WELCOME [] · · 2010-09-07WELCOME Presentation team Mr. Kiran R. Mhetre ... Assignments to individuals through Performance Appraisal.] ... Sr.No Project Saving Rs Mn

7-Sep-10 1Kirloskar Pneumatic Co. Ltd.,Pune

Kirloskar Pneumatic Co. Ltd, Pune

CII – National Award for Excellence in Energy Management-2010

WELCOME

Presentation team

Mr. Kiran R. MhetreMr. Uday V. MaratheMr. Nitin M. Bapat

Company Outline


Hadapsar Plant Saswad Plant

Plant Location Area Built-up

Hadapsar (Pune) 27 Acres 30625 m²Saswad (Pune) 65 Acres 8485 m²

Divisions:ã ACD - Air Compressor Division { Including Foundry }ã TRM - Transmission Divisionã ACR & PGS – Air Conditioning _Refrigeration & Process Gas System


Company Profile

Products :•Air Compressors

•TransmissionProducts

•Air Conditioning & Refrigeration Compressors

•Process GasSystems

Infrastructure :

• CAD / CAM Centre

• CNC machining Centers

• Fabrication facility

• In-house foundry

• Sophisticated testing labs

• Stress relieving furnaces

• SCADA based Centrifugal Test Bed

We manufacture our products under ISO 9001, EMS 14001 & OHSAS 18001


Energy & Environment Policy


Energy Conservation Culture

] Activity started since 1988-89 & part of Quality Management System

] Strong ENCON team with designated Energy Managers

] Encon week Celebration on14th to 20th December.

] Awareness program to all employees & their participation thru Encon Kaizen’s.

] Encon Projects by Vocational trainees & College students.

] Appreciation through Awards & Recognitions

] Assignments to individuals through Performance Appraisal.

] Participation at State and National Level Competitions.

] Periodical Audits by External agencies

] Energy Management approach with new techniques & technologies

] Strong commitment to renewable energy resources


• Encon MethodologyEnergy Management Activity percolated to shop floor through :

]Energy Accounting , Budgeting & Control

]Usage of Non-conventional Energy Sources

]Adoption of New Technology

]Waste Identification & Elimination

]Continuous identify the opportunity for operation and process improvement

]Environment protection

]ENCON Expertise & Knowledge into New Projects

]Elevating Plant Performance to Improve Utilization

]Energy Efficient Products to Customers

]Energy Kaizens, Training & Awareness

]Examining Ourselves through External Agencies


Encon SWOT

Threats

• Poor quality of grid supply

• Electricity tariff hike

• Fuel prize inflation

Opportunities

• Extending Encon culture to vendors,

suppliers and society.

• Reduction in fixed energy cost

• Use of non-conventional energy

• ECBC concept,

Weakness

• Excess plant capacity to meet present

market requirement

• Few energy intensive old machines

Strength

• Excellent Encon Culture

• Three EM and Four EA

• Acceptance to change quickly

• Technical expertise and leadership


Cumulative Savings Thru’ Energy Conservation

Cumulative Saving Rs 39.21 Mn


Sr. No Projects Saving Rs Mn

1 Using of Solar Water Heating System for Canteen 0.055

2 Installed Translucent Sheet for Shops 0.352

3 Solar Lantern to Security lighting 0.010

Renewable Energy Usage

Projects 03 NosSavings 0.417Mn


Compressed Air

Sr.No Project Saving Rs Mn

1 Trans-Air Zero Air Leakage Piping for Assembly 0.0622 Decentralisation of Pneumatic System – Replaced old

200 cfm Air Compressor by 2 x 96 cfm Air Compressor 0.331

3 Replaced Pneumatic tools by Electrical Tools for Deburring operation

0.106

4 Installed air blower in place of air compressor at ETP 0.1275 Energy Efficient Air Guns fitted at Open points 0.0786 Reduced plant air leakages from 22.6% to 10.3% by

rigorous maintenance0.338

7 Installed Zero air discharge auto drain valves to air receivers

0.034

8 Replaced cycle stand air compressor by manual foot operated pump

0.0008

Projects 08 NosSavings 1.077 Mn

Air Compressor Replaced by Air Blower on ETP


Objective To Eliminate Compressed Air at ETP

Details • Reciprocating air compressor was installed at ETP to cater the air requirement of De-areation process

• Compressor generated 6 bar air pressure & 30 cfm flow rate

• Energy consumption was 4.4 kWh• 24 hrs Continuously working

• Replaced air compressor by high pressure root blower

• Generate 1.5 bar air pressure & 35 cfm flow rate

• Energy consumption 1.76 kWh• Reduce maintenance cost

Photo

Investment Rs 0.075 Mn

Annual Saving Rs 0.112 Mn

Simple Payback 8 Months


Power Management


1 Controlling Maximum Demand by Wireless Remote Control System

0.961

2 Switching ‘OFF’ Power Transformer during No Load - to avoid losses

0.150

3 Switching ‘OFF’ Lighting Transformer during Day Time - to avoid losses

0.015

4 Optimised plant operating voltage by 10% during night shift

0.727

5 Re-scheduled TOD consumption of Zone C & D to Zone A & B

0.246

6 Obtained “Unity” Power Factor and 1% prompt discount benefits from MSEDCL

4.132



Process Improvement


1 Process integration for carburising and hardening at Heat Treatment

1.440

2 Process Change – Reduced number of set ups of Axis Arm Product

0.126

3 Replaced Oil bath heating system by Induction heating

0.178

4 Replaced LDO fired furnace burner at Foundry 0.138

5 Retrofitted conventional balancing machine with Microprocessor based controller

0.124


Oil Bath Heating Replaced by Induction Heating


Objective To reduce process time and cost

Details • Oil Bath heating was used for the heating of bearings, gears & pinion.

• Process cycle time 3 hrs

• Oil bath replaced by induction heating process.

• Process cycle time 10 min• Eliminate process oil consumption

Photo





New Technology


1 LDO fired stress reliving furnace converted into Compartmentalised Electrical Furnace

1.429

2 Replaced nine (9) conventional welding rectifier by Inverter based controlled welding machine

0.389

3 Installed Fan less cooling towers for Product Testing and Foundry Utility

0.006

4 Shop Air Circulator’s Aluminum fan blades replaced by FRP fan blades

0.031

5 Replaced CRT monitors by LCD Monitors – 85 Nos 0.0456 Installed Energy Efficient T5 Tube Lights for TRM

Shop Lighting0.114

7 Installed Variable Frequency Drive for 55 kW Test bed motor

0.048



Energy Efficient T5 Lighting TRM Shop

Objective To reduce fixed energy cost

Details • 75 x 250 watt HPMV lamps were installed in Old TRM shed

• Poor lux level • Maintenance cost was more• Natural day lighting was poor hence

shop lights needed to keep ‘ON’ in a day

• Roof height was low• Poor Ventilation

• Renovated Shop with PEB concept• Installed 4x48 Energy Efficient T5 lights,

70 Nos• Increased Lux level • Installed translucent sheet for natural day

lighting.• Shop height increased for proper

ventilation• Burning hrs are more than HPMV

Photo





HVAC Projects


1 Installed Time switch for UPS air conditioners 0.4162 Replaced old window air conditioners by Star Label

Energy Efficient air conditioner0.040

3 Used stand fan instead of 40 ton package air conditioner operation during weekly off & holiday

0.029

4 Converted all AHU motors from Delta to Star 0.005

5 Increased office air conditioner temperature by 2 C 0.012



Waste Elimination


1 Installed Time switch for Shops and canteen lighting/Fans

0.003

2 Temp. controlled interlock to heat treatment cooling tower

0.052

3 Old furnace revamped by providing insulation over jacket and heat repellant paint to reduce skin losses

0.096

4 Provided Interlock for cooling tower operation with 40T Package air conditioner

0.036

5 Installed Motion sensors for toilets and offices 0.0026 Optimised the heat treatment cooling pit pump

capacity from 7.5 kW to 2.2 kW0.175

7 Reduced component resting base plate weight from 1250 Kgs to 300 Kgs at stress reliving furnace

0.103



Oven Base Plate Weight Reduction

Objective To reduce stress reliving oven energy cost

Details • Cast iron base plate was used on furnace bed to support the component

• No of base plates – 34 Nos • Weight of each plate 32.25 Kgs• Additional heat load due to heavy weight

1986.6 kCal/plate• Total heat load 67544.4 kCal• Energy losses 78.54 kWh

• Cast iron plate replaced with MS sheet plate

• No. of MS plates – 02 Nos• Weight of MS sheet plate is 84Kgs• Heat load reduced due to reduction

of weight from 67544.4 kCal to 5174.4 kCal

• Energy losses reduced by 72.52 kWh

Photo



Simple Payback 15 days

Innovative Project


Power Regeneration from 1MW Gear Test Bed

Power Regeneration from 1MW Gear Test Bed


Background

v1MW Gear Boxes operate on top of the 70 Meter Tower in UN-Mannedcondition vLife expectancy of 20 years. vConventional method of gear box testing at full load by employing water brakedynamometer. vTesting cycle time for 8 Hrs / test / Gear BoxvIn WBD test entire power lost in heating of water. vElectrical Energy cost of Rs 7.68 Mn (Considered kWh consumption &Maximum Demand charges) for 102 Nos gear boxes

KPCL designed with innovative solution where in the Gear Box wassubjected to complete performance test with power regeneration and reverse feed into system. This reduces testing cost substantially

Schematic Diagram


v 1.15 MW motor operates on 6.6 KV with variable frequency drive. v The mechanical power drives the KPCL 1 MW gearbox.v 1 MW asynchronous generator is coupled , which generates variable power.v It is converted into DC; chopped and inverted. v The inverted power is fed to input side of variable frequency drive with proper

line synchronization.

1.5 MVA OLTC

Transformer22kV / 415 kV

Step Up Transformer 690V/6600V

Variable Frequency

Drive

1150 kW, Induction

Motor

KPCL Aux Reduction Gear Box

KPCL 1MW

Gear Box

Moventas 1MW

Gear Box

Frequency Converter

ABB Generator

1 MW

(2.5%) (4.5%)

(2%) 143 RPM(2%) 23 RPM(2%) 136 RPM(3%) 136 RPM(4%)

(2%) (2%)2948 RPM1092 kW

1071 kW1049 kW1028 kW997 kW

958 kWKPCL PLANETARY GEAR BOX

1.5 MVA Step up

Transformer415V / 690 kV

(2%)

Saving Calculations


Power required to test the gear box on full load 1.15 MWPower regenerated by innovative system 958 kWPower consumed in Losses 239 kW

Testing time 8 hrs/test/gear boxNo. of gear boxes 102 NosTotal testing time 816 hrsProto type testing time 60 hrsGrand total testing time 876 hrs

Energy required for conventional testing 1.007. Mn kWhActual Energy consumed by innovative system 0.209 Mn kWh

Total Energy saving 0.798 Mn kWhAverage industrial electricity unit rate Rs 5.90 / kWhEnergy Saving Rs 4.708 Mn

Saving Calculations


Additional benefits is because of reduction in Maximum Demand Charges as,

Maximum Demand Saving 1197 kVA @ 0.8 PFMaximum Demand Charges Rs 150/kVAAnnual Saving Rs 3.41 Mn

Investment Made Rs 14.50 Mn

Net Annual Saving Rs 8.118 Mn

ROI 55.98%

Carbon Emission reduction 678.33 MT/Annum

Innovative Project 2


Wireless Maximum Demand Controller



BackgroundäNo maximum demand control mechanism äDue to uncertain testing of big gear boxes and air compressors. The Maximum demand shot up to 2400 KVAäAverage electricity unit rate was increased due to increase in fixed charges

ProjectäInstalled wireless controlled maximum demand controller äDuring shoot-up of Maximum Demand , it gives an alarm to operator äIf not attended, it cuts the non-critical load like AC plants & pump house äTesting feeder shifted from MSEDCL to DG setäSwitch ON the non-critical load feederäConfirm the completion of testing & Switch OFF the DG Set



22 kV Express feeder Maximum Demand Sanctioned 2700 kV

Maximum Demand Controller Set 1800 kVA

DG set utilized to sustain the MD 11900 kWhCost for DG Set Operation Rs 0.119 Mn

SavingsMSEDCL kVA Rate 150/kVAMonthly Saving Rs 0.090 MnAnnual Saving Rs 1.08 Mn

Net Annual Saving Rs 0.961 Mn


Specific Energy ConsumptionAir Compressor Products ( kWh/cfm )

Years

kWh/

cfm

FY’10 SEC increased by 3.33% due to lower production but it is reduced by 34.28% over FY’07


Specific Energy ConsumptionTransmission Products ( kWh/Eq.Gear )

Years

kWh/

Eq.

Gea

r

FY’10 SEC reduced by 11.19% and Wrt FY’07 reduced by 4.06%


Specific Energy ConsumptionAir Conditioning & Refrigeration Products ( kWh/Cyl )

Years

kWh/

Cyl

inde

r

Over FY’10 reduced by 8.49% and Over FY’07 reduced by 16.16%


Specific Energy ConsumptionFoundry Products ( kWh/MT )

Years

kWh/

Met

ric T

on

FY’10 SEC reduced by 1.65% and Wrt FY’07 reduced by 3.11%


Encon Cell Review Mechanism

APEX

GROUP

CORE

GROUP

WORKING

GROUP

SMALL

GROUP

Members Function

Executive DirectorVP ACD, TRM & ACR

Review SECR & ENCON ProjectsDecision for high investment

Energy ManagerAll Dept. Heads

Prioritize energy projectsReview & value additionBench marking and MIS reporting

Encon Team Members Create data base for bench markingEvaluation of data base & Internal Audit Implement of Approved Projects

Front line EmployeesCross Functional Team

Kaizens & suggestionsImplementation of Energy Efficiency Projects

Holding the Gains


] Measurement ,Verification & Control through new target setting

] Training and awareness programs to employees

] Display ENCON activities & Conducting Encon competitions

] Conducting in-house Encon audits and review of implemented projects

] Use QC tools for further improvement like Brain-Storming, Parato, Fishbone PDCA etc. It is now part of ENCON culture

] In-house & external agency audits – Corrective Actions

] Periodic calibration of Instruments like meters and gauges

] Periodically efficiency monitoring of utility equipments

] Define Encon targets in performance appraisals to individuals

Efforts to Employees & Society


] Celebration of Energy Conservation Week between 14th Dec and 20th

] Distributed Encon Logo badges, Encon Oath & addressed Executive Director to all employees

] Energy Efficient products like CFL, LED Lamps & Gas saver exhibition arranged for employees in company premises & sold products at discounted rates

] Organised Encon Posters, Slogans and Kaizen competition for employees and

] Guest lectures were arranged on Green Energy and Energy Conservation Act’ 2001

] Awareness program conducted for 450 students of V to VIII Class at Shri Sant Dhanyaneshwar Vidyalaya, Kothrud Pune,

] Conducted Energy Audits at Three Vendors and helped to implement 14 Project Which saved Rs 0.675 Mn / annum

] All India Radio and KPCL jointly arranged Encon awareness program on “How to save energy at home” and “Solar energy”

] The special issue of “Susamwad” home magazine published on Energy Conservation

] On the occasion of KPCL Golden Jubilee celebration two 18watt and one 23 watt compact florescent lamps were distributed to 900 employees


KPCL – Energy Efficient ProductOur commitment to Energy Conservation is not only limited to conserving energy in our plants, but manufacturing highly energy efficient products as well.

KCX CompressorsDeveloped air cooled compressor for refrigeration application there by eliminating water for cylinder coolingC - Force CompressorsDeveloped high efficiency CNG compressor for CNG filling stations.

Balanced Opposed Reciprocating Piston CompressorsDeveloped Modular cylinder combinations and valve design optimization to give energy savings of 5 to 8% in view of improved overall process plant efficiency.Electric Screw Air Compressors9.85 to 42.5 m³/min capacity range, 7 to 13 bar; supplies compressed air as demanded in air network within the pressure range set. 35% savings in energy with the use of energy efficient motors and variable frequency drives.

Wind Turbine GearboxDNV approved Wind Turbine Gearbox being manufactured to promotenon-conventional energy.


KPCL Product - SEC

Product Range KPCL COP Competitor 1 COP Competitor 2 COPKirloskar KCX compressor

-15°C Evaporating / 35°C Condensing Ref Capacity around 180 kW, refrigerant NH3

3.17 3.15 3.17

Products Range Unit KPCL Competitor % Redu

Reciprocating Compressors

21 m3/min @ 45 Kg/cm2 kW/m3/min 9.22 kW 9.52 kW (3.15)23.33 m3/min @ 45 Kg/cm2 kW/m3/min 9.05 kW 9.21 kW (1.73)15.96 m3/min @ 45 Kg/cm2 kW/m3/min 8.07 kW 8.46 kW (4.60)12.35 m3/min @ 45 Kg/cm2 kW/m3/min 9.22 kW 10.12 kW (8.89)10 m3/min @ 45 Kg/cm2 kW/m3/min 9.20 kW 9.90 kW (7.07)

Railway Break Compressors

KRM1200 kW/m3/min 5.77 kW 7.08 kW (18.50)

Product Range Power rating Desired KPCL Actual

Gear Box

1 MW Wind Turbine 1 MW 98.00% 98.00%KMG 4000-20, Marine 2.7MW 98.00% 98.00%KMG 3500-20, Marine 2.7 MW 98.00% 98.00%MG-88/CW, Marine 8.1 MW 98.50% 98.50%

ACR Product

ACD Products

TRM Products


Environmental Improvement] Certified ISO 14001-2004 for Environment Management System & OHSAS 18001

] Use of Solar Heating & Lighting systemsv Flat solar water heaters for canteen – Capacity 7000 Liters /day v Solar lantern for security lighting

] Water ,Sanitation and Hygiene (WASH )Program initiated in 10 schools

] Process : Use of Non-CFC chemicals for Component Washing and Processes

] Gas Compression Products and Projects launching in R-134a, R-404a (Eco friendly) gas to support CFC phase out (R-12gas)

] All products manufactures with RoHS Complied material

] Rain water harvesting developedv constructed earther bandra at Saswad - Storage capacity 50 Lac liters waterv Roof water collected and stored in tanks – Storage capacity 1.5 Lac liters water

] Effective ETP’s as per Pollution Control Board Norms

] Achieved Zero discharge level by recycling the Water and waste

] Tree Plantation – More than 1200 trees planted in the plants & in the vicinity

] Developed Vermi-culture plant on canteen and garden waste

] Bio-gas generated on canteen waste and used to canteen cooking


Awards

National Level Awards

2008-2009 CII – National award for Energy Efficient Unit2007-2008 CII - National award for Energy Efficient Unit2007-2008 BEE - National award for Energy Excellence & Management 2007-2008 CII – State Level award for Best Kaizen for Energy Conservation

State Level Awards

2007-2008 MEDA - 3rd Prize for Excellence in Energy Conservation

Kirloskar Group Awards

2008-2009 3rd Prize for Excellence in Energy Conservation for Hadapsar Plant2007-2008 2nd Prize for Excellence in Energy Conservation for Saswad Plant2006-2007 1st Prize for Excellence in Energy Conservation for Hadapsar

and Saswad Plant


Future ProjectsS/N Project Investment

Rs MnkWh

SavingsSaving/ annum Rs Mn

1 Reducing Operating Voltage By 10% During Night Shifts Nil 125905 0.750

2 Switch 'OFF' Power And Lighting Transformer At No Load Condition Nil 29166 0.175

3Maintain Unity Power Factor And Avail The 7% Incentive Benefit From MSEDCL On Electricity Consumption

Nil 000 3.250

4Reduce to operating power of induction furnace from 750 kW to 600 kW to get MD benefits (Lean period only)

Nil 15000 0.090

5Operation of independent 150 cfm air compressor for foundry to eliminate the losses

Nil 5800 0.035

6 Reduce compressed air system pressure from 7.0 bar to 6.0 bar Nil 16600 0.100

7 Installation of Electropnuematic compressed air control valve to TRM main header Nil 9166 0.055

8 Rigorous Maintenance Of Air Compressed Grid And Reduce Air Leakage Losses 0.050 9524 0.057

9 Underground low pressor compressed air piping repalcement to Welded overhead 0.060 12000 0.072

10 Remove the Open Air Cleaning Pipes And Installation Of Energy Efficient Air Guns 0.035 6566 0.040

11 Installation of Gas-O-Max for Liquid Petroleum Gas (LPG) saving 0.030 000 0.036

12 Energy Efficient Star Label Split Air Conditioner 0.500 30833 0.185

13 Use of High Pressure air blower instead of low pressure compressed air 0.035 12000 0.072

14 Replacement of 250 watt Mercury vapor lamps by 150 watt Metal halide lamps 0.125 18000 0.108

15 Insulation over jacket and heat repellant painting to heat treatment furnaces 0.090 26667 0.160



Rs MnkWh

SavingsSaving/ annum Rs Mn

16Replacement of 1.0 Ton melting pot by 2.0 Ton for avoiding the heat loss for above 1.5 Ton casting

1.800 79168 0.475

17Replacement of old 40 Ton water cooled package air conditioner by Split air conditioner

0.650 87500 0.525

18 Replacement of conventional ballast by Electronic ballast 0.125 14600 0.088

19 Replacement of Pneumatic burr removing tools by Bosch Electrical operated tools 0.200 2267 0.014

20 Installation of Wind ventilators 0.180 3500 0.021

21Heat Treatment Process Control through Process Timer and indicating the visual and audio alarm after process completion

0.035 14083 0.085

22 Replacement of old threaded compressed air piping by welded overhead 0.180 18300 0.110

23 Installation of solar light pipe in Electrical screw assembly 0.125 3600 0.022

24Lighting Improvement - replacement of T12 tube lights by T5 Energy Efficient Tube light

0.200 13500 0.082

25 Elimination of unwanted water circulation through Water System 0.030 14000 0.084

26Plant Pump audit and optimize the pump delivery by impeller trimming or installing under sizing pump

0.075 20000 0.120

27 Optimize The Capacity Of Water Circulation Pump Of Spray Painting At Dispatch 0.012 1133 0.007

28 PID Controller System For Carburizing And Tempering Heat Treatment Furnace 0.650 42000 0.252

29 Installation Of Variable Frequency Drives To Old Hobbing Machines 0.145 12762 0.076



Rs LacskWh Savings Saving/

annum Rs Lacs

30Replacement of 25Ton Package Air Conditioner by Energy Efficient Split Air Conditioner - R&D

0.550 54166 0.325

31 Fan less Cooling Tower For BTDGM Air Compressor 0.175 10650 0.064

32 Street Lighting Improvement - LED Lighting 0.320 14160 0.085

33Installation of Electro-pneumatic solenoid valve to Machine to control compressed air usage

0.017 7500 0.045

Total 6.444 730949 7.724

Summery

No. of Projects identified 33 NosInvestment Planned 6.444 MnAnnual Energy Saving 730949 kWhAnnual Saving Rs 7.724 MnPayback 10 Months

Thank You


Documents

WELCOME [] · · 2010-09-07WELCOME Presentation team Mr. Kiran R. Mhetre ... Assignments to individuals through Performance Appraisal.] ... Sr.No Project Saving Rs Mn