block compressors and E block, with this system become flexible & optimized the water pumping operations. Studied the system and backward calculation done for water requirement, pipe line sizes and frictional losses.Benefits: 1) By separating systems & optimizing pumping saved power Rs.24.48 Lac per year. 2) Eliminated chances of cooling water contamination with oil carried with E- block water.
After ( with Two Independent system)
Annual Energy saving in Rs. 24.48 Lakh ;Annual Energy Saving in KWh 5.03Lakh ;
Annual CO2 Reduction in 423 tCO2.Investment in Rs. 3.69 Lakh
15
CVBU Pune 29
Before : Fan operated Cooling Tower After : Fanless Cooling Tower
Energy Saving by installation of Natural Draft –
Fanless Cooling Tower at D-blk Compressor House:-
Before: Earlier, induced draft type conventional cooling tower, suction of air takes place with the help of electrical operated Fan.
After: Now, Cooling Tower water cooled by air using Natural Draft, Suction of air takes place with venturi effect created in the tower by using specially designed nozzles.
Annual Energy saving in Rs. 2.64 Lakh ;Annual Energy Saving in KWh 0.587Lakh ;
Annual CO2 Reduction in 70 tCO2.Investment in Rs. 2.7 Lakh
CVBU Pune 30
Energy Saving by Introduction of CORO COAT for Pump Casing & Impeller at D-blk Comp. House:-
Before: Earlier, over the period of pump operation, pump efficiency get reduced
due to normal wear and tear of impeller and casing of pump. Due to this friction loss of pump increases & in turn energy is wasted.
After: By introduction of Coro Coating for Impeller & Casing of pump, the frictional
losses of pump are reduced. Coro Coating is fluid glide coating & hydrophobic (i.e. it repels water) in nature. After Coro Coating the pump efficiency is increased by 8 to 10% with corresponding energy saving of 5%.
Annual Energy saving in Rs. 0.58 Lakh ;Annual Energy Saving in KWh 0.105Lakh ;
Annual CO2 Reduction in 9 tCO2.Investment in Rs. 0.46 Lakh
16
CVBU Pune 31
CVBU Pune 32
Comp.Performance Monitoring System covers… Air Intake Filter Air inlet Intercooler , after cooler, Water inlet & outlet temp. Compressed Air outlet temperature Compressor Efficiency Specific Energy Consumption of Compressor
Compressor Performance Monitoring system :-
Results into…1. Increased involvement of People.2. Increased Level of knowledge3. Predictive maintenance & enhanced pro-
actions.
4. Reliability & cost effectiveness.
17
CVBU Pune 33
CVBU Pune 34
Inlet
Temperature (0C)
Relative Air
Delivery (%)
Power Saved
(%)
10.0 102.0 + 1.4
15.5 100.0 Nil
21.1 98.1 - 1.3
26.6 96.3 - 2.5
32.2 94.1 - 4.0
37.7 92.8 - 5.0
43.3 91.2 - 5.8
Effect of Intake Air temperature on Power Consumption
For Every 40C rise in inlet air temperature results in a higher energy consumption by 1 % to achieve equivalent output.
Hence, cool air intake leads to a more efficient compression.
18
CVBU Pune 35
Centrifugal Compressor Air & Cooling Water Temperature Audit
2nd
Stage
3rd
Stage
1st
Stage
After
cooler
30.6ºC 47.6ºC140ºC 118.2ºC 43.2ºC 76.2ºC 35.8ºC
32.8ºC 32.8ºC 32.8ºC
40.2ºC 38.2ºC 35ºC
Inlet Water
Outlet Water
1st Stage
Inter
cooler
2nd
Stage
Inter
coolerAir In Air Out
CVBU Pune 36
Performance of Intercooler & After cooler Monitoring By… Stage wise Temperature Monitoring
Air inlet temperature IInd
Stage0C
0C
Air inlet temperature Ist
Stage
Air outlet temperature
IInd
Stage0C
Air outlet temperature
Ist
Stage0C
19
CVBU Pune 37
ENCON CASE STUDIES - 01
CVBU Pune 38
Introduction of EnergAir SX System for Reciprocating Compressor
Before ENCON :-Compressor ON-OFF operation was manual.Compressor LOAD / UNLOAD operation pressure band = 4PSI
After Introduction EnergyAir SX:-Automatic ON, OFF, LOAD & Unload operation of Recip. compressorAuto sequencing of reciprocating compressor . Load/Unload operation pressure band changed from +/-4PSI to +/- 2PSI Eliminated compressor manual starting delay .
Compressor Status Screen on Computer,
which shows, Load (Green Lamp)
OFF( RED) , Running ( Yellow) &
Comp. Ready for Operation ( Blue)
Annual Energy saving in Rs. 8.42 Lakh ;Annual Energy Saving in KWh 1.53Lakh ;
Annual CO2 Reduction in 128 tCO2.Investment in Rs. 9.09 Lakh
20
CVBU Pune 39
35 Years Old Reciprocating Compressors replaced
with new Energy efficient Centrifugal
& Screw Compressors
CVBU Pune 40
21
CVBU Pune 41
Baffle type Moisture separator
No Provision for internal
Online cleaning
Before Baffle type Moisture separator :- Pressure drop across separator is more than 3PSI Measured Moisture drain is approx. 10 Liters /Hour. Compressed air temperature after moisture separator is more. No feasibility for Internal cleaning.
After Introduction High Efficient Centrifugal Moisture Separator:- Delta P across Moisture separator is low 1 to 1.5PSI Measured Moisture drain-26 liters/hours. Compressor discharge air temperature is reduced by 1Deg.C due to whirling action. Load on Dryer is reduced results in Energy saving & Easy for maintenance.
Introduction of High Efficient Centrifugal Moisture Separator
Provision for internal
cleaning
High Efficient Centrifugal Moisture
Separator
CVBU Pune 42
Energy Saving by Transvector Nozzle for Cleaning application by using Compressed Air:-
Before: Earlier, Compressed air was used for cleaning the jobs after machining by
using open pipes or conventional nozzles.
After: Now Transvector Nozzles are installed in place of open pipe or conventional
nozzles used for cleaning the jobs after machining. It reduces the compressed Air Consumption by 30-60% & reduces the noise level by 8-10db.
Before Conventional Nozzle
After Transvector Nozzle
Before Conventional Nozzle
After Transvector Nozzle
Annual Energy saving in Rs. 2.32 Lakh ;Annual Energy Saving in KWh 0.58Lakh ;
Annual CO2 Reduction in 49 tCO2.Investment in Rs. 0.19 Lakh
22
CVBU Pune 43
Energy Saving by Installing of Master Cut-off Circuit in Compressed Air Line:-
Before: Earlier, During Non-working period like lunch time, Tea break, shift change
& C shift period minimum comp. air leakages were wasted.
After: Now Master cut-off circuit with Timer is installed in Compressed Air line which
cuts off air supply to fixture, assembly line etc Eliminating Air leakage loss effect during the non working period Lunch break, Tea break, shift change. & it saves Air
leakage loss. At Winger BIW & TCF line, E-block (50Nos. Installed)
Annual Energy saving in Rs. 3.0 Lakh ;Annual Energy Saving in KWh 0.55Lakh ;
Annual CO2 Reduction in 46 tCO2.Investment in Rs. 5.0 Lakh
CVBU Pune 44
Actions taken to reduce the compressed air leakages --
Training programme for the the Employee.
• Blockwise compressed air leakage test to check the unproductive draw of compressed air (Leakages) once in a three months.
• Physical shop leakage audit & display a Tag on leakage points & feedback to concern owner.
• Displayed banners indicating cost of compressed air leakage.
• Periodic audit of Main Header line & checking any leakages.
•Identification & Isolation of Non working areas.
23
CVBU Pune 45
A-block
C-block
J Block
Compressed air Leakage test-Compressed air network
K-block
D-blk Comp House
D-block
H-block
B-block
E-16 /17
E-block
CVBU Pune 46
Compressed Air Leakage -Performance Monitoring Format
24
CVBU Pune 47
•Auditing of leakage points all Blocks,
•Mark leakage point by -Air leakage tag or paint marked
•Mail the soft copy of Leakage points to all Factory Managers, Cx Owners
•Get feed back from the respective maintenance after correction
•Re-audit the points & detect new Leakage points generated
•Conduct Air leakage test to see the improvement.
ACTION TAKEN TO REDUCE AIR LEAKAGES
CVBU Pune 48
Air leakage detectorAir Leak detector used to detect leak points in pipe lines & joints
25
CVBU Pune 49
CVBU Pune 50
26
CVBU Pune 51
Compressed Air leakage points identified during Audit 2010-1146
0
2234
2685
1013
1637
0
500
1000
1500
2000
2500
3000
Apr
-10
May
-10
Jun-
10
Jul-1
0
Aug
-10
Sep
-10
Oct
-10
Nov
-10
Dec
-10
Jan-
11
Feb
-11
Mar
-11
Month
Cu
mu
litiv
e L
eaka
ge
po
ints
CVBU Pune 52
27
CVBU Pune 53
ZERO LEAK AIR Connectors
Swivel connectors for CL 10 Hoses
Swivel type quick release coupling for CL 10 & coiled Hoses
Swivel connectors for coiled Hoses
CVBU Pune 54
THE AIR YOU BREATHE IS FREE.THE AIR YOU USE IS NOT !
USE AIR WISELY
PREVENTLEAKAGES
28
CVBU Pune 55
CVBU Pune 56
Arise , Awake & Realise
If you realise it here & now , Yours is the infinite Gain
If you do not make an attempt to do so
Equally great is your Loss.
29
CVBU Pune 57
..….. a journey towards excellence
THANK YOU !
CVBU Pune 58
ENCON CASE STUDIES - 01
30
CVBU Pune 59
The location of air compressors and the quality of air drawn by the compressors will have a significant influence on the amount of energy consumed.
Compressor performance as a breathing machine improves with cool, clean, dry air at intake.
Importance of Location of Air Compressor & the Quality of Air
Importance of Air Intake Filter In Compressor
Pressure Drop
Across air filter
(mmWC)
Increase in Power
Consumption (%)
0 0
200 1.6
400 3.2
600 4.7
800 7.0
CVBU Pune 60
Air Intake Filter Performance Monitoring By… Manometer
Pressure drop across
Air intake filtermm WC
Pressure Drop Across the Air Intake Filter are measured & Monitored regularly.
Servicing of Air Intake filter is done after reaching the Pressure drop @ 150mm WC.
31
CVBU Pune 61
Air Intake Filter Performance Monitoring By… Manometer
Do not Wait for Preventive Maint.
Schedule
Regular
Monitoring helps to predict Health of Air Filter in turn we can save Energy.
CVBU Pune 62
Reciprocating Compressor Air & Cooling Water Temperature Audit
HP
Stage
LP
Stage
31.8ºC 32.5ºC90.4ºC 79ºC 29.8ºC
28.6ºC
28.6ºC32.4ºC
31.5ºCInlet Water
Outlet Water
Inter -
cooler
After-
cooler
Air In
32.2ºC 32.2ºC
34.2ºC
Air Out
28.6ºC
32
CVBU Pune 63
ENCON CASE STUDIES - 01
CVBU Pune 64
Before ENCON
Before ENCON :-• Cleaning of Inter-cooler / after-cooler was done whenever 2nd stage inlet & outlet temperature was increased , results in more power is required to generate compressed air
•Time required for Maintenance of Intercooler & after-cooler is 18 man-days.
•Sometimes compressor was not available for schedule maintenance in turn run the compressor with high temperature results in increase in power consumption.
C.C.H.P.
STAGEL.P.
STAGE
INTERCOOLER
AFTERCOOLER
Pr.Line Cold Water
Return Line Hot Water
Schematic of Recip. Compressor water recirculation system
Introduction of Back flushing System For Reciprocating Compressor
33
CVBU Pune 65
After ModificationAfter Introduction Back Flushing System:-•Inter-cooler & after-cooler of compressor are cleaned with out waiting for schedule maintenance .• It results into…3ºC drop in 2nd stage air temp.Approx. 0.6% reduction in energy consumption.Comp.efficiency improved by 1%Improved quality of air.Cost reduction in spares & man days.Fatigue less operationSaving in Energy consumption by 8424Kwh/annum/Compressor
Backflushing provision for ZR 250 Screw
compressors
CVBU Pune 66
Sr.
N
Item Description Before Back
Flushing Modification
After Back Flushing
Modification
1 Compressed Air Temp. after
Inter-cooler
Avg. 41 oC Avg. 37.8 oC
2 Compressed Air Temp. after
After-cooler
Avg. 36 oC Avg. 34.5 oC
3 Inter & After Cooler Maint. time
reduction
18 Mandays 2 Hrs.
4 Compressor Reliability on
account of I/C & A/C
100 %
5 Compressed Air Quality Improved
6 Energy Consumption
reduction
8426
Kwh/Comp/annum
Total Saving in Energy Consumption / Compressor =
8424 Kwh/annum/comp.
34
CVBU Pune 67
IMPROVED
QUALITY OF AIR
1. COST REDUCTION IN SPARES & MANDAYS
(162 MANDAYS / YEAR)2 FATIGUELESS
OPERATION3 DECREASE IN FREQUENCYOF OVERHAULING
ADVANTAGES OF BACKFLUSHING
3oC. Drop in
2nd Stage Air
Inlet Temp.
Compressor
Efficiency
Improved By
1%
Total Saving in Energy Consumption / Compressor =8424 Kwh/annum/comp.
Approx. 0.6%.
Reduction in Energy
Consumption.
