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Bajaj Auto Ltd. Aurangabad Division Welcomes you all

Energy Management 2013. Bajaj Auto Ltd. Aurangabad Division Welcomes you all . Contents. Company profile Manufacturing process Energy Conservation cell Scope Energy Indices /Benchmarks Energy Conservation Methodology Energy Conservation Approach Energy cost loss Tree

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Bajaj Auto Ltd. Aurangabad Division Welcomes you all

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  1. Energy Management 2013 Bajaj Auto Ltd. Aurangabad Division Welcomes you all

  2. Contents • Company profile • Manufacturing process • Energy Conservation cell • Scope • Energy Indices /Benchmarks • Energy Conservation Methodology • Energy Conservation Approach • Energy cost loss Tree • Innovative Projects • Other Encon Projects • Electrical • Use of renewable energy • Thermal • Environment & Carbon Reduction • Utilization of waste • Results • Sustenance • Future Project • Achievements

  3. Company Profile • The Bajaj group was established in 1945 by Shri. Jamanalal Bajaj, a close associate and disciple of Mahatma Gandhi. • He believed in sound and fair business practices based on respect for customers and integrity • Bajaj remains committed to these VALUES Bajaj Group Automotive Electrical & Home Appliances Steel & Engineering Finance & Insurance Power & Infrastructure Bajaj Auto Limited - The flagship Company of the Bajaj Group. • Current world market standing Ranked as the World’s fourth largest two & three wheeler manufacturer

  4. Company Profile Manufacturing locations Pantnagar Plant – • Plant and its vendors in the same premises. • Plant produces Discover, Boxer & Platina range of motorcycles. Bajaj Auto Ltd- Corporate Office Akurdi, Pune Waluj MC Plant - • Manufacturing of 2-wheelers • Caters to the major export needs. Waluj CV Plant - • Manufacturing of 3-wheelers & parts thereof. Chakan Plant - • Tries and tests various new concepts. • Manufacturing of High Performance bikes.

  5. Approach for Improvement Key Management Index Company Vision TPM Key Performance Index Company Mission Key Activity Index ISO 9001 ISO 14001 OHSAS 18001 ISO 50001- Initiated

  6. Process Flow Chart Press & Fab. Aluminium Shop Vendor parts Domestic Dispatch Paint Steel Shop Vehicle Assly Engine Assly Export Dispatch Heat Treatment Central Gear Shop Total Number of Equipments - 1840 nos.

  7. Flow Chart - Energy Conservation Program Company Vision/Mission Plant Vision/Mission Management Review Shop Level Target Execution & Monitoring Energy Manager Encon Projects Budget Allocation

  8. Energy Conservation Cell Corporate Bi-Monthly Review Plant Head Monthly Review Fortnightly Div Head Div Head Div Head Div Head Div Head Div Head Machine Shops Utility CGS/HT Press & Fab Paint Shop Assembly Energy Mgr. Weekly Dept. Head Dept. Head Dept. Head Dept. Head Dept. Head Dept. Head Daily Energy Captains Energy Captains Energy Captains Energy Captains Energy Captains Energy Captains

  9. Time spent by Senior Executives in various functions

  10. Encon Strategy • Eliminate wastage of Resourcesby maximizing Productivity of all • operations & Processes • Adopt in the faster pace for Deploymentof all ideas in all areas • of Business Thru “Maximizing Involvement of People • Focus on accomplishing investment projects, with Payback • less than two year at faster pace & its horizontal deployment • Procurementof Energy Efficient Equipmentfor new installation • Earlier-Conserve + Preserve + Reserve • Now-in addition to above: Reduce + Reuse + Recycle Share the best practices among employees, vendors,suppliers & other partners Implement More& More ENERGY KAIZEN

  11. Approach towards Encon • Micro Level Monitoring • Judicial Energy Utilization • Harnessing Solar & Wind Energy • Carbon Emission Reduction • Sustainable Business Growth • Green Factory 2010 -2015 Improvements • Technology Up gradations • Energy Optimization • System Auto controls • Waste Minimization 2002-2009 • Energy Conservation Techniques- • Localized control • Human Dependent systems 1998-2001 • Working on Legacy system 1985-1997 Year

  12. Specific Energy Consumption Energy Consumption per unit of production

  13. Specific Energy Consumption-Benchmark No Standard Benchmarks are available for Automobile sector , However, we are setting our own internal targets as: Min 5 % Reduction in specific energy consumption wrt last year

  14. Stratification of Energy consumption Electrical Energy consumption LPG Energy consumption

  15. Energy Conservation Methodology

  16. Energy Conservation Methodology & Idea Electrical Energy Loss Reduction / Elimination Technological Improvement Operational Control Loss Elimination Alternate Source Efficient Equipment

  17. ENCON Idea Table Reduction of Electrical Energy Consumption Per Vehicle

  18. ENCON Idea Table Reduction of Compressed Air Consumption Per Vehicle

  19. Energy Conservation Methodology & Idea Fuel (LPG) Energy Loss Technological Improvement Operational Control Loss Elimination Alternate Source Efficient Equipment

  20. ENCON Idea Table Reduction of LPG consumption per Vehicle

  21. Innovative projects

  22. Distribution Loss reduction Innovative Project -1 132 KV supply from MSEDCL GTL Limited Energy meter Shop Wise Energy meters MRS + MSEB Metered consumption Plant Metering = Distribution Loss

  23. Reduce Losses of distribution network Innovative Project -1 Distribution Transformer-2 MVA( 11 KV/433 Volts) – 29 Nos. in Waluj Plant

  24. Reduction of Inductive load losses Innovative Project -2 Power Factor /Reactive power compensation at Press & Fabrication shop • Unity Power Factor Ensures reduction in distribution loss & get Incentives . • Balanced & stable Load can be catered using switched capacitors & can be contactor or Thyrister based. • Capacitors contributes in amplifying harmonics in system due to resonance. • Unbalanced load are large single phase loads distributed on 3 phase system with lot of diversity • Two Phase MIG welding machines are in use in large no. This is typical form of unbalanced load . As a result KVAR requirement differs in each phase & also changes very quickly . • It is not possible to compensate such requirement with simple switching capacitors.

  25. Reduction of Inductive load losses Innovative Project -2

  26. Reduction of Inductive load losses Innovative Project -2 Power Factor /Reactive power compensation at Press & Fabrication shop Before • We can see • KVAR requirement varies from 75 KVAR to 200 KVAr • Current varies from 500 A to 1200 A • Different in different phase – Typical unbalanced load Power factor also varies from 0.6 to 0.95 & correction required is also unequal

  27. Reduction of Inductive load losses Innovative Project -2 Power Factor /Reactive power compensation at Press & Fabrication shop After

  28. Reduction of Inductive load losses Innovative Project -2 Saving : 1.26 LKwh/ Yr Investment : Rs. 15 lacs

  29. Reduction of compressed air loss Innovative Project -3

  30. Reduction of compressed air loss No Job No Air Dial Gauge Solenoid valve Sensor Switch

  31. Electrical- Lighting

  32. Electrical- Lighting

  33. Electrical- Lighting Paint Booth Lighting( flame proof) Task Lighting in machine shops Before After Before After Use of Structure Tube lights (2*40 Watt) at 5 meter height Use of 36 W Tube light at 1 Meter Height Use of 8 X 40 W Tubes Use of 6X 36 W CFL 300 Fittings Saving : 0.35 LKwh/ Yr Investment : Rs. 2.5 lacs Saving : 1.26 LKwh/ Yr Investment : Rs. 30 lacs

  34. Electrical- Fans & Blowers Installation of Spot cooling System to replace Old type ARP system Replacement of 30 inch size Air circulator by 24 inch ( 150 Nos) Before After Before After Centralized ARP cooling system With 100HP motor 350 Watts air circulators 200 Watts air circulators Breeze air spot coolers used With 2 HP blowers (18 No.) Saving : 1.21 Lacs Kwh /Year Investment : Rs. 7.5 Lacs Saving : 1.28 Lac kwh/Yr. Investment : Rs.16 lacs

  35. Electrical- Pumps & Motors Pump Elimination Pump Optimization Before After Before After Application :Therrmic fluid circulation Motor power-25HP 37 Kw Motor Total Load -67 Kw 75 Kw Motor Total Load -102 Kw 25 HP gland pump replaced with mechanical seal pump . Also eliminate gland cooling pump of 5 HP Energy Saving : Rs. 13.28 Lacs/Yr Investment : Rs.26 Lacs Energy Saving : Rs. 2.27 Lacs/Yr Investment : Rs. 2.68 Lacs Horizontal deployment – 3 Locations

  36. Electrical- Pumps & Motors Installation of VFD for Exhaust blower in paint shop Use of Energy Efficient motors Before After Before After No VFD, Exhaust blowers-7 Nos. running at constant speed for 18 hours /day Conventional Motor used for Actual Load – 37 KW Energy Efficient motor IE3 motors in paint shop VFD Installed Blowers running at 50 % speed in recess time Saving : Rs. 0.56 Lacs / Yr Investment : Rs. 0.78 Lacs Horizontal deployment : 5 Saving : 0.35 Lacs Kwh/Year Rs. 2.45 Lacs Investment :Rs. 4.3 Lacs Horizontal deployment : 2

  37. Electrical- Compressed air

  38. Electrical- Cooling Fanless Cooling Tower Optimum temperature for ACs / coolers Before After Temperature settings Localised storage tank Air Movement in cooling Tower induced with the help of Exhaust Fan of 4 HP Provided cooling tower equipped with water jet technology. i.e. Air movement in cooling tower induced with the help of water Jet. Energy Saving : Rs.1 Lacs/Yr Investment : Rs.1.8 Lacs Horizontal deployment : 3 locations Saving : 0.1 Lacs kwh/Yr. Investment : Zero

  39. Electrical- Cooling Energy Efficient equipment installation Before After Air Dryers -5000 CFM capacity With Reciprocating compressors replaced with Scroll compressors air dryers – 4 Nos. CED Reciprocating chiller 110 TR (0.9 Kw/TR) Screw chiller 80 TR (0.71Kw/TR) Energy saving : 0.4 Lacs Kwh /Annum Investment: 13 Lacs Energy saving : 0.8 Lacs Kwh /Annum Investment: 8 Lacs

  40. Electrical –Method change Electrical Heating TO LPG Heating Electrical Heating TO Heat Pump After Before After Before Heat pump For washing machine water heating Electric Heater Electric Heater LPG Burner For Heating Electric Heater was used for Water heating of pre washer on CGC Furnace -54 KW Electric Heater was used for Water heating of washing machine LPG Heating is used Saving : Rs.1.75L / Year Investment : Rs. 3.1 Lacs Horizontal deployment : 20 locations Saving : Rs.3.26L / Year Investment : Rs. 3.5 Lacs

  41. Thermal Total Identified Points – 24 Heat Loss- 63456 K Cal /Hr Rectified Insulation of High heat Zone Saving - 27 Ton LPG /Year We have conducted Thermal Imaging for identifying heat losses in paint ovens

  42. Thermal

  43. Use of Renewable Energy Installation of transparent roofs in dispatch yard Solar water Heating System Make up water is heated by Solar water heating system which reduces load on LPG water heater Transparent roofs- Qty: 78 No.s LPG Saving : 3396 Kg / Year Saving : Rs.1.4 Lacs / Year Investment : Rs. 5 Lacs Saving : Rs. 4 Lacs / Year Investment : Rs. 3.12 Lacs

  44. Use of Renewable Energy Reflective system Solar Lighting – Use of Light Pipes in assembly Light Collector & diffuser Roof Installation Horizontal Deployment : 25

  45. Use of Renewable Energy Generation of Electrical Energy with Windmill Power Project At SATARA & SUPA area in Maharashtra Wind mills are installed for Electrical Power Generation. Target

  46. Use of Renewable Energy

  47. Use of Renewable Energy Solar Photo voltaic Power Plant- 20 Kw Future Projects : • Rooftop Solar Power Plant Up to 10 MW • Open access Power trading

  48. Summary of ENCON projects

  49. Result Electrical Energy Consumption / Vehicle Kwh/Veh 69 %

  50. Result Thermal Energy Consumption / Vehicle 48 % Kg/Veh

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