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    Energy Saving

    Uploaded by

    Bikram Jit Singh Sehgal
    savings

    Copyright:

    © All Rights Reserved
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    Energy Saving

    Uploaded by

    Bikram Jit Singh Sehgal
    13 views22 pages
    savings

    Copyright

    © © All Rights Reserved

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    savings

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    13 views22 pages

    Energy Saving

    Uploaded by

    Bikram Jit Singh Sehgal
    savings

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    You are on page 1of 22

    PISTON FOUNDRY 07/07/2008 1

    Diameter : 38 TO 228 mm
    O
    U
    R

    R
    A Alco Alco Steel AL 680 TCAC Mahindra 245 SL 90 250 KVA L&T 320 TC
    Cap
    N
    G
    E

    O HINO HINO WO6DTI TATA KOEL 3R860 TATA 697 TD 2650 FTI
    WO6ERC CUMMINS
    F

    P
    R
    O MAHINDRA -
    NEF
    BD 154 AVL MINIDOR CNG INDIGO 486 PL FIAT PALIO

    D
    U
    C SC 66.7 AC BULLET 500 SPLENDOR TVS VICTOR KAWASAKI TVS XL
    T CC

    S
    PISTON FOUNDRY 07/07/2008 2
    LEADING CUSTOMERS

    PISTON FOUNDRY 07/07/2008 3


    ENERGY & MAN POWER
    SAVING
    PROJECTS IN
    PISTON FOUNDRY PATIALA

    THROUGH
    EQUIPMENT MODIFICATION
    PISTON FOUNDRY 07/07/2008 4
    PISTON FOUNDRY 07/07/2008 5
    • THERE IS AN URGENT NEED OF ENERGY SAVING
    WHEN THE OIL PRICES ARE MOVING TOWARDS $150
    PER BARREL
    • FOR CLEANER ENVIRONMENT WE NEED TO USE
    LESS OIL AND ENERGY
    • OF THE TOTAL ENERGY USED IN A PISTON PLANT
    65% IS USED IN FOUNDRY

    THERE IS MORE SCOPE OF ENERGY SAVING IN


    FOUNDRY THAN ANY OTHER DEPARTMENT

    PISTON FOUNDRY 07/07/2008 6


    MODIFIED VERSION OF TWIN WARM HOLDING FURNACE

    IMPROVEMENT STAGE 1 OLD LINING

    M.S.
    SHEET

    MINERAL ASBESTOS CERAMIC CERAMIC HYSIL INSULATING FORM CRUCIBLE


    WOOL
    PISTON FOUNDRY SHEET WOOL BLOCK BLOCK BRICK BRICKS
    07/07/2008 7
    IMPROVEMENT STAGE 2
    AIR GAP

    ASBESTOS
    SHEET

    CERAMIC
    WOOL

    CERAMIC
    BLOCK

    INSULATING
    BRICK

    FORM
    BRICKS

    CRUCIBLE

    HYSIL
    BLOCK

    PISTON FOUNDRY 07/07/2008 8


    IMPROVEMENTS IN CORPORATED

     CAPACITY INCREASED FROM 300 KGS TO 500KGS.

     ELEMENT SIZE EARLIER USED WAS 16 ×1.5,NOW IT


    HAS BEN CHANGED TO 12 × 1.5 ,WHICH IN TURN
    REDUCES THE POWER LOAD.

     CONNECTING LOAD REDUCED FROM 32 KW TO


    25KW.

     MINERAL WOOL OUTER LAYER REPLACED BY AIR


    GAP.

     ELEMENT LIFTED UP BY 50MM FROM TOP OF THE


    CRUCIBLE.

    PISTON FOUNDRY 07/07/2008 9


    MULTIPLE MACHINE OPERATION ON
    CASTING MACHINES

    PREVIOUS PRACTICE EXISTING PRACTICE

    CASTING DCM 17
    MACHINE CA CASTING DCM 17
    17 CAST DCM 17
    M/C
    (UPTO 60 DIA) ST
    CM
    M/C
    M I (UPTO 60 MM DIA)
    D E ) (U A NG (UPTO 60MM DIA)
    G N A
    IN HI DI PT C D
    O HIN CM
    ST AC 60 60 E 1

    (UPTO 60MM DIA)

    CASTING DCM 17
    A M TO DI 7

    (UPTO 60MM DIA)


    C

    CASTING DCM 17
    P

    MACHINE
    A)
    (U

    MACHINE

    SAVINGS IN
    * MANPOWER
    * ENERGY
    * FLOOR SPACE

    PISTON FOUNDRY 07/07/2008 10


    LAYOUT FOR MACHINES WITH
    DIPPING FURNACES

    /C
    M
    G
    IN
    ST
    CA

    CASTING MACHINE CASTING MACHINE


    DCM 20 UPTO DIA DCM 20 UPTO DIA
    115MM 115MM
    CASTING M/C
    /C
    M
    NG

    CASTING MACHINE CASTING MACHINE


    I

    DCM 20 UPTO DIA


    ST

    DCM 20 UPTO DIA


    115MM
    CA

    115MM

    2 MAN/ 3 M/C CONCEPT 1 MAN/ 2 M/C CONCEPT

    PISTON FOUNDRY 07/07/2008 11


    IMPROVEMENTS INCORPORATED

     MORE NUMBER OF MACHINES CAN BE FEEDED


    THROUGH SAME AMOUNT OF HOLDING FURNACES

     MORE FLOOR SPACE IN THE SHOP FLOOR.

     SAVING IN MANPOWER.

    PISTON FOUNDRY 07/07/2008 12


    ENERGY AND FUEL
    SAVING IN OIL
    FIRED FURNACES
    USED IN PISTON
    FOUNDRY.
    PISTON FOUNDRY 07/07/2008 13
    NEED FOR IMPROVEMENT

     INTERNATIONAL PRICE HIKE TOWARDS 150 PER


    BARREL OF CRUDE OIL WAS ALSO A CAUSE OF
    CONCERN.

     OUT OF THE TOTAL MELTING IN PISTON FOUNDRY,


    60 % OF THE METAL IS MELTED IN OIL FIRED
    FURNACES AND 40% IN INDUCTION FURNANCES,
    THAT IS WHY WE SELECTED THIS AREA FOR
    IMPROVEMENT.

    PISTON FOUNDRY 07/07/2008 14


    CHANGES IN CORPORATED

    BURNER MODIFICATIONS

     BURNER NOZZLE REDUCED TO 1.5 MM FROM


    2.0MM.
     OIL PRSSEURE BROUGHT DOWN
    FROM 2.0 KG/CM2 TO
    0.5KG/CM2.
     SEPARATE VALVE FOR REGULATING OIL
    SUPPLY.

    PISTON FOUNDRY 07/07/2008 15


    RECUPERATOR

    • ORIGINAL AIR TEMP. 65-70 °C

    • WITH RECUPERATOR 95-125°C max

    • 1% OIL SAVING WITH 20°C RISE OF AIR TEMP

    PISTON FOUNDRY 07/07/2008 16


    PISTON FOUNDRY 07/07/2008 17
    FURNACE AFTER MODIFICATION

    PISTON FOUNDRY 07/07/2008 18


     AIR PIPE EXPOSED TO FLUE GASES 90-100°C

     DOUBLE LOOP PROVIDED 140 –150°C

     AIR PIPES ENCLOSED WITH MS SHEET 180-200°C

     FURNACE EXHAUST CLOSED

     AIR PIPES ENCLOSED WITH PROPER PANELS


    MADE FROM HEAT RESISTANT STEEL SHEET 306
    GRADE WITH PROPER LINING WITH CERAMAIC
    FIBRE BOARD 1250°C,128 DENSITY,TEMP. >225°C

    PISTON FOUNDRY 07/07/2008 19


     PREVIOUS OIL CONSUMPTION = 130 LTRS
    /TON

     AFTER MODIFICATION = 80 LTRS/TON ( FOR MELT


    UPTO TEMP 730°C)

     SAVING = 50 LTRS /TON

    PISTON FOUNDRY 07/07/2008 20


    CONSERVATION OF NATURAL RESOURCES

    BETTER WORKING CONDITIONS


    • Lesser heat radiations
    • Lesser smoke emission to the surroundings
    • Lesser noise

    PISTON FOUNDRY 07/07/2008 21


    PISTON FOUNDRY 07/07/2008 22

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