Lucas-TVS Limited Padi (Chennai)

UNIT PROFILE Lucas-TVS is a part of the TVS group. It was setup in 1961 as a joint venture of Lucas Industries plc, UK and TV Sundaram Iyengar and Sons at Chennai to manufacture automotive electrical systems.

Lucas-TVS has since inception has been maintaining its leadership as an automobile electrical systems supplier. Lucas-TVS manufactures a complete range of auto electrical products consisting of direct drive and gear reduction Starters, internal and external fan alternators, wipers, fan motors, blower motors, window lift motors, mechanical and electronic distributors, cam sensors, headlamps etc. The Auto Electricals division now has three plants situated in Padi, Pondicherry and Rewari. The Padi plant, which is the mother plant, manufactures all range of electrical automobile products. ENERGY MANAGEMENT POLICY We are committed to reduce the Specific Energy consumption (Electrical units per Equivalent Starter Unit) for our products comparing to the previous year consumption THROUGH 1. Maximize the Capacity utilization. 2. Fine tuning our Operations and Maintenance continuously to achieve the above goal. 3. Technology up-gradation with energy efficient processes and equipments. 4. People involvement suggestion, Small group activities, quality improvement team and work team. 5. Waste elimination reduce, reuse and recycling. 6. Promote awareness in every employee through training, competition and factory visit. 7. Large cell formation. 8. Process changes. 9. Setting up a system to continuously monitor the progress. 10. Comply with Energy legislation and Environment regulation. APPROACH Training Formation of Task force team Cross functional Team QC story Employees involvement through 1. S.G.A. (Small Group Activities) 60 2. Suggestion Scheme & Voluntary 1200 / year 3. Work Teams (5S, TPM, ENVIRO, SAFETY) 520 members 4. Energy Audits (Internal & External) 5. Quality Improvement Team (QIT).

ROLE OF ENERGY MANAGER Prepares Annual Plan with Targets and Budget Establish an Energy conservation cell within the firm with managements concern about the mandate and task of the cell. Acts as a Facilitator in implementing the Encon Projects Interacts with core team members / cross functional team periodically to review the progress Constitutes a team of Auditors to monitor the Retainment of Improvements Presents the achievements to Top Management

MONITORING AND REPORTING SYSTEM

AWARENESS OF POTENTIAL SAVINGS TOP MANAGEMENT COMMITMENT TEAM FORMATION BY ENERGY MANAGER PRELIMINARY ENERGY AUDIT DETAILED ENERGY AUDIT IMPLEMENT QUICK HITS HIGH COST PROJECTS

TRAINING

MONITOR

FEASIBILITY STUDIES

Feed back to top management

IMPLEMENT HIGHER COST MEASURES

ENERGY CONSERVATION ORGANISATION - STRUCTURE

ENERGY CONSERVATION ACHIEVEMENTS

During the period 2004 2006 Lucas TVS Ltd has implemented around 33 projects through Engineering initiatives and workmans suggestion schemes resulting into total saving of Rs. 103.23 Lacs with an investment of Rs. 78 Lacs. This has been resulted in a reduction from 15 units per product to 13.4 units per product in specific electrical energy consumption. ELECTRICAL SAVINGS. A. Screw compressor with variable frequency drive
Compressor - Energy Consumption per product (ESU)

3.0

2.5

2.0

ESU

1.5

1.0

0.5

0.0

200 200 200 200 200 102 Plan 06-07 plan 06-07 act. 234503 04 05 '06

Apr06

Ma y06

Jun- Jul06 06

Au Se gp06 06

Oct06

No De vc06 06

Jan- Feb- Mar07 07 07

200 200 200 67809 1 07 08 1.3 1.3

2.0 1.9 1.7 1.6 1.4 1.4 1.40 1.401.40 1.381.38 1.381.36 1.351.33 1.321.30 1.401.30 1.301.30 1.281.25

Before

After

Before installation: For 2200 cfm output compressed air requirement, plant was running five compressors having total motor capacity of 675 HP Motor capacity = 675 HP Power consumption per annum = 22 Lakhs Kwh Operating cost = Rs. 102.3 Lakhs / annum After installation: Screw compressor with VFD running in replacement of old inefficient reciprocating compressor by high efficiency Screw compressor with sigma logic controller with existing compressors having total motor capacity of 485 HP Motor capacity = 485 HP Power consumption per annum = 15.87 Lakhs KWh Operating cost = 73.8 Lakhs / annum Saving = Rs. 28.5 Lakhs / annum B. Introduction of blower less cooling tower

BEFORE Before 10 HP purpose in Motor capacity (10HP X 5 Nos) Power consumption per annum Operating cost motor each = 50 HP = 1.80 Lakhs units = 8.37 Lakhs / Annum

AFTER installation: is used for cooling cooling tower.

After installation: Motors are eliminated due to natural cooling. Motor capacity Power consumption per month Operating cost = Nil = 0 units = Nil

Saving = Rs. 8.37 Lakhs / Annum C. Replacing high consumption Air conditioners 15 Nos.

BEFORE AFTER Before installation: 45 Nos. of old and high consumption air conditioners were used. Power consumption per annum = 3.47 Lakhs Operating cost = 16.2 Lakhs After installation: 45 Nos. old Air conditioners are replaced with timer controlled new high efficiency Air conditioners Power consumption per annum = 2.20 Lakhs Operating cost = 10.3 Lakhs Saving = Rs. 5.9 Lakhs

D. Exhaust duct provision for screw compressor.

BEFORE

AFTER

Before installation: Compressor exhaust hot air re circulated and the suction air temperature increased 5 C from the ambient. Power consumption per month = 1,97,000 Operating cost = Rs. 9.16 Lakhs After installed Exhaust duct. Suction Air temperature reduced to ambient level. Hence energy consumption reduced 5 units/Hour and Current consumption from 155amps to 145 amps Power consumption per month = 1,71,000 units Operating cost = Rs. 7.96 Lakhs Saving = Rs. 14.4 Lakhs / annum

E. Genset Cooling system changed from cooling tower to coil coiling

BEFORE AFTER Before installation: Forced cooling tower with 15 HP jack water pump and 10HP blower motor for cooling the engine. Power consumption per annum = 0.90 Lakhs Operating cost = 4.185 Lakhs After installation: Replaced the cooling tower by coil cooler and eliminated the 15 HP jack pump. Power consumption per annum = 36000 units Operating cost = 1.67 Savings = Rs. 2.5 Lakhs / annum Water savings = 5000 Kilo litres / year F. Substation III Reduction in transmission power loss by eliminating 300 metres of LT cable by HT supply provided with localized Transformer. Power consumption per month = 26.64 Lakhs units Transmission loss (3 %) = 0.799 Lakhs units Savings = Rs. 3.71 Lakhs / annum G. Power factor incentives By maintaining 0.995 power factors, every month we got incentives of around Savings = Rs. 18.0 Lakhs / annum H. Power management. By operating TET, water treatment and other plants during non peak hours and got the incentives of Rs. 12000 / month (5 % rebate) Savings = Rs. 1.44 Lakhs / annum I. Linear Head For Shaft Feeding Arrangement In Induction Hardening Machines Before installation: The feed system for shaft in the induction-hardening machine is by a hydraulic pump and cylinder. The variable feed rate is achieved by selecting the flow control valves. Motor capacity = 3 HP Power consumption per annum = 10800 Kwh Operating cost = Rs. 0.54 Lakhs / annum 1.5 Lakhs

After installation: The hydraulic system is replaced with synchronous motor operated linear feed head. The current consumption during operation is 60Watts. Motor capacity = 60 Watts Power consumption per annum = 180 KWh Operating cost = Rs 900 / annum Saving = Rs. 0.53 Lakhs / annum / machine. Total savings Rs 3.7 Lakhs / annum

J.

Introduction of Solid State Power source in place of MG set in Starter Performance testing rig Before installation: 25 HP motor is used as prime mover for DC Generator which produces 0 30 VDC for a load upto 2000 Amperes. The motor runs throughout the day. Motor capacity = 25 HP Power consumption per annum = 0.78 Lakhs units Operating cost = Rs 3.9 Lakhs / Annum After installation: Solid State electronics controlled power supply that consumes power only during Testing is used. The average testing time per starter is 10 seconds and daily production per line is 400 nos. The power consumption during idle time is 150 Watts. Idle power consumption = 150 Watts Power consumption per annum = 0.048 Lakhs units Operating cost = Rs 0.24 Lakhs / Annum Saving = Rs. 3.66 Lakhs / Annum

K. Modification of Infra Red Heater array in Armature varnishing plant Before modification: The armatures are pre heated and cured in the conveyorised plant, which has 180 IR heaters installed in the sides. Each heater is of 500 Watts. Total heater capacity = 90 KW Power consumption per annum = 2.70 Lakhs units Operating cost = Rs 13.5 Lakhs / Annum

After modification: The IR Heater array was re-positioned to optimise heat radiation and 40 Heaters were removed retaining the operating efficiency of the plant. Now the no. of heaters is 140 only. Present heater capacity = 70 KW Power consumption per annum = 2.10 Lakhs units Operating cost = Rs 10.5 Lakhs / Annum Saving = Rs. 3.0 Lakhs / Annum L. Elimination of ONE pump in 150 Ton Yoke Sizing Presses (two machines) Before modification: One 75 HP and One 25 HP motors are used to drive 3 Pumps for a capacity of 150 Ton operation. The actual load requirement is 50 Ton. The actual usage time is 10 Hours (900 yokes X 20 seconds X 2 shifts) the idle power consumption is 400 KWH. Motor capacity = 100 HP Power consumption per annum = 3.0 Lakhs units Operating cost = Rs 15.0 Lakhs / Annum After modification: The utilized capacity is 50 Ton. The idle time power consumption is reduced by cutting off the 25HP motor and running only the 75HP motor. There is no increase in cycle time, which is 20 seconds. Present motor capacity = 75 HP Power consumption per annum = 2.6 Lakhs units Operating cost = Rs 13.0 Lakhs / Annum Saving = Rs. 4.0 Lakhs / Annum (For 2 machines) M. MG set to static high current power source. Before modification: MG set power consumption per annum = 789900 units Operating cost = Rs. 36.73 Lakhs

After modification: Power consumed by Static power source = 14400 units / annum Operating cost per annum = Rs. 0.67 Lakhs Savings = Rs. 36.06 Lakhs.

N.

Elimination of High pressure compressed air for agitation by using High Volume Low Pressure blower at auto plating

Before Before Installation: Power consumed per annum = 40500 units Operating cost = 1.88 Lakhs After Installation

After

Power consumed by the compressor = 27000 units / annum Operating cost = Rs. 1.25 Lakhs Savings = 0.63 Lakhs / annum.

Fuel savings Through solar water heater, LPG to SKO conversion

SKO RUN CANTEEN BOILERS

14

STEP CHANGES IN CANTEEN BOILER FUEL CONSERVATION

12

Work In Progress

12.89

Savings / Annum - in Rs.Lacs

HSD to SKO CONVERTION 10 Savings: Rs.5.18 Lacs/Annum @ Rs.4 / Ltr. 8

7.71
6
PRE-HEATING THE FEED WATER BY SOLAR PLATES Savings: 32,400 Lts/Annum

2 LPG to HSD Conversion: LPG:396 Kg/Day * Rs.20/Kg HSD:432 Lts/Day * Rs.16.50/Lt 0 1997

2.37

1999

2004

SOLAR PLATE HEATING FOR CANTEEN

20 PLATES-2000 LTS. CAPACITY

FUEL (LPG)CONSERVATION
CONVERSION OF LPG FIRED BOILER INTO HSD FIRED REVOMAX BOILER. PURPOSE : ENERGY SAVING HAZARD MINIMIZATION & OPERATIONAL ADVANTAGES

BENEFITS
LPG BOILER Operating hrs 22 LPG consumption 396 kg /day LPG COST/DAY Rs 7920 HSD BOILER Operating Hrs 16 HSD Consumption 432 lts /day HSD COST/DAY Rs 7128

FUEL COST SAVING/ANNUM Rs 2.38 lacs

Fuel savings in captive Genset (Trendsetter). SPECIFIC FUEL CONSUMPTION (ml)

SPECIFIC FUEL CONSUMPTION (ml) 300

297

286
285

286

276
AFTER EXHAUST MODIFICATION

277

270

268

260
AFTER INTAKE AIR MODIFICATION

255

255

AFTER RETURN FUEL COOLING

240

225 FEB MAR APR MAY JUN JUL AUG SEP

Improvements: Exhaust system straight outlet chimney modified from canopy outlet. To reduce the suction air temperature the air inlet pipes were extended to three metres away from the engine where the air had nearly ambient temperature The return fuel is cooled through heat exchanger to reduce the temperature Before improvement SFC 3.36 units per litre of Diesel After improvement SFC 3.9 units per litre of Diesel Benefits: This improvements has resulted in the savings of 10930 litres per annum of HSD Fuel saving due to SFC reduction Savings = Rs. 29.5 Lakhs = 29 ml per unit

SPECIFIC ENERGY CONSUMPTION

20 UNITS PER PRODUCT 15 10 5 0 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 YEAR
18 16 15 14.5 13.5 13

E n e r g y C o n s e r v a tio n P ro je c ts
EM EN TS

E n c o n d e s ig n C h a n g e s P ro je c ts -1 4 / 2 0 0 6 -0 7 -P L A N E n c o n d e s ig n C h a n g e s P ro je c ts -2 9 / 2 0 0 5 -0 6
1 3 L a c s u n it s

E n c o n & F u e l P r o je c t & T N E B p o w e r in c e n t iv e -4 2 2 0 0 4 -0 5 E n e r g y M a n a g e m e n t w a s te e lim in a t io n P o w e r f a c t o r Im p ro v e m e n t p ro je c ts -2 2 . 2 0 0 3 -0 4

1 3 L a c s u n it s

IM

PR

9 . 2 la c s u n it s

E n c o n P ro je c ts & p o w e r M a n a g e m e n ts -1 2 2 0 0 2 -0 3 E n c o n & fu e l P ro je c ts -1 0 2 0 0 1 -0 2 E n c o n p ro je c ts -2 1 2 0 0 0 -0 1 E n c o n p ro je c ts -2 6 1 9 9 9 -0 0
2 7 .4 la c s u n it s 8 .9 8 la c s u n it s 1 4 .8 la c s u n it s 9 .0 3 la c s u n it s

1 2 .1 6 la c s u n it s

T o ta l n o . o f p r o je c ts:1 6 6 T o ta l E n e r g y s a v in g s : 9 6 .9 5
L a c .u n i t s ( 1 2 5 6 .L a c .u n it s ) S A V I N G 7 .7 % A S O N A U G 0 6

W ED

O VE R A L L E L E C T R IC A L E S U T R E ND
210 203 200 19 193 18 16 180 15

U N ITS in lacs

190

14.5

180 13.5 170 163 162 160 8.7 150

0 0 '-0 1 0 1 '-0 2 162 9 .0 5 18 0 2 '-0 3 163 9 .8 7 16 0 3 '-0 4 180 1 1 .3 4 15 0 4 '-0 5 193 1 3 .5 1 4 .5 0 5 -'0 6 203 1 4 .5 1 3 .4

14.5

13.4

163 9.87

11.34

9.05

U N IT IN L AC S P R O D .E S U IN L AC S U N ITS /P R O D U C T

163 8 .7 19

Specific Energy Consumption Trend

26 25 24 2 3 2 3 .5 22 21 20 19 18 17 16 15 14 13 12 11 10
95-96

22

2 1 .5 20 19

SELF BENCH MARK (06 07)

18 17 16 15 1 4 .5 1 3 .4 13

KWHR / ESU

96-97

97-98

98-99

99-00

00-01

01-02

02-03

03-04

04-05

05-06

Y E AR

06-07

IM P R O V E M E N T IN P o w e r Facto r er

P o w e r facto r C a p a cito r B an k s
* C ap acito rs b an k d istrib u ted b ased o n the lo ad cen ter. * C ap acito rs b an k p ro vid ed for th e lig hting * C ap acito rs p ro vid ed for the hig h p o w er m ach ines . * A u to m atic P o w er facto r correctio n b ank in d ifferent lo catio ns * G a s filled cap acito rs/ N o los s 26 N os. 100 K V A R B A N K S 2 N o s. 2 5 K V A R B A N K S

IM

VE RO

EN

TS

P o w e r Facto r Cap a cito r B an k s

* Fixed cap acito r b a nk at SS en d * D o ub le film foil cap acito rs * T ail en d cap a cito rs p ro vid ed 22 N o s. 100 K V A R B A N K S

P o w e r Factor C a p acito r B an ks
* Fix ed cap acito r b anks at su p p ly en d * M o re En erg y 1 8 N o s. 10 0 K V A R B A N K S

0.995 P.F 0.97 P.F

0. 95 P.F
1 9 98 - 2 00 3 2 0 03 - 2 00 5

1 9 95 - 1 99 8

W ED

ENERGY CONSERVATION FOR THE YEAR 2005 2006 Sen. 1. 2. 3. Title of Energy saving project Implemented Introduction of VFD for compressor Replacement of in-efficient compressor Blower less cooling tower Savings In Lakhs 18.0 10.0 8.37 Investment in Lacs 12.00 9.00 10.00

4. 5. 6. 7. 8. 9.

Replacement of in-efficient A/C units Solar water heater for canteen Replacement of in-efficient transformer Ring main system for compressed Air system Sleep timers for dust collectors Energy efficient motor for utilities

1.2 1.50 4.00 2.50 0.50 2.00

2.00 4.00 9.00 3.00 0.20 2.00

10.

Star Delta star converter for high power machine

2.00

1.00

11.

Introduction of AC drive motors in place of DC motors Power management during off peak hour and lunch hour TOTAL

1.00

2.0

12.

4.00

53.07

54.2

ENERGY CONSERVATION IN 2006 2007 (plan) 1. Replacing high consumption Air conditioners 15 Nos 2. Introducing screw compressors in place of Reciprocating air compressors - 2 Nos 3. Introducing blower less cooling tower - 2 Nos 4. Introducing heat exchanger in place of 15 TR chiller Plant at IF0005 induction hardening machine CMSBU 5. Air leak audit & correction 6. Energy efficient pumps - 6Nos 7. Exhaust Duct provision for Screw Compressors 8. Reduction in cooling tower pump capacity- compressor house pump room 9. 40HP compressor removed 10. Compressor cooling pump 10HP not in use 11. Head lamp chiller plant modification 30TR to 3 TR 12. Removal of low efficiency compressor 150 HP 13. Solar power street light for remote area - 10 Nos 14. Air cooled fluid cooler for IY0017 860 KVA Genset and IY0045 1000 KVA - 2 Nos 15. Introduction of Bio mass gasifier in place of SKO usage for thermal application.

We at Lucas TVS are committed to Protection, preservation and improvement of the environment by continually orienting our activities, products and services.

INNOVATIVE TECHNOLOGY FOR ENERGY AND ENVIRONMENT

One of the remarkable contributions this year was the establishment of indigenous waste coolant treatment system, which was not done before by any of the industries in the world, which involves recovering waste oil from waste coolant, thereby the quantity of waste disposed has reduced by 55% compared to last year.

ENVIRONMENTAL AND ENERGY BENEFITS

This process is unique one. It uses RO Rejection water & solar evaporation for coolant oil treatment process. No Chemical treatment is involved in this process whereas other companies are using chemicals & Electrolysis for treatment. High TDS water (RO Reject) disposal problem is solved. Meeting out the PCB standard to sell the oil for recycling (0.8% water & 99.2% oil against PCB norms of 15 % water & 85% Oil) Cost saving Rs 6.52 lacs per annum. Energy Consumption is very less

SUN

RO REJECTION WITH HIGH TDS OF 5000

RO PLANT

FACTORY

LUCAS - TVS WASTE COOLANT WITH OIL

FACTORY USED COOLANT OIL FROM FACTORY UNLOADING

WATER TREATMENT PLANT

LUCAS - TVS WATER

VALUE YARD
OIL BARREL

DISPOSAL TO RECYCLER WITH PAYMENT

CPCB & TNPCB

COOLANT OIL STORAGE AREA

STORAGE TANK ( 2 LAKH LITRE CAPACITY )

STOPPED

HAZARDOUS WASTE STORAGE AREA

SOLID & POWDER

SOLAR POND VALUE YARD ( FOR SALE OF OIL )

BEFORE IMPROVEMENT

AFTER IMPROVEMENT

Next to this the reduction of lead soldering stations for armatures by the introduction of brazing method, and also a new system for solder recovery from waste lead solder dross where by we can able to reduce the solder waste disposed. ENVIRONMENTAL AND ENERGY BENEFITS Elimination of usage of lead in product Power consumption is reduced from 0.7 units to 0.3 units per armature Design scrap reduction (Copper saving) due to raiser less commutator from 60% to 33%. Total energy savings of 1.8 Lacs units/year

BRAZED ARMATRE AFTER IMPROVEMENT

LEAD SOLDERED ARMATURE BEFORE IMPROVEMENT

ENERGY AND ENVIRONMENT CONSERVATION AWARENESS PROGRAM

We have organized a various energy conservation awareness programs for the contractors, employees and their families and general public and circulated templates about energy conservation at home.

We are in the process of switching over to trivalent chrome plating from Hexavalent Chrome.

RAIN WATER HARVESTING

Development of greenery, rainwater harvesting, water conservation are our routine activites, Even though the production has increased by 1.08 times compared to last we can able to reduce the water consumption from 18 Litrs/Product to15 Litrs/Product. Due to such activites we could able to reduce the bought out water valued Rs 300000/- per annum as the ground water table is enriched through rain harvesting system.

GREENERY DEVELOPMENT

Treated sewage water recycling for gardening and this year we added 300 Nos of tree saplings to our existing green belt. .

INTRODUCTION OF FLUIDIZED AREATION BED IN PLACE OF SURFACE

We could able to save a considerable amount of energy by the introduction of Fluidized aeration bed in AGITATOR FOR SEWAGE TREATMENT sewage treatment plant in place of surface aeration by agitator.

ROOTS AIR BLOWER 2WORKING

POWER CONSUMPTION IS 25 KW/HOUR BEFORE IMPROVEMENT

POWER CONSUMPTION IS 18 KW/HOUR

AFTER IMPROVEMENT

TOTAL ANNUAL POWER SAVINGS: 75000 UNITS PER ANNUM

ENERGY SAVINGS DUE TO THE SOLAR EVAOPARTION OF POND IN PLACE OF ELECTRICAL HEATING SYSTEM

Energy savings due to elimination of Electrical Heater : 72000 UNITS PER ANNUM

WASTE TO WEALTH FROM CANTEEN WASTE THROUGH BIOCOMPOSTING PROCESS

We are utilizing the canteen waste to generate manure by the way of Bio-composting.