INDIA’S LEADING PUMP MANUFACTURER IS SAVING 2.28 CRORES A YEAR MONITOIRNG ENERGY PATTERN AT THE FOUNDRY PLANT.

ABSTRACT

The leading and award-winning manufacturer of pumps in India is monitoring energy consumption pattern remotely at their foundry plant to cut energy consumption by 3,60,000 units/ year and save 2.28 crores.

 

CUSTOMER PROFILE

The client is India’s number one pump manufacturer with an award-winning captive foundry, motor lamination, and winding wire units. They deploy pumps for agricultural, wastewater treatment and domestic applications. Total productive maintenance has allowed the group to maintain consistency in quality.

 

PROBLEM

The organization was consuming 20% more energy to melt one ton of metal at their foundry plant. One way to bring down energy consumption was through energy pattern monitoring. Because a furnace that ran at full load capacity would consume a lot less energy compared to furnace that was not operating at full load capacity. The organization had supervisor report with data on the energy consumption but to quote in their words “the report generated every hour was nothing short of post-mortem report, as it was too late to take corrective actions.” The energy pattern varied on a minute-to-minute basis and hence they needed data in near real time to monitor the foundry plant for optimization.

 

SOLUTIONS AND OUTCOME

When consulted with the problem, METI introduced remote energy monitoring solution in the plant, where energy consumption pattern from the furnace was logged in as graphs every other minute. The analysis revealed that the operators varied the furnace load irregularly over the entire shift. The irregularity in loading the furnace was costing addiotional 200 units in energy consumption for the organization. Only by monitoirng energy pattern the organisation was able to find out the reason for excess energy consumption.

Remote energy monitoring helped the oraganisation manage power fatcor and calculte the optimum peak load as well. Effective monitoring ensured optimization of furncae usage and reduced the energy consumption by 14.08%. This transaltes to 2.29 crores in savings every year.