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18th National Award for Excellence in Energy Management 2017
Hadapsar, Pune
30-Aug-17 Kirloskar Pneumatic Co. Ltd. 1
KIRLOSKAR PNEUMATIC CO. LIMITEDA Kirloskar Group Company
Outline
30-Aug-17 Kirloskar Pneumatic Co. Ltd. 2
Company Profile
Specific Energy Consumption & Benchmarking
ENCON Projects Summary
Innovation in ENCON Projects
Carbon Footprints Reduction Projects
Utilization of Waste Materials
Environment Projects
Renewable Energy Initiatives
Green Initiative
ENCON Management Structure
Energy Monitoring & Reporting
Employee Engagement in ENCON & CSR
Recognition for ENCON Efforts
Future ENCON Projects
Rakesh A ParmarCorporate Energy
Manager
Parag D BhusariManager HT Shop
Presentation Team
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Company Profile
Manufacturing Plant
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Products & Application
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Air Compressor Division CentrifugalReciprocatingRotary ScrewOil Free Screw
Transmission Division Locomotive TransmissionIndustrial Gear BoxesHydraulic Marine
Traction Gears and Pinions
Products & Application
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ACR Equipments & VACRefrigeration CompressorsRECIP Bare / Packages
Screw PackagesKirloskar - Ebara Vapor Absorption Chillers
PGS & ProjectsMarine HVACR Systems / Solutions Refrigeration Systems Gas Compression
Packages
Integrated Manufacturing Operations
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Design & Manufacturing of High Quality products
Project Design, Fabrication, Packaging & Testing Facility
Ability To Manufacture Wide Product Range
Integrated Manufacturing Operations
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P
D
C
A
MenMachineMethodMaterialSOPResources
Input Output
Process
CUSTOMER
QA PE ME HR PPC R&E Mktg.
Management
Mission Vision
Mission Vision
ValuesValues
LRP / AOPLRP / AOP
Strategy / PolicyStrategy / Policy
SHEQPC
HD
Competition Environment Society
I.T. Support
Waste EliminationWaste Elimination
•Waste Elimination Approach
Workplace PracticesWorkplace Practices
•Best Practices
Standard PracticesStandard Practices
•Standardized Work
Continual ImprovementContinual Improvement
•Kaizen, VSM• Problem Solving
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KPCL Mission, Vision & Values
30-Aug-17 9Kirloskar Pneumatic Co. Ltd.30-Aug-17 10
ISO 9001-2008
Company certification:
OHSAS 18001-2007ISO 14001-2004
Kirloskar Pneumatic Co. Ltd
Kirloskar Pneumatic Co. Ltd.
30-Aug-17 11
Company certification:
KPCL is Certified to Integrated Management System (IMS) by TUV
NORD
IMS isIntegration of
ISO 9001-2008, ISO 14001-2004 &
OHSAS 18001-2007
Kirloskar Pneumatic Co. Ltd.
Energy Policy
30-Aug-17 Kirloskar Pneumatic Co. Ltd. 12
Managing Director Shri. Aditya Kowshiksigned Energy Policy – indicates strongcommitment from top managementtowards ENCON
Policy reviewed 4 times from firstpublished in 2005 in view of energyperformance scenario
KPI Strategy Deployment
Plant Level Goals
Dept. Level Goals
ENCON Key Projects Individual Goals
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SEC & Benchmarking
Specific Energy Consumption
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Air Compressor Division
Increase in R&E TestingTrials, Testing & Customer InspectionSubstantial Increase in Third Party Inspection
0
1000
2000
3000
4000
14-15 15-16 16-17 17-18Actual 2915 2828 3128Target 2700 2700 2700 2700
kWh / No. of UnitsBetter
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Specific Energy ConsumptionTransmission Division
Increase in R&E TestingDifferent product mix - High Speed & IGB Addition of New Machines
010002000300040005000
14-15 15-16 16-17 17-18Actual 4287 4294 4293Target 4080 4080 4080 4080
kWh / MT Better
Specific Energy Consumption
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Foundry
Better
0
200
400
600
800
14-15 15-16 16-17 17-18Actual 635 628 640Target 638 630 620 620
kWh / MT
Increase in new design productsFrequent power failure from MSEDCL leads to molten metal holding
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Specific Energy Consumption
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16-17 17-18Actual 42 31Target 40
01020304050
Shot Blast ing M/ckWh / MT
16-17 17-18Actual 1050 1087Target 998
950
1000
1050
1100
Ferrous ShopkWh / MT
16-17 17-18Actual 2763 3347Target 2625
01000200030004000
Non-Ferrous ShopkWh / MT
16-17 17-18Actual 71 85Target 67
020406080
100
Air Compressor - FoundrykWh / MT
16-17 17-18Actual 1.36 1.28Target 1.32
1.241.261.281.301.321.341.361.38
ACD OperationsLac kWh / Year New target developed in
year 2016-17
Focus on process benchmarking
Benchmarking For Foundry Operation
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0
320
640
KPCL Foundry Target NationalBenchmark
InternationalBenchmark
630 620 610 560kWh / MT
Source for National & International Benchmark: UNIDO Global Benchmarking Tool 2010
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Energy Projects Summary
ENCON Summary – 2014 to 2017
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ENCON Projects Summary
Energy Saving: 1.03 Million
kWh
Cost Saving: Rs. 14.65 Mn
Investment: Rs. 9.59 Mn
Payback Period:
8 Months
Investment No. of Projects
Energy Saving in Million kWh
Cost Saving in Rs. Mn
Investment in Rs. Mn
Zero Fund 33 0.66 5.41 0.00Low Fund 16 0.27 2.42 0.52High Fund 14 0.10 6.82 9.07
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Zero Fund Projects
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33 Projects
5 Programs
5.41 Rs. Mn
Immediate
0.66 kWh Mn
Low Fund ProjectsInvestment < 2.0 Lac
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16 Projects
5 Programs
2.42 Rs. Mn
2.6 Months
0.27 kWh Mn
High Fund ProjectsInvestment > 2.0 Lac
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14 Projects
5 Programs
6.82 Rs. Mn
16.0 Months
0.10 kWh Mn
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Innovation in ENCON Projects
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Fixture modification for heat treatment process
Net weight loading - 78%Net weight loading - 40%
Energy Saving
• 166650 kWh
Cost Saving
• 14.53 Rs. Lac
Investment
• 0.20 Rs. Lac
Payback
• Immediate
Productivity ImprovedCarbon Emission Reduction 137 MT / Annum
30-Aug-17 Kirloskar Pneumatic Co. Ltd., Pune 25
Innovation In ENCON
Job loading in 2 layer Capacity utilization
improved Energy consumption
reduced up to 0.85 kWh / kg
3Ton furnace capacityEnergy loss due to low capacity utilizationComplex fixtureEnergy Consumption 1.4 kWh/kg
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Carbon Foot Print Reduction Projects
50 % Energy Conservation AchievedCarbon Emission Reduction 24 MT / Annum
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Energy Efficient Lighting Energy Efficient LED Lighting For • Office – 72 Watt Replaced By 36 Watt• Conference Hall – 36 Watt Replaced By 15 Watt.
Energy Efficient LED Lighting For• Shop Lighting• 250 Watt MH Lamp Replaced By 150 watt
Energy Efficient LED Lighting For• Street Lighting• 125 Watt MV Replaced By 40 Watt
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Utilization of Waste
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Utilization Of Waste
Aluminum Burr Recycling
7 MT / year aluminum recycled
AfterBefore
30-Aug-17 Kirloskar Pneumatic Co. Ltd., Pune 29
Oil recovery from metal chips generated during gear cutting
73 % oil recovered from metal chips generated during gear cuttingNatural resources conservation
34 kL
9 kL
25 kL
Purchased
Recycled
Requirement
30-Aug-17 Kirloskar Pneumatic Co. Ltd., Pune 30
Utilization Of Waste
30-Aug-17 Kirloskar Pneumatic Co. Ltd., Pune 31
Reduction Of Energy Wastage By Improving Machine Availability (Maintenance Performance)
Air Compressor Division – Critical Machine Performance
Transmission Division – Critical Machine Performance
0
500
14-15 15-16 16-17 17-18
MTBF
Actual Target
0
10
14-15 15-16 16-17 17-18
MTTR
Actual Target
0
500
14-15 15-16 16-17 17-18
MTBF
Actual Target
0
10
14-15 15-16 16-17 17-18
MTTR
Actual Target
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Environment Projects
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Environment ProjectWater Conservation By using dry type paint booth
BeforeBefore AfterAfter
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Wet paint boothEnvironment concerns i.e. water pollutionEnergy consumption – 91823 kWh/yearWater Consumption – 142 Kl / Year
Dry type paint boothNo Water pollutionEnergy consumption – 60262 kWh / year
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Dry type Paint Booth
Kirloskar Pneumatic Co. Ltd., Pune
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Dry type Paint Booth
Kirloskar Pneumatic Co. Ltd., Pune 30-Aug-17 Kirloskar Pneumatic Co. Ltd. 36
Renewable Energy Initiatives
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30-Aug-17 Kirloskar Pneumatic Co. Ltd., Pune 37
Solar Power Plant
Connected load : Fan, lights, refrigerator of OHC and Society office
Energy Saving 1057 kWh/year
91 9077
6186 75
11079
21
114130 122
0 0
38
8860 69
44 32
116
15 1538
0
50
100
150
Solar MSEDCL
Cost Saving Rs. 9216/year
GHG Emission 0.87 Tons of CO2/Year
Renewable – Solar Energy
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20kWp SPP
(On Grid Type)
Projection of 18 MWh
/ year
HR & Canteen building will get benefit
Target completion
in 2017
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Green Initiative
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Green belt @ KPCL Hadapsar plant
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Energy Management
ENCON Management Structure
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Apex Team
Managing Director
VP – ACD
VP TRM
VP - ACR
Core Team
Energy Manager
All Dept. Heads
Working Team
Team Members• Prod.• PE• ME• HR• Finance• Assly.• Purchase• QA
Small Team
Cross Functional Team• Prod. • PE• ME• HR• Finance• Assly.• Purch.• QA
ENCON Team – 78 Nos.
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Energy Management – Team Members
Employee Name Certificate holds
U V Marathe Energy Auditor
A M Bhide Energy Auditor
S P Bhargave Energy Auditor
R A Parmar Energy Manager
S D Jere Energy Manager
Mahesh M. Shinde Energy Manager
ENCON Methodology
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• Assignment to Team• Energy Budget• Monitoring• Kaizen• Creative Ideas• Special Team for Project
• Monthly Review• Holding Gains• Fine Tuning & Plan for
further Improvement
• Brain Storming• Sub Project• Area of Concern• New Technology• Renewable Energy• Internal / External Energy
Audit
• Analysis of Energy Consumption
• Target Setting for Goal Achievement
Result Approach
DeploymentAnalysis & Review
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Energy Monitoring & Reporting
Monitoring & Reporting
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DG Set Running Monitoring -Monthly monitoring - Record Book
kWh /kVAr Power Factor Main Plant Recording Monitoring-Daily - Data Register in Computer- SCADA system for H.T. furnaces only
Cell wise kWh Energy Recording & Review- Monthly
Compressor Energy Monitoring -Daily -Monthly -Data Register & in Computer
Foundry Energy Monitoring -Daily-Monthly-Recording in Computer
Monitoring Energy
Consumption
Monitoring & Reporting
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Monitoring & Reporting
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Monitoring & Reporting
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Energy Monitoring System @ Test beds
30-Aug-17 50Kirloskar Pneumatic Co. Ltd., Pune
SCADA System - Heat Treatment
SCADA System for Heat Treatment Process Control
Programming For Individual Furnaces Real Trend Charts for Temp. & Cp
30-Aug-17 51Kirloskar Pneumatic Co. Ltd., Pune
Monitoring & Measuring Instruments
30-Aug-17 52Kirloskar Pneumatic Co. Ltd., Pune
Energy Management
System is planned in
year 2017-18
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Sustainability Report (Internally Published)
Sustainability Reporting
Gap Analysis
Process Improvements
Integration Into Existing
Processes
Responsible Business
ProcessesSUSTAINABILITY
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GHG Emission – Tons of CO2e
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0
5000
10000
14-15 15-16 16-17
7220 7409 7045
KPCL
% Reduction
• 2.40% over FY15 (KPCL)• 1.60% over FY15
(Hadapsar)
0
5000
10000
14-15 15-16 16-17
6105 6414 6005
Hadapsar
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Employee Engagement In ENCON & CSR
Global Warming
GHG Emission
E-Waste Recycling
Compressed Air leakage
GreenCo Certification
En MS ISO 50001
Training @ Office & shop floor area
30-Aug-17 Kirloskar Pneumatic Co. Ltd., Pune 56
Employee Engagement In ENCON
Training On
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30-Aug-17 Kirloskar Pneumatic Co. Ltd., Pune 57
Training to EmployeesS. N. Programme Title Nos.
Level of TrainingDurationin Hours
DateEngineers /
WorkersSupervisor /
Managers1 Plastic recycling awareness 43 11 32 1.0 Jun.-16
2 Why Energy Conservation Required? 355 162 193 4.0 Sep-16
Total 398 173 225
S. N. Programme Title Nos.Level of Training
Durationin Days
DateEngineers / Workers
Supervisor / Managers
1Workshop on Solar Photo-voltaic and Hybrid Wind Energy Systems 2 -- 2 1 Day Sep-16
2Challenges in implementation of open access in Maharashtra 1 - 1 1 Day Oct-16
3 Workshop on enhanced energy efficiency in industrial lubricants 3 1 2 1 Day Nov-16
4 CII Green Conclave 2016 1 - 1 1 Day Nov-16
Total 7 1 6
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Employee Engagement In ENCON
ENCON Quiz
Swachhata Abhiyan
ENCON Week Celebration
World Environment Day
KVIFF
SR Report
Vendor Engagement
Performance Appraisal
ENCON Painting Competition
Susamwad In-house Magazine
ENCON Week Celebration Glimpses
30-Aug-17 Kirloskar Pneumatic Co. Ltd., Pune 59
Desktop Wallpaper ENCON Oath
Opening Ceremony ENCON Quiz awardSolar Lantern
Banner
World Environment Day
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Bike Pooling/ Cycling
Walking
CAR PoolingAwareness on Plastic
recycling
LED bulb / Sapling distribution
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61Kirloskar Pneumatic Co. Ltd., Pune30-Aug-17
ENCON Awareness in Community
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Recognition For ENCON Efforts
Appreciation @ CII
30-Aug-17 Kirloskar Pneumatic Co. Ltd., Pune 63
2007-08Energy Efficient Unit
2008-09Best
ENCON projects & Energy Efficient Unit
2009-10 Energy Efficient Unit
2010-11 Energy Efficient Unit
2014-15 Energy Efficient Unit
Appreciation @ Kirloskar Group ENCON Committee
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2008-09 3rd Prize
2009-10Best Innovative project
2011-12 2nd Prize
2012-13 Best Innovative Project
2014-15 3rd Prize
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BEE’s National Energy Conservation Award 2015
30-Aug-17 Kirloskar Pneumatic Co. Ltd., Pune 65
CII’s National Energy Management Award 2015
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MEDA Energy Management Award 2015 Kirloskar Group ENCON Award 2015-16
68
3rd Best managed energy efficient unit – Large plant category
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Kirloskar Group ENCON Award 2015-16
69
Best ENCON Project – Induction furnace utilization at Foundry
Kirloskar Group ENCON Award 2016-17
70
3rd Best managed energy efficient unit – Large plant category
30-Aug-17 Kirloskar Pneumatic Co. Ltd., Pune 71
Recognition For ENCON Efforts
Accolades Gallery
Future ENCON Projects
30-Aug-17 Kirloskar Pneumatic Co. Ltd., Pune 72
Sr. No.
Project Driver
1 Use of LED lights for office/Shop floor / Street lights Energy Efficiency
2 Off Grid Solar Power plant installation for Security Office, HR, Canteen Green Energy
3 Replacement of refractory & brick lining of Heat Treatment furnace for energy performance improvement
ENCON
4 Use of solar energy for KPCL operation under open Access mechanism GreenEnergy
5 Replacement of old 500 kVA transformers - 2 Nos. with energy efficient transformer
ENCON
6 Active harmonic filter to control the harmonic level in electrical distribution system of air compressor test bed
ENCON
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Sr. No.
Project Driver
7 Introduction of SCADA based energy monitoring system at Hadapsar & Saswad plant
ENCON
8 Use of VRF based air conditioning system for the building air conditioning requirement
ENCON
9 Energy generation by using compressed air generated during testing ENCON
10 Inverter based air conditioners for new requirement ENCON
Future ENCON Projects
www.kirloskarkpcl.com
KIRLOSKAR PNEUMATIC CO. LIMITEDA Kirloskar Group Company
Kirloskar Pneumatic Co. Ltd. 7430-Aug-17
Thank You