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
Branch Offices: Bangalore, Chandigarh, Chennai, Delhi NCR, Hyderabad, Indore, Jaipur, Mumbai, Nagpur, Raipur & Kuala Lumpur (Malaysia)
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