Kirloskar Pneumatic Co. Ltd, Pune - CII

Transcription

Kirloskar Pneumatic Co. Ltd, Pune - CII
WELCOME
CII – National Award for
Excellence in Energy Management-2010
Kirloskar Pneumatic Co. Ltd, Pune
Presentation team
Mr. Kiran R. Mhetre
Mr. Uday V. Marathe
Mr. Nitin M. Bapat
Kirloskar Pneumatic Co. Ltd.,Pune
7-Sep-10
1
Company Outline
Saswad Plant
Hadapsar Plant
Plant Location
Area
Built-up
Hadapsar (Pune)
Saswad (Pune)
27 Acres
65 Acres
30625 m²
8485 m²
Divisions:
ã ACD - Air Compressor Division { Including Foundry }
ã TRM - Transmission Division
ã ACR & PGS – Air Conditioning _Refrigeration & Process Gas System
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
2
Company Profile
Products :
•Air Compressors
Infrastructure :
• CAD / CAM Centre
• CNC machining Centers
•Transmission
Products
•Air Conditioning
& Refrigeration
Compressors
• Fabrication facility
• In-house foundry
• Sophisticated testing labs
• Stress relieving furnaces
•Process Gas
Systems
• SCADA based Centrifugal
Test Bed
We manufacture our products under ISO 9001, EMS 14001 & OHSAS 18001
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
3
Energy & Environment Policy
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
4
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
Kirloskar Pneumatic Co. Ltd.,Pune
7-Sep-10
5
• Encon Methodology
Energy Management Activity percolated to shop floor through :
]Energy
]Usage
Accounting , Budgeting & Control
of Non-conventional Energy Sources
]Adoption
]Waste
of New Technology
Identification & Elimination
]Continuous identify
]Environment
]ENCON
the opportunity for operation and process improvement
protection
Expertise & Knowledge into New Projects
]Elevating
Plant Performance to Improve Utilization
]Energy
Efficient Products to Customers
]Energy
Kaizens, Training & Awareness
]Examining
7-Sep-10
Ourselves through External Agencies
Kirloskar Pneumatic Co. Ltd.,Pune
6
Encon SWOT
Strength
Weakness
• Excellent Encon Culture
• Excess plant capacity to meet present
• Three EM and Four EA
market requirement
• Acceptance to change quickly
• Few energy intensive old machines
• Technical expertise and leadership
Threats
Opportunities
• Extending Encon culture to vendors,
suppliers and society.
• Reduction in fixed energy cost
•
Poor quality of grid supply
•
Electricity tariff hike
•
Fuel prize inflation
• Use of non-conventional energy
• ECBC concept,
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
7
Cumulative Savings Thru’ Energy
Conservation
Cumulative Saving Rs 39.21 Mn
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
8
Renewable Energy Usage
Projects 03 Nos
Savings 0.417Mn
Sr. No
Projects
1
2
Using of Solar Water Heating System for
Canteen
Installed Translucent Sheet for Shops
3
Solar Lantern to Security lighting
7-Sep-10
Saving Rs Mn
0.055
0.352
0.010
Kirloskar Pneumatic Co. Ltd.,Pune
9
Compressed Air
Projects 08 Nos
Savings 1.077 Mn
Sr.No
Project
Saving Rs Mn
1
Trans-Air Zero Air Leakage Piping for Assembly
0.062
2
0.331
4
Decentralisation of Pneumatic System – Replaced old
200 cfm Air Compressor by 2 x 96 cfm Air Compressor
Replaced Pneumatic tools by Electrical Tools for
Deburring operation
Installed air blower in place of air compressor at ETP
5
Energy Efficient Air Guns fitted at Open points
0.078
6
Reduced plant air leakages from 22.6% to 10.3% by
rigorous maintenance
Installed Zero air discharge auto drain valves to air
receivers
Replaced cycle stand air compressor by manual foot
operated pump
0.338
3
7
8
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
0.106
0.127
0.034
0.0008
10
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
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
11
Power Management
Projects 06 Nos
Savings 6.231 Mn
Sr.No
Project
Saving Rs Mn
1
Controlling Maximum Demand by Wireless Remote
Control System
Switching ‘OFF’ Power Transformer during No Load
- to avoid losses
Switching ‘OFF’ Lighting Transformer during Day
Time - to avoid losses
Optimised plant operating voltage by 10% during
night shift
Re-scheduled TOD consumption of Zone C & D to
Zone A & B
Obtained “Unity” Power Factor and 1% prompt
discount benefits from MSEDCL
0.961
2
3
4
5
6
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
0.150
0.015
0.727
0.246
4.132
12
Process Improvement
Projects 05 Nos
Savings 2.006 Mn
Sr.No
Project
Saving Rs Mn
1
Process integration for carburising and hardening
at Heat Treatment
Process Change – Reduced number of set ups of
Axis Arm Product
Replaced Oil bath heating system by Induction
heating
Replaced LDO fired furnace burner at Foundry
1.440
Retrofitted conventional balancing machine with
Microprocessor based controller
0.124
2
3
4
5
0.126
0.178
0.138
Kirloskar Pneumatic Co. Ltd.,Pune
7-Sep-10
13
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
7-Sep-10
Investment
Rs 0.075 Mn
Annual Saving
Rs 0.178 Mn
Simple Payback
29 Months
Kirloskar Pneumatic Co. Ltd.,Pune
14
New Technology
Projects 07 Nos
Savings 2.062 Mn
Sr.No
Project
1
LDO fired stress reliving furnace converted into
Compartmentalised Electrical Furnace
Replaced nine (9) conventional welding rectifier by
Inverter based controlled welding machine
Installed Fan less cooling towers for Product Testing
and Foundry Utility
Shop Air Circulator’s Aluminum fan blades replaced
by FRP fan blades
Replaced CRT monitors by LCD Monitors – 85 Nos
1.429
Installed Energy Efficient T5 Tube Lights for TRM
Shop Lighting
Installed Variable Frequency Drive for 55 kW Test
bed motor
0.114
2
3
4
5
6
7
Kirloskar Pneumatic Co. Ltd.,Pune
7-Sep-10
Saving Rs Mn
0.389
0.006
0.031
0.045
0.048
15
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
Investment
Rs 0.378 Mn
Annual Saving
Rs 0.129 Mn
Simple Payback
35 Months
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
16
HVAC Projects
Projects 05 Nos
Savings 0.502 Mn
Sr.No
Project
Saving Rs Mn
1
Installed Time switch for UPS air conditioners
0.416
2
0.040
4
Replaced old window air conditioners by Star Label
Energy Efficient air conditioner
Used stand fan instead of 40 ton package air
conditioner operation during weekly off & holiday
Converted all AHU motors from Delta to Star
5
Increased office air conditioner temperature by 2 C
0.012
3
7-Sep-10
0.029
0.005
Kirloskar Pneumatic Co. Ltd.,Pune
17
Waste Elimination
Projects 07 Nos
Savings 0.442 Mn
Sr.No
1
2
3
4
5
6
7
7-Sep-10
Project
Saving Rs Mn
Installed Time switch for Shops and canteen
lighting/Fans
Temp. controlled interlock to heat treatment cooling
tower
Old furnace revamped by providing insulation over
jacket and heat repellant paint to reduce skin losses
Provided Interlock for cooling tower operation with
40T Package air conditioner
Installed Motion sensors for toilets and offices
0.003
Optimised the heat treatment cooling pit pump
capacity from 7.5 kW to 2.2 kW
Reduced component resting base plate weight from
1250 Kgs to 300 Kgs at stress reliving furnace
0.175
Kirloskar Pneumatic Co. Ltd.,Pune
0.052
0.096
0.036
0.002
0.103
18
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
Investment
Rs 0.005 Mn
Annual Saving
Rs 0.103 Mn
Simple Payback
15 days
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
19
Innovative Project
Power Regeneration from 1MW Gear Test Bed
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
20
Power Regeneration from 1MW Gear
Test Bed
Background
v1MW Gear Boxes operate on top of the 70 Meter Tower in UN-Manned
condition
vLife expectancy of 20 years.
vConventional method of gear box testing at full load by employing water brake
dynamometer.
vTesting cycle time for 8 Hrs / test / Gear Box
vIn 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 was
subjected to complete performance test with power regeneration and reverse
feed into system. This reduces testing cost substantially
Kirloskar Pneumatic Co. Ltd.,Pune
7-Sep-10
21
Schematic Diagram
1.5 MVA
OLTC
Transformer
22kV / 415 kV
1.5 MVA
Step up
Transformer
415V / 690 kV
Step Up
Transformer
690V/6600V
Variable
Frequency
Drive
(2%)
(2.5%)
(2%)
958 kW
(2%)
1150 kW,
Induction
Motor
KPCL PLANETARY GEAR BOX
1028 kW
997 kW
Frequency
Converter
(4%)
v
v
v
v
v
ABB
Generator
1 MW
(3%) 136 RPM
(4.5%)
2948 RPM
1092 kW
1071 kW
1049 kW
Moventas
1MW
Gear Box
KPCL
1MW
Gear Box
(2%) 136 RPM
(2%) 23 RPM
KPCL Aux
Reduction
Gear Box
(2%) 143 RPM
1.15 MW motor operates on 6.6 KV with variable frequency drive.
The mechanical power drives the KPCL 1 MW gearbox.
1 MW asynchronous generator is coupled , which generates variable power.
It is converted into DC; chopped and inverted.
The inverted power is fed to input side of variable frequency drive with proper
line synchronization.
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
22
Saving Calculations
Power required to test the gear box on full load
Power regenerated by innovative system
Power consumed in Losses
1.15 MW
958 kW
239 kW
Testing time
No. of gear boxes
Total testing time
Proto type testing time
Grand total testing time
8 hrs/test/gear box
102 Nos
816 hrs
60 hrs
876 hrs
Energy required for conventional testing
Actual Energy consumed by innovative system
1.007. Mn kWh
0.209 Mn kWh
Total Energy saving
Average industrial electricity unit rate
Energy Saving
0.798 Mn kWh
Rs 5.90 / kWh
Rs 4.708 Mn
Kirloskar Pneumatic Co. Ltd.,Pune
7-Sep-10
23
Saving Calculations
Additional benefits is because of reduction in Maximum Demand Charges as,
Maximum Demand Saving
Maximum Demand Charges
Annual Saving
1197 kVA @ 0.8 PF
Rs 150/kVA
Rs 3.41 Mn
Investment Made
Rs 14.50 Mn
Net Annual Saving Rs
8.118 Mn
ROI
55.98%
Carbon Emission reduction
MT/Annum
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
678.33
24
Innovative Project 2
Wireless Maximum Demand Controller
Kirloskar Pneumatic Co. Ltd.,Pune
7-Sep-10
25
Wireless Maximum Demand Controller
Background
äNo maximum demand control mechanism
äDue to uncertain testing of big gear boxes and air compressors. The Maximum
demand shot up to 2400 KVA
äAverage electricity unit rate was increased due to increase in fixed charges
Project
äInstalled 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 set
äSwitch ON the non-critical load feeder
äConfirm the completion of testing & Switch OFF the DG Set
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
26
Wireless Maximum Demand Controller
22 kV Express feeder
Maximum Demand Sanctioned
2700 kV
Maximum Demand Controller Set
1800 kVA
DG set utilized to sustain the MD
Cost for DG Set Operation
11900 kWh
Rs 0.119 Mn
Savings
MSEDCL kVA Rate
Monthly Saving
Annual Saving
150/kVA
Rs 0.090 Mn
Rs 1.08 Mn
Net Annual Saving
Rs 0.961 Mn
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
27
Specific Energy Consumption
Air Compressor Products ( kWh/cfm )
kWh/ cfm
FY’10 SEC increased
by 3.33% due to lower
production but it is
reduced by 34.28% over
FY’07
Years
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
28
Specific Energy Consumption
Transmission Products ( kWh/Eq.Gear )
kWh/ Eq. Gear
FY’10 SEC reduced by
11.19% and Wrt FY’07
reduced by 4.06%
Years
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
29
Specific Energy Consumption
Air Conditioning & Refrigeration Products ( kWh/Cyl )
kWh/ Cylinder
Over FY’10 reduced by
8.49% and Over FY’07
reduced by 16.16%
Years
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
30
Specific Energy Consumption
Foundry Products ( kWh/MT )
kWh/Metric Ton
FY’10 SEC reduced by
1.65% and Wrt FY’07
reduced by 3.11%
Years
Kirloskar Pneumatic Co. Ltd.,Pune
7-Sep-10
31
Encon Cell Review Mechanism
Members
Function
Executive Director
VP ACD, TRM & ACR
Review SECR & ENCON Projects
Decision for high investment
Energy Manager
All Dept. Heads
Prioritize energy projects
Review & value addition
Bench marking and MIS reporting
Encon Team Members
Create data base for bench marking
Evaluation of data base & Internal Audit
Implement of Approved Projects
Front line Employees
Cross Functional Team
Kaizens & suggestions
Implementation of Energy Efficiency Projects
APEX
GROUP
CORE
GROUP
WORKING
GROUP
SMALL
GROUP
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
32
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
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
33
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
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
34
KPCL – Energy Efficient Product
Our commitment to Energy Conservation is not only limited to conserving energy in our plants,
but manufacturing highly energy efficient products as well.
KCX Compressors
Developed air cooled compressor for refrigeration application there by
eliminating water for cylinder cooling
C - Force Compressors
Developed high efficiency CNG compressor for CNG filling stations.
Balanced Opposed Reciprocating Piston Compressors
Developed 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 Compressors
9.85 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 Gearbox
DNV approved Wind Turbine Gearbox being manufactured to promote
non-conventional energy.
Kirloskar Pneumatic Co. Ltd.,Pune
7-Sep-10
35
KPCL Product - SEC
ACR Product
Product
Kirloskar KCX
compressor
Range
-15°C Evaporating / 35°C
Condensing Ref Capacity
around 180 kW, refrigerant
NH3
KPCL COP
Competitor 1 COP
Competitor 2 COP
3.17
3.15
3.17
ACD Products
Products
Reciprocating
Compressors
Railway Break
Compressors
Range
21 m3/min @ 45 Kg/cm2
23.33 m3/min @ 45 Kg/cm2
15.96 m3/min @ 45 Kg/cm2
12.35 m3/min @ 45 Kg/cm2
10 m3/min @ 45 Kg/cm2
KRM1200
Unit
kW/m3/min
kW/m3/min
kW/m3/min
kW/m3/min
kW/m3/min
kW/m3/min
Range
1 MW Wind Turbine
KMG 4000-20, Marine
KMG 3500-20, Marine
MG-88/CW, Marine
Power rating
1 MW
2.7MW
2.7 MW
8.1 MW
KPCL
9.22 kW
9.05 kW
8.07 kW
9.22 kW
9.20 kW
5.77 kW
Competitor
9.52 kW
9.21 kW
8.46 kW
10.12 kW
9.90 kW
7.08 kW
% Redu
(3.15)
(1.73)
(4.60)
(8.89)
(7.07)
(18.50)
TRM Products
Product
Gear Box
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
Desired
98.00%
98.00%
98.00%
98.50%
KPCL Actual
98.00%
98.00%
98.00%
98.50%
36
Environmental Improvement
]
Certified ISO 14001-2004 for Environment Management System & OHSAS 18001
]
v
v
Use of Solar Heating & Lighting systems
Flat solar water heaters for canteen – Capacity 7000 Liters /day
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
]
v
v
Rain water harvesting developed
constructed earther bandra at Saswad - Storage capacity 50 Lac liters water
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
Kirloskar Pneumatic Co. Ltd.,Pune
7-Sep-10
37
Awards
National Level Awards
2008-2009
CII – National award for Energy Efficient Unit
2007-2008
CII - National award for Energy Efficient Unit
2007-2008
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 Plant
2007-2008
2nd Prize for Excellence in Energy Conservation for Saswad Plant
2006-2007
1st Prize for Excellence in Energy Conservation for Hadapsar
and Saswad Plant
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
38
Future Projects
S/N
Project
Investment
Rs Mn
kWh
Savings
Saving/
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
Nil
000
3.250
Nil
15000
0.090
Maintain Unity Power Factor And Avail The 7% Incentive Benefit From MSEDCL
On Electricity Consumption
Reduce to operating power of induction furnace from 750 kW to 600 kW to get MD
benefits (Lean period only)
Operation of independent 150 cfm air compressor for foundry to eliminate the
losses
3
4
5
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
Kirloskar Pneumatic Co. Ltd.,Pune
7-Sep-10
39
Future Projects
S/N
16
17
Project
Replacement of 1.0 Ton melting pot by 2.0 Ton for avoiding the heat loss for above
1.5 Ton casting
Replacement of old 40 Ton water cooled package air conditioner by Split air
conditioner
Investment
Rs Mn
kWh
Savings
Saving/
annum
Rs Mn
1.800
79168
0.475
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
21
Heat 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
24
Lighting 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
26
Plant 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
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
40
Future Projects
S/N
Project
Investment
Rs Lacs
kWh Savings
Saving/
annum
Rs Lacs
30
Replacement 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
33
Installation of Electro-pneumatic solenoid valve to Machine to control
compressed air usage
0.017
7500
0.045
6.444
730949
7.724
Total
Summery
No. of Projects identified
33 Nos
Investment Planned
6.444 Mn
Annual Energy Saving
730949 kWh
Annual Saving
Rs 7.724 Mn
Payback
10 Months
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
41
Thank You
7-Sep-10
Kirloskar Pneumatic Co. Ltd.,Pune
42