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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) .