By

TATA Motors Ltd. CVBU, Pimpri, Pune

CVBU Pune

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

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

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

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

407 SFC
EX

16.6%

207 DI

22.0%

SPACIO

14.70%

2515 LPT
(697 TCIC)

15.30%

12.3%
1

1613 SE/ LPT

9.8%
CUM - 22 %
.
19.2%
1510 LP

8.1%
CUM - 27.3%

709 LP/ LPT

EX

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

Jul-03

Apr-03

Jun-03

2002-03

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

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

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

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

Sr.

Name of

No

Automobile Player

TATA Motors Pune

(Excluding Foundry)

Year
Kwh/Eq.Veh.
% reduction
over 2000Kwh/Eq.Veh.

TATA Motors Jsr

TATA Motors Pant

Nagar

Mahindra & Mahindra

, Kandiwali Plant
(Maharashtra)

Mahindra & Mahindra

, Medak Plant (AP)
Mahindra & Mahindra
, Nashik Plant
(Maharashtra)
General Motors
(India) Pvt. Ltd.
(Gujarat)

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

20022003

1175.0 1003.0

% reduction
over 200708
Kwh/Eq.Veh.

Sp. Energy Consumption

20012002

835

Data Not
Available

% reduction
over 200001
Kwh/Eq.
Veh.
% reduction
over 200708
Kwh/Veh.

TATA Motors Car

Plant Chikhali

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

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

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

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

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

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

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

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

140C

30.6C

1st
Stage

47.6C

118.2C

1st Stage
Inter
cooler

2nd
Stage

43.2C

76.2C

2nd
Stage
Inter
cooler

3rd
Stage

35.8C

After
cooler
Air Out

Air In

32.8C

32.8C

32.8C

Inlet Water
40.2C

38.2C

35C

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

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

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.

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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.

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Reciprocating Compressor Air & Cooling Water Temperature Audit

32.2C

32.2C

32.5C

90.4C

31.8C

Inter cooler

LP
Stage

79C

29.8C
Aftercooler

HP
Stage

Air Out

Air In
28.6C
32.4C
Inlet Water

28.6C

28.6C

31.5C

34.2C

Outlet Water

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ENCON CASE STUDIES - 01

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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

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After Introduction
After
ModificationBack Flushing System:-

Inter-cooler & after-cooler of compressor are cleaned with out waiting for
schedule maintenance .
It results into
3C 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

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Sr. Item Description

N

Before Back
After Back Flushing
Flushing Modification Modification

Compressed Air Temp. after

Inter-cooler

Avg. 41 oC

Avg. 37.8 oC

Compressed Air Temp. after

After-cooler

Avg. 36 oC

Avg. 34.5 oC

Inter & After Cooler Maint. time

reduction

18 Mandays

2 Hrs.

Compressor Reliability on
account of I/C & A/C

100 %

Compressed Air Quality

Improved

Energy Consumption
reduction

8426
Kwh/Comp/annum

Total Saving in Energy Consumption / Compressor =

8424 Kwh/annum/comp.
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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.
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