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Energy Consciousness

The next genera+on product development mantra

Dr. S. Satyanarayanan

Awareness

The provision of energy such that it meets the needs of the present without compromising the ability of future generation

üSustainable energy has 3 key components 1.Monitoring and control of energy use 2.Energy efficiency 3.Renewable energy usage

3 key components 1.   Monitoring and control of energy use 2.   Energy efficiency 3.

What is the cost of energy?

In 2001

Rs. 1.6/1000 Kcal for Furnace Oil Rs. 0.6/1000 Kcal for Biomass fired

In 2012 – 2013

Rs. 5.9/1000 Kcal for FO (3.7 Nmes) Rs. 1.1/1000 Kcal for Biomass (1.8 Nmes)

Solar Rs. 0/Kcal But what about CAPEX

Source of data 1. h/p://petroleum.nic.in/pngstat.pdf 2. h/p://www.rrecl.com/PDF/

Biomass%20Price%20Analysis%20report_main%20report.pdf

Higher cost directly leads to infla2on and poverty
Higher cost directly leads to infla2on and poverty

AddiNonal kWh required for universal energy access

Billion units of electricity requirement

for universal energy access Billion units of electricity requirement Source: Energy poverty, IEA publicaIon, 2010

Source: Energy poverty, IEA publicaIon, 2010

7 Billion World PopulaNon 3.1 Billion Rural populaNon 1.4 Billion 1.27 Billion India PopulaNon
7 Billion World PopulaNon 3.1 Billion Rural populaNon 1.4 Billion 1.27 Billion India PopulaNon

7 Billion

World PopulaNon

3.1

Billion

Rural populaNon

1.4

Billion

1.27

Billion

India PopulaNon

0.83

Billion

Rural populaNon

0.4

Billion

Abject poverty

Abject poverty

Access to affordable energy plays a significant role
Access to affordable energy plays a significant role

The “ Nega ” Wa^

The “ Nega ” Wa^
The “ Nega ” Wa^

Levels of Energy Consciousness

Sustainable

Environment

&

Sustained Energy

Efficiency

Next Prac2ce Biomass Waste Boilers

Waste Heat Recovery

Solar energy

Payback >2yrs

Process Knowledge - Energy Efficiency

&

Cost of Ownership

Ease of Ops & Maintenance

+

Safety

Op2mize Efficiency MEE

Boiler Efficiency Boilers

Hot water systems / Solar HW System

Stop Wastage Steam leaks- Zero leakage 5%

InsulaNon Efficiency Moisture Removal

Condensate Flash Steam Recovery 5% Temperature Control 2%

7-10% (Payback 12-18 mths )

13%

(Payback

6-12mths with

diagnosNcs)

The Negawa^ Approach

The Negawa^ Approach GeneraNon DistribuNon Recover/Renew •   Waste heat from Flue gas •   Choice
The Negawa^ Approach GeneraNon DistribuNon Recover/Renew •   Waste heat from Flue gas •   Choice
The Negawa^ Approach GeneraNon DistribuNon Recover/Renew •   Waste heat from Flue gas •   Choice

GeneraNon

DistribuNon

Recover/Renew •   Waste heat from Flue gas •   Choice of Fuel •  

Recover/Renew Waste heat from Flue gas Choice of Fuel Design of heat transfer elements Monitor

•   Design of heat transfer elements •   Monitor Save •   Design correctly •

Save Design correctly Insulate and Monitor

of heat transfer elements •   Monitor Save •   Design correctly •   Insulate and

UNlizaNon

Recover and Reuse Condensate heat recovery Correct usage pressure Monitor

A few of Our Products

Waste heat recovery - Condensate

of Our Products •   Waste heat recovery - Condensate ü   Pressure powered pump ü

üPressure powered pump ürecovers 20% of Fuel energy which would otherwise be lost to the drain

Simple soluNons – Maximum savings – Easy to Sell !!!

Forbes Vyncke Boilers

Forbes Vyncke Boilers
Forbes Vyncke Boilers

Solar CHP System - Spec

Aperture area ~ 15.5 m 2 * 2 dish Output

Electrical – 7.5 kW peak (DC)* Thermal – 15,000 kCal / hr (peak at receiver) Maximum hot water temperature ~ 60°C (Can go up to 150 °C on CSP mode)

2 axis tracking - ± 0.2° accuracy Roof top / ground mounted system Glass based curved mirror segment Wind speed

OperaNng: 10 m/s Survival: 45 m/s

IEC 62670-3 - 1000 W/m2 and 25 °C & 1.5 AM

Godrej Lawkim , Satara 20-03-2013 Single CHP System Grid Tied inverter Hot Water – Boiler

Godrej Lawkim, Satara

20-03-2013

Single CHP System Grid Tied inverter Hot Water – Boiler feed water, -- Canteen

Monitoring and DiagnosNcs

Monitoring and DiagnosNcs Helps plants save energy in every aspect of boiler efficiency

Helps plants save energy in every aspect of boiler efficiency

Monitoring and DiagnosNcs Helps plants save energy in every aspect of boiler efficiency
Monitoring and DiagnosNcs Helps plants save energy in every aspect of boiler efficiency

And obviously – the GAPS

Intelligent and connected process plants Design for reliability and robustness Design with human factors in mind Technology made in India for India

Cater to local market and economic condiNons – One example - ORC

Energy recovery - potenNal systems

Energy recovery - potenNal systems Back pressure steam turbines, Installed cost ~800 to 2000 $/ kW,

Back pressure steam turbines, Installed cost ~800 to 2000 $/ kW, Cannot tolerate wet steam

Wet steam screw expanders, Installed cost ~800 to 1500$/kW Wide operaNonal range and turn down potenNal Payback = 18 months to 30 Months with CoE > 5.5 Rs/unit

= 18 months to 30 Months with CoE > 5.5 Rs/unit Low temperature heat recovery applicaNon
= 18 months to 30 Months with CoE > 5.5 Rs/unit Low temperature heat recovery applicaNon

Low temperature heat recovery applicaNon (heat to electricity), from 95 C and upwards Installed cost ~2000 to 6000$/kW Ideal for fully wasted heat, Payback within 3 years with cost of electricity > 7 Rs/unit

Design Philosophy

Bad Product

Bad Product
Bad Product
Bad Product

Good Product

Good Product •   Easy and intuiNve to use •   Does what it is designed

Easy and intuiNve to use Does what it is designed to do reliably every Nme

Always look at it from customer usage perspecNve

to use •   Does what it is designed to do reliably every Nme Always look

Keep it Simple

Keep it Simple Is there an All in One A/V connector?

Is there an All in One A/V connector?

Understanding customer needs

How to Watch?

How to Watch? Observe No biases. No Pre judgements. Team Members with different perspec2ves.
Observe
Observe

No biases. No Pre judgements. Team Members with different perspec2ves.

Why to Observe ?

Observe
Observe

Needs last longer than any specific SoluNon: punch card, floppy, magneNc tape for data storage

Needs are opportuniNes waiNng to be explored. Not guesses at the future

Needs provide a roadmap for development : kodak

Needs spur acNon

Needs are obvious awer the fact, not before :

Boiler ladder & Bajaj/ Honda

Observe
Observe

Boiler @ Nestle, Canada

Obs 1: Only 1 boiler operator….he is present only for 8 hours of the day… and when he away for the rest of 16 hours, he gets call from company if any problem … Obs 2: Operators daily rouNne – trip to boiler house….listens to noise levels…and then either takes some acNon or comes back to control room…. Obs 3: operator looks at pressure and temperature readings on PLC display….then look at pressure/temperature gauges…then touch few surfaces… Obs 4: feed water pump and air blower are electrically powered and also has steam turbine as back-up drive in case of power failure…

Needs

Ask ~ 5 WHY and then HOW

Solu2ons
Solu2ons

Eg: operators see pressure and temperature readings on PLC display….then look at pressure/temperature gauges…then touch few surfaces…

WHY

1. To Cross check values 2. They don’t believe values

HOW

??

??

3. Mismatch in what's seen and felt/experienced

??

4. Either instrument is off-set or not working

??

5. Instrument is not calibrated or maintained

??

IdeaNon:

Need – “To Cross check values”….

Internet of Things

Internet of Things

Always try to solve the real problem

Always try to solve the real problem

Structured Approach

The Product Development Flow Chart

Sub modules/ projects

The Product Development Flow Chart Sub modules/ projects Gather user needs/ inputs Project budget and schedule

Gather user needs/ inputs

Flow Chart Sub modules/ projects Gather user needs/ inputs Project budget and schedule Aim/ObjecNves Defined Detailed
Flow Chart Sub modules/ projects Gather user needs/ inputs Project budget and schedule Aim/ObjecNves Defined Detailed

Project budget and schedule

Aim/ObjecNves

Defined

inputs Project budget and schedule Aim/ObjecNves Defined Detailed Engineering, development and launch Requirements
inputs Project budget and schedule Aim/ObjecNves Defined Detailed Engineering, development and launch Requirements

Detailed Engineering, development and launch

Requirements

document

Knowledge gap table/analysis
Knowledge gap
table/analysis

FM SPEED Process

Main Decisions Goal of Project Market Requirements specifications S Study of Feasibility Main Tasks •
Main Decisions
Goal of Project
Market Requirements
specifications
S
Study of Feasibility
Main Tasks
• Evaluation of risks
• Technical feasibility
• Checking Patents
• Write specifications
• Determine Markets
• Work out Projet Plan
• Budget
• Project group
• Etc
See
Checklist
Main Decisions Main Decisions Goal of Project Specifications Financial/ Budget Project Plan / Project Group
Main Decisions
Main Decisions
Goal of Project
Specifications
Financial/ Budget
Project Plan / Project Group
P
Cost of production
Delivery variant list
Planning Project
Documentation and tests done
Product discrepancies
Acceptance of test strategy/plan
Acceptance of Documentation
plan
Preparation of a
functional model
E 1
Documentation plan Preparation of a functional model E 1 Main Tasks • Realisation of functional model
Documentation plan Preparation of a functional model E 1 Main Tasks • Realisation of functional model
Main Tasks • Realisation of functional model • Test according specifications • Develop Architecture •
Main Tasks
• Realisation of
functional model
• Test according
specifications
• Develop
Architecture
• Optimisation
Production Costs
• Software Test
Strategy

Evaluation & Improvement of prototypes & Pre- series in production

Main Decisions Specification Changes. Cost of production Decision on launch and Market Introduction Planning Project
Main Decisions
Specification Changes.
Cost of production
Decision on launch and
Market Introduction
Planning Project
Green light for deliveries
Acceptance of field Test
results
Main Decisions Results of Production series Remaining actions Externalisation (Pilot Production batch) D
Main Decisions
Results of Production
series
Remaining actions
Externalisation (Pilot
Production batch)
D
actions Externalisation (Pilot Production batch) D E 2 Main Tasks • Design, Implementation and test of
actions Externalisation (Pilot Production batch) D E 2 Main Tasks • Design, Implementation and test of
E 2 Main Tasks • Design, Implementation and test of final housing and PCBs, as
E 2
Main Tasks
• Design, Implementation and
test of final housing and PCBs,
as well functional software.
• Produce pre-series in
production department and test
• Test according specifications
by Quality Department
• Update external info if needed
• Prepare large scale production
• Preparation of Launch activities
• Pre-Compliance Test
EMC ,PED,Ex .
• Finalize Documentation
• Field Tests

Main Tasks

Production and test on large scale, production series

Launch of production.

Sales and Marketing activities for launch.

Information package

Update Documentation

Etc

Voir Checklist

Systems Approach Industrial Design InformaNon and CommunicaN on Tech Mechanical A good product Engineering
Systems Approach
Industrial
Design
InformaNon
and
CommunicaN
on Tech
Mechanical
A good
product
Engineering
Electrical and
electronics
Chemical
Engineering

How do engineering techniques handle contradicNons?

OpNmize!

Trade Offs

"You can't have it both ways "

How do engineering techniques handle contradicNons? OpNmize! Trade Offs "You can't have it both ways "

Example: Efficient Support Spiles

FoundaNon supporNng spiles ContradicNon: Easy to Drive vs. Good Support

Sharp Spile:

Easy to Drive in

  ContradicNon: Easy to Drive vs. Good Support Sharp Spile: Easy to Drive in Compromise Blunt

Compromise

Blunt Spile:

Good for Support

Compromise-Free SoluNon

Sharp when driven in

Compromise-Free SoluNon Sharp when driven in Explosive Blunt when supports Concrete Filled

Explosive

Blunt when supports

Compromise-Free SoluNon Sharp when driven in Explosive Blunt when supports Concrete Filled

Concrete

Filled

A Steam Trap

A Steam Trap

Float trap - Example

The problem – Process takes too long to a^ain desired temperature

1. Why – Steam trap is water logged 2. Why – Condensate discharge capacity not sufficient 3. Why – Heavy condensate load during cold start 4. Why – Orifice opening not enough 5. Why – Orifice designed for running load

How – Open bypass valve during start-up

Operators tend to leave it open always!! – steam loss

The SoluNon - TOFT

The SoluNon - TOFT
The SoluNon - TOFT
The SoluNon - TOFT

Electric Car

Electric Car Do electric cars need to be stubby and unpracNcal? Not really!! We need to

Do electric cars need to be stubby and unpracNcal?

Car Do electric cars need to be stubby and unpracNcal? Not really!! We need to accommodate
Car Do electric cars need to be stubby and unpracNcal? Not really!! We need to accommodate

Not really!! We need to accommodate all requirements and not accept trade off!

Summing up

Focus on the “4-Es” in your design approach

Energy, Exergy , Environment and Economics

Product design is a team sport – Focus on your customer to get your ideas Try to eliminate trade-off in your design – opNmize later InnovaNon is not necessarily something new – it is a change that improves performance and makes lives be^er!

And life comes a full circle!!

And life comes a full circle!! Thanks!!

Thanks!!