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11/1/2014
1
National award for “Excellence in
Energy Management - 2014”
Ashok Leyland Hosur- Unit 1
2 11/1/2014 CII- National award for Excellence in Energy Management- 2014 ALH1
Presentation contents
1. Introduction
2. Energy management at Hosur, Unit - 1
3. SEC Energy Conservation- Project Management
4. Innovative projects
5. Horizontal deployment & Knowledge sharing
6. Towards GREEN
7. Wealth from Waste
8. External awards
9. Way Forward
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A 64-year old pedigree
• Founded in 1948 as Ashok Motors
• Became ‘Ashok Leyland’ in 1955 with equity participation from Leyland Motors, UK
Touching lives of millions across worldwide
One of India’s largest commercial vehicle manufacturers
Ashok Leyland A comprehensive portfolio of transport solutions
Manufacturing Facilities
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Ashok Leyland Hosur Unit-1
MAIN GATE ENTRY
N
• DRG NOT TO SCALE
• FOR OVERVIEW ONLY
HOSUR - I LAYOUT
S No Resources Hosur-1
01 Total Area (Acres) 102.58
02 Plant and Machinery ~ 517 Rs. Cr
03
Permitted Maximum Demand
7000 kVA
Usable captive capacity 4875 kVA
04 Manpower (Associates +Exe)
1220
05 Trees (nos) 3315
Established in 1980 as an Engine manufacturing center
Having current capacity of 1 lakh engines per annum • H Engines - 40 K • P15 Engines - 60 K
Products
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Production Process Flow
H-Engine In-house machining
BOR
Bought Out Finish
Engine Assembly
Engine Testing Dispatch to
Vehicle Assembly Units /
PSB Yards
P15-Engine BOR
Bought Out Finish
Engine Assembly
In-house machining
Engine Testing Dispatch to H-2
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Ashok Leyland - Energy policy
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Energy Cell @ Hosur, Unit 1
EnCon activities by Energy cell
Monitoring & Reporting- SAP Continual improvement
Improvement activities Awareness thro’ campaigns Promoting involvement
Horizontal deployment Best practices Waste elimination
Self-Calibration System
compliances
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Energy management @ Hosur, Unit 1
Reviewing
Plant Level review
Department review
Machining
Assembly
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Real time Load monitoring Plant & Shop Level
• 8 Zones, 95 Meters hooked up to network enabling the real time monitoring.
• Real time monitoring- Load, consumption & power quality parameters.
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Reporting & Reviewing system-SAP
Plant level reporting-Daily Shop level reporting – Daily & Weekly
32% 16% 9%
9% 8% 7% 6% 5% 3% 3% 1%
32%
48% 57% 66%
74% 80% 87% 92% 96% 99% 100%
0%
25%
50%
75%
100%
Energy Consumption
Current Power consumption pattern
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P15 Engine with bench marked SEC
Towards setting bench marking SEC - Energy audit conducted by PCRA
(Petroleum conservation research association) in 2012.
Sly No
Component Norms Units/Component
1 Cylinder Block 36.16
2 Cylinder Head 33.06
3 Engine Assembly 24.99
Units/Engine 94.21
Norms as per PCRA audit
194
128 104 94
94
2011-12 2012-13 2013-14 2014-15
Target
(-19%) (-10%)
(-52%)
P15- Units/Engine trend
• 2013-14- 104 units/Engine • Targeted to achieve the PCRA norms in 2014-15. Plan for 2014-15
Installation of VFD’s for AHU blowers in Engine assembly, Staggered power management based on production demand, Air Ventilation system for Engine assembly enclosure in place of Ac’s.
SEC
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H- Engine SEC
276 264 273 265 258 250
250
2011-12 2012-13 2013-14 2014-15 2015-16 2016-17
TargetProduction
42202
25633 24000
H- Units/Engine & Production trend
• A target of 250 units/Engine is set based on the past best performance(07-08: 55 k engines).
• Despite the drastic drop in volumes, SEC maintained almost flat by Focusing more on converting the fixed energy into
variable.
Elimination of hidden loss in energy. Planning to reduce SEC by 8% in next 2
years. Plan for 2014-15
Installation of VFD’s for AHU blowers in Engine assembly, Machine shop - 5 Units Energy savings per machine per
shift planned for top 100 power intensive machines
47442
-11%
-39%
30.9
27.1 29.6 28.2
2010-11 2011-12 2012-13 2013-14
Indirect area- Consumption
Lakhs KWH
* Includes- Data center & R&D
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Energy Cost
4.75 5.74
4.47
2011-12 2012-13 2013-14
H - Rs per Kwh
Over all Rs per Kwh reduced by 22%. Demand cost reduced by Rs 90 lakhs from
Rs 315 lakhs to Rs 225 lakhs. This fixed element made in to semi variable.
Reduction in Self generation from 36% to 11 %.
9.35 10.63
9.50
2011-12 2012-13 2013-14
P15 - Rs per Kwh
Over all Rs per Kwh reduced by 11%. Low volume managed with low cost
EB power & stopped production with DG supply.
P15 Engine testing time reduced from 14 min to 9 min.
-22% -11%
4.15 3.64
2012-13 2013-14
Kwh per Month - Fixed (in lakhs)
-12%
Variable consumption brought down from 651 to 625 (4% reduction).
46 Energy saving projects completed & realized 3.3 lakh Kwh reduction (recurring).
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814 1147
2193
720
5774 4359
3511
2361
2010-11 2011-12 2012-13 2013-14
Power interruption-Hrs Self generation-KWH/Hr
Renewable energy & Self generation
243 209 212
144
29
42
12
34
157
118
124
93
57
50 77
17
0
200
400
2010-11 2011-12 2012-13 2013-14
Power Mix (Kwh in Lakhs)
Total EB WM CAPTIVE
WM 65%
EB 24%
CAPTIVE 11%
Ratio of WM energy in
2013-14
• Power is drawn thro’ 3 different sources, o Power generated thro’ Wind Mill o Power supply from EB o Self generation thro’ DG
• Green power (Wind Energy) utilization accounted up to 61% of total power consumption.
Self generation units / hour of power interruption
Year
Power interruption in Hrs
DG units in lakhs KWH
Generated Units/hour
2010-11 814 47 5774
2011-12 1147 50 4359
2012-13 2193 77 3511
2013-14 720 17 2361
-25%
-19% -33%
• Self Generation reduced by 29% in 13-14 w.r.t 10-11 by optimizing the utilization of EB & WM power for production,
• Restricting DG usage only for critical loads.
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Engine developed by AL will be tested at our R&D before taking up for manufacturing These developed Engines will be tested through Hydraulic dynamometers and eddy current
dynamometers. To meet EURO III emission norms Engines are suitably developed by AL R&D team and testing of these
engines, new Engine test beds are planned. New test beds are planned with latest Technology, i.e. transient Dynamometer. In absorption mode the frequency dependent machine current is converted into alternating current with
the frequency of the mains supply via a voltage source converter and it’s feedback into the power supply system.
Separate arrangements are made to capture import & Export of Energy Consumption / Regeneration, from this Dynamometer during Engine testing.
Regenerative power during 2013-14 - 3.02 lakh Kwh & YTD Sept 2014 - 0.93 lakh Kwh and used for test bed utility Equipments.
Transient Dynamometer
Total number of test cell : 4, 2013-14 : 3.02 lakh Kwh, YTD Sept 14* : 0.93 lakh Kwh
Regeneration of Energy during Engine Testing
Online data measured value
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Monitoring & Implementation Gemba Structure
People involvement
EnCon Improvements
Energy conservation- Project Management
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Improvement program model
EnCon @ Unit 1,Hosur
39%
61% 76%
2011-12 2012-13 2013-14
Employee involvement in EnCon Projects
Source: GembaMpower
Idea Generation thro’ 1. Theme based brainstorming sessions 2. Walk through audits 3. Quick hit campaigns 4. CMI week celebrations
• All generated ideas will be recorded and their progress monitoring -Mpower
• Evaluation and approvals for implementation – Mpower
• Recording benefits and monitoring sustenance- Mpower
• Rewarding - Mpower
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EnCon @ Unit 1,Hosur
• More focus on converting Fixed cost overheads to Variable • Optimization of demand setting based on production strategy.
• More focus on optimizing compressor air usage • Optimizing compressed air usage in air gauges Innovative ideas at point
of use • Power saving in air gauges thro’ wastage elimination • Introduction of additive in machine spindle gear boxes, to reduce friction
losses -Special initiatives-Theme based improvements • Saving 500 units/electrical executive. • Cross audits
Approach adopted
Sly No
Year No.of projects
KWH saved – Lakh units
Cost savings-Rs Lakhs
Investment-Rs lakhs
1 2011-12 14 4.95 25.22 78.65
2 2012-13 141 13.7 144.4 12.5
3 2013-14 76 4.6 163.8 6.4
Total 231 23.25 333.42 97.55
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Significant Projects-2011-12
Hosur 1 - List of Energy Saving Projects Completed
Sl.no
Completed projects : Month of
completion Investment ROI
Details of savings per day in Kwh
1 Energy efficient motors, pumps, blowers, lighting & air conditioners (5/3star rating) installed in new P15 Engine assembly area.
11-Apr Planned during selection stage & implemented
795
2 Energy efficient lamps introduced in place of conventional lamps at shop 2 stores & engine dispatch area.
11-Apr Rs 1.0 lakhs less than 6 months
152
3 Provide Energy efficient 90KW motor with soft starter. 11-Apr Rs 6.08 lakhs 15 Months 40
4 Solar water heaters of 7KLD & 2KLD introduced at canteens. 11-May Rs 13.00 lakhs
less than 2 years
448
5 Introduce energy efficient water pumps (7.5 HP X 2 nos, 3.0 HP X 2 nos & 3.0 HP X 2 nos).
11-May Rs 0.72 lakhs 1 year 29
6 Introduce energy efficient air conditioned units at Shop 1 Metrology, Shop 5 E/A & Work Office & System area (100TR).
11-Jun Rs 15.00 3 years 394
7 Provide Energy efficient 200 KW motor with soft starter. Replace CPT1 Air compressor by energy efficient air compressor.
11-Nov Rs 25.00 lakhs
24 Months 576
8 Introduce energy efficient motors for shop 5 test bed blowers (40HPX4 nos).
11-Dec Rs 6.00 lakhs less than 2 years
384
9 To provide separate circuit for Shop 1 extension to ensure switching off during non production hours.
11-Dec Rs 0.25 lakhs 2 Months 75
10 LED street lighting - replace conventional 150 watt SV lighting to 54 watt LED lighting (33 nos)
12-Jan Rs 4.5 lakhs less than five years
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Significant Projects 2012-13
Hosur 1 - List of Energy Saving Projects Completed
Sl.no
Completed projects : Month of completio
n Investment ROI
savings in Rs.Lakhs
1 Eliminate lunch hour, dinner break & shift change hour idle running in shop-1 & shop-5
Apr'12 3.0 Lakhs Less than a
month 20.21
2 Optimization of test bed operation at Shop 5 (TB17-TB32) Apr'12 1.5 Lakhs 6 months 3.0
3 Energy saving in Heat Treatment of D9056211 Axle shafts by by changing the work centre in GCF line at HT shop III
Apr'12 0.75 Lakhs 6 Months 1.58
4 Make use WM power during power holidays on Satuarday & Sundays (May 12).
May'12 Nill NA 27.45
5 Elimination of hidden loss in Machine shop-5 during 1st shift. May'12 3.5 Lakhs 2 Months 20.38
6 Elimination of blower running in 680 conveyor and testing areas May'12 0.5 Lakhs 12 Months 0.52
7 De rating of Exhaust Blower motors in Test Cell-1, Test Cell-2 & Test Cell-3
Jun'12 1.25 Lakhs 9 Months 1.98
8 Staggered power management during normal & peak hour, thereby maintaining optimum demand (July 12).
July'12 Nill NA 8.26
9 Regulate compressed air supply to Shop-9 PDI, by replacing 40KW compressor with portable compressor
July'12 0.4 Lakhs 6 Months 0.77
10 Optimimum utilization of captive power during power failure/peak hours
Jan'13 Nill NA 25.83
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Significant Projects- 2013-14
Hosur 1 - List of Energy Saving Projects Completed
Sl.no
Completed projects : Month of
completion Investment ROI
savings in Rs.lakhs
1
Power cost reduction through shifting of activities from Peak hour to Off-peak and normal hours, low volume production planned with low cost EB power & restricted/eliminated during costly DG Power.
Dec'13 0.60 Lakhs Less than a
month 98.46
2 Auto cut off introduced in Mag & Makino machines through control circuit modification
Oct'13 1.25 Lakhs 3 Months 7.5
3 Energy saving in Robo wash by replacing 50 hp pump with 30 hp pump for cleaning cylinder block
Nov'13 Nill NA 0.52
4 Avoiding running of dedicated air compressor for P15 EA in 2nd & 3rd shift, by linking air line with central air compressor
Aug'13 0.75 Lakhs 9 Months 1.11
5 Energy Saving in HMC machines - 7 Machines Oct'13 0.4 Lakhs 4 Months 1.32
6 Avoid idle running by enable auto shut off in AHU Oct'13 0.20 Lakhs 2 Months 1.10
7 Air gauge automation to eliminate Compressed air wastage in Etamic gauge units
Jun'13 1.5 Lakhs 3 Months 7.13
8 Energy Saving (On Fixed Costs) & Gear box Reliability Improvement in Engine Machine Shop 5 through Innovation. (3.55 Kwh per block)
Dec'13 2 11 months 3.16
9 Establishing SGN process in GCF ( savings of 80 Kwh per charge) Jan'14 1 6 months 2.88
10 Spray pump power saving mode incorporation to eliminate idle running LA9696 / 9697
Jun'13 0.20
6 Months 0.44
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Innovative projects
Project # 1 : LOW COST AUTOMATION IN PNEUMATIC GAUGES.
Project # 2 : HIDDEN LOSS ELIMINATION FROM SOURCE SIDE
Project # 3 : P15 ENGINE TESTING CYCLE TIME REDUCTION
Project # 4 : INTRODUCTION OF AUTO CUT-OFF IN CNC/PLC
MACHINES
Project # 5 : GEARBOX LOAD REDUCTION THROUGH ADDITIVE
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Innovation Project # 1
Before After
LOW COST AUTOMATION IN PNEUMATIC GAUGES
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Innovation Project # 1
• Compressed air utilization time in air gauges reduced from 960 mints/day to 60 mints
• Inspection equipments air leak reduced from 68% to 7%
LOW COST AUTOMATION IN PNEUMATIC GAUGES
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Innovation Project # 1
COMMUNICATIONS to other AL units on replication of the idea
Recurring savings through the project: 10.92 lakhs/annum
LOW COST AUTOMATION IN PNEUMATIC GAUGES
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HIDDEN LOSS ELIMINATION FROM SOURCE SIDE
Innovation Project # 2
Hidden Power loss at Home Hidden Power loss at Industry
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Innovation Project # 2
HIDDEN LOSS ELIMINATION FROM SOURCE SIDE
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Innovation Project # 2
HIDDEN LOSS ELIMINATION FROM SOURCE SIDE
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Innovation Project # 2
Knowledge shared in HIA forum to other industries
HIDDEN LOSS ELIMINATION FROM SOURCE SIDE
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P15 ENGINE TESTING CYCLE TIME REDUCTION
Innovation Project # 3
Engine testing consumes 35% of the total power consumption in P15 engine assembly
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9.1
6.6
Before After
Average power
consumption/Engine
Average power consumption reduced by 27%
3.5
2.98
Before After
Diesel consumption/Engine
Revised Manufacturing Pass off Norms – V11
Parameters Validated 1. Engine Performance over Operating
range 2. Coolant Temperature 3. Specific Fuel consumption 4. Oil Temperature 5. Exhaust Gas Temperature
Diesel consumption reduced by 15%
Innovation Project # 3
P15 ENGINE TESTING CYCLE TIME REDUCTION
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INTRODUCTION OF AUTO CUT-OFF IN
CNC/PLC MACHINES
Eliminating idle running of motors thro’ control circuit modification.
Tripping of hydraulic systems when not in use thro PLC program modification.
Spindle/ hydraulic motor cutoff thro’ limit switch/ timer.
Auto power saving features
Innovation Project # 4
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• Both Makino & Mag has Econo mode
which is a Human dependent action
• Failing to enable Econo mode again will defeat its purpose
• The team designed and incorporated a control circuit which ensures the motors will get off after a time delay
Innovation Project # 4
Idle cut-off mapping
Makino & Mag are the power guzzlers
First time, Auto idle cutoff circuit incorporated in an imported machine!!! Total savings amounting to 1.26 lakh KWH/year
INTRODUCTION OF AUTO CUT-OFF IN
CNC/PLC MACHINES
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Gear box oil Additive introduced in 34 Machines in HCB Line by 23rd Dec 2013.
Gear box load reduction through additive
Innovation Project # 5
Kwh Block Kwh per
Block Before Additive
5459 124 44.18 After Additive
5590 131 42.61
-130 -8 -1.57
-2% -6% -3.55%
3.55% reduction in power consumption
Trials in LA8263 Spindle gear box
Before After
% reduction
Kw load drawn at no load condition
4.00 3.80 -5%
Kw Load drawn in full load condition
8.50 8.16 -4%
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Idea Generation Summary
No.Of Plant engineering executives participated
67
Total Number of Projects identified 197
Expected Units savings per day 16138 units
Phase 1 : Idea Generation
Phase 2 : Feasibility study and Categorization Idea Generation Summary- Feasibility study
Ideas Feasible for Implementation -2012-13
173
Expected Units savings per day 10475 Units
Theme of Initiative : Savings of 500 units / day / Executive – PE Launch : Nov’12 Duration : 3 months
Idea Generation Summary- Investment details
Ideas with less than 2 lakh investment 166
Expected Units savings per day 7216 Units
Energy saving initiative Launched by Unit head
Out of 166 Feasible ideas based on ROI 86 projects implemented. Total Number of executives involved : 12 (86 Projects) Achieved KWH reduction/ Exe/day : 208.25 Total Investment : 4.3 Lakhs.
Total saving of 7.5 lakh KWH/year
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Project Description: • Carburizing process in GCF is high power intensive furnace working @ 24 x 6. • Earlier air cooling of charge is in practice. • With detailed analysis, process changed to equalize cooling method. • Realized savings of 140 Kwh / charge (no of charges in 2011-12 is 103).
Before Improvement
After Improvement
Energy consumption:
0.53 lakh units
Investment: -- Total savings/Annum: 0.87 lakhs
0.39 lakh units
Heat Treatment process improvement in GCF 520 KWH/charge to 380 KWH/charge
Energy consumption reduced by: 27%
2011-12
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Project Description: • Earlier Package A/C with reciprocating compressor (22 Years old - 7.5 Ton x 4 no’s 7&5 TR X 5 no centralized
package A/C units ) running in Metrology & HDC (Data center) . • Based on revised heat load calculation, 25 TR package A/C units replaced by 1.5 TR X 6 nos five star split A/C in
HDC. • Energy efficient Scroll compressor ductable package air conditioners with duct modification done in Metrology.
Before Improvement After Improvement
Energy consumption: 3.69 lakh units
Investment: 7 Lakhs Total savings/Annum: 14 lakhs
1.33 Lakh units
Energy Efficient Air Conditioners 1314 KWH/day to 474 KWH/day
2011-12
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Project Description: • Hot water is required for dish washing at canteen to maintain hygiene, introduced solar water
heaters in place of conventional electrical heaters. • Required hot water per day for dish washing is 9000 liters. • Two solar panels (7 KLD & 2 KLD) introduced at two canteen blocks. • Energy required to heat 9KL water from 25 Deg to 70 Deg C = (70-25) X 9000 = 405000 Kcal /
860 = 471Kwh per day. • Realized savings of 471 Kwh per day
Before Improvement After Improvement
• Electrical heaters were used for hot water generation.
Energy consumption :
1.41 lakh units/year
Investment: 13 Lakhs Total savings/Annum: 7.63 lakhs
0 units/Year
Renewable Energy -Solar water heaters for canteen 471 KWH/day to 0 KWH/day
2011-12
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Project Description: • Machine Shop 5, cylinder block head face tapping machine supported with dedicated 5 HP
portable compressors. • Through reformed design concept, air intensifier unit introduced along with existing pneumatic
circuit & eliminated usage of portable compressor. • Realized energy savings 17.60 Kwh per day.
Before Improvement After Improvement
• Pressure : 6.00 kg per sq.cm • Dedicated air compressor
Energy consumption : 0.1 lakh units/year
Investment: 0.22 Lakhs Total savings/Annum: 0.32 lakhs
0.053 lakh units/Year
pneumatic intensifier to eliminate portable compressor. 17.6 KWH/day reduction
2011-12
• Pressure : 6.00 kg per sq.cm • Ensured with existing pneumatic line with
air intensifier.
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Project Description: • Earlier 250 W MV lamps used at 9.1 meter height. • Due to ageing (>30 years) transparent acrylic cover faded & lighting level dropped by 40 - 60%. • Introduced 72 W LED lighting in a same street pole @ 5.0 meter height. • Implemented in 68 street light poles. • Since 1980, Shop-2 Stores & dispatch area general lighting provided by conventional 65 watts
florescent lamp.
• 2 x 65 watts florescent lamp luminaires replaced by T5 lamps with electronic ballasts.
Before Improvement After Improvement Before: 250 Watts MV lamp @
9.1 meter height, Now disconnected
After: 72 Watts LED lamp @ 5.0 meter height
Energy consumption :
1.28 Lakh units/year
Investment: 8.5 Lakhs Total savings/Annum: 5.8 lakhs
0.31Lakh units/Year
Energy efficient lighting.
2011-12
• 65 W florescent luminaires – 324 nos
• Kwh per day for 8 hours = 168.48
• 8 x 14W T5 luminaires – 36 nos
• KW – 4.03 • Kwh per day for
8 hours = 32.24
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Project Description: • Earlier 22 years old 1219 CFM reciprocating air compressor was powered with 200 KW slip ring
induction motor (84% efficiency). Average consumption was 180 Kwh per hour • Implemented with energy efficient screw compressor of 1302 CFM with 200 KW sq. cage
induction motor (94% efficiency) & also eliminated auxiliary equipment’s. Average power consumption per run hour is 156 Kwh.
• Realized 24 Kwh savings per run hour.
Before Improvement After Improvement
Energy consumption : 8.64 lakh units/year
Investment: 25 Lakhs Total savings/Annum: 6.91 lakhs
7.48 lakh units/Year
Energy efficient screw compressor 180 KWH/day to 156 KWH/day
Energy consumption reduced by : 13%
2011-12
• Energy efficient screw compressor Reciprocating air compressor (dismantled)
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Project Description: • Shop 5 cylinder blocks machining, each head changer machines consists of 3 HP x 3 numbers
coolant motors (Cutting, Fixture & bed flushing). • Earlier all three motors were running during machining cycle. • Coolant circuit modified & eliminated one 3 HP motor without affecting performance. • Implemented this modification in six machines. • Total energy savings realized in a year = 24.50 x 6 machines x 300 days = 44100 Kwh
Before Improvement After Improvement
Energy consumption : 1.32 Lakh units/year
Investment: 3 Lakhs Total savings/Annum: 2.65 lakhs
0.88 Lakh units/Year
Coolant system design modification in Engine block machining. 73.5 KWH/day to 49.0 KWH/day
Energy consumption reduced by : 33%
2011-12
• Coolant motors : 3 HP X 2 no • Kwh per machine per day : 49.00
• Coolant motors : 3 HP X 3 no • Kwh per machine per day : 73.50
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Project Description: • An earlier fresh air blower motor of 15 KW was running for each test bed. • Based on details in blower suction volume & Engine exhaust volume, required motor
downsized to 5 HP. • Realized energy saving per day per bed 118 Kwh • Implemented in three Engine test beds • Total realized energy saving per day in three TB = 354 Kwh
Before Improvement After Improvement
Energy consumption : 1.51 lakh units/year
Investment: 0.5 Lakhs Total savings/Annum: 6.37 lakhs
0.42 lakh units/Year
Downsizing of blower motor in test bed 15 KW to 3.7 KW
2011-12
• Motor capacity : 3.7 KW • Motor capacity : 15 KW
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Project Description: • Earlier we need to run two pump of 7.5 KW for running reciprocating compressor cooling water system (KC02)
(7.5KW*2*14HRS*6Rs*300days) =RS 3.78Lakhs with open loop system. • To Reduce Power cost hot water pump eliminated by redesigning of open loop to closed loop.( 100 units/day
savings realized) (7.5KW*14Hrs*6Rs*300days)=Rs 1.89 Lakhs
Before Improvement After Improvement
Energy consumption: 0.63 lakh units
Investment: 0.01 Lakhs Total savings/Annum: 1.89 lakhs
0.33 lakh units
Energy conservation in Compressed Air 100 KWH/day reduction
2012-13
• (7.5KW*2*14HRS*6Rs*300days) =RS 3.78Lakhs
(7.5KW*14Hrs*6Rs*300days)=Rs 1.89 Lakhs
Cold Well
Hot Well
cold Well
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Horizontal Deployment
Inputs for Horizontal deployment
Tracking mechanism
Results
• Fortnight implementation reports with finance vetting.
Sharing of projects thru’ AL PORTAL with photo graphs & cost impact
Fortnightly review by CMI-CFT, to drive horizontal deployment across all units
40
52
38
52
20.25 23.21
2012-13 2013-14
Projects identified
Implemented
Savings in Rs Lakhs
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Horizontal Deployment: Sample of Tracking sheet
Recurring One time
1 H113S1246
Power - Demand Management by
optimizing normal hour demand Hosur -1 Power
1099000 0
Alwar to
restudy and
revert 284000
CPPS to
capture the
cost saving
details
NF
1099000
H2 to
capture the
cost saving
details
Application has been
given to UPCL.
Expected to be done
by Jan'14 ( 5200000) 1383000
2 H112S1517
Energy savings through compressed air
usage Optimization in pneumatic
equipments, functions & air guages Hosur -1 Power
1092600 28000
UP
400000
CPPS to
capture the
cost saving
details
UP
1092600
H2 to
capture the
cost saving
details
UP
1492600
3 B113S0102
Machine Pannel A/C Made off in winter
season
Bhandara Power
369000
Alwar to
capture the
cost saving
details
369000
CPPS to
capture the
cost saving
details NF
P15 all machines
Panel AC &
LA10109,LA10225
Coolant Chiller
units usage
Optimised.
H2 to
capture the
cost saving
details
PNR to capture the
cost saving details
369000
4 H113S1908
Bio Diesel in place of Hs diesel for
canteen boilers, furnaces, forklifts,
Engine testing and Gensets Hosur -1 Power /
Consumables 473237
0
Alwar to
restudy and
revert
Quotation
taken from
supplier.
Activities are
in progress.
Feasible yet
to start Implemen
ted in
canteen
boilers473237
UP Impact is very low as
Bio-Diesel is being
brought from Gujrat 473237
5 H112S1639
Waste oil reclamation by Recycling thru
supplier and reuseHosur -1 Consumables
1365000
NF UP TBS TBS
1365000
H2 to
capture the
cost saving
details
PNR to restudy and
revert 1365000
6
Optimizing fork lift movement .
Hosur -2 Consumables TBS
Bhandara to
capture the
cost saving
details
NF UP
118800
H2 to
capture the
cost saving
details
UP
118800
7 H113S1951
DIANANO Gear box Additive to reduce
energy consumption Hosur -1 Power
4000000
NF
Feasible yet to
start NF
Feasible
yet to
start
UP NF NF
CMI - POH (K54) Horizontal Deployment projects as on 23.01.2014
SL.NO
Project
registration
number
Project Description
Parent
plant of
the project
Resources Cost saving in Rs.
Investment Alwar Bhandara CPPS Ennore Hosur -1 Hosur -2 PNRExpected Cost
saving in Rs.
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47 11/1/2014 CII- National award for Excellence in Energy Management- 2014 ALH1
Horizontal Deployment: Significant project
Wind Mill energy sharing with CPPS
Before: CPPS plant was running with EB source up to 548 KVA & balance 500 KVA with
DG supply. Daily 8-12 hours DG sets were running to meet demand shortage (400-500 KVA). After: CPPS plant was recommended to utilize EB source up to sanctioned demand
(1250 KVA ) through WM connection. Running of DG sets totally stopped due to demand shortage.
5.6 5.7 6.1
1.8
2.85
4.4
1.3
3.3
2.8
3.4
3.15
3.53
Apr'13 May'13 Jun'13 Jul'13 Aug'13 Sep'13 Oct'13 Nov'13 Dec'13 Jan'14 Feb'14 Mar'14
CPPS - Power cost Rs/Storke
WM transfered
After Avg: Rs 3.3/Stroke
Before Avg: Rs 5.5/Stroke
Realized savings Rs 88 lakhs in 2013-14
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Towards Green Awareness thro’ competitions and celebrations
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Significant GREEN projects
Sl.no Project Description Month/Year Investment (Rs in
lakhs)
Benefits
11-12 12-13 13-14
Benefits Benefits Benefits
1 Bio Diesel introduction in canteen Boilers Dec-13 0
Reduced
emission
2 Recycling of packing wood Dec-12 0 11960 cft 27390 cft
3 Reuse of Corrugated packing Jan-13 0 924kgs 616 kgs
4 Coolant recovery system in Shop 5 Feb-12 5 96000lits 96000lits
5 Hazardous waste reduction at ETP area Mar-12 0 2000kgs 1750kgs
6 Rain water Harvesting for process direct usage Apr-13 5 400KL
7 Usage of RO reject water Mar-13 0.5 20KLD 30KLD
8 Solar water heater application Jun-11 11 9KLD 9KLD 9KLD
9 Bio Gas plant using canteen food waste Jul-14 2 120 cylinders
10 Recycling copper hammer under material conservation Dec-11 0 1350KGS 1400KGS
11 Online purification of Hydraulic oil Jan-11 1 2.7 lac lits 5 lac lits
12 Usage of STP sludge as manure Apr-13 0 178MT 2.5 MT
13 Reuse of Printer ink cartridges by refilling the inks. May-12 0 9.5 lakhs 8.5 lakhs 7 lakhs
14 Recharging of Rain water perculation wells Jun-11 0 150KL 150KL 150KL
15 Enhancing the life of tools by process recondition in Project resurgence Nov-11 0 500 NOS 900 NOS
STP recycled water- 175 KLD used for gardening ZDP recycled water- 25 KLD used for washing machines
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Water Management 13-14 (KLD) 519
406 25 20 20 20 10 8 4 3 2 1
0
100
200
300
400
500
600
12
-13
Avg
Sin
tex
tan
kfo
r R
est
roo
m
Maj
or
leak
sid
enti
fica
tio
n &
Arr
esti
ng
Mai
nC
ante
enR
Ore
ject
re
use
Man
Po
we
rR
edu
ctio
n
Ind
.RO
Rej
ect
reu
se
Elim
inat
ion
of
Val
veo
pen
ing
in1
st s
hif
t…
R&
D R
Ore
ject
re
use
Dri
nki
ng
RO
re
ject
Re
use
inin
div
idu
al…
Cle
anin
gh
ose
Elim
inat
ion
in R
est
…
Rai
n W
ater
Har
vest
ing
13
-14
Avg
Water consumption Water reduction
12-13 Q1 Q2 Q3 Q4
AVG Per Capita Consumption 124 103 85 79.9 79.1
13--14 Target 118 100 85 85 85
124 103 85 79.9 79.1
85
0
20
40
60
80
100
120
140
Per
cap
ita
con
sum
pti
on
in L
tr
Per Capita Consumption (Domestic + Canteen) Litres/Day/Person 12-13 - 124 Litres 13-14- 79 liters
Significant improvements : • Rain water Harvesting and reuse projects - 3 nos • RO Reject water collection and reuse projects - 4 nos
Annual Monetary Savings : Rs 13.34 Lakhs
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Sly. No.
Area of Usage UOM 2012-13 2013-14 % Improvement
A Total building area available for rain water harvesting
Sqm 125000 125000
B Building covered under Rain Water harvesting - Shops / Office building.
Sqm 1500 8000 433%
C % Age building area covered connected to Rain water harvesting Structure (B/A)
% age area wise
1.20% 6.40% 433%
D Rain Water Harvesting capacity through pond
KL 11000 11600 5%
E Rain Water Harvesting capacity @ Buildings
KL 70000 99400 42%
F Natural Water recharging (20 acres Lawn) KL 15030 15030 0%
G Capacity of available rain water harvesting structure (D+E+F)
KL 96030 126030 31%
Key Actions RWH ETP Pond 600 KL established from Apr'13 Shop-1 & Shop-2 E/A roof gutters connected to RWH tanks P15 M/C Shop & Shop-5 M/C Shop roof gutters connected to RWH tanks 285 KL from RW utilized to process application in 2013-14
Rain Water Harvesting
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Carbon footprint
• Carbon negative in terms of both Scope 1 and 2 • Increased green coverage from 43% to 48% in 2013-14
ASHOK LEYLAND - CARBON CREDITS / DEBITS
Category Hosur - 1 2012-13 2013-14
Carbon debits: Data tCO2e tCO2e
Scope 1 Foot print -12-13 base year 6859 2340
Scope 2 Foot print (Electricity purchased) 1200000 1524 5632
Scope 1 & 2 Total emissions 8383 7972
Carbon Credits:
Wind Power 12372000 15708 10295
Plantation 2800 57 62
KWH reduced through EC projects 151600 192 396
Total credits earned 15957 10753
Net credit / debit wrt Scope1 -9098 -8413
Net credit / debit wrt Scope1+Scope2 -7574 -2781
Remarks wrt Scope1 C -ve C -ve
Remarks wrt Scope1 + Scope2 C -ve C -ve
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Location Thermax RXA 06 Boiler at Main
Canteen Project /O&T no H113S2165 /PUR 04 dt 07.12.13
Canteen Boiler Bio Fuel(PME) Feeding Trials
PM 2.5 with HSD : 39 ppm
PM 2.5 with Bio Fuel : 9 ppm
Flue Gas Analyser
Renewable energy -Alternate fuel for Canteen boiler in place of HSD
Benefits
•Fresh HSD procurement of 7500
Litres/Month reduced.
•Cost Savings : Rs 44475 /Month
•GHG Emissions Reduction : 80%
•Carbon Neutral Initiatives
•Steam Temperature : 140 Deg C
VOC 0.11%
•Steam Temperature : 140 – 160 Deg C
•No.of Hrs of Boiler Running : 10 Hrs/Day
After:
•Palm Methyl Easter(PME) Bio Diesel
introduced
•Average Cost of Fuel/Month: Rs 3.97 Lakhs
•Stack Emissions : CO 13 mg/m3
SO2 0 mg/m3
VOC 0.02 %
Before:
•Boiler Steam Capacity: 600 Kgs/Hour
•BS3 grade HSD Consumption :300 Litres/Day
•Average Cost of Fuel/Month : Rs 4.42 Lakhs
•Stack Emissions: CO 55 mg/m3
SO2 9 mg/m3
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•Reclamation of used oil through recycling for rough cutting operations – Recurring saving of 1.3 lakhs/ month effected from Aug 2011 •Recycling of 2900lits of coolant /month •Installation of purifying system for soluble cutting oil recycling from Dec’11 – Recurring saving of Rs.40000/ month
COOLANT RECLAMATION PLANT
RECYCLE
ISO 14001: O&T No – S5 MS/0043
Wealth from Waste
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55 11/1/2014 CII- National award for Excellence in Energy Management- 2014 ALH1
0
1000
2000
3000
4000
5000
6000
7000
8000
Apr'13 May'13 Jun'13 Jul'13 Aug'13 Sep'13 Oct'13 Nov'13 Dec'13 Jan'14 Feb'14 Mar'14
oil sent Yield
Analysis
Used cutting oil from machines
scraped as hazardous waste
Status
Used cutting oil collected from various
machines recycled & reused in machines
SC LC AP
WP WE RD
cutting oil recycling from hazardous waste cutting oil Hazardous waste cutting oil 9
barrels reclaimed from 15 barrels of waste cutting oil
Avg.1800 lit of hazardous waste generation reduction /month
Avg.1800 lit of hazardous waste generation reduction /month .
Waste cutting oil hazardous waste generation Reduced from 3000lit/month to 1200 lit s/Month
.
Benefits
Reduction of Hazardous waste generation by 1800 lits/month
Recycling of 1800lits of coolant /month
Operating cost reduction of Rs 1.15 lakhs/month
Waste oil reclamation - To Protect Our Environment by Reducing Hazard Waste Generation
Oil Sent for reclamation :71800 ltrs Usable oil received : 45952 ltrs Yield : 64%
2013-14 Oil reclamation trend
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All 5 trials resulted in achieving 100% tool life and performed at par with OE tool The trial phase where low / medium cost tools were tried out has yielded an overall
cost savings of Rs. 2.04 Lacs In addition to the above durable accessories like insert wedges and insert cartridges
can also be repaired / reconditioned by the supplier.
Earlier Methodology
Damaged item
Replace with new one
Scrap disposal
Damaged Cutter
Disposal
Modified Methodology
Damaged item
Repair
Reuse
Reuse @ 100% tool life, same quality and
lower investment
Damaged Cutter
Cutter body Regeneration
Pocket Milling on regenerated body
Cutter ready for use
Project Resurgence …..an initiative from - Hosur-1 Team
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57 11/1/2014 CII- National award for Excellence in Energy Management- 2014 ALH1
• Dignitaries from Left to Right-Lt.Gen.JS Ahluwalia, PVSM (Retd),
• Vindi Banga, Ex Chairman HUL, Anders Spare CEO, Hinduja Automotive Ltd, Rt.Hon.Baroness Verma, Minister in Govt of UK.
Golden Peacock Climate Security Award 2011
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Awards in Energy Efficiency
and Environment Protection
Categories
External awards for energy efficiency and Environment management
Project : Recovery of fresh coolant from waste coolant
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• Individual monitoring and reporting system
• Limited cross communication • Knowledge islands
Present system
New System
System installed in all Mfg units & monitoring started from 1st Oct 2014 .
Way forward….
New tools to cut Energy waste
Cloud hosted infrastructure , can be accessed by any internet enabled devices including cell phones
Real time energy monitoring . Faster, richer & more informative. All Mfg units connected to cloud server. Effective utilization of internal expertise across
all Units. Energy CFT – on line auditing, sharing of ideas & finding solutions via internal resources
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New tools to cut Energy waste
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ALWAR plant contracted demand is 950 KVA & present load is 850 KVA. Expecting more load in view of new bus body activity, “mistake proof arrangement” implemented. Expected benefits are: Alwar plant can make use of existing contracted demand to maximum extent without running of DG sets with less no of power interruptions. This system will give ALRAM alert through SMS / E mail to Executives, Audio & Visual indication to operators. If no response to ALRAM, then system will trip to avoid excess penalties to SEB.
Maximum Demand Control Alarm & Tripping Circuit at Alwar Plant
Solutions through Energy CFT
Capacitors are energy saving devices, internal losses from standard capacitor will be less than 0.5 watts per kvar.
H2 load, 10 pm to 1 am : 2200 KW & 1 am to 8 am : 400 KW as per latest trend & consumption will be around 13000 Kwh from 10 pm to 8 am.
Transmission & distribution (T&D) losses will be around 6% , estimated T&D losses 13000 Kwh x 6% equal to 780 Kwh.
Reduction in T&D losses = T&D losses x (1-(old pf/new pf)2) = 780 x (1-(0.95/0.99)2)= 780 x (1-0.96) = 780 x .04 = 31.5 Kwh per day.
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Solar roof top panels at Mfg plants
Heat pumps for high power intensive washing machines
Solar light pipes for engine assembly area
New Air ventilation system in place of Air conditioners
LED lighting for streets & store areas
VFD for high power intensive AHU blower motors
Improve Power Quality at selective areas
Reconditioning of power intensive furnaces
Replace old conventional lighting to energy efficient lighting
Modification in AHU’s & test bed ventilation system
Future plans
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Thank you