PISTON FOUNDRY 07/07/2008 1

Diameter : 38 TO 228 mm
O
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A Alco Alco Steel AL 680 TCAC Mahindra 245 SL 90 250 KVA L&T 320 TC
Cap
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O HINO HINO WO6DTI TATA KOEL 3R860 TATA 697 TD 2650 FTI
WO6ERC CUMMINS
F

P
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BD 154 AVL MINIDOR CNG INDIGO 486 PL FIAT PALIO

D
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C SC 66.7 AC BULLET 500 SPLENDOR TVS VICTOR KAWASAKI TVS XL
T CC

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PISTON FOUNDRY 07/07/2008 2
 LEADING CUSTOMERS

PISTON FOUNDRY 07/07/2008 3

 ENERGY & MAN POWER
SAVING
PROJECTS IN
PISTON FOUNDRY PATIALA

THROUGH
EQUIPMENT MODIFICATION
PISTON FOUNDRY 07/07/2008 4
PISTON FOUNDRY 07/07/2008 5
 • THERE IS AN URGENT NEED OF ENERGY SAVING
WHEN THE OIL PRICES ARE MOVING TOWARDS $150
PER BARREL
• FOR CLEANER ENVIRONMENT WE NEED TO USE
LESS OIL AND ENERGY
• OF THE TOTAL ENERGY USED IN A PISTON PLANT
65% IS USED IN FOUNDRY

THERE IS MORE SCOPE OF ENERGY SAVING IN

FOUNDRY THAN ANY OTHER DEPARTMENT

PISTON FOUNDRY 07/07/2008 6

 MODIFIED VERSION OF TWIN WARM HOLDING FURNACE

IMPROVEMENT STAGE 1 OLD LINING

M.S.
SHEET

MINERAL ASBESTOS CERAMIC CERAMIC HYSIL INSULATING FORM CRUCIBLE

WOOL
PISTON FOUNDRY SHEET WOOL BLOCK BLOCK BRICK BRICKS
07/07/2008 7
 IMPROVEMENT STAGE 2
AIR GAP

ASBESTOS
SHEET

CERAMIC
WOOL

CERAMIC
BLOCK

INSULATING
BRICK

FORM
BRICKS

CRUCIBLE

HYSIL
BLOCK

PISTON FOUNDRY 07/07/2008 8

 IMPROVEMENTS IN CORPORATED

 CAPACITY INCREASED FROM 300 KGS TO 500KGS.

 ELEMENT SIZE EARLIER USED WAS 16 ×1.5,NOW IT

HAS BEN CHANGED TO 12 × 1.5 ,WHICH IN TURN
REDUCES THE POWER LOAD.

 CONNECTING LOAD REDUCED FROM 32 KW TO

25KW.

 MINERAL WOOL OUTER LAYER REPLACED BY AIR

GAP.

 ELEMENT LIFTED UP BY 50MM FROM TOP OF THE

CRUCIBLE.

PISTON FOUNDRY 07/07/2008 9

 MULTIPLE MACHINE OPERATION ON
CASTING MACHINES

PREVIOUS PRACTICE EXISTING PRACTICE

CASTING DCM 17
MACHINE CA CASTING DCM 17
17 CAST DCM 17
M/C
(UPTO 60 DIA) ST
CM
M/C
M I (UPTO 60 MM DIA)
D E ) (U A NG (UPTO 60MM DIA)
G N A
IN HI DI PT C D
O HIN CM
ST AC 60 60 E 1

(UPTO 60MM DIA)

CASTING DCM 17
A M TO DI 7

(UPTO 60MM DIA)

C

CASTING DCM 17
P

MACHINE
A)
(U

MACHINE

SAVINGS IN
* MANPOWER
* ENERGY
* FLOOR SPACE

PISTON FOUNDRY 07/07/2008 10

 LAYOUT FOR MACHINES WITH
DIPPING FURNACES

/C
M
G
IN
ST
CA

CASTING MACHINE CASTING MACHINE

DCM 20 UPTO DIA DCM 20 UPTO DIA
115MM 115MM
CASTING M/C
/C
M
NG

CASTING MACHINE CASTING MACHINE

I

DCM 20 UPTO DIA

ST

DCM 20 UPTO DIA

115MM
CA

115MM

2 MAN/ 3 M/C CONCEPT 1 MAN/ 2 M/C CONCEPT

PISTON FOUNDRY 07/07/2008 11

 IMPROVEMENTS INCORPORATED

 MORE NUMBER OF MACHINES CAN BE FEEDED

THROUGH SAME AMOUNT OF HOLDING FURNACES

 MORE FLOOR SPACE IN THE SHOP FLOOR.

 SAVING IN MANPOWER.

PISTON FOUNDRY 07/07/2008 12

 ENERGY AND FUEL
SAVING IN OIL
FIRED FURNACES
USED IN PISTON
FOUNDRY.
PISTON FOUNDRY 07/07/2008 13
NEED FOR IMPROVEMENT

 INTERNATIONAL PRICE HIKE TOWARDS 150 PER

BARREL OF CRUDE OIL WAS ALSO A CAUSE OF
CONCERN.

 OUT OF THE TOTAL MELTING IN PISTON FOUNDRY,

60 % OF THE METAL IS MELTED IN OIL FIRED
FURNACES AND 40% IN INDUCTION FURNANCES,
THAT IS WHY WE SELECTED THIS AREA FOR
IMPROVEMENT.

PISTON FOUNDRY 07/07/2008 14

 CHANGES IN CORPORATED

BURNER MODIFICATIONS

 BURNER NOZZLE REDUCED TO 1.5 MM FROM

2.0MM.
 OIL PRSSEURE BROUGHT DOWN
FROM 2.0 KG/CM2 TO
0.5KG/CM2.
 SEPARATE VALVE FOR REGULATING OIL
SUPPLY.

PISTON FOUNDRY 07/07/2008 15

 RECUPERATOR

• ORIGINAL AIR TEMP. 65-70 °C

• WITH RECUPERATOR 95-125°C max

• 1% OIL SAVING WITH 20°C RISE OF AIR TEMP

PISTON FOUNDRY 07/07/2008 16

PISTON FOUNDRY 07/07/2008 17
FURNACE AFTER MODIFICATION

PISTON FOUNDRY 07/07/2008 18

  AIR PIPE EXPOSED TO FLUE GASES 90-100°C

 DOUBLE LOOP PROVIDED 140 –150°C

 AIR PIPES ENCLOSED WITH MS SHEET 180-200°C

 FURNACE EXHAUST CLOSED

 AIR PIPES ENCLOSED WITH PROPER PANELS

MADE FROM HEAT RESISTANT STEEL SHEET 306
GRADE WITH PROPER LINING WITH CERAMAIC
FIBRE BOARD 1250°C,128 DENSITY,TEMP. >225°C

PISTON FOUNDRY 07/07/2008 19

  PREVIOUS OIL CONSUMPTION = 130 LTRS
/TON

 AFTER MODIFICATION = 80 LTRS/TON ( FOR MELT

UPTO TEMP 730°C)

 SAVING = 50 LTRS /TON

PISTON FOUNDRY 07/07/2008 20

 CONSERVATION OF NATURAL RESOURCES

BETTER WORKING CONDITIONS

• Lesser heat radiations
• Lesser smoke emission to the surroundings
• Lesser noise

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