India-Japan Environmental Week

The Japan-India Technology Matchmaking Platform (JITMAP)

Seminar On….

Introduction Of Energy Efficiency Improvement
Through JITMAP Activities )Mr. Dinesh Raskar (BE- I&C)

Mr. Pravin Narsale (BE-Mech)(Assistant Manager - MAINTENANCE)
Working with TRINITY since last 7 years

India-Japan Environmental Week

(Assistant Manager – MAINTENANCE)
Working with TRINITY since last 5 years

IGESTERIABOUT US…..
Trinity Engineers Pvt. Ltd., known as the Master Blacksmiths is a company engaged
in the manufacture of forgings for the automotive and non – automotive applications,which has been in operation since 1973. Its manufacturing facilities are located atChinchwad, Maharashtra, Pune 411 019 (India)
Trinity Engineers, exemplifies High Quality, Quest for Perfection and Innovativeapproach. Over last four decades, we have forged ahead to become a ONE-STOP
SOLUTION PROVIDER, from forging and machined automotive components toproduction of sub-assemblies as required by the automotive industry.
Our clientele represent different sectors like Automobile, Power, Mining, Oil and Gas,and Constructions. For the future, we have plans to diversify into specialized productrange to meet the forged parts requirements of the Petrochemical and Foodprocessing industry among others.

India-Japan Environmental Week

IGESTERIIntroduction of Activities

Trinity Engineers Participated In JITMAP Activities For Low Carbon Technology“Compressed Air System”
Japanese Experts visit was arranged in 2017-18 for assessment and improvement
scope. A compressed air system study was done with IGES support, & Energy
Measurement done, Leakage test for Pipeline and Hammer air.
Based on the assessment and suggestion by Japanese expert Saito San, Pipeline
modifications were done, and hammer leakages were plugged. This resulted inenergy savings of almost 20%. Further, in addition to this, we started replacing theOld AIR Pipeline which will definitely further improved the more Energy savings.

India-Japan Environmental Week

IGESTERIPoints given for Improvement By JapaneseExpert in Visit 2017-2018:
1

Replacement of 3 compressors of 110kW or combined units of 110kW & 200kW with
one inverter compressor of 280kW

2

Replacement all older compressors with new ones (Target: A1, A2, A3, A4, A5, A6, A7,and CP except for SULLAIR)

3Taking measures against broken Screw rotor trouble (broken shaft)4

Improving environment for compressor

5

Conducting inspection of receiver tank annually and checking thickness of the tankover 10 or more years old

6

Detecting the points causing air leakage and taking proper measures

7

Adopting an efficient multiple-unit panel

8Adopting energy monitoring system

9

Savings Achieved by controlling air leakages and air guns

India-Japan Environmental Week

IGESTERI

Actions Taken on given points for
Improvement By Japanese Expert in Visit:
1

All Old Compressors are discarded Now, New 3 ATLAS Compressors of 160kW (1000Cfm) purchased except Sullair 2 Compressor

2Old system with 3408 CFM output with power of 679.5 kW is replaced with 3000 CFM
with Power of 480kW

3Separate 375 CFM with 55kW VFD based ATLAS Compressor is placed for Machine
shop, which saved 30% Energy.

4Compressor Shop is totally renewed with proper ventilation & all standard
requirements guideline of Atlas Manufacturer. All points of Japanese Expert Improving
environment for compressor is done.

567Started Replacing all old leakage air pipelines with New Aluminum air Pipeline.
With replacement 30% of total factory pipeline resulted in 5% Air savings. Expecting
30% Air savings with 100% replacement of Planned New Air Pipeline.
IOT based monitoring system is placed to monitor All Energy parameters ofCompressors.
Pneumatic hammer sleeve leakage work is done, which reduced air leakage of almost
500 CFM- 90 kW equivalentIndia-Japan Environmental Week

IGESTERI

Results We have achieved:
Energy Consumption Ratio in kWH/Tons
25,000.00
20,000.00 18,548.13

19,158.26

15,000.00

13,269.79
10605.858

10,000.00

7,988.39

8,006.05

5,000.00
-300

280

310

3202851802017201820182019

20192020

20202021

20212022

2022 totill

19,158.26

7,988.39

8,006.05

13,269.79

10605.858

280

310

320285180

Yearly Production
18,548.13
in Tons
Ratio
300
kWH/Tons

Yearly Productionin Tons

The Japan-India Technology
Matchmaking Platform (JITMAP)

Ratio
kWH/Tons

IGES

線形 (Ratio
kWH/Tons)

TERI

Future Action Plan and Energy
Savings Proposals
1. Separate Air Line for each shop with loop and pressure regulation from the main air
compressor station to avoid air leakages.
Savings of 109 kW – Rs. 70.6 lakhs/annum ( Pipe line investment cost Rs. 20 lakhs ) ,Payback period 4 months
2. Separate air line with 200 CFM air compressor for Machine shop – post forging during
weekly off day – to avoid use of 1000 CFM ( 200 kW ) air compressor – Savings -156000
kWh , Rs. 14 lakhs/annum , investment Rs. 20 lakhs , Payback period 17 months
3. Installation of new 2 inverter air compressors of 160 kW each ( 1088 CFM each), Savings– 111 kW, Rs. 71.9 lakhs/annum, investment Rs. 100 lakhs, Payback period 16 months.
4. Air Guns and Air leakage at machine level hammer is controlled one by one presently

India-Japan Environmental Week

IGESTERI

Thanks to……
Institute for Global Environmental Strategies (IGES)

The Energy and Resources Institute (TERI) of India
Ministry of Environment of Japan & India•

For Launching Japan-India Technology Matchmaking Platform (JITMAP) Framework.

•Providing Comprehensive Support For The Transfer Of Low-carbon Technologies FromJapanese Companies To Indian Companies.

•Implementing Activities Which Aimed At Promoting The Transfer Of Japanese Low-carbon
Technologies In The Indian Manufacturing Sector

India-Japan Environmental Week

IGESTERI