This document provides details of a project to convert a steam system from using high-speed diesel (HSD) to lighter diesel oil (LDO) to reduce costs. The project is led by Sabarinath.U at Elgi Ultra Ltd and aims to reduce monthly steam energy costs by an estimated Rs. 3.47 lakhs. The project team has completed conversion work such as replacing burner rods and nozzles, fuel pumps, and connecting new diesel lines. Analysis shows LDO costs Rs. 0.0031 per kcal less than HSD, with estimated annual savings of Rs. 3.96 lakhs after recovering conversion costs of Rs. 9.85 lakhs within 2 years. Validation trials

1. PROJECT DETAILS
Unit M/s Elgi Ultra Ltd Project Leader Sabarinath.U Champion
Mr.JK
Project Title: HSD TO LDO COVERSION FOR COST REDUCTION Project Number
CFT – MAIN-01/2020
Problem Statement :
Diesel cost high and variable
Project Objective :
To reduce the steam energy cost
Current defect
Level
Initial project
goal
To reduce steam
energy cost
Estimated
benefits
Estimate savings per
month 365656.00 Rs/-
Approval Date 13.09.2020
Target
Completion
13.11.2020 Project Area Rubber division
PROJECT TEAM
Role Name Phone E-Mail Address
Team Leader Sabarinath.U 7539902926 jayachandran@elgiultra.com
Team Member Mr.V.Paul raj
Team Member Mr. S.Jayachandran
Team Member Mr.Sathyaseelan
PROJECT MEASURES
Metrics Base Line Goal Improvement Savings (Ann)
To reduce the diesel cost
consumption
Process Charter
1

2. Data Analysis
Phase/Time Line Status
20-Jul 20-Aug 20-Sep 20-Oct
W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4 W1 W2 W3 W4
Problem
Definition
Plan
Actual
Data Analysis
Plan
Actual
Developing
Solution
Plan
Actual
Validation
Plan
Actual
Standardization
Plan
Actual
Review
Plan
Actual

3. Data Analysis
COST COMPARISON:
Cost per Kcal of Energy consumed:
FUEL Rs./ Kg Kcal./ Kg Rs./ Kcal
HSD 91.82 11300 0.0081
LDO 52.94 10500 0.0050
0.0031
CAPEX for LDO conversion:
1 FUEL PUMP 12634 25268
2 NOZILE 637 1274
3 BURNER ROD 10986 21972
4 Diesel tank with stand 40000
5 PIPE AND FITTINGS 10000
TOTAL 98514
DIESEL Vs LDO COMPARISION Litres Rs Rs yearly
DIESEL PER MONTH CONSUMPTION APPROX 12000 76.4 916800 11001600
LDO PER MONTH CONSUMPTION APPROX 12914.3 45 581143.5 6973722
COST SAVING APPROX PER MONTH 335656.5 3967878
AMC FOR BOILER RX-400 AND RX-600 PER YEAR 60000
Cost Savings per month: (considering monthly volume as 12 KL/ Mon. of HSD)
FUEL Kg/ Mon. Kcal./ Kg Kcal./Mon.
HSD 9984 11300 112819200
347907.2
3.47 Lakhs
Savings on using LDO
Hence, Net Savings per month
Say

4. 4
S.L Work carried on boiler 1 and 2 HSD to LDO conversion work
1 Main diesel tank dead stock cleaning work
2 LDO filled on 12000 litters
3 Burner rod and nozzle changing boiler 1 & 2
4 Fuel pump changing boiler 1 & 2
5 From diesel yard to boiler room diesel line coupled and connected
6 Diesel storage tank cleaned and LDO makeup
7
Both boiler setting checked and trail run completed.
DEVELOPING SOLUTION

5. 5
DEVELOPING SOLUTION
Pictorial Representation
ANALYSYS BEFORE AFTER
Main diesel tank
cleaning work

6. 6
DEVELOPING SOLUTION
Pictorial Representation
ANALYSYS BEFORE AFTER
Burner rod and
nozzle replaced

7. 7
DEVELOPING SOLUTION
Pictorial Representation
ANALYSYS BEFORE AFTER
From diesel yard to boiler
room diesel line coupled
and connected

8. 8
DEVELOPING SOLUTION
Pictorial Representation
ANALYSYS BEFORE AFTER
Diesel storage tank
cleaned and LDO makeup

9. 9
DEVELOPING SOLUTION
Pictorial Representation
ANALYSYS LDO FILLED ON BOILER ROOM TANK BOILER RUNNING AT LDO
Diesel filled and boiler
running condition