Oil Engines Limited Kagal Kolhapur

KIRLOSKAR OIL ENGINES LIMITED
Introduction Of KOEL
Energy Management
Specific Energy Consumption & Benchmarking
Energy Conservation Projects
Waste Recovery Projects
Energy Monitoring & Reporting
Water Conservation & Management
Environmental Improvements
Green Energy
Corrective Preventive Actions
Energy Efficient Products
Trainingg & Awareness
Corporate Society Responsibility
Introduction Of KOEL
KOEL Vision & Values

Vision
To Be Amongst The Top Ten Global Players
I Off-high
In
Off hi h Way
W Engines
E i
B i
Business
KOEL
Values
TRANSPARENCY
Kagal Plant Location & Overview

KOEL Total Sales Turnover
KOEL Power & Fuel Cost
Rs.
2,276
Crs..
Crs
Mumbai Pune
Kolhapur
Rs.
27 41
27.41
Crs..
Crs
% of Energy Cost wrt

Sales Turnover
1.20 %
KAGAL Plant Sales Turnover @

KAGAL Plant Power & Fuel Cost @
KOEL Kagal
Rs.
902
Crs..
Crs
Rs.
11.92
C
Crs
6.5 km
% of Energy Cost wrt

Sales Turnover
1.32
1 32 %
Satellite View of Kagal Plant
Expansion
p
in Progress
g
Helipad
CPCP
Rainwater Harvesting Pond
4.5
4
5 MW Captive
Genset plant
Main Plant
Genset Plant
Products & Application

Export as well as Domestic
Engines:
Air cooled and water cooled engines of
2 3 & 4 Cylinder
2,3
C li d Engines
E i
10 0 ~ 105 HP
10.0
Varsha Pump sets
Gensets with Air cooled & Liquid

Cooled Engines.
5 ~ 600 KVA
Production Process
Machining Lines
Receive Bought out

finished components
Crank Case
Storage
Cylinder
y
Head
Engine Assembly
Crank Shaft
Engine
Test
Engine
Paint
Cam Shaft
Connecting Rod
Engine
Up fitment
Storage
Engine
Dispatch
Energy Management
KOEL-- Energy Policy

KOEL
Energy Management Program Of
KOEL Has Driven With Respective To
Energy
gy Policy
Policy.
y.
Established On Global Energy
Scenario, Challenges & Revised Time
To Time As Essential
Energy
E
C
Conservation
ti
Obj
Objectives,
ti
Targets & Programs Are Derived In
Line With The Policies
Policies..
KOEL Policy Is Signed By Executive
Chairman - Mr
Mr.. Atul Kirloskar, This
Represents Strong Commitment
From Top Management To The
Subject
Energy Policy
First Published In 2003
3rd Revision In Dec 2011
3rd
Revision
on 14th
Dec 11
Dec.11
ENCON Committee
ENCON
Team Kagal
ENCON
Team Pune
ENCON
Team Nashik
ENCON
Team Rajkot
ENCON Team
From Cross Functional Departments (at each Location)
Utility
Maintenance
Machine
Shop
Assembly
Genset
Plant
Finance
HR
Admin
CPCP
Stores
Driving Mechanism
Annual
Assessment
for
Achievements
& Celebration
Annual
Budget &
Projects
Finalization
EMS
Monitoring &
p
g
Reporting
Projects Study,
Assignments to
Team &
Execution
Improvements
Th Kaizens
Thru
K i
KOEL
ENCON
Management
Training &
Awareness
Implementation
of Suggestions
From Employees
Cross
Funtional
Team Regular
Meetings
Monthly
Review By
Plant Head
External Audits
- Projects
Finalization &
Implementation
Bi-monthly
Review By
Executive
Director
ENCON Part of Individual's PMS
ENCON Part of Individual's PMS
Specific
p
Energy
gy
Consumption Reduction &
Benchmarkingg
Reduction in Specific Energy Consumption

Electricity (kWh / BHP)
6.17
200809
Production in
BHP
Addition of
Load in kW
900708
39%
Reduction
Over FY09.
KWh/BHP
3.86
3 73
3.73
3 72
3.72
200910
201011
2011-12
2989151
3579117
3033468
450
300
Reduction in Specific Energy Consumption

Fuel (Liters / BHP)
16 %
Reduction
Over FY09
Liters /BHP
0.19
0.16
200809
Production in
BHP
900708
0.15
0 15
0.16
200910
201011
2011-12
2989151
3579117
3033468
SEC Benchmarking
MNC Compititor 1
MNC Compititor 2
3.72
4.00
4.80
kWh / BHP
KOEL Kagal
* Source Data : MEDA Presentations

CII
CII-- Code For Ecologically Sustainable
Growth - Benchmarkingg
Specific Consumption Of Energy And
Water
Reduce By 3-5% Every Year
Over Next Ten Years.
Specific Generation Of Waste & Waste

Reduce By 3-5%
3 5% Every Year
G i TTo LLand
Going
d Fills
Fill
Use Of Renewables Energy
Increase By 5% Every Year
GHG Emissions And Other Process

Emissions
Reduce
Red ce B
By 3
3-5%
5% Every
E er Year
O er Ne
Over
Nextt Ten Years
Years.
Recyclable And Enhance Recyclability Increase Use Of Recyclable And Enhance Recyclability Of
Of Resources
Resources Embedded In The Product.
Share Of Harvested Rainwater In The
Overall Annual Use Of Water
Increase By 5% Every Year
Life Cycle Assessment Criteria For

New Products.
Incorporate Life Cycle Assessment in Alternative

Technologies And Products.
Adopt Green Purchase Policy

Product Stewardship Program
Depletion Of Natural Capital
Adopt Green Purchase Policy & Incorporate Clean

Technologies At Design Stage
Promoting & Managing Product Stewardship
Program, By Forging Partnership With Business And
Communities
Communities.
Reduce By 5% Every Year
Over Next Ten Years
Energy Conservation
Projects
Project Summary (2009 12)
Total No. of
Encon
Projects: 50
Annual
Energy
Savings in
kWh
(Units):
2.10 Mn.
Annual
Energy
Savings:
Rs. 11.75
Mn
Total
Investment:
R 13.36
Rs
13 36
Mn
Simple
Payback :
14
Months.
ENCON Projects Zero Investment
SN
Title of Energy
gy savingg project
p j implemented
p
Machine Power Pack Motors interlocking with

machine cycle
Stop the wastage of metal halide lamps in Genset
2
shop floor
Year
Annual Electrical
Invest
Savings
Units
Rs
Rs
Mn
Mn
Mn
Payback
months
th
2009-10
0.004
0.309
Nil
Immediate
2009-10
0.017
0.104
Nil
Immediate
3 Logic for base flush coolant motor
2009-10
0.018
0.099
Nil
Immediate
4 Timer
Ti
f h
for
hydraulic
d li motor operation
i
2009 10
2009-10
0 004
0.004
0 022
0.022
Nil
I
Immediate
di
2010-11
0.099
0.567
Nil
Immediate
2010 11
2010-11
0 023
0.023
0 132
0.132
Nil
Immediate
2010-11
0.027
0.11
Nil
Immediate
2010-11
2010
11
0 09
0.09
0 036
0.036
Nil
Immediate
2010-11
0.002
0.013
Nil
Immediate
All Induction motor switched OFF, after machine

was idle for more then 5 min in RCC
Con rod Line power saving through logic
6
modification of Milling spindle.
Air supply shut down after machine was idle for
7
more then 5 min at RCC -13, CRS - 7.
8 OP 10A & OP 10B transfer cylinder air blocked

9
Replacement of sodium vapor lamps substation

area with energy efficient T-5 Lightings.
22
ENCON Projects Zero Investment
SN
Title of Energy
gy savingg project
p j implemented
p
Year
Selector switch was placed on control panel for ON

2010-11
and OFF of work light
Logic modification for for hyd. & coolant motor to
11
2011-12
stop after 5 min idle running at Con Rod Line
Reducing the Pressure setting of Laser cutting
12 machine to Min Specified Pressure thereby
2011-12
reducing total plant pressure by 0.9 bar
10
13 Instead of two motor for coolant one motor

Power saving by modifying logic of PT line basket
operation
Power saving logic modification for RCH & HCH
15
OP90/120 Widma machine.
Gauging station at HCH & CON line power saving
16
through modifing circuit
circuit.
14
Annual Electrical
Invest
Savings
Units
Rs
Rs
Mn
Mn
Mn
Payback
months
th
0.001
0.001
Nil
Immediate
0.074
0.483
Nil
Immediate
0.060
0.390
Nil
Immediate
2011-12
0.018
0.117
Nil
Immediate
2011-12
0.016
0.105
Nil
Immediate
2011-12
0.007
0.043
Nil
Immediate
2011-12
0.002
0.011
Nil
Immediate
Zero Investment Innovative Project

Program Modification
All Auxiliary equipments
All Auxiliary equipments
used to be ON during
get switched OFF after 5
Machine Idle time.
Mins of Idle time.
CNC Machines
Hydraulic Oil Pump 1
Panel Cooler
Logic Modification
Coolant Pump
Air Supply Valve
Hydraulic Oil Pump 2
KIRLOSKAR OIL ENGINES LIMITED KAGAL PLANT
Oil Chiller
Illumination lamp
24
ENCON Projects Low Investment
SN
Title of Energy saving project implemented
Use of regenerative load bank instead of resistive

load bank for 10 kVA-30 kVA
Air saving through pressure regulating flow control
2
valve on RCH OP-50
Speed reduction of blower motor of batch type
3
oven
Speed reduction of Blower motor on Pretreatment
4
Line
Year
Annual Electrical
Savings
U i
Units
R
Rs
Mn
Mn
Invest.
Rs
R
Mn
Payback
months
2009-10
0.041
0.245
0.025
2009-10
0.026
0.158
0.008
2009-10
0.026
0.158
0.058
2009-10
0.013
0.079
0.058
5 Use of Energy Efficient motor on Thermopac
2009-10
0.013
0.079
0.058
6 Reduce
R d
C
Consumption
ti off A
Auto
t conveyor motor
t
2009 10
2009-10
0 002
0.002
0 009
0.009
0 001
0.001
0.266
0.013
0 234
0.234
0 025
0.025
0.133
0.010
Use of regenerative load bank for 3 phase 220V 60

2010-11 0.046
HZ genset
Use of regenerative load bank instead of resistive
8
2010-11 0.041
0 041
load bank for single phase gensets in ME
Load optimization of LT 2.5 MVA transformers and
9
2010-11 0.023
stopping one 2.5 MVA transformer.
7
ENCON Projects Low Investment
SN
Con rod Line Coolant lift up pump power saving

through logic modification.
Use of regenerative load bank for testing 3ph, 220V,
11
60Hz gensets in ME Genset testing
Modification of Water line in Plant 2 to eleiminate
12
Pump Operation
Installation of humidity sensors in all AHU pump
13
motors
10
14 Installation of occupancy sensors in all toilets

Stopping of Fume collector during machine idle
time
For operating APG foot paddle was given to reduce
16
air consumption and leakage . op (10A & OP 100 )
15
17 Automatic
A
i timer
i
switch
i h ffor Li
Lightings
hi
iin Pl
Plant 2
Year
Annual Electrical
Savings
U i
Units
R
Rs
Mn
Mn
Invest.
Rs
R
Mn
Payback
months
2010-11
0.010
0.059
0.007
2010-11
0.063
0.025
0.008
2010-11
0.023
0.018
0.002
2011-12
0.010
0.068
0.036
2011-12
0.009
0.059
0.042
2011-12
0.006
0.037
0.001
2011-12
0.006
0.036
0.002
2011 12
2011-12
0 002
0.002
0 013
0.013
0 001
0.001
Innovative Project - Use Regenerative Load Bank

For testing of Single phase Gensets (15 to 30 kVA) Genset Resistive
load banks were in used. In which Energy get wasted for testing.
Test Beds
d are shifted
h f d on Regenerative Load
d bank.
b k
Energy Savings
Calculations
Numbers of Testing of Single Phase Gensets @ 200 per

month.
Average units saved per Genset = 17 units
Total Saving per Annum : Rs. 0.234 Mn
ENCON Projects Moderate Investment
SN
Year
Annual Electrical
Savings
U i
Units
R
Rs
Mn
Mn
Invest.
Rs
R
Mn
Payback
months
1 VFD Installation for plant 2 compressor
2010-11
0.103
0.615
0.450
2 VFD installation for CPCP Screw Compressor
2010 11
2010-11
0 073
0.073
0 417
0.417
0 315
0.315
2010-11
0.072
0.413
0.220
2010-11
2010
11
0 058
0.058
0 333
0.333
0 250
0.250
2010-11
0.045
0.259
0.345
16
2010-11
2010
11
0 041
0.041
0 236
0.236
0 370
0.370
19
7 Replacement of Centrifugal Compressor Intercooler. 2010-11
0.031
0.179
0.175
12
8 Replacement of Low efficiency cooling tower pump 2010-11
0.029
0.167
0.290
21
0.025
0.143
0.400
34
Use of induction heating furnace for Crank shaft

Gear heating
VFD Installation for preheating blowers and
4
circulation blowers in Powder coating plant
Replacement of water pumps with higher efficiency
5
pumps with VFD control
Above 5 Hp Coolant motor power saving through
6
VFD interfacing in all 5C.
3
Installation of Fanless cooling tower for Small

engines with elimination of Varsha Cooling tower.
2010-11
ENCON Projects Moderate Investment
SN
10

VFD Installation for Burner blowers and dust
collector motor in CPCP ( 4 Motors)
Year
Annual Electrical
Savings
U i
Units
R
Rs
Mn
Mn
Invest.
Rs
R
Mn
Payback
months
2010-11
0.024
0.138
0.318
28
11 Installation of VFD for Cooling tower fan and pump
2010-11
0.019
0.112
0.232
25
12 VFD Installation for Shot blasting machine
2010-11
0.014
0.083
0.129
19
2010-11
2010
11
0 012
0.012
0 069
0.069
0 100
0.100
17
13
Shifting CPCP load to 500kVA Power house

transformer and stopping 1MVA Transformer.
Common Fan-less Cooling Tower

Objective Of Energy Conservation Measure: Install Common Fanless Cooling Tower
Instead of Two for Fan & Pump Energy Saving with added Chemical Cost reduction
Saving
Calculations
Energy saving per
day 79.92 Units
Energy saving Units /
Annum 24 935 Units
Energy Cost saving /
Annum -Rs 0.143 Mn
Investment : Rs. 0.4
M with
Mn
ith Pack
P k back
b k
34 Months
VFD For Screw Compressor

Objective of Energy Conservation Measure
Reduce Energy Consumption of Compressor
Use Feedback of Pressure thru Pressure

transducer & vary the motor speed to get
desired pressure & meet Air demand at end use
Energy savings
gy savingg 233 kWh ((Units)) p

Energy
per dayy
Energy Units saving per annum is 72700 kWh (Units)
Total cost saving per annum is Rs 0.42 Mn
Total Investment: Rs. 0.315 Mn
Simple Payback : 9 Months
Replacement of Intercoolers for Centrifugal

p
Compressors
Objective Of Energy Conservation Measure:
Reduction In Inter Stage Air Temperature By 10OC by Replacing the
Intercooler of Compressor, Energy Consumption also get Reduced
Energy savings Calculations
Energy saving observed per day : 100 Units
Energy saving / month observed 2600 Kwh
Energy Cost saving per month
: Rs 0.015 Mn
Total Annual Energy Cost saving : Rs 0.179 Mn

Total Investment
: Rs. 0.175 Mn
Simple Payback
: 12 Months
ENCON Projects High Investment
SN
Installation of Polycarbonate roofing sheets to

utilize Daylight
Replacement of 5 MVA transformer with low loss
2
transformer
Installation of Separate Lighting Stabilizer for
3
lighting load and other single phase equipment's.
Above 5 HP Coolant motor power saving through
4
VFD interfacing in 5C (Total 6 m/cs ) .
Year
Annual Electrical
Savings
U i
Units
R
Rs
Mn
Mn
Invest.
Rs
R
Mn
Payback
months
2010-11
0.321
1.841
4.897
32
2010-11
0.034
0.182
2.300
152
2011-12
0.301
1.956
1.650
10
2010-11
0.065
0.374
0.562
18
Polycarbonate Sheets for Day Light
Savings
Calculations
Energy saving due to utilization of High-bay Lamps per day : 1030 kWh
Energy saving: 26780 kWh (Units) / Month
Cost Saving / Month
h is - Rs. 0.153 Mn
Total cost Saving / year - Rs 1.85 Mn
Total Investment: Rs. 4.90 Mn
Simple Payback : 32 Months
Innovative Project Energy Saving Panel

for Single Phase Loads
Main Control Panel
MLDB Main Plant
MLDB Genset Plant
Offices Panel
Street Lighting Panel

Main Control Panel
MLDB Main Plant
MLDB Genset Plant
Offices Panel
Street Lighting Panel

650 kVA ES Panel for MP1

& Genset
G
t Load
L d
60 kVA ES Panel for CPCP

& Power House
Units Saving Per

Month
17220
1195
Units Saving per

Annum
206640
14350
Energy Cost Saving per

Annum
Rs. 1.36 Mn
Rs. 0.095 MN
Major ENCON Projects During Expansion Projects

- FY12
Air Dryer
T5- Lighting
5-Star AC
AHU with VFD
Spiral Duct - Inside Insulatio
In New Dining & Kitchen, T5 Energy Efficient Tube lights

Energy Efficient Air Conditioning Unit with high efficiency
for MP1 Building
For Plant3, Compressor with high Energy Efficient Motors
Energy Efficient Dryer for Air Compressor
All ACs procured with 5 Star rated efficiency
Machine Shop AHU with VFD installed
New Spiral ducting having internal insulation introduced
For Dining 5 star rated Fans
5-Star Rated Fan
Saving Achieved Thru New Energy Efficient

Equipment's During Project Stage
GENSET AHU-1 Consumption
80801
GENSET AHU2 Consumption

76128
27665
Saving Achieved Thru

kWh/Year If Energy
kWh/Year
Efficient
would
not
implemented
Equipments
Installation in
implemented Project Stage
Humidity Sensors
23436
kWh/Year If
would not
implemented
15392
kWh/Year
implemented
25956
kWh/Year If
kWh/Year
would not implemented
@implemented
2.35 Lacs Units per
O Annum
Occupancy
SSensors
A
18448
9225
kWh/Year If
would not
implemented
kWh/Year
implemented
Waste Recovery Projects
Steps Taken To Recover Energy Generated In

Testing
Electricity Generation By Utilizing Waste Energy During Engine Testing Process. More Than
3.03 Lac Units of Energy Generated in FY12
Reduce Component Weights to Reduce

Machining Time, Waste & Energy
Net
NEW
Weight
Initiatives to Reduce the weight of Crank Case Previous
Weight
Castings without affecting Reliability.
Reliability
Weight (Kg)
Reduction
(Kg)
(Kg)
16
2R1040 CRANK NCASE
94
78
19
9
3R 1040
040 CRANK CASE
CAS
117
7
98
15
4R 1040 CRANK CASE
136
121
5
HA2 CRANK CASE
56
51
26.5
HA3 CRANK CASE
98
71.5
24
HA4 CRANK CASE
122
98
23
HA5 CRANK CASE
147
124
23
HA6 CRANK CASE
168
145
16.8
RB 22 CRANK CASE
63.8
47
13
RB 33 CRANK CASE
79
66
30
6R CRANK CASE
204
174
5
6R HEADER
9
4
10
SL90 CRANK CASE
238
228
Improve OLE by Improving Maintenance

gy Wastage
g
Performance to Reduce Energy
MTBF - GENSET
MTTR - GENSET
MTTR in Hrs.
3.0
2.8
2.6
2.4
2.2
2.0
18
1.8
1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0.0
1.7
1.55
1.16 1.25 1.18
0.73
1.09
0.94
0.87
0.74
0.59
0.91
0.59
Avg. Avg. Apr-11 May- Jun-11 Jul-11 Aug-11Sep-11 Oct-11 Nov-11Dec-11Jan-12 Feb-12Mar-12
09-10 10-11
11
Avg. 09-10
MTTR
90
85
85
85
85
85
85
85
85
85
85
85
80
Y-09 Apr- May- Jun- Jul- Aug- Sep- Oct- Nov- Dec- Jan- Feb- Mar10 10 10 10 10 10 10 10 10 11 11 11
Avg 09-10
TARGET
OLE
401
394
395
406.0
393
392 395 401 396
399
Avg. 09-10
94
85
410.0
392
405
395
Avg. Avg. Apr-11 May- Jun- Jul-11 Aug- Sep- Oct-11 Nov- Dec- Jan09-10 10-11
11
11
11
11
11
11
12
Target
OLE -4R Assembly Line

100
MTBF in Hrs.
1.9
500.0
450.0
400.0
350 0
350.0
300.0
250.0
200.0
150.0
100.0
50 0
50.0
0.0
MTBF
Feb- Mar12
12
TARGET
Reduction in Overall Down time

Reduction in Repairs time
Analysis of Breakdown root causes &
eliminate
Training & Awareness
Coordination with Support
D
Department
t
t
Actions Review & Close Monitoring
Energy Monitoring &

Reporting
Schematic of Energy & Utility Management

System
I - Power EMS
RS 232 to RS 485 Data

Converter
Utility
Electricity
Main
Plant
Electricity
Gen-set
Plant
Electricity
Storage
Tank
levels
Diesel Flow
Air Flow
Energy Consumption Monitoring & Reporting

Energy Monitoring System:
Energy Monitoring Devices

1)
2))
3)
4)
5)
Energy Meters
122 Nos.
Air Flow meters
11 Nos.
Diesel Flow Meters
4 Nos.
Water Flow Meters
44 Nos.
Local Flow-meter Displays (Air, Water, & Diesel
Total 17 Nos) for User Monitoring
6) Single
Si l point
i t Computer
C
t display
di l att Utility
Utilit section
ti
(Energy Monitoring Software)of all flow meters
and Energy Meters.
Additional Flourishing Actions In Metering

New Meters Added (20#) For Power House & CPCP Plant for More
Detailing Of Energy Consumption at Various Load Centers
For detailed Water Consumption Monitoring New 20 Meters
Installed
Report Formatting Changed with Target Included (Trials Is In
Progress)
Air Flow Monitoring Started
Fuel Consumption Monitoring Accuracy Improvements Done
All Real & Historical Energy Consumption Data from all Meters are
connected to the EE-Lan
Lan Software.
Software
Auto Generated Report (Daily)
Demand Management
Maximum Demand (kVA) - FY12
6000
5000
4000
3000
2000
1000
0
April'11May'11June'11 July'11 Aug'11 Sep'11 Oct'11 Nov'11 Dec'11 Jan'12 Feb'12 Mar'12
Sanctioned Demand (kVA)
50% of SD
Power Factor - FY12

1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
1.00
0.99
1.00
1.00
1.00
Max Demand (KVA)
0.98
0.97
0.96
0.95
April'11May'11 June'11 July'11 Aug'11 Sep'11 Oct'11 Nov'11 Dec'11 Jan'12 Feb'12 Mar'12
Power Factor
Energy Balance
Total - Energy Balance
Fixed
Variable
Khadki Units
6%
4%
Fixed Energy Balance
90%
Administration building
ETP
Fire Hydrant
31%
1%
Power House
2%
Central Kitchen
41%
25%
Energy Balance
Variable Energy Balance
Machine Shop
Medium Engine
9%
GENSET
12%
19%
60%
Small Engine
Energy Monitoring Chart - Formats

Energy Monitoring Format used by each Area ENCON representative
Description
Apr
May
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Area/Section :Energy
Consumed
in (kWh)
Cumulative
Energy
Consumed
in (kWh)
Production
Quantity
Cumulative
Production
Quantity
SEC
Jan
Feb
Mar Total SEC
Energy Saving Reporting Format

Location
Title
Description of the energy conservation measure:
Picture before modification
Picture after modification
Total investment in Rs.

Annual Savings in Rs
Payback Period
Implementation Date:
Energy savings Calculations
Estimated Annual Energy Savings
Technology
SEC Monitoring Load Center Wise
SEC Monitoring Load Center Wise
Water Conservation &

Management
Water Conservation
Year
2008 2009
2009 2010
2010 2011
2011 2012
2012 2013
SWC - Engines (Lit/BHP)

Target
Performance
50
50
20
19
18
17
16 5
16.5
31
30.4
SWC Reduction Target not achieved because of Increase

Water Consumption
p
substantiallyy for New Kitchen,, which
has started for employees to get Fresh & Hot Food
(Breakfast & Meals) for All Shifts
Rain Water Harvesting

Rain Water Harvesting: 14 lacs Rs Spent last year for collection of Rain water, Total
80,000 M3 of rain water can be stored.
Environmental
Improvements
Kagal Plant Green Initiatives
Total Land Area
M2
650,900
,
650,900
,
Total Built-Up
Area
M2
55,688
72,797
Plantations
Area
M2
101,000
101,000
No. Off Trees
Nos.
5,097
7,245
M2
3,346
3,483
Natural Grass
M2
12,506
11,582
Rainwater
Harvesting
Mn Ltr.
18.35
18.35
Lawn
Plantation on Occasions of World Environment Day
Other Environmental Improvements
Packaged type Domestic

Effluent treatment Plant
Genset Test beds

Ventilation System
Industrial Effluent
Treatment Plant.
Machine shop
p Spot
p
cooling System.
Oily Water separation

unit for Compressors
ETP Chemical Dosingg

System
Green Energy
Renewable Energy Projects

Installation Site
Pachphatta
Nashik
Maharashtra
Wind Mill Capacity
7 x 800 KW
5.6 MW
Investment
in Rs. Mn.
Expected Annual
Generation in kWh
Units
266.00
11.20 Mn
Renewable (Windmill) Energy Performance

2009-10
Type of
RES
Wind
Installed
Energy
Capacity
Generated
in kW
(kWh)
5600
3757342*
Annual
Savings
(Rs. Mn)
19.01
2010-11
2011-2012
Energy
Annual
Energy
Generated Savings Generated
(kWh)
(Rs. Mn)
(kWh)
4015090*
21.27
4719173*
* 50% Energy Considered for KAGAL Plant as decided
Annual
Savings
(Rs. Mn)
28.92
Wind Mills
MillsBenefits of Green Energy
Windmill Details FY-12
WEC Name Generation (KWH) Capacitor Factor Machine Availability % Grid Availability %
KOEPP_01
1293016
18.40
97.35
99.05
KOEPP_02
1723153
24.52
99.21
99.05
KOEPP_03
1786210
25.42
98.13
99.00
KOEPP 04
KOEPP_04
1762708
25 08
25.08
98 90
98.90
99 00
99.00
KOEPP_05
1771483
25.21
98.36
98.98
KOEPP_06
1543982
21.97
97.53
99.00
KOEPP_07
1536776
21.86
98.12
99.00
CDM Benefits For Wind Power ProjectKOEL is getting the benefits of emission reductions thru appointed M/s E
& Y, Mumbai. Under the Voluntary Carbon Standards 2007, KOEL submitted
project development documents to VCS. For validating the emission
reductions, KOEL has appointed Perry Johnson.
In Dec 11, KOEL has received first VER benefits of worth Of Rs.
11,696/KIRLOSKAR OIL ENGINES LIMITED
Total GHG Emission Reduction (Scope I & II)

kg / BHP of Engine
12.13 %
Reduction
over PY
4 00
4.00
3.35
3.00
2.97
2.00
kg / BHP of Engine
2.94
09 - 10
10 - 11
11 - 12
2.97
3.35
2.94
Second - Corporate Sustainability

Report
Industries recognizing the Needs of Addressing the Environmental and Social

Impacts of their Activities & these Impacts with Profits are Popularly Known as
the 'Triple Bottom Line' Issues Of Sustainable Development.
KOELs Corporate Sustainability Reports on GRI- G3 Guidelines are Released to
Public Domain for Years FY10 & FY11 Magnificently
KOEL is The First Engine Manufacturing Company In India, Who Released The
Corporate Sustainability Report & Received Highest Level Check Certification
Of A+ after being Validated By Global Reporting Initiative (GRI), Netherland
Carbon Foot Print Assessment Report

Carbon Foot-print Assessment being undertaken by KOEL is pioneering
efforts in their sector
An
A integral
i
l step for
f its
i future
f
carbon
b strategy, which
hi h helps
h l to KOEL to
be advanced prepared for Emission Based Regulations
Also, It reap business benefits out of the Green Movement
The exercise add tremendous value to brand KOEL & it will also help
KOEL to identify:
GHG intensive
i t i areas off their
th i GHG intensive
i t i sites
it and
d operations
ti
Opportunities for reducing emissions & costs
Strategize its operations to abide with new national and international
regulations
Ways to achieve the target of reducing its environmental footprint
Reports for year 2009-10 & 2010-11 were released

Corrective Preventive
Actions
ENCON Corrective Preventive Actions
Project
Problem
Corrective
Actions
Preventive
Actions
Installation Of Stabilizer For Lighting

Objective:
j
Reduce Operating
p
g Voltage
g From 245 V To 210 V To Save Energy
gy
By 15% For Lighting
Reduction In Voltage By 15%, Causes Switching Off Some Lamps Creating
Dark Zones.
Zones
Ballasts (Chokes) & Igniter Found Weaken Due To Continuous High
Operating Voltages
Voltage Reduction Done Up To 220 V Instead Of 210 V (By 10.2%)
Replacement Of Ballasts & Igniter For Those Lamps Are Done
Study Carried Out For All Lamps For Those, Ballast & Igniter Needs To Be
Replaced
Replacement Started & Now Operating Voltage Can Be Further Reduced
ENCON Corrective Preventive Actions
Project
Installation of Common Fan-Less Cooling Tower for two product test beds.
Objective: Reduce Energy Consumption for 2 different conventional cooling
towers of fans & pumps by Single Fan-less
Fan less Cooling tower with two lower
HP pumps
Problem
Failure: Less water flow to one shop

p due to insufficient suction
The reason is common header for both pumps & low pipe size designed
than actual required
Corrective
actions
One conventional cooling tower started with keeping cooling fan off
Suction for fan-less cooling tower throttled to desired output yields in 65%
of saving targeted
Preventive
actions
Additional suction pipeline to pump for cooling tower basin planned

Work is in progress

Our Constant Endeavor To Develop Efficient And Environment
Friendly Products, & Our Typical Focus On The Following Areas
Upgrading
Technology
Improving Present Designs To Reduce The

Consumption Of Naturally Available Fuel And
Lubricating Oil
Improving Power
To Weight Ratio
Reducing Required Raw Material, to Develop

the Same Power Output From The Engine.
Emissions
Reduction
All Engine Series Comply With The Currently

Applicable Emission Norms
The Process Of Being Ready for The Next
Generation Of Emission Norms.
Energy Efficient Products to Market

9 KOEL had set a new benchmark in the Power Generation
market by launching of 32 kVA / liters Power Density Engine
9 4R-1040
4R 1040 Engine
E i series
i to
t 4 valves/cylinder
l / li d to
t meett forthcoming
f th
i
Emission Norms with improved Fuel Efficiency.
kVA rating Present Engine
Product with New K1080 engine
100
6R1080TC 6 cylinder
Turbocharged, inline, 6.32 Liters
4K1080TA 4 cylinder Turbo after

cooled, inline, 4.32 Liters
12
125
6R1080TA 6 cylinder
li d TTurbo
b after
f
4K1080TA 4 cylinder
li d TTurbo
b after
f
140
6SL90TA - 6 cylinder Turbo after


160
6SL90TA - 6 cylinder Turbo after


Renewable Energy Product - Kirloskar Sanjeevani

Sanjeevani means one that gives life
Designed as home energy system for rural and semi-urban
households
Hybrid system that combines two renewable energy sources viz. Biogas
and solar consists of
9 Primarily of A biogas digester of capacity two thousand liters / day
9 Solar photovoltaic of 9 wp with 2 lanterns lighting of up to 8 hrs
Availability for feed like cow dung and food
waste
Easily produce sufficient biogas to fulfill the
cooking requirements of A small family.
The system is provided with accessories such as
suitable biogas burners along with appropriate
plumbing for domestic use.
Training & Awareness
ENCON Week Celebration 14th 21st Decemeber
Encon Week
Efforts / Plans / Programs For Increasing

Awareness
Celebration of National Energy Conservation Day & Week
Every year 14th Dec is celebrated as a "National Energy
Conservation Day"
And 14-20
14 20th Dec as Energy Conservation Week
80
Programs and Activities In ENCON Week
Oath Program
Quiz Competition
Poem Competition
Poster Competition
Suggestions
Projects
Seminar for Suppliers.
Encon Week Competitions Response
Poem Competition
Poster Competition
Suggestions
Projects
Slogan
Totall
ENCON Week Competition Award Distribution
- 54
- 45
- 13
- 04
-152
- 268
Corporate Social
Responsibility
ENCON Efforts Extended to Suppliers & Vendors

Seminars thru External Agencies were
organized
g
for Suppliers
pp
to initiates
ENCON activities
Some of Important Seminars from
Siemens
IPCPL
Baldor
KBL
Recon Consultant
Enthusiastic response
p
received from
Suppliers & Vendors
For FY13 - Energy Conservation Audits are
Scheduled thru ENCON team & External
agencies for benefit of Suppliers
ENCON Efforts in Community
ENCON Poster Competition

p
at Talangade
g
Village for School Children
FY12 Accolades KAGAL Plant
KOEL, Kagal received Excellent Energy

Efficient Unit Award by CII
KOEL is honored by Sustainability Award

Sustainability Initiatives & Sustainability
Report organized by Mahindra & Mahindra
Ltd.
Top 10 Projects Planned for next 3 yrs.

1.
100kW Grid- connected Concentrated Solar Photo Voltaic Power Plant
2.
Solar Energy based Steam generation system for Cooking application.
3.
Briquette Fired Thermopack for Paint Shop & Component washing machines
4.
Heat recovery from Exhaust gases generated during Engine Testing Process.
5.
Speed Reduction of Centrifugal compressor by using V.F.D.
6.
Heat pump application for heating system for Washing machines.
7.
Installation of Solar Street Lights on South Side 250 m Long road.
8.
Replacement of Street lights with LED type Light Fittings
9.
Replacement of High Bay Lights with LED Lights
10. Energy Efficient Equipment's for New Project Buildings


Oil Engines Limited Kagal Kolhapur

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KIRLOSKAR OIL ENGINES LIMITED

KIRLOSKAR OIL ENGINES LIMITED

KOEL Vision & Values

KIRLOSKAR OIL ENGINES LIMITED

Kagal Plant Location & Overview

% of Energy Cost wrt

KAGAL Plant Sales Turnover @

KIRLOSKAR OIL ENGINES LIMITED

% of Energy Cost wrt

Satellite View of Kagal Plant

KIRLOSKAR OIL ENGINES LIMITED

Products & Application

Gensets with Air cooled & Liquid

KIRLOSKAR OIL ENGINES LIMITED

Receive Bought out

KIRLOSKAR OIL ENGINES LIMITED

KIRLOSKAR OIL ENGINES LIMITED

KOEL-- Energy Policy

KIRLOSKAR OIL ENGINES LIMITED

KIRLOSKAR OIL ENGINES LIMITED

ENCON Part of Individual's PMS

KIRLOSKAR OIL ENGINES LIMITED

ENCON Part of Individual's PMS

KIRLOSKAR OIL ENGINES LIMITED

KIRLOSKAR OIL ENGINES LIMITED

Reduction in Specific Energy Consumption

KIRLOSKAR OIL ENGINES LIMITED

Reduction in Specific Energy Consumption

KIRLOSKAR OIL ENGINES LIMITED

* Source Data : MEDA Presentations

Reduce By 3-5% Every Year

Over Next Ten Years.

Specific Generation Of Waste & Waste

Over Next Ten Years.

Use Of Renewables Energy

Increase By 5% Every Year

Over Next Ten Years.

GHG Emissions And Other Process

Increase By 5% Every Year

Life Cycle Assessment Criteria For

Incorporate Life Cycle Assessment in Alternative

Adopt Green Purchase Policy

Over Next Ten Years.

Adopt Green Purchase Policy & Incorporate Clean

Over Next Ten Years

KIRLOSKAR OIL ENGINES LIMITED

Project Summary (2009 12)

KIRLOSKAR OIL ENGINES LIMITED

ENCON Projects Zero Investment

Machine Power Pack Motors interlocking with

3 Logic for base flush coolant motor

All Induction motor switched OFF, after machine

8 OP 10A & OP 10B transfer cylinder air blocked

Replacement of sodium vapor lamps substation

KIRLOSKAR OIL ENGINES LIMITED

ENCON Projects Zero Investment

Selector switch was placed on control panel for ON

13 Instead of two motor for coolant one motor

KIRLOSKAR OIL ENGINES LIMITED

Zero Investment Innovative Project

Air Supply Valve

Hydraulic Oil Pump 2

KIRLOSKAR OIL ENGINES LIMITED KAGAL PLANT

ENCON Projects Low Investment