View
6
Download
0
Category
Preview:
Citation preview
IMTMA-ACE MICROMATIC PRODUCTIVITY
CHAMPIONSHIP AWARDS 2019
Reduction of Specific Carbon Footprint by using Waste to Wealth, TPM
and Industry 4.0 Concept in the Utility Management area
Presenter : Mr. Sandip D Priolkar – DGM-CMD/PPS/CECM/ENCON
Date : 21th August 2019
Case study of Mahindra & Mahindra Ltd., Mumbai
Sandip Priolkar
Energy Auditor,
Mentor and
Presenter
Sandeep Rege
Rajesh Mhatre
Hemant Joshi
Vinayak Gokarn
Team Auto Sector Plants
Revenue contribution 39%
IgatpuriEngine
Manufacture
KandivliFully
Integrated
Plant
Supplies
Aggregates
to Other
Plants
ChakanMahindra
Vehicle
Manufacturing
Plant
NashikVehicle
Manufacturing
Plant
Zaheerabad
Vehicle
Manufacturing
Plant
HaridwarVehicle
Manufacturing
Plant
Mahindra- Kandivli Plant-AFS Headquarters
Kandivli Plant Manufacturing Process Started at 1964, Oldest in
Mahindra
Mother Plant supplying
aggregates like Axle/
Transmission and Engine
Components to other
plants.
The only integrated
Manufacturing Plant in
Metro city
(Foundry to Vehicle
assembly)
Plant Area : 64 Acres
4500+Employees
Highest SPACE
PRODUCTIVITY3
Salient Feature of the Project Project Start Date 27/04/2018
Project End Date 30/10/2018Target
Reduce Specific Carbon Footprint Promise 2019
Challenges
To Reduce Dependency
on Fossil fuel related
Energy
Affordable Business Case
Challenges -
Conceptualisation Make a Road Map from
Concept to reality where
No Benchmark is available
Suitable Vendor for
execution
No chance for Error as
Solution is to be
implemented on A rank
Equipment
Challenge -Execution
Peak Production
season, Very low
Window for execution
Cramped space in
Utility House to fit
Hardware
Safety concern as a lot
of work is involved at
Height with Ground
movement
Integration with
Conventional Washing
Machines by leveraging
Industry 4.O
Results Achieved
Morale Boosting
project, First in
Mahindra Group
Project implemented
against OEM
recommendation
Intended results achieved
with “First time Right”Spirit
Helped us in achieving
the Deliverables as per
Promise 2019
Huge scope for
Horizontal Replicationacross Mahindra plants
and in other Industries
Climate Change- Global Challenge
Climate Change- Global Challenge
Climate
Change
Food
Security
Energy
& Water
Health
Jobs &
Prosperity
Income &
Poverty
Education
Gender
Equality
Conflict &
Security
“By 2030, we will reduce
emissions by 33 to 35% per
cent of 2005 levels. 40% of
energy requirement will be
through Non-Fossil fuel”
“We have contributed to the
problem and it’s up to us to
help mitigate it…”
Increase of CO2 in
Atmosphere by 47% as
compared to Pre-industrial
areaGlobal Warming, Extreme
Weather Pattern
Threat to Entire
ECO-System
M&M Journey towards Sustainability
Achieve
Carbon
Neutrality
Commitment - Rejuvenating the Environment
Commitment to Doubling the Energy
Productivity by 2030 (Baseline 2009)
Carbon Price
Declared internal carbon price
$ 10 / Ton of carbon
M & M is first company in world to sign
EP 100 with Climate Group
M & M is first company in India to declare
internal price of carbonEP 100 by 2030
(Energy Management)
Carbon Pricing declared - 2016
($ 10 per Ton of carbon emission)
Thrust on Renewable
Energy & tree plantation
program
Science based Targets(SBT) by 2034
(2~5% reduction in Carbon intensity YoY)
Carbon Neutrality by 2040
( EP100+SBT+Offsets)
Our Promise Statement/ Challenges/Targets…
Our DREAM
To Be Amongst
the Top 10 Global
Automotive Brand
To Reduce Specific Carbon and Water
Footprint by 15 % over FY16
Mahindra Rise Framework..
Accepting No Limit Alternative Thinking Driving Positive Change
100
105.4 105.1 106
112.9115 116
118 118
F11 F12 F13 F14 F15 F16 F17 F18 F19
Connected Load in KW
CO2 Emission
Scope 1 & 2
F16
Baseline
F19 Target
Plant Excluding
Foundry
227.6 Kg/
Eq. Veh
193.5 Kg/
Eq. Veh
Standalone
Foundry
1089.4 Kg/
LMT
926 Kg/
LMT
Target Setting
10
QImprove
Customer
Centricity◌ ◌ ◌ ◌
P & DStrengthen
Domestic
Dominance◌ ◌ ◌ ◌
MOrganizational
Effectiveness ● ◌ ◌ ●S Sustainability ● ● ● ● ●C
Cost
Leadership ◌ ◌ ◌ ◌
● ● ◌ ◌ ●
● ●◌ ● ● ● ●◌ ◌ ◌ ●◌ ◌ ◌ ●
О О О О
Strong
Relation
Medium
Relation
Weak
Relation
● О ◌Legend
Number of Kaizens related to
Energy Management
Number of Projects related to
Renewable Energy
Number of Kaizens related to
Water Management
Number of Kaizens Related to
Hazardous Waste
Number of Kaizens Related to
Non-Hazardous Waste
Number of People trained on
Sustainability Related Topics
Sustainability Pillar
Specific Cabon
EmissionEnergy Cost
Specific Water
Consumption
Hazardous
Waste
Generation
Non Hazardous
Waste
GenerationKAIKPI
KMI
KMI-KPI-KAI Relationship Matrix…
Specific
Carbon
ReductionSustainability
Understanding Carbon Footprint and its Contributors..
Head Carbon Potential
Expressed in
Kg/Unit
PNG 2.19 Kg/M3
LPG 2.98 Kg/Kg
Diesel 2.65 Kg/Litre
Electricity 0.82 Kg/KWh
11%
89%
Scope 1 V/s Scope 2
Thermal Electrical
10000 Kcal/Hr
11.6 kWh Electricity
1.2 SCM Of PNG
9.53 Kg of CO2
6.6 Kg of CO2
40% Efficiency
Impact of Switching of Fuels
Safety & Statute related concerns
Scope1&2- 55613 Tons of CO2
Scope 3- 42119 Kg of CO2
FY16 Data
Energy Efficient appliance
LED Lighting
Induction Lighting
Screw Compressors
Star Rated Air Conditioners
VFD
Energy Efficient Motors
HVLS Fans
Process for Energy Efficiency
Low Temperature Degreasing
Cold Box in Foundry
Fixture Modification for More charge
per Heat
Sharing of Resources
Optimise Temperature/ Pressure
Elimination/ Combining
Cycle time reduction
Alternate Fuel
Renewable Energy Waste to Wealth
Solar Photo-Voltaic
Wind Power Bio Gas from Canteen Waste
Waste Heat recovery34% of Energy is used for Heating
12
Idea Generation for Sp. Carbon Footprint Reduction….
Work done so far in Waste Heat Recovery…
WHR in Re-cuperator
to Heat Pre-washer
Solution and also For
heating ambient
incoming air to Burner
Heat from the
Compressed refrigerant
of AC units is used for
heating washing machine
solution
Heat from flue gases used for
heating fresh air supplied to
the Burners using the Heat
Pipe Technology
(In paint Shop)
2006~2009 2010~2013 2014~2016
12 Locations 6 Locations 8 Locations
14
Pre-amble for Waste Heat Recovery…
Mc Details Consumption
Average/ Hr
Conversi
on Unit
Energy
Transfer
Soln
inlet
Soln
outlet
Diff
kWh SCM Kcal/Unit Kcal/ Hr D.Cel D.Cel D.Cel
T.Washer-7396 33 860 28380 40 55 15
T.Washer-7392 45 860 38700 40 55 15
T.Washer-652 36 860 30960 40 55 15
Vacuum Pre-wash 34 860 29240 40 55 15
Washing Mc-7525 5 8300 41500 40 55 15
Washing Mc-7378 5 8300 41500 40 55 15
Washing Mc-1817 36 860 30960 40 55 15
Washing Mc-1791 34 860 29240 40 55 15
TOTAL 218 10 270480
Application
For HeatingSource of
Waste Heat
Options Hunted
Heat Recovery from
the Flue gases of
Heat Treatment
Furnace
Heat Recovery
from the Flue gases
of Hot water
Generator
Can we extract
Heat from
circulating
Lubrication oil
of Nearby
Compressors??
Already
Done
Inadequate
Heat
No
Experience
but Worth
Giving a
TRY
Pre-amble for Waste Heat Recovery-Analysis Sankey Diagram for
Compressed Air System
This is heat available in the oil
at 80-100 ⁰C
How This Heat can be used
in useful Energy?
Heated oil + air mixture at 90-100C exits
the screw element towards air/oil
separator to reject heat via radiators or
cooling towers
Energy
Input
Com
pre
ssed A
ir
Genera
tion
Useful Energy at Point of Usage-10%
Frictional/Other Losses & Misuse
10-15%
WASTE HEAT
75~80%
Utility Compressor House layout
Compressor
Specifications
1. Make- Sullair
Lubricated
2. FAD- 2179 CFM
3. 2 Stage Design
4. Set Pressure-
75 & 95 psi
5. Motor- 315 KW
6. 24 Hours
Operations
1. 12 Year Old Compressor-
2. Base load Compressor-
3. Space constraint in
Compressor House-
17
Developing alternative solutions…
Oil Cooler
Screw
Compressor
Air + Oil
95 Deg. C
Air-Oil
Separator
Air + Oil
IN Air OUT
Oil, 95 Deg. C
Oil, 80 Deg. C
Water INWater OUT
Opportunity
for Heat
Recovery
Working Principle RISKS Associated with Project
Options Worked out
Option 1Refurbishment
Of Existing
Compressor
by OEMRegret
from OEM
Option 2New Compressor
with Built-in
Waste Heat
RecoveryHuge CAPEX
Huge Space
Option 3
Collaborate with
Local Vendor to
pursue the project
Mahindra Rise
Philosophy
Circulating oil flow-
16,320 Ltrs/Hour
Inlet Temp- 95 Deg,
Outlet temp- 70 Deg
Design Temp Diff- 25 Degree
Max possible heat Recovery-
312120 Kcal/Hour
Design Parameter for Heat Recovery
18
Hot oil
from air-oil
separator
Cool oil to
element
Hot DM water at 70-80 C
towards washing machines
Cooled DM water at 60-70 C
back to Heat Recovery
55 Deg Cel to
Washing tanks
40-45 C from
Washing Solution
tanksCirculating Pump
Primary
Heat
recovery
Heat
Sink
Project devised to recover heat from compressors to heat washing machine fluid
Putting concept to Reality.. Breakthrough
Compressor Side Equipment Side
Secondary
Heat
Recovery
Uniqueness
Compressor Side
System is isolated
from Equipment
side system
19
Compressor
Oil CircuitOil Heat
Recovery
System
Water
Distribution
Circuit
Washing Fluid
Heating SystemWashing
Fluid Circuit
Schematic Diagram for WHR…Breakthrough
Inputs from
FMEAInputs from
HIRA
Inputs from
USER DEPARTMENT
Project Plan.. Close monitoring for success..
21
Project Layout….
Insulated Overhead Pipeline
800+ Running Meters
Compressor
House
22
Implementation…-Innovation
80 Deg C
Equip. Side
Piping
Heat Excha.+
Pump Skid
Electrical
Control Panel
2x Base-load
Compressors
23
Safety Features in Project…
Benefit
1. Zero chances of
Intermixing of Oil and water
2. Visual detection of any leak
Benefit
1. Acts as Fluid Buffer for
make-up water
2. Take cares of Thermal
expansion
Double walled Heat
Exchanger on compressor
side for safety purposePressurised Expansion Tank Diverter Valve
Benefit
3-Way Valve
Isolates Secondary Heat
Exchanger once desired
Temperature is achieved
24
Conquering the Challenges & Actions ..
Challenge Action Taken Benefit
Laying of Pipe line of water
at a Height-800 Running Meters
Safe execution of Project.
Execution Time Optimized
Accommodating Heat
Exchanger & other units
in Cramped area
Made the Project Viable
@ Optimized Cost
Accommodating Secondary
Heat Exchanger and Pumps
near individual washing M/cs
Buy-off taken from
Production/
Maintenance Teams
Easy to Operate and
Maintain
Simply execution is not the Success of project, Effective working is the key
to the success.. We leveraged INDUSTRY 4.O for the same
Modification in
Compressor- Chances
of Leak, & Stoppages
Maintainability
Deployment of Pre-insulated
pipes with Flanged joints
Footprint optimization
w/o compromising
Design Parameters
Adopted Valves in
Circuit With
reversible design
Principal of
InteroperabilityMachines, devices,
sensors, and people to
connect and communicate
with each other via Internet
of People (IoP)
To Achieve BHAG of becoming ‘Top 10 global automotive brands’ we aligned our
Utility process towards Industry 4.0
Leveraging “INDUSTRY 4.O”…
8 washing machines in Axle PU and
Transmission PU attached to the heat
recovery system
HX
HRS
Return Line from Washing Machines (60C)
Supply to PUs (70-75C)Sullair air
compressor
Primary
HRS
Oil from
compressor
(90C)
Oil return to
compressor
(75C)
Expansion
tank
HRS HRS HRS HRS HRS HRS HRS
All machines working properly
Leveraging “INDUSTRY 4.O”…
26
8 washing machines in Axle PU and Transmission PU
attached to the heat recovery system
HX
HRS
Return Line from Washing Machines (60C)
Supply to PUs (70-75C)Sullair air
compressor
Primary
HRS
Oil from
compressor
(90C)
Oil return to
compressor
(75C)
Expansion
tank
HRS HRS HRS HRS HRS HRS HRS
All machines working properly
When Filter gets choked, the Machine
is automatically stopped, and
intimation for maintenance is sent out
Leveraging “INDUSTRY 4.O”…
27
28
GPRS Cloud Based system integrated with Air
Compressor and washing machine All Critical parameters
covered under Industry 4.OData Storage
to Local PC
Washing Machine Data
1. Air Compressor Oil and Water
Temperature
2. Washing Machine fluid
Temperature
3. Air Compressor and Washing
Machine Energy data
4. Air Compressor Vibration and
Pressure
Washing Machine Real time Temp. Graph Air Compressor Data
Real Time Graph- Leveraging “INDUSTRY 4.O”…
30
Ability to deep-dive into identifying issues
Ability to do detailed analytics on motor vibration
and temperature data to prevent failure and
understand failure points
Deep-dive on energy consumption and pressure
delivered at various times during the shift
Real Time Graph- Leveraging “INDUSTRY 4.O”…
Variety of sensors installed on compressors
Energy meters for capturing
power consumption and PF
Pressure sensors for outlet
pressure of airVibration sensors for motor
vibration and temperature
Feeling of OEM’s Representatives…From: Varun Bajpai <varun_bajpai@hitachi-hirel.com> Sent: Wednesday, January 14, 2019 2:06 PM To: JOSHI HEMANTKUMAR <JOSHI.HEMANTKUMAR@mahindra.com> Subject: Air Compressor model LS 32S
Dear Sir This has reference to the Air Compressor Model LS 32S 400 manufactured by Sullair USA running
in your Kandivli works. The HEAT RECOVERY PACKAGE which you have designed and installed for this machine is a very innovative attachment to the machine and we appreciate this engineering modification done by you to get the best energy saving form the machine. We also thank you for obtaining the best performance from our machine which serves as a very good reference for us. Best Regards Varun Bajpai Asst. Vice President- Air Compressor Division Mobile: +91 7045349306 I Email: varun_bajpai@hitachi-hirel.com
Hitachi Hi-Rel Power Electronics Pvt. Ltd. Address: B-62, Corporate House, Judges Bungalow Road, Bodakdev, Ahmedabad - 380 054, GJ India Phone: +91-79-6604 6223 (Ext.: 223) I Fax: +91-79-6604 6201 Website: www.hitachi-hirel.com
From: Kiron Pande <kcp@godrej.com> Sent: Wednesday, December 9, 2018 3:30 PM To: PRIOLKAR SANDIP <priolkar.sandip@mahindra.com> Cc: JOSHI HEMANTKUMAR <JOSHI.HEMANTKUMAR@mahindra.com> Subject: WHR Retrofit on Lubricated Screw Compressor
Mahindra & Mahindra has been a front runner in implementing energy saving projects to reduce carbon footprint. Our association with them over 20 years. When we had a partnership with Sullair Compressors, M&M had procured and installed the first ever Two-Stage Screw Air Compressor of 2179 cfm flow capacity sold by us. At that time, M&M saved large amount of energy with improved efficiency of Tandem Screw technology over their earlier Air Compressors. Keeping up to their tradition of achieving further and further improvement in energy efficiency, they thoroughly studied operation of the Air Compressor. With their continued efforts for recovering the heat of compression, M&M Engineering team got a CUSTOMISED ‘WASTE HEAT RECOVERY SYSTEM’ (WHR) designed and made to retrofit on the Air Compressor.
This is the first installation of WHR on any Sullair Compressor in India! It was amazing to see successfully retrofitting a WHR system on a 12 year old Air Compressor! This WHR is a fully automatic system and does not require any manual intervention – not even operating a valve or a pump. While implementing the WHR system, M&M team has leveraged Industry 4.0 techniques through sensors, communication, monitoring, digital electronics and control to ensure that the Screw Elements in the Air-End (which is the heart of a screw compressor) are maintained with the right amount of temperature and flow rate of the lubricant.
This idea has enormous potential to replicate in the industry which can be horizontally deployed by the Users and Air Compressor manufacturers. Regards, Kiron Pande ***************** Mr. Kiron C. Pande AVP & Business Head – Automation & Energy Management Godrej & Boyce Mfg. Co. Ltd. Electricals & Electronics Division Pirojshanagar, Vikhroli, Mumbai – 400079. India Tel.: +91(22)67962211 / 2251; Fax: +91(22)67961525 Mobile: +91-9820348824 Website: www.godrej-airsolutions.com
Users Voice….
• Scope for horizontal Deployment – ( Pl tick )
M & M
Mfg
plants
Other
Auto
ind.
All
Mfg
Ind.
33
Balance Sheet…Entire project Cost with Taxes
Rs. 51 Lakhs - One Time Investment
PNG Saved- 9,600 SCM/Annum,
Rs. 3.282 Lakhs
Electricity Saved- 600,000 kWh/AnnumRs. 60.00 Lakhs
Total Cost Saving – Rs. 63.82 Lakhs/Annum
CO2 Mitigation by this unique Project
513 Ton/Annum
First of its Kind
In Mahindra Group
Huge Potential for
Horizontal Deployment
In all Sector Plants
Results- Sp. Carbon Footprint
“PROMISE 2019” Delivered
MP Sheet Made and
Shared with DM Pillar
Simple Payback- 9.6 Months
Patent Idea-
2579 / PAT / 2019
228194 192
F16BM
F19Tgt
F19Act
Plant Excl. FdryKg/Eq. Veh
1089
926 913
F16BM
F19Tgt
F19Act
Standalone FdryKg/LMT
National Awards and Accolades in FY19…..
Breakthrough Kaizen Award in
34th TPM Kaizen competition
Mahindra AFS
Best Energy Efficient Project
1st prize in SOPEP
CII National ENCON Award SEEM- Gold Award for ENCON
3rd Year in Row
“ACCELERATE to EXCELERATE”
at Plant Level
IE3/IE4
Motors
Inverter
Based ACs
LED
Lighting
Wind Mill
Bio-Gas Plant
HVLS Fans
Process
Improvement
And Many More….
Way Forward to achieve Carbon Neutrality …
Recommended