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

Sustainable energy has 3 key components

1. Monitoring and control of energy use
2. Energy efficiency
3. Renewable energy usage
 What is the cost of energy?
In 2001
Rs. 1.6/1000 Kcal for Furnace Oil
Rs. 0.6/1000 Kcal for Biomass red
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 ina2on and poverty

AddiNonal kWh required for
universal energy access
Billion units of electricity requirement

Source: Energy poverty, IEA publicaIon, 2010

 1.27
7 Billion
Billion
World PopulaNon India PopulaNon

3.1 0.83
Billion Billion
Rural populaNon Rural populaNon

1.4 0.4
Billion Billion
Abject poverty Abject poverty

Access to aordable energy plays a signicant role

The Nega Wa^
Levels of Energy Consciousness
Sustainable Next Prac2ce
Environment Biomass Waste Boilers
& Waste Heat Recovery Payback >2yrs
Sustained Energy Solar energy
Efficiency
Op2mize Eciency
Process Knowledge MEE
- Energy Efficiency
Boiler Eciency 7-10% (Payback 12-18
& mths)
Boilers
Cost of Ownership
Hot water systems / Solar HW
System
Stop Wastage
Ease of Ops &
Steam leaks- Zero leakage 5%
Maintenance 13% (Payback
InsulaNon Eciency
+ 6-12mths with
Moisture Removal
Safety diagnosNcs)
Condensate Flash Steam Recovery 5%
Temperature Control 2%
 The Negawa^ Approach

GeneraNon DistribuNon UNlizaNon

Recover/Renew Save Recover and Reuse

Waste heat from Flue gas Design correctly Condensate heat
Choice of Fuel Insulate and recovery
Design of heat transfer Monitor Correct usage pressure
elements Monitor
Monitor
 A few of Our Products...
Waste heat recovery - Condensate

Pressure powered pump

recovers 20% of Fuel energy which would
otherwise be lost to the drain

Simple soluNons Maximum savings Easy to

Sell !!!
Forbes Vyncke Boilers
 Solar CHP System - Spec
Aperture area ~ 15.5 m2 * 2 dish
Output
Electrical 7.5 kWpeak (DC)*
Thermal 15,000 kCal/hr (peak at receiver)
Maximum hot water temperature ~ 60C (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 Godrej Lawkim, Satara
Wind speed 20-03-2013
Single CHP System
OperaNng: 10 m/s Grid Tied inverter
Survival: 45 m/s Hot Water Boiler feed water,
-- Canteen
IEC 62670-3 - 1000 W/m2 and 25C & 1.5 AM
Monitoring and DiagnosNcs
Helps plants save energy in
every aspect of boiler eciency
 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
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

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

Always look at it from customer usage perspecNve

Keep it Simple

Is there an All in One A/V connector?

Understanding customer needs
 How to Watch?

Observe

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

 Why to Observe ? Observe

Needs last longer than any specic SoluNon: punch card,

oppy, 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
Boiler @ Nestle, Canada Observe

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 levelsand 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 gaugesthen 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 Solu2on
s

Ask ~ 5 WHY and then HOW

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

WHY HOW
1. To Cross check values ??
2. They dont believe values ??
3. Mismatch in what's seen and felt/experienced ??
4. Either instrument is o-set or not working ??
5. Instrument is not calibrated or maintained ??

IdeaNon:
Need To Cross check values.

Internet of Things..
Always try to solve the real problem
Structured Approach
The Product Development Flow Chart
Gather user needs/ Sub modules/
inputs projects

Project budget and

Aim/ObjecNves schedule
Dened

Requirements
Detailed Engineering,
document
development and launch

Knowledge gap
table/analysis
Main Decisions
FM SPEED Process
Goal of Project
Market Requirements
specifications
S Study of Feasibility
P Acceptance of Documentation
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 Cost of production
Financial/ Budget Delivery variant list
Project Plan / Project Group Planning Project Main Decisions
Documentation and tests done
Product discrepancies Specification Changes.
Acceptance of test strategy/plan Cost of production
plan
Decision on launch and
Market Introduction
Planning Project
Preparation of a
functional model E1 Green light for deliveries
Acceptance of field Test
Main Decisions
Evaluation & results Results of Production
Improvement of series
prototypes & Pre- Remaining actions
series in production
Externalisation (Pilot
Main Tasks
E2 Production batch)
Realisation of
functional model
Test according
specifications Main Tasks
D
Develop Design, Implementation and
Architecture test of final housing and PCBs,
Optimisation as well functional software.
Production Costs Produce pre-series in
Software Test Main Tasks
production department and test
Strategy Test according specifications Production and test on
by Quality Department large scale, production
Update external info if needed series
Prepare large scale production Launch of production.
Preparation of Launch activities Sales and Marketing
Pre-Compliance Test activities for launch.
EMC ,PED,Ex . Information package
Finalize Documentation Update Documentation
Field Tests Etc ..Voir Checklist
 Systems Approach
Industrial
Design
InformaNon
and
CommunicaN
on Tech
Mechanical
A good Engineering
product
Electrical and
electronics
Chemical
Engineering
 How do engineering techniques
handle contradicNons?
OpNmize! Trade Os
"You can't have it both ways..."
 Example: Ecient Support Spiles
FoundaNon supporNng spiles
ContradicNon: Easy to Drive vs. Good Support

Sharp Spile: Blunt Spile:

Easy to Drive in Good for Support

Compromise
 Compromise-Free SoluNon
Sharp when driven in Blunt when supports

Explosive
Concrete
Filled
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 sucient
3. Why Heavy condensate load during cold start
4. Why Orice opening not enough
5. Why Orice designed for running load
How Open bypass valve during start-up
Operators tend to leave it open always!! steam loss
The SoluNon - TOFT
 Electric Car

Do electric cars need to be stubby and Not really!! We need to accommodate all
unpracNcal? requirements and not accept trade o!
 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-o 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!!

Thanks!!