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Sagar B. Dhage
Roll No. 2008 ENE 01
Project Details
Project Title : Energy Efficiency Improvement Project at Kirloskar Oil Engines Ltd.
Mr. M.B. Deore Energy Manager Kirloskar Oil Engines Ltd, Khadki. Pune Starts : 16th June, 2009
Project Duration
Coverage
KOEL Nagar Plant Electricity Bill Study PF analysis TOD incentives MD reduction Compressed Air System Reduction in Compressed air Pressure Energy efficient motor Efficient transmission system Exhaust air recovery Study of Illumination system Natural Daylight Energy Efficient illumination system Performance Analysis of Furnaces Excess air control Reduction in heat loss KOEL Khadki Plant Compressed Air System FAD Trap Survey Bearing Plant Motor survey TOD benefits Load Rescheduling ENCON opportunity for Compressed air Tech Centre Energy consumption trend Cooling Tower Assessment Illumination System Compressor assessment
Energy Policy
Sr. No. Parameters 1 Vision/Mission committed for Nation 2 Objective of ENCON 3 Commitment from Top Management 4 Reduction in SEC 5 Energy Efficient Operation 6 Energy Efficient Products 7 Efficient use of energy 8 Minimise wastage 10 Energy Efficient Building Projects Continuous study & measures 11 implementations 12 Benchmarking 13 Renewable Energy 14 Information shearing 15 Recycling /reuse 16 Employee Involvement 17 Training / awareness 18 Efforts recognition 19 Issue Date 20 Revise date KOEL X X X X X X X KFIL X X X X X X X X KBL, KBL, KBL, Kirloskarwadi Kodhapur Dewas i X X X X X X X X X X X X X X X X X X X Kolhapur KPCL, Steel Ltd. Hadapsar X X Designation not mention X X x X X X X X X X X X X
ENCON Competition.
2. Contribution in documenting National Energy Conservation Award
ENCON Awareness
ENCON Awareness Activities in Schools ENCON Lectures ENCON Essay Competitions ENCON Poster Competitions ENCON Awareness Activities in KOEL Chalta Bolta Quize Competition ENCON Awareness Activities for Household Womens ENCON Lectures ENCON workshops
Actual Free Air Delivery = 11.6 m3/min = 409.65 cfm Volumetric Efficiency = Actual FAD* 100/ Rated FAD = 409.65 *100/ 500 = 82 % Specific Energy Consumption = Actual FAD/ Actual Power Consumed = 409.65 / 51.06 = 8.02 cfm/kWh
8
500 300
409.65 173
82 % 57.66 %
Action: Maintenance was done. Performance test again conducted on compressor no. 5 Vol. Efficiency of compressor no 5 found to be 87 %
Comp. No. Before After Annual Energy Saving in kWh Annual Energy Saving in Rs. 15,162
82 % 8.02
87.5 % 8.56
3032
10
11
Bearing Shop
Process Flow Diag.
Pressing Electrical Energy Compressed air Nicking Electrical energy Compressed air
F2 : Water Cooling Tower, TR A/C Plant, Radial Drilling M/c F3 : 4R Crank case line, Milling M/C line
Electrical Distribution
Transformer
F1 : (Dispatch Section, Packing Section)
Nick milling Electrical energy Compressed air J/F broaching Electrical Energy Compressed air Oil hole punching Electrical energy Compressed air Oil hole sinking Electrical energy Compressed air ABB - Auto bore broaching Electrical energy Compressed air Insepection
F6 : Arjun 5 & 6
F7 : Arjun 3 & 4 F8 : Arjun 1 & 2, Packing section, Purchase dept, elect dept
Oiling
12
Bearing Shop
Energy Distribution
F8 27%
F1 5%
F2 11% F3 8% F4 4%
F7 18%
F6 17%
F5 10%
13
Bearing Shop
Energy Consumption Trend
kWh
07:00- 08:00- 09:00- 10:00- 11:00- 12:00- 13:00- 14:00- 15:00- 16:00- 17:00- 18:00- 19:00- 20:00- 21:00- 22:00- 23:00- 00:00- 01:00- 02:00- 03:00- 04:00- 05:00- 06:0008:00 09:00 10:00 11:00 12:00 13:00 14:00 15:00 16:00 17:00 18:00 19:00 20:00 21:00 22:00 23:00 00:00 01:00 02:00 03:00 04:00 05:00 06:00 07:00
F1
8.6
14
Bearing Shop
Motor Survey Guideline for Energy Saving in Motor Application
For Permanent Star Connection Estimated Energy Saving (% of Actual Loading) 15% 12% 10% 8%
Sr. No.
1. 2. 3. 4.
Upto 30% Between 30% to 40% Between 40% to 50% Between 50% to 55%
Annual Energy Saving = 38, 530 kWh Annual Cost Saving @Rs. 5.29/kWh = Rs. 2.35 Lakh Investment = Nil Payback = Immediate
15
Machine
Type
Rated
Eff.
Rated
Current
Estimated Saving in %
kWh Saving
% 85.0 86.4
I1 2.2 2.2
I2 2.1 1.9
I3 2.7 2.1
I 2.3 2.1 1.2 1.0 66% 40% NIL 10.0 NIL 0.1 NIL 769.2 769.2 7608.1 9146.60 699.8 781.7 NIL Rs. 4,069 Rs. 4,069 Rs. 40,247 Rs. 48,386 Rs. 3,702 Rs. 4,135
Motor 1 Motor 2
2.0 2.2
86.4 86.4
3.5 4.8
1.7 1.4
1.3 1.4
1.7 1.4
1.6 1.4
0.8 0.7
34% 27%
12.0 15.0
0.1 0.1
59%
NIL
NIL
NIL
NIL
Motor 1 Motor 2
1.8 2.2
85.0 86.4
3.4 4.8
2.4
2.6
2.1
2.4
1.3
60%
NIL
NIL
0.6 4.0
0.3 2.1
13% 35%
15.0 12.0
0.1 0.3
378.9 1925.4
7940.6 10244.9
Motor 1 Motor 2 2.2 86.4 4.8 2.13 2.1 2.1 4.2 2.76 2.7 4.8 2.3 2.4 4.1 1.2 1.2 2.0 45% 46% 33% 10 10 12 0.1 0.1 0.2 867.3 880.9 1816.4 Rs. 4,588 Rs. 4,660 Rs. 9,609
6.7
3.3
54%
0.3
2241.1
Rs. 11,856
16
38530.0 Rs. 2,35,427
Bearing Shop
Exhaust Air Recovery
Description : Energy saving calculations: Total nos of machines = 4 Cylinder dia = 12 Stroke length = 1 Volume = 0.0654 f3 Cycle time = 20 stroke/min Air available = 20 x 0.0654 = 1.308cfm Per day saving in CA = 1.308 x 18hr =23.54 cfm Per annum saving = 7345.72 cfm Total saving on all ABB machines = 7345.72 cfm x 4 = 29,383 cfm Total saving in kWh = 29,383 cfm / 5 cfm/kWh = 5877 kWh Total Annual Cost Saving = Rs. 29,383/-
The saving in compressed air can be achieved by using this exhaust air for cleaning & machining application.
17
Technical Centre
The electrical distribution :
Test Cell
18
Technical Centre
Percentage Energy Distribution
Reliab lab+canteen+PR asssly Old design+blower Test cell Jig mill+mc shop emission/endurance lab store, new PR assly
4%
10%
9% 23%
16%
38%
19
Technical Centre
Energy consumption trend
80.0
Rs. 0/kWh
70.0
Rs. 0.8/kWh
Rs. 0/kWh
Rs. 1.10/kWh
Rs. - 0.85/kWh
60.0
50.0
kWh
40.0
30.0
20.0
10.0
0.0
06:00 07:00 08:00 09:00 10:00 11:00 12:00 13:00 14:00 15:00 16:00 17:00 18:00 19:00 20:00 21:00 22:00 23:00 00:00 01:00 02:00 03:00 04:00 05:00 07:00 08:00 09:00 10:00 11:00 12:00 13:00 14:00 15:00 16:00 17:00 18:00 19:00 20:00 21:00 22:00 23:00 00:00 01:00 02:00 03:00 04:00 05:00 06:00 4.7 6.6 10.9 24.2 24.5 25.4 23.4 22.3 20.5 19.8 12.7 6.4 5.7 5.6 5.6 5.8 6.0 6.2 6.3 6.4 6.3 6.3 6.4 6.4 15.7 20.4 25.8 28.4 29.7 30.9 29.1 30.9 34.0 34.6 33.5 34.0 35.7 35.7 35.4 36.7 38.7 34.3 25.9 25.2 25.2 25.1 24.1 22.8 15.5 56.9 65.5 73.7 73.6 73.6 69.8 70.9 71.4 66.5 68.8 63.8 61.8 53.7 48.1 38.6 35.2 28.9 26.9 25.2 24.3 24.3 23.8 21.4 10.7 16.4 25.5 35.9 37.3 39.7 38.4 39.4 44.2 42.7 40.7 31.9 18.8 10.8 2.5 1.6 6.5 8.9 10.5 9.8 6.1 7.4 7.3 8.5 6.5 3.6 0.6 9.3 2.7 3.7 3.2 2.2 14.6 27.4 35.9 32.3 29.1 22.5 31.4 35.7 35.4 26.5 7.6 3.0 1.0 6.7 3.1 1.0 6.8 3.2 1.1 7.0 3.3 1.1 6.8 3.4 1.1 6.8 3.3 1.2 6.8 3.3 1.2 6.8 3.3 1.2 6.8 3.3 1.2 7.0 3.2 1.2
Reliab lab+canteen+PR asssly Test cell emission/endurance lab Old design+blower Jig mill+mc shop store, new PR assly
20
Technical Centre
Key Technical Specification
Sr. No. 1 2 3 4 5 6 7 8 9 Parameter Type of Cooling Tower Number of cells per tower Area per cell Water flow Pumping power Pumping head Fan power Design hot water temperature Design cold water temperature P H Pfan m /hr kW m kW C C
3
Units Forced draft 30 3.5 8 2.237 40 30 Forced draft 30.28 3.5 8 2.237 40 30
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Technical Centre
Use of Fanless Cooling Tower
Description : In the existing system induced draft type cooling tower is used. It requires 2.24W of power is needed to drive the fan. By installing fanless natural draft cooling tower leads to conserve the energy Energy saving calculations: Energy savings Calculations Existing Energy Consumption : 2.24 kW x 2 nos x 22 hrs x 26 days x 12 months = 32,148 kWh Proposed system energy consumption = 0 kWh Estimated Annual Energy Saving = 32,148 kWh Estimated Annual Cost Saving = Rs. 1.70 lakhs
Payback Period
14 months
22
Technical Centre
Performance Assessment of Compressor System
Parameters Initial Pressure Final Pressure Atm. Pressure Receiver Storage Volume including pipe work Time taken to build up Final Pressure Actual measured I/P power Initial Temp. Final Temp. P1 P2 P0 V T P T1 T2 0.5 8.0 1.026 250 6.5 3.73 27 45 Units kg/cm2 kg/cm2 kg/cm2 Lit min kW C C
Actual Free Air Delivary =(80.5)/1.013 x 250/6.5 x (273+27)/(273+45) = 269 lit/min Actual Free Air Delivery = 269 lit/min Volumetric Efficiency = Actual FAD* 100/ Rated FAD = 269 *100/ 991 = 27.2 % Specific Energy Consumption = Actual FAD/ Actual Power Consumed = 9.5 cfm / 3.73kW = 2.54 cfm/kWh
23
Rated FAD Actual FAD SEC Volumetric Efficiency 991 lit/min 269 lit/min 2.54 cfm/kWh 27.2 %
Technical Centre
Performance Assessment of Compressor System
Total Investment in Nil Rs. (approx.) Annual Energy 4320 Savings in kWh Annual Cost Savings 22, 853 in Rs. (Rs.5.29/kWh)
Payback Period Immediate
Total Investment in Nil Rs. (approx.) Annual Energy 2340 Savings in kWh Annual Cost Savings 12, 378 in Rs. (Rs.5.29/kWh) Payback Period Immediate
24
Technical Centre
Use of Natural Day-light
Description :
Energy saving calculations: Existing Energy Consumption = (250 + 30)W x 27 nos x 8 hrs x 26 days x 12 months = 18869.7 kWh Proposed system energy consumption: 220 kWh Estimated Annual Energy Saving = 18869.7 kWh Estimated Annual Cost Saving Rs. 99,821/25
In the existing system artificial illumination system are use for lighting system. By using transparent sheet natural day light can be use which leads to reduction in energy consumption.
Total Investment in Rs. (approx.) Annual Energy Savings in kWh
Annual Cost Savings in Rs. (Rs.5.29/kWh)
1, 50,000/-
7,188
38,027/4 years
Payback Period
Technical Centre
Use of Natural day-light by Light Pipe
Payback Period
10 months
26
Technical Centre
Optimization of pumping system
Description of the energy conservation measure: By providing individual valves to each bed water flow can be made OFF when not required. It reduces water flow in the system. Therefore new system will have variable water flow but requires constant head.
Total Investment in Rs. (approx.) Annual Energy Savings in kWh
Annual Cost Savings in Rs. (Rs.5.29/kWh)
Existing System Single Pump Make : Kirloskar KDS-1537++ Power: 11 kW Measured Head : 24 m Measured flow: 32 lps Required flow: 24 lps
1, 2 lakh
51, 480
2.72 lakh 5.5 month
Payback Period
Proposed System Parallel operation of two pump Make : Kirloskar KDS- 830++ Power: 5.5 kW Measured Head : 26 m Required flow: 14 lps
27
Technical Centre
Optimization of pumping system
5 HP
Hot sink
Cold sink
By Gravity
Test Cell
28
Technical Centre
Optimization of pumping system
Hot sink
Cold sink
c
By Gravity
Test Cell
29
Training Centre
Energy efficient illumination system
Description : Existing Sytem : 1. 72W FTL fitting x 8 nos 2. 15W cfl x 9 nos Proposed System: Energy Efficient T5 , 7 nos
Total Investment in Rs. (approx.) Annual Energy Savings in kWh
Annual Cost Savings in Rs. (Rs.5.29/kWh)
Energy saving calculations: Existing Energy Consumption = 0.666 kWh Proposed system energy consumption: 0.47 kWh Estimated Annual Energy Saving = 1760 kWh Estimated Annual Cost Saving Rs. 8800/-
15, 000/-
1760
8800
Payback Period
1.7 years
30
Training Centre
Energy efficient illumination system
Description : It is found that 1 nos of FTL lamp fittings is not necessary. (Trial was taken). Existing CFL lamps are use for aesthetic purpose. Replacement of 4 FTL lamp fittings (each of 18W x 4 nos) by energy efficient 3 nos of T5 lamp fitting (14W x 4 nos). Replaced 15 nos CFL lamps by LED lamps.
Energy saving calculations: Existing Energy Consumption = 1055.81 kWh/year Proposed system energy consumption = 220 kWh/year Estimated Annual Energy Saving = 853.81 kWh Estimated Annual Cost Saving Rs. 4179/31
11400
853.81
4179
Payback Period
2.7 years
Training Centre
Use of occupancy sensors Description : Use of occupancy sensors.
Energy saving calculations: Existing Energy Consumption = 1378 kWh/year Proposed system energy consumption = 516 kWh/year Estimated Annual Energy Saving = 862 kWh/year Estimated Annual Cost Saving Rs. 4310/32
2, 000
862
4310
Payback Period
6 months
Training Centre
Convert Delta to Star operation of motor & Use of flat belt
Description : Fan motor was operated on lower loading. Thus by converting motor connection from delta to star connection leads to save 10% of energy. Using energy efficient flat belt, 3% saving can be achieved.
Total Investment in Rs. (approx.) Annual Energy Savings in kWh
Annual Cost Savings in Rs. (Rs.5.29/kWh)
5,000
1493 7465
Payback Period
9 months
Training Centre
Optimize Use of Cooling Tower System
Description : Avoid use of cooling tower when not required by using temperature switch. Thus avoid use of 3.7 kW pump Energy saving calculations: Existing Energy Consumption = 3.7 x 5 hrs/day x 26 days x 12 months = 5772 kWh Proposed system energy consumption =3.7 x 5 hrs/day x 26 days x 6 months = 2886 kWh Estimated Annual Energy Saving = 2886 kWh Estimated Annual Cost Saving = Rs. 14,430/-
5,000
2, 886 14, 430
Payback Period
4 months
34
Training Centre
Optimize Use of Cooling Tower System
Water Tank
Engine
T E
Water Sump
35
IT
Cooling Load Calculations:
Objective 1. Provide information for equipment selection, 2. System sizing and system design Space Heat Gain Solar radiation through transparent surfaces such as windows Heat conduction through exterior walls and roofs Heat conduction through interior partitions, ceilings and floors Heat generated within the space by occupants, lights, appliances, equipment and processes Loads as a result of ventilation and infiltration of outdoor air Other miscellaneous heat gains Sensible heat a. Heat transmitted thru floors, ceilings, walls b. Occupants body heat c. Appliance & Light heat d. Solar Heat gain thru glass e. Infiltration of outside air f. Air introduced by Ventilation 36
IT
Cooling Load Calculations:
Latent Heat Loads a. Moisture-laden outside air form Infiltration & Ventilation b. Occupant Respiration & Activities c. Moisture from Equipment & Appliances External Cooling Load Roof Walls Solar Heat Load through glass Partitions, ceiling & floors Internal Cooling Load Infiltration Air People Equipments Lights
37
IT
38
IT
Use of VRV/ VRF HVAC system
Existing system Specific Energy Consumption : 1.4 kW/TR Proposed system Specific Energy Consumption : 0.8 kW/TR Reduction in Specific Energy Consumption : 42 %
Energy savings Calculations Existing Energy Consumption : 25 TR x 1.4 kW/TR x 8 hrs x 26 days x 12 months = 87,360 kWh/year Proposed system energy consumption: 25 TR x 0.8 kW/TR x 8 hrs x 26 days x 12 months = 49920 kWh/year Estimated Annual Energy Saving = 37440 kWh/year Estimated Annual Cost Saving = Rs. 1.98 lakhs
39
Dv Shop
Avoid idle running of Spiral Conveyor
Description : In the existing CNC machines, it is observed that spiral conveyor operates idle even when job is not loaded on the machines. By doing modification in programming, idle running cab be avoided.
Total Investment in Rs. (approx.) Annual Energy Savings in kWh
Annual Cost Savings in Rs. (Rs.5.29/kWh)
Energy saving calculations: Estimated Annual Energy Saving = 0.4 kW x 2 x 8 nos x 2 hrs x 26 days x 12 months = 4000kWh/year Estimated Annual Cost Saving = Rs. 21,126/-
Nil
18.870 99, 821
Payback Period
40
DV Shop
Use of Fanless Cooling Tower
Description : In the existing system induced draft type cooling tower is used. It requires 2.24W of power is needed to drive the fan. By installing fanless natural draft cooling tower leads to conserve the energy Energy saving calculations: Energy savings Calculations Existing Energy Consumption : 2.24 kW x 2 nos x 22 hrs x 26 days x 12 months = 32,148 kWh Proposed system energy consumption = 0 kWh Estimated Annual Energy Saving = 32,148 kWh Estimated Annual Cost Saving = Rs. 1.70 lakhs
Payback Period
14 months
41
Technical Centre
Conversion of motor connection from delta to star
Description : In the existing CNC machines, motors are used for many purposes included conveyor, hydraulic motors etc. In some of motors loading found lower than the capacity. By converting motors from delta to star energy saving can be achieved.
Total Investment in Rs. (approx.) Annual Energy Savings in kWh Annual Cost Savings in Rs. (Rs.5.29/kWh) Payback Period
Transformer
Sr. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Transformer No. Transformer No. 1 Transformer No. 2 Transformer No. 3 Transformer No. 4 Location A Shop A shop 1 Comp MSEB B Shop Trans. 1 I/C B Shop Trans. 2 I/C Rated kVA 500 750 750 750 400 1000 750 500 750 750 750 750 1000 750 750 AVERAGE Measured % kVA Loading 82 329 176 115 234 239 209 92 225 125 28 67 185 156 142 16 44 23 15 58 24 28 18 30 17 4 9 19 21 19 PEAK HOUR Measured % kVA Loading 183 447 334 211 275 313 397 144 391 154 66 165 334 272 256 37 60 44 28 69 31 53 29 52 20.6 9 22 33 36 34 582 406 424 406 369 477 213 472 161 193 235 353 367 291 78 54 57 102 37 64 43 63 21.4 26 31 35.3 49 39 Max Peak KVA Max Peak loading
Transformer No. 5 B shop 4 R SL 90, 380 V Transformer No. 7 Bearing Panel Incomer Transformer No. 8 Transformer No. 9 Transformer No. 10 Transformer No. 11 Transformer No. 12 Transformer No. 13 Transformer No. 15 Transformer No. 17 HT1 & 2 HT Canteen, lab, IT F1 MSEB F2 MSEB F7 MSEB F4 MSEB F3 MSEB F5 MSEB Tech. Center
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Transformer
Sr. No. Transformer No. Location Rating NL Loss (kW) 1.4 1.225 1.225 1.225 1.4 1.15 1.225 1.4 1.225 1.225 1.225 1.225 1.15 1.225 1.225 Load Loss Losses (kW) (kWh) 7 9.5 9.5 9.5 7 12 9.5 7 9.5 9.5 9.5 9.5 12 9.5 9.5 1.41 1.26 1.23 1.23 1.55 1.16 1.24 1.41 1.24 1.23 1.23 1.23 1.15 1.23 1.23 Total Annual Loss Annual Loss in Rs. (Rs. (kWh) 5.29/kWh) 11148.2 9960.1 9775.8 9733.5 12270.6 9162.3 9806.2 11162.9 9821.9 9738.9 9703.9 9712.6 9140.5 9759.8 9750.2 150647.5 58,974.01 52,688.82 51,714.17 51,490.47 64,911.59 48,468.66 51,874.84 59,051.70 51,958.05 51,518.67 51,333.50 51,379.50 48,353.45 51,629.21 51,578.60 7,96,925.23
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
A Shop A shop 1 Comp MSEB B Shop Trans. 1 I/C B Shop Trans. 2 I/C
500 750 750 750 400 1000 750 500 750 750 750 750 1000 750 750
Transformer No. 5 B shop 4 R SL 90, 380 V Transformer No. 7 Bearing Panel Incomer Transformer No. 8 Transformer No. 9 Transformer No. 10 Transformer No. 11 Transformer No. 12 Transformer No. 13 Transformer No. 15 Transformer No. 17 HT1 & 2 HT Canteen, lab, IT F1 MSEB F2 MSEB F7 MSEB F4 MSEB F3 MSEB F5 MSEB Tech. Center
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