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