By
TATA Motors Ltd. CVBU, Pimpri, Pune
CVBU Pune
1
Facilitator
Mr. M B Kulkarni
(Sr. General Manager – C,C,E & CQH)
Energy Manager
TATA Motors Ltd. CVBU, PUNE
EnCon in Compressed Air System
Presentation by
 Kishor G Ghude
Assistant General Manager (CPED & Environment)
CVBU Pune
2
1
Company Profile
Spread of Plant
Production Level
- 568 acres.
- 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
3
TATA Motors's Manufacturing Process
- Axle Assembly Painting
-Gear Box Assembly-
Finished product for
Finished product for
Vehicle Assy.
Vehicle Assy.
Vehicle Assembly Line
Vehicle
Assembly
- Engine Assembly-
- Cowl Assembly-
- Chassis Assembly-
Finished product for
Finished product for
Finished product for
Vehicle Assy.
Vehicle Assy.
Vehicle Assy.
CVBU Pune
4
2
ENERGY POLICY
Safe and energy efficient operations
To improve the life of people by…
Real Time Power Factor Controller
Pond at Shelu Village
To minimise the adverse
impact
on Environment
FUEL EFFICIENCY
IMPROVEMENT
ENGINEERING
SR. NO
Thumbnail
Model
%IMPROVEMENT
SR. NO
Thumbnail
Model
%IMPROVEMENT
5
407 SFC
EX
16.6%
6
207 DI
22.0%
7
SPACIO
14.70%
8
2515 LPT
(697 TCIC)
15.30%
12.3%
1
1613 SE/ LPT
9.8%
CUM - 22 %
.
19.2%
1510 LP
2
8.1%
CUM - 27.3%
3
709 LP/ LPT
EX
4
709 SFC
EX
19.8%
12.0%
Energy Efficient & Eco-friendly Technology
T ar g et fo r Y ear 2004-05 W ind P o w er - 500 Lacs W ind U nits
446
464
474
404
Mar-04
382
Feb-04
251
Jan-04
106
67
158
Oct-03
36
Sep-03
18
Aug-03
0
Jul-03
Apr-03
Jun-03
2002-03
0
2001-02
Dec-03
293
Nov-03
486
350
May-03
Cummulative Wind Units in Lacs
700
Comparison with national and international
Automobile Players.
CVBU Pune
5
TATA Motors, CVBU Pune: ENCON STRATEGY
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.

AtShare
saturated
performance
level introduce
break thro’ improvement
the
best practices
& performances
with
by adopting suitable modern technology through adequate
vendors , suppliers , partners & other industries
investment .
& assist them to reduce their ENERGY
INTENSITY …..=> ENERGY KAIZEN
CVBU Pune
6
3
SUSTAINABILITY
Trend of Reduction in Specific Energy Consumption
- Electricity -
Sp. Energy Cons.(Kwh/Eq.Veh)
600
561
559
536
531
500
5.01%
Reduction over the
year 2006-07
400
06-07
07-08
08-09
09-10
CVBU Pune
7
SUSTAINABILITY
-Trend of Reduction in Specific Energy Consumption
Fuel -
(LDO + FO + Propane)
SpFuel Consum. (Mkcal/Eq.Veh.)
0.5
0.3897
0.3712
0.3500
0.4
0.3091
20.68%
Reduction over the
year 2006-07
0.3
06-07
07-08
08-09
CVBU Pune
09-10
8
4
Sr.
Name of
No
Automobile Player
1
TATA Motors Pune
(Excluding Foundry)
2
Year
Kwh/Eq.Veh.
% reduction
over 2000Kwh/Eq.Veh.
TATA Motors Jsr
TATA Motors Pant
Nagar
5
Mahindra & Mahindra
, Kandiwali Plant
(Maharashtra)
6
Mahindra & Mahindra
, Medak Plant (AP)
Mahindra & Mahindra
, Nashik Plant
(Maharashtra)
General Motors
(India) Pvt. Ltd.
(Gujarat)
7
8
20062007
20072008
20082009
734
698
580
552.8
513.1
502.7
536.3#
560.9
531.3
12.1%
16.3%
30.5%
33.8%
38.5%
39.8%
35.7%
32.8%
36.3%
1181
937
776
630.0
550.0
475.0
472.0
578.0
551.0
---
20.7%
34.3%
46.7%
53.4%
59.8%
60.0%
51.1%
53.3%
905.2
755.9
664.8
657.1
647.0
613.3
625.2
648.5
35.7%
43.4%
44.1%
44.9%
47.8%
46.8%
44.8%
---
---
---
---
---
---
---
439.0
290.0
---
---
---
---
---
---
---
---
33.9%
832
687
632
594
538
510
488
---
17%
24%
28.6%
35.3%
38.7%
41.3%
524
511
500
448
395
344
---
2.5%
4.6%
14.5%
24.6%
346
316
290
Data Not Available
% reduction
Kwh/Car
---
8.7%
16.2%
754
701
534
29.2%
Data Not Available
% reduction
Kwh/Eq.Veh.
% reduction
Data Not
Available
4650
---
7.0%
1310
1280
1230
1097
911
825
37.0%
34.4%
http://www.beeindia.nic.in/ecaward.php
Data Not
Available
Data Not
Available
http://www.beeindia.nic.in/ecaward.php
Data Not
Available
Data Not
Available
http://www.beeindia.nic.in/ecaward.php
Data Not Available
----
2.3%
6.1%
16.3%
30.5%
4381
4119
4038
3483
3474
http://www.beeindia.nic.in/ecaward.php
Data Not
Available
http://www.beeindia.nic.in/ecaward.php
Data Not Available
% reduction
5.8%
11.4%
13.2%
25.1%
25.3%
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
% reduction
-----
23%
43%
29.9%
43.2%
52.9%
54.6%
www.gm.com
Data Not Available
Data Not Data Not
58.0% Available Available
2094
Data Not Available
% reduction
www.bmwgroup.com
3663
Kwh/Eq.Veh.
Tata Daewoo
Commercial Vehicle,
Korea
Data Not
Available
Data Not Available
Kwh/Eq.Veh.
BMW
#. Increased due to addition of New
shops/Activity like J-11/12 New Paint,
Xenon Assy, Panel Van shop, Dicor
Engine Assy shop.
Data Not Available
% reduction
Volvo Truck
12 Corporation Banglore,
India
20092010
23.0%
Kwh/Eq.Veh.
13
Referenece
20052006
---
Kwh/Eq.Veh.
General Motors
11
Data
20042005
14.6%
Kwh/Eq.Veh.
10
20032004
---
% reduction
Ashok Leyland ,
Hosur
9
20022003
1175.0 1003.0
% reduction
over 200708
Kwh/Eq.Veh.
Sp. Energy Consumption
4
20012002
835
Data Not
Available
% reduction
over 200001
Kwh/Eq.
Veh.
% reduction
over 200708
Kwh/Veh.
TATA Motors Car
Plant Chikhali
3
20002001
-----
www.volvo.com
Data Not
Available
CVBU Pune
6000
13000
Scannia
12000
12000
5102
11000
5000
12000
11000
4827
Volvo Brazil
Kwh / Eq. Vehicle
4329
Volvo China.
4298
8716
4000
3000
9
3800
3788
8000
Volvo INDIA.
3268
6729
6111
Ashok Leyland
4954
4943 2111
2000
1354
1097
1181
937
1000
M&M
832
835
776
687
632
734
698
594
581
2001-02
2002-03
2003-04
911
630
538
553
0
2000-01
TATA Motors JSR
4000
3957
1230
1280
4102
2004-05
825
578
550
510
475
488
513 503
2005-06
472
536
561
551
531
0
2006-07
2007-08
2008-09
2009-10
TATA Motors CVBU Pune
CVBU Pune
10
5
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.
1.
2.
3.
4.
We are following robust process of assessment of performance vis a vis
comparative information / benchmark from different organisation & standards.
Our emphasis would be: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.
Use of Latest technologies wherever possible.
Maximize the use of non-conventional Energy resources wherever possible.
Under climate change initiatives, assessment & abatement measures are being
taken to reduce carbon foot print through resource conservation.
CVBU Pune
CVBU
(Commercial Vehicle
Business Unit)
Production- LCVs,MCVs & HCVs
Compressor Installed Capacity
27500CFM
Tata
Motors
Pune
11
PCBU
(Passenger Car
Business Unit)
Production – Passenger Cars
Compressor Installed Capacity
27500CFM
CVBU Pune
12
6
Planning for
Selection of
Compressor &
Associated
equipments
Operation &
Maintenance of
the Compressor
installation
Compressed air
Management
Planning of
compressed air
pipeline in
Compressor
house & Shop
Installation of
Compressor &
Associated
equipments &
pipeline
CVBU Pune
SQDCM
5-S
TPM (Total
Productive
Maintenance)
Management tools
Adopted & Implemented
13
ISO 14001
Six Sigma
TS 16949
Poka Yoke
TBEM (Tata Business
Excellence Model)
CVBU Pune
14
7
CVBU Pune
15
Spread of the TML CVBU - Compressed Air System
Installed Capacity of compressor 
27,500CFM
Centrifugal Compressor
--
2*5500CFM
4*3000CFM
 Screw Compressor -3*1500CFM
 Compressed Air Peak Draw15000CFM
 Compressed Air Consumption in Kwh
Avg.
40000Kwh/Day
 Length of Header Pipe line -- 3.0 KM
 Total Pipe length -19 KM.
CVBU Pune
16
8
CVBU Pune
17
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.
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.
CVBU Pune
18
9
CVBU Pune
19
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.





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.
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:-
Annual EnergyAir Out
saving in Rs. 56 Lakh ;
Annual Energy
Saving in KWh 14Lakh ;
Control panel
Annual CO2 Reduction in 1176 tCO2.
Modulating Valves
Auto Bypass
Investment
in Rs. 72 Lakh
Specific Compressed Air Energy Consumption in Electricity
( KWh/Eq.veh) I.e. Electricity used for producing one vehicle
69.15
66.19
66.11
66.27
May-03
Jun-03
Jul-03
Aug-03
72.11
75
69.51
Mar-03
79.06
76.94
Jan-03
74.39
Dec-02
Feb-03
79.24
Nov-02
83.33
80.98
84.70
(KWh/Eq.veh)
After installation of I/C system.
<-----(Intermediate Control System)----->
Oct-02
83.79
Sep-02
84.70
Jul-02
Jun-02
Aug-02
86.82
84.10
Apr-02
100
Before installation of I/C system.
<----- (Intermediate Control System) ---->
May-02
Cumm. Specific energy Consumption
(KWH/Eq.veh.)
Cummulative Specific Energy Consumption
125
Apr-03
Air In
50
25
CVBU Pune
20
10
A) SUPPLY SIDE MANAGEMENT
CVBU Pune
21
CVBU Pune
22
ENCON CASE STUDIES - 01
11
Energy Saving by Operating Centrifugal Air Compressors at
base 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
23
Energy Saving by Operating Centrifugal Air Compressors at
base load :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
CVBU Pune
24
12
CVBU Pune
25
CVBU Pune
26
ENCON CASE STUDIES - 01
13
Energy Saving by Modification in Cooling Water
recirculation System.:Before: Earlier, there was common water recirculation system for Dblock compressors and E block.
Before
(Common water
recirculation
System)
CVBU Pune
27
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
Annual Energy saving
Independent
system)Annual Energy Saving
in Rs. 24.48 Lakh ;
in KWh 5.03Lakh ;
Annual CO2 Reduction in 423 tCO2.
Investment in Rs. 3.69 Lakh
CVBU Pune
28
14
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.
Before : Fan operated Cooling Tower
After : Fanless Cooling Tower
Annual Energy saving in Rs. 2.64 Lakh ;
Annual Energy Saving in KWh 0.587Lakh ;
Annual CO2 Reduction in 70 tCO2.
Investment in Rs. 2.7 Lakh
CVBU Pune
29
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%.
Annual Energy saving in Rs. 0.58 Lakh ;
Annual Energy Saving in KWh 0.105Lakh ;
Annual CO2 Reduction in 9 tCO2.
Investment in Rs. 0.46 Lakh
CVBU Pune
30
15
CVBU Pune
31
Compressor Performance Monitoring system :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
Results into…
1. Increased involvement of People.
2. Increased Level of knowledge
3. Predictive maintenance & enhanced proactions.
4. Reliability & cost effectiveness.
CVBU Pune
32
16
CVBU Pune
33
Effect of Intake Air temperature on Power Consumption
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
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.
CVBU Pune
34
17
Centrifugal Compressor Air & Cooling Water Temperature Audit
140ºC
30.6ºC
1st
Stage
47.6ºC
118.2ºC
1st Stage
Inter
cooler
2nd
Stage
43.2ºC
76.2ºC
2nd
Stage
Inter
cooler
3rd
Stage
35.8ºC
After
cooler
Air Out
Air In
32.8ºC
32.8ºC
32.8ºC
Inlet Water
40.2ºC
38.2ºC
35ºC
Outlet Water
CVBU Pune
35
Performance of Intercooler & After cooler Monitoring By…
Stage wise Temperature Monitoring
st
Air inlet temperature I
Stage
Air outlet temperature
st
I Stage
nd
Air inlet temperature II
Stage
Air outlet temperature
nd
II Stage
CVBU Pune
0
C
0
C
0
C
0
C
36
18
ENCON CASE STUDIES - 01
CVBU Pune
37
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. compressor
Auto sequencing of reciprocating compressor .
 Load/Unload operation pressure band changed from +/-4PSI to +/- 2PSI
 Eliminated compressor manual starting delay .
Annual Energy saving
in Status
Rs. 8.42 Lakh ;
Compressor
Screen on Computer,
which
Annual Energy Saving
inshows,
KWh 1.53Lakh ;
Load (Green Lamp)
OFF( RED)in
,
Annual CO2 Reduction
128 tCO2.
Running ( Yellow) &
Comp.
Ready
for
Investment in
Rs.
9.09
Lakh
Operation ( Blue)
CVBU Pune
38
19
35 Years Old Reciprocating
Compressors replaced
with new Energy efficient
Centrifugal
& Screw Compressors
CVBU Pune
39
CVBU Pune
40
20
Introduction of High Efficient Centrifugal Moisture Separator
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.
Baffle type
Moisture separator
No Provision
for internal
Online
cleaning
High Efficient
Centrifugal Moisture
Separator
Provision
for internal
cleaning
CVBU Pune
41
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.
After
Before
Before
Conventional Nozzle Transvector Nozzle Conventional Nozzle
After
Transvector Nozzle
Annual Energy saving in Rs. 2.32 Lakh ;
Annual Energy Saving in KWh 0.58Lakh ;
Annual CO2 Reduction in 49 tCO2.
Investment in Rs. 0.19 Lakh
CVBU Pune
42
21
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)
Annual Energy saving in Rs. 3.0 Lakh ;
Annual Energy Saving in KWh 0.55Lakh ;
Annual CO2 Reduction in 46 tCO2.
Investment in Rs. 5.0 Lakh
CVBU Pune
43
Actions taken to reduce the compressed air
leakages -• 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.
•Identification & Isolation of Non working areas.
• Periodic audit of Main Header line & checking any leakages.
• Displayed banners indicating cost of compressed air leakage.
Training programme for the the Employee.
CVBU Pune
44
22
Compressed air Leakage testCompressed air network
Ablock
Bblock
C-block
H-block
D-block
J Block
E-16
/17
K-block
Eblock
D-blk Comp
House
CVBU Pune
45
CVBU Pune
46
Compressed Air Leakage Performance Monitoring Format
23
ACTION TAKEN TO REDUCE AIR LEAKAGES
•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.
CVBU Pune
47
Air Leak detector used
to detect
leak points in pipe lines & joints
Air leakage
detector
CVBU Pune
48
24
CVBU Pune
49
CVBU Pune
50
25
Sep-10
Month
Mar-11
Feb-11
Jan-11
Dec-10
Nov-10
Oct-10
2234
2685
3000
Aug-10
1637
2500
Jul-10
1013
2000
Jun-10
460
1500
May-10
Apr-10
Cumulitive Leakage points
Compressed Air leakage points identified during Audit 2010-11
1000
500
0
CVBU Pune
51
CVBU Pune
52
26
ZERO LEAK AIR Connectors
Swivel connectors for CL 10 Hoses
Swivel connectors for coiled Hoses
Swivel type quick release coupling for CL 10 & coiled Hoses
CVBU Pune
53
THE AIR YOU BREATHE IS FREE.
THE AIR YOU USE IS NOT !
PREVENT
LEAKAGES
USE AIR WISELY
CVBU Pune
54
27
CVBU Pune
55
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.
CVBU Pune
56
28
..….. a journey towards excellence
THANK YOU !
CVBU Pune
57
CVBU Pune
58
ENCON CASE STUDIES - 01
29
Importance of Location of Air Compressor & the Quality of Air
 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 Air Intake Filter In Compressor
Pressure Drop
Across air filter
(mmWC)
Increase in Power
Consumption (%)
0
200
400
600
800
0
1.6
3.2
4.7
7.0
CVBU Pune
59
Air Intake Filter Performance
Monitoring By… Manometer
Pressure drop across
mm WC
Air intake filter
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.
CVBU Pune
60
30
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
61
Reciprocating Compressor Air & Cooling Water Temperature Audit
32.2ºC
32.2ºC
32.5ºC
90.4ºC
31.8ºC
Inter cooler
LP
Stage
79ºC
29.8ºC
Aftercooler
HP
Stage
Air Out
Air In
28.6ºC
32.4ºC
Inlet Water
28.6ºC
28.6ºC
31.5ºC
34.2ºC
Outlet Water
CVBU Pune
62
31
ENCON CASE STUDIES - 01
CVBU Pune
63
Introduction
of Back
flushing System For Reciprocating
Before
ENCON
Compressor
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.
INTERCOOLER
L.P.
STAGE
C.C.
H.P.
STAGE
Return Line Hot Water
Pr.Line Cold Water
Schematic of
Recip. Compressor
water recirculation
system
AFTERCOOLER
CVBU Pune
64
32
After Introduction
After
ModificationBack Flushing System:-
•Inter-cooler & after-cooler of compressor are cleaned with out waiting for
schedule maintenance .
• It results into…
3ºC 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 operation
Saving in Energy consumption by 8424Kwh/annum/Compressor
Backflushing provision
for ZR 250 Screw
compressors
CVBU Pune
65
Sr. Item Description
N
Before Back
After Back Flushing
Flushing Modification 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.
CVBU Pune
66
33
3oC. Drop in
2nd Stage Air
Inlet Temp.
Approx. 0.6%.
Reduction in Energy
Consumption.
Compressor
Efficiency
Improved By
1%
ADVANTAGES OF BACKFLUSHING
1. COST REDUCTION IN
SPARES & MANDAYS
(162 MANDAYS / YEAR)
2 FATIGUELESS
OPERATION
3 DECREASE IN
FREQUENCY
OF OVERHAULING
IMPROVED
QUALITY OF AIR
Total Saving in Energy
Consumption / Compressor
=8424 Kwh/annum/comp.
CVBU Pune
67
34