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W orld Leaders in Vapour Absorption T echnolog y

Encon in Compressed Compressed

Air SystemsAir Systems

(DTVS Experience)(DTVS Experience)

W orld Leaders in Vapour Absorption T echnolog y

Delphi - World’s one of the largest Automotiv e Tier-1 Systems Supplier joined ha nds with

TVS - India’s largest Tier-1 Automotive Systems

Supplier to offer State-of-the -Art Diesel Fuel Injection Tec hnology

PL ANT I MANNUR,CHENNAI

PL ANT II – UTTAR AKH AND,

PL ANT III – ORAGAD AM, CHENNAI

Company Profile

W orld Leaders in Vapour Absorption T echnolog y

Escorts

Our Valued Customers

W orld Leaders in Vapour Absorption T echnolog y

• 70 - 90% of compressed air is lost

• Compressed Air is Energy Intensiv e

• Electricity sav ings: 20 - 50%

Compressed Air Systems

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W orld Leaders in Vapour Absorption T echnolog y

KAE 400 CFM

KAE 400 CFM

ATLAS 600 CFM

IR 600 CFM

ATLAS 600 CFM .VSD

SULLAIR 600 CFM

DRYER

DRYER

DRYER

DRYER

PV PV AIR REGULATOR

KAE 200 CFMUPCR

DRYERUPCR

UPCR

ROTARY

IR 200 CFM .VSD

IR 100 CFM

PV PV For measuring instrumentsDRYER

KAISER 200 CFM .VSD

IR 100 CFM

PV PV FOR E&D SECTIONDRYER

Total available capacity – 3800 CFMRequired capacity – 2400 CFM

Compressed Air Systems at DTVS

W orld Leaders in Vapour Absorption T echnolog y

Compressor16%

Lighting 2%

E&D8%

Others16%

MFG + HT45%

A/C 13%

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W orld Leaders in Vapour Absorption T echnolog y

Online Compressor Power Monitoring

W orld Leaders in Vapour Absorption T echnolog y

Online Compressor Power Monitoring

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W orld Leaders in Vapour Absorption T echnolog y

Differential pressure gauge

Differential pressure gauges are f itted to monitor f ilters and their elements continuously. The degree of pollution of a f ilter is linked to the rise of the dif ferential pressure across the f ilter element.

2 PSI (138 MBAR) OF PRESSURE DIFFERENTIAL CAUSES 1% POWER LOSS

COMPRESSOR MON ITORING AND CONTROLLING SYSTEM

W orld Leaders in Vapour Absorption T echnolog y

Conducting Periodic Inspection by

• Thermography

• Vibration Analysis

Compressor Monitoring

W orld Leaders in Vapour Absorption T echnolog y

Encon Measures at DTVS

• Installation of VFD for the Screw Compressor in R & D block.

• Use of Automatic Intelligent Monitoring and Control for

Compressed Air Systems.

• Use of Variable Capacity Compressor (Sullair) - 630 CFM.

• Reduction of Compressed Air Room Temperature by

• Improving Ventilation by Providing Wind Ventilators.

• By providing exhaust duct and to release hot air outside.

• Roots blower for Low Pressure Applications (Phospating Plant

& Sewage Treatment Plant).

• Installation of Pressure Booster for High Pressure Machines and reducing

the compressor Pressure Setting from 6.3 to 5.9 Bar.

W orld Leaders in Vapour Absorption T echnolog y

Design

CFM =200Power = 37.28 kW Pressure = 7.0 bar

Compressor

Receiver

DryerRunning

Pressure = 6.0 bar

Installation of VFD for screw compressor in R & D block

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W orld Leaders in Vapour Absorption T echnolog y

• Loading Hours - 1515 hrs• Running Hours - 3742 hrs• Unloading % - 59.6%• Power consumption measure d

• Loading Power - 18.5 kW• Unloading power - 5.9 kW

Savings• Annual Sav ing - Rs 2.74 Lakhs.• Inv estment - Rs 1.50 Lakhs.• Payback - 7 Months.

Analysis

v During unloading no useful work done by the compressor. Good

potential to ins tall VFD with feed back control

Installation of VFD for screw compressor in R & D block

W orld Leaders in Vapour Absorption T echnolog y

Use of Automatic Intelligent Monitoring & Control systems (Godrej) to utili ze the compressor according to th e requirements.

Ø EnergAir (Supply side manageme nt)Automatic Switch on and off (or) load and unload of multiple compressors according to the pressure

setting. Reduces the unnecessary running of Compressors and thereby power consumption.

Ø ControlAiR (Dema nd side mana gement)

This system is on load end which sense the actual load requirement and maintains the system pressure according to requirement. This in turn additionally increases the system efficiency and reduces overall power consumption.

Use of Automatic Intelligent Monitoring and control for

Compressed Air Systems.

W orld Leaders in Vapour Absorption T echnolog y

COMPRESSOR MONITORING AND CONTROLLING SYSTEM

ReceiverCompressorExisting Va lve

Existing Air lineDryerC Filter

Modifie d Air line

Data Cable Dm3

Ø6”Ø6”

C5

C6

C1

C2

Ø4”

Ø6”

Atlas Cop co600 cf m

90 kW

Dominick Hunter 800 cfm

C3

IR600 cf m

90 kW

Atlas Cop coVSD, 600 cf m

90 kW

Ø4”

Ø4”

Ø4”

3m3

Kaeser400 cf m 75 kW

Kaeser400 cf m75 kWControlAiR

GE-402000 cfm

Energ Air X C

Plan

t

C4SULLAI R 600 CFM

S.V, 600 cf m90 kW

NC

GEM 600 cfm

Summits 750 cfm

ANI

Ø6”

Ø6”

Ø4”

Ø4”

FLOW M ETER

AFTER COCOOLER

2m3

1m3

Ø4”Ø3”

NC

NC

NC

Summits 1500 cfm

GEM 200 cfm

NCNC

NC NC

NC

NC

W orld Leaders in Vapour Absorption T echnolog y

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W orld Leaders in Vapour Absorption T echnolog y W orld Leaders in Vapour Absorption T echnolog y

Annual energy savings = 4.2 Lakhs

Introduction of Variable Capacity Compressor (Spiral Valve Control)

THIS COMPRESSOR AUTOMOTICALY CONTROLS PART LOAD DEMAND & NOT CONSUMING UNLOAD POWER, WHICH GIVES DIRECT ENERGY SAVINGS.

W orld Leaders in Vapour Absorption T echnolog y

Reduction in Compressed air room temperature

- 5 Nos of Wind Ventilators Installed In

Compressor Room

Compressed Air Room Temperature Reduction

W orld Leaders in Vapour Absorption T echnolog y

37.2 °C

38.2°C

33.5 °C

35.1°C 29.5°C

ATLAS

IR

ATLASVSD

SULLAIRKaiser

Before

28.5 °C

28.5°C

28.5 °C

28.5°C 28.5°C

ATLAS

IR

ATLASVSD

SULLAIRKaiser

After

Intake Air 26 ºc

IntakeAir 32 ºc

Reduction in Compressed air room temperature(by providing duct for exhaust air)

Redu ction of Compressed Air Room Temperature by Providing Exhaust duct and rel easing hot ai r outsid e

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W orld Leaders in Vapour Absorption T echnolog y

• Reduction in Suction Air Tempera ture - 6 º C.

• Reduction in Power Consumption /Day - 128KWH.• Savings in Power Consumption /Month - 3840KWH

Reduction in Compressed air room temperature(by providing duct for exhaust air)

W orld Leaders in Vapour Absorption T echnolog y

Roots Blower for low pressure air required area (Phospating Plant & STP)

• Eliminate Compressed air by introducing Roots Blower in Surface Treatment

area for low Pressure requirements.

BeforeAir required - 5500 cfm/day

Cost of air /day - 5500 x 0.26 –Rs. 1430

Cost / Annum - Rs. 429000

After5 hp roots blower used in place of Compressed Air

Power consumption - 3.7 x 0.8 x 16 hrs/day x 300 days

- 14208 units

Cost / Annum - Rs. 58000

Savings = 3.7 Lakhs

W orld Leaders in Vapour Absorption T echnolog y

Booster for MIKROS A and C HIR ON machines required pressure 5.8 kg/sq cm

After introdu cing the booster for high pressure required machines we can able to redu ce compressor pressure setting from 6.3 kg/sq cm to 5.9 kg/sq cm

Investment - 2.50 Lakhs (5 Nos)

Savings - 2.0 Lakhs

Pressure Booster for High Pressure Machines

W orld Leaders in Vapour Absorption T echnolog y

Zero Disch arge Drain Valves were used for

dryers and pipe lines for to avoid en ergy

losses at the time of condensate drain

Zero Discharge Auto Drain Valve

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W orld Leaders in Vapour Absorption T echnolog y

Future Projects

• Improving Insulation of Exhaust duct of Compressors to reduce the heat loss.

• Improving Power Factor at Motor End.

• Centralized Driers in Shop Floors to reduce the Pressure drop.

• Replacement of Inefficient 600CFM Drier by Energy Efficient Drier.

• Replacement of Inefficient Single Stage Compressor by Efficient Multi Stage

Compressor(600CFM) .