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
MnYearProject DetailsSN
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
08Number of Projects In Last 3 years
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
MnYearProject DetailsSN
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
MnYearProject DetailsSN
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
06Number of Projects In Last 3 years
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
MnYearProject DetailsSN
0.345Total Cost Saved in Rs. Mn0.065Electrical Units Saved In Mn
04Number of Projects In Last 3 years
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
MnYearProject DetailsSN
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
Waste Identification & Elimination
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
MnYearProject DetailsSN
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
Waste Identification & Elimination
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
Cooling Capacity (Btu/Hr)
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
Cooling Capacity (Btu/Hr)
Benchmarking – EER Improvement For Medium Temp. Market Requirement
52
Today
Plan
0 1000 2000 3000 4000 5000 6000 7000
Cooling Capacity (Btu/Hr)
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
* Source : Product Catalogues
27
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Cooling Capacity (Btu/Hr)
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
* Source : Product Catalogues
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