Data and energy analytics for a foundry case study of various foundries ifc2017

Managing Foundry Through Real Time Data & Energy Acquisition Presented by: Shyam Kulkarni, Energy Consultant, Pune & Ecolibrium, Ahmedabad At 65th Indian Foundry Congress, Kolkata

Areas Concern For Foundry Energy Maintenance

Environment

Productivity

Process

OEE Rejections Handling

Manpower Waste Costs

SmartSense Services

Enterprise Level Analytics Billing

Network

Foundry

Insights

Insights

Insights

Asset level analytics Motor Insights

Pumps Insights

SmartSense Basic Monitor

Analyze

Optimize

Maintain

Induction Furnace Insights

Smartsense: Monitor your Utilization of Energy for every asset in our process

Cost Benefit Analysis Cost Benefit Analysis Sl.No

1

Annual Savings kWh

Description

Present Actual Details

Annual InvestROI Savings ment Months Lacs Lacs

PF Improvement Contract Demand Optimization

NA NA

38.32 6.3

15 Nil

5 Immediate

Running KVA

750

400

470

Running Running Rated kW kW Hrs

Motor overload (Bearing problem) Pump PF low (Motor interchanged) Impact on total KVA and losses

PF

CMD KVA

Total Plant kW

Running KVA

PF

0.85

500.00

400

420

0.95

PF

Running kW

Rated kW

Running Hrs

PF

56210

4.49

0.2

1

25

22

22

0.95

18

22

22

0.95

NA

1.008

Nil

Immediate

27

45

22

0.85

27

30

22

0.95

Furnace Capacity Running Efficiency Furnace Capacity Running Efficiency kW Kgs Hrs % kW Kgs Hrs %

Asset or Process Analytics 3

Total Plant kW

Billing Insights Network Insights

2

CMD KVA

Proposed System

Efficiency of Induction furnace

25550

2.044

Nil

Immediate

270

900

22

52.4

290

1200

22

65.1

Holding time optimization

211700

16.936

Nil

Immediate

290

1200

22

65.1

290

1200

20

65.1

1. Billing insights • Poor Power Factor is Sign of Inefficiency • Poor Power Factor could cost you dearly: Penalty in our Bills • Low Power Factor indicates you can have Three Phase

Low Power Factors

Contract Demand – Under utilization

Contract Demand – Over utilization

2.Network Insights-Motor Alerts

A Sand Mixer Motor of 15HP should has a rated maximum current 20A. It can be clearly seen that motor is overloaded which draws current of 37.72A Check your Motor Parameters and manage its health: Maximum Current (Overload Conditions) RPM Limit Under Voltage Over Voltage Temperature Power Factor Total Harmonic Distortion Bearing Noise/Physical Check

3. Foundry Insights Controlled Output Vs Uncontrolled Output of Sand rate (T/Hr)

Uncontrolled and erratic output of Sand Rate #No Resource Management

Results After Controlled output of Sand Rate #Better Production with Resource Management

4. Asset Analytics

Reduce Power Consumption without compromising your Production Charge your Furnace rapidly and attain the full load earlier and avoid long charging times Long Charging times mean low Equipment utilization and Energy loss

A foundry in Maharashtra charges the furnace rapidly and avoid long waits to achieve the desire temperature in lesser time. #Energy Saved

A foundry in Gujarat follows a long charging time process to attain the required temperature and hence huge loss of Power Consumption. #Energy Loss

How is the Smartsense 2.0 is different than available EMS

Ecolibrium Energy Pvt. Ltd.

Rhino Machines Pvt Ltd

504, Venus Atlantis,

Plot No 1A & 1B

100 Ft Anand Nagar Road, Prahladnagar,

GIDC Phase II, Vithal Udyognagar,

Ahmedabad- 380015, India

Anand - 388325, India

www.ecolibriumenergy.com

www.rhinomachines.net

info@ecolibriumenergy.com

rhino@rhinomachines.net

1800 103 8252 | +91 79 4016 5151

+91.9227970133 | +91.9227124977

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