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Indore Foundry Cluster Ministry of New and lw{e] y?kq ,oa e/;e m|e Renewable MICRO, SMALL & MEDIUM ENTERPRISES Energy Bureau of Energy Efficiency Promoting Energy Efficiency and Renewable Energy in Selected MSME Clusters in India A GEF-UNIDO-BEE Project Best Operating Practices Indore Foundry Cluster FOREWORD With its objective to reduce energy intensity of the Indian economy, Bureau of Energy Eficiency has partnered with United Nations Industrial Development Organization (UNIDO) to implement the Global Environment Facility (GEF) funded national project on “Promoting Energy Eficiency and Renewable Energy in Selected MSME Clusters in India”. I am pleased to share the handbook on “Best Operating Practices” for MSME units which has been published under the project. This handbook has been conceptualized as a single source of information and is an effort to provide summarized and lively presentation to enhance the knowledge on underlying issues in energy eficiency. I trust that this book will be able to make wider reach in the clusters and will be greatly accepted by the engineers and managers as a ready reference for enhancing their knowledge and implementation of energy eficient operating practices. I would like to record my appreciation for members of the Project Monitoring Unit – Shri Milind Deore (Energy Economist, BEE), Shri Niranjan Rao Deevela (National Technology Coordinator, UNIDO) and Shri Ashish Sharma (Project Engineer, BEE) for their hard efforts and tireless commitments to bring out this publication. I also compliment the efforts of all participating MSME units towards their endeavor in contributing to energy eficiency and making this project a big success. New Delhi (Abhay Bakre) Best Operating Practices – Indore Foundry Cluster ABOUT THE DOCUMENT As the MSME units are limited in their capacities and lack access to latest technological advancements in the field of energy efficiency, the GEF-UNIDO-BEE project is spread across 12 MSME clusters under 5 different sectors (Brass, Ceramic, Dairy, Foundry and Handtools) with an inclusive approach to promote energy efficient technologies and use of renewable energy. Under the project, sample energy audits were conducted in each cluster, which helped to understand the basic pattern of energy consumption and possible energy conservation measures in the units within a cluster. As an outcome of the activity, Best Operating Practices (BOP) were identified for each cluster, the implementation of which are very effective, easy to implement and, economically viable to avoid improper use of energy and reduce the energy cost. Through this handbook energy professionals in the units will be able to identify to the underlying issues with the energy consumption and make quick reference for the best possible solutions. ii Best Operating Practices – Indore Foundry Cluster Contents FOREWORD .................................................................................................................................................................................. I ABOUT THE DOCUMENT ........................................................................................................................................................ II CHAPTER 1: INTRODUCTION ............................................................................................................................................... 1 1.1 BRIEF ABOUT THE PROJECT ........................................................................................................................................................... 1 1.2 BRIEF ABOUT THE CLUSTER AND PRODUCTION PROCESS ......................................................................................................... 1 CHAPTER 2: BEST OPERATING PRACTICES - INDUCTION FURNACE ...................................................................... 4 2.1 INTRODUCTION ................................................................................................................................................................................ 4 2.2 OPERATING PRINCIPLE ................................................................................................................................................................... 4 2.3 TYPES OF INDUCTION FURNACE .................................................................................................................................................... 4 2.4 BEST OPERATING PRACTICES FOR INDUCTION FURNACE .......................................................................................................... 5 2.5 DO’S AND DON’TS IN INDUCTION MELTING FURNACE ............................................................................................................... 9 CHAPTER 3: BEST OPERATING PRACTICES – CUPOLA FURNACE ..........................................................................10 3.1 INTRODUCTION ............................................................................................................................................................................. 10 3.2 OPERATING PRINCIPLE ................................................................................................................................................................ 10 3.3 BEST OPERATING PRACTICES FOR CUPOLA FURNACE ............................................................................................................. 11 3.4 DO’S AND DON’TS IN CUPOLA FURNACE OPERATIONS ............................................................................................................ 16 3.5 PROBLEMS AND SOLUTIONS ........................................................................................................................................................ 17 CHAPTER 4: BEST OPERATING PRACTICES - COMPRESSED AIR SYSTEM ..........................................................19 4.1 INTRODUCTION ............................................................................................................................................................................. 19 4.2 BEST OPERATING PRACTICES FOR COMPRESSED AIR SYSTEM ............................................................................................... 19 4.3 DO’S AND DON’TS IN COMPRESSED AIR SYSTEM ..................................................................................................................... 24 CHAPTER 5: BEST OPERATING PRACTICES - MOTORS AND PUMPS ....................................................................25 A. MOTOR ................................................................................................................................................................................................ 25 5.1 INTRODUCTION ............................................................................................................................................................................. 25 5.2 TYPES OF MOTORS ........................................................................................................................................................................ 26 5.3 BEST OPERATING PRACTICES FOR MOTORS .............................................................................................................................. 27 5.4 DO’S AND DON’TS IN MOTOR OPERATIONS .............................................................................................................................. 28 B. PUMPS ................................................................................................................................................................................................. 29 5.5 INTRODUCTION ............................................................................................................................................................................. 29 5.6 EFFICIENT PUMPING SYSTEM OPERATION ................................................................................................................................ 29 5.7 BEST OPERATING PRACTICES FOR PUMPS................................................................................................................................. 30 5.8 DO’S AND DON’TS IN PUMP OPERATION ................................................................................................................................... 31 CHAPTER 6: BEST OPERATING PRACTICES - REHEATING FURNACE ...................................................................32 6.1 INTRODUCTION ............................................................................................................................................................................. 32 6.2 OPERATING PRINCIPLE ................................................................................................................................................................ 32 6.3 TYPE OF RE-HEATING FURNACE ................................................................................................................................................. 33 6.4 BEST OPERATING PRACTICES IN RE-HEATING FURNACE ........................................................................................................ 33 6.5 DO’S & DON’TS IN RE-HEATING FURNACE OPERATIONS ........................................................................................................ 38 CHAPTER 7: BEST OPERATING PRACTICES –LIGHTING ...........................................................................................39 7.1. INTRODUCTION ............................................................................................................................................................................
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