CASE STUDY – SUMMARY maxiox (²-Series): For Industrial Fuel Utility CASE...

download CASE STUDY – SUMMARY maxiox (²-Series): For Industrial Fuel Utility CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.) Client: M/s. Mahindra Mahindra Ltd. (A.S.), Igatpuri.

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Transcript of CASE STUDY – SUMMARY maxiox (²-Series): For Industrial Fuel Utility CASE...

  • CASE STUDY SUMMARY

    I. Oil & Natural Gas Corporation Limited (O.N.G.C.), Rajahmundry Asse Fuel -HSD

    II. Hindustan Petroleum Corporation Limited, (L.O.B.P.) Silvassa Gujtat Fuel - FO

    III. Mahindra & Mahindra Ltd. (A.S.) Igatpuri Maharashtra Fuel - LPG

    IV. R.M.I.Cycles Ltd., Rajpura, Punjab. Fuel - HSD

    V. Ranbaxy Laboratories Limited, Goa. Fuel - HSD

    VI. Excel Process Pvt.Ltd., Killa Pardi, Dist.Valsad-Gujarat Fuel - LPG

    VII. L & T John Deere Limited, Pune, Maharashtra Fuel - LPG

    VIII. Escotel Mobile Communications Ltd., Meerut, U.P. Fuel - LPG

    IX. Rich Kwality Products Ltd., Pune Mahagashtra Fuel - LDO

    X. Garware- Wall Ropes Limited, Wai, Satara, Maharashtra Fuel - LDO

    XI. Bajaj Electricals Limited, Ranjangaon, Dist.Pune Maharshtra Fuel - LPG

    XII. Excel Insustries Limited, Roha, Maharastra Fuel - FO

    XIII. ITC Limited, Bhadrachalam, (A.P.) Fuel - FO

    XIV. ITW Signode India Limited, Rudraram Village, (A.P.) Fuel - LPG

    XV. Cadila pharmaceuticals Limited, Ankleshwar, Gujaarat Fuel - NG

    XVI. J.K.Pharma Chem Limited, Cudalore, Tamil Nadu Fuel - FO

    XVII. Hindustan Lever limited, Chimbal, Goa. Fuel - FO

    XVIII. Kirloskar Copeland Ltd., Karad & Atit, Dist. Satara- Maharashtra Fuel - FO

    XIX. Ford India. Maraimalainagar,Tamil Nadu. Fuel - HSD

    XX L & T Komatsu, Bangalore Fuel - LPG XXI Sterlite Industries (I) Ltd. Silvassa Fuel FO XXII Badve Enggineering Limited, Aurangabad Fuel LPG

  • CASE STUDIES:

    FLUX maxiox (-Series): For Industrial Fuel Utility CASE STUDY I: APPLICATION FOR D.G. SET (H.S.D.)

    Client: Oil & Natural Gas Corporation Limited (O.N.G.C.), Rajahmundry Asset SYSTEM DETAILS:

    Name of equipment : D.G. Set

    Capacity : 1430 KVA

    Make of the unit : Cummins

    Type of fuel used : HSD

    OBSERVATIONS:

    Particulars Fuel

    Consumed

    Units

    Generated

    Units

    generated/litre Hours Run % Change

    Without Flux maxiox 5790 13900 2.40 120 hours

    With Flux maxiox 3480 9200 2.64 100 hours + 10%

    2.4

    2.64

    2.252.3

    2.352.4

    2.452.5

    2.552.6

    2.652.7

    Bef

    ore

    Afte

    r

    Units Generated/litre

    Fuel Efficiency

  • FLUX maxiox (-Series): For Industrial Fuel Utility CASE STUDY II: APPLICATION FOR BOILER (FO)

    Client: Hindustan Petroleum Corporation Limited (H.P.C.L.), Lube Oil Blending Plant, Silvassa SYSTEM DETAILS:

    Name of equipment : Smoke Tube Boiler

    Capacity : 6 TPH

    Make of the unit : Thermax FM60

    Type of fuel used : FO

    OBSERVATIONS:

    Particulars

    (One Month Data

    Compiled for

    each case)

    Fuel Consumed

    per day (Monthly

    Avg.)

    Steam Generated

    per day (Monthly

    Avg.)

    Steam generated/Fuel

    consumption

    % Difference

    Before 679 3243 4.77

    After 596 3062 5.13 + 7.5%

    4.77

    5.13

    Bef

    ore

    Afte

    r

    Steam generated/Fuel consumption

    Fuel Efficiency

  • FLUX maxiox (-Series): For Industrial Fuel Utility

    CASE STUDY III: APPLICATION FOR FURNACE (L.P.G.)

    Client: M/s. Mahindra & Mahindra Ltd. (A.S.), Igatpuri.

    SYSTEM DETAILS:

    Name of equipment : Furnace (no. 14645)

    Capacity : 540 kgs. melt

    Make of the unit : Pioneer Margon (Fuel Furnaces Baroda)

    Year of commissioning : 1988

    Type of fuel used : LPG

    OBSERVATIONS:

    Period LPG Consumed (kgs.)

    Castings Poured (kgs.)

    Average Casting poured per kg. LPG

    Percentage Savings

    From 6.06.00 to 14.09.00 (Before Installation)

    12350 23,592 1.91 9.47%

    From 15.09.00 to 24.11.00 (After Installation)

    19650 41,424 2.11

    1.91

    2.11

    1.81.851.9

    1.952

    2.052.1

    2.15

    BeforeInstallation

    AfterInstallation

    Average Casting per kg. LPG

  • FLUX maxiox (-Series): For Industrial Fuel Utility

    CASE STUDY IV: APPLICATION FOR BOILER (H.S.D.)

    Client: R.M.I. Cycles Ltd.; Rajpura, Punjab.

    SYSTEM DETAILS:

    Name of equipment : Water tube Boiler

    Capacity : 2 T/Hr.

    Make of the unit : Nestler

    Year of Commissioning : 1970

    Operational details : 6 to 7 hours daily operation

    Type of fuel used : HSD

    Boiler : Fuel Consumption

    98

    99

    100

    101

    102

    103

    104

    105

    106

    107

    108

    26/08

    /99

    28/08

    /99

    31/08

    /99

    03/09

    /99

    06/09

    /99

    08/09

    /99

    17/09

    /99

    20/09

    /99

    22/09

    /99

    24/09

    /99

    27/09

    /99

    29/09

    /99

    01/10

    /99

    05/10

    /99

    07/10

    /99

    09/10

    /99

    12/10

    /99

    14/10

    /99

    16/10

    /99

    20/10

    /99

    22/10

    /99

    25/10

    /99

    27/10

    /99

    29/10

    /99

    01/11

    /99

    03/11

    /99

    05/11

    /99

    09/11

    /99

    11/11

    /99

    14/11

    /99

    16/11

    /99

    18/11

    /99

    20/11

    /99

    23/11

    /99

    Date

    Fuel

    Cos

    umpt

    ion

    (litr

    es/h

    r.)

    * FLUX maxiox installed on 12/10/1999 Results: Fuel saving of around 25 liters per day

  • FLUX maxiox (-Series): For Industrial Fuel Utility CASE STUDY V: APPLICATION FOR D.G. SET (H.S.D.)

    Client: Ranbaxy Laboratories Limited, Goa.

    SYSTEM DETAILS:

    Name of equipment : D.G. Set

    Capacity : 437.5 KVA

    Make of the unit : Cummins

    Year of commissioning : 1983

    Operational details : crossed 7000 running hours

    Type of fuel used : HSD

    OBSERVATIONS:

    Month April May June July August September October Increase in Efficiency

    Fuel Efficiency

    2.77 2.89 2.97 3.18 3.29 3.31 3.30 12%

    FLUX maxiox installed on June 15, 2000

    Increase in Fuel Efficiency

    3.33.313.293.18

    2.972.89

    2.77

    2.42.52.62.72.82.9

    33.13.23.33.4

    April May Jun Jul Aug Sept Oct

    Month

    Fuel

    Effi

    cien

    cy

  • FLUX maxiox (-Series): For Industrial Fuel Utility

    CASE STUDY VI: APPLICATION FOR OVEN (L.P.G.)

    Client: M/s. Excel Process Pvt. Ltd., Killa Pardi, Dist. Valsad, Gujarat SYSTEM DETAILS: Name of equipment : Overhead Tubular Radiant Heater Max. inject gas pressure : 50 M Bar Make of the unit : Ambi-Rad (R) ARE 22 Unit, uk

    Type of fuel used : LPG

    OBSERVATIONS:

    Period LPG Consumed (19.2 Kg. Cylinders)

    Total Minutes

    Per Cyl. LPG Consumption in minutes

    Percentage Savings

    From 22.11.00 to 10.12.00 (Before Installation)

    5 5,766.0 1,153.2

    From 25.12.00 to 21.01.001 (After Installation)

    5 6,027.0 1,205.4 8.69%

    From 21.12.00 to 24.12.00 (Before Installation)

    1 1,167.0 1,167.0

    From 21.01.01 to 25.01.001 (After Installation)

    1 1,272.0 1,272.0 9.00%

    1153.2

    1167.0

    1205.4

    1272

    0

    500

    1000

    1500

    2000

    2500

    minutes

    before after

    cylinder consumption (in minutes)

    5 cylinders average data single cylinder data

    single cylinder data 1167.0 12725 cylinders average data 1153.2 1205.4

    22.11.00 21.01.01

    19.2 19.2

  • FLUX maxiox (-Series): For Industrial Fuel Utility

    CASE STUDY VII: APPLICATION FOR OVEN (L.P.G.)

    Client: L&T John Deere Limited, Pune, Maharashtra SYSTEM DETAILS:

    Name of equipment : PPS Colour Oven

    Type of fuel used : LPG

    OBSERVATIONS:

    Particulars (One Month Data Compiled)

    Time taken for the Temperature in the Oven to rise from 35 degrees C to 70 degrees C (hours)

    % Difference

    Before 0.35

    After 0.28 20%

    0.35

    0.28

    Bef

    ore

    Afte

    r

    time taken for fixed temperature increase

    Time (hours)

  • FLUX maxiox (-Series): For Industrial Fuel Utility CASE STUDY VIII: APPLICATION FOR D.G. SET (H.S.D.)

    Client: Escotel Mobile Communications Ltd., Meerut, U.P.

    SYSTEM DETAILS:

    Name of equipment : D.G. Set

    Capacity : 200 KVA

    Make of the unit : Cummins

    Type of fuel used : HSD

    Model: NTA 743-G Mfg. Date: 7/10/96 Type: CPLX - 044

    Engine No : 25218922 Inj. Timing: A 0.0415 ", 6 Cylinder type

    Maximum Loading Permitted by DG set Manufacturer = 278 Amps

    Flux Maxiox Installed on 27 January, 2003.

    Period Units Diesel Units % Generated used Generated improvement (KWH) (Litres) Per litre 06 Jan to 27 Jan, 2003 9367.70 3100.00 3.02 28 Jan to 24 Feb, 2003 6632.52 2070.00 3.20 5.625 % 25 Feb to 24 Mar, 2003 6545.26 1943.00 3.37 10.38 %

    3.02

    3.2

    3.37

    2.9

    3

    3.1

    3.2

    3.3

    3.4

    3.5

    Effic

    ienc

    y

    Before After (Jan-Feb)

    After (Feb-Mar)

    Efficiency of D.G. Set

  • FLUX maxiox (-Series): For Industrial Fuel Utility CASE STUDY IX: APPLICATION FOR BOILER (LDO)

    Client: Rich Kwality Products Ltd., Pune SYSTEM DETAILS:

    Name of equipment : Boiler

    Capacity : 300 kg./hr.

    Working Pressure : 8 kg/cm2

    Make of the unit : Thermax

    Type of fuel used : LDO

    OBSERVATIONS:

    Particulars Before