IMTMA-ACE MICROMATIC PRODUCTIVITY

CHAMPIONSHIP AWARDS 2019

Reduction of Specific Carbon Footprint by using Waste to Wealth, TPM

and Industry 4.0 Concept in the Utility Management area

Presenter : Mr. Sandip D Priolkar – DGM-CMD/PPS/CECM/ENCON

Date : 21th August 2019

Case study of Mahindra & Mahindra Ltd., Mumbai

Sandip Priolkar

Energy Auditor,

Mentor and

Presenter

Sandeep Rege

Rajesh Mhatre

Hemant Joshi

Vinayak Gokarn

Team Auto Sector Plants

Revenue contribution 39%

IgatpuriEngine

Manufacture

KandivliFully

Integrated

Plant

Supplies

Aggregates

to Other

Plants

ChakanMahindra

Vehicle

Manufacturing

Plant

NashikVehicle

Manufacturing

Plant

Zaheerabad

Vehicle

Manufacturing

Plant

HaridwarVehicle

Manufacturing

Plant

Mahindra- Kandivli Plant-AFS Headquarters

Kandivli Plant Manufacturing Process Started at 1964, Oldest in

Mahindra

Mother Plant supplying

aggregates like Axle/

Transmission and Engine

Components to other

plants.

The only integrated

Manufacturing Plant in

Metro city

(Foundry to Vehicle

assembly)

Plant Area : 64 Acres

4500+Employees

Highest SPACE

PRODUCTIVITY3

Salient Feature of the Project Project Start Date 27/04/2018

Project End Date 30/10/2018Target

Reduce Specific Carbon Footprint Promise 2019

Challenges

To Reduce Dependency

on Fossil fuel related

Energy

Affordable Business Case

Challenges -

Conceptualisation Make a Road Map from

Concept to reality where

No Benchmark is available

Suitable Vendor for

execution

No chance for Error as

Solution is to be

implemented on A rank

Equipment

Challenge -Execution

Peak Production

season, Very low

Window for execution

Cramped space in

Utility House to fit

Hardware

Safety concern as a lot

of work is involved at

Height with Ground

movement

Integration with

Conventional Washing

Machines by leveraging

Industry 4.O

Results Achieved

Morale Boosting

project, First in

Mahindra Group

Project implemented

against OEM

recommendation

Intended results achieved

with “First time Right”Spirit

Helped us in achieving

the Deliverables as per

Promise 2019

Huge scope for

Horizontal Replicationacross Mahindra plants

and in other Industries

Climate Change- Global Challenge

Climate Change- Global Challenge

Climate

Change

Food

Security

Energy

& Water

Health

Jobs &

Prosperity

Income &

Poverty

Education

Gender

Equality

Conflict &

Security

“By 2030, we will reduce

emissions by 33 to 35% per

cent of 2005 levels. 40% of

energy requirement will be

through Non-Fossil fuel”

“We have contributed to the

problem and it’s up to us to

help mitigate it…”

Increase of CO2 in

Atmosphere by 47% as

compared to Pre-industrial

areaGlobal Warming, Extreme

Weather Pattern

Threat to Entire

ECO-System

M&M Journey towards Sustainability

Achieve

Carbon

Neutrality

Commitment - Rejuvenating the Environment

Commitment to Doubling the Energy

Productivity by 2030 (Baseline 2009)

Carbon Price

Declared internal carbon price

$ 10 / Ton of carbon

M & M is first company in world to sign

EP 100 with Climate Group

M & M is first company in India to declare

internal price of carbonEP 100 by 2030

(Energy Management)

Carbon Pricing declared - 2016

($ 10 per Ton of carbon emission)

Thrust on Renewable

Energy & tree plantation

program

Science based Targets(SBT) by 2034

(2~5% reduction in Carbon intensity YoY)

Carbon Neutrality by 2040

( EP100+SBT+Offsets)

Our Promise Statement/ Challenges/Targets…

Our DREAM

To Be Amongst

the Top 10 Global

Automotive Brand

To Reduce Specific Carbon and Water

Footprint by 15 % over FY16

Mahindra Rise Framework..

Accepting No Limit Alternative Thinking Driving Positive Change

100

105.4 105.1 106

112.9115 116

118 118

F11 F12 F13 F14 F15 F16 F17 F18 F19

Connected Load in KW

CO2 Emission

Scope 1 & 2

F16

Baseline

F19 Target

Plant Excluding

Foundry

227.6 Kg/

Eq. Veh

193.5 Kg/

Eq. Veh

Standalone

Foundry

1089.4 Kg/

LMT

926 Kg/

LMT

Target Setting

10

QImprove

Customer

Centricity◌ ◌ ◌ ◌

P & DStrengthen

Domestic

Dominance◌ ◌ ◌ ◌

MOrganizational

Effectiveness ● ◌ ◌ ●S Sustainability ● ● ● ● ●C

Cost

Leadership ◌ ◌ ◌ ◌

● ● ◌ ◌ ●

● ●◌ ● ● ● ●◌ ◌ ◌ ●◌ ◌ ◌ ●

О О О О

Strong

Relation

Medium

Relation

Weak

Relation

● О ◌Legend

Number of Kaizens related to

Energy Management

Number of Projects related to

Renewable Energy

Number of Kaizens related to

Water Management

Number of Kaizens Related to

Hazardous Waste

Number of Kaizens Related to

Non-Hazardous Waste

Number of People trained on

Sustainability Related Topics

Sustainability Pillar

Specific Cabon

EmissionEnergy Cost

Specific Water

Consumption

Hazardous

Waste

Generation

Non Hazardous

Waste

GenerationKAIKPI

KMI

KMI-KPI-KAI Relationship Matrix…

Specific

Carbon

ReductionSustainability

Understanding Carbon Footprint and its Contributors..

Head Carbon Potential

Expressed in

Kg/Unit

PNG 2.19 Kg/M3

LPG 2.98 Kg/Kg

Diesel 2.65 Kg/Litre

Electricity 0.82 Kg/KWh

11%

89%

Scope 1 V/s Scope 2

Thermal Electrical

10000 Kcal/Hr

11.6 kWh Electricity

1.2 SCM Of PNG

9.53 Kg of CO2

6.6 Kg of CO2

40% Efficiency

Impact of Switching of Fuels

Safety & Statute related concerns

Scope1&2- 55613 Tons of CO2

Scope 3- 42119 Kg of CO2

FY16 Data

Energy Efficient appliance

LED Lighting

Induction Lighting

Screw Compressors

Star Rated Air Conditioners

VFD

Energy Efficient Motors

HVLS Fans

Process for Energy Efficiency

Low Temperature Degreasing

Cold Box in Foundry

Fixture Modification for More charge

per Heat

Sharing of Resources

Optimise Temperature/ Pressure

Elimination/ Combining

Cycle time reduction

Alternate Fuel

Renewable Energy Waste to Wealth

Solar Photo-Voltaic

Wind Power Bio Gas from Canteen Waste

Waste Heat recovery34% of Energy is used for Heating

12

Idea Generation for Sp. Carbon Footprint Reduction….

Work done so far in Waste Heat Recovery…

WHR in Re-cuperator

to Heat Pre-washer

Solution and also For

heating ambient

incoming air to Burner

Heat from the

Compressed refrigerant

of AC units is used for

heating washing machine

solution

Heat from flue gases used for

heating fresh air supplied to

the Burners using the Heat

Pipe Technology

(In paint Shop)

2006~2009 2010~2013 2014~2016

12 Locations 6 Locations 8 Locations

14

Pre-amble for Waste Heat Recovery…

Mc Details Consumption

Average/ Hr

Conversi

on Unit

Energy

Transfer

Soln

inlet

Soln

outlet

Diff

kWh SCM Kcal/Unit Kcal/ Hr D.Cel D.Cel D.Cel

T.Washer-7396 33 860 28380 40 55 15

T.Washer-7392 45 860 38700 40 55 15

T.Washer-652 36 860 30960 40 55 15

Vacuum Pre-wash 34 860 29240 40 55 15

Washing Mc-7525 5 8300 41500 40 55 15

Washing Mc-7378 5 8300 41500 40 55 15

Washing Mc-1817 36 860 30960 40 55 15

Washing Mc-1791 34 860 29240 40 55 15

TOTAL 218 10 270480

Application

For HeatingSource of

Waste Heat

Options Hunted

Heat Recovery from

the Flue gases of

Heat Treatment

Furnace

Heat Recovery

from the Flue gases

of Hot water

Generator

Can we extract

Heat from

circulating

Lubrication oil

of Nearby

Compressors??

Already

Done

Inadequate

Heat

No

Experience

but Worth

Giving a

TRY

Pre-amble for Waste Heat Recovery-Analysis Sankey Diagram for

Compressed Air System

This is heat available in the oil

at 80-100 ⁰C

How This Heat can be used

in useful Energy?

Heated oil + air mixture at 90-100C exits

the screw element towards air/oil

separator to reject heat via radiators or

cooling towers

Energy

Input

Com

pre

ssed A

ir

Genera

tion

Useful Energy at Point of Usage-10%

Frictional/Other Losses & Misuse

10-15%

WASTE HEAT

75~80%

Utility Compressor House layout

Compressor

Specifications

1. Make- Sullair

Lubricated

2. FAD- 2179 CFM

3. 2 Stage Design

4. Set Pressure-

75 & 95 psi

5. Motor- 315 KW

6. 24 Hours

Operations

1. 12 Year Old Compressor-

2. Base load Compressor-

3. Space constraint in

Compressor House-

17

Developing alternative solutions…

Oil Cooler

Screw

Compressor

Air + Oil

95 Deg. C

Air-Oil

Separator

Air + Oil

IN Air OUT

Oil, 95 Deg. C

Oil, 80 Deg. C

Water INWater OUT

Opportunity

for Heat

Recovery

Working Principle RISKS Associated with Project

Options Worked out

Option 1Refurbishment

Of Existing

Compressor

by OEMRegret

from OEM

Option 2New Compressor

with Built-in

Waste Heat

RecoveryHuge CAPEX

Huge Space

Option 3

Collaborate with

Local Vendor to

pursue the project

Mahindra Rise

Philosophy

Circulating oil flow-

16,320 Ltrs/Hour

Inlet Temp- 95 Deg,

Outlet temp- 70 Deg

Design Temp Diff- 25 Degree

Max possible heat Recovery-

312120 Kcal/Hour

Design Parameter for Heat Recovery

18

Hot oil

from air-oil

separator

Cool oil to

element

Hot DM water at 70-80 C

towards washing machines

Cooled DM water at 60-70 C

back to Heat Recovery

55 Deg Cel to

Washing tanks

40-45 C from

Washing Solution

tanksCirculating Pump

Primary

Heat

recovery

Heat

Sink

Project devised to recover heat from compressors to heat washing machine fluid

Putting concept to Reality.. Breakthrough

Compressor Side Equipment Side

Secondary

Heat

Recovery

Uniqueness

Compressor Side

System is isolated

from Equipment

side system

19

Compressor

Oil CircuitOil Heat

Recovery

System

Water

Distribution

Circuit

Washing Fluid

Heating SystemWashing

Fluid Circuit

Schematic Diagram for WHR…Breakthrough

Inputs from

FMEAInputs from

HIRA

Inputs from

USER DEPARTMENT

Project Plan.. Close monitoring for success..

21

Project Layout….

Insulated Overhead Pipeline

800+ Running Meters

Compressor

House

22

Implementation…-Innovation

80 Deg C

Equip. Side

Piping

Heat Excha.+

Pump Skid

Electrical

Control Panel

2x Base-load

Compressors

23

Safety Features in Project…

Benefit

1. Zero chances of

Intermixing of Oil and water

2. Visual detection of any leak

Benefit

1. Acts as Fluid Buffer for

make-up water

2. Take cares of Thermal

expansion

Double walled Heat

Exchanger on compressor

side for safety purposePressurised Expansion Tank Diverter Valve

Benefit

3-Way Valve

Isolates Secondary Heat

Exchanger once desired

Temperature is achieved

24

Conquering the Challenges & Actions ..

Challenge Action Taken Benefit

Laying of Pipe line of water

at a Height-800 Running Meters

Safe execution of Project.

Execution Time Optimized

Accommodating Heat

Exchanger & other units

in Cramped area

Made the Project Viable

@ Optimized Cost

Accommodating Secondary

Heat Exchanger and Pumps

near individual washing M/cs

Buy-off taken from

Production/

Maintenance Teams

Easy to Operate and

Maintain

Simply execution is not the Success of project, Effective working is the key

to the success.. We leveraged INDUSTRY 4.O for the same

Modification in

Compressor- Chances

of Leak, & Stoppages

Maintainability

Deployment of Pre-insulated

pipes with Flanged joints

Footprint optimization

w/o compromising

Design Parameters

Adopted Valves in

Circuit With

reversible design

Principal of

InteroperabilityMachines, devices,

sensors, and people to

connect and communicate

with each other via Internet

of People (IoP)

To Achieve BHAG of becoming ‘Top 10 global automotive brands’ we aligned our

Utility process towards Industry 4.0

Leveraging “INDUSTRY 4.O”…

8 washing machines in Axle PU and

Transmission PU attached to the heat

recovery system

HX

HRS

Return Line from Washing Machines (60C)

Supply to PUs (70-75C)Sullair air

compressor

Primary

HRS

Oil from

compressor

(90C)

Oil return to

compressor

(75C)

Expansion

tank

HRS HRS HRS HRS HRS HRS HRS

All machines working properly

Leveraging “INDUSTRY 4.O”…

26

8 washing machines in Axle PU and Transmission PU

attached to the heat recovery system

HX

HRS

Return Line from Washing Machines (60C)

Supply to PUs (70-75C)Sullair air

compressor

Primary

HRS

Oil from

compressor

(90C)

Oil return to

compressor

(75C)

Expansion

tank

HRS HRS HRS HRS HRS HRS HRS

All machines working properly

When Filter gets choked, the Machine

is automatically stopped, and

intimation for maintenance is sent out

Leveraging “INDUSTRY 4.O”…

27

28

GPRS Cloud Based system integrated with Air

Compressor and washing machine All Critical parameters

covered under Industry 4.OData Storage

to Local PC

Washing Machine Data

1. Air Compressor Oil and Water

Temperature

2. Washing Machine fluid

Temperature

3. Air Compressor and Washing

Machine Energy data

4. Air Compressor Vibration and

Pressure

Washing Machine Real time Temp. Graph Air Compressor Data

Real Time Graph- Leveraging “INDUSTRY 4.O”…

30

Ability to deep-dive into identifying issues

Ability to do detailed analytics on motor vibration

and temperature data to prevent failure and

understand failure points

Deep-dive on energy consumption and pressure

delivered at various times during the shift

Real Time Graph- Leveraging “INDUSTRY 4.O”…

Variety of sensors installed on compressors

Energy meters for capturing

power consumption and PF

Pressure sensors for outlet

pressure of airVibration sensors for motor

vibration and temperature

Feeling of OEM’s Representatives…From: Varun Bajpai <varun_bajpai@hitachi-hirel.com> Sent: Wednesday, January 14, 2019 2:06 PM To: JOSHI HEMANTKUMAR <JOSHI.HEMANTKUMAR@mahindra.com> Subject: Air Compressor model LS 32S

Dear Sir This has reference to the Air Compressor Model LS 32S 400 manufactured by Sullair USA running

in your Kandivli works. The HEAT RECOVERY PACKAGE which you have designed and installed for this machine is a very innovative attachment to the machine and we appreciate this engineering modification done by you to get the best energy saving form the machine. We also thank you for obtaining the best performance from our machine which serves as a very good reference for us. Best Regards Varun Bajpai Asst. Vice President- Air Compressor Division Mobile: +91 7045349306 I Email: varun_bajpai@hitachi-hirel.com

Hitachi Hi-Rel Power Electronics Pvt. Ltd. Address: B-62, Corporate House, Judges Bungalow Road, Bodakdev, Ahmedabad - 380 054, GJ India Phone: +91-79-6604 6223 (Ext.: 223) I Fax: +91-79-6604 6201 Website: www.hitachi-hirel.com

From: Kiron Pande <kcp@godrej.com> Sent: Wednesday, December 9, 2018 3:30 PM To: PRIOLKAR SANDIP <priolkar.sandip@mahindra.com> Cc: JOSHI HEMANTKUMAR <JOSHI.HEMANTKUMAR@mahindra.com> Subject: WHR Retrofit on Lubricated Screw Compressor

Mahindra & Mahindra has been a front runner in implementing energy saving projects to reduce carbon footprint. Our association with them over 20 years. When we had a partnership with Sullair Compressors, M&M had procured and installed the first ever Two-Stage Screw Air Compressor of 2179 cfm flow capacity sold by us. At that time, M&M saved large amount of energy with improved efficiency of Tandem Screw technology over their earlier Air Compressors. Keeping up to their tradition of achieving further and further improvement in energy efficiency, they thoroughly studied operation of the Air Compressor. With their continued efforts for recovering the heat of compression, M&M Engineering team got a CUSTOMISED ‘WASTE HEAT RECOVERY SYSTEM’ (WHR) designed and made to retrofit on the Air Compressor.

This is the first installation of WHR on any Sullair Compressor in India! It was amazing to see successfully retrofitting a WHR system on a 12 year old Air Compressor! This WHR is a fully automatic system and does not require any manual intervention – not even operating a valve or a pump. While implementing the WHR system, M&M team has leveraged Industry 4.0 techniques through sensors, communication, monitoring, digital electronics and control to ensure that the Screw Elements in the Air-End (which is the heart of a screw compressor) are maintained with the right amount of temperature and flow rate of the lubricant.

This idea has enormous potential to replicate in the industry which can be horizontally deployed by the Users and Air Compressor manufacturers. Regards, Kiron Pande ***************** Mr. Kiron C. Pande AVP & Business Head – Automation & Energy Management Godrej & Boyce Mfg. Co. Ltd. Electricals & Electronics Division Pirojshanagar, Vikhroli, Mumbai – 400079. India Tel.: +91(22)67962211 / 2251; Fax: +91(22)67961525 Mobile: +91-9820348824 Website: www.godrej-airsolutions.com

Users Voice….

• Scope for horizontal Deployment – ( Pl tick )

M & M

Mfg

plants

Other

Auto

ind.

All

Mfg

Ind.

33

Balance Sheet…Entire project Cost with Taxes

Rs. 51 Lakhs - One Time Investment

PNG Saved- 9,600 SCM/Annum,

Rs. 3.282 Lakhs

Electricity Saved- 600,000 kWh/AnnumRs. 60.00 Lakhs

Total Cost Saving – Rs. 63.82 Lakhs/Annum

CO2 Mitigation by this unique Project

513 Ton/Annum

First of its Kind

In Mahindra Group

Huge Potential for

Horizontal Deployment

In all Sector Plants

Results- Sp. Carbon Footprint

“PROMISE 2019” Delivered

MP Sheet Made and

Shared with DM Pillar

Simple Payback- 9.6 Months

Patent Idea-

2579 / PAT / 2019

228194 192

F16BM

F19Tgt

F19Act

Plant Excl. FdryKg/Eq. Veh

1089

926 913

F16BM

F19Tgt

F19Act

Standalone FdryKg/LMT

National Awards and Accolades in FY19…..

Breakthrough Kaizen Award in

34th TPM Kaizen competition

Mahindra AFS

Best Energy Efficient Project

1st prize in SOPEP

CII National ENCON Award SEEM- Gold Award for ENCON

3rd Year in Row

“ACCELERATE to EXCELERATE”

at Plant Level

IE3/IE4

Motors

Inverter

Based ACs

LED

Lighting

Wind Mill

Bio-Gas Plant

HVLS Fans

Process

Improvement

And Many More….

Way Forward to achieve Carbon Neutrality …