11th National Award For Excellence In Energy Management Award... · 11th National Award For Excellence In Energy Management Emerson Climate Technologies (India) Ltd, Atit-Karad Company

1

11th National Award For Excellence In Energy Management

Emerson Climate Technologies (India) Ltd, Atit-Karad

Company Outline

Certifications : ISO 9001(2008), EMS 14001(2004), ISI, CE Approval, Underwriters Laboratories (UL) & RoHS Environment Compliance

641.795 (CR Equivalent) Production FY 10 (K PCS)

Air Conditioning Series With 11.1 EER, Refrigeration Series With 6.2 EER

Energy Efficient Products

LG ,UPCL, Blue Star, FLC, Godrej, Hitachi, Videocon, Carrier, SSI OEMs & Middle East Customers

Principal CustomersRs. 81.38 Mn ( 2.12 % of Sales Turnover)Energy CostRs. 3824.5 MnCompany Turn Over

1.0 Mn / AnnumProduction Capacity1/4 H.P. to 40 H.P & Condensing UnitsProduct RangeHermetically Sealed Reciprocating CompressorsProduct

Emerson Climate Technologies, With Our Partners, Will Provide Global Solutions To Improve Human Comfort, Safeguard Food And Protect Our Environment

Vision

2

KCN KCJ

KCG

KCMCR6

Condensing Units

LBP 600 – 1500 BTUEER 3.7 – 3.9

CBP 1300 – 3200 BTUEER 6.1 – 6.2

HBP 1,000 – 12,000 BTUEER 6.1 – 8.22

45,000 – 60,000 BTUEER 9.8 - 10

HBP 12,000 – 24,000 BTUEER 10.2 – 10.7

19,000 – 42,000 BTUEER 10.6 -10.9 1200 – 66000 BTU

CK3

We Serve Our Customers With High EER Products

All Products Having R-134a & R404a Environment Friendly Gas

ECTIL Also Developing R410a & R407c Platforms To Phase-out R-22

KCE HBP 1,000 – 5,000 BTU

EER 6.1 – 8.22 CR6 Large45,000 – 60,000 BTU

EER 10 – 10.3

19,000 – 30000 BTUEER 9.0 - 9.4

Our Customer Partners

And Many More –

3

Emerson Climate India Motor Business

Acquisition in 2008-09

Compressor Manufacturing Process Raw Material

Receipt

Compressor Assembly

Welding & Leak Test

Dehydration (Heating & Dry

Air purging)

Component

Machining

Painting & Baking of

Compressor

Final Testing & Packing

Oil Charging

Shipping

Shell Shop(Housing

Assembly)

Components From Dedicated

Vendor Motors

From Auto Winding Lines

Energy Management Activity

Managing Director

Sr. Divisional Manager

Div. Manager –Support Services

Energy Manager

Team Member -Production

Supervisor & Hourly Employee

Team Member –Process Shop Supervisor &

Hourly Employee

Team Member -Utility PE

Supervisor & Hourly Employee

Energy Auditor

ENCON Team

Weekly Review

Monthly Review

Daily Review

4

13.98

15.7214.04 14.48

16.62 16.7417.54

WithoutMotor

Business

ECTIL Has Acquired Motor Business In Their Portfolio Due to Which Load Of 1350 kW Also Added. Hence The SEC Has Increased Over FY’08

1350 425

508 571741

641576

Specific Electricity Consumption / Compressor

Prod

uctio

n (Q

x100

0)kW

h /

CR

Com

p.

Rs. 9.542 MnTotal Energy Cost Saved 2.08-1.446.422.49Energy Cost Saved in Rs Mn

-253440

FY09

Units SavedAddition Of Load kW 25

FY06

513900155

FY07

3205001244880175

FY10FY08

5.5% 10.6% -3.1% 3.45%

15.88%

12.% 30% -23% 12%

Specific Fuel Consumption / Compressor

16186

132711340814193

12645

Prod

uctio

n (Q

x100

0)Fu

el K

cal /

C

R C

omp.

508 571741

641576

Rs 6.75 MnTotal Fuel Cost Saved1.330.221.783.41Energy Cost Saved in Rs Mn

8.45-

FY09

FO Saved In Kilo-Liters Addition Of KCAL 40000

FY06

119-

FY07

42.262.1--

FY10FY08

12.3% 5.56% 1.02% 4.75%

21.85%

12.% 30% -23% 12%

5

SEC Benchmarking

12540 kCal Not Available14415 kCalSpecific Fuel Consumption / Compressor

16.74*

(13.98) kWh

21.5 kWh17.21 kWhSpecific Electricity Consumption / Compressor

International ECT Thailand Plant (2009)

ECTIL Atit –Karad (2010)

International ECT Suzhou (China)

Plant (2009)

Equivalent Compressor Manufacturing Industry

• ECT India Is A Leading Reciprocating Refrigeration Compressor Manufacturer In The World

• Very Few Competitors Are Manufacturing Compressors Of Same Range, But Since Their Manufacturing Processes Are Completely Different, Energy Data Can Not Be Comparable Directly

Renewable Energy Usage

Payback In Months

Invest Rs. Mn

Savings Rs. Mn

Units Saving

MnYearProject DetailsSN

040.020.34812.01 KL Fuel 2008-09Solar System Usage Improvement

For Crankcase Washer2

ImmediateZero 0.0650.0112009-10Solar Heating System For Shaft Washer1

12.01Furnace Oil Saved In KL 0.14Total Cost Saved in Rs. Mn

0.011Electrical Units Saved In Mn

02Number of Projects In Last 3 years

Savings Rs. Mn

Units Saving MnSaving YearProject DetailsSN

68.3411.722007-2010Captive Power Generation Through 3.46MW Windmill1

Windmill Savings

Renewable Energy Projects

Global Warming Potential CO2

Reduction– 9962 Ton

6

• Solar Heating System Installed For The Tanks Parallel To Thermal Heating

• Total 45 Nos. Panels System With 28,000 Kcal Output Per Hour In Sunny Days In Use

• @12015 Liters Of FO Saved Per Annum By Interlocking Of Thermic Fluid Heating System with Solar Water Circulation Pump ON/OFF Cycle

• Saving: Rs. 0.348 Mn

System Details

Project : Usage Improvement Of Solar Heating SystemTheme: Solar Water Heater Usage Improvement Using Temperature Sensors

WasherSolar Working in sunny Hrs

Working in nightThermal Heaters

Feedback Loop

Temp.Controller

Investment : Rs. 0.02 Mn

Wind Mills : Installed Capacity 3.46 MW (6 No.)

7

Wind Mills – Capacity , Generation Details

30.1022.04 (Avg)6.696.80Total

22.12

21.90

22.10

PLF % Achieved

21.10

4.95

4.05

Amount Realized

in Electricity

Bills In Rs. Mn

4.65

1.15

0.89

Actual Generation for FY10 in kWh Units

In Mn

4.80

1.10

0.90

Estimated Annual

Generation in kWh

Units In Mn

Installation Phase / Year of Commissioning

Capacity In MW

Investment in Rs. Mn.

Phase I / 2001 0.46 30.40

Phase II / 2001 0.60 36.00

Phase III / 2007 2.40 114.00

• All 3 Sites Are In Maharashtra & our PLF% 22.04 (Avg.) Is Nearer To The Best Achieved Of 23.92 In The State

• 100% Power Being Utilized For Self Use Only (i.e. @ 60% of Our Total Consumption)

Wind Mills – Carbon Credit Details

-Nil0.2659732001Windmill Of 1.06 MW at MATREWADI

2

4.30.281.044002007Windmill Of 2.4 MW at PANCHPATTA

1

Rs. MnRs. MnNo of CER / VER s

Payback months

Invest. Made

Total Annual Savings

Total Reduction In t CO2 e

Year of Implemen

tation

Title of project implemented

SN

*Projects Validated and Registered Under VCS 2007 Scheme with APX VCS Registry, USA, And Verification Is In Process

8

Compressed Air System

060.0250.0480.0082009-10Roots Blower Instead Of Compressed Air3

Payback In

Months

Invest Rs. Mn

Savings Rs. Mn

Units Saving


280.3500.1460.0272007-08Use Of Auto Control Shut Off Valves For Comp. Air Grid To Individual Workshops8

030.1500.6540.1052007-08Replacement Of Flexible PU Piping By Permanent MS Piping7

150.1500.1210.0222007-08Energy Efficient Guns & Nozzles6

010.0150.3370.0622008-09Reduction & Maintaining Plant Air Leakage Level Below 5%5

140.2150.1820.0332008-09Level Based Condensate Auto Drain Valves To Reduce Fixed Air Loss4

ImmediateZero0.0340.0062009-10Air Leakage Reduction 12% To 7% AMU2

ImmediateZero0.0340.0062009-10Optimize The Operating Pressure Air1

1.556Total Cost Saved in Rs. Mn0.269Electrical Units Saved In Mn


Roots Blower For Air Blowing Operation

Conventional Air Blowing– 6 Kg Pressure Air Used for Cleaning The

Component After Washing To Remove the Water & It’s Traces, Hence High Volume of Loss of Compressed Air

– Flexible & PU Piping, Hence Frequent Maintenance.

– The Compressed Air Cost For The Same Was Rs. 0.76 Mn

Investment :Rs. 0.025 Mn Annual Saving: Rs. 0.048 Mn Simple Payback : 6 Months

Use of Roots Blower for Air Blowing– The Requirement of Component Cleaning

Operation is majorly flow with low pressure.

– Work Station Identified & Installed A Roots Blower Unit Instead of Compressed Air.

– Localized Control With Electrical Supply. – The Consumption of Roots Blower Is Rs.

0.276 MnNoise Reduction & Cleaning Quality Improvement Are Added Advantages

9

Level Based Condensate Auto Drain Valves

l Project Details:

– Earlier, Timer Based Drain Valves In Use

– Timer Circuit Is Base Of Operation

– Regardless Of Condensate Level, Drain Action Takes Place For 4 Sec

– Condensate Level Based Auto Drain Valves Used

– Drain Action Only When Sensor Passes Signal For Filled Container

– As Line Shut Off After Drain Is Quick Due To Diaphragm, There Is No Air Loss

Investment: Rs. 0.215 Mn Annual Savings: Rs. 0.182 Mn Payback : 14 Months

Technology Refinement & Up gradation

220.2750.1460.0242009-10Replacement Of Conventional Sodium Vapor High Bay Lamps With Energy Efficient Shop Light 96 Nos

6

150.2470.1980.0362008-09Use Of Variable Frequency Drive For Blowers7

Payback In Months

Invest Rs. Mn

Savings Rs. Mn

Units Saving


370.2250.0703.514Kl FO2007-08

Monitoring & Controlling Of Boiler Inputs To Improve Efficiency & Control Flue Gas Measurement Under EMS Norms

9

110.0480.0520.0092007-08FRP Fan Blades8

150.1100.0840.0202009-10Bluing Furnace Conversion For ThyristorFiring Circuit5

140.2500.1920.0322009-10Use Of VFD For Variable Load Motors4

310.2850.1100.0202009-10Replace Conventional Motors By Energy Efficient Motors 2

110.1120.1320.0242009-10Replacement Of Old QR15 Compressor By Energy Efficient Scroll Compressor 1

10

Technology Refinement & Up gradation

330.2370.0870.0162007-08Use Of Inverter Based DC Welding Rectifier10

350.2500.0850.0152007-08VFD For Grinding Machine12

110.2350.2500.0452007-08Use of Variable Frequency Drive for Pumps.13

220.2750.1450.0262007-08Energy Efficient FL lamps for Street lighting 11

Payback In Months

Invest Rs. Mn

Savings Rs. Mn

Units Saving


3.515Fuel Saved In KL1.706Total Cost Saved in ` Mn

0.267Electrical Units Saved In Mn13Number of Projects In Last 3 years

Project: Energy Efficient High Bay Lighting

Investment :Rs. 0.500 Mn Annual Saving: Rs. 0.327 MnSimple Payback : 18 Years

360 1440

200

400Energy Consumption Per Day

1.430.67Other Benefit 2. Pupil Lumen FactorImproved To 8027Other Benefit 1. Color Rendering Index

Energy Efficient ElectronicsConventional (Copper)Ballast180 Watt (36 W X 5 PL Tube) 300 Watt (Including Choke)Power Requirement in WattEnergy Efficient PL TubeSodium VaporType of Lamp

AfterBefore Details

Before

After

Uni

ts P

er D

ay

11

Project: Energy Efficient Street Lighting

Investment : Rs. 0.275 Mn Annual Saving: Rs. 0.146 Mn

Simple Payback : 2 Years

52200 259200

30000

60000Energy Consumption Per Annum

Energy Efficient ElectronicsConventional (Copper)Ballast144 Watt (36 Watt PL Tube) 290 Watt (Including Choke)Power Requirement in WattEnergy Efficient PL TubeSodium VaporType of Lamp

AfterBefore Details

Before After

Uni

ts

Fuel Consumption Reduction

190.3650.22816.122008-09Scroll Heat pump for Degreasing tank of Paint shop 1

Payback in Months

Invest Rs. Mn

Savings Rs.Mn

K Liters SavingYearProject DetailsSN

080.1800.275164.62008-09Emulsification of Furnace Oil at Atit plant with 5% water. 6

Immediate Zero0.0371.682008-09Furnace oil Emulsification process, Increase water % by 1.5% at Karad From 5%

5

010.0120.32010.062008-09Air Infiltrations By Using Mechanical Draft4

ImmediateZero0.1123.472009-10F.O. emulsification 5% to 6.5 % Motor Unit Karad3

Immediate Zero 1.16836.522009-10F.O. emulsification 5% to 7.5 % Main Plant Atit2

232.45Fuel Saved In KL2.140Total Cost Saved in Rs. Mn


12

Innovative Project -Scroll Heat Pump For Degreasing TankBack Ground

• In Refrigeration Cycle, The Heat Generated At Condenser Side Is Lost In Air Resulting In Waste

• Similarly, The Majority Heat Pump Application Are Restricted To Domestic • Our ENCON Team Has Decided To Take This Application For Industrial Heating. • The Maximum Achievable Temperature Is @ 65oc

Scope

• Study Carried Out For Heat Pump Application for Temperature Requirement Is @ 40-60OC

• Selected Degreasing Tank Of 7 Tank Process Of Paint Shop.

Existing Industrial Practices To Serve The Purpose Heating Are

• Electrical Heating• Oil Fired Heating• Solar System (Rarely Used Due To Space And Major Investment Requirement)

Innovative Project -Scroll Heat Pump For Degreasing Tank

Degreasing Tank Heat Pump 7 TR Capacity

Harvested CoolingTemperature Achieved

13

Innovative Project –Scroll Heat Pump For Degreasing TankFeatures

• Low Running Cost• Moderate Investment• High Safety Features Over Other Systems (Electrical And Thermal)• Cooling Has Harvested• Environment Friendly

Details Of System• Scroll Compressor Used Is ZR11 Model Of Emerson Copeland Make (Our Own)• Heat Generation From Zr11-scroll Heat Pump Is @ 15400 Kcal / Hr. (Eqvl. To 21 KW)• The Electricity Consumption For Scroll Compressor To Generate Above Heat Output Is 10.4 Units. • Cooling Capacity Harvested @ 4 Ton

1690 9650

1000

2000

Before After

Daily Energy Expenses

In R

s.

Saving of Rs. 725/- Per Day

Investment: Rs. 365,000/- (Inclusive Taxes)

Simple Payback : 19 Months

( Top Management Approval For Another 11 No. Heat Pump is in Progress)

Waste Heat Recovery

140.0150.0190.0082007-08Utilize Paint Baking Oven Exhaust For Compressor Drying At Pre-treatment Plant

4

220.2250.1470.0262007-08Recovered Waste Heat From 300 CFM Air Compressor And Used To Washing Purpose

3

060.0360.0660.0112009-10Use of Condenser Heat in Central AC plant instead o Heaters 1

150.1500.1140.0202008 -09Installation Of Air Pre-heating System On Thermic Fluid Boiler Exhaust 2

Payback in

Months

Invest Rs. Mn

Savings Rs. Mn

Units Saving


0.345Total Cost Saved in Rs. Mn0.065Electrical Units Saved In Mn


14

Innovative Project: Waste Heat RecoveryUse Of Waste Heat From Condenser Of Centralized A/C System To Control Assembly Shop HumidityProject Details: Heat Generated In Condenser Of 20 TR Centralized A/C System is Removed Thru Cooling TowerModifications Are Made In System To Utilize This Waste Heat Instead Of Electrical Heaters To Control HumidityAdditional Heat Is Removed Thru Cooling Tower

Details Of Energy Saving:Electrical Heaters Rating 24 kW

Average Heaters ON Time / Day 3 Hrs

Total Power Consumption Of Heaters 72 kWh / Day

No Of Days When Heaters In Use 160 Days In Year

Total Power Consumption Of Heaters 11520 kWh

Saving Per Annum Rs. 0.063 Mn

A Kaizen Idea Generated From Our Team Member

Waste Identification & Elimination

020.0500.3300.0542007-08Delta – Star Starting For Blower Motor Of Dehydration Ovens Instead Of Permanent Delta Running

7

240.0750.0120.0022007-08Centralized Hydraulic Pump For Grinding Machine8

Payback In Months

Invest Rs. Mn

Savings Rs. Mn

Units Saving


200.020.0120.0022008-09Use Of Occupational Sensors In Toilets & Stores.6

010.030.3470.0632008-09Star Connection Of Under-loaded Motors5

ImmediateZero0.1100.0202008-09Utility Control To Save Power & Fuel For Low Production Volumes4

ImmediateZero1.0320.1942009-10Avail Benefits To Maintain Power Factor Unity3

120.0100.0120.0032009-10Paint Shop Chiller System Changeover On Cooling Tower (Recommended In CII Audit)

2

050.0250.0720.0172009-10Installation Of Servo Stabilizer For Lighting System (Recommended In CII Audit)

1

15


ImmediateZero0.38412 KL of FO2008-09

Utility Control To Save Fuel For Low Production Volumes (Lean Season Management)

10

Payback In Months

Invest Rs. Mn

Savings Rs. Mn

Units Saving


ImmediateZero0.1100.022008-09Utility Control To Save Power For Low Production Volumes (Lean Season Management)

9

12.01Fuel Saved In KL0.384Total Cost Saved in Rs. Mn

0.375Electrical Units Saved In Mn10Number of Projects In Last 3 years

Process / Productivity Improvements

0.335Total Saving in Rs. MnNumber of Projects : 07

Reduction In Other Equipment Consumption

One Pump Eliminated

Reduction In Shift

Output Increased & Shift Reduced

Vacuum Pump Consumption Reduced

Dressing Cycle Timing Reduced

Heating of Oil Thru Reclaimer Reduced

Benefit To Energy

Effective Utilization Of Equipment

Elimination Of One Stage Washing

Increase The Throughput

Increase The Throughput

Cycle Time Reduction

Setup Time Reduction

Common Oil For All Major Model

Main Benefit

0.0262009-10Elimination Of One Tank Out Of 5 Tank Process

6

0.0042008-09Common Circuit For Checking Of 1-pahse & 3-Phase Compressor On Same Rig Fro Effective Utilization

7

0.1802009-10Increase Paint Shop & Leak Test Conveyor Speed By 12%

5

0.0062009-10Final Test Cycle Staggering To Increase The Line Speed

4

0.0162009-10Oil Charging Cycle Modification

3

0.0422008-09Dressing Cycle Modification For Cylindrical Grinding

2

Energy Cost Savings In `

Mn

YearProject DetailsSN

0.0612009-10Use Oil-tote For Compressor Oil Charging

1

16

ENCON Projects Saving Summary Of Last 3 Years

0.987 Mn Units231.4 KL Fuel

0.375

0.065

232.4

0.2670.269

0.011

Units Savings Mn

2.140Fuel Conservation 4

1.706Technology Refinement & Up-gradation

3

0.335Process & Productivity Improvement 7

Rs. 6.607 Mn*

W/O Windmill Benefit

Total Saving

0.141Renewable Energy 1

0.384Waste Elimination 60.345Waste Heat Recovery5

1.556Compressed Air System2

Saving Rs. MnAreaSN

Utilization Of Waste As Fuel

No Outside Water Tanker Required

Use For Gardening*

200 KL Per DayProcess Water

2

Used For Canteen Food Preparation. 15% Cost For LPG Reduced.

3.7 Kg Bio-gas Per Day

21 Tons Per Annum

Canteen Waste

1

Waste Fuel As % Of Total Energy

Equivalent Of Conventional Energy Used

( LPG)

Quantity Of Waste (Tons)

Type Of Waste

Sn

17

Water Conservation Projects

Wastage & Overuse Controlled (Saving 5KL/Day)

Push Cocks Instead Of Simple Taps At Vantage Locations

4

Wastage & Overuse Controlled (Saving 20KL/Day)

Optimize Flushing Quantity (Replace 10 Liter Flushing Tanks With 5 Lit)

3

Backwash Water Recycled For Pretreatment & Frequency Of Tank Cleaning Reduced Saving Water (20 KL/Day)

Modification In Water Treatment Plant

2

Total Treated Water Is Available For Gardening Purpose, Hence Zero Discharge(200 KL/Day In Main Plant & Ancillary)

Modification Of ETP With Tertiary Treatment Of Sand Filter

1

BenefitsProjectSN

Water Saving 0.245 Mn Liters Per Day

AOP Energy Target

Input

ABC Analysis/ Pareto Analysis

Brain Storming And Project Finalization

SEC Reduction As Per Target?

Production AOP

Projects By Member / CFT ( Drill Down Activity Plan)

Review Progress W.R.T. Target

Progress Is As Per Plan?Gap

Analysis

Validation From Finance

AOP Guide Lines From Top Mgt-

Approach, Audits

Assumptions

Past Learning's

Yes

No Yes

Energy Management Program ISO9000-2008

SWOT Analysis

Corrective & Preventive

Actions

Report Preparation

No

Results Of PY

Project Budget & Capital Investment

Approvals

18

ENCON Corrective / Preventive Action - Examples

Good Saving Observed

Process Parameter Doesn't Affects.

1. Auto Switch Over From TF To Solar After Reaching Solar Temp Above 65OC

Losses In Heat Exchanger Causes Slow Heating

Insufficient Bath Temp. In Early Morning

Use Of Solar System For Washing

No Tripping Observed

1. For Proper Torque During Starting, Motors Are Started In Delta Connection & Then Converted To Star.

Incoming Low Supply Voltage, Torque Developed By Star Connection Motor Was Low

Motor Overload & Trips During Starting Occasionally

Star Connection For Under Loaded Motors Of Dehydration Oven

Sufficient Head Developed By Pump Yields In Good Energy Saving.

1. Use Of VFD & Reduced RPM

2. Pressure Gauge Installed For Monitoring & Control

Suction Pressure Is Insufficient In Margin Above Its Vapor Pressure For Water Based Coolant

(Net Positive Suction Head Required Varies Propionate With Speed)

Initially By Impeller Trimming Loss Of Head (Pressure) Developed By Pump

Reduction Common Coolant System Pump Consumption

Insufficient Sterilization Of Emulsifying Agent With Water & FO.

Root Cause Analysis

1. Separate Tank With Small Pump For Sterilization Purpose

2. Confirmation Of Proper Mixing Before Loading To Day Tank

Corrective / Preventive Actions

Addition Of Water Percentage Raised To 8%

Results Project Name Problem / FaultFurnace Oil Emulsification

Water Not Properly Mixed Up In Furnace Oil Causing Steam Pockets In FO Line

ENCON - Approach & Methodology

Energy Accounting, Budgeting & Control

Major Thrust On Non-conventional Energy Usage

Technology Refinement & Up-gradation

Making Processes Better & Energy Efficient

Elevating Plant Performance To Improve Utilization

Energy Efficient Products To Customers

Energy Kaizen, Training & Awareness

ENCON Expertise & Knowledge Into New Projects

Strong ENCON Team With Certified Energy Manager

Activity Started in 1988-89 & Is a Part of QMS ISO9000


Periodic Examining Ourselves Thru External Auditors

19

ENCON - SWOTOur Strengths:

• Excellent ENCON Culture Since 16 Years & Leaders In Energy Management

• Three Certified Energy Manager & One Energy Auditor (BEE)

• Use Of Green Energy (Wind Mill/Solar)• Commitment From Top To Bottom & Across

The Group• Active Participation Of Vendors And Suppliers

In ENCON Activity• Joint Working With Associates For Energy

Labling Programs

Weaknesses:

• Seasonal Product & Product Mix• Same Processes With Different Cycle Time• Some Processes Are Energy Intensive

Traditional Processes• No Direct Comparison Base For Energy Due

To Non Similarity In Manufacturing Processes

Opportunities:

• Adopt Energy Efficient Technology• Learning's Form Emerson Group of Companies • Explore Opportunity Of Captive Power

Generation Further Use Of Green Power For Captive Use

• Explore Collaborators Expertise In Manufacturing

• Encash Govt Policies & Incentives

Threats:

• Continuous Inflation in Power & Fuel • Poor Quality Grid Power• Fossil Fuel Reserves

We Use Our Strengths To Overcome The

Weaknesses & Threats

As Lot Of Opportunities Are There To Overcome The

Energy Crises

38

Major Project - Plant Restructuring FY10

Mai

n Pl

ant

Anc

illar

y

Assly / Paint /

Final ProcessMachining

KARAD ATIT

CR/CK MachiningAssly / Paint / Final

Process –CR/CK/KCE/KCJ/KCG

RotorMachining

StatorWinding

Stator Winding CR/CK/KCE/KCJ/KCG

Shell SubAssly Vendor

KCE/N

Shell SubAssly Vendor

KCJ/G

Machining VendorsKCE/KCJ/KCG

KCE/N CompressorAssly Vendor

KCJ CompressorAssly Vendor

l Project Goals– Shut Down Karad Main Plant & Move Assembly, Paint &

Final Pack Line To Atit– Consolidate All Stator Manufacturing Into Atit Ancillary– Eliminate One Assembly Vendor, One Shell Assly Vendor

l Investment– Rs. 74. 03 M ( USD 1465 K )

l Savings– Rs. 38.45 Per Compressor – Out of Which Rs. 5.45/- Saving Per Compressor

From Energy

Status As On Today

Before AfterAtit Assembly Line Rearranged

Atit Final Pack Line Rearranged

Dock Enclosure Work Started

Before After

Eng & Labs

Getting Shifted

Getting Closed

Continue As It Is

20

Energy Monitoring & Reporting SystemMain Panel Air Compressor Machine Shop ETP

Paint Shop

MINT-BB MINT-BB MINT-BB MINT-BB

MINT-EMMINT-EMMINT-EM MINT-EM

MINT-BB

MINT-EM

Ancillary Shed 1 & 2 Ancillary Shed 3 & 4

Ethernet Switch Oracle Dept.

Ethernet Switch Production office Ethernet Switch

Canteen

Ethernet Switch Main office

Ethernet Switch Ancillary

Modbus 485 wiring up to 500 mtr.

Monitoring, Online Trending And Graphic As Well As Customized Reports With ELIPSE SCADA

MINT-BB

MINT-EM

MINT-BB

MINT-EM

Weekly Review - HODMonthly Review - Operation HeadMonthly Review – Managing Director

Quarterly Review - Corporate (AP)

Cultivation of ENCON Culture & Sustenance Of Gains v ENCON Week Celebration -14th To 21st December.v Awareness Program To All Employees & Their Participation Thru

Ø ENCON Kaizen’s & SuggestionsØ Appreciation – Awards & Recognitions

v ENCON Specific Assignments To Individuals Thru Performance Appraisalv Measurement ,Verification & Controls To Individual Load Centers.

v Use Of QC Tools Like Brain-storming, Scatter Equations, Paratoo, Fishbone PDCA Etc. Is Part Of ENCON Culture

v Periodic Calibration Of Energy Measuring Instrumentsv Efficiency Monitoring Of Equipments

v ENCON Projects To Vocational Trainees & College Studentsv Participation At State & National International Level Competitionsv Countermeasures For The Weakness Like Lean Season Management, Power & Fuel

Inflations Etc.

21

Participation Of Employees In ENCON Activity Thru Energy Kaizen

Interlocking Of Pump Of Main Tank With Day Tank Level Switch. Reduction In Manual Monitoring & Overflow Of The System Saving Of Rs. 10,000/-Per Annum

Maintenance Group Kaizen

2008-09Utility Operator

7

Interlocking Of Mist Collectors With Machine Cycle For 10 Machines. Reduction In Electrical Consumption @ 28,720 Units Per Annum.

Maintenance Operator Group Kaizen

2008-09Maintenance Operator

6

Interlocking Of Chip Conveyor With Machine Cycle For 4 Machines. Reduction In Electrical Consumption @ 12560 Units Per Annum.

Maintenance Operator Group Kaizen

2008-09Maintenance Operator

5

Coolant Filtration System For Two Machines Is Integrated To Avoid Parallel Running, Benefit :6600 KWh/Annum

Shop Supervisor, Maintenance Supervisor, Production Manager

2007-08Supervisors, Middle Management

4

Sensor Control To Air Flushing Point To Avoid Air Loss, 1818 KWh/Annum

Shop Operators, Supervisor

2007-08Operators3

Unitization Of Machine Hydraulic System To Avoid Running Of Two Pumps, 3200 KWh/Annum

Shop Supervisor, Maintenance Supervisor

2007-08Supervisor2

Problem Of Air Pocket Forming In Boiler Fuel Pump Solved Having Additional Benefit Of 300 Liters FO Saving Per Annum.

Boiler Operator, Section Supervisor

2006-07Workman1

Progress Of Implementation Extent Of Man-power Involved

YearSource Of EnCon Idea

SN

Participation Of Employees In ENCON Activity Thru Energy Kaizen

Eliminate Working Of Low Pressure Screw Compressor By Using High Pressure Reciprocating Compressor On Weekly Off Day, Where The Air Requirement For Some Continues Testing Is Required Reduction In Energy Consumption Of Air Compressor By @ 21,480 Units Per Annum.

Maintenance Group Kaizen

2009-10Plant Engineering Operator

10

Reduction In Energy Units 15,450 Per AnnumImplemented 15 Ideas Out Of 23 Ideas.

Maintenance & Other Department Operators

2009-10Operators SuggestionScheme

9

Paint Baking Oven Temperature Reduction, Fuel Reduction @ 9800 Liters Per Annum

Maintenance Supervisor, Manufacturing Supervisor & Manager

2009-10Sr. Management Personnel

8

Progress Of Implementation Extent Of Man-power Involved

YearSource Of EnCon Idea

Sn

Total Saving of 86625 Units / Annum Saving of FO 1100 Liters / Annum

22

Best Practices Implemented On Energy Front Through Associates l ECTIL Is Very Keen About Energy Management Program At Ancillary Vendors & Also For

Vendors In Nearby Industrial Estate.

l ECTIL Helps Their Vendors By

– Monitoring & Analyzing Their Consumption.

– Review Meeting To Put Their Ideas Of Energy Saving In Their Premises. Actions Are Initiated & Planned Based On Such Finding

– Invitation In Guest Lectures For Knowledge Sharing.

– In Every External Energy Assessment, Some Of The Vendors Are Covered For Their Benefits

– ENCON Week Celebration In Their Premises

– Vendors With Extra Achievement In ENCON Are Appreciated & Awarded In A Function

l ECTIL Is Jointly Working With BEE For Their Products Promotions For Energy Efficiency & Majority Products Are Rated By BEE With Star Rating.

l ECTIL IS Also Jointly Working With Customer For Their Product’s Star Rating

l Energy Efficient Products Are Focused & Promoted In Society Through Stalls & Demos In Company Premises & Outside Also. Special Discounts Are Offered On Such Products

Sharing Of ENCON Practices to Vendors

Sharing Of Energy Best Energy Practices To Vendors & Support Them To Reduction In Energy Consumption

Exhibition Of Energy Efficient Products For Vendors Yearly Vendor Meet - ENCON

Monitoring & Controlling Consumption of In-house Vendors

23

Extend ENCON Efforts To Emerson Group Companies

] Top Management Of Emerson Group Appreciated The ENCON Efforts Of ECTIL Atit-Karad & Decided To Carry Energy Audits Of Other Plants To Share The Experience & Best Practices.

] In This Connection, Energy Manager of ECT-India Has Carried Out Energy Assessment Of Shenyang Plant In China From 17th Nov 2008 To 28th Nov 2008. During Assessment, Total 14 Major Projects Are Identified Of Worth Rs. 1.54 Mn

] Similarly, Energy Audit Of Emerson Network Power, Thane has Carried Out During FY08.

l To Help Bureau Of Energy Efficiency (BEE) Successfully Spread The Awareness On AC Energy Labeling, Emerson Climate Developed The Channel Education Program

l This Program Targets The Salesmen In Showrooms And Equips Them With Sales Tools To Sell The Concept Of Star Labeling To Consumers Visiting The Showroom

l A Web Site www.saveenergy.co.in Has Been Created And Maintained To Help Prospective AC Buyers Workout For Themselves The Energy Saving Potential In The Energy Calculator Available There

l BEE Conducted A Nation-wide Training Programs For Showroom Salesmen Last Year, Covering 2,000+ Salesmen And Found Our Sales Tools To Be Valuable In The Program

Energy Saving Potential: BEE Star Labeling India: Air Conditioners Labeling Program

24

v ISO 14001 For Environment Management System Certified By BVQIv Products: All Products Having R-134a & R404a (Environment Friendly Gas)

Attuned, ECTIL Also Have R410a & R407c Platforms To Replace R-22v Processes: All Types Of Refrigerants Are Reused Through Reclaimer Units, All

Process Materials Are Non CFC.v Scrap Yards To Segregate All Waste Generated In Factory Under Hazardous &

Non Hazardous Categoryv All Products Manufactures With RoHS Complied Materialv Water Treatment Plant To Cater Drinking Water Very Efficiently With Yield Of

Almost 1 Lac Liters Per Dayv 90 Lacks Liters Capacity Earthen ‘Bandhara’ For Rain Water Harvestingv Effective ETP’s As Per Pollution Control Board Norms & Achieved Zero Discharge

Level By Recycling The Wastev Promoting Plantation – More Over 5000+ Plantation Has Carried Out In The Plants

& The Vicinity Areasv Vermiculture Plant & Biogas For Cooking Purpose From Canteen Waste

Environmental Improvements

Environmental Performance Of Plant

Area Covered : 3 Acres, Roof Rainwater Drain Also Connected To The Ponds (Capacity : 90 Lac Liters)

Treats Domestic As Well As Industrial Effluent.Treated Effluent Water Used For Gardening(Zero Discharge Industry)

Effluent Treatment Plant

Biogas Plant For Canteen

Gas Generation : 5.3 Kg / Day, Uses Canteen Waste & Is Reutilized For Cooking

Oxygen Park

Rain Water Harvesting

Trees, Those Expel More Oxygen In Air Are Planted In 5000 Sq ft Areas

25

Environment Friendly Refrigerantsl In FY11 It Is Planned To Develop Products With Environment Friendly

Refrigerants

l The Refrigerants Like R 407 C & R 290 A have Lower Ozone Depletion Or Global Warming Potential

l 4 Models With Hydro Carbon Refrigerant R290a I .e Propane is Planned To Replace R 134 a Models

l Like wise For Air conditioning R407 C product Range Is Being Developed To Replace R22

Parameter R 134 A R 290 a R22 R407 COzone

Depletion Power

0 0 0.034 0.0

Global Warming Power

1300 3 1500 1520

Our Products Energy Efficiency Improvementl Energy Efficiency Improvement Has Given A Major Thrust Due To The

Energy Regulation In India As Well As Middle East Market

l The Energy Efficiency Improvement Was Bench Marked Against To Meet Current & Future Energy Regulations

l In First Phase Improvement Of 7 % & In Second Phase by 15 % Planned

l The CK3 – 50 / 60 Hz Air conditioning Products Were Redesigned To Improve Efficiency By 7 -18 %

l The Largest Selling Refrigeration Model For Bottle Cooler Models Like KCE 444 HAG & KCJ 498 HAG Were Redesigned To Improve Efficiency By 5.2 & 4.7 % Resp .

26

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000

Cooling Capacity (Btu/Hr)

Benchmarking – EER Improvement For High Temp. Market RequirementToday

Plan

0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000


Competitor 1

Emerson

Emerson

R22

KCJ

EER

7.3 – 8.4

7.8 – 8.9

EER

6.0 – 8.4

7.8 – 8.9

6.8 – 8.0

8.5

R134a

KCE

KCE

KCJ

* Source : Product Catalogues

0 1000 2000 3000 4000 5000 6000 7000


Benchmarking – EER Improvement For Medium Temp. Market Requirement

52

Today

Plan

0 1000 2000 3000 4000 5000 6000 7000


Competitor 2

Emerson

EER

5.5 – 6.1

5.0 – 6.56.5 – 7.1

EER5.2 – 6.04.5 – 5.6

5.4 – 5.64.9 – 6.46.0 – 7.1

Emerson

R290R134a R404A

KCE/NKCJ

KCJ


27

0 500 1000 1500 2000 2500 3000 3500 4000 4500


Benchmarking – EER Improvement For Low Temp. Market Requirement

53

Today

Competitor 2

Emerson

EER

3.7 – 4.2

3.6 – 4.4

EER

2.6 – 3.9

3.5 – 4.1

3.5 – 4.2

3.3 – 4.5

KCN KCJ

KCJKCN

Plan

Emerson

0 500 1000 1500 2000 2500 3000 3500 4000 4500Cooling Capacity (Btu/Hr)

R134a R404A HC


Air Conditioning Product EER ImprovementParameter CK20K3PFV

(Current)CR20K6MPFV

(New Replacement)

CK24K3PFV (Current)

CR24K6MPFV (New

Replacement)Capacity BTU/Hr 20000 20500 23500 23900Current (Amp) 9.6 9.0 11 10.3Power (Watt) 2140 2000 2500 2350EER 9.4 10.1 9.4 10.17% Efficiency Improvement

7.4 8.2

10.19.4

0

3

6

9

12

EE

R

7.4% Improvement

10.179.4

0

3

6

9

12

EE

R

8.2% Improvement

CR20K6MPFV (New

Replacement)

CK20K3PFV (Current)

CR24K6MPFV (New Replacement)

CK24K3PFV (Current)

28

Parameter CK27K3PFV (Current)

CR28K6MPFV (New

Replacement)

CK24K3PFZ (Current)

CR24K6MPFZ (New

Replacement) Capacity BTU/Hr 26500 28500 19800 19800Current (Amp) 14.5 12 19.7 8.5Power (Watt) 3225 2650 2100 1950EER 9.1 10.75 9.4 10.15% Efficiency Improvement

18.1 8

Air Conditioning Product EER Improvement

10.759.1

0

3

6

9

12

EE

R 18.1% Improvement

10.159.4

0

3

6

9

12

EE

R 8 % Improvement

CR28K6MPFV (New )

CK27K3PFV (Current)

CR24K6MPFZ (New

Replacement)

CK24K3PFZ (Current)

Parameter KCE444 HAG B830 (Current)

KCE444 HAG B332H

(Modified)

KCJ 498 HAG Old KCJ 498 HAG New

Capacity BTU/Hr 3675 3675 8200 8340Current (Amp) 2.2 2.2 5.9 4.6Power (Watt) 475 450 975 940EER 7.73 8.16 8.41 8.8% Efficiency Improvement

5.6 4.6

Refrigeration Product EER Improvement

8.167.73

0

5

10

EE

R 5.6% Improvement8.888.41

0

3

6

9

12

EE

R

4.6% Improvement

KCE444 HAG B332H (Modified)

KCE444 HAG B830 (Current)

KCJ 498 HAG New

KCJ 498 HAG Old

29

Highly Efficient Scroll Condensing Units

2.33

2.57

2.55

2.23

2.78

2.36

EER

10.3 %

14.3 %

17.8 %

Delta

3.457.70KHR542

3.849.80ZX0400

5.5414.26ZX0600

6.214.5KHG572

2.86

2.91

Power Watts

7.97

6.88

Capacity Watts

ZX0300

KHR536

Models

• Condensing Units Used For Milk Cooling, Super Market Food & Vegetable Storage / Cooling Application Are Developed With Scroll Technology Compressors whose Efficiency Is 10 % Better

Accolades-Energy Conservation

FY 06 “Certificate Of Merit” In General Category By Bee By Auspicious Hands Of Dr. A P J Abdul Kalam –President Of India

FY 03 Award for Excellence in Energy Conservation & Management by Institute of Engineers, Pune

FY 01, FY02, FY07

National Level Award “Excellence In Energy Management By CII

FY06

National Level Award “Energy Efficient Unit” By CII

FY04

“Innovative Project Award” In The Year 2004 For HRU Project Of Decarb Plant By CII

FY 04, FY06

State Level Award For Excellence In Energy Conservation & Management By MEDA

FY05

“First Prize” Award For Promotion To Non-conventional Energy Utilization By MEDA

FY03

State Level Second Prize At In Energy Conservation By

National Level Awards State Level Awards

14 Times Winner Of Inter-Group Company Award, Since From 1991

30

Awards & Accolades - Engineering

BRY Air Asia Excellence In Product Design Energy Efficiency Improvement In Refrigeration Compressors

2007

Indira Innovation International Summit

“Innovative & Environment Friendly”Products

2008

By IEEMA (India Electrical Manu. Association)

“Hermetic Motor Efficiency Improvement“ Paper Presented

2007

International Congress For Sound & Vibration, Cairns Australia

Sound Reduction Through Resonator “Paper Presented In 2007

2007

Government Of IndiaR & D Recognized By “ Ministry of Science & Technology2007

BRY Air Asia Excellence In Product Design Energy Efficiency Improvement In Refrigeration Compressors

2008

Confederation Of India Industry Chennai

Energy Efficient Product For Scroll Condensing Unit

2009

Confederation Of India Industry Chennai

Innovative Energy Efficient ProductFor Economized Vapor Injection Digital Scroll

2009

Organization AwardYear

FY11 Cost Reduction Projects

223.501.955Briquette Or Alternative Fuel Fired Thermopack Instead Of FO Fired8

7

6

5

4

3

2

1

SN

220.140.095Energy Efficient Lighting For Fencing

090.170.216Replace Low Efficiency Motors By Energy Efficient Motors

280.470.215Use Of Energy Efficient Lighting For Decarb & Stator Winding Plant

242.35 1.214Scroll Heat Pump of Different Tanks of the Bath

090.210.396Improve The Heat Transfer Efficiency Of TF System By On Line TF Cleaning

090.240.326Using VFD Reduction in Air Compressor Motor Consumption By Using Start/Stop method

3674.07Rs. 5.15 / Comp.Plant Integration Project (Energy Saving Benefit)

Payback In Months

Investment Rs Mn

Saving in Rs. MnMajor Project

31

What Will Do In Future – LRP

10000075000Waste Heat Recovery In Kcal

7 TR Each5 TR EachOptimization / Elimination Of Air Conditioning System

0.200.22Reduction Of Water Consumption K-liters / Eq. Cr

15.80 14.30

1016011286Reduction Of Specific Heat KCal/Eq. Compressor

Reduction Of Specific kWh/Eq. CR Compressor Consumption (With Motor)

FY12FY11Performance Area

Thank You

Documents

11th National Award For Excellence In Energy Management Award... · 11th National Award For Excellence In Energy Management Emerson Climate Technologies (India) Ltd, Atit-Karad Company