Ashok Leyland Hosur- Unit 1 · Energy Management - 2014” Ashok Leyland Hosur- Unit 1 2 11/1/2014...

11/1/2014

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National award for “Excellence in

Energy Management - 2014”

Ashok Leyland Hosur- Unit 1

2 11/1/2014 CII- National award for Excellence in Energy Management- 2014 ALH1

Presentation contents

1. Introduction

2. Energy management at Hosur, Unit - 1

3. SEC Energy Conservation- Project Management

4. Innovative projects

5. Horizontal deployment & Knowledge sharing

6. Towards GREEN

7. Wealth from Waste

8. External awards

9. Way Forward

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A 64-year old pedigree

• Founded in 1948 as Ashok Motors

• Became ‘Ashok Leyland’ in 1955 with equity participation from Leyland Motors, UK

Touching lives of millions across worldwide

One of India’s largest commercial vehicle manufacturers

Ashok Leyland A comprehensive portfolio of transport solutions

Manufacturing Facilities


Ashok Leyland Hosur Unit-1

MAIN GATE ENTRY

N

• DRG NOT TO SCALE

• FOR OVERVIEW ONLY

HOSUR - I LAYOUT

S No Resources Hosur-1

01 Total Area (Acres) 102.58

02 Plant and Machinery ~ 517 Rs. Cr

03

Permitted Maximum Demand

7000 kVA

Usable captive capacity 4875 kVA

04 Manpower (Associates +Exe)

1220

05 Trees (nos) 3315

Established in 1980 as an Engine manufacturing center

Having current capacity of 1 lakh engines per annum • H Engines - 40 K • P15 Engines - 60 K

Products

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Production Process Flow

H-Engine In-house machining

BOR

Bought Out Finish

Engine Assembly

Engine Testing Dispatch to

Vehicle Assembly Units /

PSB Yards

P15-Engine BOR

Bought Out Finish

Engine Assembly

In-house machining

Engine Testing Dispatch to H-2


Ashok Leyland - Energy policy

http://www.google.co.in/url?url=http://www.ukm.my/car/index.php/research-lab/39-internal-combustion-engine&rct=j&frm=1&q=&esrc=s&sa=U&ei=3rU4VPLsJYKluQTm24CIBQ&ved=0CCUQ9QEwCA&sig2=J-ezbELEOuRKyTwguR0-Wg&usg=AFQjCNELufOZcTiIRGl6a-m30zbU7WNG8Q

http://www.google.co.in/url?url=http://www.alibaba.com/product-detail/Ashok-Leyland-Diesel-Generator-Sets_105524626.html&rct=j&frm=1&q=&esrc=s&sa=U&ei=ebY4VLrNBIKAuwTF_oLYBg&ved=0CCMQ9QEwBw&sig2=9O2GejV2oH3E2euZXyULYA&usg=AFQjCNHrJ_EzZfNpnDg8ZCnPUpAngtLhbA

http://www.google.co.in/url?url=http://www.zigwheels.com/news-features/recent-launches/ashok-leyland-launches-limited-edition-dost/14121/&rct=j&frm=1&q=&esrc=s&sa=U&ei=Brk4VLmDM9PIuASIjID4Dw&ved=0CCkQ9QEwCQ&sig2=A26BNMcDQ665SM6oqIj_RQ&usg=AFQjCNFpUm3dl8YuzOu2Rq0Y-2YXWtMY5A

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Energy Cell @ Hosur, Unit 1

EnCon activities by Energy cell

Monitoring & Reporting- SAP Continual improvement

Improvement activities Awareness thro’ campaigns Promoting involvement

Horizontal deployment Best practices Waste elimination

Self-Calibration System

compliances


Energy management @ Hosur, Unit 1

Reviewing

Plant Level review

Department review

Machining

Assembly

http://www.google.co.in/url?url=http://www.triplepundit.com/2014/10/twitter-chat-millennials-social-entrepreneurship-making-impact-work/&rct=j&frm=1&q=&esrc=s&sa=U&ei=Yv48VNqqPM_guQTRiYGACw&ved=0CCcQ9QEwCQ&sig2=kt0FNazhnloGcpNgL_Guig&usg=AFQjCNEeixV6ZabeoXKNXGWeA10eJdj-EQ

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Real time Load monitoring Plant & Shop Level

• 8 Zones, 95 Meters hooked up to network enabling the real time monitoring.

• Real time monitoring- Load, consumption & power quality parameters.


Reporting & Reviewing system-SAP

Plant level reporting-Daily Shop level reporting – Daily & Weekly

32% 16% 9%

9% 8% 7% 6% 5% 3% 3% 1%

32%

48% 57% 66%

74% 80% 87% 92% 96% 99% 100%

0%

25%

50%

75%

100%

Energy Consumption

Current Power consumption pattern

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P15 Engine with bench marked SEC

Towards setting bench marking SEC - Energy audit conducted by PCRA

(Petroleum conservation research association) in 2012.

Sly No

Component Norms Units/Component

1 Cylinder Block 36.16

2 Cylinder Head 33.06

3 Engine Assembly 24.99

Units/Engine 94.21

Norms as per PCRA audit

194

128 104 94

94

2011-12 2012-13 2013-14 2014-15

Target

(-19%) (-10%)

(-52%)

P15- Units/Engine trend

• 2013-14- 104 units/Engine • Targeted to achieve the PCRA norms in 2014-15. Plan for 2014-15

Installation of VFD’s for AHU blowers in Engine assembly, Staggered power management based on production demand, Air Ventilation system for Engine assembly enclosure in place of Ac’s.

SEC


H- Engine SEC

276 264 273 265 258 250

250

2011-12 2012-13 2013-14 2014-15 2015-16 2016-17

TargetProduction

42202

25633 24000

H- Units/Engine & Production trend

• A target of 250 units/Engine is set based on the past best performance(07-08: 55 k engines).

• Despite the drastic drop in volumes, SEC maintained almost flat by Focusing more on converting the fixed energy into

variable.

Elimination of hidden loss in energy. Planning to reduce SEC by 8% in next 2

years. Plan for 2014-15

Installation of VFD’s for AHU blowers in Engine assembly, Machine shop - 5 Units Energy savings per machine per

shift planned for top 100 power intensive machines

47442

-11%

-39%

30.9

27.1 29.6 28.2

2010-11 2011-12 2012-13 2013-14

Indirect area- Consumption

Lakhs KWH

* Includes- Data center & R&D

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Energy Cost

4.75 5.74

4.47

2011-12 2012-13 2013-14

H - Rs per Kwh

Over all Rs per Kwh reduced by 22%. Demand cost reduced by Rs 90 lakhs from

Rs 315 lakhs to Rs 225 lakhs. This fixed element made in to semi variable.

Reduction in Self generation from 36% to 11 %.

9.35 10.63

9.50

2011-12 2012-13 2013-14

P15 - Rs per Kwh

Over all Rs per Kwh reduced by 11%. Low volume managed with low cost

EB power & stopped production with DG supply.

P15 Engine testing time reduced from 14 min to 9 min.

-22% -11%

4.15 3.64

2012-13 2013-14

Kwh per Month - Fixed (in lakhs)

-12%

Variable consumption brought down from 651 to 625 (4% reduction).

46 Energy saving projects completed & realized 3.3 lakh Kwh reduction (recurring).


814 1147

2193

720

5774 4359

3511

2361

2010-11 2011-12 2012-13 2013-14

Power interruption-Hrs Self generation-KWH/Hr

Renewable energy & Self generation

243 209 212

144

29

42

12

34

157

118

124

93

57

50 77

17

0

200

400

2010-11 2011-12 2012-13 2013-14

Power Mix (Kwh in Lakhs)

Total EB WM CAPTIVE

WM 65%

EB 24%

CAPTIVE 11%

Ratio of WM energy in

2013-14

• Power is drawn thro’ 3 different sources, o Power generated thro’ Wind Mill o Power supply from EB o Self generation thro’ DG

• Green power (Wind Energy) utilization accounted up to 61% of total power consumption.

Self generation units / hour of power interruption

Year

Power interruption in Hrs

DG units in lakhs KWH

Generated Units/hour

2010-11 814 47 5774

2011-12 1147 50 4359

2012-13 2193 77 3511

2013-14 720 17 2361

-25%

-19% -33%

• Self Generation reduced by 29% in 13-14 w.r.t 10-11 by optimizing the utilization of EB & WM power for production,

• Restricting DG usage only for critical loads.

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Engine developed by AL will be tested at our R&D before taking up for manufacturing These developed Engines will be tested through Hydraulic dynamometers and eddy current

dynamometers. To meet EURO III emission norms Engines are suitably developed by AL R&D team and testing of these

engines, new Engine test beds are planned. New test beds are planned with latest Technology, i.e. transient Dynamometer. In absorption mode the frequency dependent machine current is converted into alternating current with

the frequency of the mains supply via a voltage source converter and it’s feedback into the power supply system.

Separate arrangements are made to capture import & Export of Energy Consumption / Regeneration, from this Dynamometer during Engine testing.

Regenerative power during 2013-14 - 3.02 lakh Kwh & YTD Sept 2014 - 0.93 lakh Kwh and used for test bed utility Equipments.

Transient Dynamometer

Total number of test cell : 4, 2013-14 : 3.02 lakh Kwh, YTD Sept 14* : 0.93 lakh Kwh

Regeneration of Energy during Engine Testing

Online data measured value


Monitoring & Implementation Gemba Structure

People involvement

EnCon Improvements

Energy conservation- Project Management

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Improvement program model

EnCon @ Unit 1,Hosur

39%

61% 76%

2011-12 2012-13 2013-14

Employee involvement in EnCon Projects

Source: GembaMpower

Idea Generation thro’ 1. Theme based brainstorming sessions 2. Walk through audits 3. Quick hit campaigns 4. CMI week celebrations

• All generated ideas will be recorded and their progress monitoring -Mpower

• Evaluation and approvals for implementation – Mpower

• Recording benefits and monitoring sustenance- Mpower

• Rewarding - Mpower


EnCon @ Unit 1,Hosur

• More focus on converting Fixed cost overheads to Variable • Optimization of demand setting based on production strategy.

• More focus on optimizing compressor air usage • Optimizing compressed air usage in air gauges Innovative ideas at point

of use • Power saving in air gauges thro’ wastage elimination • Introduction of additive in machine spindle gear boxes, to reduce friction

losses -Special initiatives-Theme based improvements • Saving 500 units/electrical executive. • Cross audits

Approach adopted

Sly No

Year No.of projects

KWH saved – Lakh units

Cost savings-Rs Lakhs

Investment-Rs lakhs

1 2011-12 14 4.95 25.22 78.65

2 2012-13 141 13.7 144.4 12.5

3 2013-14 76 4.6 163.8 6.4

Total 231 23.25 333.42 97.55

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Significant Projects-2011-12

Hosur 1 - List of Energy Saving Projects Completed

Sl.no

Completed projects : Month of

completion Investment ROI

Details of savings per day in Kwh

1 Energy efficient motors, pumps, blowers, lighting & air conditioners (5/3star rating) installed in new P15 Engine assembly area.

11-Apr Planned during selection stage & implemented

795

2 Energy efficient lamps introduced in place of conventional lamps at shop 2 stores & engine dispatch area.

11-Apr Rs 1.0 lakhs less than 6 months

152

3 Provide Energy efficient 90KW motor with soft starter. 11-Apr Rs 6.08 lakhs 15 Months 40

4 Solar water heaters of 7KLD & 2KLD introduced at canteens. 11-May Rs 13.00 lakhs

less than 2 years

448

5 Introduce energy efficient water pumps (7.5 HP X 2 nos, 3.0 HP X 2 nos & 3.0 HP X 2 nos).

11-May Rs 0.72 lakhs 1 year 29

6 Introduce energy efficient air conditioned units at Shop 1 Metrology, Shop 5 E/A & Work Office & System area (100TR).

11-Jun Rs 15.00 3 years 394

7 Provide Energy efficient 200 KW motor with soft starter. Replace CPT1 Air compressor by energy efficient air compressor.

11-Nov Rs 25.00 lakhs

24 Months 576

8 Introduce energy efficient motors for shop 5 test bed blowers (40HPX4 nos).

11-Dec Rs 6.00 lakhs less than 2 years

384

9 To provide separate circuit for Shop 1 extension to ensure switching off during non production hours.

11-Dec Rs 0.25 lakhs 2 Months 75

10 LED street lighting - replace conventional 150 watt SV lighting to 54 watt LED lighting (33 nos)

12-Jan Rs 4.5 lakhs less than five years

50


Significant Projects 2012-13


Sl.no

Completed projects : Month of completio

n Investment ROI

savings in Rs.Lakhs

1 Eliminate lunch hour, dinner break & shift change hour idle running in shop-1 & shop-5

Apr'12 3.0 Lakhs Less than a

month 20.21

2 Optimization of test bed operation at Shop 5 (TB17-TB32) Apr'12 1.5 Lakhs 6 months 3.0

3 Energy saving in Heat Treatment of D9056211 Axle shafts by by changing the work centre in GCF line at HT shop III

Apr'12 0.75 Lakhs 6 Months 1.58

4 Make use WM power during power holidays on Satuarday & Sundays (May 12).

May'12 Nill NA 27.45

5 Elimination of hidden loss in Machine shop-5 during 1st shift. May'12 3.5 Lakhs 2 Months 20.38

6 Elimination of blower running in 680 conveyor and testing areas May'12 0.5 Lakhs 12 Months 0.52

7 De rating of Exhaust Blower motors in Test Cell-1, Test Cell-2 & Test Cell-3

Jun'12 1.25 Lakhs 9 Months 1.98

8 Staggered power management during normal & peak hour, thereby maintaining optimum demand (July 12).

July'12 Nill NA 8.26

9 Regulate compressed air supply to Shop-9 PDI, by replacing 40KW compressor with portable compressor

July'12 0.4 Lakhs 6 Months 0.77

10 Optimimum utilization of captive power during power failure/peak hours

Jan'13 Nill NA 25.83

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Significant Projects- 2013-14


Sl.no

Completed projects : Month of

completion Investment ROI

savings in Rs.lakhs

1

Power cost reduction through shifting of activities from Peak hour to Off-peak and normal hours, low volume production planned with low cost EB power & restricted/eliminated during costly DG Power.

Dec'13 0.60 Lakhs Less than a

month 98.46

2 Auto cut off introduced in Mag & Makino machines through control circuit modification

Oct'13 1.25 Lakhs 3 Months 7.5

3 Energy saving in Robo wash by replacing 50 hp pump with 30 hp pump for cleaning cylinder block

Nov'13 Nill NA 0.52

4 Avoiding running of dedicated air compressor for P15 EA in 2nd & 3rd shift, by linking air line with central air compressor

Aug'13 0.75 Lakhs 9 Months 1.11

5 Energy Saving in HMC machines - 7 Machines Oct'13 0.4 Lakhs 4 Months 1.32

6 Avoid idle running by enable auto shut off in AHU Oct'13 0.20 Lakhs 2 Months 1.10

7 Air gauge automation to eliminate Compressed air wastage in Etamic gauge units

Jun'13 1.5 Lakhs 3 Months 7.13

8 Energy Saving (On Fixed Costs) & Gear box Reliability Improvement in Engine Machine Shop 5 through Innovation. (3.55 Kwh per block)

Dec'13 2 11 months 3.16

9 Establishing SGN process in GCF ( savings of 80 Kwh per charge) Jan'14 1 6 months 2.88

10 Spray pump power saving mode incorporation to eliminate idle running LA9696 / 9697

Jun'13 0.20

6 Months 0.44


Innovative projects

Project # 1 : LOW COST AUTOMATION IN PNEUMATIC GAUGES.

Project # 2 : HIDDEN LOSS ELIMINATION FROM SOURCE SIDE

Project # 3 : P15 ENGINE TESTING CYCLE TIME REDUCTION

Project # 4 : INTRODUCTION OF AUTO CUT-OFF IN CNC/PLC

MACHINES

Project # 5 : GEARBOX LOAD REDUCTION THROUGH ADDITIVE

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Innovation Project # 1

Before After

LOW COST AUTOMATION IN PNEUMATIC GAUGES



• Compressed air utilization time in air gauges reduced from 960 mints/day to 60 mints

• Inspection equipments air leak reduced from 68% to 7%


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COMMUNICATIONS to other AL units on replication of the idea

Recurring savings through the project: 10.92 lakhs/annum



HIDDEN LOSS ELIMINATION FROM SOURCE SIDE


Hidden Power loss at Home Hidden Power loss at Industry

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Knowledge shared in HIA forum to other industries



P15 ENGINE TESTING CYCLE TIME REDUCTION


Engine testing consumes 35% of the total power consumption in P15 engine assembly

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9.1

6.6

Before After

Average power

consumption/Engine

Average power consumption reduced by 27%

3.5

2.98

Before After

Diesel consumption/Engine

Revised Manufacturing Pass off Norms – V11

Parameters Validated 1. Engine Performance over Operating

range 2. Coolant Temperature 3. Specific Fuel consumption 4. Oil Temperature 5. Exhaust Gas Temperature

Diesel consumption reduced by 15%


P15 ENGINE TESTING CYCLE TIME REDUCTION


INTRODUCTION OF AUTO CUT-OFF IN

CNC/PLC MACHINES

Eliminating idle running of motors thro’ control circuit modification.

Tripping of hydraulic systems when not in use thro PLC program modification.

Spindle/ hydraulic motor cutoff thro’ limit switch/ timer.

Auto power saving features


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• Both Makino & Mag has Econo mode

which is a Human dependent action

• Failing to enable Econo mode again will defeat its purpose

• The team designed and incorporated a control circuit which ensures the motors will get off after a time delay


Idle cut-off mapping

Makino & Mag are the power guzzlers

First time, Auto idle cutoff circuit incorporated in an imported machine!!! Total savings amounting to 1.26 lakh KWH/year

INTRODUCTION OF AUTO CUT-OFF IN

CNC/PLC MACHINES


Gear box oil Additive introduced in 34 Machines in HCB Line by 23rd Dec 2013.

Gear box load reduction through additive


Kwh Block Kwh per

Block Before Additive

5459 124 44.18 After Additive

5590 131 42.61

-130 -8 -1.57

-2% -6% -3.55%

3.55% reduction in power consumption

Trials in LA8263 Spindle gear box

Before After

% reduction

Kw load drawn at no load condition

4.00 3.80 -5%

Kw Load drawn in full load condition

8.50 8.16 -4%

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Idea Generation Summary

No.Of Plant engineering executives participated

67

Total Number of Projects identified 197

Expected Units savings per day 16138 units

Phase 1 : Idea Generation

Phase 2 : Feasibility study and Categorization Idea Generation Summary- Feasibility study

Ideas Feasible for Implementation -2012-13

173

Expected Units savings per day 10475 Units

Theme of Initiative : Savings of 500 units / day / Executive – PE Launch : Nov’12 Duration : 3 months

Idea Generation Summary- Investment details

Ideas with less than 2 lakh investment 166

Expected Units savings per day 7216 Units

Energy saving initiative Launched by Unit head

Out of 166 Feasible ideas based on ROI 86 projects implemented. Total Number of executives involved : 12 (86 Projects) Achieved KWH reduction/ Exe/day : 208.25 Total Investment : 4.3 Lakhs.

Total saving of 7.5 lakh KWH/year


Project Description: • Carburizing process in GCF is high power intensive furnace working @ 24 x 6. • Earlier air cooling of charge is in practice. • With detailed analysis, process changed to equalize cooling method. • Realized savings of 140 Kwh / charge (no of charges in 2011-12 is 103).

Before Improvement

After Improvement

Energy consumption:

0.53 lakh units

Investment: -- Total savings/Annum: 0.87 lakhs

0.39 lakh units

Heat Treatment process improvement in GCF 520 KWH/charge to 380 KWH/charge

Energy consumption reduced by: 27%

2011-12

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Project Description: • Earlier Package A/C with reciprocating compressor (22 Years old - 7.5 Ton x 4 no’s 7&5 TR X 5 no centralized

package A/C units ) running in Metrology & HDC (Data center) . • Based on revised heat load calculation, 25 TR package A/C units replaced by 1.5 TR X 6 nos five star split A/C in

HDC. • Energy efficient Scroll compressor ductable package air conditioners with duct modification done in Metrology.

Before Improvement After Improvement

Energy consumption: 3.69 lakh units

Investment: 7 Lakhs Total savings/Annum: 14 lakhs

1.33 Lakh units

Energy Efficient Air Conditioners 1314 KWH/day to 474 KWH/day

2011-12


Project Description: • Hot water is required for dish washing at canteen to maintain hygiene, introduced solar water

heaters in place of conventional electrical heaters. • Required hot water per day for dish washing is 9000 liters. • Two solar panels (7 KLD & 2 KLD) introduced at two canteen blocks. • Energy required to heat 9KL water from 25 Deg to 70 Deg C = (70-25) X 9000 = 405000 Kcal /

860 = 471Kwh per day. • Realized savings of 471 Kwh per day


• Electrical heaters were used for hot water generation.

Energy consumption :

1.41 lakh units/year

Investment: 13 Lakhs Total savings/Annum: 7.63 lakhs

0 units/Year

Renewable Energy -Solar water heaters for canteen 471 KWH/day to 0 KWH/day

2011-12

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Project Description: • Machine Shop 5, cylinder block head face tapping machine supported with dedicated 5 HP

portable compressors. • Through reformed design concept, air intensifier unit introduced along with existing pneumatic

circuit & eliminated usage of portable compressor. • Realized energy savings 17.60 Kwh per day.


• Pressure : 6.00 kg per sq.cm • Dedicated air compressor

Energy consumption : 0.1 lakh units/year

Investment: 0.22 Lakhs Total savings/Annum: 0.32 lakhs

0.053 lakh units/Year

pneumatic intensifier to eliminate portable compressor. 17.6 KWH/day reduction

2011-12

• Pressure : 6.00 kg per sq.cm • Ensured with existing pneumatic line with

air intensifier.


Project Description: • Earlier 250 W MV lamps used at 9.1 meter height. • Due to ageing (>30 years) transparent acrylic cover faded & lighting level dropped by 40 - 60%. • Introduced 72 W LED lighting in a same street pole @ 5.0 meter height. • Implemented in 68 street light poles. • Since 1980, Shop-2 Stores & dispatch area general lighting provided by conventional 65 watts

florescent lamp.

• 2 x 65 watts florescent lamp luminaires replaced by T5 lamps with electronic ballasts.

Before Improvement After Improvement Before: 250 Watts MV lamp @

9.1 meter height, Now disconnected

After: 72 Watts LED lamp @ 5.0 meter height

Energy consumption :

1.28 Lakh units/year


0.31Lakh units/Year

Energy efficient lighting.

2011-12

• 65 W florescent luminaires – 324 nos

• Kwh per day for 8 hours = 168.48

• 8 x 14W T5 luminaires – 36 nos

• KW – 4.03 • Kwh per day for

8 hours = 32.24

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Project Description: • Earlier 22 years old 1219 CFM reciprocating air compressor was powered with 200 KW slip ring

induction motor (84% efficiency). Average consumption was 180 Kwh per hour • Implemented with energy efficient screw compressor of 1302 CFM with 200 KW sq. cage

induction motor (94% efficiency) & also eliminated auxiliary equipment’s. Average power consumption per run hour is 156 Kwh.

• Realized 24 Kwh savings per run hour.





Energy efficient screw compressor 180 KWH/day to 156 KWH/day

Energy consumption reduced by : 13%

2011-12

• Energy efficient screw compressor Reciprocating air compressor (dismantled)


Project Description: • Shop 5 cylinder blocks machining, each head changer machines consists of 3 HP x 3 numbers

coolant motors (Cutting, Fixture & bed flushing). • Earlier all three motors were running during machining cycle. • Coolant circuit modified & eliminated one 3 HP motor without affecting performance. • Implemented this modification in six machines. • Total energy savings realized in a year = 24.50 x 6 machines x 300 days = 44100 Kwh


Energy consumption : 1.32 Lakh units/year


0.88 Lakh units/Year

Coolant system design modification in Engine block machining. 73.5 KWH/day to 49.0 KWH/day

Energy consumption reduced by : 33%

2011-12

• Coolant motors : 3 HP X 2 no • Kwh per machine per day : 49.00

• Coolant motors : 3 HP X 3 no • Kwh per machine per day : 73.50

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Project Description: • An earlier fresh air blower motor of 15 KW was running for each test bed. • Based on details in blower suction volume & Engine exhaust volume, required motor

downsized to 5 HP. • Realized energy saving per day per bed 118 Kwh • Implemented in three Engine test beds • Total realized energy saving per day in three TB = 354 Kwh





Downsizing of blower motor in test bed 15 KW to 3.7 KW

2011-12

• Motor capacity : 3.7 KW • Motor capacity : 15 KW


Project Description: • Earlier we need to run two pump of 7.5 KW for running reciprocating compressor cooling water system (KC02)

(7.5KW*2*14HRS*6Rs*300days) =RS 3.78Lakhs with open loop system. • To Reduce Power cost hot water pump eliminated by redesigning of open loop to closed loop.( 100 units/day

savings realized) (7.5KW*14Hrs*6Rs*300days)=Rs 1.89 Lakhs


Energy consumption: 0.63 lakh units


0.33 lakh units

Energy conservation in Compressed Air 100 KWH/day reduction

2012-13

• (7.5KW*2*14HRS*6Rs*300days) =RS 3.78Lakhs

(7.5KW*14Hrs*6Rs*300days)=Rs 1.89 Lakhs

Cold Well

Hot Well

cold Well

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Horizontal Deployment

Inputs for Horizontal deployment

Tracking mechanism

Results

• Fortnight implementation reports with finance vetting.

Sharing of projects thru’ AL PORTAL with photo graphs & cost impact

Fortnightly review by CMI-CFT, to drive horizontal deployment across all units

40

52

38

52

20.25 23.21

2012-13 2013-14

Projects identified

Implemented

Savings in Rs Lakhs


Horizontal Deployment: Sample of Tracking sheet

Recurring One time

1 H113S1246

Power - Demand Management by

optimizing normal hour demand Hosur -1 Power

1099000 0

Alwar to

restudy and

revert 284000

CPPS to

capture the

cost saving

details

NF

1099000

H2 to

capture the

cost saving

details

Application has been

given to UPCL.

Expected to be done

by Jan'14 ( 5200000) 1383000

2 H112S1517

Energy savings through compressed air

usage Optimization in pneumatic

equipments, functions & air guages Hosur -1 Power

1092600 28000

UP

400000

CPPS to

capture the

cost saving

details

UP

1092600

H2 to

capture the

cost saving

details

UP

1492600

3 B113S0102

Machine Pannel A/C Made off in winter

season

Bhandara Power

369000

Alwar to

capture the

cost saving

details

369000

CPPS to

capture the

cost saving

details NF

P15 all machines

Panel AC &

LA10109,LA10225

Coolant Chiller

units usage

Optimised.

H2 to

capture the

cost saving

details

PNR to capture the

cost saving details

369000

4 H113S1908

Bio Diesel in place of Hs diesel for

canteen boilers, furnaces, forklifts,

Engine testing and Gensets Hosur -1 Power /

Consumables 473237

0

Alwar to

restudy and

revert

Quotation

taken from

supplier.

Activities are

in progress.

Feasible yet

to start Implemen

ted in

canteen

boilers473237

UP Impact is very low as

Bio-Diesel is being

brought from Gujrat 473237

5 H112S1639

Waste oil reclamation by Recycling thru

supplier and reuseHosur -1 Consumables

1365000

NF UP TBS TBS

1365000

H2 to

capture the

cost saving

details

PNR to restudy and

revert 1365000

6

Optimizing fork lift movement .

Hosur -2 Consumables TBS

Bhandara to

capture the

cost saving

details

NF UP

118800

H2 to

capture the

cost saving

details

UP

118800

7 H113S1951

DIANANO Gear box Additive to reduce

energy consumption Hosur -1 Power

4000000

NF

Feasible yet to

start NF

Feasible

yet to

start

UP NF NF

CMI - POH (K54) Horizontal Deployment projects as on 23.01.2014

SL.NO

Project

registration

number

Project Description

Parent

plant of

the project

Resources Cost saving in Rs.

Investment Alwar Bhandara CPPS Ennore Hosur -1 Hosur -2 PNRExpected Cost

saving in Rs.

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Horizontal Deployment: Significant project

Wind Mill energy sharing with CPPS

Before: CPPS plant was running with EB source up to 548 KVA & balance 500 KVA with

DG supply. Daily 8-12 hours DG sets were running to meet demand shortage (400-500 KVA). After: CPPS plant was recommended to utilize EB source up to sanctioned demand

(1250 KVA ) through WM connection. Running of DG sets totally stopped due to demand shortage.

5.6 5.7 6.1

1.8

2.85

4.4

1.3

3.3

2.8

3.4

3.15

3.53

Apr'13 May'13 Jun'13 Jul'13 Aug'13 Sep'13 Oct'13 Nov'13 Dec'13 Jan'14 Feb'14 Mar'14

CPPS - Power cost Rs/Storke

WM transfered

After Avg: Rs 3.3/Stroke

Before Avg: Rs 5.5/Stroke

Realized savings Rs 88 lakhs in 2013-14


Towards Green Awareness thro’ competitions and celebrations

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Significant GREEN projects

Sl.no Project Description Month/Year Investment (Rs in

lakhs)

Benefits

11-12 12-13 13-14

Benefits Benefits Benefits

1 Bio Diesel introduction in canteen Boilers Dec-13 0

Reduced

emission

2 Recycling of packing wood Dec-12 0 11960 cft 27390 cft

3 Reuse of Corrugated packing Jan-13 0 924kgs 616 kgs

4 Coolant recovery system in Shop 5 Feb-12 5 96000lits 96000lits

5 Hazardous waste reduction at ETP area Mar-12 0 2000kgs 1750kgs

6 Rain water Harvesting for process direct usage Apr-13 5 400KL

7 Usage of RO reject water Mar-13 0.5 20KLD 30KLD

8 Solar water heater application Jun-11 11 9KLD 9KLD 9KLD

9 Bio Gas plant using canteen food waste Jul-14 2 120 cylinders

10 Recycling copper hammer under material conservation Dec-11 0 1350KGS 1400KGS

11 Online purification of Hydraulic oil Jan-11 1 2.7 lac lits 5 lac lits

12 Usage of STP sludge as manure Apr-13 0 178MT 2.5 MT

13 Reuse of Printer ink cartridges by refilling the inks. May-12 0 9.5 lakhs 8.5 lakhs 7 lakhs

14 Recharging of Rain water perculation wells Jun-11 0 150KL 150KL 150KL

15 Enhancing the life of tools by process recondition in Project resurgence Nov-11 0 500 NOS 900 NOS

STP recycled water- 175 KLD used for gardening ZDP recycled water- 25 KLD used for washing machines


Water Management 13-14 (KLD) 519

406 25 20 20 20 10 8 4 3 2 1

0

100

200

300

400

500

600

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-14

Avg

Water consumption Water reduction

12-13 Q1 Q2 Q3 Q4

AVG Per Capita Consumption 124 103 85 79.9 79.1

13--14 Target 118 100 85 85 85

124 103 85 79.9 79.1

85

0

20

40

60

80

100

120

140

Per

cap

ita

con

sum

pti

on

in L

tr

Per Capita Consumption (Domestic + Canteen) Litres/Day/Person 12-13 - 124 Litres 13-14- 79 liters

Significant improvements : • Rain water Harvesting and reuse projects - 3 nos • RO Reject water collection and reuse projects - 4 nos

Annual Monetary Savings : Rs 13.34 Lakhs

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Sly. No.

Area of Usage UOM 2012-13 2013-14 % Improvement

A Total building area available for rain water harvesting

Sqm 125000 125000

B Building covered under Rain Water harvesting - Shops / Office building.

Sqm 1500 8000 433%

C % Age building area covered connected to Rain water harvesting Structure (B/A)

% age area wise

1.20% 6.40% 433%

D Rain Water Harvesting capacity through pond

KL 11000 11600 5%

E Rain Water Harvesting capacity @ Buildings

KL 70000 99400 42%

F Natural Water recharging (20 acres Lawn) KL 15030 15030 0%

G Capacity of available rain water harvesting structure (D+E+F)

KL 96030 126030 31%

Key Actions RWH ETP Pond 600 KL established from Apr'13 Shop-1 & Shop-2 E/A roof gutters connected to RWH tanks P15 M/C Shop & Shop-5 M/C Shop roof gutters connected to RWH tanks 285 KL from RW utilized to process application in 2013-14

Rain Water Harvesting


Carbon footprint

• Carbon negative in terms of both Scope 1 and 2 • Increased green coverage from 43% to 48% in 2013-14

ASHOK LEYLAND - CARBON CREDITS / DEBITS

Category Hosur - 1 2012-13 2013-14

Carbon debits: Data tCO2e tCO2e

Scope 1 Foot print -12-13 base year 6859 2340

Scope 2 Foot print (Electricity purchased) 1200000 1524 5632

Scope 1 & 2 Total emissions 8383 7972

Carbon Credits:

Wind Power 12372000 15708 10295

Plantation 2800 57 62

KWH reduced through EC projects 151600 192 396

Total credits earned 15957 10753

Net credit / debit wrt Scope1 -9098 -8413

Net credit / debit wrt Scope1+Scope2 -7574 -2781

Remarks wrt Scope1 C -ve C -ve

Remarks wrt Scope1 + Scope2 C -ve C -ve

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Location Thermax RXA 06 Boiler at Main

Canteen Project /O&T no H113S2165 /PUR 04 dt 07.12.13

Canteen Boiler Bio Fuel(PME) Feeding Trials

PM 2.5 with HSD : 39 ppm

PM 2.5 with Bio Fuel : 9 ppm

Flue Gas Analyser

Renewable energy -Alternate fuel for Canteen boiler in place of HSD

Benefits

•Fresh HSD procurement of 7500

Litres/Month reduced.

•Cost Savings : Rs 44475 /Month

•GHG Emissions Reduction : 80%

•Carbon Neutral Initiatives

•Steam Temperature : 140 Deg C

VOC 0.11%

•Steam Temperature : 140 – 160 Deg C

•No.of Hrs of Boiler Running : 10 Hrs/Day

After:

•Palm Methyl Easter(PME) Bio Diesel

introduced

•Average Cost of Fuel/Month: Rs 3.97 Lakhs

•Stack Emissions : CO 13 mg/m3

SO2 0 mg/m3

VOC 0.02 %

Before:

•Boiler Steam Capacity: 600 Kgs/Hour

•BS3 grade HSD Consumption :300 Litres/Day

•Average Cost of Fuel/Month : Rs 4.42 Lakhs

•Stack Emissions: CO 55 mg/m3

SO2 9 mg/m3


•Reclamation of used oil through recycling for rough cutting operations – Recurring saving of 1.3 lakhs/ month effected from Aug 2011 •Recycling of 2900lits of coolant /month •Installation of purifying system for soluble cutting oil recycling from Dec’11 – Recurring saving of Rs.40000/ month

COOLANT RECLAMATION PLANT

RECYCLE

ISO 14001: O&T No – S5 MS/0043

Wealth from Waste

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0

1000

2000

3000

4000

5000

6000

7000

8000

Apr'13 May'13 Jun'13 Jul'13 Aug'13 Sep'13 Oct'13 Nov'13 Dec'13 Jan'14 Feb'14 Mar'14

oil sent Yield

Analysis

Used cutting oil from machines

scraped as hazardous waste

Status

Used cutting oil collected from various

machines recycled & reused in machines

SC LC AP

WP WE RD

cutting oil recycling from hazardous waste cutting oil Hazardous waste cutting oil 9

barrels reclaimed from 15 barrels of waste cutting oil

Avg.1800 lit of hazardous waste generation reduction /month

Avg.1800 lit of hazardous waste generation reduction /month .

Waste cutting oil hazardous waste generation Reduced from 3000lit/month to 1200 lit s/Month

.

Benefits

Reduction of Hazardous waste generation by 1800 lits/month

Recycling of 1800lits of coolant /month

Operating cost reduction of Rs 1.15 lakhs/month

Waste oil reclamation - To Protect Our Environment by Reducing Hazard Waste Generation

Oil Sent for reclamation :71800 ltrs Usable oil received : 45952 ltrs Yield : 64%

2013-14 Oil reclamation trend


All 5 trials resulted in achieving 100% tool life and performed at par with OE tool The trial phase where low / medium cost tools were tried out has yielded an overall

cost savings of Rs. 2.04 Lacs In addition to the above durable accessories like insert wedges and insert cartridges

can also be repaired / reconditioned by the supplier.

Earlier Methodology

Damaged item

Replace with new one

Scrap disposal

Damaged Cutter

Disposal

Modified Methodology

Damaged item

Repair

Reuse

Reuse @ 100% tool life, same quality and

lower investment

Damaged Cutter

Cutter body Regeneration

Pocket Milling on regenerated body

Cutter ready for use

Project Resurgence …..an initiative from - Hosur-1 Team

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• Dignitaries from Left to Right-Lt.Gen.JS Ahluwalia, PVSM (Retd),

• Vindi Banga, Ex Chairman HUL, Anders Spare CEO, Hinduja Automotive Ltd, Rt.Hon.Baroness Verma, Minister in Govt of UK.

Golden Peacock Climate Security Award 2011


Awards in Energy Efficiency

and Environment Protection

Categories

External awards for energy efficiency and Environment management

Project : Recovery of fresh coolant from waste coolant

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• Individual monitoring and reporting system

• Limited cross communication • Knowledge islands

Present system

New System

System installed in all Mfg units & monitoring started from 1st Oct 2014 .

Way forward….

New tools to cut Energy waste

Cloud hosted infrastructure , can be accessed by any internet enabled devices including cell phones

Real time energy monitoring . Faster, richer & more informative. All Mfg units connected to cloud server. Effective utilization of internal expertise across

all Units. Energy CFT – on line auditing, sharing of ideas & finding solutions via internal resources


New tools to cut Energy waste

http://www.google.co.in/url?url=http://www.exelanz.com/2013/06/what-is-a-cloud-server/&rct=j&frm=1&q=&esrc=s&sa=U&ei=yTw-VLWtGdSJuAS7xYDADw&ved=0CDcQ9QEwEQ&sig2=oK-P-dCG4qiZ26B15d_Hzw&usg=AFQjCNGnGQoH2wBULabO86clwiTBmPz6RQ

http://www.google.co.in/url?url=http://www.123rf.com/clipart-vector/way_forward.html&rct=j&frm=1&q=&esrc=s&sa=U&ei=McZAVOztGo-JuATju4CYBw&ved=0CDMQ9QEwDzgo&sig2=Ia3ONeS_GfKVnrN5oT2FkA&usg=AFQjCNGzO6hRjHqjHVlgMnjCDPrbd6yFCg

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ALWAR plant contracted demand is 950 KVA & present load is 850 KVA. Expecting more load in view of new bus body activity, “mistake proof arrangement” implemented. Expected benefits are: Alwar plant can make use of existing contracted demand to maximum extent without running of DG sets with less no of power interruptions. This system will give ALRAM alert through SMS / E mail to Executives, Audio & Visual indication to operators. If no response to ALRAM, then system will trip to avoid excess penalties to SEB.

Maximum Demand Control Alarm & Tripping Circuit at Alwar Plant

Solutions through Energy CFT

Capacitors are energy saving devices, internal losses from standard capacitor will be less than 0.5 watts per kvar.

H2 load, 10 pm to 1 am : 2200 KW & 1 am to 8 am : 400 KW as per latest trend & consumption will be around 13000 Kwh from 10 pm to 8 am.

Transmission & distribution (T&D) losses will be around 6% , estimated T&D losses 13000 Kwh x 6% equal to 780 Kwh.

Reduction in T&D losses = T&D losses x (1-(old pf/new pf)2) = 780 x (1-(0.95/0.99)2)= 780 x (1-0.96) = 780 x .04 = 31.5 Kwh per day.


Solar roof top panels at Mfg plants

Heat pumps for high power intensive washing machines

Solar light pipes for engine assembly area

New Air ventilation system in place of Air conditioners

LED lighting for streets & store areas

VFD for high power intensive AHU blower motors

Improve Power Quality at selective areas

Reconditioning of power intensive furnaces

Replace old conventional lighting to energy efficient lighting

Modification in AHU’s & test bed ventilation system

Future plans

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Thank you

Ashok Leyland Hosur- Unit 1 · Energy Management - 2014” Ashok Leyland Hosur- Unit 1 2 11/1/2014...

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