mr k g ghude,. tata motors

1

CVBU Pune 1

By TATA Motors Ltd. CVBU, Pimpri, Pune

CVBU Pune 2

TATA Motors Ltd. CVBU, PUNEEnCon in Compressed Air System

Facilitator

Mr. M B Kulkarni (Sr. General Manager C,C,E & CQH)

Energy Manager

Presentation by

Kishor G Ghude

Assistant General Manager (CPED & Environment)

2

CVBU Pune 3

Company ProfileSpread of Plant - 568 acres.Production Level - 178696 Eq.Veh

(PUNE Commercial Vehicle)

Total Sales turn over Rs. 38364 Crores

(Incl.Pune, Jamshedpur, Lucknow & Pantanagar)

Total shop Sub-stations - 63 Nos.

Total connected load - 172 Mw.

Contract demand - 55372 KVA.

( Incl. CVBU & PCBU)

CVBU Pune 4

TATA Motors's Manufacturing Process

Vehicle Assembly Line

- Chassis Assembly-

Finished product for

Vehicle Assy.

- Axle Assembly -


Vehicle Assy.

- Cowl Assembly-


Vehicle Assy.

- Engine Assembly-


Vehicle Assy.

-Gear Box Assembly-


Vehicle Assy.

Painting

Vehicle

Assembly

3

CVBU Pune 5

SR. NO Thumbnail Model % IMPROVEMENT SR. NO Thumbnail Model % IMPROVEMENT

12.3%

9.8%

CUM - 22 %

. 19.2%

8.1%

CUM - 27.3%

3709 LP/ LPT

EX 19.8% 7 SPACIO 14.70%

4709 SFC

EX12.0% 8

2515 LPT

(697 TCIC) 15.30%

16.6%

22.0%6 207 DI

5407 SFC

EX

FUEL EFFICIENCY IMPROVEMENT

1 1613 SE/ LPT

21510 LP

ENGINEERING

293

486

0 18 36

67

106 1

58

251

382 40

4 446 464

474

0

350

700

2001

-02

2002

-03

Apr-0

3

May

-03

Jun-

03

Jul-0

3

Aug-

03

Sep-

03

Oct-

03

Nov-

03

Dec-

03

Jan-

04

Feb-

04

Mar

-04

Cum

mul

ative

Win

d Un

its in

Lac

s

Target for Year 2004-05 Wind Power - 500 Lacs Wind Units

Energy Efficient & Eco-friendly Technology

To minimise the adverse impact on Environment

Real Time Power Factor Controller

Pond at Shelu VillagePond at Shelu Village

To improve the life of people by

Comparison with national and international

Automobile Players.

Safe and energy efficient operations

ENERGY POLICY

CVBU Pune 6

Eliminate wastages of resources by maximising NO INVESTMENT projects & emphasize on improved productivity of all operations & processes.

Adopt the faster pace for deployment of all ideas in all areas of business thro maximizing involvement of people

Focus on accomplishing investment projects with payback less than 2 years at faster pace & deploy across all TATA Motors plants Jamshedpur, Lucknow & Pantanagar.

At saturated performance level introduce break thro improvement

by adopting suitable modern technology through adequate

investment .

Share the best practices & performances with vendors , suppliers , partners & other industries & assist them to reduce their ENERGY INTENSITY ..=> ENERGY KAIZEN

TATA Motors, CVBU Pune: ENCON STRATEGY

4

CVBU Pune 7

Trend of Reduction in Specific Energy Consumption

- Electricity -

559536

561

531

400

500

600

06-07 07-08 08-09 09-10

Sp. Energy Cons.(Kwh/Eq.Veh)

5.01%

Reduction over the

year 2006-07

SUSTAINABILITY

CVBU Pune 8

-Trend of Reduction in Specific Energy Consumption

Fuel -(LDO + FO + Propane)

0.38970.3712

0.3500

0.3091

0.3

0.4

0.5

06-07 07-08 08-09 09-10

SpFuel Consum. (Mkcal/Eq.Veh.)

20.68%

Reduction over the

year 2006-07

SUSTAINABILITY

5

CVBU Pune 9

Year 2000-

2001

2001-

2002

2002-

2003

2003-

2004

2004-

2005

2005-

2006

2006-

2007

2007-

2008

2008-

2009

2009-

2010

Kwh/Eq.Veh. 835 734 698 580 552.8 513.1 502.7 536.3 560.9 531.3

% reduction

over 2000---- 12.1% 16.3% 30.5% 33.8% 38.5% 39.8% 35.7% 32.8% 36.3%

Kwh/Eq.Veh. 1181 937 776 630.0 550.0 475.0 472.0 578.0 551.0

% reduction

over 2000-

01

--- 20.7% 34.3% 46.7% 53.4% 59.8% 60.0% 51.1% 53.3%

Kwh/Eq.

Veh.1175.0 1003.0 905.2 755.9 664.8 657.1 647.0 613.3 625.2 648.5

% reduction

over 2007-

08

--- 14.6% 23.0% 35.7% 43.4% 44.1% 44.9% 47.8% 46.8% 44.8%

Kwh/Veh. --- --- --- --- --- --- --- 439.0 290.0

% reduction

over 2007-

08

--- --- --- --- --- --- --- --- 33.9%

Kwh/Eq.Veh. 832 687 632 594 538 510 488

% reduction --- 17% 24% 28.6% 35.3% 38.7% 41.3%

Kwh/Eq.Veh. 524 511 500 448 395 344

% reduction --- 2.5% 4.6% 14.5% 24.6% 34.4%

Kwh/Eq.Veh. 346 316 290

% reduction --- 8.7% 16.2%

Kwh/Car 754 701 534

% reduction --- 7.0% 29.2%

Kwh/Eq.Veh. 1310 1280 1230 1097 911 825

% reduction ---- 2.3% 6.1% 16.3% 30.5% 37.0%

Kwh/Eq.Veh. 4650 4381 4119 4038 3483 3474

% reduction 5.8% 11.4% 13.2% 25.1% 25.3%

Kwh/Eq.Veh. 3160 3080 3210 2940 2940 2940 2900

% reduction ----- 2.5% -1.6% 7.0% 7.0% 7.0% 8.2%

Kwh/Eq.Veh. 8716 6729 4943 6111 4954 4102 3957 3663

% reduction ----- 23% 43% 29.9% 43.2% 52.9% 54.6% 58.0%

Kwh/Eq.Veh. 2094

% reduction -----

Data Not

Available

Data Not

Available

Data Not

Available

Data Not

Available

Data Not

Available

3TATA Motors Car

Plant Chikhali

12

Volvo Truck

Corporation Banglore,

India

13

4TATA Motors Pant

Nagar

9

5

6

Data Not

Available

Data Not

Available

Data Not

Available

7

8

General Motors

(India) Pvt. Ltd.

(Gujarat)

Data Not

Availablewww.volvo.com

Referenece

www.gm.com

www.bmwgroup.com

Sr.

No

Name of

Automobile Player

10

Mahindra & Mahindra

, Kandiwali Plant

(Maharashtra)

1

. Increased due to addition of New

shops/Activity like J-11/12 New Paint,

Xenon Assy, Panel Van shop, Dicor

Engine Assy shop.

http://www.bee-

india.nic.in/ecaward.php

http://www.bee-


http://www.bee-


http://www.bee-


http://www.bee-


11 BMW

TATA Motors Pune

(Excluding Foundry)

TATA Motors Jsr 2

General Motors

Mahindra & Mahindra

, Medak Plant (AP)

Mahindra & Mahindra

, Nashik Plant

(Maharashtra)

Data Not Available

Data Not Available

Data Not Available

Sp

. En

erg

y C

on

sum

pti

on

Tata Daewoo

Commercial Vehicle,

Korea

Ashok Leyland ,

Hosur

Data Not

Available

Data Not Available

Data Not Available

Data

Data Not Available

Data Not Available

Data Not

AvailableData Not Available

##

CVBU Pune 10

578 551

3788

5102

4329

832

2111

4298

4827

3800

1280 1230 1097911

1354

825937 776

630 550

1181

475 472

3268

632687 594 538 510 488

11000

12000

13000

12000

11000

6729

3957

531

8716

6111

4954

41024943

513553581698

734835

503536 561

0

1000

2000

3000

4000

5000

6000

2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10

Kw

h / E

q. V

eh

icle

0

4000

8000

12000

Ashok Leyland

M & M

Volvo INDIA.

Volvo China.

Scannia

Volvo Brazil

TATA Motors JSR

TATA Motors CVBU Pune

6

CVBU Pune 11

Roadmap to achieve Benchmark / Global best :-Based on above results of National & International companies, TATA Motors CVBU

plant is Highly Energy Efficient Automobile company. As part of continual improvement we would further reinvestigate all our processes to achieve further cost reduction by reducing Energy consumptions at all levels.

To sustain the best achieved level. We are following robust process of assessment of performance vis a vis

comparative information / benchmark from different organisation & standards.

Our emphasis would be:-

1. To optimise the use of Resources while using appropriate and innovative method to reduce the energy consumption in all the areas of operation on the continuous basis through evaluation and improvement.

2. Use of Latest technologies wherever possible.3. Maximize the use of non-conventional Energy resources wherever possible.4. Under climate change initiatives, assessment & abatement measures are being

taken to reduce carbon foot print through resource conservation.

CVBU Pune 12

Tata Motors

Pune

CVBU(Commercial Vehicle

Business Unit)

PCBU(Passenger Car Business Unit)

Production- LCVs,MCVs & HCVs Production Passenger Cars

Compressor Installed Capacity27500CFM

Compressor Installed Capacity27500CFM

7

CVBU Pune 13

Compressed airManagement

Planning for Selection of

Compressor & Associated equipments

Planning of compressed air

pipeline in Compressor

house & Shop

Operation & Maintenance of the Compressor

installation

Installation of Compressor &

Associated equipments &

pipeline

CVBU Pune 14

TPM (Total Productive

Maintenance)SQDCM

5 - S

ISO 14001

TS 16949Poka Yoke

TBEM (Tata Business Excellence Model)

Six Sigma

Management toolsAdopted & Implemented

8

CVBU Pune 15

CVBU Pune 16

Spread of the TML CVBU - Compressed Air SystemInstalled Capacity of compressor -

27,500CFM

Centrifugal Compressor --

2*5500CFM

4*3000CFM

Screw Compressor --3*1500CFM

Compressed Air Peak Draw-15000CFM

Compressed Air Consumption in Kwh Avg.

40000Kwh/Day

Length of Header Pipe line -- 3.0 KM

Total Pipe length -- 19 KM.

9

CVBU Pune 17

CVBU Pune 18

B) Demand side Management

Plant level Leakage Test

Block wise leakage as & when required.

Machine Compressed Air Leakage Audit.

Special Type of Nozzles

New Technology Item -Intermediate controller

C) Procurement Guideline/Check-List for New Compressor.

A) Supply side Management

Compressor Performance Monitoring System

Optimization of Pressure & Operation of Compressors.

Intake Air Performance measures.

Water Recirculation system - Pump , Cooling Tower etc.

Compressor Efficiency Measurement

New Technology Item - EnergAir SX System.

10

CVBU Pune 19

CVBU Pune 20

Energy Saving by introduction of Intermediate Control System(IC Unit) for Compressed Air Network :-

Intermediate Control System:It has electronic controller Continuously monitors the downstream demand. Directs the I/C to increase or decrease flow accordingly to correct the deviation from set point. Peaks demands are met with stored energy instead of additional horse power. Air Pressure Boosters are also provided to meet high pressure demand on critical machines.

Benefits:- Operating pressure is 72PSI (5.06Kg/cm2) instead of 84PSI (5.91Kg/cm2) Constant Air pressure within 1PSI (0.07Kg/cm2) Annual Energy Saving in 14 Lakh KWh. Maintenance cost saving due to less pressure operation. Leakage reduction due to optimum pressure.

Control panel

Auto Bypass

Air OutAir In

Modulating Valves

Specific Compressed Air Energy Consumption in Electricity

( KWh/Eq.veh) I.e. Electricity used for producing one vehicle

79

.06

74

.39

76

.94

72

.11

69

.51

69

.15

66

.19

66

.11

66

.2779

.24

80

.98

83

.33

84

.70

83

.79

84

.70

84

.10

86

.82

25

50

75

100

125

Ap

r-0

2

Ma

y-0

2

Ju

n-0

2

Ju

l-0

2

Au

g-0

2

Sep

-02

Oct

-02

No

v-0

2

Dec

-02

Ja

n-0

3

Feb

-03

Ma

r-0

3

Ap

r-0

3

Ma

y-0

3

Ju

n-0

3

Ju

l-0

3

Au

g-0

3

Cu

mm

. S

pe

cif

ic e

ne

rgy

Co

ns

um

pti

on

(KW

H/E

q.v

eh

.)

Cummulative Specific Energy Consumption (KWh/Eq.veh)

Before installation of I/C system.

After installation of I/C system.

Annual Energy saving in Rs. 56 Lakh ;Annual Energy Saving in KWh 14Lakh ;

Annual CO2 Reduction in 1176 tCO2.Investment in Rs. 72 Lakh

11

CVBU Pune 21

A) SUPPLY SIDE MANAGEMENT

CVBU Pune 22

ENCON CASE STUDIES - 01

12

CVBU Pune 23

Energy Saving by Operating Centrifugal Air Compressors atbase load :-

Before: Earlier Reciprocating and Centrifugal air compressors were connected to the upstream of the Intermediate Controller Unit. In this set-up, each compressor was generating compressed air at 84 psi (5.91Kg/cm2) pressure to cater the final pressure requirement of 72 psi (5.06Kg/cm2) at the end-use point inside the Shops.

Before

CVBU Pune 24

After : The base load of CVBU plant is more than 5500 cfm, for which round the clock running one 3000 cfm centrifugal compressor was essential. The 3000 cfm centrifugal compressor has been now connected directly to the down stream of the Intermediate Controller Unit as shown in the following fig.. Pressure setting of the compressor was reduced from 84 psi to 72 psi, since the same is feeding to the compressed air network directly.

Energy Saving :- Rs 12.00 Lac per annum

After

Annual Energy saving in Rs. 12 Lakh ;Annual Energy Saving in KWh 2.67Lakh ;

Annual CO2 Reduction in 224 tCO2.Investment about Nil

Energy Saving by Operating Centrifugal Air Compressors atbase load :-

13

CVBU Pune 25

CVBU Pune 26


14

CVBU Pune 27

Energy Saving by Modification in Cooling Water recirculation System.:-

Before: Earlier, there was common water recirculation system for D-block compressors and E block.

Before

(Common water

recirculation

System)

CVBU Pune 28

Energy Saving by Modification in Cooling Water recirculation System.:-After: Separated water recirculation systems for D-block compressors and E block, with this system become flexible & optimized the water pumping operations. Studied the system and backward calculation done for water requirement, pipe line sizes and frictional losses.Benefits: 1) By separating systems & optimizing pumping saved power Rs.24.48 Lac per year. 2) Eliminated chances of cooling water contamination with oil carried with E- block water.

After ( with Two Independent system)

Annual Energy saving in Rs. 24.48 Lakh ;Annual Energy Saving in KWh 5.03Lakh ;

Annual CO2 Reduction in 423 tCO2.Investment in Rs. 3.69 Lakh

15

CVBU Pune 29

Before : Fan operated Cooling Tower After : Fanless Cooling Tower

Energy Saving by installation of Natural Draft

Fanless Cooling Tower at D-blk Compressor House:-

Before: Earlier, induced draft type conventional cooling tower, suction of air takes place with the help of electrical operated Fan.

After: Now, Cooling Tower water cooled by air using Natural Draft, Suction of air takes place with venturi effect created in the tower by using specially designed nozzles.



CVBU Pune 30

Energy Saving by Introduction of CORO COAT for Pump Casing & Impeller at D-blk Comp. House:-

Before: Earlier, over the period of pump operation, pump efficiency get reduced due to normal wear and tear of impeller and casing of pump. Due to this friction loss of pump increases & in turn energy is wasted.

After: By introduction of Coro Coating for Impeller & Casing of pump, the frictional losses of pump are reduced. Coro Coating is fluid glide coating & hydrophobic (i.e. it repels water) in nature. After Coro Coating the pump efficiency is increased by 8 to 10% with corresponding energy saving of 5%.



16

CVBU Pune 31

CVBU Pune 32

Comp.Performance Monitoring System covers Air Intake Filter Air inlet Intercooler , after cooler, Water inlet & outlet temp. Compressed Air outlet temperature Compressor Efficiency Specific Energy Consumption of Compressor

Compressor Performance Monitoring system :-

Results into1. Increased involvement of People.2. Increased Level of knowledge3. Predictive maintenance & enhanced pro-

actions.

4. Reliability & cost effectiveness.

17

CVBU Pune 33

CVBU Pune 34

Inlet

Temperature (0C)

Relative Air

Delivery (%)

Power Saved

(%)

10.0 102.0 + 1.4

15.5 100.0 Nil

21.1 98.1 - 1.3

26.6 96.3 - 2.5

32.2 94.1 - 4.0

37.7 92.8 - 5.0

43.3 91.2 - 5.8

Effect of Intake Air temperature on Power Consumption

For Every 40C rise in inlet air temperature results in a higher energy consumption by 1 % to achieve equivalent output.

Hence, cool air intake leads to a more efficient compression.

18

CVBU Pune 35

Centrifugal Compressor Air & Cooling Water Temperature Audit

2nd

Stage

3rd

Stage

1st

Stage

After

cooler

30.6C 47.6C140C 118.2C 43.2C 76.2C 35.8C

32.8C 32.8C 32.8C

40.2C 38.2C 35C

Inlet Water

Outlet Water

1st Stage

Inter

cooler

2nd

Stage

Inter

coolerAir In Air Out

CVBU Pune 36

Performance of Intercooler & After cooler Monitoring By Stage wise Temperature Monitoring

Air inlet temperature IInd

Stage0C

0C

Air inlet temperature Ist

Stage

Air outlet temperature

IInd

Stage0C

Air outlet temperature

Ist

Stage0C

19

CVBU Pune 37


CVBU Pune 38

Introduction of EnergAir SX System for Reciprocating Compressor

Before ENCON :-Compressor ON-OFF operation was manual.Compressor LOAD / UNLOAD operation pressure band = 4PSI

After Introduction EnergyAir SX:-Automatic ON, OFF, LOAD & Unload operation of Recip. compressorAuto sequencing of reciprocating compressor . Load/Unload operation pressure band changed from +/-4PSI to +/- 2PSI Eliminated compressor manual starting delay .

Compressor Status Screen on Computer,

which shows, Load (Green Lamp)

OFF( RED) , Running ( Yellow) &

Comp. Ready for Operation ( Blue)



20

CVBU Pune 39

35 Years Old Reciprocating Compressors replaced

with new Energy efficient Centrifugal

& Screw Compressors

CVBU Pune 40

21

CVBU Pune 41

Baffle type Moisture separator

No Provision for internal

Online cleaning

Before Baffle type Moisture separator :- Pressure drop across separator is more than 3PSI Measured Moisture drain is approx. 10 Liters /Hour. Compressed air temperature after moisture separator is more. No feasibility for Internal cleaning.

After Introduction High Efficient Centrifugal Moisture Separator:- Delta P across Moisture separator is low 1 to 1.5PSI Measured Moisture drain-26 liters/hours. Compressor discharge air temperature is reduced by 1Deg.C due to whirling action. Load on Dryer is reduced results in Energy saving & Easy for maintenance.

Introduction of High Efficient Centrifugal Moisture Separator

Provision for internal

cleaning

High Efficient Centrifugal Moisture

Separator

CVBU Pune 42

Energy Saving by Transvector Nozzle for Cleaning application by using Compressed Air:-

Before: Earlier, Compressed air was used for cleaning the jobs after machining by using open pipes or conventional nozzles.

After: Now Transvector Nozzles are installed in place of open pipe or conventional nozzles used for cleaning the jobs after machining. It reduces the compressed Air Consumption by 30-60% & reduces the noise level by 8-10db.

Before Conventional Nozzle

After Transvector Nozzle

Before Conventional Nozzle

After Transvector Nozzle



22

CVBU Pune 43

Energy Saving by Installing of Master Cut-off Circuit in Compressed Air Line:-

Before: Earlier, During Non-working period like lunch time, Tea break, shift change & C shift period minimum comp. air leakages were wasted.

After: Now Master cut-off circuit with Timer is installed in Compressed Air line which cuts off air supply to fixture, assembly line etc Eliminating Air leakage loss effect during the non working period Lunch break, Tea break, shift change. & it saves Air

leakage loss. At Winger BIW & TCF line, E-block (50Nos. Installed)



CVBU Pune 44

Actions taken to reduce the compressed air leakages --

Training programme for the the Employee.

Blockwise compressed air leakage test to check the unproductive draw of compressed air (Leakages) once in a three months.

Physical shop leakage audit & display a Tag on leakage points & feedback to concern owner.

Displayed banners indicating cost of compressed air leakage.

Periodic audit of Main Header line & checking any leakages.

Identification & Isolation of Non working areas.

23

CVBU Pune 45

A-block

C-block

J Block

Compressed air Leakage test-Compressed air network

K-block

D-blk Comp House

D-block

H-block

B-block

E-16 /17

E-block

CVBU Pune 46

Compressed Air Leakage -Performance Monitoring Format

24

CVBU Pune 47

Auditing of leakage points all Blocks,

Mark leakage point by -Air leakage tag or paint marked

Mail the soft copy of Leakage points to all Factory Managers, Cx Owners

Get feed back from the respective maintenance after correction

Re-audit the points & detect new Leakage points generated

Conduct Air leakage test to see the improvement.

ACTION TAKEN TO REDUCE AIR LEAKAGES

CVBU Pune 48

Air leakage detectorAir Leak detector used to detect leak points in pipe lines & joints

25

CVBU Pune 49

CVBU Pune 50

26

CVBU Pune 51

Compressed Air leakage points identified during Audit 2010-1146

0

2234

2685

1013

1637

0

500

1000

1500

2000

2500

3000

Apr

-10

May

-10

Jun-

10

Jul-1

0

Aug

-10

Sep

-10

Oct

-10

Nov

-10

Dec

-10

Jan-

11

Feb

-11

Mar

-11

Month

Cu

mu

litiv

e L

eaka

ge

po

ints

CVBU Pune 52

27

CVBU Pune 53

ZERO LEAK AIR Connectors

Swivel connectors for CL 10 Hoses

Swivel type quick release coupling for CL 10 & coiled Hoses

Swivel connectors for coiled Hoses

CVBU Pune 54

THE AIR YOU BREATHE IS FREE.THE AIR YOU USE IS NOT !

USE AIR WISELY

PREVENTLEAKAGES

28

CVBU Pune 55

CVBU Pune 56

Arise , Awake & Realise

If you realise it here & now , Yours is the infinite Gain

If you do not make an attempt to do so

Equally great is your Loss.

29

CVBU Pune 57

.... a journey towards excellence

THANK YOU !

CVBU Pune 58


30

CVBU Pune 59

The location of air compressors and the quality of air drawn by the compressors will have a significant influence on the amount of energy consumed.

Compressor performance as a breathing machine improves with cool, clean, dry air at intake.

Importance of Location of Air Compressor & the Quality of Air

Importance of Air Intake Filter In Compressor

Pressure Drop

Across air filter

(mmWC)

Increase in Power

Consumption (%)

0 0

200 1.6

400 3.2

600 4.7

800 7.0

CVBU Pune 60

Air Intake Filter Performance Monitoring By Manometer

Pressure drop across

Air intake filtermm WC

Pressure Drop Across the Air Intake Filter are measured & Monitored regularly.

Servicing of Air Intake filter is done after reaching the Pressure drop @ 150mm WC.

31

CVBU Pune 61

Air Intake Filter Performance Monitoring By Manometer

Do not Wait for Preventive Maint.

Schedule

Regular

Monitoring helps to predict Health of Air Filter in turn we can save Energy.

CVBU Pune 62

Reciprocating Compressor Air & Cooling Water Temperature Audit

HP

Stage

LP

Stage

31.8C 32.5C90.4C 79C 29.8C

28.6C

28.6C32.4C

31.5CInlet Water

Outlet Water

Inter -

cooler

After-

cooler

Air In

32.2C 32.2C

34.2C

Air Out

28.6C

32

CVBU Pune 63


CVBU Pune 64

Before ENCON

Before ENCON :- Cleaning of Inter-cooler / after-cooler was done whenever 2nd stage inlet & outlet temperature was increased , results in more power is required to generate compressed air

Time required for Maintenance of Intercooler & after-cooler is 18 man-days.

Sometimes compressor was not available for schedule maintenance in turn run the compressor with high temperature results in increase in power consumption.

C.C.H.P.

STAGEL.P.

STAGE

INTERCOOLER

AFTERCOOLER

Pr.Line Cold Water

Return Line Hot Water

Schematic of Recip. Compressor water recirculation system

Introduction of Back flushing System For Reciprocating Compressor

33

CVBU Pune 65

After ModificationAfter Introduction Back Flushing System:-Inter-cooler & after-cooler of compressor are cleaned with out waiting for schedule maintenance . It results into3C drop in 2nd stage air temp.Approx. 0.6% reduction in energy consumption.Comp.efficiency improved by 1%Improved quality of air.Cost reduction in spares & man days.Fatigue less operationSaving in Energy consumption by 8424Kwh/annum/Compressor

Backflushing provision for ZR 250 Screw

compressors

CVBU Pune 66

Sr.

N

Item Description Before Back

Flushing Modification

After Back Flushing

Modification

1 Compressed Air Temp. after

Inter-cooler

Avg. 41 oC Avg. 37.8 oC

2 Compressed Air Temp. after

After-cooler

Avg. 36 oC Avg. 34.5 oC

3 Inter & After Cooler Maint. time

reduction

18 Mandays 2 Hrs.

4 Compressor Reliability on

account of I/C & A/C

100 %

5 Compressed Air Quality Improved

6 Energy Consumption

reduction

8426

Kwh/Comp/annum

Total Saving in Energy Consumption / Compressor =

8424 Kwh/annum/comp.

34

CVBU Pune 67

IMPROVED

QUALITY OF AIR

1. COST REDUCTION IN SPARES & MANDAYS

(162 MANDAYS / YEAR)2 FATIGUELESS

OPERATION3 DECREASE IN FREQUENCYOF OVERHAULING

ADVANTAGES OF BACKFLUSHING

3oC. Drop in

2nd Stage Air

Inlet Temp.

Compressor

Efficiency

Improved By

1%

Total Saving in Energy Consumption / Compressor =8424 Kwh/annum/comp.

Approx. 0.6%.

Reduction in Energy

Consumption.

mr k g ghude,. tata motors

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