Lucas-TVS Limited Padi (Chennai)

UNIT PROFILE Lucas-TVS is a part of the TVS group. It was setup in 1961 as a joint venture of Lucas Industries plc, UK and TV Sundaram Iyengar and Sons at Chennai to manufacture automotive electrical systems.

Lucas-TVS has since inception has been maintaining its leadership as an automobile electrical systems supplier. Lucas-TVS manufactures a complete range of auto electrical products consisting of direct drive and gear reduction Starters, internal and external fan alternators, wipers, fan motors, blower motors, window lift motors, mechanical and electronic distributors, cam sensors, headlamps etc. The Auto Electricals division now has three plants situated in Padi, Pondicherry and Rewari. The Padi plant, which is the mother plant, manufactures all range of electrical automobile products. ENERGY MANAGEMENT POLICY We are committed to reduce the Specific Energy consumption (Electrical units per Equivalent Starter Unit) for our products comparing to the previous year consumption THROUGH 1. Maximize the Capacity utilization. 2. Fine tuning our Operations and Maintenance continuously to achieve the above goal. 3. Technology up-gradation with energy efficient processes and equipments. 4. People involvement suggestion, Small group activities, quality improvement team and work team. 5. Waste elimination reduce, reuse and recycling. 6. Promote awareness in every employee through training, competition and factory visit. 7. Large cell formation. 8. Process changes. 9. Setting up a system to continuously monitor the progress. 10. Comply with Energy legislation and Environment regulation. APPROACH Training Formation of Task force team Cross functional Team QC story Employees involvement through 1. S.G.A. (Small Group Activities) 60 2. Suggestion Scheme & Voluntary 1200 / year 3. Work Teams (5S, TPM, ENVIRO, SAFETY) 520 members 4. Energy Audits (Internal & External) 5. Quality Improvement Team (QIT).

ROLE OF ENERGY MANAGER Prepares Annual Plan with Targets and Budget Establish an Energy conservation cell within the firm with managements concern about the mandate and task of the cell. Acts as a Facilitator in implementing the Encon Projects Interacts with core team members / cross functional team periodically to review the progress Constitutes a team of Auditors to monitor the Retainment of Improvements Presents the achievements to Top Management

MONITORING AND REPORTING SYSTEM

AWARENESS OF POTENTIAL SAVINGS TOP MANAGEMENT COMMITMENT TEAM FORMATION BY ENERGY MANAGER PRELIMINARY ENERGY AUDIT DETAILED ENERGY AUDIT IMPLEMENT QUICK HITS HIGH COST PROJECTS

TRAINING

MONITOR

FEASIBILITY STUDIES

Feed back to top management

IMPLEMENT HIGHER COST MEASURES

ENERGY CONSERVATION ORGANISATION - STRUCTURE

ENERGY CONSERVATION ACHIEVEMENTS

During the period 2004 2006 Lucas TVS Ltd has implemented around 33 projects through Engineering initiatives and workmans suggestion schemes resulting into total saving of Rs. 103.23 Lacs with an investment of Rs. 78 Lacs. This has been resulted in a reduction from 15 units per product to 13.4 units per product in specific electrical energy consumption. ELECTRICAL SAVINGS. A. Screw compressor with variable frequency drive
Compressor - Energy Consumption per product (ESU)

3.0

2.5

2.0

ESU

1.5

1.0

0.5

0.0

Plan

2.0 1.9 1.7 1.6 1.4

1.3 1.3

Saving = Rs. 8.37 Lakhs / Annum C. Replacing high consumption Air conditioners 15 Nos.

BEFORE

AFTER

BEFORE AFTER efore nstallation: B i Forced cooling tower with 15 HP jack water pump and 10HP blower motor for cooling the engine. Power consumption per annum = 0.90 Lakhs

J.

Introduction of Solid State Power source in place of MG set in Starter Performance testing rig efore nstallation: B i 25 HP motor is used as prime mover for DC Generator which produces 0 30 VDC for a load upto 2000 Amperes. The motor runs throughout the day. Motor capacity = 25 HP Power consumption per annum = 0.78 Lakhs units Operating cost = Rs 3.9 Lakhs / Annum After nstallation: i Solid State electronics controlled power supply that consumes power only during Testing is used. The average testing time per starter is 10 seconds and daily production per line is 400 nos. The power consumption during idle time is 150 Watts. Idle power consumption = 150 Watts Power consumption per annum = 0.048 Lakhs units Operating cost = Rs 0.24 Lakhs / Annum Saving = Rs. 3.66 Lakhs / Annum

K. Modification of Infra Red Heater array in Armature varnishing plant efore modifcation: B i The armatures are pre heated and cured in the conveyorised plant, which has 180 IR heaters installed in the sides. Each heater is of 500 Watts. Total heater capacity = 90 KW Power consumption per annum = 2.70 Lakhs units Operating cost = Rs 13.5 Lakhs / Annum After modifcation: i The IR Heater array was re-positioned to optimise heat radiation and 40 Heaters were removed retaining the operating efficiency of the plant. Now the no. of heaters is 140 only. Present heater capacity = 70 KW Power consumption per annum = 2.10 Lakhs units Operating cost = Rs 10.5 Lakhs / Annum Saving = Rs. 3.0 Lakhs / Annum L. Elimination of ONE pump in 150 Ton Yoke Sizing Presses (two machines) efore modifcation: B i One 75 HP and One 25 HP motors are used to drive 3 Pumps for a capacity of 150 Ton operation. The actual load requirement is 50 Ton. The actual usage time is 10 Hours (900 yokes X 20 seconds X 2 shifts) the idle power consumption is 400 KWH. Motor capacity = 100 HP Power consumption per annum = 3.0 Lakhs units Operating cost = Rs 15.0 Lakhs / Annum After modifcation: i The utilized capacity is 50 Ton. The idle time power consumption is reduced by cutting off the 25HP motor and running only the 75HP motor. There is no increase in cycle time, which is 20 seconds. Present motor capacity = 75 HP Power consumption per annum = 2.6 Lakhs units Operating cost = Rs 13.0 Lakhs / Annum Saving = Rs. 4.0 Lakhs / Annum (For 2 machines) M. MG set to static high current power source. efore modifcation: B i MG set power consumption per annum = 789900 units Operating cost = Rs. 36.73 Lakhs

After modification: Power consumed by Static power source = 14400 units / annum Operating cost per annum = Rs. 0.67 Lakhs Savings = Rs. 36.06 Lakhs.

N.

Elimination of High pressure compressed air for agitation by using High Volume Low Pressure blower at auto plating

Before efore nstallation: B I Power consumed per annum = 40500 units Operating cost = 1.88 Lakhs After nstallation I

After

Power consumed by the compressor = 27000 units / annum Operating cost = Rs. 1.25 Lakhs Savings = 0.63 Lakhs / annum.

Fuel savings Through solar water heater, LPG to SKO conversion

SKO RUN CANTEEN BOILERS

14

STEP CHANGES IN CANTEEN BOILER FUEL CONSERVATION

12

Work In Progress

12.89

Savings / Annum - in Rs.Lacs

HSD to SKO CONVERTION 10 Savings: Rs.5.18 Lacs/Annum @ Rs.4 / Ltr. 8

7.71
6
PRE-HEATING THE FEED WATER BY SOLAR PLATES Savings: 32,400 Lts/Annum

2 LPG to HSD Conversion: LPG:396 Kg/Day * Rs.20/Kg HSD:432 Lts/Day * Rs.16.50/Lt 0 1997

2.37

1999

2004

SOLAR PLATE HEATING FOR CANTEEN

20 PLATES-2000 LTS. CAPACITY

FUEL (LPG)CONSERVATION
CONVERSION OF LPG FIRED BOILER INTO HSD FIRED REVOMAX BOILER. PURPOSE : ENERGY SAVING HAZARD MINIMIZATION & OPERATIONAL

Improvements: Exhaust system straight outlet chimney modified from canopy outlet. To reduce the suction air temperature the air inlet pipes were extended to three metres away from the engine where the air had nearly ambient temperature The return fuelTd8ooled through heat exchanger to reduce the temperature Before impr8oovement SFC 3.36 units per litre of Diesel After improvement SFC 3.9 units per litre of Diesel

18 16 15 14.5

O VE R A L L E L E C T R IC A L E S U T R E ND
210 203 200 19 193 18 16 180 15

U N ITS in lacs

190

14.5

180 13.5 170 163 162 160 8.7 150

0 0 '-0 1 0 1 '-0 2 162 9 .0 5 18 0 2 '-0 3 163 9 .8 7 16 0 3 '-0 4 180 1 1 .3 4 15 0 4 '-0 5 193 1 3 .5 1 4 .5 0 5 -'0 6 203 1 4 .5 1 3 .4

14.5

13.4

163 9.87

11.34

9.05

U N IT IN L AC S P R O D .E S U IN L AC S U N ITS /P R O D U C T

163 8 .7 19

Specific Energy Consumption Trend

26 25 24 2 3 2 3 .5 22 21 20 19 18 17 16 15 14 13 12 11 10
95-96

22

2 1 .5 20 19

SELF BENCH MARK (06 07)

18 17 16 15 1 4 .5 1 3 .4 13

KWHR / ESU

96-97

97-98

98-99

99-00

00-01

01-02

02-03

03-04

04-05

05-06

Y E AR

06-07

IM P R O V E M E N T IN P o w e r Facto r er

IM

VE RO

EN

TS

P o w e r facto r C a p a cito r B an k s * C ap acito rs b an k d istrib b ased o n the lo ad cen ter. * C ap acito rs b an k p ro vid ed for th e lig hting * C ap acito rs p ro vid ed for the hig h p o w er m ach ines . * A u to m atic P o w er facto r correctio n b ank in d ifferent lo catio ns * G a s filled cap acito rs/ N o los s 26 N os. Tw K V A R B A N K S 2 N o s. 2 5 K V A R B A N K S

P o w e r Factor C a p acito r B an ks * Fix ed cap acito r b anks at su p p ly en d * M o re En erg y 1 8 N o s. 10 0 K V A R B A N K S 0. 95 P.F

0.995 P.F 0.97 P.F

1 9 95 - 1 99 8

1 9 98 - 2 00 3

2 0 03 - 2 00 5 w 3

W ED

ENERGY CONSERVATION FOR THE YEAR 2005 2006 Sen. 1. 2. 3. Title of Energy saving project Implemented Introduction of VFD for compressor Replacement of in-efficient compressor Blower less cooling tower Savings In Lakhs 18.0 10.0 8.37 Investment in Lacs 12.00 9.00 10.00

4. 5. 6.

Replacement of in-efficient A/C units Solar water heater for canteen Replacement of in-efficient transformer

1.2 1.50 4.00

2.00 4.00 9.00

.6
7. Ring main system for compressed Air system

Replacement of in-1 ref479.46 735.38 0.

e at ucas VS are committed to rotection, reservation and mrovement of the envronment by W L T P p i p i continually orienting our actites, roducts and servces iv i p i .

INNOVATIVE TECHNOLOGY FOR ENERGY AND ENVIRONMENT

One of the remarkable contributions this year was the establishment of indigenous waste coolant treatment system, which was not done before by any of the industries in the world, which involves recovering waste oil from waste coolant, thereby the quantity of waste disposed has reduced by 55% compared to last year.

ENVIRONMENTAL AND ENERGY BENEFITS

This process is unique one. It uses RO Rejection water & solar evaporation for coolant oil treatment process. No Chemical treatment is involved in this process whereas other companies are using chemicals & Electrolysis for treatment. High TDS water (RO Reject) disposal problem is solved. Meeting out the PCB standard to sell the oil for recycling (0.8% water & 99.2% oil against PCB norms of 15 % water & 85% Oil) Cost saving Rs 6.52 lacs per annum. Energy Consumption is very less

SUN

RO REJECTION WITH HIGH TDS OF 5000

RO PLANT

FACTORY

LUCAS - TVS WASTE COOLANT WITH OIL

FACTORY USED COOLANT OIL FROM FACTORY UNLOADING

WATER TREATMENT PLANT

LUCAS - TVS WATER

VALUE YARD
OIL BARREL

DISPOSAL TO RECYCLER WITH PAYMENT

CPCB & TNPCB

COOLANT OIL STORAGE AREA

STORAGE TANK ( 2 LAKH LITRE CAPACITY )

STOPPED

HAZARDOUS WASTE STORAGE AREA

SOLID & POWDER

SOLAR POND VALUE YARD ( FOR SALE OF OIL )

BEFORE IMPROVEMENT

AFTER IMPROVEMENT

Next to this the reduction of lead soldering stations for armatures by the introduction of brazing method, and also a new system for solder recovery from waste lead solder dross where by we can able to reduce the

Development of greenery, rainwater harvesting, water conservation are our routine activites, Even though the production has increased by 1.08 times compared to last we can able to reduce the water consumption

ENERGY SAVINGS DUE TO THE SOLAR EVAOPARTION OF POND IN PLACE OF ELECTRICAL HEATING SYSTEM