Energy Management –2018”

KIRLOSKAR OIL ENGINES LIMITED


1

19th National Award for “Excellence in Energy Management – 2018”

Confederation of Indian Industry

Presentation by ,Kirloskar Oil Engines Limited (KOEL)

Kagal, Kolhapur Plant

Mr. NN Kulkarni-Corporate Energy ManagerMr. VM Deshpande-Sr. GM-Maintenance & UtilitiesMr. SP Parab-Sr. Manager-Utilities



2

Content of the Presentation

Company profile

Specific Energy Consumption (Last 3 years)

Information of Competitors, National and Global Benchmarks

Energy Saving Projects for last 3 years

Innovative projects implemented 2017-18

Utilization of Renewable energy

Utilization of waste as a fuel

GHG Inventorisation

Green Supply Chain

Team Work, Employee involvement and monitoring

Implementation of corrective / preventive actions from ISO 50001, IGBC and GreenCorating


Kirloskar Oil Engines Ltd-Kagal plant

Total Employees as on date

- 1181

Managers ( TL, GL & UL)

- 191

Operators (Team Associates)

- 990

Initiatives

5S

QMS, EMS & OHSAS

ENCON

Kaizen & POKA YOKE

Autonomous Maintenance

Six Sigma, QC Activities

Standardized Work

TPS

Kagal ( Kolhapur ) Plant

3

Incorporated in 1946 as a part of the Kirloskar Group of Companies, KOEL is an engineering conglomerate, founded by the late Mr. Laxmanrao Kirloskar.


Specific Energy And Water Consumption•Reduce by 3-5% every year over next tenyears.

Specific Generation Of Waste & WasteGoing To Land Fills•Reduce by 3-5% every year over next tenyears

Use Of Renewables Energy• Increase by 5% every year over next tenyears.

GHG Emissions And Other ProcessEmissions•Reduce by 3-5% every year over next tenyears

Recyclable And Enhance Recyclability OfResources• Increase use of resources embedded in theproduct.

Share Of Harvested Rainwater In TheOverall Annual Use Of Water• Increase by 5% every year over next tenyears

Life Cycle Assessment Criteria For NewProducts.• Incorporate Life Cycle Assessment inalternative technologies and products.

Adopt Green Purchase Policy•Adopt Green Purchase policy &incorporate clean technologies at designstage

Product Stewardship Program•Promoting and managing ProductStewardship Program, By forgingpartnership with business and communities.

Depletion Of Natural Capital•Reduce by 5% every year over next tenyears

KOEL adopted CII program Mission for Sustainable Growth - 2007

4


Executive Chairman Shri. AtulKirloskar signed Energy Policy -indicates Strong Commitmentfrom Top Management towardsENCON

3rd Revision in repsect toChanges in Global EnergyScenario

KOEL- Energy Policy

5

Key

Hig

hlig

hts

of

Po

licy

Benchmarking of products with the regional and national best.

Procurement of high energy efficient products and technologies

Eliminating wastage of energy and promoting reuse and recycling of

resources

Promoting and increasing use of renewable energy resources, within

and outside

Adopting New Building Norms

Involving all stake holders in the energy conservation

Sharing and enriching our experiences on energy conservation within &

Outside group

In line with the

requirements of ISO 50001

EnMS



ENERGY CONSERVATION

Share of various sources of Energy FY17-18

32.9%

18.6%

39.8%

8.7%

MSEDCL Renewable energy HSD



ENERGY CONSERVATION

Cost wise Share of various sources of Energy (Rs. M) FY17-18

113.152

17.659

77.417

10.007

1.875

MSEDCL Renewable energy HSD LPG FO Biogas Solar canteen



ENERGY CONSERVATION

% Share of various sections in Energy Consumption FY17-18

28.66%

9.23%

1.92%10.68%8.28%

5.46%

6.81%0.20%

1.02%

7.19%

20.56%EP-1 Machine shop

EP-1 ME -ATPP

EP-1 SE-ATPP

EP-2 Machine shop

EP-2 ATPP

Genset and fabrication

Common utilities

Fire fighting

ETP

Lighting

Compressor



Specific Energy Consumption

Year


Electricity

kWh/BHP

Thermal

kCal/BHP

2015-16 3.13 0.0023

2016-17 2.68 0.0022

2017-18 2.46 0.0019

Specific Energy Consumption (SEC) Reduction

Year% Reduction in Specific Energy Consumption

Electricity Thermal

2015-16 11% -15%

2016-17 14% 4%

2017-18 8% 14%


Reduction in Specific Energy Consumption

Electrical Load of 10000 kW has added in different areas in last few years, still we are able to reduce SEC 1718 by 8% compared to SEC 1617.

0

0.5

1

1.5

2

2.5

3

3.5

2015-16 2016-17 2017-18

3.13

2.682.46

kWh

/BH

P

Specific Electrical Consumption (kWh/BHP) 8% reduction over FY 1617


Reduction in Specific Energy Consumption

Various machine lines and testing facilities has added in different areas in last few years, still we are able to reduce SEC 1718 by 14% compared to SEC 1617.

0

0.0005

0.001

0.0015

0.002

0.0025

2015-16 2016-17 2017-18

0.0023 0.0022

0.0019

kCal

/BH

P

Specific Thermal Consumption (kCal/BHP)14% reduction over FY 1617


12

Energy Pyramid for Efficient use and adoption of renewable energy

Grid Energy dependency

further reduced by increased

use of Renewable Energy

sources & devices

Energy Requirement

reduced by adoption of

energy efficiency measures,

process changes & new

products

Business As usual

energy requirements

& adopting operating

changes

Sustainability


13

Method of arriving at SEC Target

Practice of regression analysis followed in fixing energy consumption andSEC targets.

Help in forecasting, monitoring, targeting energy and other resourcesplanning.

Decision of continuing or stopping production based on fixed and variable energy consumption can be justified

0.80

1.00

1.20

1.40

1.60

1.80

2.00

45000 55000 65000 75000 85000 95000 105000 115000 125000

kWh/BHP

BHP Production

y = 0.3815x + 69590

60000

70000

80000

90000

100000

110000

120000

40000 50000 60000 70000 80000 90000 100000 110000

kWh/month

BHP



Target setting and Benchmarking

Sr. No


Present Status (kWh/BHP) Short term target for specific Energy

Consumption reduction

Long term target for specific Energy Consumption reduction

FY 16 FY 17 FY 18 FY 19 FY 20 FY 21 FY 22 FY23

1Specific Energy Consumption

3.25 2.68 2.462.39(3%

Reduction)

2.32(3%

Reduction)

2.20(3%

Reduction)

2.10(5%

Reduction)

2.00(5%

Reduction)

Involvement of People

Initiated

Advanced EMS for Data Analysis

Installed

Data Analysis and prioritization

Initiated

Adoption of new technologies, Implementation of renewable projects

Implementation

ISO 50001 EnMSCertification, GreenCo Up gradation

Initiated

Certified Lead Auditor - EnMS• Santosh Parab• Nitin Kulkarni



Target setting and Benchmarking

Parameter Specific Energy Consumption (kWh/BHP)

Year 15-16 16-17 17-18 18-19

Target 3.40 3.03 2.60 2.39

Actual 3.25 2.68 2.462.47

(Till end of quarter 1)

Remarks

Started monitoring with installation of new EMS system

Even though 50% increase in load, 18% reduction over previous year

Even though change in product mix, 8% reduction over previous year

Repetitive proto testing


MNC Compititor 1(80 HP to 280 HP)

Kagal (20 HP to 150HP)

11

7.0

0

95

.90

* Source Data : MEDA

Benchmarking (National)

kWh / BHP (Internal)

Energy Consumption per Engine (ATP)

KOEL Pune KOEL Kagaltarget 1718

KOEL KagalBest

Achieved

4.0

1

2.4

6

2.2

5

For Benchmarking kWh / Engine is available from a Close Competitor product

range. Equivalent Conversion taken for KOEL engines

16

Better


Compititor1

KOEL Compititor2 (MNC)

30

20

12

Cycle time in Min.

Benchmarking (International)

DG Set Testing Time

Engine Testing Cycle Time

17

Better

0

20

40

60

80

100

120

Competitor 1KOEL Kagal-16

KOEL Kagal-17Competitor 2

120

55

50

30

DG Set Testing Time in Minutes


18

Projects implemented to achieve the target for last 3 years

Total No. of

ENCONProjects: 185

Annual

EnergySavings in

kWh

(Units): 29.00Lakh

AnnualFuel Saving(Kcal) :

690.9

Lakh

Total Cost

Saving:

Rs 433

Lakh

Investment

: Rs.

78.3

Lakh

SimplePayback : 3

Months

ROI:98%

Simple Payback : 3 Months

CategoryNo. of

projects

Units

saving

In lakhs

Fuel

saving

lakhs Kcal

Cost

saving

in lakhs

Investment

in lakhs

Low Investment 117 16.1 669.3 183.6 2.4

Moderate Investment 60 9.5 21.6 121.6 7.5

High Investment 8 3.4 0 127.8 68.4

Total 185 29.0 690.9 433.0 78.3


19

Projects implemented to achieve the target for last 3 years

42%

28%

30%

Savings in Rs. Lakhs

Low Investment Moderate Investment High Investment

63%

33%

4%

No.of projects completed

Low Investment Moderate Investment High Investment

63% of low investment

project given 42% savings

33% of medium investment

project given 28% savings


20

FY 2015-16


Low Investment Projects

21

S.No. Title of Project Year

Annual Electrical Saving, Million

kWh

Annual Electrical

Cost Saving,

Rs Million

Annual Thermal Saving, Million

kcal

Annual Thermal Saving,

Rs Million

Total Annual Savings,

Million Rs

Investment Made (Rs

million)

Payback months

1 Conversion cost reduction by saving fork lift diesel 2015-16 6.30 0.21 0.21 0.00 0

2 To reduce the power consumption of hydraulic motor on leak test machines 2015-16 0.022 1.89 1.89 0.00 0

3 To reduce consumption of K cool 2015-16 2.40 0.30 0.30 0.00 0

4Elimination of Diesel wastage during 6R Engine Rigging & De-rigging in Test Cell 2015-16 0.15 0.04 0.04 0.00 1

5Reduce fuel consumption for DV Test Cell No.1 2015-16 4.53 0.27 0.27 0.00 0

6 Power Saving in Idle condition 2015-16 0.007 0.06 0.06 0.00 0



9 Power Save from running instead of one MTR.than two 2015-16 0.001 0.01 0.01 0.00 0

10 Power Save from running instead of one MTR.than two 2015-16 0.0074 0.07 0.07 0.00 0





15 Save wastege of air when guage not in use 2015-16 0.015 0.14 0.14 0.00 0

16 Save wastege of air when guage not in use 2015-16 0.07 0.07 0.07 0.00 0

17 To reduce the power consumption of bush press hydr motor running 2015-16 0.004 0.04 0.04 0.00 0

18

Paint Booth flame proof Light Continuous power ON for shift. Even if no engine or part for painting

2015-160.018

0.01 0.01 0.00 0

Total 0.156 2.387 13.380 0.813 3.200 0.008


22

Moderate Investment ProjectsInvestment between Rs. 1 Lakh – 10 Lakh



kWh

Annual Electrical

Cost Saving,

Rs Million


kcal


Rs Million

Total Annual Savings, Million

Rs

Investment Made

(Rs million)

Payback months

1Energy saving by replacing non energy efficient bearing with energy efficient bearing for AHU blower motor.

2015-160.032 0.27

0.27 0.03 1

2Save wastege of air when guage not in use 2015-16

0.23 2.092.09 0.01 0

3Power Saving by using LED Bulb 2015-16

0.001380.01 0.01 0.03 30

4Coolant wastge elimination 2015-16

2.160.00 0.00 0.01 21

5Energy cost reduction through cycle time reduction on DV crank case line Op-80 2015-16

0.0170.17 0.17 0.05 4

Total 0.280 2.542 2.160 0.003 2.545 0.116 0.547


23

High Investment Projects Investment > Rs. 10 Lakh & above



kWh

Annual Electrical

Cost Saving,

Rs Million


kcal


Rs Million


Million Rs

Investment Made (Rs million)

Payback months

1To reduce Energy consumption of R1040 Assembly lighting 2015-160.072 0.97

0.97 0.54 7

2To reduce Energy consumption of EP2 Machine shop lighting 2015-160.048

0.41 0.41 1.60 47

Total 0.120 1.378 - - 1.378 2.140 18.636


24

FY 2016-17



25

S.No. Title of Project

Annual Electrical Saving, Million kWh

Annual Electrical Cost Saving, Rs Million

Annual Thermal Saving, Million kcal

Annual Thermal Saving, Rs Million

Total Annual Savings, Million Rs


1 HA6CC, Op40, Intermediate washing m/c heater elimination & CT optimization 0.004 0.03 0 0.033 Nil

2 HA6CC, Op140, Continuity test m/c heater elimination 0.004 0.04 0 0.036 Nil

3

HA6CC, Op10/130, Cleaning tool eliminated by replacing with thro' coolant tool (6mins) & M.C. cutting parameter optimized (4mins)

0.011 0.09 0 0.093 Nil

4 HA6CC, Power cost saving thro' optimization of tool magzine rotation on HMC 0.001 0.01 0 0.005 Nil

5 HA6CC, Op120, CT reduction by changing the Thrust tool cutter 0.002 0.02 0 0.020 0.2

6 HA6CC, Op100, Power saving mode introduced 0.005 0.04 0 0.040 Nil

7

HA6CC, Op150, Power saving thro' elimination of heater by use of CUMI make washing media

0.012 0.10 0 0.100 Nil

8 DVCBX, Washing m/c CT optimization 0.002 0.02 0 0.019 Nil

9 DVCBX, To reduce the comp washing frequency on washing m/c 0.002 0.02 0 0.021 Nil

10 DVCBX, Op30/50 CT reduction 0.018 0.15 0 0.154 Nil

11 DVCBX, Op40 CT reduction by cutting parameters optimisation 0.009 0.08 0 0.080 Nil

12 DVCC, Op110, Hyd motor ON/OFF during only cycle start/off 0.014 0.12 0 0.121 Nil

13

DVCC, Op50, 60, 80, Tool no sequencial arrangement to save power during magazine rotation

0.009 0.08 0 0.077 Nil

14

DVCC, Op60, CT reduction implementing Lakshya suggestions & rearranging the tool sequence

0.005 0.04 0 0.040 Nil

15 DVCC, Op10, Reducing the temp range of washing media 0.009 0.07 0 0.073 Nil

16 DVCC, Op90, Elimination of heater on washing m/c 0.129 1.10 0 1.099 Nil

17

Energy Saving through Hydaulic power pack optimization at Toyoda Top center - R1040 Crank case line & Crank shaft line

0.00528 0.522 0.520

18 Varsha Paintbooth water tank level optimisation 0.003 0.22 0.22 0



26








19Energy Saving through Hydaulic power pack optimization at OP-170 at Crankshaft line 0.00043 0.003836 0.00

020 Reduce power cost of RCH line OP 40 by modification of PLC logic. 0.00156 0.01404 0.01 021 Reduce power cost of RCH line OP 30 by modification of PLC logic. 0.001989 0.0179 0.02 022 Energy saving by optimize Hydraulic power on Pressing machine RCH Op80 0.016728 0.1505 0.15 0

23EP2 --Stop the HYD .motor and Chip conveyour motor to run in ideal mode of 15 min . Machine No : 2636

0.001923 0.017313 0.017 0

24EP2-- Power saving logic implemented for Ideal run for Hyd , coolant and maganatic sepetor Motor Machine No : 2842

0.009324 0.058287 0.058 0

25 EP2 --Stop the HYD .motor to run in ideal mode of 10 min . Machine no 6739 0.008165 0.083916 0.084 0

26EP2--Power saving of induction motor In ideal cycle time of 15 Min . Machine no 5418 0.008514 0.073483 0.073 0

27EP2--Power saving of induction motor In ideal cycle time of 15 Min. Machine no 5405 0.013986 0.076621 0.077 0

28EP2--Instead of two one power pack is used to save the Enegry . Machine no 6726 0.000312 0.086148 0.086 0

29EP2--Hyd oil chiller will on only after control on ,previsoly it will on when machine main supply on . Machine no 2974

0.000312 0.002808 0.003 0

30EP2-- Hyd oil chiller will on only after control on ,previsoly it will on when machine main supply on . Machine no 2977

0.016464 0.002808 0.003 0

31 EP2--Power save of HYD press on camshaft .Machine no 7043 0.000005 0.148176 0.148 032 EP2--Machine lamp made switched off after EMG. PB pressed .Machine no 5433 0.003978 0.000045 0.000 033 EP2--Compressed air made off after EMG P.B Pressed .Machine no 5433 0.00171 0.034992 0.035 0

34EP2--Power saving logic implemented in ideal run to avoided the running of motor of HYD and chip conveyor . Machine No 931

0.004623 0.001709 0.002 0

35EP2--Power saving logic implemented in ideal run to avoided the running of motor of DM and Qunch .Machine No 8109

0.0225 0.04158 0.042 0

36EP2-- Power saving with alternate use of chemical in washing machine .Machine no OP 150 HA CRANK CASE

0.00432 0.2025 0.203 0.0095

37 EP2--Power saving with alternate use of chemical in washing machine 9041 0.0084 0.02616 0.026 0.00115238 EP2--Power saving with alternate use of chemical in washing machine 7800 0 0.1566 0.157 0.01152

39EP2--Interface flow control valve in pnumatic line which reduced the pressure from 6 bar to 2 bar 0.0003 0.00255 0.003 0.01


27




kWh

Annual Electrical

Cost Saving,

Rs Million


kcal


Rs Million


Million Rs


1To Provide electrical switch/autosenses near to the core plug pressing station on DV-Cylinder Head Line on OP-80 station 0.000941 0.008

0.0080.0002

2

To save electrical power cost by providing separate hydraulic motor ON/OFF system on OP40/50 Pressing machine & also provide only one hydraulic system for two m/c in single piece flow On R810 Cylinder head line

0.016118 0.1370.137

0.003

3

To save electrical power cost by activating hydraulic motor in power saving mode instead of continuously running in idle condition with in house modification in PLC logic on op-80 WIDMA m/c on 6R6K Cylinder head line

0.001024 0.0090.009

0

4To save electrical power cost by use 250 kg crane against 500 kg at input conveyor (component wt only 8 kg)on SL-90 Cy.head line 0.000353 0.003

0.0030

5 Reduce HA Crankcase line power consumption from 14.59 Units/Cyl. to 13 Units/Cyl. 0.070421 0.669 0.669 06 Reduce HA Crankcase line Air(power) consumption cost 0.009474 0.090 0.090 0.00157 To save electrical power cost on Micromatic (OP 70) m/c 0.006 0.050 0.050 08 To save electrical power cost on Toyoda (OP 80A) M/c 0.006 0.050 0.050 0

9To use the washing machine coolant at room temperature instead of hot coolant which is heated up to 55 to 60 degree Celsius 0.190737 1.812

1.8120

10 To reduce power consumed in heaters at OP130 final washing machine 0.010706 0.091 0.091 0

11To save 50% electrical power cost by Utilize all washing stations by using second chamber & start to wash at time two component in single cycle ( op-70 ) 0.01 0.085

0.0850.001

12 To reduce power consumption on rough washing machine on 6R/HA6 Crankshaft line 0.005529 0.047 0.04713 To reduce power cost by reducing cycle time of washing machine 0.002353 0.02 0.02014 DV CON ROD- Maintain line power consumption below 23kwh per component 0.037895 0.360 0.360 015 To eliminate heater of continuity test machine OP140 0.005059 0.043 0.04316 Reduce air consumption On r1040 crankcase line 0.003368 0.032 0.032 0.00217 Air consumption to be reduced when APG not in use 0.007053 0.067 0.067 0.00518 Power Consumption Saving on OP150 A , SL90 Lapping M/c 0.000588 0.005 0.00519 Power Consumption Saving on OP50, Fortuna M/c 0.000471 0.004 0.00420 Power Consumption Saving on OP140, Balancing M/c 0.000824 0.007 0.00721 To Reduce power cost by disconnecting mist collector on Op-85 0.005053 0.048 0.048 0

22To save electrical power cost on Streightening (OP 40), Micromatic (OP 70), Toyoda (OP 80A) & Washing (OP 120) M/cs 0.021 0.180

0.1800

23 To save electrical power cost by eliminating dirty tank coolant transfer 0.014 0.115 0.115 0

24To save Compressed air cost on Horizontal Induction Hardening (OP 20), Landis (OP 50), Micromatic (OP 70), & Radial Drilling (OP 100) M/cs 0.001 0.008

0.0080.002


28









25 To reduce power consumption of OP100 by keeping machine in power saving mode 0.013 0.107 0.107 0

26Reduce power cost of RCH line by using single power pack for both Valve seat & valve guide pressing on op-80

0.015789 0.1500.150

0

27 Make separate ON/OFF Switch for Marposs Gauge 0.001209 0.105 0.105 0

28 Power consumption saving on OP180 , Final Washing m/c 0.008941 0.076 0.076

29 Power consumption saving on OP100, TAL M/c 0.000353 0.003 0.003

30 To Reduce Power consumption of hydraulic motor on OP80 WIDMA machine 0.001059 0.009 0.009 0

31 To Reduce Power consumption of hydraulic motor on v/s & v/g pressing machine 0.016118 0.137 0.137 0

32

To Reduce Electrical Power consumption on SL90 cylinder head line by changing man- machine work combination with cell wise time study 0.019292 0.164

0.1640

33

To Reduce Electrical Power consumption on R810 cylinder head line by changing man- machine work combination with cell wise time study 0.006 0.051

0.0510

34

To optimize compressed air flushing time on primary washing machine & save compressed air cost with ZERO investment 0.011412 0.097

0.0970

35

To Provide electrical switch/autosenses near to the core plug pressing station on DV-Cylinder Head Line on OP-80 station 0.000941 0.008

0.0080.0005

36

To save electrical power cost by use 250 kg crane against 500 kg at input conveyor (component wt. only 8 kg)on SL-90 Cyl.head 0.000353 0.03

0.030

37 Hot cure tank cleaning & DM water changing frequency is changed from once in a month to twice in a month 0.001684 0.016 0.016 0

38 To Reduce Power consumption cost by reducing cycle time of OP120 0.011579 0.110 0.110 0

39 Optimize Heating temp. ( OP- 80) for Final Washing on Camshaft line 0.02225 0.20025 0.200 0

40

To reduce power consumption cost from Rs.11.5 per cylinder to below Rs.10 per Cylinder, on R14040 Crankcase line 0.038211 0.363

0.3630

41

To reduce electrical cost by switch off the hitters while machine keep in emergency mode on op-70 ( Final washing) R810 cylinder head line 0.002942 0.025

0.0250

42 To reduce the Electrical power cost on OP-40 washing m/c on DV Cylinder head line 0.008471 0.072 0.072 0

43 Final Conveyor -Make Separate ON/OFF Switch for Tube , Fan ,Bulb . 0.000243 0.0213 0.021 0

44 Tooling Area Make Separate ON/OFF switch for Tube ,Fan , Pre Setter . 0.000248 0.02162 0.022 0

45 op-30 Mist Collector OFF during PDT . 0.001904 0.167 0.167 0

46 op-170 Torquening M/c logic modification for Integral model 0.001925 0.168 0.168 0

47 DV CON ROD- Reduce power consumption by providing power saver to op.120 0.007842 0.074495 0.074 0


29

High Investment Projects Investment > Rs. 10 Lakh & above



Annual Electrical Cost Saving, RsMillion


Annual Thermal Saving, RsMillion


Investment Made (Rsmillion)

1 Energy efficient lighting 0.191 2.92 2.92 1.37

2 Solar roof top pumping system 0.029 0.25 0.25 1.61

3 Bio gas generator 0.0072 0.06 0.06 1

4 Rainwater Filtration plant 0.32 0.32 0.6

5 Open access Renewable energy purchase 5.047 5.05

6Cost saving through improving diesel draining process at Genset PDI lines 2.8

2.800.116


30

FY 2017-18



31








1 To eliminate air leakage of OP10 washing m/c 0.027 0.230 0.23 0.00

2 To reduced cycle time of DV 16 cc for PCN operation 0.001 0.007 0.01 0.00

3 To reduce power consumption in continuously coolant gun motor 0.002 0.013 0.01 0.00

4 To reduced cycle time of DVCBX R56 milling operation 0.008 0.064 0.06 0.00

5 To reduce the CT of OP70 by optimizing the cutting parameter 0.006 0.050 0.05 0.00

6 To reduce the CT of OP110/130 by optimizing the cutting parameter 0.003 0.022 0.02 0.00

7To reduced the power consumed in heating washing media on HA6CC, DVCC, R810CH, DVCH & SL90CH line

0.783 6.650 6.65 0.00

8 LPG cost reduction 53.55 0.191 0.19 0.00

9 To reduced power consumption by operation shifting 0.002 0.014 0.01 0.00

10 To reduce power consumption by implementing power saving mode in M/c 0.001 0.005 0.01 0.00

11 To reduce power consumption in idle condition due to hydraulic motor continuously ON 0.001 0.008 0.01 0.00

12 To reduce power consumption in idle condition due to chip conveyor continuously ON 0.002 0.014 0.01 0.00

13 To improve capacity by using combination tool for 6R BS3 0.002 0.020 0.02 0.00

14 To reduce cycle time by using combination tool for CRDI models 0.008 0.027 0.03 0.00

15 To reduce cycle time by eliminating probe cycle from mazak machine 0.003 0.027 0.03 0.00

16 To switch off nozzle operation from widma machine 0.003 0.023 0.02 0.00

17 To eliminate the pneumatic stopper from input stage 0.002 0.021 0.02 0.00

18 To improve line capacity by 45% 0.023 0.198 0.20 0.00

19 To improve line capacity by 10% 0.008 0.066 0.07 0.00

20Power saving logic implemented for Ideal run for , coolant chiller and magnetic separator Motor. 0.058 0.06 0.00

21Made selector switch is provided to on & off of 11 watt Tube light near Magazine. As tube light is runing when machine on .

0.004 0.00 0.00

22Selector switch is provide at Front side of operating panel for making on/off machine lamp at loading/unloading section .

0.004 0.00 0.00

23Foot switch used for Pneumatic Baker gauge which will stop the air when gauge is not used 0.035 0.04 0.00



32


Annual Electrical Saving,

Million kWh

Annual Electrical

Cost Saving, Rs Million


Million kcal


Rs Million


Million Rs


24Foot switch used for Pneumatic Baker gauge which will stop the air when gauge is not used 0.035 0.04 0.00

25Saving the electrical enegry for unneseery ruing of HYD motor during unclamping cycle. 0.084 0.08 0.00

26 External Fixture Flushing kept off during auto cycle 0.8 0.80 0.00

27Power cost saving on DV con rod line. 0.020 0.18 0.18 0.0028Power cost saving on HA con rod line 0.067 0.60 0.60 0.0029Power cost saving on HA Crank Case line 0.082 0.08 0.0030Power cost saving on HA Crank Case line 0.007 0.062 0.06 0.0031Power Consumption reduction 0.020 0.183 0.18 0.0032One engine testing for ten 3R engines of reliance code 0.002 0.021 0.05 0.07 0.00

33To reduce electricity consumption through modification in cooling tower fan motor starter 0.1 0.10 0.00

34Reducing the electric power consumption for DV Test Cell No.1 when engine not present for testing. 0.03 0.03 0.00

35Reducing the electric power consumption for DV Test Cell No.1 during test cell empty 0.03 0.03 0.00

36E-series canopy & base welding and finishing reduction 0.014 0.01 0.00

37Terminal box welding reduction 0.002 0.00 0.00

38DV integrated base welding reduction 0.013 0.01 0.00

39DV & SL90 baseplate rib cutting shifted from laser cutting to shearing machine0.010 0.01 0.00

40Elimination of use of EOT crane for Loading & unloading of fabricated material 0.205 0.21 0.00

41Energy conservation in D8.5325 baseplate laser cutting by reducing piercing & common cutting0.012 0.01 0.00

42To elimimnate latch catcher plate laser cutting by punching & shearing for all canopy0.019 0.02 0.00

43To reduce the power consumed in heating the washing media 0.017 0.14 0.14 0.00

44

To reduce Energy consumption of Gurukul and improve the illumination level 0.075 0.9 0.09 0.00

45Oil skimmer power saving on MAZAK FH7800 HA CRANK CASE M/C No : 0.02 0.02 0.00


33









1 We have installed Vaayu MIG24 unit at ME tool room office instead of AC. Comparison of vaayu MIG 24 & AC.

0.019 0.154 0.154 0.20

2Energy/Power cost reduction by utilization of renewable solar energy for heating up the washing tank water at Medium Engines Paint booth.

0.037 0.375 0.375 0.42


Innovative Projects 2017-18

34


30-Aug-18 35

Innovative Project 1- Elimination of electrical heaters for Component washing machine

Detailed information- Earlier for component washing machines, 5-6% concentration of washing chemical with water was heated to 55-600C to achieve the desirable results with electrical heaters. By replacing washing chemical with “Cumiclean CWF242” same results were achieved at room tempe rature and electrical heaters of the washing machines were eliminated. Throughout the factory, electrical heaters were eliminated for 33 numbers of washing machines. Same will be horizontally deployed for rest of the areas. Before-

Total connected load of electrical heaters-871 KW Electrical consumption per day -2612 kWh Electrical consumption per annum (@ 25 days per month, 12 months a year)- 783450 kWh

Savings achieved-

Savings per annum (@ Rs. 8.5/kWh)-Rs. 6659325/-


30-Aug-18 36

Innovative Project 2- Solar Hot water system for Paint booth

Detailed information-Previously EP-1 Paint booth tank washingwater was heated with the help of electricheaters with the help of 4 heaters of 10 kWeach. Water temperature is maintained at50 Deg.± 5 Deg. Power consumptionmeasured was about 320kWh/day. It wasdecided to use solar hot water systemreceived from one of the company premisesto minimize the use of electric heaters byproviding hot water through solar system.After implementation of solar plant to heatup the water only in paint booth degreasingtank the Power consumption observed 200kWh/day.

Total Savings-3.18Lac/annum


30-Aug-18 37

Innovative Project 3- Installation of Vaayu unit replacement to conventional AC

DESCRIPTION VAAYU AC

Coverage Area 1000 Sq. Ft 1000 Sq. Ft

MachineVaayu MIG 24

(Nos.1)10 Ton

Power Supply 230V, 1PH, 50Hz 230V, 1PH, 50Hz

Power Input 800 W 10,000 W

Per Hr. Power Consumption 800 W 10,000 W

10 Hr. Power Consumption 8,000 W 1,00,000 W

Monthly Power

Consumption2,40,000 W 30,00,000 W

Units Per Month 240 3000

Tariff @ Average Rs. 7 Rs. 7

Monthly Bill(Approx) Rs. 1680 Rs. 21,000

Yearly Expenses(7 Months) Rs. 11,760 Rs. 1,47,000

Savings Against Ac 92%

Detailed information-

We have installed Vaayu MIG24 unit at ME tool room office

instead of AC. Comparison of vaayu MIG 24 & AC.


38

Gayatri Mantra-The source to sustenance

Utilisation of Renewable Energy Sources


Renewable Energy-On site Installations

LAKE

KUND

Main

Plant 2

FGL-

588.40

FFL-

588.80

Main

Plant 1

FGL-

588.40

FFL-

588.80

H

M.S.E.B

Plot

A

BC

EF

D D

A - Fixed Axis Solar PV – 3.8 MWp

B – Single Axis Tracking Solar PV- 0.45 MWp

C- Roof Top Mounted Solar PV- 1.25 MWp

D- Admin Building Roof Top Mounted Solar PV- 0.082 MWp

E – Solar Parabola Steam Generator – 350 Kg/Day

F – 1 KW Solar Lighting and15 KW Solar Pumping System

G

G – Biogas Plant and Biogas Generator– 30 Cum / Day

15 KVA Generator

H

H – Solar Hot water System for Paint Booth – 1500 LPD

2


Renewable Energy –OA and Solar PV

Windmill and Solar Units

kWh

Units

% of total Energy

consumption

Renewable Energy Used

(FY 15-16)

36,88,500

23.00%

SEM Meter Installation


(FY 16-17)

58,07,286

36%


(FY 17-18)

60,98,889

36% Against Target 50%

Obligations from Govt. and MSEDCL after Tariff change

Target

(FY 18-19)

50%

5.5 MWp Solar Captive Power

plant

Open Access energy

purchase

The share of renewable energy in total electrical consumption for FY 17-18 – 36%This has resulted into tremendous saving of Rs. 38 Lakhs

40


Renewable Energy –Onsite installations

Units

Present Renewable energy generated

on - site

Present Renewable energy generated

on - site Achievement Target for 2018-19

(Additional 5% wrt 17-18)

(2015-16) (2016-17) In 2017-18

Biogas Plant (Cum.) 5494 6327 5881 6175

Solar Parabola Steam Generator (Kg

of Steam)28361 31991 16872 17715

Solar Pumping (kWh.)

NA NA 6600 6930( Addition of DC Solar Pump )

41


Renewable Energy -5.5MWp Solar Captive PV Plant

• Total Plant Capacity-5.5MWp (DC output)

• Total no of solar modules-17220 modules

• Four types of Installations-Rooftop :1.25MWp – 3520 modulesSingle axis tracker ground mounted- 0.45MWp-1680 modulesFixed axis ground mounted – 3.80 MWp-11760 modulesAdmin bldg. roof mounted-0.082MWp- 260 modules

• Approximate yearly unit generation-8040 MWh

• Approximate carbon offset- 6500tons/annum

• Approximate % in total electricity consumption- 50%

• Generation till date- 17,00,000 kWh42

SOLAR Movie.mp4


43

Utilisation of Waste material as a fuel

Analysis Report received for co processing ( Using alternate fuel ) of paint sludge, ETP sludge,Phosphate sludge and Cotton waste which are our major Hazardous Wastes generates fromprocesses at M/s Ambuja Cement Works which is clearly indicating that above wastes can beco- processed.

We are awaiting for financial proposal from the waste co- processing agency.

Sr. no

Waste name CategoryGeneration Quantity TPM

Moisture Content %

Gross CV cal / gm

NCV (Cal/gm) Calculated

Ash content %

Sulphur %

Chlorides%

pH(5% sol )

Observations & comment

1 Paint Sludge 21.1 3.5 38 2560 2163 24.39 0.27 0/03 6.67

Waste can be co-

process in cement

kiln.

2 ETP sludge 34.3 8 78.43 388 NIL 12.52 0.02 0.003 7.7

3Phosphate sludge

12.5 0.8 73.27 39 NIL 21.5 0.002 NIL 3.85

4Cotton Waste

5.2 1 7.75 6094 5623 3.2 0.28 0.09 8.3

35% Hazardous WasteCan be Co-Processed


KIRLOSKAR OIL ENGINES LTD., KAGAL – RKQP 29th July’14KIRLOSKAR OIL ENGINES LTD. 40

We have 350-400kkg/daybiogas capacity with a gasgeneration of about 25-30cum/day. Part of the gas isused for canteen thermalapplication & remaining gas isfed to biogas generator togenerate electricity.

All street lights of EP1 and

Genset plant will be powered

by Biogas Generator

Daily electricity generation-25 to 30kWh/day

Utilisation of Waste material as a fuel

Generation started from May-17

Generation till date-9000 kWh



GHG Inventorisation

Carbon Foot Print Report Data - Kagal-1 Plant Sr. No. Source Scope Unit Consumption GHG Emission (tco2)

FY15-16 FY16-17 FY17-18 FY15-16 FY16-17 FY17-18

1 HSD 1 kl 972.00 1,139.00 1,295.00 2,552.08 2,990.56 3,400.15

2 LPG 1 kg 184,870.00 162,478.00 195,034.50 554.61 487.43 585.10

3 FO 1 kl 28.73 26.77 58.29 85.59 79.76 173.65

4Compact Natural Gas (CNG)

1 SCM - - - - -

5 CO2 for cutting 1 kg - - - - -

6 CO2 for welding 1 kg - - - - -

7 CO2 in fire extinguisher 1 kg - - - - -

Total Scope 1 = 3,192 3,558 4,159

Scope 2

1 Electricity Purchased 2 kWh 11,954,222 10,161,709 10761047 10,907 9,271 9,818

Total Scope 2 = 10,907 9,271 9,818

Offset

1 Electricity Renewable kWh 4,038,736 5,807,286 6098889 3,685 5,299 5,565

2 Biogas m3 5,494 6,327 5880.5 10 12 11

3 Solar kg of steam 28,361 31,906 16872.25 0.00 0.00 0.00



GHG Inventorisation

Action started to offset carbon footprint from FY16-17Difference between Total emission and Offset -5240 Tons of CO2 FY17-18

Sources of Emission:Scope 1- In house consumption of HSD, LPG, Refrigeration, CO2 Cylinders etc.Scope 2- Purchase of electricityScope 3- Will be started in FY 1819



Green Supply Chain

Supply Chain Policy



Green Supply Chain

Activities at Supplier EndSr.

NoSupplier Name Audit Name Faculty

Conducted in

year

Duration

(Hr.)

1 KFIL Supplier Process Audit Mr. Abhijit Koparde

2016-17 8 Hr

2 Rajrajeshvari Supplier Process Audit Mr. AbhijitKoparde

2017-18 8 Hr

3 K K Foundry Supplier Process Audit Mr. Abhijit Koparde

2017-18 8 Hr

4 Jadhav Industry Supplier Process Audit Mr. Suresh Patil

2017-18 4 Hr

5 Sound Casting Supplier Process Audit Ajit Konkire 2017-18 6 Hr

580600620640

Before After

63

5

61

0

K K Foundry

Furnace Energy Units / ton

0

5

Before After

1

2.5

Jadhav Industry

Saving in Rs. Lac

1200

1300

1400

Before After

13

50

12

50

Sound Casting

Plant Units…



Milk Run -Model

Before Milk Run

After Milk Run

Delivery To KOEL

Return To Supplier



Milk Run -Model/Vehicle Optimization

Present Traffic Incoming Avg. 77 vehicle entries/day. - Aprox. 21% reduction

Avg. monthly Diesel Consumption 2200 ltrs. - Approx. 12% reduction

Reduction Freight Payment by 4.13 Crs in last three years. - Avg. 13.8 % reduction per year.

Advance information Proactive alerts.

Reduced personal visits .

Defined accountability & Responsibility.

Improved relationship .


51

Employee Involvement



ENCON Awareness Creation Celebration ENCON WEEK Every Year (14 Dec. to 20Dec.)



ENCON Awareness Creation Celebration ENCON WEEK Every Year (14 Dec. to 20Dec.)

Dindi.mp4

Dindi.mp4

Without music without Bharud dance.mp4


54

Corporate Sustainability Report

KOEL is the First Engine Manufacturing company in India, whoreleased Corporate Sustainability Report & received highest levelcheck certification of A+ after being validated by global reportinginitiative (GRI), Netherland


Sustainability Reporting

Sr. no.

Year Frequency Guiding Principles

1 Sustainability Report 2009-10

Annually GRI G3


Annually GRI G3


Annually GRI G3.1


Biannually GRI G3.1


Biannually GRI G4


Annually GRI G4


56

GreenCo – “Gold” Certified Plant


57

IGBC – “Gold” Certified Building


58

CII - National Award for “Excellence in Energy Efficient Unit 10-11, 11-12 , 13-14,14-15,16-17 & “ Energy Efficient Units” 12-13 & 15-16

KOEL won for “Parivartan Corporate Sustainability Stewardship Award” for their efforts in Resource Conservation 2 times 10-11 & 13-14

Accolades Energy & Environment

Kagal Plant also bagged “First prize” for year 16-17 and “Certificate of Excellence” award for 15-16 in State Level Energy competition by MEDA in Engineering Sector

Consecutive 8 times winner at National level -CII


59

Accolades Energy & Environment

Kirloskar Group Inter-competitionAwards by auspicious hands ofEminent Personalities in Energy Sector

Tree Plantation by auspicious hands ofEminent Personalities in EnvironmentSector

Kirloskar Tree Plantation.mp4


Thank You………….

[email protected]

60

mailto:[email protected]

Documents

Energy Management –2018”