05 Kirlosker Pneumatic - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/Auto Engg/05... · D ] ] } v U s ] ] } v s o µ ï ì r µ P r í ó

8/30/2017

1

18th National Award for Excellence in Energy Management 2017

Hadapsar, Pune

30-Aug-17 Kirloskar Pneumatic Co. Ltd. 1

KIRLOSKAR PNEUMATIC CO. LIMITEDA Kirloskar Group Company

Outline


Company Profile

Specific Energy Consumption & Benchmarking

ENCON Projects Summary

Innovation in ENCON Projects

Carbon Footprints Reduction Projects

Utilization of Waste Materials

Environment Projects

Renewable Energy Initiatives

Green Initiative

ENCON Management Structure

Energy Monitoring & Reporting

Employee Engagement in ENCON & CSR

Recognition for ENCON Efforts

Future ENCON Projects

Rakesh A ParmarCorporate Energy

Manager

Parag D BhusariManager HT Shop

Presentation Team


Company Profile

Manufacturing Plant


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Products & Application


Air Compressor Division CentrifugalReciprocatingRotary ScrewOil Free Screw

Transmission Division Locomotive TransmissionIndustrial Gear BoxesHydraulic Marine

Traction Gears and Pinions

Products & Application


ACR Equipments & VACRefrigeration CompressorsRECIP Bare / Packages

Screw PackagesKirloskar - Ebara Vapor Absorption Chillers

PGS & ProjectsMarine HVACR Systems / Solutions Refrigeration Systems Gas Compression

Packages

Integrated Manufacturing Operations


Design & Manufacturing of High Quality products

Project Design, Fabrication, Packaging & Testing Facility

Ability To Manufacture Wide Product Range

Integrated Manufacturing Operations


P

D

C

A

MenMachineMethodMaterialSOPResources

Input Output

Process

CUSTOMER

QA PE ME HR PPC R&E Mktg.

Management

Mission Vision

Mission Vision

ValuesValues

LRP / AOPLRP / AOP

Strategy / PolicyStrategy / Policy

SHEQPC

HD

Competition Environment Society

I.T. Support

Waste EliminationWaste Elimination

•Waste Elimination Approach

Workplace PracticesWorkplace Practices

•Best Practices

Standard PracticesStandard Practices

•Standardized Work

Continual ImprovementContinual Improvement

•Kaizen, VSM• Problem Solving

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KPCL Mission, Vision & Values

30-Aug-17 9Kirloskar Pneumatic Co. Ltd.30-Aug-17 10

ISO 9001-2008

Company certification:

OHSAS 18001-2007ISO 14001-2004

Kirloskar Pneumatic Co. Ltd

Kirloskar Pneumatic Co. Ltd.

30-Aug-17 11

Company certification:

KPCL is Certified to Integrated Management System (IMS) by TUV

NORD

IMS isIntegration of

ISO 9001-2008, ISO 14001-2004 &

OHSAS 18001-2007

Kirloskar Pneumatic Co. Ltd.

Energy Policy


Managing Director Shri. Aditya Kowshiksigned Energy Policy – indicates strongcommitment from top managementtowards ENCON

Policy reviewed 4 times from firstpublished in 2005 in view of energyperformance scenario

KPI Strategy Deployment

Plant Level Goals

Dept. Level Goals

ENCON Key Projects Individual Goals

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SEC & Benchmarking

Specific Energy Consumption


Air Compressor Division

Increase in R&E TestingTrials, Testing & Customer InspectionSubstantial Increase in Third Party Inspection

0

1000

2000

3000

4000

14-15 15-16 16-17 17-18Actual 2915 2828 3128Target 2700 2700 2700 2700

kWh / No. of UnitsBetter


Specific Energy ConsumptionTransmission Division

Increase in R&E TestingDifferent product mix - High Speed & IGB Addition of New Machines

010002000300040005000

14-15 15-16 16-17 17-18Actual 4287 4294 4293Target 4080 4080 4080 4080

kWh / MT Better



Foundry

Better

0

200

400

600

800

14-15 15-16 16-17 17-18Actual 635 628 640Target 638 630 620 620

kWh / MT

Increase in new design productsFrequent power failure from MSEDCL leads to molten metal holding

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16-17 17-18Actual 42 31Target 40

01020304050

Shot Blast ing M/ckWh / MT

16-17 17-18Actual 1050 1087Target 998

950

1000

1050

1100

Ferrous ShopkWh / MT

16-17 17-18Actual 2763 3347Target 2625

01000200030004000

Non-Ferrous ShopkWh / MT

16-17 17-18Actual 71 85Target 67

020406080

100

Air Compressor - FoundrykWh / MT

16-17 17-18Actual 1.36 1.28Target 1.32

1.241.261.281.301.321.341.361.38

ACD OperationsLac kWh / Year New target developed in

year 2016-17

Focus on process benchmarking

Benchmarking For Foundry Operation


0

320

640

KPCL Foundry Target NationalBenchmark

InternationalBenchmark

630 620 610 560kWh / MT

Source for National & International Benchmark: UNIDO Global Benchmarking Tool 2010


Energy Projects Summary

ENCON Summary – 2014 to 2017


ENCON Projects Summary

Energy Saving: 1.03 Million

kWh

Cost Saving: Rs. 14.65 Mn

Investment: Rs. 9.59 Mn

Payback Period:

8 Months

Investment No. of Projects

Energy Saving in Million kWh

Cost Saving in Rs. Mn

Investment in Rs. Mn

Zero Fund 33 0.66 5.41 0.00Low Fund 16 0.27 2.42 0.52High Fund 14 0.10 6.82 9.07

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Zero Fund Projects


33 Projects

5 Programs

5.41 Rs. Mn

Immediate

0.66 kWh Mn

Low Fund ProjectsInvestment < 2.0 Lac


16 Projects

5 Programs

2.42 Rs. Mn

2.6 Months

0.27 kWh Mn

High Fund ProjectsInvestment > 2.0 Lac


14 Projects

5 Programs

6.82 Rs. Mn

16.0 Months

0.10 kWh Mn


Innovation in ENCON Projects

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Fixture modification for heat treatment process

Net weight loading - 78%Net weight loading - 40%

Energy Saving

• 166650 kWh

Cost Saving

• 14.53 Rs. Lac

Investment

• 0.20 Rs. Lac

Payback

• Immediate

Productivity ImprovedCarbon Emission Reduction 137 MT / Annum

30-Aug-17 Kirloskar Pneumatic Co. Ltd., Pune 25

Innovation In ENCON

Job loading in 2 layer Capacity utilization

improved Energy consumption

reduced up to 0.85 kWh / kg

3Ton furnace capacityEnergy loss due to low capacity utilizationComplex fixtureEnergy Consumption 1.4 kWh/kg


Carbon Foot Print Reduction Projects

50 % Energy Conservation AchievedCarbon Emission Reduction 24 MT / Annum


Energy Efficient Lighting Energy Efficient LED Lighting For • Office – 72 Watt Replaced By 36 Watt• Conference Hall – 36 Watt Replaced By 15 Watt.

Energy Efficient LED Lighting For• Shop Lighting• 250 Watt MH Lamp Replaced By 150 watt

Energy Efficient LED Lighting For• Street Lighting• 125 Watt MV Replaced By 40 Watt


Utilization of Waste

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Utilization Of Waste

Aluminum Burr Recycling

7 MT / year aluminum recycled

AfterBefore


Oil recovery from metal chips generated during gear cutting

73 % oil recovered from metal chips generated during gear cuttingNatural resources conservation

34 kL

9 kL

25 kL

Purchased

Recycled

Requirement


Utilization Of Waste


Reduction Of Energy Wastage By Improving Machine Availability (Maintenance Performance)

Air Compressor Division – Critical Machine Performance

Transmission Division – Critical Machine Performance

0

500

14-15 15-16 16-17 17-18

MTBF

Actual Target

0

10

14-15 15-16 16-17 17-18

MTTR

Actual Target

0

500

14-15 15-16 16-17 17-18

MTBF

Actual Target

0

10

14-15 15-16 16-17 17-18

MTTR

Actual Target


Environment Projects

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Environment ProjectWater Conservation By using dry type paint booth

BeforeBefore AfterAfter


Wet paint boothEnvironment concerns i.e. water pollutionEnergy consumption – 91823 kWh/yearWater Consumption – 142 Kl / Year

Dry type paint boothNo Water pollutionEnergy consumption – 60262 kWh / year

30-Aug-17 34

Dry type Paint Booth

Kirloskar Pneumatic Co. Ltd., Pune

30-Aug-17 35

Dry type Paint Booth

Kirloskar Pneumatic Co. Ltd., Pune 30-Aug-17 Kirloskar Pneumatic Co. Ltd. 36

Renewable Energy Initiatives

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Solar Power Plant

Connected load : Fan, lights, refrigerator of OHC and Society office

Energy Saving 1057 kWh/year

91 9077

6186 75

11079

21

114130 122

0 0

38

8860 69

44 32

116

15 1538

0

50

100

150

Solar MSEDCL

Cost Saving Rs. 9216/year

GHG Emission 0.87 Tons of CO2/Year

Renewable – Solar Energy


20kWp SPP

(On Grid Type)

Projection of 18 MWh

/ year

HR & Canteen building will get benefit

Target completion

in 2017


Green Initiative


Green belt @ KPCL Hadapsar plant

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Energy Management

ENCON Management Structure


Apex Team

Managing Director

VP – ACD

VP TRM

VP - ACR

Core Team

Energy Manager

All Dept. Heads

Working Team

Team Members• Prod.• PE• ME• HR• Finance• Assly.• Purchase• QA

Small Team

Cross Functional Team• Prod. • PE• ME• HR• Finance• Assly.• Purch.• QA

ENCON Team – 78 Nos.


Energy Management – Team Members

Employee Name Certificate holds

U V Marathe Energy Auditor

A M Bhide Energy Auditor

S P Bhargave Energy Auditor

R A Parmar Energy Manager

S D Jere Energy Manager

Mahesh M. Shinde Energy Manager

ENCON Methodology


• Assignment to Team• Energy Budget• Monitoring• Kaizen• Creative Ideas• Special Team for Project

• Monthly Review• Holding Gains• Fine Tuning & Plan for

further Improvement

• Brain Storming• Sub Project• Area of Concern• New Technology• Renewable Energy• Internal / External Energy

Audit

• Analysis of Energy Consumption

• Target Setting for Goal Achievement

Result Approach

DeploymentAnalysis & Review

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Energy Monitoring & Reporting

Monitoring & Reporting


DG Set Running Monitoring -Monthly monitoring - Record Book

kWh /kVAr Power Factor Main Plant Recording Monitoring-Daily - Data Register in Computer- SCADA system for H.T. furnaces only

Cell wise kWh Energy Recording & Review- Monthly

Compressor Energy Monitoring -Daily -Monthly -Data Register & in Computer

Foundry Energy Monitoring -Daily-Monthly-Recording in Computer

Monitoring Energy

Consumption





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Energy Monitoring System @ Test beds

30-Aug-17 50Kirloskar Pneumatic Co. Ltd., Pune

SCADA System - Heat Treatment

SCADA System for Heat Treatment Process Control

Programming For Individual Furnaces Real Trend Charts for Temp. & Cp


Monitoring & Measuring Instruments


Energy Management

System is planned in

year 2017-18

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Sustainability Report (Internally Published)

Sustainability Reporting

Gap Analysis

Process Improvements

Integration Into Existing

Processes

Responsible Business

ProcessesSUSTAINABILITY


GHG Emission – Tons of CO2e


0

5000

10000

14-15 15-16 16-17

7220 7409 7045

KPCL

% Reduction

• 2.40% over FY15 (KPCL)• 1.60% over FY15

(Hadapsar)

0

5000

10000

14-15 15-16 16-17

6105 6414 6005

Hadapsar


Employee Engagement In ENCON & CSR

Global Warming

GHG Emission

E-Waste Recycling

Compressed Air leakage

GreenCo Certification

En MS ISO 50001

Training @ Office & shop floor area


Employee Engagement In ENCON

Training On

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Training to EmployeesS. N. Programme Title Nos.

Level of TrainingDurationin Hours

DateEngineers /

WorkersSupervisor /

Managers1 Plastic recycling awareness 43 11 32 1.0 Jun.-16

2 Why Energy Conservation Required? 355 162 193 4.0 Sep-16

Total 398 173 225

S. N. Programme Title Nos.Level of Training

Durationin Days

DateEngineers / Workers

Supervisor / Managers

1Workshop on Solar Photo-voltaic and Hybrid Wind Energy Systems 2 -- 2 1 Day Sep-16

2Challenges in implementation of open access in Maharashtra 1 - 1 1 Day Oct-16

3 Workshop on enhanced energy efficiency in industrial lubricants 3 1 2 1 Day Nov-16

4 CII Green Conclave 2016 1 - 1 1 Day Nov-16

Total 7 1 6


Employee Engagement In ENCON

ENCON Quiz

Swachhata Abhiyan

ENCON Week Celebration

World Environment Day

KVIFF

SR Report

Vendor Engagement

Performance Appraisal

ENCON Painting Competition

Susamwad In-house Magazine

ENCON Week Celebration Glimpses


Desktop Wallpaper ENCON Oath

Opening Ceremony ENCON Quiz awardSolar Lantern

Banner

World Environment Day


Bike Pooling/ Cycling

Walking

CAR PoolingAwareness on Plastic

recycling

LED bulb / Sapling distribution

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61Kirloskar Pneumatic Co. Ltd., Pune30-Aug-17

ENCON Awareness in Community


Recognition For ENCON Efforts

Appreciation @ CII


2007-08Energy Efficient Unit

2008-09Best

ENCON projects & Energy Efficient Unit

2009-10 Energy Efficient Unit



Appreciation @ Kirloskar Group ENCON Committee


2008-09 3rd Prize

2009-10Best Innovative project

2011-12 2nd Prize

2012-13 Best Innovative Project

2014-15 3rd Prize

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BEE’s National Energy Conservation Award 2015


CII’s National Energy Management Award 2015



MEDA Energy Management Award 2015 Kirloskar Group ENCON Award 2015-16

68

3rd Best managed energy efficient unit – Large plant category

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Kirloskar Group ENCON Award 2015-16

69

Best ENCON Project – Induction furnace utilization at Foundry

Kirloskar Group ENCON Award 2016-17

70

3rd Best managed energy efficient unit – Large plant category


Recognition For ENCON Efforts

Accolades Gallery



Sr. No.

Project Driver

1 Use of LED lights for office/Shop floor / Street lights Energy Efficiency

2 Off Grid Solar Power plant installation for Security Office, HR, Canteen Green Energy

3 Replacement of refractory & brick lining of Heat Treatment furnace for energy performance improvement

ENCON

4 Use of solar energy for KPCL operation under open Access mechanism GreenEnergy

5 Replacement of old 500 kVA transformers - 2 Nos. with energy efficient transformer

ENCON

6 Active harmonic filter to control the harmonic level in electrical distribution system of air compressor test bed

ENCON

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Sr. No.

Project Driver

7 Introduction of SCADA based energy monitoring system at Hadapsar & Saswad plant

ENCON

8 Use of VRF based air conditioning system for the building air conditioning requirement

ENCON

9 Energy generation by using compressed air generated during testing ENCON

10 Inverter based air conditioners for new requirement ENCON


www.kirloskarkpcl.com

KIRLOSKAR PNEUMATIC CO. LIMITEDA Kirloskar Group Company

Kirloskar Pneumatic Co. Ltd. 7430-Aug-17

Thank You

Documents

05 Kirlosker Pneumatic - greenbusinesscentre.comgreenbusinesscentre.com/energyaward2017presentations/Auto Engg/05... · D ] ] } v U s ] ] } v s o µ ï ì r µ P r í ó