Scope of Audit

It is customized audit focused on low hanging fruit.

To explore is there any areas which are not the part of existing energy
efficiency improvement plan.

What is excluded

• Power quality analysis.

• Generators analysis.
• Motors energy consumption data and power quality analysis.
• Machine level thermography and ultrasonic testing of bearing.
Focused on

1. Compressed Air System.

and other areas of significant energy consumption such as

2. Forging Dept.

3. Heat Treatment Dept. Etc.

Compressed Air System
Compressed Air System Evaluation
Compressor Performance Testing Power
Actual Flow EnPI
Sr. No Compressor ID Consumption
(m³/min) (kW/m³/min)
(kW)

1
75 kW (141001) 77.83 10.40 7.48

2
37 kW (140401) 33.23 4.6 7.22

3
75 KW (141002) 73.01 10.1 7.22

4
75 kW (140201) 78.5 10.5 7.47

5
37 kW (140101) N/A
 Observation

High Specific Energy consumption of compressors as compared to latest technology.

Two stage screw compressor

Source : ALMiG compressors technologies Germany

Installation of one (75 kW) two stage screw compressor with
permanent magnetic motor

Saving Potential
Avg daily air consumption = 8.1 m3/min
Existing EnPI of compressor = 7.34 kW/m3/min
EnPI of Energy Efficient compressor= 6.0 kW/m3/min
Savings = 1.34 kW/m3/min

= 1.34 x 8.1 (min/h) x 7000 (hrs./year)

= 75,978 kWh/year
= 1,291,626 PKR/year
Installation of new generation, 2 stage screw compressor with permanent
magnetic motor

Investment = contact vender

 0
100
120

20
40
60
80
13:15:48
13:16:39
13:17:28
13:18:18
13:19:09
13:19:59
13:20:50
13:21:40
13:22:30
13:23:18
13:24:05
13:24:53
13:25:41
13:26:31
13:27:22
13:28:13
13:29:03
13:29:51
13:30:40
13:31:28
13:32:17
13:33:06
13:33:55
13:34:44
13:35:36
13:36:30
13:37:23
13:38:17
13:39:06
13:39:56
Compressed Air System Evaluation

13:40:46
13:41:36
13:42:26
13:43:16
13:44:05
13:44:57
13:45:52
13:46:45
13:47:40
13:48:33
13:49:25
13:50:18
13:51:10
13:52:03
13:52:56
13:53:49
13:54:45
13:55:42
13:56:39
13:57:36
Leakage Test

Series1
Compressed Air System Evaluation Leakage Test

This leakage test is performed without Tong Tie Machines

On load time = 404 Sec.

Off Load Time = 1526 Sec

Loading % = 26.47 %

Actual Air delivery of the compressor under test = 10.1 m³/min

So leakage Volume = 10.40 x 26.47 % =

= 2.67 m³/min
Energy Loss Associated with leakages

Avg. EnPI of compressors = 7.34 (kW/m³/min)

Air leakage volume = 2.674 m³/min

Avg Daily demand (As per Sep 2019 Data) = 8. 11 m³/min

System Leakage % = 2.67/8.11x 100

= 32.92 %
Energy Loss Associated with leakages

System Leakage % = 32.924 %

Leakage Allowance = 5 %

Leakage loss within allowance = 2.67/32.92 x 5

= 0.40 m³/min

Leakage loss beyond allowance = 2.67 – 0.40 = 2.26 m³/min

Energy Loss = 2.26 x EnPI

= 3.3 x 7.34 = 16.58 kW

Energy Loss Associated with leakages

Energy Loss = 16.58 x 7000 (hr.) x 17 (Rs/kWh)

= 1,973,020 Rs/a
 Air Leakage Report
Sr. # Section Location / Machine Leakage Point Remarks
1 Crack Detector 170201 FRL Leakage
2 121001 M/c Back side Handle Valve Back side
3 Handle Valve Back side
CNC Turning section U-02 100104 M/c
4 FRL Leakage
5 51/12 FRL Leakage Back side Major
6 331301 Valve Leakge
7 Quality Unit-02 Paking Area T-Type Joint Leakge
8 Maintenance Area U-02 Maintenance Area Valve and Union Leakage
9 Pressure Switch Leakge
10 Tong Tai 090702 Air Gun Leakage
11 FRL leakge back side
Tong Tai 090701
12 Air Gun Leakage
13 GSK 121503 Pressure Switch Leakge Major
14 130301 Valve Leakge back side
15 Pipe joint leakage
Pnumatic Thread 480301
16 Handle Valve Back side pipe damage
17 55/64 FRL leakge back side Major
18 Number punch Machine 350702 FRL leakge
19 Single drill machine 190901 Valve leakage
20 Milling Hall 342001 con rod line Nylon pipe leakage Major
21 Slat M/c 341701 Air Gun Joint Leakage
22 55/26 Joint Leakage back side
23 Valve leakage
Matsura 300
24 Air pipe system leakage
25 Crack Detector 170102 FRL joint Leakage
26 FRL joint Leakage upper side 2 Points
55/63
27 Down FRL joint Leakage
28 55/26 FRL Leakage
29 Valve Leakage
Milling Hall Main Panel
30 FRL Leakage
31 Super Max FRL Leakage Major
32 Reviting Machine 400401 Joint Leakage Major
33 Solenoid Valve Leakage
34 310101 FRL Leakage Major
35 Joint Leakage
36 Cylender Leakage Major
Intake Testing M/C 570101
37 Pipe joint leakage
38 T-Type Joint Leakge Major
190702
39 Pnumatic Valve Leakage Major
40 Fiat Testing M/c 570104 FRL Leakage
41 Fiat Testing M/c 570103 Handle Valve Leakage
42 Clutch Assembly Section U- Laser Marking M/c FRL Leakage
43 02 470106 Handle Valve Leakage
44 Fiat Clutch Assembly Line FRL Leakage
45 Joint Leakage
46 490101 Pnumatic Valve Leakage Major
47 FRL Leakage Major
48 Joint Leakage Major
20102
49 T-Type Joint Leakge
50 Near Shafique Sb Table Handle Valve Leakage
51 490102 Spring Tester Internal Leakge Major
52 FRL Leakge 2 Points Major
490103 Pressure Spring machine
53 Cylender Leakage
54 Compressor 37 KW 140101 Internal Leakge
Compressor Room U-01
55 Compressor 75 KW 140201 Internal Leakge Valve
56 120401 Internal Leakage Major
C & G Section U-01
57 YCM 100101 Internal Leakage Major
58 1350 Ton Press Handle Valve Leakage Major
59 Upsetter Internal Leakge Major
Forging U-01
60 Drop Hammer Press Handle Valve Leakage
61 250 Ton Press FRL Leakage
Some glimpses of air leakages points
Recommendations
1. Scan the leaks effectively on regular basis with ultrasonic leak detector.

2. Prepare a master plan to eliminate the reoccurring leaks.

3. Avoid one touch push fitting and use tow tough screw fitting.

4. Use properly dry air with dew pint of not less than 4-6 oC.

5. Replace old harden flexible pipes with new flexible pipes.

6. Install new solenoid relays to replace faulty ones.

7. Install new fittings instead of repairing it.

Recommendations

Compression fittings for leakage elimination

Other Observations in Compressed Air System

Observation 1

Theirs is no condensate drain system in header, inside the

compressor room.

Recommendation

Install bucket type condensate drain system at the lowest point.

 Other Observation in Compressed Air System
Observation 2

There is a manual ball valve to drain the condensate from main header and
some at other places too.

Recommendation

Install bucket type condensate drain system instead of timer based system.
Bucket type moisture drain system
Other Observation in Compressed Air System

Observation 3

Excessive bends in piping layout in machining

areas across the pillars and walls.

Recommendation

Redesign the layout in such a way to avoid

excessive bends.
Other Observation in Compressed Air System

Observation 4

Excessive joints in flexible pipes.

Recommendations

Use proper fitting and pipe size for

connections.
 Heat Treatment Section
During the evaluation of HT process control parameters following observations were made.

Observations

1. Actual dwell time varies from the designed schedule.

2. Data loggers were not installed to correct furnace.
3. Dataloggers are not properly used for any analysis.

May be the energy wastage is not a major issue but quality parameters are sensitive for
time and temperature.
Few example from the month of MAY 2019 on next slides
 Remarks

1. Time duration of the batch as per daily progress report does not match with
datalogger given data.

Dwell time was 16 min extra

 Remarks
1. According to daily progress report, batch was entered into furnace at 6:00 PM and taken
out at 7:00 PM.
2. As per datalogger, the batch was entered into furnace at 5:45 PM and taken out at 6:30
PM. So dwell time was 16 min short.
 Remarks

Daily progress report & graph trends don't match.

It means datalogger was not installed on prescribed furnace.
 Remarks
Daily progress report & graph trends don't match
It means datalogger was not installed on prescribed furnace.
 Remarks

17 Extra Min for heat treatment.

 Remarks
Daily progress report & Graph trends don't match.
It means datalogger was not installed on prescribed furnace.
 Remarks

1. daily progress report & Graph trends don't match.

It means datalogger was not installed on prescribed furnace.

 Remarks
Daily progress report & Graph trends don't match.
It means datalogger was not installed as prescribe furnace.
 Remarks
Daily progress report & Graph trends don't match.
It means datalogger was not installed on prescribed furnace.
 Remarks
Daily progress report & Graph trends don't match.
It means datalogger was not installed on prescribed furnace.
Recommendations

1. Connect the temperature datalogger correctly to furnaces.

2. Download the data from logger every day and match the graph with
SOP of that process.

3. Installed timer based siren to alert the operator for correct dwell time.
Important
If a batch is treated for 30 min extra

Energy wastage = 15 kWh

= 15 x 17

= 255 PKR
Misc. Observations
Idle running of cooling water pump for quenching bath. A lot of water that is not
being used always in ST Dept. is being wasted.

Cause
• Manual ON/OFF control technique .
• No storage tank for water.

Recommendations

Use over head tank to store the water in case of no demand in ST department.
A level switch will turn off the pump, when not used for quenching furnace.
Forging Section
Observation 1
Energy wastage through chimney of batch type Re-
heating furnace.

Cause

High positive pressure due to over sized burners

Effect

High heat energy loss

Recommendations
Option 1

Use appropriate size burner. Heating time may be 15 –

20 % more than current time. But energy efficiency
will be improve mora than 20- %.

Option 2

Recover the waste heat

Recommendations

Option 2

Recover the waste heat as per

suggested layout

Furnace 1 Furnace 2
Observation 2
Energy wastage through open door of reheating
furnace

Effect

High heat energy loss.

Recommendations

Keep the door closed as max as possible.

Observation 3

Personal cooling fan is directed towards the furnace

opening is often.

Effect

Large amount of cool air enters into the furnace and

cool down the heating system, means low efficiency.

Recommendations

Redirect the fan from back side.

 Operating Parameters
Cooling Tower 80 TR
Open Circuit
Description
.
Hot Water In Cold water Out dT

51 45.1 5.9
Reading 1
50.9 45.1 5.8
Reading 2
Observation 1

Range (dT) is just OK , it should be in the range of 6-10

Cooling Tower 80 TR

Observation 2

Cooling Tower if over loaded, water temperature at inlet of cooling tower is too
high i.e. 51 ° C

Cause

High heat Load.

(80 TR) cooling tower is attached with 800 kW induction furnace, while large
(120 TR) cooling tower is attached with small 350 KW induction furnace.
Cooling Tower 80 TR

Recommendations

1. It is recommended to connect 800 kW induction furnace with 120 TR cooling

tower.

2. Measure the outlet water (cool) temperature , it should be up-to 30-38 °C.
Recommendations

3. Prepare and maintain a log sheet to record operating parameters of cooling

towers such as
a) Hot water (at inlet of cooling tower) temperature.
b) Cool water (at outlet of cooling tower) temperature.
c) Cool water (at inlet of machine) temperature.
d) Hot water (at outlet of machine) temperature.
e) Ambient air dry bulb temperature.
f) Ambient air wet bulb temperature.

In case of high outlet water temperatures, mass flow rate should to be revised
by optimizing the coolant flow rate for equipment safety and cooling tower
efficiency.
 Operating Parameters

Cooling Tower 120 TR Open Circuit

Description.
Hot Water In Cold water Out dT

41 37.1 3.9
Reading 1

41 37.2 3.8
Observation 1 Reading 2

Range (dT) is Low, it should be in the range of 6-10

 Cooling Tower 120 TR

Observation 2

Water sprinkler is not working, causing

low range.

Recommendations

Repair the sprinkler system immediately.

Cooling Tower 120 TR
Observation 3

• Water basin level is out and water flows out and

goes into drain.

• No water level switch is installed. Cause over flow

of makeup water.

Recommendations

• Balance the cooling tower basin.

• Install float ball type water level switch, as in
Observation 4

Hot water that is circulated through drop hammer.

was observed being wasted even during the
operation of a cooling tower.

Water wastage measured = 680 L/hr ± 5%

Recommendations

Water should be re-circulated through cooling tower

(even it is operational or not)
Observation 5
Idle running of cooling towers (120 TR and 80 TR) of forging
section, during break time and after shut down of induction
machine.

Cause

Manual ON/OFF control system .

Recommendations

Automation is recommended to shut down the cooling tower

when temperature of coils are reached to prescribed level.
Observation 6
Float ball vale of cam shaft induction hardening furnace cooling
tower is not working properly.

Water Loss (measured) = 168 L/hr

= 168 x 24
= 4032 L/day
= 1.17 Million Litre /year

Recommendations

Good quality level switch should be installed to prevent fresh water

loss.
Intelligent control system of Cooling Tower

In existing case, cooling tower fan continuously run

to evaporate the water at constant speed
irrespective of heat load, ambient temperature, and
humidity.

The capacity requirements of a cooling tower vary by

day and by night, by the temperature conditions of
the season, as well as by the heat load.

Power can be saved by operating at the optimal

power that matches the load by means of the
inverter with Fan motor.
Intelligent control system of Cooling Tower

Suggestion

Automation of cooling tower is a well know measure

to meet the cooling demand in energy efficient way.

How it works

It regulates the fan speed as per heat load and

ambient weather condition by adjusting the fan
speed. In cool days it even stop the fan.
Intelligent control system of Cooling Tower

Saving Potential

Avg power consumption = 2.5 kW

Annual Energy consumption = 2.5 x 5000
= 12500 kWh
Saving Potential = 20 %
= 12500 x 20 %
= 2500 kWh/a
= 2500 x 17
= 42,500
Intelligent control system of Cooling Tower

Note

Saving will be much more. Idle running of cooling tower will be eliminated and that savings will also
be added.

Investment = 70,000 PKR (Approx.)

General Observation 1
Poor exhaust system at some areas
Air short circuiting
 Recommendations

• Install the exhaust ducts in dusty or high

fumes areas.

• Breathe out the system effectively as

shown in diagram
Observation 2

• No Dust collectors in grinding area.

Recommendation

• Install dust collectors

General Observation 2

Idle running of Fans and lights

Suggestion

Low cost PIR Sensors can eliminate the idle

running of lights /fans
Observation 3
Few events of Idle running of hydraulic pump of CNC
machines has been reported by IEL energy team.

Recommendations

It is recommended to automate the pumps with

machine control system
Observation 3
There are many conveyer belts in forging section to
transport the parts.

70 % of the time conveyer runs idly .

Recommendations

Simple automation can save handsome energy.

Lighting system
Observations
• Lighting survey is being conducted on regular basis.
• Energy Team has the record of lux levels in all areas
• Areas with faulty lights and low lux levels are already has been identified.
• Repaired COP Led Flood lights are being used, which are very inefficient.

Recommendation

• Ensure to clean the reflectors at regular interval

• Do not repair COB flood lights.
• Install PIR sensors at suitable location to avoid idle running of lights.
Thermography of Electrical
System
Forging Main panel (561013)
Observations:
Loose /oxidized or bad connection of phase 2 i.e. 95.4 Celsius.
Repair immediately.
Forging Main panel (561013)
Observations:
Loose /oxidized or bad connection of phase 2 i.e. 95.4 Celsius.
Repair in routine maintenance.
drop forging main (260401)
Observations:
Over loaded cables 2 i.e. Upto 85 Celsius.
May cause fire, Change wires immediately.
cam shaft induction hardening (2901001)
Observations:
Loose /oxidized or bad connection of phase 2 i.e. 63 Celsius.
Repair immediately.
C&G main breaker (560104)
Observations:
Loose /oxidized or bad connection of phase 1 i.e. 41 Celsius.
Repair in routine maintenance.
maintenance Dept.(561012)
Observations:
Over loaded cables 2 i.e. Up to 85 Celsius.
Change wires immediately.
machine shop (560105)
Observations:
Resistance is developed at cable joints. heat will weaken the
insulation and damage of wire.
i.e. 58-60 Celsius.
Repair the connection in appropriate way..
machine shop (560105)
Observations:
Over loaded cables 2 i.e. Up to 60 Celsius.
Change wires immediately.
cam section (561011)
Observations:
Circuit breaker is heated up due to derating.
Change breaker in routine maintenance.
R&D section (560108)
Observations:
Over loaded cables i.e. Up to 82 Celsius.
Change wires immediately.
R&D section (560108)
Observations:
Over loaded / De-rated cables i.e. Up to 66 Celsius.
Change wires immediately.
HT (560124)
Observations:
Loose /oxidized or bad connection of phase 2
Repair in routine maintenance.
HT (210203)
Observations:
Loose /oxidized or bad connection of phase 2.
Repair in routine maintenance.
ST (560124)
Observations:
Loose /oxidized or bad connection of phase 2 i.e. 77 Celsius.
Repair immediately.
short blast (450401)
Observations:
Current imbalance on phase 2 of connector..
Check for current balance in routine maintenance.
clutch assembly
Observations:
Loose /oxidized or bad connection of all 3 phases i.e. 60 Celsius.
This is may be due to the de-rated circuit breaker.
Repair in routine maintenance.
P.F panel milling hall
Observations:
Over Loaded / de-rated wires. Up-to 58 Degree Celsius.
Replace in routine maintenance.
P.F panel milling hall
Observations:
Loose /oxidized or bad connection of phase 3 i.e. 53 Celsius.
Repair immediately.
clutch assembly Dept (560121)
Observations:
Loose /oxidized or bad connection of phase 3 i.e. 67 Celsius.
Repair immediately.