Fatima Safety Glass 2001
Fatima Safety glass produces safety glass for automobiles. Process required cutting heating bending and quenching of glass. Due to 2 hour load shedding after every 4 hours there was additional 1.5 hour production loss as furnace took time to reach temperature where production could start. Production was 2 ½ hours every 6 hours. Diesel generator could not operate furnace and blower simultaneously. By interlocking and separate operation of furnace and blower production was possible during load shedding. On first visit normal production on Diesel generator started with operation of furnace and blowers alternatively.
Plant manager informed me about workers operating plant on generator even though electric supply was present. On enquiry workers told me, “Furnace remain red when generator supply is used”. It was due to voltage DG set voltage was 415 Volts compared to K-Electric voltage 340 Volts. Power of resistance heating is proportional to square of voltage meaning 50% more heating with DG set supply. An auto transformer was designed with 3 steps of 40 Volts which helped to operate plant with full efficiency at K-Electric supply. Final result was per piece production time was reduced to 3 minutes 40 seconds from 8 ½ minutes.
Now Fatima safety glass is producing car wind shields.
Recoveries from utility companies
Calriant Pakistan Ltd Rs. 1.15 Million
Shell Pakistan Ltd. Rs. 1.62 Million
Shell Pakistan Ltd. Rs 0.797 Million
Atals Battery Ltd. R.s 3 Million
Atlas Engineering Ltd. Rs. 2.06 Million
Indus motors Ltd. Rs. 20.85 Million
Sitara Chemicals Industries Ltd.
Cooling tower management resulted in operation of cooling tower with 3 pumps 93 kW each previously 4 pumps were used saving 1 Million units per year.
Predictive maintenance and motor condition monitoring resulted in smooth operation of plant.
Tariff management at Aziz Fatima hospital saved Rs 10 million per year.
Thermography revealed poor insulation of aluminum melting furnaces. Base line consumption per kg Aluminum melting was calculated by installing energy meters and measuring mass of total Aluminum ingots melted.
Base line consumption 2.53 kWh / kg Al melting
Installation of furnace covers 2.13 kWh/ kg Al melting
Rebuilding furnace with rock wool insulation 1.58 kWh / kg Al melting
Peak off peak consumption management resulted in saving of Rs 2.4 million per year..
Change of tariff
Clariant Pakistan Ltd. Rs 3 million per year
Shell LOBP Rs 1 Million per year
Sun light wood plant Rs 7.5 Million per year
Aziz Fatima Hospital Rs 10 Million per year
Design and supply of RPM meter for gas turbine PNEC (Pakistan Naval Engineering college Karachi)
Design improvement of gas fired aluminum melting furnace Reduced gas consumption by 40%
1.2 kW PM wind mill
1.2 kV high potential testing setup