Award Book2011

NATIONAL AWARDS
ON
ENERGY CONSERVATION
FOR
INDUSTRIES, OFFICE & BPO BUILDINGS,
HOTELS & HOSPITALS, MUNICIPALITIES,
STATE DESIGNATED AGENCIES, THERMAL
POWER STATIONS, ZONAL RAILWAYS,
AND MANUFACTURERS OF BEE STAR
LABELED APPLIANCES/EQUIPMENT - 2011
Presented on
National Energy Conservation Day
14th December, 2011
Instituted by
MINISTRY OF POWER
Government of India
CONTENTS
Messages
National Energy Conservation Awards .................................................... 1
National Energy Conservation Award Winners 2011 .............................. 9
Highlights of the Award Winners
Aluminium.................................................................................. 17
Automobile Manufacturing ............................................................ 33
Cement ...................................................................................... 58
Chemicals .................................................................................. 83
Chlor-Alkali ................................................................................ 94
Consumer Goods Manufacturing .................................................... 98
Dairy ........................................................................................ 118
Drugs & Pharmaceuticals............................................................. 136
Edible Oil/Vanaspati .................................................................... 147
Fertilizers .................................................................................. 153
Food Processing ......................................................................... 179
Foundry .................................................................................... 193
General Category ....................................................................... 199
General Category (Subsectors of EC Award) .................................. 227
Glass ........................................................................................ 249
Integrated Steel ......................................................................... 254
Mining ...................................................................................... 266
Paper & Pulp.............................................................................. 273
Petrochemicals........................................................................... 279
Plastics ..................................................................................... 291
Refinery .................................................................................... 309
Sponge Iron .............................................................................. 329
Steel Re-rolling .......................................................................... 338
Sugar ....................................................................................... 346
Tea ........................................................................................... 361
Textile....................................................................................... 365
Tyre.......................................................................................... 371
Office Buildings .......................................................................... 381
BPO Buildings ............................................................................ 407
Hotels ....................................................................................... 417
Hospitals ................................................................................... 429
Municipalities ............................................................................. 443
State Designated Agencies (SDAs) ............................................... 457
Thermal Power Stations .............................................................. 491
Zonal Railways ........................................................................... 517
Manufactures of BEE Star Labeled Appliances/Equipment ................ 549
National Energy Conservation Awards 2011:
Award Committee....................................................................... 580
National Energy Conservation Awards 2011:
Technical Sub-Committee ............................................................ 581
I am happy to learn that the Ministry of Power, Government of India is
celebrating "The National Energy Conservation Awards Day" on December 14, 2011.
As energy prices soar globally, time has arrived when India needs to put
forth a roadmap, to prioritize implementation of measures which ensure judicious
utilization of available energy resources. This would bring down the energy intensity
of our economy and lead to gains in the efficiency of energy consumption. In the
backdrop of the prevailing global warming threat, it is imperative for India to
immediately take cognizance of the widening gap between energy demand and
availability. Efforts should be made for low carbon growth in the future. In this
context efficient use of energy and its conservation, is the only cost effective
alternative available to help bridge the gap between rising energy demand and
supply, while also lowering anthropogenic emissions.
The Energy Conservation Awards have been a successful initiative of the
Ministry of Power, conducted each year with an objective of recognizing and
felicitating innovations and achievements leading to energy savings.
On this occasion, I congratulate the winners and convey my best wishes. I
again take this opportunity to appeal to every citizen of our country, to use energy
efficiently.
(PRATIBHA DEVISINGH PATIL)
New Delhi
November 23, 2011
MESSAGE
=|- +|- =|- +|- =|- +|- =|- +|- =|- +|-
||=- =|- = ||=- =|- = ||=- =|- = ||=- =|- = ||=- =|- =
PRESIDENT
REPUBLIC OF INDIA
Energy is one of the most important ingredients in any industrial activity.
However, its availability is not infinite. Hence, efficient use of energy resources
and their conservation becomes of paramount importance and is essential for
sustainable development of the country. Since last decade, several initiatives have
been taken in the country to conserve energy in different end uses of the economy.
We have launched a National Mission on Enhanced Energy Efficiency, which
aims to provide institutional framework and support mechanism to bring about
improvements in energy efficiency, especially in major energy using industries.
We are also proposing to improve fuel efficiency of passenger cars by laying down
fuel efficiency norm.
On the occasion of National Energy Conservation Day, I congratulate the
awardees for making exemplary contribution in conservation and efficient use of
energy in their respective domain. I hope that they would continue to deliver
excellence in the field of energy conservation and also serve as a mentor to others.
Let us make sincere efforts for improving energy efficiency through adopting
energy conservation measures at all possible places and contribute to the social
and economic development of India. Let us adopt a motto of efficient use of energy
in every walk of our life.
(SUSHILKUMAR SHINDE)
(SUSHILKUMAR SHINDE)
|+ - = =. |+ - = =. |+ - = =. |+ - = =. |+ - = =.
||=- ==+|= ||=- ==+|= ||=- ==+|= ||=- ==+|= ||=- ==+|=
-; |--.- -; |--.- -; |--.- -; |--.- -; |--.-110 001
Minister of Power
Government of India
New Delhi-110 001
MESSAGE
|+ - =|= = =. |+ - =|= = =. |+ - =|= = =. |+ - =|= = =. |+ - =|= = =.
||=- ==+|= ||=- ==+|= ||=- ==+|= ||=- ==+|= ||=- ==+|=
-; |--.- -; |--.- -; |--.- -; |--.- -; |--.-110 001
Minister of State for Power
Government of India
New Delhi - 110 001
K. C. VENUGOPAL
MESSAGE
Energy is a key factor for enabling developing economies to provide a decent
quality of life to its citizens. In order to enhance the quality of life in India, access
to affordable and clean energy is essential for all of us. Government of India has
taken several tangible policy measures to meet our increasing energy demand in a
sustainable manner.
In the present scenario of fuel price volatility and increasing dependency on
the imported energy resources, Energy Efficiency would prove to be a strategic
tool for achieving dual goals of energy security and climate change mitigation.
Adoption of Energy Efficient technologies, both at demand and supply side, would
bring stability in energy requirement in India. On this National Energy Conservation
Award 2011, I congratulate all the stakeholders and winners of the Energy
Conservation Award for their achievements.
I would appeal to all the energy consumers to optimize their energy use and
adopt more energy efficient practices in order to bring down the energy intensity
of our country. This would provide a clean and sustainable environment for future
generations.
I wish the National Energy Conservation Award a grand success.
(K. C. VENUGOPAL)
P. UMA SHANKAR
=|=+ =|=+ =|=+ =|=+ =|=+
||=- ==+|= ||=- ==+|= ||=- ==+|= ||=- ==+|= ||=- ==+|=
|+ - = =|= |+ - = =|= |+ - = =|= |+ - = =|= |+ - = =|=
== -||+- |+- == -||+- |+- == -||+- |+- == -||+- |+- == -||+- |+-
-; |--.- -; |--.- -; |--.- -; |--.- -; |--.-110 001
Secretary
Government of India
Ministry of Power
Shram Shakti Bhawan
New Delhi - 110 001
MESSAGE
Energy plays a pivotal role in everyday life mirroring the growth of an economy
which is dependent on adequate supply of energy. The per capita energy
consumption is one of the indicators for gauging the prosperity of a country. The
energy demand is broadly from five major sectors namely, households, industry,
transport, electric power generation and agriculture. To overcome the existing
demand supply gaps in electricity sector the power generation capacity of the
nation needs to be augmented through capacity addition and with its rational
usage.
Therefore, for sustainable growth, need of the hour vindicates a concomitant
effort to improve the energy efficient technologies and renewable energy resources
apart from capacity expansion. We are aggressively moving to reduce the energy
intensity through a combination of appropriate regulatory frameworks leadership
and best emulation programs and outreach and awareness campaigns.
The Government of India through a voluntary programme National Energy
Conservation Award recognizes innovation and achievements in Energy
Conservation by Industries, Buildings, Railways, States and Municipalities. On the
occasion of National Energy Conservation Awards I extend my best wishes to the
participating units which have contributed in this national endeavor by reducing
their energy consumption.
(P. UMA SHANKAR)
=|=+ =|=+ =|=+ =|=+ =|=+
||=- ==+|= ||=- ==+|= ||=- ==+|= ||=- ==+|= ||=- ==+|=
=+|| +-| =|= =+|| +-| =|= =+|| +-| =|= =+|| +-| =|= =+|| +-| =|=
=|| + =|+ |-+ |+-=| = =||= =|| + =|+ |-+ |+-=| = =||= =|| + =|+ |-+ |+-=| = =||= =|| + =|+ |-+ |+-=| = =||= =|| + =|+ |-+ |+-=| = =||=
=+|| +-| =|= |+||= =+|| +-| =|= |+||= =+|| +-| =|= |+||= =+|| +-| =|= |+||= =+|| +-| =|= |+||=
+ |-| |+-, -; |--.- + |-| |+-, -; |--.- + |-| |+-, -; |--.- + |-| |+-, -; |--.- + |-| |+-, -; |--.-110 003
Secretary
Government of India
Ministry of Consumer Affairs
Food and Public Distribution
Department of Consumer Affairs
Krishi Bhawan
New Delhi-110 001
RAJIV AGARWAL
MESSAGE
It is heartening to learn that the Ministry of Power is celebrating National
Energy Conservation day on 14th December, 2011.
2. Energy Conservation is an important element of the energy policy aimed
at reducing consumption and consequently lowering emissions. Besides, energy
conservation would held in reducing the need for new capacity addition, cutting
energy costs and driving down the need for imports.
3. Often it has been observed that there is a lack of awareness with respect
to the nature of energy conservation actions that the consumers can take. The
energy labeling of appliances and equipment, launched by Ministry of Power through
Bureau of Energy Efficiency, will overcome this barrier and would encourage the
proliferation of energy-efficient systems and products for the imporvement of the
economy and the environment.
4. On the occasion of the National Energy Conservation Day, I urge all energy
consumers to conserve energy on a continuous basis and curb its wasteful application
and also like to congratulate all the winners of energy conservation award and
wish all success to Energy Conservation day function.
(RAJIV AGARWAL)
=|=+ =|=+ =|=+ =|=+ =|=+
||=- ==+|= ||=- ==+|= ||=- ==+|= ||=- ==+|= ||=- ==+|=
+=| +=| + +- = =|= +=| +=| + +- = =|= +=| +=| + +- = =|= +=| +=| + +- = =|= +=| +=| + +- = =|=
+=| +=| |+- +=| +=| |+- +=| +=| |+- +=| +=| |+- +=| +=| |+-
-; |--.- -; |--.- -; |--.- -; |--.- -; |--.-110 003
Secretary
Government of India
Ministry of Environment
and Forests
Paryavaran Bhawan
New Delhi - 110 003
MESSAGE
I am happy to learn that the Ministry of Power is celebrating the National
Energy Conservation Day on 14th December 2011 and organizing the National
Energy Conservation Award function. The award function showcases to the corporate
sector our appreciation of their efforts towards energy efficiency and its conservation.
The development of modern civilization has been dependent on both the
availability and the advancement of energy. We have witnessed a progression from
animal and steam power, to the internal combustion engine and electricity generation
and to the harnessing of alternative sources of energy. The majority of our energy
stems from fossil fuels such as coal, oil and natural gas. However, the burning of
these fuels is a large sources of carbon dioxide emissions which contributes to
adversely affecting the environment. Energy and environment concerns have now
widened to cover regional and global issues such as acid rain and the greenhouse
effect. Such problems have now become major political issues and the subject of
international debate and regulation. Moreover wasting energy effects the
environment in numerous ways but mostly through the use of non-renewable
resources.
Therefore, energy efficiency and its conservation is a critical element of our
energy policy, which aims at reducing consumption and thereby lowering emissions.
Besides, energy conservation helps reduce the need for capacity addition, a
significant reduction in costs and environmental concerns. Energy efficiency is no
longer just a moral luxury or a personal virtue. A smarter use of energy is part of
a critical national effort to regain control of our own energy for future. It is not
always a matter of making due with less energy. It is a matter of using energy in
smarter ways. Energy conservation is therefore an important tool for global
environmental protection.
I wish the event all success and sincerely hope that the example set by
award winners will give a thrust to other entities to conserve the scarce energy
resources and protect the global environment.
(T. CHATTERJEE)
TISHYA CHATTERJEE
(G. C. CHATURVEDI)
=|=+ =|=+ =|=+ =|=+ =|=+
||=- ==+|= ||=- ==+|= ||=- ==+|= ||=- ==+|= ||=- ==+|=
+ | |== + + |+ |-+ = = = =|= + | |== + + |+ |-+ = = = =|= + | |== + + |+ |-+ = = = =|= + | |== + + |+ |-+ = = = =|= + | |== + + |+ |-+ = = = =|=
-||=. |+- -||=. |+- -||=. |+- -||=. |+- -||=. |+-
-; |--.- -; |--.- -; |--.- -; |--.- -; |--.-110 001
Secretary
Government of India
Ministry of Petroleum &
Natural Gas
Shastri Bhawan
New Delhi - 110 001
MESSAGE
I am happy to learn that the Ministry of Power is observing National Energy
Conservation Day on December 14, 2011.
As you are all aware that Bureau of Energy Efficiency, Ministry of Power,
Government of India is celebrating 14
th
of December every year as Energy
Conservation Day in order to create awareness on the importance of energy efficiency
as well as conservation of energy among all sectors.
Conservation of energy is the most efficient way for the energy security of
the country. On occasion of the National Energy Conservation Day, I urge all energy
users to conserve energy on a continuous basis and curb its wasteful application
since each unit of energy conserved is energy produced. Let us strive to achieve
high levels of enhanced energy efficiency and contribute to the progress of the
nation.
I also take this opportunity to congratulate the award winners, who are
being felicitated with the National Energy Conservation Awards.
(G. C. CHATURVEDI)
GIREESH B. PRADHAN
=|=+ =|=+ =|=+ =|=+ =|=+
||=- ==+|= ||=- ==+|= ||=- ==+|= ||=- ==+|= ||=- ==+|=
-+.- | = -+.+=|.= =| = =|= -+.- | = -+.+=|.= =| = =|= -+.- | = -+.+=|.= =| = =|= -+.- | = -+.+=|.= =| = =|= -+.- | = -+.+=|.= =| = =|=
| -. =| = | -. =| = | -. =| = | -. =| = | -. =| =
-; |--.- -; |--.- -; |--.- -; |--.- -; |--.-110 003
Secretary
Government of India
Ministry of New And
Renewable Energy
Lodi Road
New Delhi - 110 003
MESSAGE
Energy conservation is a crucial step in our move towards greater energy
security, enhanced energy access, and a low carbon economy. It is also an important
precursor to the greater deployment of renewable energy sources, especially because
the energy demand from renewable sources can be minimized by accompanying
energy efficiency actions.
The Energy Conservation Day recognizes the actions and efforts of industry
in moving towards enhanced energy efficiency and greater sustainability. I
congratulate all the award winners of the National Energy Conservation Awards,
and hope that they all become global pioneers as they move beyond international
frontiers of both energy efficiency and renewable energy.
(GIREESH B. PRADHAN)
Efficient use of energy resources and their conservation assumes tremendous
significance in order to achieve the targeted growth in GDP and for sustainable
development.
On the Occasion of the Energy Conservation Day, I congratulate all awardees
for their commendable effort in propagating conservation of energy in their
respective fields, and expect an enthusiastic response in the times ahead. I would
also like to draw attention to the lovely messages expressed by our little
ambassadors on energy conservation through their paintings, which give us hope
for the year ahead.
There is immense potential for adopting energy efficient measures in every
sector of the economy. Even as we encourage our children to be the ambassadors
of energy conservation, it is equally, if not more, essential that we set an example
by ourselves adopting energy conservation as a habit. It is necessary that the
traditional value of Kifayat is once again inculcated in society and the thrifty use of
resources becomes a way of life. Conservation need not always be technology
driven or dictated by the dwindling of resources. Thrift can equally be a virtue of
abundance as it would indicate our reverence for nature and respect for the future.
I congratulate the winners of the Awards programme and the Painting
Competition, and wish all success to the 2011 Energy Conservation Day function.
(ASHOK LAVASA)
ASHOK LAVASA
+= =|=+ += =|=+ += =|=+ += =|=+ += =|=+
||=- ==+|= ||=- ==+|= ||=- ==+|= ||=- ==+|= ||=- ==+|=
|+ - = =|= |+ - = =|= |+ - = =|= |+ - = =|= |+ - = =|=
== -||+- |+- == -||+- |+- == -||+- |+- == -||+- |+- == -||+- |+-
-; |--.- -; |--.- -; |--.- -; |--.- -; |--.-110 001
Additional Secretary
Government of India
Ministry of Power
Shram Shakti Bhawan
New Delhi-110 001
MESSAGE
MESSAGE
It is a matter of great pride for us that many Indian industries are at the
global forefront of energy efficiency. It is also a matter of satisfaction that many
industries have greatly enhanced their energy utilization performance not only
during the past year, but have been doing for many years. There are, of course,
direct financial benefits to those industries which have benefited from energy
efficiency interventions. However, they also serve as role models for all other
industries, who see their performance and achievements as concrete examples of
action. We also recognize that in being leaders, these industries who have proactively
enhance their energy efficiency, have taken technical and financial risks, as well
as created knowledge and human capacity.
The National Energy Conservation Awards is the national recognition for
these pioneers. It captures their leadership, salutes their initiatives, and highlights
their technological achievements. We have seen, over the years, that these
achievements have had a remarkable replicative impact, and that the technological
actions of the National Energy Conservation Award winners are picked up by others
within a few years. The rapid dissemination is, very often, due to the generous
sharing of information and experience by the awardees. We would like to thank
them for this.
I extend warm congratulations to every award winner, and also extend my
appreciation to all the other applicants for the awards. We thank you for your
efforts, and look forward to your continuing leadership.
(AJAY MATHUR)
AJAY MATHUR
=r||-- -|+ =r||-- -|+ =r||-- -|+ =r||-- -|+ =r||-- -|+
=| --|-| = =| =| --|-| = =| =| --|-| = =| =| --|-| = =| =| --|-| = =|
|+ - = =|=, ||=- ==+|= |+ - = =|=, ||=- ==+|= |+ - = =|=, ||=- ==+|= |+ - = =|=, ||=- ==+|= |+ - = =|=, ||=- ==+|=
-; |--.- -; |--.- -; |--.- -; |--.- -; |--.-110 066
Director General
Bureau of Energy Efficiency
Government of India
Ministry of Power
New Delhi - 110 066
(DEVENDER SINGH)
= = +- =|=+ = = +- =|=+ = = +- =|=+ = = +- =|=+ = = +- =|=+
||=- ==+|= ||=- ==+|= ||=- ==+|= ||=- ==+|= ||=- ==+|=
|+ - = =|=, == -||+- |+- |+ - = =|=, == -||+- |+- |+ - = =|=, == -||+- |+- |+ - = =|=, == -||+- |+- |+ - = =|=, == -||+- |+-
-; |--.- -; |--.- -; |--.- -; |--.- -; |--.-110 001
Joint Secretary
Government of India
Ministry of Power
Shram Shakti Bhawan
New Delhi - 110 001
MESSAGE
India needs to sustain a high GDP growth per annum over the next two or
three decades in order to mitigate poverty, meet the millennium development
goals and achieve inclusive development. Energy consumption will need to grow
at a commensurate pace for such a GDP growth. This raises concerns about energy
security as well as environmental issues, given that the additional energy
requirement will be met largely by fossil fuels. The need for efficient use of resources
and energy conservation therefore assumes significance and must be an integral
part of the policy tools. There is a need to engage all stakeholders, create awareness
amongst citizens and encourage the use of energy efficient products, services and
technologies. The Govt. of India has initiated an ambitious drive to reduce energy
intensity of the economy.
The energy conservation in industries has taken a giant leap and the Energy
Conservation Awards is one such instance in which the best performing industries
in each sector are recognized for their outstanding performance. The number of
participants has increased tremendously and an avoided capacity addition of more
than 350 MW is recorded over the past few years as a result of adoption of various
initiatives of promoting energy efficiency by the industries.
On the occasion of the National Energy Conservation Day, I wish to congratulate
award winners in particular and all the participating units in general for making
commendable efforts in conservation and efficient use of energy in their respective
fields. I hope that they would serve as beacons to their fellow citizens.
(DEVENDER SINGH)
ENERGY CONSERVATION EFFORTS
AND
ACHIEVEMENTS OF THE
NATIONAL ENERGY CONSERVATION AWARDS 2011
WINNING UNITS
1
NATIONAL ENERGY CONSERVATION AWARDS - 2011
Introduction
Energy is a key factor for enabling developing economies to provide a decent
quality of life to its citizens. In order to enhance the quality of life in India, access
to affordable and clean energy is essential for all of us. The entire fabric of
developmental goals is webbed around a successful energy strategy.
Government of India has taken several tangible policy measures and strategies
to meet its increasing energy demand in a sustainable manner. Given the fact that
other renewable energies have yet to become cost effective, apart from having
limited potential, fossil fuels have naturally emerged as a mainstay in energizing
the growth requirements of the developing country like India.
Energy Efficiency would prove to be a strategic tool for achieving dual goals of
energy security and climate change sustainability. Among the various strategies to
be evolved for meeting energy demand, efficient use of energy and its conservation
emerges out to be the least cost option in any given strategies.
Recognizing the importance and benefits of energy efficiency, the Government
of India has enacted the Energy Conservation Act, 2001 which has come into force
from 1st March, 2002. Under the provisions of the Act, Bureau of Energy Efficiency
has been established with effect from 1st March 2002. The Bureau is responsible
for spearheading the improvement of energy efficiency of the economy through
various regulatory and promotional instruments. The mission of Bureau of Energy
Efficiency (BEE) is to institutionalize energy efficiency services, promote energy
efficiency delivery mechanisms, and provide leadership to improvement of energy
efficiency in all sectors of the economy.
One of the voluntary innovative schemes, initiated by the Government of India,
Ministry of Power, to promote energy conservation has been the Energy Conservation
Awards. BEE coordinates the Energy Conservation Award scheme of the Ministry of
Power.
This National Energy Conservation Award programme propagates the use of
energy in an efficient manner at domestic and industrial level and boost up the
adoption of energy efficient technologies at end users of energy. This programme
enhances the creativity in an area of energy efficiency through the use of clean and
innovative technologies and discourages the use of energy inefficient technologies.
The course of initiatives taken by various industrial sectors under the framework of
energy efficiency has a good result with a better learning rate therefore the number
of participants has been significantly increased over a period of time.
2
These annual awards recognize innovation and achievements in energy
conservation by the Industries, buildings, hotels, hospitals, railways, state designated
agencies, aviation, manufacturers of BEE star labeled appliances, municipalities
and thermal power station and also raise awareness that energy conservation plays
a big part in India's response to reducing global warming through energy savings.
The Awards were given away for the first time in December 14 , 1991, which is
celebrated as 'National Energy Conservation Day' throughout the country.
Response for EC Awards 2011
The responses among the industrial and commercial units have become very
encouraging as is evident from the increasing participation level (from 123 in 1999
to 644 in 2011). In the current year award scheme, three new sub-sectors have
also been introduced (BPO Buildings, Sponge Iron and Mini hot blast furnaces)
Award Scheme Methodology
An advertisement regarding inviting applications was released in the month
of September 2011 in the various leading newspapers published from all over
the country. Also, the Award scheme has been posted on BEE's website
(www.bee-india.nic.in) and www.energymanagertraining.com
An Energy Conservation Award Committee has been set up under the
Chairmanship of Secretary, Ministry of Power for deciding the award winners. The
members of the Committee are drawn from the Ministry of Power, Central Electricity
Authority (CEA), National Productivity Council (NPC) and from the Bureau of Energy
Efficiency (BEE) which also provides the administrative and technical support to
3
the committee. The Ministry of Power (MOP) has also set up a Technical Sub-
Committee to assist Award Committee in the finalization of Awards. The Technical
Sub-Committee for the year 2011 is headed by the Deputy Director-General (National
Productivity Council), with members drawn from Central Electricity Authority,
National Productivity Council, Bureau of Indian Standards, Ministry of Railways,
GIZ and the Bureau of Energy Efficiency.
The Awards
The Award Committee considered the nominations received for the year 2011
from Industries, Office & BPO buildings, Hospitals, Hotels, Shopping Malls, Zonal
Railways, State Designated Agencies, Municipalities, Manufactures of BEE star labeled
appliances/equipment and Thermal Power Stations. The Award Committee this
year has selected 28 units for First prize, 34 units for Second Prize and 36
units for Certificate of Merit. The awards are recognition of their demonstrated
commitment to energy conservation and efficiency.
Performance indicator of Award Scheme
The Award Scheme has motivated the participating units to undertake serious
efforts in saving energy and environment.
The participating units of EC Award 2011 have collectively invested Rs.2201
Crores in energy conservation measures, and achieved a monetary savings of Rs.
2390 Crores last year, implying a payback period of 11 Months only, once again
proving the fact that energy conservation is a least cost option. The participating
units have also saved electrical energy of 3421 Million kWh, which is equivalent to
the energy generated from a 504 MW thermal power station at a PLF of 0.775. In
other words, these participating units have avoided the installation of power
generating capacity equivalent to 504 MW thermal power stations in 2010-11,
which would otherwise have been required to meet the power demand of these
units.
In the last 13 years of Award Scheme of the period 1999-2011, the participating
units have collectively saved Rs15789 Crores and the investment made on energy
efficiency projects was recovered back in 18 months. In energy terms, 17956
Million kWh of electrical power, 31 lakhs kilolitre of oil, 124 lakhs metric tonne of
coal and 22.44 billion cubic metre of gas was saved, through the energy conservation
measures of the participating units.
The progressive industrial units and other establishments have already realized
the cost effectiveness of energy conservation measures and honouring their efforts
on National Energy Conservation Day, gives a message to thousands of other
industrial units and establishments who may have not yet fully utilized their cost
effective potential through energy conservation.
It is hoped that National energy Conservation Award Scheme would help in
motivating the other energy consumers in joining and promotion of a nationwide
energy conservation movement.
4
E
N
C
O
U
R
A
G
I
N
G

R
E
S
P
O
N
S
E

F
R
O
M

I
N
D
I
A
N

I
N
D
U
S
T
R
Y

A
N
D
O
T
H
E
R

E
S
T
A
B
L
I
S
H
M
E
N
T
S

I
N

T
H
E

N
A
T
I
O
N
A
L

E
N
E
R
G
Y
C
O
N
S
E
R
V
A
T
I
O
N

A
W
A
R
D

S
C
H
E
M
E

(
1
9
9
9
-
2
0
1
1
)
5
E
L
E
C
T
R
I
C
A
L

E
N
E
R
G
Y

S
A
V
I
N
G
S

I
N

T
E
R
M
S

O
F

E
Q
U
I
V
A
L
E
N
T
A
V
O
I
D
E
D

C
A
P
A
C
I
T
Y

I
N

(
M
W
)
6
M
O
N
E
Y

S
A
V
I
N
G
S

A
C
H
I
E
V
E
D

P
E
R

Y
E
A
R

B
Y

P
A
R
T
I
C
I
P
A
T
I
N
G
U
N
I
T
S

I
N

T
H
E

N
A
T
I
O
N
A
L

E
N
E
R
G
Y

C
O
N
S
E
R
V
A
T
I
O
N

A
W
A
R
D
S
C
H
E
M
E

(
1
9
9
9
-
2
0
1
1
)
7
SALIENT FEATURES OF NATIONAL ENERGY
CONSERVATION AWARDS -2011
ANNUAL ACHIEVEMENT BY PARTICIPATING UNITS FROM
INDUSTRIES, OFFICE & BPO BUILDINGS, HOTELS & HOSPITALS,
MUNICIPALITIES, STATE DESIGNATED AGENCIES, THERMAL POWER
STATIONS, ZONAL RAILWAYS, AND MANUFACTURERS OF BEE STAR
LABELED APPLIANCES/EQUIPMENT IN THE YEAR 2010-11
1. MONETARY SAVINGS
Annual Savings : Rs. 2390 Crores
One Time Investment : Rs. 2201 Crores
Average Payback Period : 11 months
2. ANNUAL ENERGY SAVINGS
Electricity : 3421 Million kWh (or Avoided Capacity
Equivalent to a 504 MW Thermal Power
Station)
Furnace Oil : 3.29 Lakhs Kilo Liters (kL)
Gas : 4085 Lakhs Cubic Meters
Coal : 33.21 Lakhs Metric Tonnes (MT)
8
Y
E
A
R

W
I
S
E

E
N
E
R
G
Y

S
A
V
I
N
G
S

A
C
H
I
E
V
E
D
B
Y

P
A
R
T
I
C
I
P
A
T
I
N
G

U
N
I
T
S

I
N

M
I
N
I
S
T
R
Y

O
F

P
O
W
E
R
S

N
A
T
I
O
N
A
L
E
N
E
R
G
Y

C
O
N
S
E
R
V
A
T
I
O
N

A
W
A
R
D

S
C
H
E
M
E
(
1
9
9
9
,

2
0
0
0
,

2
0
0
1
,

2
0
0
2
,

2
0
0
3
,

2
0
0
4
,

2
0
0
5
,

2
0
0
6
,
2
0
0
7
,

2
0
0
8
,

2
0
0
9
,

2
0
1
0

&

2
0
1
1
)
Y
e
a
r
N
o
.

o
f
A
n
n
u
a
l
O
n
e

E
l
e
c
t
r
i
c
a
l

E
n
e
r
g
y

S
a
v
i
n
g
F
u
r
n
a
c
e

O
i
l
C
o
a
l
G
a
s
G
H
G

E
m
i
s
s
i
o
n
P
a
r
t
i
c
i
p
a
t
i
n
g
S
a
v
i
n
g
s

i
n
t
i
m
e
&

O
t
h
e
r
S
a
v
i
n
g
s
S
a
v
i
n
g
s
r
e
d
u
c
t
i
o
n
,
u
n
i
t
s
R
s
.

C
r
o
r
e
s
i
n
v
e
s
t
m
e
n
t
M
i
l
l
i
o
n
E
q
u
i
v
a
l
e
n
t
l
i
q
u
i
d

f
u
e
l
i
n

L
a
k
h
i
n
M
i
l
l
i
o
n
i
n
k
W
h
a
v
o
i
d
e
d
S
a
v
i
n
g
s
,

i
n
M
e
t
r
i
c
L
a
k
h

c
u
b
i
c
t
C
O
2
R
s
.

C
r
o
r
e
s
c
a
p
a
c
i
t
y

i
n
L
a
k
h
s

k
L
T
o
n
n
e
s
m
e
t
r
e
s
M
W
2
0
1
1
6
4
4
*
*
*
*
2
3
9
0
2
2
0
1
3
4
2
1
5
0
4
3
.
2
9
3
3
.
2
1
4
0
8
5
9
.
2
3
6
2
0
1
0
5
9
2
*
*
*
*
2
1
3
8
5
4
5
7
2
4
2
2
3
5
7
3
.
4
1
2
3
.
4
2
8
3
3
8
7
.
8
1
0
2
0
0
9
5
5
8
*
*
*
2
3
7
7
3
1
8
0
2
4
5
1
3
5
9
5
.
6
5
1
2
.
4
4
2
7
4
.
9
6
.
1
2
5
2
0
0
8
3
6
8
*
*
1
8
5
9
2
4
9
3
2
2
1
6
3
2
5
1
.
8
5
3
.
4
7
1
5
7
2
9
5
.
6
2
0
2
0
0
7
3
8
4
*
1
8
4
3
2
9
2
3
1
6
2
0
3
0
8
1
.
2
5
5
.
8
6
1
5
3
7
9
5
.
2
8
7
2
0
0
6
3
8
8
*
1
1
3
5
1
2
6
6
1
2
8
8
2
4
5
1
.
1
9
5
.
1
7
2
9
0
4
4
7
.
4
0
4
2
0
0
5
3
4
3
9
9
3
1
3
1
9
1
3
2
7
2
5
2
2
.
4
7
.
5
8
1
3
1
2
2
5
.
2
5
7
2
0
0
4
2
9
7
7
6
3
1
3
6
4
8
1
4
1
5
5
2
.
4
9
5
.
3
7
1
8
5
8
5
5
.
5
3
1
2
0
0
3
1
9
1
5
3
9
1
0
7
1
5
4
2
1
0
3
2
.
2
1
1
2
.
6
5
7
3
1
8
1
1
6
.
2
2
0
2
0
0
2
1
7
4
5
9
4
6
9
1
6
4
1
1
2
2
1
.
7
7
.
4
3
5
5
8
8
8
.
5
4
7
2
0
0
1
1
5
7
5
8
7
6
5
9
4
8
5
9
0
2
.
2
1
4
.
7
9
3
9
2
9
2
.
4
0
9
2
0
0
0
1
2
0
3
6
6
6
3
0
5
2
4
1
0
0
1
.
3
2
7
0
.
6
4
7
0
7
1
.
0
1
2
1
9
9
9
1
2
3
2
0
5
9
4
0
2
0
5
4
5
1
.
6
2
2
.
1
5
2
4
4
4
1
.
3
6
5
T
o
t
a
l
1
5
7
8
9
2
4
1
9
4
1
7
9
5
6
2
9
6
5
3
1
1
2
4
2
2
4
4
0
6
8
1
.
8
2
1
3
y
e
a
r
s
*
P
a
r
t
i
c
i
p
a
t
i
n
g

u
n
i
t
s

i
n
c
l
u
d
e

I
n
d
u
s
t
r
i
a
l

u
n
i
t
s
,

B
u
i
l
d
i
n
g
s

a
n
d

Z
o
n
a
l

R
a
i
l
w
a
y
s
*
*

P
a
r
t
i
c
i
p
a
t
i
n
g

u
n
i
t
s

i
n
c
l
u
d
e

I
n
d
u
s
t
r
i
a
l

u
n
i
t
s
,

B
u
i
l
d
i
n
g
s
,

Z
o
n
a
l

R
a
i
l
w
a
y
s
,

S
t
a
t
e

D
e
s
i
g
n
a
t
e
d

A
g
e
n
c
i
e
s

a
n
d

M
u
n
i
c
i
p
a
l
i
t
i
e
s
*
*
*

P
a
r
t
i
c
i
p
a
t
i
n
g

u
n
i
t
s

i
n
c
l
u
d
e

I
n
d
u
s
t
r
i
a
l

u
n
i
t
s
,

B
u
i
l
d
i
n
g
s
,

Z
o
n
a
l

R
a
i
l
w
a
y
s
,

S
t
a
t
e

D
e
s
i
g
n
a
t
e
d

A
g
e
n
c
i
e
s
,

M
u
n
i
c
i
p
a
l
i
t
i
e
s

a
n
d
M
a
n
u
f
a
c
t
u
r
e
s

o
f

S
t
a
r

L
a
b
e
l
l
e
d

A
p
p
l
i
a
n
c
e
s

(
E
n
e
r
g
y

s
a
v
i
n
g
s

o
f

s
t
a
r

l
a
b
e
l
l
e
d

a
p
p
l
i
a
n
c
e
s

n
o
t

i
n
c
l
u
d
e
d
)
*
*
*
*

P
a
r
t
i
c
i
p
a
t
i
n
g

u
n
i
t
s

i
n
c
l
u
d
e

I
n
d
u
s
t
r
i
a
l

u
n
i
t
s
,

B
u
i
l
d
i
n
g
s
,

Z
o
n
a
l

R
a
i
l
w
a
y
s
,

S
t
a
t
e

D
e
s
i
g
n
a
t
e
d

A
g
e
n
c
i
e
s
,

M
u
n
i
c
i
p
a
l
i
t
i
e
s
,
M
a
n
u
f
a
c
t
u
r
e
s

o
f

S
t
a
r

L
a
b
e
l
l
e
d

A
p
p
l
i
a
n
c
e
s

a
n
d

T
h
e
r
m
a
l

P
o
w
e
r

S
t
a
t
i
o
n
s

(
E
n
e
r
g
y

s
a
v
i
n
g
s

o
f

s
t
a
r

l
a
b
e
l
l
e
d

a
p
p
l
i
a
n
c
e
s

n
o
t

i
n
c
l
u
d
e
d
)
9
ALUMINIUM
2
nd
Prize : 1. Hindalco Industries Ltd, Renukoot unit,
Distt. Sonebhadra (Uttar Pradesh)
2. National Aluminium Company Limited,
Smelter Plant, Distt. Angul (Odisha)
AUTOMOBILE MANUFACTURING
1
st
Prize : Mahindra & Mahindra Ltd., Zaheerabad,
Distt. Medak (Andhra Pradesh)
2
nd
Prize : Tata Motors Limited- CVBU - Lucknow
(Uttar Pradesh)
Certificate of Merit : 1. Tata Motors Limited -CVBU, Pimpri, Pune
(Maharashtra)
2. GKN Driveline (I) Ltd., Faridabad (Haryana)
CEMENT
1
st
Prize : Dalla Cement Factory, Dalla, Distt. Sonebhadra
(Uttar Pradesh)
Certificate of Merit : 1. Kalyanpur Cements Limited, Banjari,
Distt. Rohtas (Bihar)
2. Ultratech Cement-Kotputli Cement Works,
Kotputli, Distt. Jaipur (Rajasthan)
3. JK Lakshmi Cement Ltd., Distt. Sirohi
(Rajasthan)
4. Chunar Cement Factory, Distt. Mirzapur
(Uttar Pradesh)
CHEMICALS
2
nd
Prize : 1. IOL Chemicals And Pharmaceuticals Limited,
Barnala (Punjab)
2. Jubilant Life Sciences Limited, Gajraula,
Distt. J.P. Nagar (Uttar Pradesh)
NATIONAL ENERGY CONSERVATION AWARD WINNERS 2011
10
CHLOR-ALKALI
1
st
Prize : The Andhra Sugars Limited, Saggonda,
Distt. West Godavari (Andhra Pradesh)
CONSUMER GOODS MANUFACTURING
1
st
Prize : Carrier Airconditioning & Refrigeration Limited,
Gurgaon (Haryana)
2
nd
Prize : LG Electronics India Pvt. Ltd., Greater Noida
(Uttar Pradesh)
Certificate of Merit : Godrej & Boyce Mfg. Co. Ltd.,
Appliance Division, Khandala, Distt. Satara
(Maharashtra)
DAIRY
1
st
Prize : Mother Dairy, Patparganj, Delhi
2
nd
Prize : Mysore Dairy (A Unit of Mysore Chamarajanagar
Dist. Milk Union Ltd.) Siddarthanagar,
Mysore (Karnataka)
Certificate of Merit : Shimoga Dairy (A Unit of Shimoga Milk Union),
Shimoga (Karnataka)
DRUGS & PHARMACEUTICALS
1
st
Prize : USV Limited, Unit - 1, Baddi (Himachal Pradesh)
Certificate of Merit : Orchid Chemicals & Pharmaceuticals Ltd.,
Alathur, Distt. Kancheepuram (Tamil Nadu)
EDIBLE OIL / VANASPATI
2
nd
Prize : Ruchi Soya Industries Ltd., Buti Bori,
Distt. Nagpur (Maharashtra)
FERTILIZERS
1
st
Prize : Rashtriya Chemicals & Fertilizers Ltd.,
Trombay Unit,Chembur, Mumbai (Maharashtra)
2
nd
Prize : Shriram Fertilisers & Chemicals,
Shriram Nagar, Distt. Kota (Rajasthan)
Certificate of Merit : 1. Kribhco Shyam Fertilizers Limited,
Distt. Shahjahanpur (Uttar Pradesh)
11
2. Gujarat State Fertilizers & Chemicals Ltd.,
Distt. Vadodara (Gujarat)
FOOD PROCESSING
2
nd
Prize : Marico Limited, Kanjikode, Palakkad (Kerala)
Certificate of Merit : Glaxo Smithkline Consumer Health Care
Limited, Nabha (Punjab)
FOUNDRY
2
nd
Prize : Grey Iron Foundry-Indian Ordnance Factories,
Jabalpur (Madhya Pradesh)
GENERAL CATEGORY
1
st
Prize : Schneider Electric India Pvt. Ltd.,
Hyderabad (Andhra Pradesh)
2
nd
Prize : Kulkarni Power Tools Limited,Shirol,
Distt. Kolhapur (Maharashtra)
Certificate of Merit : 1. Reynolds Pens India Private Limited,
Sriperumbudur, Distt. Kancheepuram
(Tamil Nadu)
2. GMR Hyderabad International Airport
Limited, Hyderabad (Andhra Pradesh)
3. Bharat Electronics Limited, Bangalore
(Karnataka)
GENERAL CATEGORY (SUBSECTORS OF EC AWARD)
1
st
Prize : Kirloskar Ferrous Industries Limited,
Distt. Koppal (Karnataka)
2
nd
Prize : 1. Inorbit Malls (India) Pvt. Ltd., Malad (W),
Mumbai (Maharashtra)
2. AIR INDIA LTD, Mumbai (Maharashtra)
GLASS
1
st
Prize : HNG Float Glass Ltd., Andheri East Mumbai
(Maharashtra)
12
INTEGRATED STEEL
1
st
Prize : Tata Steel Limited, Jamshedpur, (Jharkhand)
2
nd

Prize : Rourkela Steel plant, SAIL, Rourkela (Odisha)
MINING
2
nd
Prize : MOIL Limited, Ukwa Mine, Ukwa, Distt. Balaghat
(Madhya Pradesh)
Certificate of Merit : Beach Minerals Company Pvt. Ltd., Kuttam,
Distt. Tirunelveli,(Tamil Nadu)
PAPER & PULP
1
st
Prize : BILT Graphic Paper Products Limited,
(Unit- Bhigwan) Distt. Pune (Maharashtra)
PETROCHEMICALS
1
st
Prize : Reliance Industries Limited, Hazira Manufacturing
Division, Distt. Surat (Gujarat)
Certificate of Merit : Continental Carbon India Limited, Ghaziabad
(Uttar Pradesh)
PLASTICS
2
nd
Prize : Jagdamba Polymers Pvt. Ltd., Balasore (Odisha)
Certificate of Merit : 1. Raychem RPG Pvt. Limited, Vasai, Distt. Thane
(Maharashtra)
2. The Supreme Industries Ltd., Khuskhera,
Distt. Alwar (Rajasthan)
REFINERY
1
st
Prize : Indian Oil Corporation Limited (Assam Oil
Division) Digboi Refinery, Distt. Tinsukia
(Assam)
2
nd
Prize : Reliance Industries Ltd., SEZ Refinery,
Distt. Jamnagar (Gujarat)
Certificate of Merit : Indian Oil Corporation Ltd. - Gujarat Refinery,
Vadodara (Gujarat)
13
SPONGE IRON
2
nd
Prize : Welspun Steel Ltd., Taluka- Anjar (Gujarat)
Certificate of Merit : Vandana Global Limited, Siltara, Raipur
(Chhattisgarh)
STEEL RE-ROLLING
2
nd
Prize : JSL Stainless Ltd., Hisar (Haryana)
Certificate of Merit : Remi Edelstahl Tubulars Limited, Tarapur,
Boisar (Maharashtra)
SUGAR
2
nd
Prize : K.C.P. Sugar and Industries Corporation
Limited, Lakshmipuram, Distt. Krishna
(Andhra Pradesh)
Certificate of Merit : 1. Dalmia Chini Mills
Unit - Nigohi, Distt. Shahjahanpur
(Uttar Pradesh)
2. K.C.P Sugar and Industries Corporation
Limited, Vuyyuru, Distt. Krishna
(Andhra Pradesh)
TEA
2
nd
Prize : Hindustan Unilever Ltd. Instant Tea Plant,
Etah (Uttar Pradesh)
TEXTILE
1
st
Prize : Zenitex Pvt. Ltd., Surat (Gujarat)
TYRE
2
nd
Prize : Balkrishna Industries Limited, Bhiwadi,
Distt. Alwar (Rajasthan)
Certificate of Merit : TVS Srichakra Limited, Vellaripatti, Madurai
(Tamil Nadu)
14
OFFICE BUILDINGS
1
st
Prize : Cognizant Technology Solutions (GVC),
Bangalore, (Karnataka)
2
nd
Prize : 1. Bharat Sanchar Nigam Ltd.,
Telephone Exchange, Palarivattam,
Ernakulam (Kerala)
2. Bharat Sanchar Nigam Limited
(Canada Corner Telephone Exchange),
Nashik (Maharashtra)
Certificate of Merit : Indian Railways, DRM Office,N.E. Railways,
Izatnagar, Bareilly (Uttar Pradesh)
BPO BUILDINGS
2
nd
Prize : 1. Infosys BPO Limited, IBPO-1, Tal-Mulshi,
Distt. Pune (Maharashtra)
2. Infosys BPO Limited, BPO-Building 48,
Bangalore (Karnataka)
HOTELS
1
st
Prize : Royal Orchid Central, ICON Hospitality Pvt. Ltd.,
Certificate of Merit : Aditya Park, A unit of Manjeera Hotels and
Resorts Ltd., Hyderabad (Andhra Pradesh)
HOSPITALS
1
st
Prize : Divisional Railway Hospital, Western Railway,
Sabarmati, Ahmedabad (Gujarat)
2
nd
Prize : Fortis Hospital, Noida (Uttar Pradesh)
MUNICIPALITIES
2
nd
Prize : Vadodara Municipal Corporation, Street lighting
Department, Vadodara (Gujarat)
Certificate of Merit : Surat Municipal Corporation,
Hydraulic Department, Surat (Gujarat)
15
STATE DESIGNATED AGENCIES (SDAs)
1
st
Prize : Punjab Energy Development Agency,
Chandigarh
2
nd
Prize : 1. Renewable Energy Department,
Haryana & Haryana Renewable Energy
Development Agency (HAREDA), Chandigarh
2. Nagaland State Designated Agency,
Department of Power, Government of
Nagaland, Kohima (Nagaland)
Certificate of Merit : 1. Uttarakhand Renewable Energy
Development Agency (UREDA), Dehradun
(Uttarakhand)
2. Chhattisgarh State Renewable Energy
Development Agency (CREDA), Raipur
(Chhattisgarh)
THERMAL POWER STATIONS
1
st
Prize : Adani Power Limited,Tal.- Mundra,
Distt. Kutch (Gujarat)
2
nd
Prize : Captive Power Plant, Vedanta Aluminium
Limited, Bhurkamunda, Jharsuguda (Odisha)
Certificate of Merit : 1. GMR Vemagiri Power Generation Limited,
East Godavari (Andhra Pradesh)
2. Thermal Power plant, Maral Overseas Ltd.,
Goyal Nagar, Distt. Indore (Madhya Pradesh)
ZONAL RAILWAYS
1
st
Prize : South Central Railway, Secunderabad
(Andhra Pradesh)
2
nd
Prize : Central Railway, Mumbai (Maharashtra)
Certificate of Merit : 1. Northern Railway, New Delhi
2. East Coast Railway, Bhubaneswar (Odisha)
16
MANUFACTURES OF BEE STAR LABELED APPLIANCES
(Air Conditioner)
1
st
Prize : Samsung India Electronics Pvt. Ltd., Noida
(Uttar Pradesh)
2
nd
(Uttar Pradesh)
Certificate of Merit : Hitachi Home & Life Solution (India) Ltd.,
Distt. Mehsana (Gujarat)
(Refrigerator)
1
st
Prize : Videocon Industries Ltd., Gurgaon (Haryana)
Certificate of Merit : Samsung India Electronics Pvt. Ltd., Noida
(Uttar Pradesh)
(Tubular Fluorescent Lamp)
1
st
Prize : Surya Roshni Limited, Malanpur, Distt. Bhind
(Madhya Pradesh)
(Agriculture Pump Set)
1
st
Prize : CRI Pumps Private Limited, Saravanampatty,
Coimbatore (Tamil Nadu)
(Ceiling Fan)
1
st
Prize : Havells India Ltd., Haridwar (Uttarakhand)
(Colour Television)
1
st
(Uttar Pradesh)
(Storage Water Heater)
1
st
Prize : Racold Thermo Limited,Chakan Distt. Pune
(Maharashtra)
17 17
INDUSTRIAL INDUSTRIAL
INDUSTRIAL INDUSTRIAL INDUSTRIAL
SECT SECT
SECT SECT SECTOR OR
OR OR OR
INDUSTRIAL INDUSTRIAL
INDUSTRIAL INDUSTRIAL INDUSTRIAL
SECT SECT
SECT SECT SECTOR OR
OR OR OR
18
19
Second Prize Aluminium
HINDALCO INDUSTRIES LTD.
Renukoot Unit, Distt. Sonebhadra (Uttar Pradesh)
Unit Profile
Hindalco Industries Ltd. (Hindalco), a Flagship Company of the Aditya Birla Group,
was incorporated in 1958. It's Renukoot unit was set up in technical collaboration
with Kaiser Aluminium and Chemicals corporation, USA and commenced commercial
production in 1962.
Hindalco, at Renukoot, houses a fully integrated plant, comprising of 3 main plants
i.e. Alumina, Smelter & Fabrication Plants. Hindalco produces some By products,
which include Gallium Metal, Vanadium Sludge and Aluminium Dross. Each plant
employs varying Technology. With integrated facilities, output from various plants
is used by next, along with varying raw materials. Company has its own captive
power plant at Renusagar (35 Km away from Renukoot) with installed capacity of
741.7 MW and 84 MW of Co-Generation Plant at Renukoot itself.
20
Alumina Plant: - It was commissioned with an initial capacity of 40,000 MTPA,
which has now increased, to 700000 MTPA. The plant has been expanded in phases
using new technology from time to time for energy efficiency and capacity
enhancement. It employs the basic Bayer's process and the major raw materials
for the plant are Bauxite, Steam, Caustic Soda and Furnace oil.
Aluminium Smelter: - It has 11 Pot lines with 2133 Pots installed with annual
production capacity of 3,45,000 MT. The Smelter employs the Hall Heroult Electrolysis
Process for the extraction of Aluminium from Alumina. Basic raw materials for the
smelter are Alumina, Power, Anodes and Aluminium Fluoride.
Fabrication Plant (Value Added Products): - The Fabrication Plant at Renukoot
comprises of 4 Main Sections Remelt Shop, Cast House, Rolling Mills, Extrusion &
Conform which produce Wire Rod, Slabs/Billets, Rolled, Coils and Extruded Products.
Hindalco, an ISO 14001, ISO 9001:2000 and OHSAS 18001 Company. Recently
these three systems have integrated as IMS (Integrated Management System).
Energy Consumption
Manufacturing of Aluminium is one of the most energy intensive processes. With
the implementation of various energy saving projects, cost of energy has reduced
to 37.99 % in the year 2010-11 against 39.45 % for the year 2009-10. Hindalco
uses 3 types of Energy resources to manufacture Aluminium i.e. Coal, Oil and
Electricity. Out of these three, electricity has the highest share (almost 76.44 % of
total energy consumption cost). Total cost of energy for last year was Rs. 1299.43
Crore, which includes Rs. 218.84 Crore for Fuel oil, Rs. 993.38 for Electricity, and
Rs. 87.20 Crore for Coal. Last year company consumed 515,151 MT of Coal,
88,687.45 KL of Fuel Oil, 65234.39 lac kWh of Electricity and 225796.62 MT of
purchased steam.
With sincere efforts in the direction of Energy Efficiency by the company there has
been significant reduction in the consumption of energy as given in the summary
sheet. Graphical representation of few areas is attached below: -
Specific Energy Consumption (Electrical Trends)
21
Specific Energy Consumption (Thermal Trends)
22
Energy Conservation Commitment, Policy & Set Up
In the present scenario of
increasing cost trend towards
Energy, Hindalco's well-
established Energy Management
System is continuously working
on Energy conservation. The
company has a well-defined
Energy Policy to underscore its
commitment towards Energy
Conservation.. To inculcate
awareness on the importance of
Energy Conservation not only to
the employees of the company
but also to the society, the
following setup is followed.
Setting up a dedicated
Energy Cell with following
agenda to enable the
Company to reduce specific
energy consumption on
continual basis and thus
becoming one of the lowest
cost producers in the World:
1. To identify potential area
for energy saving in
consultation with
department
2. To take care of latest technological developments in the field of energy
conservation
3. To suggest measures for better energy efficiency for the implementation
in the plants and new projects.
4. To monitor the quantum of energy saved on account of energy conservation
initiatives.
23
Energy Monitoring Methodology
A well defined Energy Management Organization Structure
A BOTTOM-UP & TOP-DOWN APPROACH
Process Mgr Elect. Maint.Mgr Inst. Maint.Mgr Mech Maint.Mgr
D K Kohly
Chief Officer Operations
(Aluminium & Power)
Central Technical Cell
Energy Auditor/
Manager
Input from Monthly Energy
Meetings, Daily Review
Meetings & Qrtly PARTA
revision
Direction, Guidance,
Conceptualization,Target
Setting, resource providing
Energy Audit, Walk Through Audit, Quality Circles, Shop Floor Committees, WCM sub-committees &
Suggestion Schemes from respective areas covering staff & workmen
Preparing action plans,
monitoring & timely
implementation
Central Technical Cell for
MIS,Inputs and Audits
Energy Conservation Achievements
The company's efforts towards energy conservation have been consistently
recognized by the competent authorities. During FY 2006-07 to FY 2010-11 company
has implemented 306 measures to improve Energy Efficiency (including capacity
enhancement) by investing Rs. 293.52 Crore which resulted in a saving of energy
worth Rs. 46.30 Crore / Year and also increased production.
24
Major projects implemented during the year 2009-2010 are listed
below:
The practices (metal pad,
pot voltage and anode
cover) of Smelting process
has optimized to reduce
energy consumption and
maintain heat balance with
increased amperage. With
the above effort, 140 Lac
kWh has been saved during
FY 2010-11.
Investment : Nil
Money saving : Rs.. 314.25 Lac/Year
Conversion of existing high
temperature Digestion
technology with energy
efficient double digestion
technology to reduce HP
steam requirement
Investment : Rs. 13845 Lac
Money saving : Rs. 361.22 Lac/
Year
Reduction in specific fuel consumption of Billet production through
1. Reduction of excess air in combustion to reduce stack loss through ratiotrol.
2. Modification in regeneration chamber of furnace to recover max waste heat
which is utilized for pre heating of combustion air.
Investment : 1.00 Lac
Money saving : Rs. 25.38 Lac/Year
25
Switching off standby transformer,
when they are at no load to
reduce losses due to charging
the transformer.
Investment : Negligible
Installation of HP Heater in Co - gen. 1 to reduce coal consumption.
Installation of HP Heater in Co-gen. 1 to increase feed water temperature resulting
reduction of coal consumption. In Boiler # 4, originally there were 2 numbers of HP
heater installed to increase feed water temperature up to 208
0
C from 122
0
C by
charging turbine extraction-1 (20 ata pressure) & 2 (11 ata pressure) steam in HP
heater # 2 & 1 respectively.
Investment : Negligible
Besides above, a number of energy conservation projects have been completed
through Small Group Activities; only some of these have been included above.
Energy Conservation Plans and Targets
Following energy conservation projects have already identified and implementation
is in progress:-
1. Installation of capacitor banks to improve power factor. (6 Nos.)
2. Installation of VFDs for HID spent liquor pumps # 1 & 2. (2 Nos.)
3. Installation of Energy efficient motor for vanadium plant freon compressor and
fine seed reslurry pumps. (4 Nos.)
4. Installation of VFDs & LT motors for Slurry dosing pumps # 1 & 2.
5. Implementation of Advance process control in Calciner # 2 to reduce oil
consumption per Ton.
6. Upgrade of digesters interconnecting piping from 14 to 16 inch for 2 No.
Digesters in Dig-II
26
7. Air washer to be installed for centrifugal compressor to reduce specific power.
8. Redesigning of bag house of line-5, 6 DSS as line-9, 10 & 11 DSS.
9. DSS line-5 to 11 dry header modifications for lowering down pressure drop.
10. Mechanical locking arrangement for center punch holding in next 400 pots.
11. Bronx Cut - to - Length Line - All the Conveyors continue to run even when the
product is not being processed but the line is selected in Auto or Run Mode.
This results in unnecessary consumption of energy. Logic is to be developed to
stop the Conveyors during such condition. The Conveyors can be restarted by
pressing the Reset button when the material is to be processed.
12. Charging car hydraulic motor to be stopped, when not in the use (30 min to 5
min)
13. Roll Forming Line - Its Recoiler hydraulic Pump Motor and Gear Lube Pump
Motor does not stop even when the line is stopped (even in case of pressing
the emergency Push Button). Energy is unnecessarily consumed and Safety is
also compromised. A logic is to be developed to Stop the motors when the Line
is stopped.
14. Replacement of Sodium vapour lamps by LED lamps in Caster plant
15. In DC # 2 Vapor Exhaust Fan 7.5 HP can be stopped when not required by
providing one interlock with casting stop.
16. In DC # 4 Vapour Exhaust Fan 15 HP can be stopped when not required by
providing one interlock with casting stop.
17. To implement the automatic switch off the cooling fans at the extrusion press
no 2 according to the puller length.
18. Up-gradation of Boiler #1 bare tube economizer to improve efficiency by reducing
flue gas temperature.
19. Replacement of Co-gen.-I Hot well Pump motor by low rating motor.
20. Replacement of Old 60 MVA Transformer T-2 with new 75 MVA Transformer for
efficiency gain and reliability improvement.
21. Replacement of conductor of Transmission line #1 & 2 with AAAC and provision
of TWIN ZEBRA conductor on Transmission line #5 & 6 to reduce transmission
loss.
22. Installation of additional Busbar in Potline #1, 2 & 3 to minimize losses in bus
bars.
27
Environment and Safety
Hindalco, Renukoot is fully committed to sustainable development as a responsible
corporate house. Company consider it extremely vital that it meet the needs of
today without compromising the welfare of future generations. Company understand
a tremendous intrinsic linkage between economic growth and environment
protection. Therefore running out plants at Renukoot in an eco-efficient manner
comes naturally. Environmental protection continues to be a key process in Hindalco's
business of manufacturing aluminium and for its continual growth. Hindalco is fully
committed to conserving raw material and minimizing wastes with a clear focus on
pollution prevention.
At Renukoot, to demonstrate the commitment of continual improvement in
environment protection, two old Baking furnaces have been retrofitted successfully
to achieve the low particulate emission. Further it has been proposed to replace
Baking Furnace No 1& 2 by a new state-of art environment friendly technology
based Baking Furnace. Statutory requirement for approval of new baking furnace
has been taken from UPPCB.
Advance Hi-Tech Dry Scrubbing systems on all pot lines, fuel-efficient calciners &
boilers with high efficiency ESPs and computerised firing system with FTP installed
in baking furnaces ensure a cleaner environment in and around Renukoot round
the clock throughout the year. Upgraded STP and State- of-the-art industrial effluent
treatment plant are in place and effluent streams generated within the plant and
colony are treated. The treated water is recycled within the plant for various uses
e.g. process, horticulture etc. Thus the company has attained a status of zero
discharge company for water management.
At Renukoot, Hindalco's strength lies in handling and utilisation of all its solid wastes
in environment friendly ways. Hindalco was the first company to introduce dry
stacking of Red Mud. It also pioneered the recycling of Spent Pot Lining to produce
cryolite for its internal consumption requirements. All the ETP/STP sludge is used
as soil conditioner for plantation in the company's horticulture activities. Company
has dry ash disposal in all of its four Boilers and all fly ash presently generated
(100%) is being given to various users. Substantial amount of earlier dumped ash
is also lifted by users. It is also being used internally in building construction activity
and to fill low-lying areas.
28
Second Prize Aluminium
NATIONAL ALUMINIUM COMPANY LIMITED
Smelter Plant, Distt. Angul (Odisha)
Unit Profile
National Aluminium Company Limited (NALCO) is the only Public Sector Undertaking
in India producing alumina, primary aluminium and semi-finished products. NALCO
is the largest integrated Aluminium Complex with operations spanning from mining,
refining, power generation, smelting and production of value added products such
as strips, billets, wire rod, ingots & rolled sheets etc. The Smelter unit is located in
Angul district of Odisha. The Smelter unit has increased its production capacity
from 3,45,000 MT to 4,60,000 MT with the commissioning of 4th Pot Line consisting
of 240 electrolytic pots. There are total 960 pots of 185 KA rating. Smelter unit has
adopted technology from Aluminium Pechiney, France.
29
POT LINE ELECTROLYSIS (185 KA Pots)
Captive Power
Plant
Electricity AC to
DC Conversion
Anode Baking
Al
2
O
3
Green Anode
Fume Treatment
Plant
Anode Rodding
CAST HOUSE
DESPATCH
FLOW CHART
Specific Energy Consumption
Aluminium production is the most energy intensive process. For the smelter unit,
energy cost is 39% of total production cost and out of total energy consumption
electrical energy is 94 % and the rest is thermal energy i.e. fuel oil/gas consumption
contributes to only 6 % of total energy consumption. Fuel oil consumption is mainly
due to baking of anodes and for operation of Melting cum holding furnaces of Cast
House. Smelter unit has always strived to reduce specific electrical and thermal
energy consumption by improving several operating practices, adopting best of
technologies and doing in-house R&D projects. NALCO has also gone for
mathematical modelling and heat balance of pots for improving energy consumption
figure.
30
Energy Conservation Commitment, Policy and Organizational Set Up
Smelter unit has an Energy Conservation Cell (ECC) under the Chairmanship of
General Manager (O&M). A senior Executive has been nominated as Energy Manager
and he is also the convener of Energy Cell. Smelter unit has 14 BEE certified
Energy Auditors &1 certified Energy Managers. Members of ECC have also been
nominated from various cross functional departments e.g. Production, Maintenance,
R&D etc. The ECC members meet regularly to discuss various strategies and action
plans to implement energy conservation measures in line with NALCOs energy
conservation policy and objectives. Apart from that small group activity (SGA)
involving employees from various functions and levels and Quality Circle teams are
encouraged to work on energy saving projects. The small groups identify scope for
improvement and implement energy conservation projects. NALCO has a reward
scheme named Sarjana for felicitating employees.
Energy Conservation Measures Implemented in 2010-11
Reduction of DC energy consumption in Pot line-2 achieved by
Use of advanced beam raising jig from ECL, France to enable better stem
beam contact, better anode clamps which prevent slippage of anode and better
31
contact, regular cleaning of beam contact area, arresting of alumina leakage during
filling, reduced anode resistivity etc. Production achieved during the year was
1, 06,719.40 t. The specific energy consumption came down from 13560.958
to 13,497.8349 kWh/t.
Annual saving of electrical energy / HFO ( in kWh/ kL) is 67,36,459 kWh
Financial benefits per year is 165.925709 Lacs @ 2.4631 per kWh
Reduction of DC energy consumption in Pot line-4 achieved by
Use of advanced beam raising jig from ECL, France to enable better stem
beam contact, better anode clamps which prevent slippage of anode and better
contact, regular cleaning of beam contact area, reduced anode resistivity etc.
Production achieved was 1, 15, 839 t. The specific energy consumption came
down from 13698.619.958 to 13,478.378 kWh/t.
Annual saving of electrical energy / HFO ( in kWh/ kL) is 2,55,12,485 kWh
Financial benefits per year is 628.39802 Lacs @ 2.4631 per kWh
Reduction of HFO consumption in ABF-2 achieved by
Modification of flue wall heating curve, replacement of damaged peep hole
covers (investment of 0.95 Lakh), reduction in flue wall height (Investment of
1 Lakh), provision of thermal expansion clearance, replacement of backlog
outlived flue walls, replacement of all damaged top blocks to arrest cold air
ingress and optimised heat recovery from cooling sections by increasing the
pre heating sections. Overall Investment of 1.95 Lacs incurred in the project.
Production achieved during the year was 95,967 t of baked anodes. Specific
HFO consumption came down from 56.2 L/t to 53.70 L/t.
Annual saving of electrical energy / HFO ( in kWh/ kL) is 239.9175 kL
Financial benefits per year is 67.99742 Lacs@ 28,342 per kWh
Energy saving by reducing the speed of coke and butt circuit blower
in Green Anode plant 2 achieved by
Speed reduction from 1464 to 1226 rpm (16%) by reducing the drive pulley
diameter (355 to 335mm) and increasing the driven pulley diameter (355 to
400mm). The damper was fully opened and efficient fan running was ensured.
The flow maintained as per system requirement. The fan power consumption
came down significantly. The project was implemented on 30-03-11.
Annual saving of electrical energy / HFO ( in kWh/ kL) = 1,27,200 kWh
Financial benefits per year is 3,13,306 @ 2.4631 per kWh
32
Energy Policy
33
First Prize Automobile Manufacturing
MAHINDRA & MAHINDRA LTD.
Zaheerabad, Distt. Medak (Andhra Pradesh)
Unit Profile
The Mahindra Group focuses on enabling people to rise. Mahindra operates in the
key industries that drive economic growth, enjoying a leadership position in tractors,
utility vehicles, information technology and vacation ownership. Mahindra has a
presence in the automotive industry, agribusiness, aerospace, components,
consulting services, defence, energy, financial services, industrial equipment,
logistics, real estate, retail, steel and two wheelers.
A US $12.5 billion multinational group based in Mumbai, India, Mahindra employs
more than 119,900 people in over 100 countries.
Its flagship company Mahindra & Mahindra Limited is the only Indian automobile
manufacturer to feature in the top 10 list of the Carbon Disclosure Leadership
Index in India - 2010, created by the Carbon Disclosure Project (CDP).
Mahindra Automotive sector has six manufacturing units, four in the state of
Maharashtra located at Kandvili, Igatpuri, Chakan & Nasik; fifth unit located at
Zaheerabad, Medak- Andhra Pradesh and the sixth unit located at Haridwar,
Uttaranchal.
Mahindra & Mahindra Ltd. - Zaheerabad unit, Medak - AP
34
Year Product
Specific Electrical
Energy Consumption
kWh/ Eq. Veh
% Reduction over
2009-10
Specific Thermal
Energy
Consumption
MKcal/ Eq. Veh
% Reduction over
2009-10
2009-2010
Utility Vehicles, light
Commercial Vehicles, 3 Wheeler
188.34 -- 0.8673 --
2010-2011
Utility Vehicles, light
Commercial Vehicles, 3 Wheeler
127.46 32.33 % 0.5187 40.19 %
The Zaheerabad unit is a certified ISO14001:2004 & OHSAS 18001:2007, ISO
27001:2002 unit.
One of the unique features of this plant is its total dependence on ground water as
it does not get water supply from the state administration. The plant has taken
measures to become self sustainable by conserving water through rainwater
harvesting, ETP & STP Waste water treatment, Bio filter treatment plant, Green
belt Development & Environmental projects etc.
Process Flow Chart
Energy Consumption Details
Description Unit 2009-10 2010-11
Total Electrical energy consumption per annum Lac. kWh 117.06 103.16
Specific electrical energy consumption kWh/ Eq. vehicle 188.32 127.46
Total thermal ( Fuel) consumption per annum MKcal 16203.2 14693.25
Specific thermal(Fuel) energy consumption per annum MKcal / Eq. Veh 0.8498 0.5187
Specific Energy Consumption (SEC) Reduction during the period
2010- 2011
35
Energy Consumption Trends
1. Installation of 21 nos of VFDs for circulation fans & Pumps
Before:
Motors used to be run at Full speed
(Controlling the air / water flow by
throttling the valves)
After:
Now Plant is controlling the air /water
flow through VFD by adjusting the
supply frequency.
No. of kWh Saved : Rs. 23.44 Lacs units
Savings per annum : Rs. 105.47 Lacs
Investment : Rs. 51.45 Lacs
36
2. Installation of LPG flux savers in Ovens
Before:
Existing gas train & burner for ovens does not convert
complete LPG after combustion in to heat energy
resulting in loss of fuel. The un-burnt LPG gas gets
accumulated in the burner in the form of carbon soot
which is undesirable
After:
3. Implementation of Heat recovery system
Before: After:
Flue gases are left to atmosphere Extraction of heat from flue gases and
heating the inlet air temperature 80-95
O
C
LPG flux saver installed which ensures complete
burning of LPG resulting in elimination of fuel loss
LPG Fuel savings : 63.75 MTOE
Savings per annum : Rs. 24.373 Lacs
Investment : Rs. 6 Lacs
37
Energy Conservation Plans & Targets
Here with listed some of the major Energy conservation initiatives planned for the
next year 2010-11 & 2011-12
Sl
no.
Energy conservation measures ( ENCON)
planned
Anticipated
savings in
energy
in Rs Lacs
Approx.
Investment
in Rs Lacs
Project
commencement
& completion
year.
1 Installation of natural draft cooling tower 1.65 3 2011-12
2 Installation of Compressor Heat Recovery System 3.25 16
2011-12
3 Replacing 50 nos existing lamps with induction lamps 3.5 15
2011-12
4
Providing mechanical auto shut off taps for admin
building
1.8 2
2011-12
5
Providing Solar Heating Systems for Canteen
4 10
2011-12
6 Providing Solar Heating Systems for LPG vaporizer 2.6 5
2011-12
7 Provision of street light energy savers 0.85 0.5
2011-12
With the implementation of the above Energy Conservation measures, plant would
achieve the following targeted results.
Year
Electrical
(kWh/ Eq.Veh)
Thermal
(MTOE / Eq. Veh)
Reduction over the year 2010-11
Electrical% Thermal%
2010-11 127.46 0.5187 __ __
2011-12 95.59 0.3890 25% 25%
Environment & Safety
Mahindra & Mahindra limited, Zaheerabad has a well-established integrated
Safety, Occupational Health and Environmental Policy to ensure the optimum
safety of the employees, public, plant and equipment, which are embedded in
the core organizational values.
The Policy interalia necessitates compliances with all statutory rules and
regulations, imparting training to employees, carrying safety audits of the
various facilities of the company, conducting regular medical check up of
company employees and promoting eco-friendly activities.
M & M Ltd, Zaheerabad has been certified for Occupational Health and Safety
Management System (OHSAS 18001:2007) certification which aims to
eliminate or minimize risk to employees and other parties who may be exposed
to Occupational Health and Safety risks associated with the activities of
Company.
38
Various environmental good practices and clean environmental promotion
campaigns and special initiatives were carried out in the plant. M & M Ltd,
Zaheerabad has been certified with the amended standards for Environmental
Management System (ISO 14001:2004).
M&M, Zaheerabad shall ensure that its stake holders including the suppliers
are totally engaged with it in this endeavor through the Green supply Chain
Management initiative.
M&M, Zaheerabad plant also takes various initiatives towards community
development in the areas of Health, Education and Environment.
Energy Policy
The plant has formed Energy Conservation (ENCON) Cell to establish, Implement,
& Sustain the Energy conservation initiatives.
39
Second Prize Automobile Manufacturing
TATA MOTORS LIMITED-CVBU
Lucknow (Uttar Pradesh)
Unit Profile
Tata Motors Limited is India's largest automobile company, with consolidated
revenues of Rs. 123, 133 crores (US $ 25.65 billion) in 2010-11. It is the leader in
commercial vehicles in each segment, and among the top three in passenger
vehicles with winning products in the compact, midsize car and utility vehicle
segments. The company is the world's fourth largest truck manufacturer, and the
world's second largest bus manufacturer.
Tata Motors - CVBU Lucknow is one
of the youngest production facilities
among all the Tata Motors locations
and was established in 1992 to meet
the demand for Commercial Vehicles
in the Indian market.
In light of Company's aggressive
growth plans, company is currently
in expansion phase and production
at Lucknow would grow many-fold
in near future. The expansion has
been completed in areas of painting,
welding, vehicle assembly & testing
and utility services, driven by latest technology.
This plant, rolls out commercial vehicles and is specialized in the designing and
manufacturing of a range of modern buses which includes Low-floor, Ultra
40
Plant Process Flow
SUPPLY
CHAIN
Material from
Local Vendor
base, Pune &
Jamshedpur
Vehicle Assembly Line
Western Complex
Bus Assembly Line
TML-Marcopolo
Vehicle Assembly Line
Eastern Complex
Engine
Assembly
Transmis-
sion
Assembly
Axle
Assemb
ly
Chassis
Assembl
y
Cowl
Assembl
y
BIW
Shop
Paint
Shop
DISPATC
STU***
DTC**
JnNURM
*
Private
Operator
Energy Consumption
Low-floor, CNG & RE Buses. The Lucknow facility also specializes in manufacturing
HCBS (High capacity Bus System) buses. Latest vehicles being manufactured include
the JnNURM buses for different STU's.
41
Energy Conservation
1. Energy Conservation Measures taken in 2006-07 to 2010-11
The TATA Motors - CVBU Lucknow has always been cognizant of the need for
conservation of energy and has been steadily making progress towards this end.
Energy Conservation measures have been implemented at all the shops, offices
of the plant and special efforts are being put on undertaking specific energy
conservation projects like,
Variable frequency drives
Wind driven turbo ventilators
Energy efficient motors, blowers & Pumps
CFL & LED lights
Polycarbonate transparent sheers
Optimized compressed air system
Reuse of furnace exhaust for preheating application
Solar lighting, heating & signal flashers
North Lighting based design of all new shops in
the Eastern complex
Timer based control of street lights etc
These Energy Conservation (ENCON) Projects have resulted
in specific energy consumption 375 KWH/Eq vehicle
2. ENCON Summary : 2006-07 to 2010-11
153
2010 - 2011
ENCON Summary 2006-07 2007-08 2008-092009-10 2010-11
Total ENCONS 46 52 98 135 153
Total ENCONS - Cumulative 46 98 196 331 484
Zero & low Investment ENCONS 21 32 45 61 74
Total Investment : Rs. Millions : 7.59 45.89 21.47 47.34 32.14
Saving Potential : Rs. Millions : 13.96 20.02 11.21 27.11 28.13
42
3. Some of the ENCONs
Switching OFF the alternate street light
Plant is using 250 W HPSV lamps in street lights installed in the plant. Lamps of
alternate street light poles were disconnected in non-critical areas as an energy
conservation measure. The modification in control circuit was done in such a way
that 66% of the lights are 'ON' from 19:00 hrs to 23:15 hrs. and only 33% light
are 'ON' after 23:15 hrs upto 06:00 hrs in the morning, keeping in view the less
movement of man and material during night. The reduction in Lux level in these
areas was studied and ensured that it did not adversely affect the road traffic
movement and operation in these areas. This delivered energy savings of more
than 41%.
Before Condition After Condition
Total Investment : 0.00 Lacs Total Savings : 5.15 Lacs/annum
Payback :Immediate
Optimisation of Sealer Oven- Cowl Baking in Paint Shop
Total Investment : 0 Lacs
Total Savings : 2.136 Lacs/annum
Payback : Immediate
43
Optimizing the Compressor Pressure
Total Savings : 0.32 Lac/annum
Payback : Immediate
Use of energy efficient motors & pumps in Paint Shop
Energy efficient motors have been used in paint shop to provide better savings of
energy. On an average plant has 315 motors ranging from 5 HP to 630 HP. These
energy efficient motors provide better energy efficiency and less operating cost.
Total load of motor is taken to be 7.2 MVA.
Motors Installed In paint shop
Total Investment : 49 Lac
Total Savings :16.5 Lac/annum
Payback : 2.2 Years
44
Environment & Energy Policy
TML-Lko pays special attention towards conserving the environment and reaffirming
its commitment to minimize the adverse impact of its products, operations and
services on the environment. In order to address the requirements of environmental
standards and regulations, plant has defined and deployed policies for environment.
The Environmental Policy of TML-Lko reaffirms its commitment to the environment.
Also, its commitment to Environment is reflected through Enterprise Process Manual
(EPM) process on Environment Management.
45
Certificate of Merit Automobile Manufacturing
TATA MOTORS LIMITED-CVBU
Pimpri, Pune (Maharashtra)
Unit Profile
Tata Motors Limited is India's largest automobile company, with annual turnover
of Rs. 48,223.72 Crores in 2010-11. It is the leader in commercial vehicles in
each segment, and among the top three in passenger vehicles with winning products
in the compact, midsize car and utility vehicle segments. The company is the
world's fourth largest truck manufacturer, and the world's second largest bus
manufacturer.
With more than 130 models covering a wide range of Commercial Vehicles,
Passenger Cars and Multi-Utility Vehicles, Tata Motors provides the wheels for
India's growth. Experience the evolution of an auto giant through a virtual drive
More than half a century of impressive presence and Tata Motors continues to
provide India with top of the line commercial vehicles. Tata Motors is India's largest
and among the world's top ten commercial vehicle manufacturers.
Plant has over 130 models providing a wide variety of commercial transport
solutions.
46
Energy Consumption
Annual Eq. Vehicle production Nos. 178696 212345
Total Electrical Energy
Consumption per annum
Lacs kWh 949.42 1079.41
Specific Electrical Energy
Consumption
kWh / Eq.Veh. 531.31 508.33
Total Fuel Consumption per
annum
MKCal 61740 66834
Specific Fuel Consumption MKCal / Eq.Veh. 0.3455 0.3147
Electrical & Thermal Energy Consumption
949.42
1079.41
C
o
n
u
m
p
t
i
o
n
i
n
L
a
k
h
K
W
H
2009-10 2010-11
Electrical Energy consumption in
Lakh KWH
61740
66834
C
o
n
s
u
m
p
t
i
o
n
i
n
M
K
c
a
l
2009-10 2010-11
Thermal Energy Consumption in
MKCal
Electrical & Thermal Specific Energy Consumption
531.31
508.33
K
W
H
p
e
r
E
q
.
V
e
.
2009-10 2010-11
Specific Electrical Energy
consumption (KWH / Eq. Vehicle)
Reducion
4.32%
0.3455
0.3147
M
K
C
a
l
/
E
q
.
V
e
h
2009-10 2010-11
Specific Thermal Energy
Consumption
(MKCal / Eq. Vehicle)
Reducion
8.9%
47
During the period 2010-2011, M/s. Tata Motors, CVBU Pune has implemented
around 46 energy conservation projects through different initiatives
Internal Energy audit,
Suggestion schemes,
Kaizen activity
TPM activity
Equipment performance monitoring system
Resulting into Savings of Rs 1490.49 Lacs
Major Energy Conservation Projects implemented during 2010-11 details are as
follows.
Energy Saving by Installation of VFD in place of Step-down
Transformer for Electrical Heating System of CCH Furnace.
Before -: Earlier at Heat Treatment area the
component heating was carried out by electrical
heating. The supply voltage for the heaters was
85 volt and it was given through a step down
transformer.
After -: Now, 340KW variable frequency drive
with variable voltage option was installed on Pre-
heating zone and the step down transformer was
removed. The out put voltage of the drive was
set to 85 volt line voltage. 13% of Electrical
energy savings observed.
Annual Energy saving in Rs. 13.72 Lac ;
Annual Energy Saving in kWh 2.49 Lac ;
Annual CO
2
Reduction in 205.8 tCO
2
;
Investment in Rs. 14.4 Lac
Before
After
48
Energy Saving by Energy Saving by Installation of Active grills at Data
centre at I- building
Before
After: Solar Photovoltaic System
Before -: Earlier Due to increase
in heat load in data centre, air
supply from bottom grill is not
sufficient, and to maintain desire
temperature stand by AC system
need to operate.
After -: Now, Active grills at Data
centre at I building. After
installation of active grills, air
velocity is increased in the area
and it result in Temperature inside
the data centre is maintain with
out working of stand by units (2
nos. X2TR unit kept OFF) and
customer satisfaction is
improved.
Annual Energy saving in Rs.
0.69 Lac;
Annual Energy Saving in kWh
0.115 Lac;
Annual CO2 Reduction in 9.66
tCO
2
;
Investment in Rs. 0.35 Lac.
Energy Saving by Down sizing of DG jacket water circulation pump
Before -: Earlier 18.5 KW pump system was
used for jacket water circulation for Engine
preheating in standby mode.
After -: Now, 3.5 KW pump system is used
for jacket water circulation for Engine
preheating in standby mode MAN DG set #
1 at MAN DG House.
Annual Energy saving in Rs. 4.09 Lac ;
Annual Energy Saving in kWh 0.744 Lac;
Annual CO2 Reduction in 62.5 tCO
2
;
Investment in Rs. 0.2 Lac.
Engine Jacket
water circulation
pump 18.5KW.
Before
Engine Jacket
water circulation
pump 3.5KW.
After
49
Energy Saving by installing motorized damper control for fresh air
supply.
Before -: Earlier manual damper control was
used for fresh air supply at Model shop Air
conditioning plant.
After -: Now, motorised damper control
system installed for fresh air supply. This
damper controls fresh air supply on the
ambient temperature. The system provides
free cooling during winter/night and
subsequently load on AC plant is reduced.
Annual Energy saving in Rs. 0.93 Lac;
Annual Energy Saving in kWh 0.17 Lac;
Annual CO2 Reduction in 14.28 tCO
2
;
Investment in Rs. 2.4 Lac
Display of
ambient
temperature.
Actuators.
After
Unity Power Factor Management and Sustenance
Inspite of Dynamic Load conditions and Expansions over the period PF improved
from 0.95 to 0.997 (UPF) and sustained over the period. This effort has reduced
the Transmission and Distribution losses at Plant level and also state grid supply
level. This effort have reduced the maximum demand of the plants to the
tune of 3.3 MVA approx. and that much capacity is reduced at generation level.
Conversion of DG sets into Dual-Fuel Operation (LDO+Natural Gas)
2 DG Sets converted to operate on dual fuel, namely LDO for firing engine and
Natural Gas for running engine. Cost of retro-fitment of required spares was borne
by NEDO Japan, while cost of dismantling and re-installation of new spares was
borne by Tata Motors. Performance improved. The whole effort have reduced
325.79MT of LDO per year.
Energy Conservation Commitment, Policy and Set up
As per the Energy policy of our Company, the Energy Conservation activities are
given utmost importance and the awareness has been percolated upto down the
line workmen for their involvement in these activities & projects using various
methods such as;
Total Productive Maintenance (TPM) activities
Cross Functional Teams (CFT)
Self-Directed Teams (SDT).
Shop level Energy Conservation Groups (ENCON).
Low Cost Automation (LCA)
Suggestion Scheme
50
Energy Policy & Environment Policy
51
52
Certificate of Merit Automobile Manufacturing
GKN DRIVELINE (I) LTD.
Faridabad (Haryana)
Unit Profile
GKN Driveline is a UK based multinational employing 40,000 people worldwide and
has its presence in 30 countries. A market leader in the manufacture of driveshafts
for cars, it is supplying to OEM's like Maruti, Hyundai, Ford, GM, Fiat, Tata motors,
Mahindra etc.
It is also manufacturing driveshafts for three wheelers as well. GKN Driveline has
three plants in India at Faridabad, Dharuhera and Oragadam. The Faridabad plant
commenced production on 13th April 1989. It is employing 300 people. It has a
test centre at Faridabad factory. The centre is equipped with all testing facilities
related to driveshafts and houses various test rigs like functional test rig, Endurance
test rig, Fatique test rig, Backlash test rig and various boot testing machines.
53
Energy Consumption in 2010
The Energy consumption in 2010 was 84.87 Lac kWh for producing 7120 tonnes
of driveshaft whereas it was 93.46 Lac kWh for producing 6480 tonnes of driveshaft.
The saving was 8.59 Lac kWh which amounted to Rs 68.72 Lac rupees in a year
with a nominal investment of 18 Lac rupees. Out of units consumed in 2010,
64.24 Lac kWh were purchased electricity and 20.63 Lac kWh were own generation
through DG sets. 9.19% Electricity was saved in 2010 with comparison to 2009.
All this has been made possible by implementing various Energy saving projects
during the year.
Energy Saving Projects
1. Elimination of Heaters in Washing machines
Earlier washing machines used for washing component was using a washing
chemical which required heating at 60 degree centigrade by 6 nos heaters of 4KW
each. A Kaizen was initiated. Washing chemical was replaced The new chemical
works at room temperature thus eliminating the usage of heaters without sacrificing
Quality. Wattage of machine along with heaters = 10.6 KW Energy consumption
by a washing in a year = 49608 kWh This Kaizen was horizontally applied to 7 no.
washing machines. Thus energy saving was 49608*7 = 3.47 Lac kWh/year
Investment in this project was 5 Lac Rupees
54
2. Replacement of compressors with new ones having energy efficient
motors:
2 Nos compressor replaced. Earlier compressors were having 90KW motor. New
compressors were having motor of 75KW. Thus Energy saved = 2.15 Lac kWh
from 2 compressors in a year
3. Overcapacity motors replaced with Optimum rating
Overcapacity motors generally provided by manufacturers on some machines to
be on a safer side whereas the required rating is less. Judiciously these motors
were replaced with optimum Rating suitable to our requirement. This Kaizen was
done for 5 No. motors resulting in saving of 18HP. The saving achieved was 0.97
Lac kWh. Per year
55
4. Removal of crack operation in Manufacturing process in CAGE CELL
In two of our Cage cells for manufacturing child components for driveshafts, two
crack Machines were being used at the end of the operation of each cell for
checking the Crack in the component. But for last several years no crack was
reported. Thus it was decided to eliminate this process by accessing the pro and
cons but without sacrificing quality. Thus 28704 kWh was saved for one machine
by eliminating this process in Cage.
For 2 machines it was 28704*2 = 57408 kWh or 0.54 Lac kWh
Investment in this project was NIL
56
DEMAG COIL
Before
After
5. Switching off Demagnetising coil in crack machine of Tulip Cells
Unit was able to eliminate the process of removal of crack in CAGE cell. But the
possibility was not there in Tulip cells. In this Kaizen, unit was able to modify the
circuit of Demagnestising coil.
Now the coil instead of remaining ON always will get ON only when operator is
checking the Job. This Kaizen was horizontally applied for 8 machines which resulted
in energy saving of 1.09 Lac kWh per year.
57
6. Cooling tower fan replacement with FRP
Earlier cooling towers fans were of aluminium. They were replaced with FRP. This
Kaizen was implemented in 3 No. cooling towers and resulted in saving of 0.37
Lac kWh per year.
Investment in this project was Rs. 1 Lac
58
First Prize Cement
DALLA CEMENT FACTORY
Dalla, Distt. Sonebhadra (Uttar Pradesh)
Unit Profile
The Jaiprakash Associates Ltd. is 15,000 Crores well diversified infrastructural
conglomerate in India. Over the decades it has maintained its salience with leadership
in its chosen line of business like Engg. and Constructions, Cement, Power, Real
Estates, Expressway & Highways, Casting, Agro Products and Education. India's
first F-I Race track has been developed and organized by Jaypee Group.
Jaypee Group is the 3rd largest cement producer in the country. The group produces
special blend of Portland Pozzolona Cement under the brand name Jaypee Cement
(PPC). Its cement division currently operates modern, computerized process control
cement plants with an aggregate capacity of 26.20 MnTPA. The company is in the
midst of capacity expansion of its cement business in Northern, Southern, Central,
Eastern and Western parts of the country and is slated to be 35.90 MnTPA by
FY12 (expected) with Captive Thermal Power plants totaling 672 MW.
59
Dalla Cement factory was one of the Units of erstwhile Uttar Pradesh State Cement
Corporation Ltd. (UPSCCL) and taken over through global bidding Under the
Management of Jaiprakash Associates Ltd., Dalla Cement Factory has rehabilitated
an old unit of 1200 MTPD to 1500 MTPD supplied by Polysius having four stage
suspensions preheater, Kiln of Dia. 4.2 M X 68.0 M Length. Pyrosection is rehabilitated
by high efficiency top cyclone and IKN step grate Cooler. In this plant company has
installed State of Art technology of ESP and Bag Filters design for <50 mg/Nm3
dust emission. Old central discharge Raw Mill and Coal Mill is revived by High
efficiency separator and classifying liners along with weighing arrangement for
catering the requirement of raw meal and fine coal. Plant is commissioned on 28th
March 2008 and meeting all requirement of pollution control and emission level.
Plant has also installed new 4500 MTPD plant with Raw Mill and Coal Mill supplied
by M/S Polysius. The plant is equipped with high efficiency preheater, eight tracks
Polytrack Cooler with intermediate crusher. All process fans and FD fans are
equipped with Variable speed drives. Multichannel burner is provided for high flame
momentum. Raw Mill Gear Box is Equipped with DALOG System for online
monitoring form supplier premises at Germany. This state of art technology plant
is commissioned on 27th March 2009 and meeting all requirement of pollution
control and emission level.
In a very short span of time unit has not only rehabilitated an old plant but also
installed and commissioned a new unit and rejuvenate life of the region and uplifting
the society.
Apart from above, various innovative efforts have been made for further improving
energy efficiency in last 3 yrs in units. In this short span of time, approximately
three years, Unit has not only started plant but also started and established various
socioeconomic activities to uplift the level of people living nearby areas.
Energy Consumption
Energy Consumption (2008-09 to 2011-12)
60
Thermal SEC Pattern in Kcal/Kg Clinker
Electrical SEC Pattern in kWh/MT of Clinker
Electrical SEC Pattern in kWh/MT of Cement
61
Energy Conservation Achievement
Process Optimization and Maximization of Production from all sections of cement
Plant have been exercised by comprehensive process studies and its implementation
of outcome in the plant. This has improved in production of clinker from 1407 TPD
to 1477 TPD in Kiln K-4 and 3448 TPD to 4290 TPD in Kiln K-5 on an annual
Average basis in 2010-11 over 2009-10
Unit has carried out following installations, modifications and Optimization work in
plant which has resulted in reduction of Thermal and Electrical SEC.
1. Installation of Roller Press (RP-10) has increased Raw Meal
availability in turn achievement of above production in 2010-11
over 2009-10.
Investment: 20.75 Cr.
Benefits:
Power Saving of 5 kWh/MT of Clinker
Thermal Energy Saving of 27 Kcal/kg Clinker
Saving of Rs. 480 Lacs per year
Payback Period: 4.33 Yrs
2. Installation of Variable Frequency Drive in Reverse Air Fan in Kiln
K-5 bag House to reduce power consumption.
Investment: Rs. 7.76 Lacs
Benefits:
Power Saving.
Saving of Rs. 34.87 Lacs per year
3. Modification in Kiln K-4 and Kiln K-5 PH top Cyclones horizontal
portion to eliminate frequent material surging from Preheater.
Benefits:
Frequent material surging problem solved.
Saving of Rs. 200.35 Lacs per year as 4745 MT Coal Saved
62
4. Inlet louver dampers of 7 out of 9 Cooler FD Fans are removed in
Kiln K-5 for Power Saving.
Investment: NIL (In-House)
Benefits:
Power saving.
Saving of Rs 61.91 Lacs per year.
5. Optimization of Output Voltage of distribution transformers to
reduce Power Consumption in Kiln K-5 by reducing operating
voltage from 432 V to 410 V.
Benefits:
Power Saving in Kiln K-5.
Saving of Rs. 44.95 Lacs per year.
6. Three blowers of 7.5 KW stopped after increasing the slope of
Raw Mill Reject Air Slide to avoid jamming in Kiln K-4 Plant.
Benefits:
Power Saving in Kiln K-4.
Saving of Rs. 2.21 Lacs per year.
7. Manual blending of coal due to inadequate facility of blending of
various types of coal for consistency in quality of coal, in turn
efficient operation of Pyrosection and consistency in product. SD
(Standard Deviation) of Coal Ash reduced from 1.9 to 1.6 in 2010
to 2011.
Benefits:
Saving of Rs. 2061 MT of coal per annum.
8. Raw Mix Optimization by reduction in Lime Saturation Factor from
112 to 110.
63
Benefits:
16 Kcal/Kg Clinker of Thermal Energy save by optimization of Raw Mix.
9. Installation of Hi Chrome classifying liners with Controlled flow
diaphragm in Cement Mill No.2 to increase the productivity from
32 TPH to 40 TPH.
Investment: Rs. 100 Lacs
Benefits:
Productivity increases by 8 TPH.
Power Saving of Rs. 40.15 Lacs per year.
Energy Policy
64
Certificate of Merit Cement
KALYANPUR CEMENTS LIMITED
Banjari, Distt. Rohtas (Bihar)
Unit Profile
Kalyanpur Cements Limited (KCL) was incorporated in 1937. It was earlier known
as Kalyanpur Lime & Cement Works, it got its present name with effect from
March 09, 1988.
In 1989-90, the Company embarked on a modernisation-cum-expansion scheme
with the assistance of World Bank for increasing the installed capacity from 5.5
Lacs tonnes to 10 Lacs tonnes per annum based on 1,650 tonnes per day dry
process kiln with a 5-stage suspension pre-heater and pre-calciner, separate roll
presses for grinding raw materials clinker and slag. The scheme was completed in
May 94 in technical and financial collaboration with Holder Bank Management and
Consulting, Switzerland, at a cost of Rs.132 cr.
The factory of 'Kalyanpur Cements Ltd." (KCL) is located in village Kalyanpur, P.O.
Banjari, Distt. Rohtas in Bihar. Banjari is 35 Kms by road South of Dehri On Sone
Railway Station [Grand Chord Eastern Railway]. The company's operations have
shown a marked improvement in 2006-2007. The company markets about 80%
to 90% of its products in Bihar.
Now KCL intends to expand its cement production capacity from 1 MTPA to 1.15
MTPA for the near future.
Installed Capacity
Clinker: 0.55MTPA
Cement: 1.0MTPA
65
Clinker and Cement Production
354731
403354
454447
478099
0
50000
100000
150000
200000
250000
300000
350000
400000
450000
500000
550000
P
r
o
d
u
c
t
i
o
n
i
n
M
T
2
0
0
7
-
0
8
2
0
0
8
-
0
9
2
0
0
9
-
1
0
2
0
1
0
-
1
1
Year
Clinker Production
539197
597486
675744
760629
0
85000
170000
255000
340000
425000
510000
595000
680000
765000
850000
935000
P
r
o
d
u
c
t
i
o
n
i
n
M
T
2
0
0
7
-
0
8
2
0
0
8
-
0
9
2
0
0
9
-
1
0
2
0
1
0
-
1
1
Year
Cement Production
66
Specific Electrical Energy and Thermal Energy Consumption
Kalyanpur Cement Limited is committed to reduce energy consumption by
implementation of modern technology and practices for reducing its usage of
power. It installed and replaced a range of energy efficient equipments during the
year 2010-11 such as high efficient fans, motors, VFDs etc. The power consumption
during the year has decreased from 90.18 to 78.38 kWh/ton of cement.
98.13
95.62
90.18
78.38
0
20
40
60
80
100
120
K
W
H
/
T
o
f
c
e
m
e
n
t
2
0
0
7
-
0
8
2
0
0
8
-
0
9
2
0
0
9
-
1
0
2
0
1
0
-
1
1
Year
Specific Electrical Energy Consumption
788.04
754.52
785.7
770.86
0
100
200
300
400
500
600
700
800
K
c
a
l
/
k
g
o
f
c
l
i
n
k
e
r
2
0
0
7
-
0
8
2
0
0
8
-
0
9
2
0
0
9
-
1
0
2
0
1
0
-
1
1
Year
Specific Thermal Energy Consumption
67
Energy Conservation Measures Implemented during the year 2010-11
1) Replacement of low efficient compressors with high efficient
compressors
Energy Saving : 19.6 Lacs kWh/annum
Total Savings : Rs. 95 Lacs/annum
Total Investment : Rs. 150 Lacs
2) Improvement of system power factor
Total Savings : Rs. 148.5 Lacs/annum
Total Investment : Rs. 28.1 Lacs
3) Replacement of overhead crane
Total Savings : Rs. 50 Lacs/annum
4) Replacement of Process Fans
Energy Saving : 43 Lacs kWh/annum
68
5) Upgradation of Belt Bucket Elevator
6) Installation of Flyash Mechanised Silo
Energy Saving : 114 Lacs kWh/annum
Energy Management Policy
We, at Kalyanpur cements limited, Banjari are committed to optimally utilize various
forms of energy (fuel & Power) in cost effective manner to ensure conservation
of energy resources.
To meet the Above GOALS, We will strive to:-
Reduce specific energy consumption by identifying areas of energy saving
potential in the process.
Set energy consumption targets and monitor continuously.
Involve all the employees to work towards progressive improvements of
target of energy consumption.
Promote culture of awareness towards energy conservation in the organization.
Implement innovation ideas for modification improvement and upgradation of
the equipments & process for optimizing energy consumption.
Date: April - 2011 D M Sinha
Place: Banjari Sr. V P (W) & Unit Head
69
Environment
Kalyanpur Cement Limited is concerned for clean & green environment and
committed to eco-friendly processing of cement manufacturing from mining to
placement of product at users end. The entire manufacturing process is carriedout
by latest technology with controlled emission meeting the stringent national norms
through application of the latest and advanced air pollution control equipments.
Safety
Kalyanpur Cement Limited is committed for providing the safe working environment
of its employees and to work within rules and procedures that facilitate their
protection. There is a complete system of tracking accidents and causes of such
accidents. Kalyanpur Cement Limited has separate safety committee comprising
of workers and management representatives for cement plants. The key
responsibility of safety committee is to create safety awareness among all workers
suggestions, recommendations made in safety audit reports and ways to
implement them.
70
ULTRATECH CEMENT
KOTPUTLI CEMENT WORKS
Kotputli, Distt. Jaipur (Rajasthan)
Unit Profile
Kotputli Cement Works is a unit of UltraTech Cement Limited, a subsidiary of
Grasim Industries Ltd, one of the flagship organizations of Aditya Birla Group, was
setup in the year 2009. Kotputli Cement Works is located on Delhi- Jaipur National
Highway. The plant erection activities started at the end of 2006 and plant up to
clinkerization, was commissioned in March, 2009. The Unit is having rated Clinker
capacity of 2.64 MTPA (8,000 TPD). Plant is fully automated, centrally controlled,
one of the most energy efficient, eco-friendly plant with latest technology supplied
by world renowned Cement Technology Supplier, M/s KHD and Loesche - Germany.
The Unit is also equipped with Thermal Power Plant suitable for multiple fuels
(Coal, Pet Coke, and Lignite) of 2 x 23 MW capacities. Kolputli Thermal Power
Plant has a distinguished feature of being CDM registered for total carbon credits
of 21509 Tons/ year of CO2 through installation of CFBC Boiler in place of AFBC
Boiler. This is the first Thermal Power Plant under small scale sector in the globe to
achieve this milestone.
Product
Plant manufacture clinker and Cement: UltraTech OPC - 43, UltraTech OPC-53 and
UltraTech - PPC grades as per standards, published by Bureau of Indian Standards.
Kotputli Cement works is having a attached grinding unit at Panipat in Haryana.
Part of the clinker being manufactured at Kotputli Cement Works is being transferred
to Panipat for final grinding and catering to market in region.
Salient features of the plant are as given below:
One of the biggest Pre-heater towers (166 h x 37.8 w x 28.2 b).
Largest Pyro floor clinker cooler, cooling area - 196 m2 & roll crusher.
Largest Vertical Raw Mill (LM 69.6) in the world, capacity 735 TPH.
Vertical Roller Mills for Cement Grinding (LM 53.3 + 3) with rated capacity of
215 TPH in PPC.
Largest Vertical Coal Mill (LM 43.4 D) in the world for Coal / Pet coke grinding
with capacity of 50 TPH in Pet coke.
Bag house for cement mill & all pollution control equipments with Stack
emissions <30 mg/Nm3.
71
2x 23 MW Thermal Power Plant suitable for multiple fuels (Coal, Pet coke,
Lignite).
ON-LINE Cross Belt Analyzer in addition to X-ray Analyzer for efficient Quality
Control System.
Energy Consumption
With the implementation of various energy conservation measures as ongoing
practice, there is steady decline of specific energy consumption since plant
commissioning. The Specific energy consumption figures for FY 2009-2010 &
2010-2011 are shown below, which depicts reduction in energy consumption due
to plant sustained efforts to conserve it with the implementation of various energy
conservation measures & ideas to increase efficiency of equipments.
Description FY 2009-2010 FY 2010-2011
Specific Power
Consumption
kWh/MT Cement
109.04 92.85
Specific Heat Consumption
Kcal/Kg Clinker
747 714
Kotputli Cement Works have focused on all spheres of activities to identify potential
of energy consumption reduction and implemented the reduction measures. Find
below the graphs of various major processes indicating reduction in energy
consumption.
72
Energy Conservation Measures taken in FY 2010-2011
At Kotputli plant has nurtured Kaizen culture to achieve a continual improvement
in plant performance. Below mentioned are some of the initiatives which had been
taken to achieve reduction in energy consumption in all activities.
1. Implementation of Energy Monitoring System EMS to monitor performance
of all equipments.
2. Optimization of operations in all sections of plant reducing fan flows and
enhancing plant productivity.
3. Installation of Process Interface system PI System on key desktops so that
all executives/ Engineers can monitor the plant operations from their operating
desks and keep a track of performance.
4. Optimizing Raw Mill Outlet temperature to enhance Kiln feed temperature;
benefiting in reduction in specific heat consumption.
5. Modifications in plant operation logics to avoid idle running of auxiliary
equipments.
6. Modifying equipment layouts to eliminate some of the equipments; reducing
specific power consumption.
73
7. Installation of Variable frequency drives in Main bag house Fans for Dilution &
Reverse air and modification in operation logic of the fans to reduce fan
operating Speeds and power consumption in turn.
8. Various small Kaizens throughout the plant to reduce energy consumption
and to enhance equipment productivity.
9. Enhancing usage of Clinker substitute (Flyash) in PPC Cement.
74
JK LAKSHMI CEMENT LTD.
Distt. Sirohi (Rajasthan)
Unit Profile
M/s JK Lakshmi Cement Ltd (JKLC) is a member of well known JK Organisation
which is one of the largest privately owned industry group in India. Today M/s
JKLC is one of the leading cement companies in the country. The Company strongly
believes that a company can grow only when it includes largest sections of the
society in its development. Company offers a work culture where every individual
gets an opportunity to grow with the company. M/s JKLC have well defined core
values such as caring of people, integrity with intellectual honesty, openness, fairness
& trust and commitment to excellence. Company have also business vision to
become 12 Million Tones by 2012 (12 x 12) with a business mission to be
recognized as an efficient, competitive and premium cement brand.
The company is confident that with the optimal use of resources and the latest
technology, forthcoming years will take the company to even higher levels of
glory and it will live up to the rising expectation of all the stake holders in its future
journey.
75
Energy Consumption
Description Unit 2008-09 2009-10 2010-11
Installed capacity LTPA 41.975 41.975 41.975
Actual Cement
Production (excludes
cement produced
from grinding unit at
split location in
Gujarat)
LTPA 36.63 36.02 34.12
Clinker Sale
(excludes clinker
exported to grinding
unit at split location
in Gujarat)
LTPA 3.21 4.17 4.19
Total Cement
Production including
clinker sale
LTPA 39.84 40.19 38.31
% utilization % 94.91 95.75 92.46
Coal consumption Tonnes 359799 391631 373544
Electricity
consumption
Lac kWh 3153.82 3366.35 3268.84
Specific electrical
energy consumption
(excluding crusher)
kWh/Ton
of cement
80.25 80.66 80.55
Specific thermal
energy consumption
Kcal/kg
clinker
768 763 746
Coal consumption
Kg/ton of
cement
89 85 82
Sp. Elect. Energy Consumption
80.25
80.66
80.55
79.71
79.3
79.5
79.7
79.9
80.1
80.3
80.5
80.7
80.9
2008-2009 2009-2010 2010-2011 2010-2011 (excl Fly
Ash Dryer power which
was included as new
equipment)
Year
U
n
i
t
/
T
o
n
(
c
e
m
e
n
t
)
Sp. Elect.
Energy
Consumption
76
Sp. Thermal Energy Consumption
768
763
746
739
744
749
754
759
764
769
774
2008-2009 2009-2010 2010-2011
Year
K
c
a
l
/
K
g
(
c
l
i
n
k
e
r
)
Sp. Thermal Energy
Consumption
List of Energy Conservation Projects
1. Optimization of operating pressure in kiln-3 preheater blaster compressor.
2. Optimization of plant lighting voltage.
3. Interconnection of compressed air pipe lines to optimize load in on compressors
4. Removal of damper of cooler fan No-9 in Kiln-2 to avoid damper losses.
5. Arresting leakages in identified process fans to avoid false air infiltration.
6. Reduction in pressure drop across damper in CIS fan-1 of Kiln-2 and CIS fan-
2 of Kiln-3.
7. Extension of anti-swirl plate and reduction of cone gap in preheater fan of
Kiln-1.
8. Extension of anti-swirl plate and reduction of cone gap in C. A. fan of cement
mill-3 and 4.
9. Modification of PC bend to reduce fine clinker dust.
10. Installation of limit switches in cyclic valve for improving blending efficiency.
11. Reduction in false air ingress in preheater of kiln-1.
12. Modification of IKN cooler Horse-shoe of kiln-1 to avoid snowman.
13. Shifting of diaphragm in coal mill-2, to increase the length of grinding
compartment.
77
14. Modification of retainer ring to improve brick lining life.
15. Stabilization of optimized operation of fly-ash dryer:-
i) Dry fly ash connected to dry fly ash bin
ii) Replaced modified conveying line
iii) Installation of air-drier to provide dry air for instrumental operation.
16. Fine tuning of HRC control loop.
17. Reduced cement mill-2 down time by:-
i) Internal water spray control valve made operative
ii) Dedicated compressor for both bag house and separate compressor for
silo top bag-filter.
18. Installation of baffle plate at elevator separator discharge and modification of
separator inlet air path in cement mill- 3.
19. Removal of C.A. Fan damper, extension of anti swirl plate and reduction of
cone gap in cement mills Nos. 3, 4 and 6.
20. Installation of timer based low level indicator in clinker hopper.
21. Installation of 1X15 MW Waste Heat Recovery System (WHRs) to utilize waste
heat of pre-heater exhaust of Kiln-1, 2 and 3 & cooler exhaust of Kiln- 1
and 2.
22. Installation of new Chinese VRM to avoid operation of old conventional ball
mill for grinding of lime stone.
23. Conversion of cement mill No-1 ESP in to bag house.
Energy Conservation Commitment, Policy and Organizational Set Up
The management of M/s.JK Lakshmi Cement Ltd. is committed to total energy
management and prevention of energy wastage by:-
Close monitoring, control and analyze the equipment and process performance
for specific energy consumption.
Explore the possibility of cheaper alternative fuel and waste products.
Create awareness for energy conservation.
Conduct training programs for energy consumption.
78
Conduct energy audit to identify opportunities for improvement of overall
energy efficiency of the plant.
The management considers energy efficiency of equipment on the basis of cost
benefit analysis while purchasing the new equipments.
Energy Policy
79
CHUNAR CEMENT FACTORY
Distt. Mirzapur (Uttar Pradesh)
Unit Profile
Chunar Cement Factory, Unit of U.P Cement Cooperation, was started in the year
1982 with cement production capacity of 1.6 Million Ton of slag Cement per annum.
The Factory was stopped in the year 1999 due to some technical problem. The
factory remained stopped up to 2006. Thereafter Jaypee Group, " an infrastructure
conglomerate with diverse business interests ranging from Engineering &
Construction Cement, Private Hydropower, Hospitality, Information Technology
and Real Estate Development to expressways and Highways.", have acquired the
assets of U.P. State Cement Corporation Ltd. (in Liquidation) through a competitive
bidding process by the official liquidator for Uttar Pradesh and Uttara Khand. The
project has been named as UP Cement Plant and its factories are Dalla Cement
Factory, Chunar Cement Factory and Churk Industrial Complex.
80
Having taken over and to restart the Chunar Cement Factory various consent/
Approval from the State and Central Government were taken and unit started on
February 23, 2008 and since than various modifications under taken to make the
unit energy efficient. Modifications under taken are as under:
Retrofitting of Cement Mills with high efficiency Separator in place of old one for
increasing capacity and thereby reducing power consumption in all 6 Cement Mills.
- To avoid power interruption from Grid, Installed a 38 MW Captive Power Plant.
- Replaced low efficiency Mill HT drive by High Efficiency Drive.
- Low efficiency LT drive by High efficiency.
- Retrofitting of Mill Internals for increasing milling efficiency and reducing Power
Consumption.
- Installation of energy efficient lighting system.
- Highly efficient Electronic Packers in place of Old Design Packers.
- Optimization of mills for increasing Capacity and reducing power consumption.
- Retrofitting of Bucket elevators by more energy efficient.
- Installation of variable frequency drive on Separators and its Fan drive.
- Installation of High efficiency Fans in place of Low Efficiency.
- Various Interlocking provided in plant for reducing IDLE running hours.
Continuous efforts are being made for reducing Power Consumption.
Energy Consumption
81
Energy Conservation Measures at Chunar Cement Factory:
Plant has carried out following Energy Conservation Measures at our Plant which
has resulted in reduction of Electrical SEC.
Up gradation of cement mill No. 3,4,5,6 to increase the productivity from 45 to
72 TPH
i) Feeding System with Weigh Feeders.
ii) Flyash unloading System with truck, tippler.
iii) Flyash Feeding with solid flow meter at Mill inlet and outlet.
iv) Step & Classifying Liners with controlled flow diaphragm in the Mills.
v) High efficiency separator with new high efficiency fan.
Vi) New Bag filter installed.
From above said Energy Conservation Measures Electrical SEC reduced from 40.82
to 36.62 Kwh/MT of Cement.
Investment: Rs.1150 Lakh
Benefits:
Power Saving of about 4.2 kWh/MT of Cement and Rs. 470 Lakh in terms of
rupees and Productivity increased from 45 TPH to 72 TPH and Rs. 882 Lakh saved
as productivity increases.
Payback Period: 1.3 Yrs.
82
Energy Policy
JAIPRAKASH ASSOCIATES LIMITED
(CEMENT DIVISION)
CHUNAR CEMENT FACTORY
ENERGY POLICY
While ensuring continual efforts for the manufacture
of quality cement company also strive to achieve business
excellence through responsible and efficient use of Energy
both Thermal & Electrical to :-
1. Have achieve excellence in performance in the
production of cement as enshrined in
Indradhanush- The Jaypee Culture
2. Reduce specific energy consumption wherever
possible to reduce wastage of energy and fissile
fuels.
3. Reduce Green house gas (GHG) emission for better
sustainability.
SAVE ENERGY TO BE LEAN AND GREEN
83
Second Prize Chemicals
IOL CHEMICALS AND
PHARMACEUTICALS LIMITED
Barnala (Punjab)
Unit Profile
IOL Chemicals and Pharmaceuticals Limited is a chemical manufacturing industry
located in Barnala in Punjab. IOLCP began with a small project of Rs. 65 million to
manufacture 4500 TPA of Acetic Acid and has now diversified into a multi product
company to manufacture the 36000 TPA Ethyl Acetate, 18000 TPA Acetic
Anhydride, 5200 TPA Acetyl Chloride, 7200 TPA Mono Chloro Acetic Acid and
6600 TPA Iso Butyl Benzene, IOLCP is National Energy Conservation Award
Winner in continuously from 2005 to 2010 and certified with ISO: 9001, 14001
certification.
84
Specific Electrical energy Consumption
For Ethyl Acetate kWh/MT 65 62 60
For Acetic Anhydride kWh/MT 293 282 257
Specific Thermal energy consumption
For Ethyl Acetate MKCal/MT 1.60 1.43 1.35
For Acetic Anhydride MKCal/MT 2.23 2.15 2.00
Energy Conservation Commitment, policy and Set up
(Chemical Division)
Energy conservation continuous to be an area of major emphasis for IOL chemicals
& pharmaceuticals limited. Plant has been continuously making efforts to reduce
specific energy consumption by both improving the technology and energy
efficiencies. IOL consider energy management as a team approach and included
this under the Total Quality Management. Company is aware that conserving energy
is desirable not only to reduce costs but also for conserving precious & fast depleting
fossil fuel reserves and protecting the environment.
Energy Consumption: (Chemical Division)
IOLCP has identified various Energy Conservation Projects, which has resulted in
Energy Saving and contribution to the nation in preservation of precious resources
of Energy. Last three years Energy Consumption figures are shown below.
Specific Energy Consumption for Chemical Plants: (Chemical Division)
Electrical and Thermal Energy:-
85
Energy Conservation Projects Implemented during 2010-2011
1. Installation of impurities separation system in the ethyl acetate
plant for improving the reaction kinetics hence saving in thermal
energy.
Plant has installed distillation column for the separation of the impurities in the
ethyl acetate plant, By using this unit has minimized the shut down the plant
means removing the wastage of the Energy which was consuming in start up &
shut down the plant. Secondly, with the separation of impurities thermal efficiency
of the process is increased which saved the lot of amount of energy.
Steam saving = 5000 MT/Annum
Description:
Total investment, Rs. = 220 lacs
Total saving, Rs. = 80 lacs
Pay back period = 2.7 Years
2. Process Stream Flow replaced from counter to Co-current in the
radiation section of Ketene furnace of acetic anhydride Plant for
improving the process & thermal efficiency.
Plant has replaced the counter flow of process stream with the co-current process
for improving the thermal Efficiency. By using this process plant also increased the
life of the coil of the Ketene cracker & reduced the shut down's of the ketene
cracker.
Furnace oil saving = 74 Kl /Annum
Description:
Total investment, Rs. = 10 Lacs
Total saving, Rs. = 8 Lacs
86
3. Installation of High hydro Carbon feeding system in Ketene Furnace
as a fuel
HHC (High Hydro carbon) is the By product
produced in the IBB Plant & it is now using in the
Ketene furnace as a raw material in place of
Furnace oil, By using this unit increased the life
of Furnace coil ( because of better combustion
of HHC as compared to Furnace oil) & Saved
the thermal Energy.
Furnace oil saving = 200 Kl /Annum
Description:
Total investment, Rs. =10 Lacs
4. High pressure steam using in Iso Butyl Benzene plant in place of
Thermic fluid
Unit has installed the high pressure steam system
in place of thermic fluid to heating the distillation
column of Iso butyl Benzene in IBB plant. By
using this plant saved the thermal Energy.
Description:
Total investment, Rs. =25 Lacs
5. Installation of VFD's at FD fan in co-generation section to save the
power.
Plant has installed the VFD on the Forced Draft
fan of the co-generation plant for the saving of
electrical energy.
Electrical Energy saving =3 Lacs kWh/Annum
Description:
Total saving, Rs. = 15 Lacs/Annum
87
6. Installation of High efficient heat exchangers instead of
conventional Heat exchangers
Plant has replaced the conventional Shell & tube
type Heat exchanger with High efficient heat
exchangers like corrugated tubes, floating head,
Plate type heat exchangers. By using this there
is a increase in Heat transfer coefficient which
helped in saving the energy.
Electrical Energy saving = 1 Lacs kWh/Annum
Description:
7. Installation of column no 120 in acetic anhydride plant for saving
thermal energy.
Plant has installed the new distillation column no. 120 in
acetic anhydride plant for the better separation of product
with minimum consumption of thermal energy.
Description:
Pay back period = 5 Years
8. Replacement of conventional motors with energy efficient motors.
Plant has replaced the conventional electric
motors with energy efficient motors in Acetic
anhydride & Ethyl acetate Plant. By using these
motors, load on motors are decreased and
power saved.
Electrical Energy saving = 1 Lacs KWh/Annum
Description:
Total nos of motors installed = 12 nos.
Total investment, Rs. = 3.5 Lacs
Total Saving, Rs. = 5.0 Lacs/Annum
Payback period = 1 Year
88
9. Cascading of cooling tower (CT) water flow.
By installing the cascading system in Acetic anhydride & ethyl Acetate plant cooling
tower, plant has reduced the pumping cost by reducing the circulation of 500 m
3
per day cooling water. In cascading system, the outlet CT water from one heat
exchanger is used as an inlet for other heat exchanger in process for obtaining the
optimum delta of cooling water.
CT Water inlet CT Water outlet CT Water outlet
At 32 deg cel At 35 deg cel at 38 deg cel.
Electrical energy saving = 4.3 Lacs kWh /Annum
Description:
Total investment, Rs. = 5 Lacs
Power savings, Rs. = 20 lacs
Heat
Exchanger-1
Heat
Exchanger-2
10. Decreasing the elevation of coolers and condensers of Ethyl Acetate
plant for reducing the pumping cost of cooling water.
Plant has changed the position of condenser and cooler of Chemical Plant from 17
meter to 10 meter for reducing the pumping cost of cooling water pump.
Electrical Energy saving = 0.5 Lacs KWh/
Annum
Description:
Power saving, Rs. = 2.5 Lacs/Annum
Pay back period = 2 Years
The unit is committed to preserve its Environmental, Occupation Health & safety
of its employees. Health, safety and environment responsibility is fundamental to
IOLCP values. As to make IOLCP a world class company and the leader in chemicals
and Drug & Pharmaceuticals, its vision is to make measurable improvements in
the health, safety and environmental aspects of company products, services, and
operations.
89
Second Prize Chemicals
JUBILANT LIFE SCIENCES LIMITED
Gajraula, Distt. J.P. Nagar (Uttar Pradesh)
Unit Profile
The Jubilant Life Sciences Limited (formerly Jubilant Organosys Ltd.) is an integrated
Pharma and Life Sciences Company. It is the largest Custom Research and
Manufacturing Services (CRAMS) Company and a leading Drug Discovery &
Development Solutions provider out of India. The Company provides Life Sciences
products and services across the value chain, serving its customers worldwide
leveraging the global scale of its operations. The Company's Corporate Office is
situated at Noida, Gautam Budh Nagar, Uttar Pradesh. The Company has
geographically diversified manufacturing facilities at eleven locations worldwide of
which 8 are based in India and 3 in North America. Global customers in more than
sixty countries rely on company Science Active quality products.
The net sales of Jubilant Life Sciences Limited recorded a growth of 8% to
Rs. 22009 Million in 2010-11 as compared to previous year. International Business
contributed 52% to the Net Sales at Rs. 11522 million in 2010-11
Business Operation The Life Science Ingredient business comprising
Active Pharmaceutical, Ingredients (APIs), Nutrition Ingredients, Proprietary Products,
Life Science Chemicals
90
Multipurpose Production Facilities
Company multipurpose production facilities at Gajraula, strictly operating on
cGMP guidelines, are the latest addition. The facility is used to manufacture wide
range of intermediates for pharmaceutical, agrochemical and other industrial
applications. Multipurpose facilities are supported by process development, analytical
laboratories, solvent recovery and recycling facilities and incinerators for both
organic and inorganic effluents.
The company has accorded top priority for minimizing energy consumption by
putting consistent efforts towards optimization of operating / process parameters,
modernization / upgradation of plant / equipment. The main energy source is in
the form of Coal, FO, LDO, HSD and Biogas (own generation) and electricity. The
company has 100 % self-sufficiency on power front.
The annual energy bill of the company for the year 2010-11 was Rs. 18789
lacs and was 19.31% of the total manufacturing cost. Continuous efforts
have been made to bring down the figure from 25.34 % during 2009-10
indicating a significant reduction in the energy expenses as compared to previous
years, inspite of rising prices of fuels and higher production levels. This has become
possible by optimization of process parameters, technology innovation, R & D at
the plant level and through analysis of Energy data at various levels. The energy
consumption trends for the last five years as a function of the manufacturing cost
for the site have been presented in the Table below.
Note: Manufacturing cost includes DFO, IDFO, R & D, RMC, Fuel and Chemicals Cost.
Commitment
There is a full-fledged Energy Cell for close monitoring and control of Energy
consumption parameters. Losses through the distribution network are monitored
on regular basis and analyzed for preventive and corrective action.
DESCRIPTION UNIT 2009-10 2010-11
Electrical Energy Lacs
kWh
1236 1251
Thermal Energy MTOE 91391 88113
Manufacturing Cost Rs.Lacs 76821 97315
Total Energy Bill Rs.Lacs 19463 18789
Energy as
%
age of
total Cost of
Manufacturing
% 25.34 % 19.31 %
91
Energy saving proposals are prepared by the plant heads involving section incharges,
shift incharges and the workmen. The schemes are first discussed with the Head
of Engineering / Head of Six Sigma and Head of Production and once the schemes
are found feasible with 1-2 years pay back, they are forwarded to the top
management for approval. These proposals are taken in to implementation once
the top management gives the approvals.
The Energy team is functionally responsible for
1. Identification area for improvement in Yield of finished product, Specific Energy
consumption, Quality improvement and Capacity enhancement.
2. Bringing in operations ease, improving process safety and minimizing damage
to the environment.
3. Finding alternative technologies for processing fine chemicals.
4. Creating value added outlet for the waste products.
Energy Conservation Measures
Jubilant Life Sciences Limited has consistently achieved reduction in Energy
consumption at the same time increasing production and productivity consistently.
The company has improved its own earlier achieved specific consumption, norms
consistently. Various Energy Conservation schemes in house & suggested by
external agencies were taken up on continuous basis. The Major energy saving
projects/ schemes for the year 2010-11 are as follows:
Energy Conservation by high temperature refluxing in distillation columns of
MPP plant.
Energy Conservation by high temperature refluxing in distillation columns of
Pyridine and Picoline plant.
Installation of Thermo compressor to create additional steam extraction
demand by 3 TPH @8 Kg/cm2.
Installation of Desuperheater to recover the superheat of extraction steam of
TG #5.
Reduction in Power consumption by providing additional cooler in Ketene furnace
gas.
Reduction in steam consumption in Acetic Anhydride plant by vacuum distillation.
The energy consumption effort has been combined with environment management
to achieve the overall impact and the company has maintained a good track
record on the energy management front.
92
Energy Conservation Measures - Summary ( FY 2010-11)
The company has saved Rs. 354 lacs as a result of energy savings
during the year 2010-11 with an investment of Rs. 215 lacs.
Energy Policy
Company policy is to manufacture and supply products with the Lowest
specific energy consumption.
Company target to achieve this through..
Maximizing utilization of non conventional fuel.
Continuous benchmarking within the industry.
Effective management of energy resources through good operating and
maintenance practices.
Incorporating energy efficient technologies
Training & developing awareness about energy conservation programme
among employees.
Achievement of Energy Saving per year basis
Fuels S.
No.
Project Description
Power
Lacs
KWH
Coal
MT
Total fuel
(MMKcal)
Saving
(Rs. Lacs)
Investment
(Rs. Lacs)
1
Energy Conservation by high
temperature refluxing in distillation
columns of MPP plant
1460.31 5114 50 25
2
Energy Conservation by high
temperature refluxing in distillation
columns of P&P plant
1168.24 4091 40 5
3
Installation of Thermo compressor to
create additional steam extraction
demand by 3 TPH @8 Kg/cm2
1460.31 5114 50 60
4
Installation of Desuperheater to recover
the superheat of extraction steam of TG
#5
1460.31 5114 50 6
5
Reduction in steam consumption by
providing Decantor in Ethyl Acetate plant
730.15 2557 25 8
6
Reduction in Power consumption by
providing additional cooler in Ketene
furnace gas
36 3071 85 69
7
Reduction in steam consumption in
Acetic Anhydride plant by vacuum
distillation
1577.13 5523 54 42
Total 35.71 7856 30585 354 215
93
Environment Health and Safety Policy
Jubilant Life Sciences Limited is an integrated Pharma & Life Sciences Company
serving its customers globally with recognized strengths in innovation,
manufacturing and support services. Jubilant endeavors to go beyond
compliance with regulatory standards, to achieve excellence in Environmental,
Health and Safety (EHS) management practices.
We shall achieve this by:
Complying with regulatory standards on Environment, Health and Safety
Optimizing resource utilization for pollution prevention, energy & water
conservation and reduction of wastes & emissions
Identifying hazards at the design stage of the processes & services and
build appropriate measures to mitigate risks
Ensuring safe & healthy work environment with necessary infrastructure
and systems
Reviewing EHS performance for continual improvement
Promoting EHS awareness among key stakeholders
Imparting training to operating personnel
The policy will be available in public domain and it is applicable to all Indian
operations.
94
First Prize Chlor-Alkali
THE ANDHRA SUGARS LIMITED
Saggonda, Distt. West Godavari (Andhra Pradesh)
Unit Profile
The Andhra Sugars Ltd., C & F Division was established in the year 1960 at Kovvur,
W.G. District, A.P. for production of Single Super Phosphate with Sulphuric Acid
Plant having an installed capacity of 50 TPD subsequently in the year 1984, Sulphuric
Acid Plant was converted to DCDA process with 100 TPD increased capacity.
A 30 TPD Caustic Soda Plant was set up in the year 1965 and increased capacity
up to 140 TPD in the year 1980.
The Andhra Sugars Limited had installed 100 TPD Caustic Soda Plant with Energy
Efficient Membrane technology DENORA Electrolyzers at SAGGONDA Village in the
year 1997 and it had been expanded to 200 TPD with addition of 100 TPD UHDE
Electrolyzers in the year 2002 and stopped Caustic Soda production with Mercury
electrolyzers at Kovvur Plant. In the years 2005 & 2006 Caustic Soda Plant had
been further expanded stage by stage to 400 TPD with UHDE Electrolyzers at
Saggonda Village, W. G. Dist., A. P.
95
Parameter Unit 2009-2010 2010-2011
Electrical Energy kWh/ Ton of Caustic Soda 2716 2576
Thermal Energy MKcal / Ton of Caustic Soda 1.014 0.834
Energy Consumption Details and Achievements
The Table below shows the Specific Energy consumption figure of the unit during
last two years.
Energy Conservation Commitment, Policy and Set Up
1. Promote Energy saving and conservation of re-sources.
2. Comply with the Energy legislation and other regulation.
3. Promote use of Energy efficient alternatives.
4. Communicate Energy Management Policy to all employees and encourage
their involvement through training and participation.
5. Maximizing capacity utilisation.
6. To move an effort to reduce the loss continuously every year by adopting
effective Energy Management System.
During the period 2010-2011, the unit implemented several energy conservation
measures. Annual saving of around Rs. 777 Lakhs in 2010-2011 was achieved
with the investment of Rs. 4068 Lakhs.
Major Projects Implemented during 2008 2010
Energy Savings:
1) Installation Variable Frequency Drives for Various Brine Pumps:
Andhra Sugars has installed 7 nos of VFDs for Various Brine pumps to maintain
Pressure & Tank levels in place of Control valves. This way energy is saved by
reducing Motor speed from 2950 rpm to about 2000 rpm. This saves energy
required for running the motor and also meeting the requirement.
96
Before VFDs Installation:
4 Pumps Consumption: 9,50,400 kWh
3 Pumps Consumption: 3,56,400 kWh
Total Consumption : 13,06,800 kWh
After VFDs installation
Power Consumption : 7,92,515 kWh
Power Saving in KWH : 5,14,285 kWh
Saving in power after
installation of VFDs : Rs. 18 Lacs/ Annum
Investment for the VFDs : Rs. 16 Lacs
Pay Back period : 0.9 years
2) Auto On/Off Provision to the Cooling Water Fans:
Plant has provided AUTO ON/OFF provision to 5 nos of Cooling Tower fans based
on the Cooling water Temperature. Previously all the cooling water fans are used
to run continuously irrespective of temperature. After providing the AUTO ON/
OFF provision Cooling tower fans are getting stopped once the temperature
reaches to the 30 Deg. C and again getting started automatically once the
temperature reaches to 32 Deg. C. Due to this Energy is being saved as detailed
below.
Power Consumption Before auto ON / OFF
: 8,71,200 KWH
Power Consumption after auto ON/ OFF
: 7, 28,343 KWH
Power Saving due to the above in KWH
: 1,42,857 KWH
Saving in Power
: Rs. 5 Lacss / Annum
Additional Investment for the above
: Rs. 2 Lacss
Pay Back Period
: 5 Months
3) Clarified Brine System Modification:
Plant is expanded stage by stage from 100 TPD to
400 TPD Caustic Soda production from 1997 to
2008. Due to this 2 streams of Brine Circuit was
provided with 50HP Motors. But it was observed
that there is still capacity in the Pumps to give more
flow. Hence, plant has interconnected the 2 streams
and operating with only one pump.
97
Power Consumption for 2 Pumps (Each 50 HP) :2,77,200 KWH
Power Consumption for Single Pump : 1,62,914 KWH
Power Saving : 1,14,286 KWH
Additional Investment : NIL
Saving in Power : Rs. 4.0 Lacss
4) New Energy Efficient Membranes Replacement:
Plant has replaced the High power consumed Membranes with low power consumed
Membranes during the normal coarse of Membrane replacement to reduce the
Power Consumption and to increase the Efficiency of the plant in the year 2010.
Due to this Saving in Power is : 14, 28,570 KWH
Saving in Cost due to above : Rs. 50 Lacss / Annum
Savings due to Higher Efficiency : Rs. 20 Lacss /
Annum
Investment : Rs. 2.5 Crores
5) Replacement of Electrolysers:
Andhra Sugar has installed 100 TPD plant in 1997 with Bi-polar Electrolysers. As
the Power consumption in those electrolysers is very high, it was decided to
replace those electrolysers with latest high efficient and low power consumed
electrolysers in 2010.
Due to this saving in Energy are as follows:
Power Saving in KWH :100,00,000 KWH
Saving in Power due to the above
: Rs. 3.5 Crores / Annum
Saving due to higher efficiency
: Rs. 2.5 Crores/ Annum
Additional Investment : Rs. 34.0 Crores
6) Recoating of Old Electrodes:
Plant has installed 100 TPD plant of in the Year 2003, the Electrodes are needs to
be recoated once in every 8 years. In that, plant has recoated some of the
Electrodes in the year 2010 for better performance in terms of Power consumption
and Current Efficiency. Due to this recoating saving in Energy consumption is as
follows:-
Power Saving in KWH :17,14,286 KWH
Saving in Power due to the above
Savings due to higher efficiency
Additional Investment : Rs. 4.0 Crores.
Total Investment and Savings during the year 2010 2011 for Energy
Conservation:
Total Investment : Rs. 40.68 Crores
Total Savings due to the above modifications : Rs. 7.77 Crores / Annum.
98
First Prize Consumer Goods Manufacturing
CARRIER AIRCONDITIONING &
REFRIGERATION LIMITED
Gurgaon (Haryana)
Unit Profile
Carrier Airconditioning & Refrigeration Ltd is well known for its energy management
performance and commitment towards adequate protection of people & natural
resources by making Environment Health & Safety as an integral parts of its business
plan.
Carrier India was incorporated in 1992 to meet the growing demand of airconditioning
appliances in the Indian market
Carrier India has made significant improvement in the energy reduction over a
period of ten years by implementing various projects, Kaizen & Value Stream Map
events to demonstrate their commitment towards natural resource conservation.
99
Carrier India has its own Design, Development and Manufacturing facility of
Residential and Light commercial air conditioners as well as chillers and air handling
units with over 500 employees in a 224,000-square-foot facility and an annual
capacity of 0.5 million units.
Energy Consumption
Carrier India's vision of sustained and continuously improving energy management
has resulted in setup of environment friendly operations. Further, Carrier India's
broad vision and commitment towards energy management has resulted reduction
in specific energy consumption over a period of five years. Last two years (2009 &
2010) specific energy consumption figures are shown for air conditioning unit:
100
9.53
8.38
0
2
4
6
8
10
12
2009 2010
12
Specific Electricity Consumption kWh/Box
0.00052
0.00044
0
0.0002
0.0004
0.0006
2009 2010
16
Specific Thermal Consumption
Million K Cal/Box
Description Unit 2009 2010
Annual Production Box* 294167 351934
Electricity Consumption KWH 2802368 2947802
Specific Electrical Consumption KWH/Box 9.53 8.38
Thermal Energy Consuption Million K Cal 154.2 155.1
Specific Thermal Energy Consumption Million K Cal/Box 0.00052 0.00044
Reduction in Specific Electricity Consumption % 12
Reduction in Specific Thermal Energy Consumption % 16
Cost Saving - Electrical Rs (Lakhs) 14
Cost Saving - Thermal Rs (Lakhs) 6.3
Achievement of Annual energy savings in 2010 Rs (Lakhs) 20.3
*1 box = 1 ton
Energy Conservation Projects
1. Modifications of Existing Lighting Equipment: Replacement of higher energy
consumption lights (metal halide/sodium vapour conventional lamp) with TL5
energy efficient lights on shop floor.
2. Retrofitting/Minor Modifications of existing equipment - Low investment options:
Replacement of ordinary copper ballast tube-lights with energy efficient ballast,
reflector and T5 light
3. Specific Energy Reduction : Productivity Improvement in Manufacturing Process
Paint Shop :
1) Hanger Modification to accommodate the more components for painting.
2) Conveyor speed increased from 1.67m/min to 2m/min, by providing the
variable frequency drive.
101
4. Energy reduction: Avoidance of additional shift to meet requirement : Kaizen
event done on DFS assembly line to increase the shift production numbers by
17% with same manpower and line, resulting in avoiding 27 shift running in 6
months time. Thus achieved the increased customer demand with reduced
shift running and saving related to utility, lighting & air cooling.
5. Productivity improvement: through value stream mapping followed by kaizen
event : Value stream mapping followed by the kaizen event resulted in improving
the line productivity by 40% on Ducted. This was the line which used to run in
2 shift operation for the full year where as the rest of the plant runs in single
shifts for seven months. This event involved line balancing, material flow
improvement, sub assembly improvement and turn back reduction. Energy
reduction resulted in avoidance of second shift for the plant for approx. four
months resulted in saving related to equipment running, utility, lighting & air
cooling.
6. The energy reduction achieved through elimination of bottleneck from the
window room AC assembly line. The tools used were load chart balancing for
process cycle time and kaizen improvement. Earlier Unit used to run two
assembly line to meet the month requirement for four months of peak season
thus consuming more energy. Through the application of load chart balancing
plant found three bottlenecks, which were cleared by kaizen and increased the
shift production by 17% and avoided extra line running. Resulting in energy
reduction in equipment running, utility, lighting & air cooling.
Modifications of Existing Lighting Equipment
Higher energy consumption
Produces Humming sound
Start up time 5-10 minutes.
Flickers every time when switched
ON. Every flicker eats away the life
of lamp.
Low P.F. around 0.5
Lumen deprecation around
Low energy Consumption
Long life, which ensures zero
maintenance costs
Effective visibility of light output
No light Pollution - red or ultra -
violet - radiation
Environment friendly operation
Instant switch on Lower
maintenance cost.
102
Replacement of higher energy consumption lights (metal halide/sodium vapour
conventional lamp) with TL5 energy efficient lights
Total Investment Rs 3.4 Lacs
Energy Saving 21054 kWh
Energy Cost Saving Rs. 1.47 Lacs
Retrofitting/Minor Modifications of existing lighting equipment
Higher energy consumption
Ordinary copper ballast
Starter required
4 nos tube rod
Old design reflector
Low Power Consumption
Energy efficient ballast
No starter required
2 nos tube rod
Modified reflector
Lower maintenance cost.
Replacement of ordinary copper ballast tube lights with energy efficient ballast,
reflector and T5 light
Total Investment Rs. 1.12 Lacs
Energy Saving 23400 kWh
103
Painting Process Hanger Modification and Installation
Only One Component per
Hanger
Conveyor running at Fixed
Speed of 1.67 Meter / Minute
Four Component per Hanger
Conveyor Speed change to
upto 2 Meter /Min
Total Investment Rs. 1.00 Lacs
Energy Saving Electricity 12853 kWh
Energy Saving Thermal 27 KL
Energy Reduction : Kaizen event - DFS Line
104
Idle carts during vacuum process
[10 nos.]
Wastes in processes
Production capacity of 300 units/
shift
Line running at 80sec Takt time
Idle carts used for value addition,
downstream operations clubbed
with vacuum process to increase
number of carts with value addition
Wastes for waiting and motion
reduced with material feeding cycle
improvement
Production capacity of 350 units/
shift achieved
Line running at 65sec Takt time
Energy Reduction : Value Stream Mapping DS Line
1. Un balance production line load
2. Wastes in material flow
3. Production capacity of 45 units/
shift
1. Line balancing done
2. Material flow system improved
with new designed trolleys and
planned inventory on line
3. Production capacity increased to
65 units/ shift
Energy Saving Electricity 32728 kWh
105
The energy reduction achieved through elimination of bottleneck from the window room
AC assembly line. The tools used were load chart balancing fro process cycle time and
kaizen improvement. Earlier we used to run two assembly line to meet the month
requirement for four months of peak season thus consuming more energy. Through the
application of load chart balancing we found three bottlenecks, which we cleared by
kaizen and increased the shift production and avoided extra line running. Resulting in
energy reduction in equipment running, utility, lighting & air cooling.
Energy Saving Electricity 30670 KWH
Energy reduction : Process load chart balancing on RAC assembly
The Environment, Health & Safety Policy, which is the fundamental guiding policy
of Carrier India lays stress on operating environment friendly facilities and designing
and manufacturing safe and environmentally friendly products. To quote the
Managing Director Mr. Gaurang Pandya of Carrier India, "EH&S is one of the
foundation elements on which company business is built. It will always remain a
key element of value system. Company vision is to provide employees a safe and
healthy workplace and operate environmentally friendly facilities. Company would
like to ensure all its employees and partners go home safely to their families'
everyday."
106
Second Prize Consumer Goods Manufacturing
LG ELECTRONICS INDIA PVT. LTD.
Greater Noida (Uttar Pradesh)
Unit Profile
LG Electronics India Pvt. Ltd., a wholly owned subsidiary of LG Electronics,
South Korea was established in January, 1997 after clearance from the Foreign
Investment Promotion Board (FIPB).
The trend of beating industry norms started with the fastest ever-nationwide launch
by LG in a period of 4 and 1/2 months with the commencement of operations in
May 1997. LG set up a state-of-the art manufacturing facility at Greater Noida,
near Delhi, in 1998, with an investment of Rs 500 Crores. This facility manufactured
Colour Televisions, Washing Machines, Air-Conditioners and Microwave Ovens. During
the year 2001, LG also commenced the home production for its eco-friendly
Refrigerators and established its assembly line for its PC Monitors at its Greater
Noida manufacturing unit. The beginning of 2003 saw the roll out of the first locally
manufactured Direct Cool Refrigerator from the plant at Greater Noida.
The Greater Noida manufacturing unit line has been designed with the latest
technologies at par with international standards at Korea and is one of the most
Eco-friendly units amongst all LG manufacturing plants in the world.
The year 2001, witnessed LG becoming the fastest growing company in the consumer
electronics, home appliances and computer peripherals industry. The company had
till the month of October 2001 achieved a cumulative turnover of Rs 5000 Crores in
India since its inception in 1997, making it the fastest ever Rs 5000 Crores clocked
by any company in the Indian consumer electronics and home appliances industry.
Having achieved this milestone, LG achieved another benchmark with the first ever
sales of One Lac ACs (Windows and Splits) in a calendar year.
LG Electronics India is the fastest growing company in the consumer electronics,
home appliances and computer peripherals industry today. Recently, LG Electronics
India Pvt. Ltd. crossed a record $100 million export turnover figure. This achievement
is a major milestone for the company and has consolidated LG's position not only
in the domestic but the international markets as well.
The company has achieved a turnover of Rs 7500 crore in 2005
107
LG Electronics pursues its 21st century vision of becoming a true global digital
leader who can make its customers worldwide happy through its innovative digital
products and services. LG Electronics aims to be among the top 3 Electronics,
Information, and Telecommunication firms in the world by 2010.
Energy Consumption
By Continuous innovation and implementation plants has reduced our energy
consumption drastically.
LG Electronics has been actively pursuing the process of energy conservation since
its inception. Over the period between 2009 ~2010, the company has aggressively
implemented major as well as minor projects. Statistically, it would be safe to
mention about 23 mid-sized to major proposals, workmen's innovations, overseas
benchmarking exercise, BEE guidelines (such as ESCO concepts), Benchmarking
other major institutes through common platform provided by CII, TERI etc resulting
into total saving of over Rs 215.91 Lacs with an investment of Rs 180.68 Lacs. This
has resulted in a reduction of 11% in specific electrical energy consumption and
27% in specific thermal energy consumption over the period.
Description Units 2009 2010
Total Electricity
Consumption
Lacs kWh 417 390.94
Annual Prod Quantity Lacs 86.02 90.68
Specific Energy
Consumption -
Electrical
kWh/product 4.84 4.31
Total Thermal Energy M Kcal 13,558 10483
Specific Energy
Consumption -Thermal
M
Kcal/product
0.0016 0.0012
Electrical Thermal
Year Specific Energy
Consumption -Electrical
%
Reduction
over 2009
Specific Energy
Consumption -
Thermal
% Reduction
over 2009
Remarks
2009 4.84 0.0016
2010 4.31 -11% 0.0012 -27%
108
1. Electrical Energy Saving
a. Installation of Centralize Air Conditioner
Before Status: Ductable type air
conditioners were used at shop floor area
cooling.
After Status: Energy efficient chillers
installed for air conditioning.
Investment: Appx Rs 112 Lacs
Savings /Annum: Appx Rs 43.68 Lacs
b. Energy Efficient Cooling System for packing Areas
Before Status: Earlier we were using air
conditioners for packing area cooling.
After Status: Now Energy Efficient Cooling
system has installed.
Investment: Appx. Rs. 12 Lacs
Savings / Annum: Appx. Rs. 9.36 Lacs
2. Electrical Energy Savings:
a. Energy Efficient Blowers
installation at Comp Plant
Pickling m/c.
Before Status: Earlier compressed air was
used for component drying through nozzles
at pickling m/c.
After Status: Energy Efficient blowers
installed to replace compressed air for
drying.
Savings / Month: Appx. Rs. 21 Lacs
109
b. Installation of Air knife system at comp plant paint shop
Before Status: Nozzles were used for
compressed air blowing at paint shop for
component drying.
After Status: Air knife system installed to
replace nozzles.
Investment: Rs 2 Lacs
Savings / Annum: Rs 8 Lacs
c. Installation of Energy Efficient Lights at store & Finish Good Area.
Before Status : Earlier at store , finish
good area T8 lights were used.
After Status: We have installed energy
efficient T5 lights at all these areas.
Savings / Month: Appx. Rs. 6 Lacs
d. Burner's Efficiency improvement
Before Status: Earlier there was no system
to check burner efficiency due to this
sometimes burner operated at low efficiency.
After Status: Flue gas analyzer were
purchased & monthly checking was started.
Due to this now air fuel ratio & excess air is
well maintained.
Investment: Nil
Savings / Annum: Appx Rs 31.30 Lacs
44.3% 80.3% Efficiency
37.2C 36.7C Ambient Temp.
203C 264C Flue Gas Temp.
646% 52% Excess Air
7 13 CO ppm
2.2 9.3 % CO
2
18.3 6.8 % O
2
Baking Oven Dry Oven Parameters
44.3% 80.3% Efficiency
37.2C 36.7C Ambient Temp.
203C 264C Flue Gas Temp.
646% 52% Excess Air
7 13 CO ppm
2.2 9.3 % CO
2
18.3 6.8 % O
2
Baking Oven Dry Oven Parameters
110
Other projects implemented during 2009-2010
Comp Plant High Pressure Air Charging Valve open and close automation.
Installation of VFD at PU foaming machines at Ref Plant
Light pipe installation at Packing & Office Area
Energy Saver Panel installation at Lighting Load at SS2
Timer Installation on Shop Floor AHU's for auto ON/OFF during Lunch/Dinner
breaks.
All plant Power factor improvement to 0.994
Compressed Air Saving at 4 P Bender machine w/m Line by change in PLC
Logic
Finger valves provided at W/M Line riveters to eliminate air wastage.
Air Control valve installation to cut Compressed air during line stoppage at
Comp Assy Line.
Air Control valve installation to cut Compressed air during line stoppage at CTV
Line.
Wire looping at sensor operated door for cooling saving at comp assy line.
W/M Line- Box Flap Folding Modified to prevent vacuum off air release
Installation of 1.2 KWP Solar Power Generation System
Implementation of Zero Air Leakage Program
Energy Conservation campaign
Earth Hour observation
Power Management by switching off the Transformer based on load .
Energy Patrolling during Night.
Top Management Commitment
LG Electronics has maintained a steady growth in terms of turnover, and profits. A
good part of the profits is dedicated to the cause of energy conservation.
The top management commitment is shown through various activities like monthly
shop floor innovation rewards, Rolling Trophy for the best shop floor area which
includes award for all members, special MD Unique Award for any major energy
saving project.
There is a continuous review of energy initiatives by the top management and
sanctions are made to ensure its success. Energy conservation is a salient pillar in
the forums like LE-10 (10 pillars of Loss Elimination), Fi-11 (11 pillars of Factory
Innovation), CI review (Cost Innovation i.e savings) which are reviewed by the
111
management along with the middle management every month. Further, every
departments head has energy conservation as their performance evaluation criteria.
The management insists on audit by external experts as well as overseas energy
audit teams. Their recommendations are used as guidelines for further
improvements.
The commitment for energy saving is regularly demonstrated by each & every
employee by not only giving suggestions but also rigorously following the norms
set from time to time. Induction for new joinees has a special feature on Energy
Conservation and the norms to be followed. This, supported by visuals all over the
factory, sets trend from the first day. This is also carried forward by the routine
internal audits by managers, specially at night for auditing equipment / air leaks
while the machines are idle etc.
Energy Conservation Policy
The policy for ISO 50001:2011 focuses on energy conservation. Further, the top
management is guided by the head office drive from Seoul, S Korea. The regular
reviews and audits are part of the policy and commitment by the management &
employees.
112
Certificate of Merit Consumer Goods Manufacturing
GODREJ & BOYCE MFG. CO. LTD.
Appliance Division
Khandala, Distt. Satara (Maharashtra)
Unit Profile
Godrej group is one of the largest privately held diversified industrial Corporations
in India. The Company celebrated its centenary in 1997. Today Godrej Group is
leading into many manufacturing activities.
M/s Godrej & Boyce Mfg. Co. Ltd. (Appliance Div) is a Flagship division of Godrej
Group. Godrej Appliances has it's manufacturing set up at Wing-Shirwal, Maharashtra
& Mohali, Punjab.
Wing-Shirwal is a green field project of Godrej & Boyce - Appliance Division
commissioned in April 1996 to manufacture Washing Machines.
Unit also shifted its refrigerator manufacturing facility from Mumbai to Wing-Shirwal
in 2005. Presently the wing-Shirwal plant has an installed plant capacity of 9 Lacs
refrigerators and 3 Lacs washing machines per annum.
113
70%
30%
Power &
fuel cost
Other
conversion
cost
78%
22%
Power Fuel
Graphical Representation of Energy Consumption.
Power & Fuel cost as a Power & Fuel cost
% of conversion cost
Plant has an Integrated Management System with certification in ISO 9001- 2008,
ISO 14000 and OSHAS 18000 from TUV India.
Implementation methodology
Implementation methodology for energy conservation drive is as below.
1. TOP- DOWN approach
Mission on sustainable growth (MSG) initiative
MSG is CII's initiative to reduce resource intensity & emissions, discharge &
waste generation every year.
External energy audits
Organization conducts external energy audits at regular intervals.
Target setting
Every year management takes stretch targets to reduce energy
consumption.
2. Total Employee Involvement
Every employee of the organization is involved in the energy conservation drive.
There are TWO platforms in the organization PMO (Project Management Office) &
Kaizen drive.
In PMO Plant focus on targeted & big incremental improvements. These projects
are of one year horizon. Cross functional team of management cadre is involved.
In Kaizen drive focus is on small improvements which can be implemented in a
week to month period. Mainly it is operator driven.
114
Category Approach
Power Reduce variability
Fuel Use renewable source
Power
Since power cost contributes to 78% of total energy consumption unit give more
attention to reduce specific power consumption. But as mention above we are
following unique approach of making power consumption truly variable with respect
to production & by focusing on reducing fix power consumption element.
By taking various initiatives plant could reduce fix power consumption element
drastically & as a result specific power consumption has also reduced.
Specific Power Consumption Fix & variable power percentage
in kWh/Appliance
Variable power consumption Fix power consumption
Energy Conservation measures implemented in the year 2010-11
1. Reduction in power consumption of motorized load.
Optimized motor speed by VFDs, replaced high head pump with low head pump,
optimized pump header & pipeline size, down sizing of motors in accordance to
actual requirement.
Investment - Rs. 1.0 Lac
First year savings - Rs. 9.08 Lacs
Energy Conservation a unique approach
Plant is following a unique approach for energy conservation.
115
2. Use of small size hydraulic pump & removal of accumulator from
injection molding machines.
In injection molding m/cs, accumulator is provided for molding of bigger size
components. Since plant components are small so it doesn't require accumulator,
so it was removed it & also reduced hydraulic pump size.
Before After
Investment - NIL
3. Reduce power consumption of Vacuum forming machines.
Reduction in cycle time of vacuum forming machines & provided separate switch
for each heater to keep unwanted heaters off. Changed machine circuit to switch it
off automatically during lunch break.
Investment - NIL
4. Replacement of old vacuum pumps by new energy efficient pumps.
Investment Rs. 1.5 Lacs.
First year saving - Rs. 1.11 Lacs
Before After
116
5. Reducing power consumption of cooling towers
To reduce power consumption plant changed old pumps by new energy efficient
pumps, clubbing of cooling tower for optimum loading.
Investment - Rs. 2.5 Lacs.
First year saving - Rs. 5.19 Lacs
Before After
6. Elimination of transformer losses.
Unit is keeping one transformer off during night time & running night shift only on
one transformer. This has avoided transformer losses.
Investment - NIL
First year saving - Rs. 6.73 Lacs.
7. Optimum usage of hydraulic pumps in injection molding machines.
Injection machines are provided with TWO hydraulic pumps for molding of bigger
components. Unit changed PLC, modified programme & kept one pump off during
molding of small components.
Investment - NIL
First year saving - Rs. 4.2 Lacs.
117
Energy Policy
118
First Prize Dairy
MOTHER DAIRY
Patparganj, Delhi
Unit Profile
Mother Dairy, Delhi a subsidiary unit of National Dairy Development Board was set
up under the Operation Flood Project. The Dairy was commissioned on 4th
December 1974 and is located at Patparganj, Delhi.
Mother Dairy commands 40% market milk share in the organized sector in and
around Delhi, primarily because of consistent quality and service in whatever be
the crisis - floods, transport strike, curfew etc.
With a view to separating the commercial activities from developmental activities,
the NDDB merged Mother Dairy and the Fruit & Vegetable project into a wholly
owned company named Mother Fruit & Vegetable Pvt. Ltd (MDFVPL) in April,
2000.
119
Mother Dairy has a state - of the - art manufacturing facility i.e. fully automated
milk plant with best of Dairy Equipment at Patparganj in Delhi spreading over 39
acres of land and the entire bulk vended milk and ice cream are manufactured at
this site. It is one of the largest liquid milk plants in Asia with 768 captive retail
outlets in NCR popularly called "Mother Dairy Booths".
Mother Dairy has taken up the concept of Total Preventive Maintenance (TPM)
whole heartedly. The Nos. of employees involved in Kaizens and the Nos. of
Kaizen per employee are very encouraging.
Over the years Mother Dairy has grown in size and strength and is undisputedly
number one in all the three categories it operates in i.e., bulk vended milk (11
lac litres/day), pasteurized pouch milk (20.0 lac litres/day) and ice creams
(35,000 litres/day).
Mother Dairy does not just care for its customers, it also cares for the environment
people live in Bulk Vending System that is unique to Mother Dairy is an effective
and environment friendly system of milk distribution. It also maintains the cold
chain from federation to Mother Dairy customers.
In the process of adopting environment friendly and energy efficient technology,
Mother Dairy switched over to a new refrigeration plant with screw compressors
resulting Ammonia as refrigerant replacing Freon, uses PNG in Boilers, Solar water
Heating System, Rain Water Harvesting System to arrest decline of ground water
levels. Also biodegradable organic solid Waste generated is converted into Vermi
Compost using red worms.
Mother Dairy has 800 employees including all levels with educational qualification
varying from school education to masters in different streams i.e. Technical &
other professional areas, who undergo rigorous & regular training programmes on
shop floor, inter-personal skills and group activities with strong emphasis on
employee empowerment at every level so as to improve upon the overall standards
of operations in terms of shop floor skills, team work, productivity, safety and
enhancement of quality.
2009 2011
During the last two years Specific Energy figures has shown below depicts continual
reduction in specific energy consumption due to its sustained efforts to conserve
it with the implementation of various energy conservation measures and ideas to
increase efficiency of equipments
120
Year Product Specific % Specific %
Electrical Reduction Thermal Reduction
Energy over Energy over
Consumption 2009 - Consumption 2009 -
kWh/ tonne 2010 Million 2010
kCal/ tonne
2009 - 2010 Milk 34.3655 -- 0.018259 --
2010 - 2011 Milk 33.514 2.477 0.015696 14.03
Specific Electrical Energy Consumption in
KWH/Tonne
2009 - 2010,
34.3655
2010 - 2011,
33.514
33
33.2
33.4
33.6
33.8
34
34.2
34.4
34.6
2009 - 2010 2010 - 2011
Years
S
p
.
E
l
.
E
n
.
i
n
K
W
H
/
T
o
n
n
e
Series1
Series2
Specific Thermal Energy Consumption in Million
KCal/Tonne
2009 - 2010
0.018259
2010 - 2011
0.015696
0.014
0.015
0.016
0.017
0.018
0.019
2009 - 2010 2010 - 2011
Years
S
p
.
T
h
.
E
n
.
C
o
n
s
p
.
M
K
c
a
l
/
T
o
n
n
e
Series2
121
Thermal Energy Conservation Measures
Reduction in number of Drain traps on
steam headers from boiler to ICP to
reduce loss of steam.
There were 9 nos. of drain traps on steam
line (224 mtrs of Steam pipe line) from
Boiler house to ICP. All the 9 traps
condensate discharge is collected and
returned to flash vessel and steam pump
for sending to Boiler feed water tank. As
such each installed trap can handle nearly
250 Kg condensate per hour so seven
numbers of trap have been made unoperational to avoid any malfunctioning with
very low load. The condensate load on the steam line having 224 mtr line having
80mm dia at 7 bar pressure is around 58 Kg/Hr.
Total Saving of PNG / yr = 40646.4 Nm
3
Total Saving/ yr in Rs. = 12.9/- Lacs
Investment - Nil
Installation of Auto Blow Down System based on
specific time interval in place of manual/
conventional blow down system.
Timing have been reduced to 30 sec./hr from 1 min/hr.
Pipe dia-20mm
Flow of water -180 ltrs/30 sec
Energy savings/yr = 35.57X365 = 12985 Nm3
Total saving realized in Rs. /yr = 4.13 Lacs
Investment = 0.08 Lacs
Replaced the Steam Traps at various
locations from TD type to Float Type to
enhance the recovery of Condensate Water.
Condensate recovered / day = 1233 Kg
Thermal Energy saved / yr = 36000Nm3
122
Provided proper insulation to the feed
water storage tanks and lines of feed water
from Solar Plant to Boiler Plant to improve
feed water temperature of boiler.
Temp difference (delta T) achieved = 16 deg.
Energy saving /yr = 27482 Nm3
Recovery of plant steam condensate
It recovers the hot condensate and also saves
the feed water along with Chemicals.
Condensate recovered = 17200 ltrs
Energy Saved / yr. = 33975 Nm3
Electrical Energy Conservation Measures
Provided Plant Lighting Supply through ES-
25 System (Energy Saver) for lighting and
mixed load which Optimize the voltage thus
resulting saving in consumption.
Energy saving / year = 210240 KVAH
Investment = 12 Lacs
1. Dairy unit has replaced 250 W MH high Bay
with 4X28 W and 2X28 W high Bay luminaries
at different locations.
2. Replacement of 150 W MH medium Bay with
2X28 W T5 luminaries at different locations.
3. Replacement of 4X20 W recess mount with
4X14 W T5 luminaries at different locations.
4. Replacement of conventional A.C.s with 4/5
star rated A.C.s at different locations.
5. Replacement of Conventional Ceiling Fans
with 5 star rated ceiling fans at different
locations.
6. Installation of Motion / Presence sensors at
different locations.
123
Replacement of Conventional motors by Energy
Efficient motors.
Rated Capacity of motor - 22 KW
Saving realized / year - 13140 kWh
The impeller of Oversized Condenser Water Pumps were
trimmed which resulted in energy saving.
Avg. Power Consumption excluding VFD - 42.4 KW
Flow of pump (Based on Curve) - 400 m3/hr
Measured head, valve in open condition - 19 mtrs
Power cons. Of pump after trimming to match
Actual flow of 400 m3/hr (Eff motor-92% eff pump -70%) - 32.2 KW
Operating hours/yr - 17200 hrs
Energy saving after installing new pump - 176197 kWh /yr
Investment = 1 Lacs
Installation of VFD's at different locations:-
1. Installation of VFD for Dispatch Pumps - 2 nos
2. Installation of VFD for RCM Transfer Pumps - 2 nos
3. Installation of VFD for Blower motor for boiler - 1 no
4. Installation of VFD for feed Pumps - 5 nos
5. Installation of VFD for Condenser Pumps - 2 nos.
7. Replacement of Conventional motors by energy efficient motors.
8. Installation of programmable timers for operation of street lights.
Total saving realized in Rs./yr = 14.51 Lacs
124
Second Prize Dairy
MYSORE DAIRY
(A Unit of Mysore Chamarajanagar Dist. Milk Union Ltd.)
Siddarthanagar, Mysore (Karnataka)
Unit Profile
MYSORE DAIRY, A UNIT OF Mysore - Chamarajanagara District Co-Operative Milk
producers. Union Limited registered under the Karnataka co-operative act has
been commissioned in the year 1980. The rated when commissioned was 60
TKPD (Thousand Kgs per day) and was subsequently expanded to 180 TKPD by
NDDB under the turn key project in the year 1996.
The dairy receives milk in cans with temperature of 270 C to 320 C from village
co-operatives located in the districts of Mysore and Chamarajanagara and in tankers
with temperature of 50C to 60C from the three chilling centers located at Hunsur,
Kollegala and Chamarajanagara towns. Also the dairy receives milk with
temperature of 50C to 60C in tankers from 49 Bulk Milk Coolers. These bulk milk
coolers have been installed to maintain the initial quality of raw milk and also to
reduce the intake of energy intensive raw materials
The dairy processes the milk and packs the following qualities of milk:
1. Toned milk with 3.1% Fat & 8.5% Solids not fat
2. Standardised milk with 4.6% Fat & 8.5% Solids not fat
3. Double toned milk with 1.6% Fat & 9% Solids not fat
4. Homoginised Cow milk with 3.6 % Fat & 8.5 % SNF
In addition, the following milk products are manufactured in smaller quantities
Ghee
Butter
Curd
Peda
Mysore pak
Sweet Lassi
Butter milk Badam Burfi
Cashew Burfi
Nandini Bite
The dairy markets milk and milk products under the trade name "NANDINI" a
registered trade name of "Karnataka Milk Federation", the apex institution at the
state level.
125
The technical and financial assistance comes from National Dairy Development
Board, Anand, Gujarath under operation flood and vision schemes.
The one of the market developing activities taken up by the dairy is Creating
awareness about milk in public especially among the women folk and school children
through "ARIVU" programs by trained employees and the dairy has conducted
1000+ "ARIVU" programs more than 150000 people took part and also under
the consumers and school children awareness programs 75000 members
participated and 20000 houses were visited under door to door campaign till
2010-11. For the first time under consumer awareness program
Mysore Dairy has started Mini Bus Service to bring Consumers from different
areas of the town & talukas to Dairy & explain them the activities of the
Dairy as well as brief them on Saving Energy in house hold usage. Under
this program during around 8000 consumers visited the Dairy. One of the agenda
in all the above programs was educating the participants on energy conservation.
The cartoon film on "Save Energy" was screened at the school children programs.
And Mysore dairy has also arranged to bring the farmers from villages & to educate
them on clean milk production, Energy savings etc.
Energy Consumption
The energy consumption and milk handled at the dairy in the years 2009-2010 &
2010-11 is as follows:
Milk Handled M. Tonnes 355.57 410.80
Total energy consumption Electrical Lacs kWh 31.72 32.84
Specific energy consumption -Electrical KWh/Ton 24.4426 21.9063
Total energy consumption Thermal Million
Kcals
6208.77 6414.72
Specific energy consumption Thermal Million
Kcals
0.04784 0.04278
126
There has been a steady increase in milk handling and notable decrease in
consumption of energy during the years 2003-2010. The dairy had launched the
Energy Conservation Program in the year 2001. National Dairy Development Board
(NDDB), Institute Of Rural Management, Anand (IRMA) & Karnataka Milk Federation
(KMF) facilitated the launching of the said program. The outcome of this program
was that the dairy was able to gear up the employees towards saving of energy.
This has been a continuous process and the objectives of this team has been
slightly modified and this team is heading towards "TOTAL QUALITY MANAGEMENT".
During 2003-2010, Mysore dairy has implemented 31 energy saving projects
through engineers initiatives, sub section team suggestions and innovative ideas
by officers and have achieved savings of Rs. 98.22 Lacs with an investment of Rs.
259.35 Lacs.
The energy saving projects implemented during 2010-11:
1. Replacement of old 3 KLPH Curd Milk Pasteuriser with energy
efficient 5KLPH curd milk pasteuriser - Avg Production 30-35 Kl
Per Day.
Year Qty Milk Handled
(000)
Capacity Utilisation Electrical Energy
(Lakh kWhr)
Thermal Energy
(F.O (KL)
2009-10 355.57 197.54 35.02572 62.2434
2010-11 410.80 228.22 32.84680 64.3080
Sln Particulars - Thermal Old 3 Kl Plant New 5 Kl Plant
1 Operating Hours 12 7
2 Steam Consumption (Kgs) 200 180
3 Steam (Kgs) Per Day 2400 1260
4 Steam (Kgs) per Year 876000 459900
5 Savings Steam (Kgs) 416100
6 Savings F.O 32007
7 Amt Saved /Year Rs.1224294.00
127
Sln Particulars - Thermal Old 3 Kl Plant New 5 Kl Plant
6 Savings F.O 32007
Old 3 KL/Hr Curd Milk Plant New 5 KL/Hr Curd Milk Plant
2. Replacement of Old 10 Kl /Hr Milk Pasteuriser with 10 Kl /Hr
Pastueriser.
New 10 KL /Hr Milk Pasteuriser
Sln Particulars - Electrical Old 10 Kl Plant New 10 Kl Plant
2 Connected Motor Load(Hp) 10 9
3 Kwh Per Day 160 108
4 Kwh per Year 58400 39420
5 Savings - Kwh 18980
128
sln Particulars - Thermal Old 10 Kl Plant New 10 Kl Plant
6 Savings F.O 44923
3. Replacement of pneumatic packing machines with Mechanical Packing
Machines.
Old Pneumatic Packing Machine New Energy Efficient Mechanical Type
Packing Machines
4. Replacement of old florescent tube lights with energy efficient CFL
lamps
The illumination lights at Office block, Board room & other related section, are
changed from old 40 watts choke tube lights to Composite florescent Lights
which consumes less Electricity & which has helped in saving of Energy in addition
to good illumination. Mysore Dairy has changed these lights & in turn has saved
5445 kWh per annum & the amount saved is turned out to be Rs. 27000/ annum.
1 Air requirement by one double head pneumatic machine 54 M3 /hour
2 Air requirement by four machines 432.00
3 Running hours of these machines for packing milk 12 hours/day
4 Air requirement per day 5184 M3
5 Air displacement by air compressor with 37 KW motor 414 M3 /hour
6 Running hours of air compressor to displace Air 12.52
7 Energy consumed by air compressor for 12.52 hours (Kwh) 463.30
8 Energy saved for one year @ 347.38 KWh per day 169106
9 Savings per annum Rs.887806/-
129
Old Low energy efficient Tube Lights New Energy Efficient Lamps
Mysore Dairy transformed the Energy conservation team to which is putting forth
a continuous approach to sustain the achievements made on energy conservation
with due stress on improvement of product quality. Hence, the product quality
was not sacrificed while saving energy. Cross functional teams were formed and
the philosophy of energy conservation and quality improvement and sustainability
were inculcated among all the employees by way of lectures and discussions. The
dairy follows the 5 "S" house keeping principles with due stress on kaizen- continual
improvement, Good manufacturing and hygienic practices. Two 5 S teams inspects
and suggests the corrective actions on 5 S principles. The ideas from the employees
contributed to a greater extent in achieving cost reduction and quality improvement.
The sources of energy in the dairy are Electricity and Furnace oil. The energy cost
is 23 to 26 % of the total manufacturing cost of the dairy.
Electricity occupies the top position in the energy profile, since 80.% of the energy
is generated with the help of electricity. The refrigeration section is the of this
source of energy, wherein more than 50% of the total electrical energy is used by
this section. Hence, major thrust was given in conserving energy in this section.
This section has 4 ammonia compressors, two driven by 2 Nos 100 Hp, one
driven by 125 Hp and one by 120 Hp motor. In addition the dairy has 2 booster
compressors driven 2 Nos. 20 Hp motors. During 2009-10 One High Speed Frick
Viltor Compressor has been put in to operation in place of one of the 9x9 ammonia
compressor.
ENERGY USAGE AT MYSORE DAIRY
16%
4%
80%
Furnace oil Electricity Captive Power
130
Furnace oil is another source of energy. This constitutes 16 % of the total energy.
The major user of this energy is the milk processing section wherein more than
75% of the thermal energy is utilised. Thus this was the major section wherein the
thermal energy saving efforts were put forth.
Energy Conservation Plans and Targets
1. Replacement of Old inefficient 2 Mt/hr Boiler with New Energy efficient 3 MT/
hr multi solid fuel Boiler with pre Air Heater & online flue gas analyzer The
same is targeted for 2011-12.
2. Installation of butter pre-stratification tank & butter melting vat :- The dairy is
manufacturing Ghee from butter by using ghee vat. The approximate savings
expected is Rs. 3.30 Lacs and the proposed investment is Rs. 9 Lacs. This
project is targeted for 2011-12.
3. Replacement of old Frick compressor with high Speed Energy efficient Kirloskar
(KC -4) Compressors
4. Replacement of left over Pnematic Packing Machines with energy efficient
Mechanical type Packing machines
The employees & management of mysore-chamarajanagar milk union are
committed to conserve & sustain the conserved energy at all levels of processing
of milk & milk products by adopting modern, eco-friendly & energy efficient
technologies to offer the supreme quality milk & milk products to customers at
competitive price while transferring remunerative price to the producers.
Actions have been initiated to get the HACCP & EMS 14000 certification. The
target is by the end of year 2011-12. All the safety measures suggested by the
statutory authorities have been implemented. The Dairy has implemented the
On-sight Emergency Plan & Environmental Management Plan successfully
during the year 2009-11 & most of the employees are trained under this plan to
overcome the emergencies on day to day workings.
There has been no incidence of accidents from past 3 years. The ETP has been
expanded to treat the additional effluent flowing due to increased milk handling.
With the completion of Effluent treatment plant the treated water is being used
efficiently for gardening purpose. The garden has sufficient greenery to achieve
the eco-balance in the Dairy premises.
131
Certificate of Merit Dairy
SHIMOGA DAIRY
(A Unit of Shimoga Milk Union)
Shimoga (Karnataka)
Unit Profile
Shimoga Co-operative Milk Union (SHIMUL) was established in the year 1987 as
part of implementing the operation flood II programme in the state of Karnataka.
The area of operation of the union covers the three southern districts of Karnataka
i.e. Shimoga, Davanagere and Chitradurga. The operation flood and the subsequent
perspective plan program implemented in the milk shed with the financial and
technical assistance of NDDB has sought to develop dairying through establishment
of viable three tier co-operatives to link the rural dairy farmer with the urban
consumers, thereby improving the standard of living of the under privileged dairy
farmers of the region.
Shimoga Milk Union is one of the first largest Dairy Co-op. union in the northern
Karnataka, procuring on average 2.10 LLPD milk from the milk shed area. The
union establishment during 1988, with an initial share capital of Rs 100 Lacs and
milk procurement of 0.5 Lacs kgs/day, to day union has shown to have its share
capital of Rs 589 Lacs and year average per milk procurement of 2.12 LLPD.
SHIMUL has the distinctions of established 29 no of Bulk Milk coolers in the village
DCS and 7 milk chilling centers.
132
Product Profile
In order to meet the
requirement of different
segment of consumers and
their demands for more
convenience, SHIMUL
introduced Toned milk,
Standard Milk, Homogenized
standard milk, Curds, Butter
milk, Butter, Peda, Ghee.
Energy Consumption and Savings
S. No Particulars 2009-10 2010-11
1. Product (Milk & Milk product MT/yr) 52757 50998
Electrical:
1. Total Electrical Energy (Lacs KWH/yr) 21.14 19.62
2. Total Electrical Energy savings (Lacs KWH/yr) - 1.52
3. Specific Electrical Energy consumption 42.54 41.15
(KWH/ton)
4. % Of Electrical Energy Savings over
previous/ye - 3.3
Thermal:
1. Total thermal Energy (Furnace oil in KL/yr) 346.19 318.884
2. Total Thermal Energy Savings - 0.273
(in Lacs KL/ton)
3. Specific Thermal Energy (In MKCAL/ton) 3305.287 3044.55
4. % of Thermal Energy Savings over - 7.88
previous year)
133
Major Energy Conservation Measure implemented in 2010-2011
1. Description of the energy conservation measure:
Ammonia Compressor Shaft seal cooling water was drained. Company has modified
for cooling water recirculation thus saving of 62 Lac ltrs of soft water per year.
Picture/ sketch/ drawing before
modification
Ammonia Compressor Shaft seal
cooling water drained
modification
Ammonia Compressor Shaft seal
cooling water recirculation
Total investment: 30,000.00 Year of implementation: 2010-11
First year other savings: Rs. 62,000.00
The Raw milk cans are being pre rinsed to avoid dust and other foreign particles
which will mix with raw milk while pouring in the dump milk tank during milk
reception time, thereby increasing milk quality and reduction of higher milk
pasteurization. Saving steam and electricity.
The Raw milk cans are being pre rinsed to avoid dust and other foreign particles
which will mix with raw milk while pouring in the dump milk tank during milk
reception time, thereby increasing milk quality and reduction of higher milk
pasteurization. Saving steam and electricity.
134
modification
Raw milk cans were not pre rinsed
before dumping into raw milk dump
tank
modification
Pre rinse unit for raw milk cans
The cooling water for Ghee settling tank was drained. Dairy has modified for
cooling water recirculation thus saving of 25.55 Lac ltrs of soft water per year.
modification
Cooling Water was drained
modification
Cooling water Re-circulation
135
4. Description of the energy conservation measure
Three Numbers 5 KW Pump sets were under operation for 22 hours consuming
1.20 Lac kWh per year. After installation of energy efficient pump sets, only Two
Numbers 5 KW Pump sets were under operation for 22 hours consuming only
0.80 Lac kWh (Saving of 0.40 Lac kWh per year)
modification
Ordinary Pump sets
modification
Energy Efficient Pump sets
First year energy cost savings: Rs. 1,82,500.00
Other Projects Taken During the Year 2010-11.
1. Insulation for De- Super heater Hot water used for Boiler
2. Installation of Butter Melting vat
3. Installation of CFL for Street Light
4. Installation of Electronic ballast
5. Installation of CFL
6. Mechanical type double head milk packing machine
7. Steam Condensate recovery.
8. PRS installed in Ghee Section
9. Hot water for CIP Tank
10. Thawing of Butter
11. Revamping of Milk Cold Store
12. Energy Efficient Pump set for Condenser Water Sump
13. Outlet of ETP water is used for Gardening
136
First Prize Drugs & Pharmaceuticals
USV LIMITED
Unit-1, Baddi (Himachal Pradesh)
Unit Profile
USV is a 50 years old leading healthcare company, which began as a joint venture
with USV&P Inc. USA, a subsidiary of Revlon. Company markets its products
globally to 57 countries. In the financial year 2010-11, its sales were Rs. 11,400
million.
Company Indian business contributed 67% to this and the rest was from
export of APIs and Finished Dosages to various markets including USA, Europe
& Japan.
These are manufactured in its cGMP compliance plants located in India.
USV international business consists of a large portfolio of small molecule APIs. Of
the 54 products in company portfolio, 21 APIs are commercially available, with
others in various stages of development.
Company Business Contribution is 67% by Indian Market & 33 % by
International Market.
137
Company MAT Market Growth is 15%. It has moved up 1 rank in MAT to 22 with
a growth of 22%. Its month rank has also moved to 20 (up 1 rank) in Mar.2011.
The plant of USV at Baddi is built in 2006 and is located at plot No.6 HPSIDC
industrial area Baddi, Dist-Solan (HP) India. The formulation unit at Baddi is designed
to manufacture oral solid dosage unit. (Tablet, Capsule and DC/SR Granules).
Energy Consumption
USV Baddi regularly invests in adoption of new technology and practices for reducing
its usage of power. The installed and replaced a range of energy efficient equipment
during the year such as high efficiency motors, variable frequency drives etc. It
continually looks at ways to reduce the idle running of equipment.
2.1 Power Details.
Plant connected Load (KW) : 1700
Contract Demand (KVA) : 750
Supply Voltage (KV) : 11
Energy Consumption Details.
Description UNIT 2009-2010 2010-2011
Total Electrical energy Lac.kWh 27.07 25.87
consumption
Specific electrical energy kWh/Tonne 2.53 2.01
consumption
Total thermal (Fuel ) MTOE 1592.41 1708.34
energy consumption MTOE
Annum
Specific thermal (Fuel) Million 140.41 122.2
energy consumption Kcal/Tonne
Specific Power Consumption
138
Projects Details 2010-2011
Sr. Ti tl e Energy Saving Before Energy After Energy Cost Saving
Measures Cost Cost (Lac)
1. Induction Replaced condenser water 5. 55 1. 6 3. 95
Motor pump with correct size.
Raw Water Pump 1. 1 0. 19 0. 91
Air Replaced Reciprocating Air 22. 92 16. 18 6. 74
Compressor Compressor with VSD Screw
Air Compressor.
Pl ant Installed servo voltage 5. 88 4. 98 0. 9
Lighting stabilizer for lighting
No. of CFL replaced from
36 W to 18 W 2. 1 1. 1 1
Fuel To optimize water to fuel ratio 85. 18 78. 63 6. 55
Savi ng for boilers
Energy Installed VFD on Purified Water 2. 25 1. 65 0. 6
Savi ng Circulation Pump
Cooling Tower fans On/OFF
control with ref. to water
temperature. 2. 79 1. 43 1. 36
Power Saving After installation
VFD in All AHU (31 No.) 40. 44 30. 55 9. 89
Installed Turbo Ventilator 2. 6 0 2. 6
139
Resource To use Back wash and Reject
water of MGF/DM plant and UF in
toilets by gravity force. The back
wash water going to ETP will be
diverted to wash rooms. Also this
has been reduced ETP hydraulic 0. 1 0. 68 1. 4
load.
1 1 Water Recycle & use 0. 72
Total Saving 35. 9
Major Energy Saving Proposals
Replaced induction motor of 18.5 kW
with 5.5 kW & 3.7 kW with 0.65 kW
on same flow rate by reduced head as
per actual requirement.
KWh saving per Annum kWh: 1.19
Cost saving per Annum (Lac): 4.75
Monitoring & operation of Boilers for
steam requirement as per SOP.
Indication Panel has been installed for
machine running status-enabling
operator to run different sets of
boiler(s) as per requirement.
Annul Fuel Saving (Liters): 15600
Annum Cost saving: 6.55 Lac
Installed Turbo Ventilator (TV) for
Service floor
Replaced all exhaust fans with Turbo
ventilators.
Annual Energy Saving Kwh: 65000
units
Annual Cost Saving: 2.6 Lac
140
Installed VFD in AHU
Installed VFD in Air Handling Unit
(AHUs) for operate blower at low
frequency/as per requirements.
Annual Energy saving kWh: 2,47000
units
Annual Cost Saving INR : 10 Lac
ENERGYPOLICY
141
Certificate of Merit Drugs & Pharmaceuticals
ORCHID CHEMICALS &
PHARMACEUTICALS LTD.
Alathur, Distt. Kancheepuram (Tamil Nadu)
Unit Profile
Orchid Chemicals & Pharmaceuticals Ltd (Orchid) was established in 1992 as a
100% Export Oriented Unit (EOU). Commencing operations in 1994, Orchid has
achieved amazing and consistent growth, quantitatively and qualitatively to emerge
among the Top-15 companies in the Indian pharmaceutical industry in a short
span of fifteen years of operations.
Manufacturer of bulk Cephalosporin range of products (antibiotics), Intermediates
and Neutraceuticals with two sophisticated manufacturing facilities in India (One at
Alathur near Chennai and the other at Aurangabad) and formulation units at
Irungattukottai, Alathur. Largest manufacturer of Cephalosporin products in India
and one among the top five in the world.
It exports products to various International markets, covering about 75 countries.
Alathur facility has a work force of about 1200 and a turnover of Rs.789.01
Crores.
142
Energy Consumption
Electrical energy
Abstract Of Encon Measures
S. Year No. of Encon Investment Annualized Total energy
No. measures in Lacs savings in Bill in Lacs
implemented Lacs
1 2007-08 16 1311.70 966.90 4752
2 2008-09 66 208.50 424.00 4855
3 2009-10 49 33.65 385.56 3569
4 2010-11 66 95.87 518.56 3397
143
Innovative ENCON Measures
1. Installation of 3.15 MVA Cast resin Transformer for medium voltage
application instead of conventional oil filled transformer
Plant have only oil filled transformers in its earlier installation when the additional
requirement of transformer of rating 3MVA is being proposed it was decided to go
for dry type (Cast Resin) transformer of 3.15MVA capacity.
Normally oil filled transformers alone is being used in chemical and pharmaceutical
sectors owing to the degree of protection against fire where mostly flammable
vapours present (classified areas).
So the cast resin transformer is being imported from SGB Germany for the proven
resin technology which is fire retardant as well blast proof in case of internal fault.
Earlier Process:
For oil filled transformer the load loss is : 40 KW
Conventional transformer need to be kept only at ground floor level as per
statutory norms due to oil presence.
Fire risk is high due to hot flammable oil present.
Space required 10m x 10m
Soak pit needs to be provided to meet the statutory requirement
Since this transformer only can be positioned at ground floor the HT cable and
LT Bus length required would be high. (20 mts)
Modified Process:
For cast resin transformer the load loss is : 22 KW
Cast resin transformer can be installed at any suitable floor near the PCC
area.
Fire risk is low due to the high quality imported customized resin by M/s.SGB
Space required 5m x 5m
Soak pit is not required due to the absence of oil
Since this transformer can be positioned at the same floor of PCC the HT
cable and LT Bus length required is low. (5 mts)
Savings achieved:
Reduction in full load loss in units / annum (18KW x 8760) :157680 kWh
Net Savings achieved : 7.49 Lacs/Annum
144
Earlier process Modified process
2. Replacement of Incandescent Vessel Lamp with LED Lamp for
chemical process Reactors classified under Zone 2B
Existing System:
Since the installation of vessel lamp has to comply with EXd certification to fit into
the classified area requirement, the original design was with 100 W GLS lamps
with / without timer option. The main Criteria is the surface temperature should
not exceed 85 deg C (Temperature classification T6). The criticality of this vessel
lamp should indicate the foaming operations inside the reactor (Colour Index plays
a very important role)
Modified System:
Since the enclosure should be the certified Patented Flameproof fittings of EXd
certification, lot of trial with different lamps such as CFL and Power LEDs has been
made. The results are that the 3 W Power LEDs were found to be suitable on
meeting the surface temperature (limited to 50 deg C) and the white colour beam
made the visibility of foaming mass happening inside the reactor. Besides the
above mentioned advantages, the energy saving to a tune of 97W per fitting has
been achieved.
All future installations will be ensured with LED fittings and existing remaining fittings
(96 nos) will be converted in phases.
Savings Calculation:
Power rating of GLS Bulb used in fitting : 100 W
Converted rating of LED fitting : 3 W
Net Saving/fitting : 97 W
Hours of operation / Day : 12 Hrs
No. of fittings connected : 164 Nos.
Annual Saving Achieved : 164 x 12 x 0.097 x 365 x 4.75
145
3. Replacement of existing WHRB with Energy efficient WHRB in CPP
Earlier Process:
Unit has provided waste heat recovery boiler on the downstream of Captive Engine
of 3.8 MW. The boiler capacity is 1.8 TPH @ 10 bar pressure for the average load
of 85%.
Steam generation :1.8 TPH @ 10 bar
Flue gas outlet temperature : 230c
Steam generation per annum for 1460 hrs operation : 2628 TPA
Modified Process:
The above said boiler has been replaced with energy efficient waste heat recovery
boiler of JM marshall make with built in economizer as per the details furnished
below.
Steam generation : 2.5 TPH @ 10 bar
Flue gas outlet temperature : 170c
Steam generation per annum for 1460 hrs operation : 3650 Tons
Savings Calculation:
Increase in steam generation per annum : 1022 Tons
Savings in Rs.Lacs /annum @ Rs.800 per Ton : 8.176
(Cost of steam generation by coal boiler only considered for savings calculation)
146
Energy Policy
147
Second Prize Edible Oil/Vanaspati
RUCHI SOYA INDUSTRIES LTD.
Buti Bori, Distt. Nagpur (Maharashtra)
Unit Profile
Ruchi Group of Industries is a well-known industrial group based in Indore, MP with
its various manufacturing units located in all over India. The group has its corporate
headquarters in Indore, with offices in Mumbai, New Delhi, Calcutta, Chennai and
other major business centers in the country. The Group's business interests vary
in different commodities. It has manufacturing and trading facilities of Soya bean
products, Agri-business, Oils and Fats, Flat Steel, Galvanized Steel & Cold Rolled
Steel etc. The Group also has long exposure in trading of Oil, Pulses and other
agriculture crops. The combined business turnover for the year closed on 31st
March, 2011 stood at Rs.16663 Crores. Net worth is around Rs.2155 crores
RSIL NAGPUR Plant is located at Butibori, Nagpur with total capacity of 300 TPD of
refining edible Soya bean Oil and crushing capacity of 1500 TPD of Soya Bean
Seed. The unit is certified with ISO 9001:2008, ISO 14001: 2004, ISO
18001:2007, ISO 22000 : 2005, KOSHER and CERT ID standards.
The unit has a energetic team to take any assignment time to time. Total turnover
of unit for the year 2010- 11 was Rs 511 Crores.
148
Energy Consumption
Oil and Fat processing industry is a major consumer of energy, as substantial
quantities of steam and electrical power are consumed in refining and crushing
operations. As a result, plant at Nagpur unit had given major thrust and emphasis
on the conservation of energy which would give reduced costs and edge on the
market as the edible oil market is very volatile. Company adapted best
manufacturing practices and comparing the data with other units of the group
yields best results for improvement. HO team also started working closely with
individual plant teams in terms of manufacturing cost reduction thro various energy
conversation measures.
Electrical energy Lacs kWh / Year 48.084 97.00
Thermal energy Million kCal / Year 28673 60993
Specific Electrical kWh/tonne 51.047 39.12
Energy Consumption
Specific Thermal Million kCal / tonne 0.304 0.246
Energy consumption
Standards have been set based on the past data and continued conservation
practices give the momentum to reach the goals. Bench marking is done internally
based on internal as well as external figures. Apart from monitoring HO team also
gives timely input as well as supports in achieving the same.
Energy Conservation Measures Implemented
Energy is viewed as any other valuable raw material resource required running a
business not as mere overhead and part of business maintenance. Energy has
costs and environmental impacts they are managed well in order to increase
business profitability and competitiveness and to mitigate the seriousness of these
impacts.
In order to save energy following measures have been implemented
Design of Boosters of Vacuum system changed to low steam consuming
design by arresting leakages in the deodorizers and regular monitoring it,
which also resulted in power consumption reduction (Requirement of condenser
water was reduced.)
149
Before Modification After Modification
Total investment, Rs. 527000/-
First year energy cost savings, Rs. 4091574/-
Year of implementation: June 2010
Increased the height of the Hot well (used for vacuum creation) was modified
to use gravity instead of pump for spraying water over cooling tower. Initially
water was coming to cooling tower from the bottom of Hot well which modified
to take outlet line from the top.
Before Modification After Modification
Total investment, Rs. 531000/-
First year energy cost savings, Rs. 639630/-
Year of implementation: June 2010
150
In lecithin section vacuum pump (used for drying ) the lecithin plant had single
vacuum pump of 100 HP was replaced by 3 nos of 20 HP vacuum pump
which saved energy in full as well as part load of capacity utilization. (No of
driers 6 Nos). Total Investment was Rs 300000/- and first year energy
cost savings were Rs 704160/-
Plant has optimized the process by trials and control of process parameters
to reduce the Energy and to give quality product as by reducing bleaching
temp, operating temperature of Deodorizer etc.
Modified the bottle necks of the expanders chute which was supplied by the
supplier reduced the running of one conveyor.
Plant has installed 2 nos of higher capacity expenders of 185 KW each and
closed 4 Nos of expenders of 135 KW each. First year energy cost savings,
Rs.4504500 /-
Installation of water pre heater increased the feed water temperature.
Plant has purchased flue gas analyzer and regularly monitoring the excess
oxygen in flue gases has increased the efficiency of boilers.
Use of heat exchanger for the heating of Miscella from the crude oil reduced
the steam uses of steam for miscella also reduced the cooling water
requirement.
Replaced existing lightings by energy efficient CFL
Installed VFD at DOC section blowers, miscella tanks pump, cooling tower
pump, RO feed pump and ID fans of boiler.
Plant has done many small changes and started using low pressure steam
back pressure steam of turbine where earlier the connection was at higher
pressure thus increased the uses of turbine.
Started the use of flash steam from plant to heat boiler feed water which
increased the feed water temperature to 15 deg C.
Reduced the hydraulic pressure use in the flaker during the crushing of seed
from 60 Bar to 50 bar. With this change unit could stopped the running of 2
nos of flakers out of 10 Nos and able to get the desired capacity.
151
The company has been laying emphasis on the conservation of energy and taking
several measures like effective control on utilization of energy and regular monitoring
of its consumption etc. The adoption of these measures to conserve energy has
resulted in saving of the same.
This factory has the core team lead by Unit head and headed by Manager
(Production). Manager (Production) has the production team as well as Utility &
maintenance team along with him.
An Energy management Policy of the group is as under.
152
Ruchi Soya Industries Ltd. Is committed for environment and safety
153
First Prize Fertilizers
RASHTRIYA CHEMICALS &
FERTILIZERS LTD.
Trombay Unit, Chembur, Mumbai (Maharashtra)
Unit Profile
Rashtriya Chemicals and Fertilizers Limited (RCF), a Government of India
Undertaking, began its operations in 1965 as Trombay unit of the erstwhile Fertilizer
Corporation of India and became an independent company upon its re-organization
in 1978. Over the years, it has grown into two multi-plant complexes with a
product range varying from fertilizers to basic chemicals. The company's operations
started with a small group of plants at the Trombay Complex in Mumbai, while the
giant size fertilizer plants at Thal complex, in Raigad district of Maharashtra, were
commissioned in 1985. Presently the company is operating 21 plants at Trombay
Unit and 14 plants at Thal Unit.
RCF always strives for upkeep of the plants through modernizing and upgrading
technology. Revamping and de-bottlenecking is the secret that has kept the
company thriving for four and a half decades. As part of modernization, RCF has
recently modernized its Ammonia - I, Ammonia-V, Nitric Acid, Methanol and ANP
plants. This has facilitated plants to sustain operations and meet technological
challenges of improved efficiency, lower energy consumption and maintain
environmental norms.
BIRDS EYE VIEW - RCF TROMBAY UNIT
154
RCF has always selected the best available technology at the time of inception of
every plant and followed it up with up-gradation from time to time to improve
energy efficiencies and make the plants eco-friendly and competitive. RCF, Trombay
Unit is accredited with ISO-9000 certificate for its quality Management System,
ISO-14001 for its Environment Management System and OHSAS 18001 for
Occupational Health & safety Management System.
RCF is a highly energy intensive unit, using the energy in the form of
Associated gas
Electricity and
Process steam
Considerable efforts have been made to reduce consumption of raw materials
and energy in energy intensive plants since beginning. A system of reporting and
reviewing was initiated in order to optimize the energy consumption, raw material
consumption as well as utility consumption.
BOILER
3 X 170 TPH
105 ATA/510deg
ASSOCIATED GAS
COMPRESSORS
UREA
1000 MTPD
AMMONIAV
1045 MTPD
AMMONIA-I
350 MTPD
AMMONIATO SUPHALA, A.B.C.,
NITRICACID, ANP PLANT
STEAM
PRODUCT UREA
CO
2
FUEL
GAS
NH
3 METHANOL
220 MTPD
HIGH
PRESSURE
RILGAS
155
Name of the Plant 2009-10 2010-11
Ammonia-V 330235 320330
Ammonia-I 87856 97800
Methanol 44103 68700
Urea-V 306905 341090
Suphala 490000 447000
Ammonium Nitro Phosphate 17070 157935
Nitric Acid-IV 263105 254120
Nitric Acid-I 99710 108235
Sulphuric Acid 59753 77842
Phosphoric Acid 17040 27170
Production of Major Plants in 2009-10 and 2010-11 in MT/Year
Energy Consumption
Electrical Energy Consumption for 2009-10 and 2010-11
In Lacs kWh 2009-10 2010-11
Purchased Electricity 2224.32 2670.9685
Own Generated Electricity 493.04 393.56
Total Electricity Consumed 2717.36 3064.53
Total Electricity consumed by the unit can be attributed to the fact that production
levels of many of the plants has increased. Also the new projects like ANP
Granulation Unit, Rapid Wall Plant and Methanol Plant are commissioned during the
year 2010-11.
0
500
1000
1500
2000
2500
3000
2009-10 2010-11
Purchased Electricity Own generated electricity
156
Comparison for Specific Power Consumption for Ammonia-V and
Urea-V Plants
In kWh/MT AMMONIA-V Urea
2009-10 134.389 64.788
2010-11 129.496 57.815
0
50
100
150
AMMONIA-V Urea
Spec Power Consumption (kWH/MT)
2009-10
2010-11
Specific Power Consumption for Methanol Plant
In kWh/MT Methanol
2009-10 530.282
2010-11 471.800
440
460
480
500
520
540
2009-10 2010-11
Methanol Specific Power Consumption
Methanol
157
The electrical consumption of RCF Trombay unit has increased in 2010-11 as
compared to 2009-10 which is mainly due to increased production of plants like
Ammonia-I, Urea-V Methanol, ANP, Nitric Acid-I and Phosphoric Acid. In year 2010-
11, Rapid Wall plant, ANP plant Granulation and Methanol plant revamp projects
were implemented.
The Specific electrical consumption of Ammonia-V, Methanol and Urea-V plants
has decreased as indicated in above graphs.
Energy Conservation Measures implemented in Financial Year
2010-11
1. Revamping of Methanol Plant to enhance production up to 220 + 10%
MTPD with reduced specific energy consumption.
In the revamp project, New HTAS Reformer with Steam CO2 Reforming
was installed thereby reducing Fuel consumption and steam consumption due
to low Steam-carbon ratio in the Reformer. The steam production of the plant
has also increased due to installation of High Capacity Waste Heat Boiler coil.
The Specific Gas (Feed + Fuel) consumption has reduced from 986 Sm3/MT
(2009-10) to 951 Sm3 per MT (2010-11).
The Specific Steam export increased from 0.9 MT (Pressure-12 atm abs,
Temp- 260
o
C) per MT in 2009-10 to 1.42 MT (Pressure 40 atm abs, Temp-
400
o
C) per MT of Methanol produced in 2010-11.
This has enabled to reduce Specific Energy consumption for Methanol production
to 8.062 MKcal/MT from 8.924 MKcal/MT.
2. Connecting tails column bottom directly to slop water line in Methanol
Plant
Earlier the bottom stream of the tails column was pumped to the Effluent Pit
of the plant. The modification is made to connect this bottom stream directly
to the slop water line going to the effluent pit. This has resulted in stopping of
the pump and saving of electrical energy.
3. Energy Efficient Motor for Nitric Acid supply pump
Replacement of ordinary 22 KW / 3000 RPM motor by new energy efficient
motor of same rating for Nitric Acid supply pump in Nitric Acid plant leading to
saving in electrical energy.
4. Installation and commissioning of Vapour Absorption Machine (VAM)
at inlet of Process Air Compressor (PAC)
This has increasing Process Air flow to secondary reformer by 2000-2500
Nm3/hr as suction temperature of PAC reduced to 12-15
O
C against ambient
temp 30-35
O
C. This has increased the throughput of PAC. and hence the
158
plant can be operated at optimum load. This has led to increase in plant
production by about 25-30 MT per day.
Specific energy of plant reduced from 10.65 Mkcal/MT (2009-10) to 10.32
Mkcal/MT (2010-11).
5. Provision of Two out of Three voting for critical TRIP SWITCHES in
Ammonia-I plant. (Assuming 4 trips/annum)
This has reduced tripping of plant due to false alarm and thus reduced losses
due to such tripping of Ammonia-I plant. Saving of Associated gas to the tune
of 2.3 Lacs Nm3 (in form of Feed, Fuel and Steam) and saving of Electrical
Power - 5 Lacs kWh.
6. Provision of constant voltage stabilizer for plant lighting in Ammonia-I plant.
This has led to savings in electrical energy.
7. Replacement of existing Mine wool insulation by calcium silicate insulation of
105 ATA steam line for Boiler-I. This has led to savings in Steam to the tune of
about 2 MTPD.
8. Replacement of existing CS Galvanized drive shaft with composite fiber shaft
of cooling tower fans in Ammonia-V plant. This has reduced the weight of
drive shaft by 50%, and also led to saving of electrical power. In addition this
shall increase equipment life and reduce vibrations.
9. Three Steam trap were replaced with condensate pots in Urea Plant. The
steam traps at LP decomposer, Waste Water Re-boiler, 1st Vacuum Evaporator
were replaced. This has reduced losses of steam to the tune of 1-1.2 MT per
hour.
10. Installation of VFD for Ammonia Solution Recycle pump (P-607) (37 KW) in
Urea plant. This has led to savings in electrical energy.
11. Installation of VFD for Product Dryer (11 KW) in Ammonium Bi-Carbonate
plant. This has led to savings in electrical energy.
12. Installation of two number of VFD for slurry transfer pumps in Suphala plant.
13. Installation of 10 energy efficient motors in sulphur pit of Sulphuric Acid Plant.
159
Considerable efforts have been made to reduce energy consumption of age-old
plants making use of latest technology.
An Energy Cell with an Energy Manager and qualified engineers has been set up to
analyze the day to day energy consumption levels in various process plants in the
factory. Energy Conservation Opportunities are identified based on energy audits,
case histories of successful conservation measures implemented by other plants
and through suggestions received from the operating and technical personnel
160
The integrated Quality, Environment, Health and Safety Policy is attached:
161
Second Prize Fertilizers
SHRIRAM FERTILISERS & CHEMICALS
Shriram Nagar, Distt. Kota (Rajasthan)
Unit Profile
Shriram Fertilisers and Chemicals (SFC) is a division of DCM Shriram Consolidated
Ltd., a conglomerate of diverse business interests making and trading products
critical to the country's growth. SFC is engaged in the, manufacture of Urea, PVC,
Caustic Soda, Liquid Chlorine, Hydrochloric Acid, and Cement.
SFC's complex is located at Kota, Rajasthan. The Fertiliser Unit was commissioned
in February 1969 by Chiyoda Chemical Engineering and Construction Co. of Japan.
Installed plant capacities were 450 TPD of Ammonia and 700 TPD of Urea. Capacities
were expanded to 600 TPD Ammonia and 1000 TPD Urea in 1974.
Ammonia/Urea Plant
The plant was originally based on naphtha as feedstock. The various technology
licensors for the Ammonia Plant are Shell of USA, for Naphtha desulphurisation
section, HaldorTopsoe of Denmark for the reforming and synthesis sections and
Benfield Corporation of USA for the carbon dioxide removal system. Stamicarbons
Total Recycle Process has been utilised in the Urea process scheme.
The plant had been modified to use both naphtha and gas in any proportion in
Aug.-Sep.06. Plant has started using gas since 22nd Sep.07 with the
commissioning of gas pipeline by M/s GAIL. Plant has been running on full gas
since May09 and use of naphtha has been discontinued.
Immediately after expansion in 1974 the energy performance of the plant remained
below par. Many initiatives were identified and undertaken to improve the
performance of the plant since then. This has resulted in remarkable improvements
in energy consumption over the years.
Energy Consumption
Since energy cost form about 80% of the production costs, energy conservation
is a vital aspect of Ammonia - Urea Plants. The key focus has therefore always
been on the reduction of energy consumption in the existing plant as well as on
incorporating new process schemes into the plant to achieve better and better
energy efficiency.
162
The main energy consumers in the plant are the Primary Reformer, CO2 gas
removal system, the motor driven positive displacement type compressors and
the refrigeration equipment of the synthesis section. A dedicated captive power
plant of 35 MW and, to some extent, the State Electricity Board caters to the
power requirements of the complex.
In order to avoid energy losses in any form in the plant, monitoring of energy
consumption is done on daily basis. Energy audits are also carried out periodically.
This includes monitoring of critical plant parameters, steam and water balance,
pressure drop surveys etc. Process analysis based on computer simulation of the
plant process & various modifications undertaken have drastically reduced the
energy consumption.
The overall energy consumption reduced from levels of 9.02 MKCal/MT Urea to
present levels of 7.324 MKCal/MT.
Improvement in energy consumption over the years
Energy Consumption per tonnes of Urea
7.32
7.45
7.71
7.78
7.85
7.88
7.85
7.81
7.97
8.09
8.2
8.15
8.19
8.43
8.25
8.35
8.53
8.38
8.52
9.02
7
7.5
8
8.5
9
9.5
9
1
-
9
2
9
2
-
9
3
9
3
-
9
4
9
4
-
9
5
9
5
-
9
6
9
6
-
9
7
9
7
-
9
8
9
8
-
9
9
9
9
-
0
0
0
0
-
0
1
0
1
-
0
2
0
2
-
0
3
0
3
-
0
4
0
4
-
0
5
0
5
-
0
6
0
6
-
0
7
0
7
-
0
8
0
8
-
0
9
0
9
-
1
0
1
0
-
1
1
Year
M
k
c
a
l
/
M
T
U
r
e
a
Plant is committed to be one of the most energy efficient plants in the World and it
endeavor continuously to reduce the energy consumption to the levels of new
technologically advanced plants. Technical personnel are kept abreast with the
State of Art technology in various fields through interactions in various forums.
Technical personnel are nominated to participate in national and international
technical conferences and the available information and technical inputs are
absorbed into the plant processes wherever possible.
163
With daily monitoring of process parameters such as Steam / Carbon ration, fuel
consumption, water ingress into the system etc. and also daily monitoring of
energy consumption, plant have been able to reduce energy consumption
significantly.
In pro active approach to the subject plant has installed and built in adequate
pollution control devices so as to prevent any discharge of effluents or emission of
gases. Electrostatic Precipitators have been installed in the power plant. The fertiliser
plant effluent is treated and pollutants are removed and recycled to the process.
Special attention has been accorded to create a clean and green environment in
the plant and towards this goal about 4.6 lac trees have been planted.
A new Hydrolyser Stripper System has been installed in Urea Plant at an expenditure
of Rs. 6.3 Crores. This has resulted in improving effluent quality significantly. The
discharged water is now being used as boiler feed water/cooling tower make up
instead of being drained.
This unit has received recognition at the national level in 1991-92 for Prevention
and Control of Pollution from the Govt. of India. Again in 2003-2004 the unit has
received the Greentech Silver Safety Award for performance in the field of EHS.
Fertiliser and Power plants have been certified for ISO-14001 and
OHSAS-18001
Safety of manpower is accorded highest priority and all measures are taken to
ensure safe operation. Continual training is given to the operating staff and workmen
so that all operations are carried out safely and there are no accidents. Safety
audits of the buildings, plants, equipments and rotating machinery are carried out
by in-house safety officers every month and external agencies once a year to
identify and rectify any short comings.
164
165
Certificate of Merit Fertilizers
KRIBHCO SHYAM FERTILIZERS LIMITED
Unit Profile
Kribhco Shyam Fertilizers Limited (KSFL) is a gas based fertilizer plant located at a
distance of 15 Km from Shahjahanpur on Shahjahanpur-Farukhabad state highway
in Uttar Pradesh. The natural gas to the plant is supplied by HBJ pipeline.
This fertilizer plant has single stream of ammonia plant based on the "state of the
art" low energy process of Haldor Topsoe A/S and two identical streams of urea
plant based on Snamprogetti Spa technology incorporating several low energy
features. The installed capacities of ammonia & urea plants are 1350 MTPD &
2200 MTPD respectively. Ammonia & urea plants capacities were reassessed to
1520 MTPD & 2620 MTPD respectively w.e.f. 1st April 2000. The commercial
production of this plant was started in December'1995.
166
Feasibility study for revamp of ammonia & urea plants were carried out in 2006
by its process licensors M/S Haldor Topsoe & M/S Snamprogetti for increasing
ammonia & urea production capacities to 1950 MTPD & 3130 MTPD respectively.
Based on their recommendations and in-house study many attractive energy
saving schemes had been incorporated mainly in ammonia plant. By these efforts
Kribhco is now able to produce close to 1800 MTPD ammonia & 3000 MTPD urea
on consistence basis.
Upcoming Projects
(1) Power required for plant is supplied by one gas turbine and second gas turbine
used as a standby. This gas turbine is running in off grid operation but plant is
shortly going for export of surplus power by running stand by gas turbine.
(2) Feasibility study M/S HTAS is under progress for increasing ammonia production
to 2000 MTPD and producing CO2 equivalent to 3500 MTPD urea by
incorporating all feasible energy saving schemes.
(3) One additional cooling tower cell for ammonia plant.
Energy Consumption
KSFL is one of best energy Managed Industry in fertilizer Sector. Various energy
efficiency measure have been taken up by the industry time to time and uses
designed amount of energy input for per unit production of the Urea. The Energy
input level is in the close range of design data which is supposed to be best
possible levels keeping in mind with age and operating condition of the plant.
Energy consumption data for the last five years are summarized in the
table below:-
Plant 2006-07 2007-08 2008-09 2009-10 2010-11 Reduction in
FY2010-11
w.r.t.
FY 2006-07
Ammonia 8.3060 8.2260 8.2127 8.1297 7.9811 3.91 %
Urea 5.8164 5.7772 5.8014 5.7088 5.5842 3.99 %
167
All figures are in GCal/MT
450000
500000
550000
600000
650000
0
6
-
0
7
0
7
-
0
8
0
8
-
0
9
0
9
-
1
0
1
0
-
1
1
Years
7.800
7.900
8.000
8.100
8.200
8.300
8.400
0
6
-
0
7
0
7
-
0
8
0
8
-
0
9
0
9
-
1
0
1
0
-
1
1
Years
P
r
o
d
u
c
t
i
o
n
(
M
T
)
S
p
.
E
n
e
r
g
y
(
G
c
a
l
/
M
T
)
700000
800000
900000
1000000
1100000
0
6
-
0
7
0
7
-
0
8
0
8
-
0
9
0
9
-
1
0
1
0
-
1
1
Years
P
r
o
d
u
c
t
i
o
n
(
M
T
)
5.400
5.500
5.600
5.700
5.800
5.900
0
6
-
0
7
0
7
-
0
8
0
8
-
0
9
0
9
-
1
0
1
0
-
1
1
Years
S
p
.
E
n
e
r
g
y
(
G
c
a
l
/
M
T
)
Ammonia & Urea manufacturing plants are highly energy intensive. Energy cost
has tremendously gone up in last 5 years and is increasing day by day. Energy
cost contributes more than 80% of total cost of urea production therefore slight
change in energy consumption has considerable impact on the production cost of
urea.
Energy conservation is continuous & ongoing process and focused activity of the
KSFL. Energy balance, monitoring and tracking at KSFL is done by Technical Service
Department on daily basis. The energy consumption is monitored on daily basis in
each plant and appropriate and immediate measures are taken to minimize
consumption on a continuous basis by cross functional team comprising of
operation, maintenance and technical services. The companys strategy is to create
the position as Lowest Energy/Cost Consuming Urea Producer in the World.
There is well defined modification and project management system for implementing
any process changes in the plant regarding energy conservation, safety and
environment. A task team is constituted in each department who takes care of
168
day to day monitoring of plant equipment and if any variation or abnormality
observed it was brought in the notice of technical service department and this
problem was addressed with the consultation of concerned department.
Based on above, KSFL had identified and incorporated some of the attractive
energy saving schemes mainly in ammonia plant. This has resulted highest ever
ammonia & urea production with lowest ever specific energy consumption in FY
2010-11. KSFL had implemented many schemes/modifications to achieve
sustainable energy conservation and CO
2
emission reduction. Major schemes
implemented in the last three years are as under:-
S.N. Plant Name of Scheme
Year of
Implementation
Resulted Saving
(Rs Lacs/annum)
Investment
Done
(Rs Lacs)
1
Isolation valve provision in 14''
CD vapor line from process
condensate stripper ( F 1321 to
E-1322 air cooler
FY2008-09 16.77 1.20
2
Installation of Ammonia
Product Heater in the ammonia
line going to urea plant
FY2009-10 48.31 13.03
3
PAC Discharge line size
increased from 10'' to 12'' for
reduce pressure drop and
increasing air flow rate.
FY2009-10 107.36 17.92
4
FD/ID Fan duct modification by
using CFD Analysis
FY2009-10 41.17 140.33
5
Provision of Primary Reformer
Fuel NG preheating
FY2009-10 4.75 20.90
6
A
m
m
o
n
i
a
P
l
a
n
t
Installation of New Plate type
heat exchanger in synthesis
loop.
FY2010-11 26.84 12.00
Major Energy Conservation Measure implemented in FY 2010-11
a) Installation of an additional Exchanger
One additional plate type heat exchange was installed in the synthesis loop (as
shown in the schematics). This resulted reduction in gas temperature at the exit
of E-1505 heat exchanger. Reduction in temperature of gas resulted reduction in
ammonia vapor formation from chillers. This has reduced load on ammonia
refrigeration compressor thus saving of steam.
Investment incurred on the project : Rs. 12 Lacs
Total savings per annum : Rs. 32 Lacs
Payback Period : 4.5 Months
Yearly Saving : 269 MTOE
169
b) Modifications in ammonia plant synthesis gas turbine condensate
transfer system
Existing condensate header was overloaded and due to high pressure drop in
network Plant was forced to run two nos. condensate transfer pump in synthesis
gas turbine. After study it was concluded that installation of a dedicated separate
line of 8" size (to shortest possible route) will be the economical solution. The
scheme was implemented by using existing unused pipeline. Investment cost was
very less. After implementation of the scheme, Plant is able to handle the condensate
by running only one pump.
Investment incurred on the project : Rs. 1.00 Lacs
Total savings per annum : Rs. 1.26 Lacs
Payback Period : 10 Months
c) Modifications in urea plants inert washing tower (C-3/E-11) to
minimize ammonia loss
Inlet gas pipe to E-11 bottom was extended and sparger arrangement was made
for better distribution of gas in the solution. Level gauge upper tapping height was
increased thus unit was able to maintain high liquid level in E-11 bottom. This has
resulted saving of approximately 1.0 MTPD of ammonia which was otherwise
going to atmosphere.
Investment incurred on the project : Rs. 0.72 Lacs
Total savings per annum : Rs. 32.00 Lacs
Payback Period : 9 Days
Other ENCON activities
(a) Optimization of process parameters, higher plant load operation & maximizing
on-stream days.
(b) Performance monitoring of critical energy intensive rotating equipments, cooling
towers.
(c) Monitoring of energy consumption and rectifying the inefficiencies.
(d) Regular monitoring and rectification of loses from steam traps, leakages,
passing from vents.
(e) Monitoring & Rectification of losses from stack and due to improper insulation.
170
KSFL Shahjahanpur Fertilizer complex has certification for QMS, EMS & OHSM
thus maintaining an eco-friendly environment. Company is getting regular permits,
consents and authorization for hazardous wastes from statutory bodies. Regular
monitoring of emission from plant sources and ambient air are being carried out
for controlling air pollution. A huge green belt has been developed all around the
factory and township. Plant has been operating on ZERO effluent discharge by
utilizing effluent in plant as well as township for horticulture purposes. Sewage
water after treatment in sewage water treatment plant is used inside the plant
premise.
Company is maintaining a very good safety record and providing training on Fire &
Safety regularly to all employees and contract workers. Regular hazop study of
the plant is being carried out by the external agencies.
171
Certificate of Merit Fertilizers
GUJARAT STATE FERTILIZERS &
CHEMICALS LTD.
Distt. Vadodara (Gujarat)
Unit Profile
In 1962, GSFC was incorporated as Joint Sector Company with determination of
the Government of Gujarat to offer quality products and services to the farmers
and now GSFC is a leading manufacturer of various Fertilizers & Chemicals.
Ammonia production unit started in 1967 followed by Urea and then diversified to
industrial products like Caprolactam, Nylon-6, Melamine, Argon and Methyl Ethyl
Ketone (MEKO) etc. GSFC installed three nos. of Cogeneration plants in phase
wise manner. GSFC also produces various fertilizers like Di-Ammonium phosphate
(DAP), Ammonium phosphate sulphate (APS) and Ammonium sulphate (AS) along
with industrial acids like Sulphuric acid and Phosphoric acid.
GSFC has also put up plants for manufacture of Urea phosphate and has developed
various water soluble fertilizers through R&D centre with complete in-house
engineering.
172
GSFC has Central library, Training institute, online farm advisory services, well-
equipped static and mobile laboratory for soil and water testing facilities. GSFC
has invested Rs. 711 Crores to install various wind mill stations of total 123 MW
capacity.
GSFC has trained 574 employees in last financial year in the field of energy
conservation at the cost of ~Rs. 2 lacs. GSFC also organizes various seminars to
impart technical knowledge pertaining to Energy conservation / Green technology
to faculty students and professors of various universities. GSFC has Suggestion
Appraisal Committee to have valuable suggestions from employees to reduce
energy consumption.
The company also organizes farmer-training programs in consultation with
Agriculture University. GSFC also shares its advance knowledge and resource in
agri input through publication of bi-langual agriculture magazine KRISHI JIVAN.
GSFC has been cornering glory by treading the five-fold path of Excellence, Ethics
values, Dedication, Management excellence and Enhanced social responsibility.
Energy consumption per MT of Ammonia for the year 2010-11 is 7.389 Gcal/MT,
which is in lowest bracket.
Energy Conservation Projects commissioned during the year 2010-11
Sr. Project Description Electricity Total Investment
No. Lacs kWh Savings Incurred
in Rs. on the
(Lacs) Project
Rs. (Lacs)
1 Operation of Turbine driven 8.00 30.00 2.93
BFW pump for Process
requirements, A-III plant.
MP Steam generated in A-III
plant used to drive turbine
driven pump, in place of motor
driven pump to save power.
2 Supply of CW from A-I 3.60 13.50 41.10
Cooling Tower to A-III plant
to reduce power
consumption. CW supply from
CT, commonly used for A-I and
Urea plants, started to A-III
plant also, in place of using
dedicated CT for A-III plant to
save power.
173
in Rs. on the
(Lacs) Project.
Rs. (Lacs)
3 Trimming of Semi lean 9.79 36.73 1.00
solution pumps (P-0301B/R
& P0302/R) impeller, at
A-IV plant. The pumps were
developing higher head than
required. The impeller of the
pumps trimmed to the extent
possible to save power.
4 Optimization of power 120.00 450.00 20.30
generation unit operation,
at A-IV plant. About 20 MTPH
of LPS venting, due to non
functioning of power generation
unit (TG), was noticed.
Additional MPS generated at
CoGen plant and with proper
ratio of MPS to LPS, TG started,
after carrying out major
overhauling. Additional power
generation on account of LPS
could be realized.
5 Stoppage of dedicated CW 2.40 9.00 0.75
pump for MEKO plant. Supply
of CW to MEKO plant started by
interconnecting CW supply
header to Capro-1 plant and
dedicated CW pump, being
operated for MEKO plant, was
stopped to save power.
6 Stoppage of dedicated CW 1.78 6.60 0.20
pump and Cooling tower
(CT) for Zone-40 section of
Lactam plant, Capro-1.
Separate CT and CW pump
were operated to maintain AC
in LC crystal production unit
and Bagging section (Zone-40)
174
in Rs. on the
(Lacs) Project.
Rs. (Lacs)
of Lactam Plant. Supply of CW
to AC Unit of Zone 40 was
started by interconnecting CW
header of the AC Unit to the
main cooling water header. It
resulted in to power saving.
7 Judicial running of 44.00 165.00 0.50
Refrigeration compressor
at Capro-1. Operation of HX
Plant, a major consumer of
refrigeration load, was
reviewed and production level
of HX was adjusted such that it
will run at full load with two
compressors in line to built up
the inventory and then will run
at lowest possible load with
only one compressor. This
operational strategy resulted
into stoppage of one
refrigeration compressor for
many days. This resulted in to
substantial power saving.
8 Optimization of CW pumps 0.30 1.13 0.50
operation at Nylon-6 plant.
Depending upon the margin
available in CW pumps,
used for Continuous section,
CW supply started to Batch
section also. Dedicated CW
pump for Batch section is now
operated only for ~4 hrs/day,
in place of 24 hrs/day, to meet
CW requirement during specific
operation only. The change in
the operation strategy resulted
in to power saving.
175
in Rs. on the
(Lacs) Project.
Rs. (Lacs)
9 Use of Hollow FRP blades at 0.60 2.25 2.50
Nylon-6 plant. Solid aluminum
blades of 3 NOs. of fans of
Cooling tower replaced by
Hollow-FRP blade to reduce
power consumption.
10 Power conservation in 6.40 24.00 2.00
various pumps at Capro-II
plant. Various tactics viz.
supply of material by gravity,
installation of higher size
impeller to avoid running of two
pumps, direct supply of product
to avoid double pumping, use
of common pump for product
withdrawal and reflux,
installation of smaller capacity
pump, trimming of impeller etc.
adopted in different pumps to
reduce power consumption.
11 Installation of VAHP-2 in 12.00 45.00 195.00
HAS plant, Capro-II plant.
While considering sizing of stand
by VAHP unit, installation of
higher capacity unit is carried
out to take load of ANONE AHU
having 162 TR capacity
operating on electric power.
This resulted into stoppage of
power consumption for running
A.C. unit making use of excess
low pressure steam. It resulted
in to power saving.
Total 208.85 783.21 266.78
176
Sr. Project description Gas Total Investment
SM
3
in Rs. on the
(MTOE) (Lacs) Project.
Rs. (Lacs)
Thermal Energy
1 Utilization of LP Steam of 9.80 117.00 15.80
A-IV plant in Co Gen-III (816.83)
plant Deaerator. Up till now,
MPS (14 K) steam was used in
Cogen-III plant Deaerator,
operated at ~2K pressure. LPS
(4.5K) at A-IV plant is in excess
and therefore either vented or
used in TG to produce power.
LPS of A-IV plant fed to
Cogen-III Deaerator in place of
PS at rate of ~5 MTPH. MPS
generated in boilers and
exported to A-IV to maintain
power generation rate constant.
As less amount of MPS is
required in place of LPS to
produce power, there was less
steam requirement and
ultimately it resulted into less
NG consumption at boilers. It
resulted in to net NG saving
with constant power generation
rate.
2 MP steam generation from 13.60 163.00 13.20
HP condensate blow down (1133.56)
at A-IV plant. Blow down of
HP condensate was carried
out in LP Flash drum. As LPS
(5K) is in excess, it was vented.
Scheme implemented to carry
out flashing of HP condensate
first to produce MPS (37K) and
then LPS. This resulted into
additional MPS generation and
equivalent reduction in NG
consumption, used for steam
generation at boiler, realized.
Total 23.40 280.00 29.00
(1950.39)
177
1. MP steam generation from HP condensate blow down at A-IV plant.
Blow down of HP condensate was carried out in LP Flash drum. As LPS (5K) is in
excess, it was vented. Scheme implemented to carry out flashing of HP condensate
first to produce MPS (37K) and then LPS. This resulted into additional MPS generation
and equivalent reduction in NG consumption, used for steam generation at boiler,
realized. Net NG saving realized is 13.6 lacs SM
3
/year (Rs. 163 lacs/year). Cost
of modification is Rs. 13.2 lacs with payback period of 1 month.
VAHP unit of Voltas make.
GSFC has adopted energy conservation as major corporate objective. Advisor
(project & Corporate Planning), with assistance of designated Energy Manager,
coordinate the activities of energy conservation and cost reduction. GSFC has
dedicated energy cell comprising members from Operation, Electrical, Maintenance
and Design Department to discuss, evaluate and encourage energy conservation
ideas from each plants and departments. Energy conservation ideas are also
received from all employees in form of suggestion through Suggestion Appraisal
Committee. GSFC is the first Fertilizer company to obtain certificate in Energy
Management system - BS-EN-16001 and have incorporated it in Integrated
Management System (IMS).
178
179
Second Prize Food Processing
MARICO LIMITED
Kanjikode, Palakkad (Kerala)
Unit Profile
Global in vision, rooted in Indian values, the Marico group is driven by a performance
ethic pegged on value creation for its multiple stakeholders. Marico is one of
India's fastest growing Consumer Products & Services groups, in the Global Beauty
and Wellness space with a turnover of about Rs.31.3 billion (USD 695 Million)
during 2010-11.
Marico markets well-known brands such as Parachute, Saffola, Hair & Care, Nihar,
Shanti, Mediker, Revive, Kaya, Fiance, Hair Code, Caivil, Code 10 and Black Chic.
Marico has total 7 plants across India manufacturing various leading consumer
products and also Marico's branded products are present in Bangladesh, other
SAARC countries, the Middle East, Egypt and South Africa.
Parachute, the flagship brand of Marico is premium quality 100 % pure edible oil.
Parachute is a market leader, with around 56% of market share, in the coconut oil
category. Marico together with its three brands (Parachute, Nihar and Oil of Malabar)
now enjoys over 55% volume share in the 1500 crore branded coconut oil category.
Key domestic competitors are VVD, Shalimar and Cocoraj and other un-organized
players. Parachute superiority over competitor product is its unique and distinct
"Aroma" of the oil which is liked by millions of consumers over so many years.
180
Kanjikode Plant
The ISO 14001 and ISO 18000 Certified plant at Kanjikode (near Palakkad) has
the best in class manufacturing systems and Quality systems for Coconut Oil. The
best in class selection of technology helps Marico to ensure differentiated superior
competitive product. The plant certified with ISO 22000 for Food safety practices
GMP & GHP.
The plant built on green philosophy, has kept more than 50% of land under green
belt. The rain water harvesting system takes care of 40% of its process water
requirement.
Marico is engaged in constantly upgrading its technology and has been a pioneer in
deployment of many technologies. Goa unit has the most advanced coconut oil
expelling technology in India.
Energy Consumption
Year Product
Quantity
(MT)
Total Units
Consumed
(kWh)
Total FO
Consumed
(Liters)
Specific
Power
Consumption
(kWh/MT)
Specific Fuel
Consumption
(L/MT)
2008
-
09 Copra
Processed
22978
2428774.6
314798.6 105.7 13.7
2009
-
10 Copra
Processed
19896.8 2032199.5 268606.8 102.1 13.5
2010
-
11
Copra
Processed
22228.8 2159748.3 271191.1 97.2 12.2
181
Energy Conservation Activities 2010 11
Project 1: Integrating Copra Feed Conveyor
Cut copra is transferred to Oil mill for Cooking using two conveyors. Plant has
integrated the conveyor to single drive with energy efficient motor thereby reducing
the power consumption by 16700 units/Annum resulted in the savings of 0.67
Lacs/Annum.
Before After
Project 2: Flash Steam Recovery
Using flash vessel plant has generated the flash steam which was used for heating
the make up water for the boiler. This helped plant to reduce the furnace oil
consumption by 6.89 MT/year, which resulted in a savings of 2.1 Lacs/ Annum
182
Project 3: Rain Water harvesting for Boiler Feed
By using rain water harvesting able save around 650KL of ground water per annum.
This also helps to reduce the boiler blow down there by reducing the furnace oil
consumption 3.658 MT per Annum resulting in the savings of 1.5 Lacs per annum.
Project 4: Cutter Particle size optimization
Replaced the cutter mesh from 15mm to 12mm there by reduced the particle
size from 10mm to less than 5mm. The higher % smaller particle size helps in
better cooking of copra thereby helped in reducing the Fuel consumption by 6.78
MT/Annum resulting in cost savings by 2.8 Lacs/ Annum
183
Project 5: Online Load monitoring system.
Expeller loading was earlier monitoring by using the ammeter mounted on the
machine. Since it was done manually under loading of the expeller was not known
immediately.
Unit developed new system by which online monitoring of the expeller loading was
possible which enabled better control on the unloading of the expeller. This helps
to improve the per day crushing by 2 tons, which helped in reducing power & fuel
saving of 0.616 Lacs units & 8.6 MT respectively. The annual savings achieved is
2.46 Lacs & 3.44 Lacs respectively
Before After
ENCON Plan & Targets 2011
Energy Conservation Plan & Targets for 2011
Sl
No Key Process Indicators
Actual (10 -
11)
Target (11 -
12)
1 Reduction in Specific Fuel Consumption 12.22 10.75
2
Reduction in Specific Power Consumption
in OilMill 83 80
3 Increase in Rainwater usage 18
25
Sl Projects Identified Units saved Liters
Saved
Savings
( Lacs)
Investment
( Lacs)
1
Solar System for Administration block
lighting & PC 12500 0.5 10
2 Solar streetlights 12500 0.5 4
3
Energy efficient motors for Super A
Expellers 52000 2.08 5
4
PID controller for Oilmill Conditioners to
reduce steam usage 2130 0.64 1.95
5
Replacing UG oil heating sump with new
insulated sump 15000 4.5 2.5
6
Utilization of First stage Expeller
Condensate in Second stage 9482 3.75 1
7 Improving the CC 101& 102 loading 22380 15000 4.5 5
8 PRS for Copra Conditioner 4741 1.5 1.5
9 100% rain water for Boiler feed 4000 1.5 6
10 Rainwater usage for Shaft cooling 0.5
No
184
Energy Policy
Functioning of Energy Cell
Energy Audit (Internal/External)
Developing the Project Bank.
Prioritization of the Project.
Project approval from the management.
Project implementation core team formation.
Monthly team reviews with the plant champion.
Monitoring of the benefits.
185
Certificate of Merit Food Processing
GLAXO SMITHKLINE CONSUMER HEALTH
CARE LIMITED
Nabha (Punjab)
Unit Profile
Glaxo SmithKline Ltd, an Indian group company/associate of Glaxo SmithKline plc
U.K, is a leading market player in consumer food drinks in India. Glaxo SmithKline
Consumer Healthcare, Nabha (Punjab), commissioned in 1960, manufactures the
prestigious health food brands Horlicks, Boost, Junior Horlicks and Mother Horlicks
with present capacity of 40KT on product mix. The site is accredited with ISO
9001:2000, ISO 14001:2001, OHSAS 18001:1999, ISO 22000:2005, MMPO
and HACCP certification and is located over a total area of 18.17 Acres and
employing workforce of 1713.
Recipient of state energy award in last two successive years, Plant works on the
principle of "URJA PARMODHARMA" (Energy is supreme religion).
186
Energy Consumption
Site has strong energy monitoring system for reviewing of energy consumptions.
Site receives electricity supply from State Electricity Board. An induction generator
based back pressure turbine of 170KW runs in synchronism with grid supply. HSD
is being used in DG sets for Captive generation during grid power failure. Also HSD
used in burner of spray drying plant. Thermal Energy required for process heating
application is cater by steam from FBC boiler. There are more than 120 advanced
digital meter for recording electricity consumption at site. Similarly for steam energy
monitoring there are advanced electronic meters at generation end, main sections
and subsections end. Electrical and Thermal energies are recorded and reviewed
on daily basis in Plant meeting comprising of Units heads. Any deviation from plan
is immediately taken care.
Production
Volume
MT 41623 40639 46533
Energy
Consumption
kWh 110974012 105068922 107882648
Specific
Energy
kWh/TOP 2666 2585 2318
Energy Trend
187
Key Energy Measures Implemented
FBC Boiler - Earlier the site had 4 numbers of inefficient
grate fired boilers. 2 of them were of 10TPH capacity
remains operational for most of time and the remaining
were of 5 TPH and 6 TPH respectively used as stand
by. Due to their inefficiencies, complexities, safety and
environmental issues, site decided to switched over
to advanced Fluidized bed combustion technology. Site
installed Energy Efficient 20 TPH FBC boiler at site to
meet process steam requirements using reduced coal
consumption. This boiler is equipped with state of art
automation and safety features. ESP unit along with this boiler ensure Environment
compliance.
Annual Energy Cost Saving : 179 Lacs
Efficient Chillers - One of the initiatives taken involves
centralization of Air conditioning plant by replacing old,
energy & maintenance intensive, containing ODP
refrigerant reciprocating compressors with energy
efficient centralized screw compressor chiller. Installed
3 No. screw compressor type 100TR chillers (one
standby) for 9L plant & Admin cooling.
Simplification & reduced maintenance- 16 No. localized
triomatic units for air conditioning is replaced with 4 No. AHU's
Zero Freon site - Eliminated ozone depleting potential refrigerant.
Enhanced human comfort - effective cooling in Admin block.
Annual Energy Cost Saving : 7.43Lacs
Total Investment :61.0Lacs
188
Efficient Compressor - In order to meet compressed
air requirements of the factory site have 5 numbers
air fixed capacity air compressors. 4 of them remains
operational while 1 compressor takes cares of
fluctuating demand. Under Energy efficiency theme of
site, site procured a 55KW screw compressor based
air compressor. This compressor is equipped with a
variable frequency drive. The drive regulated the speed
of compressor as per the header pressure requirement.
This has resulted in stoppage of 4 numbers of earlier running compressors and
consequently a considerable saving. Moreover the new compressor is oil free type
make compressed air free from oil and lesser maintenance requirement.
Annual Energy Cost Saving : 9.28 Lacs
Advanced Evaporator- As a major toward productivity enhancement for
decreasing batch time of evaporation process forced circulation evaporator installed
in this manufacturing unit. The advantages of this technology are
Liquid is circulated at a high rate through the heat exchanger, boiling being
prevented by the virtue of pressure being maintained above the top plate
Increased velocities increase the film-tube heat transfer coefficients
Flashing: As the liquid enters the separator where the absolute pressure is
slightly
Less than in the tube bundle, the liquid flashes to form a vapor.
High volume and low head pumps used for the circulation of the concerned
liquid
Temperature rise across the tube bundle is kept low as 2-3C thus allowing
for a higher circulation. Higher circulation results in higher speeds through the
tubes hence preventing any deposition on the tubes.
LED Lights- The site lighting
power requirement is nearly
3 % of total power
requirement. As a measure
for conserving energy in these
segment of energy
conservation, Advanced
emerging LED lights were
installed in manufacturing,
administration block Corridors
and Street light. The life of these LED lights are very high as compared to
conventional lights. Furthermore these LED lights are environment friendly having
no Mercury content.
189
Total Investment : 9.28 Lacs
Efficient Pumping - Earlier the site had 4 numbers
turbine type Hot water pumps which used to pump
hot water from process to cooling towers installed
nearby. The ratings of these pumps were 10 Hp and
delivery was around 45 M3/Hr. These pumps were
inefficient apart from highly maintenance prone
&installed below ground surface level leading to its
operation and maintenance difficult. 2 numbers
centrifugal based ground surface mounted efficient
pumps were installed. The rating of these pumps are 25HP and delivery of 295
M3/Hr.
Total Investment : 3.5 Lacs
Exhaust Air Kit - The capacity reduction installed
exhaust air kit as per the requirement of process
area parameter, was achieved by installation of
spare Variable frequency drive. Using innovative
thinking, only 2 numbers of spare VFD installed in 2
groups of exhaust air kits. One group comprise of
3 exhaust air kit whereas other group had 2
numbers of exhaust air kits. This innovative thinking
resulted in reduction in VFD requires for energy saving and at the same time
ensured uniform ambience in the area.
Total Investment : 0.04Lacs
Heat Recovery Wheet - For catering the HVAC
requirement of a major portion of site biggest
manufacturing unit, the outgoing air of the AHU unit
is used to be cooler than ambient air. In order to
cool the incoming air of the unit, site installed a heat
recovery wheel. It is a sizable disk, fabricated with
material having a fairly high heat capacity, which
rotates between two side-by-side ducts: one a cold
gas duct, the other a hot gas duct. As the disk slowly
rotates, sensible heat (moisture that contains latent heat) is transferred to the
disk by the hot air and, as the disk rotates, from the disk to the cold air.
Total Investment : 2.76Lacs
190
Way Forward
Bio Fuel-As a major step toward energy
substitution, site is working extensively toward
usage of biofuels. Successful trials with biofuel based
pellet by 10 % blending with coal paving way for
10-15 % usage in 2012. Annual CO2 Emission
reduction potential - 3202 Tons
Solar Energy-As a site energy strategy for
harnessing renewable energy a initiative requiring
solar water heating application to replace steam
batteries is planned. Under this initiative, steam
required for heating water (required for various
cleaning activities) in plant would be replaced by
hot water from solar based heating system. Annual CO2 Emission reduction potential
- 115 Tons
Waste Heat Recovery- Under the site culture of recovering
waste Energy, a initiative toward utilize waste thermal energy in
the form of flash steam is planned. The initiative will reduce
annual CO2 Emission by aap. 90 Tons
LED Lighting - Site
has already taken
c o n s i d e r a b l e
initiatives toward
reduction in lighting
energy consumption.
One such initiative is use of LED based Luminaries. Site is committed towards
replacement of all its inefficient luminaries with advanced efficient LED based
luminaries. In this initiative twin tube fluorescent sets & Street light will be replaced
with LED tube rods in 3 years. Annual CO2 Emission reduction potential - 195 Tons
191
Planetary Gear Box - As an initiative to reduce
motive energy Consumption, site has planned
to replace inefficient gear boxes with advanced,
efficient and compact gearboxes. This initiative
will lead to reduction in energy consumption as
well as reduction in lubricating oil consumption
and maintenance optimization efficient Ones for
agitators. Annual CO2 Emission reduction
potential - 104 Tons
Steam Turbine - Site have already installed in
year 2008 a back Pressure steam turbine which
caters steam flow for one of its manufacturing
unit. Similar initiative is planned for extracting
energy from steam required in another
manufacturing unit. Annual CO2 Emission
VFD for Primary Air fan-It is planned to install
a VFD on primary airfan at 20 TPH Fluidized
bed boiler. It will result in smooth operation and
better control of boiler parameters along with
energy conservation. Annual CO2 Emission
Vacuum System - For conserving energy
consumption in vacuum system a initiative is
planned to install energy efficient, advanced
vacuum system in place of existing one. Annual
CO2 Emission reduction potential - 52 Tons
Process Efficiency- One of the major steps toward improvement in process
energy efficiency is to optimize evaporator running. Under this a second stage
evaporator will be stopped.
192
Energy Policy
193
Second Prize Foundry
GREY IRON FOUNDRY
INDIAN ORDNANCE FACTORIES
Jabalpur (Madhya Pradesh)
Unit Profile
Grey Iron Foundry (GIF), Jabalpur was set up for production of automobile castings
of Grey Iron & Malleable Iron required for Shaktiman & Nissan Vehicles produced
at Vehicle Factory, Jabalpur & Vijayanta Tanks produced at Heavy Vehicles Factory,
Avadi. The factory was commissioned in technical collaboration with SKODA,
Czechoslovakia under an agreement on economic cooperation with Govt. of India
& Govt. of Czechoslovakia. The production commenced from July 1976. Due to
phasing out of Nissan, Shaktiman vehicles & Vijayanta Tank, GIF has entered Civil
Trade market & diversified its production towards Ammunition items & Ammunition
Boxes in addition to supplying castings to VFJ for LPTA & Stallion vehicle.
Grey Iron Foundry is located adjacent to Vehicle Factory, Jabalpur on eastern side
of main Jabalpur - Allahabad railway line at a distance of 9 Km. from Jabalpur
Railway Station
Product Range
Product range comprises of Grey Iron Castings of four grades i.e. FG - 150, FG -
200, FG - 260, FG - 350 to IS : 210 - 1993 & Spheroidal Iron of grade 400/12,
450/10, 500/7, 800/2, 900/2 to IS : 1865 1991, Steel Castings. Weight of
individual castings varies between 350 gms to 285 Kgs.
GIF has taken up the development of castings for Ammunition items of 450 Kg,
250 Kg, and 1000 lb. Bomb Body etc. and Ammunition Boxes of C43A, c-44A,
C48A, C51A, C53A, H2A, Carrier 6AL, Carrier 13AL. etc.
Production processes involved in producing the castings / Ammunition boxes: -
(a) Sand Preparation (b) Core Making
(c) Moulding (d) Melting of Metal
(e) Fettling (f) Pattern Making
(g) Ammunition box (Fabrication & Painting)
194
Energy Consumption in Grey Iron Foundry, Jabalpur
DESCRIPTION UNIT 2008-09 2009-10 2010 -11
Annual Pr oduction MT 3705 4311 3639
Total electrical ener gy
consumption/ annum
Lacs
KWh
9445274 8992843 6892996
Speci fic electrical ener gy
consumption
kWh/MT 2549 2086 1894
ELECTRICITY
Consumption % reduction over YEAR
kWh/MT 2008-09
2008-09 2549
2009 -10 2086 18%
2010 -11 1894 25%
Specific Electrical Energy Consumption of Grey Iron Foundry, Jabalpur
2549
2086
1894
0
500
1000
1500
2000
2500
3000
S
p
.
E
n
e
r
g
y
C
o
n
s
u
m
p
t
i
o
n
2008-09 2009-10 2010-11
YEAR
Process Flow Chart
Sand Mixing Plant Pattern Shop
Core Shop Moulding Shop
Melting Shop
Fettling Shop
195
Year Wise Production & Specific Electrical Energy Consumption
Year Production (MT) Specific Electrical Energy
Consumption (kWh /MT)
2008-09 3705 2549
2009-10 4311 2086
2010-11 3639 1894
Major Energy Conservation Measures Implemented in 2010-11
(1) Contract Demand Reduction
Saving per Annum Rs.6.48 Lacs
(2) Proper scheduling, Maintenance & Other Conservation Measures in Induction
Furnaces
(3) Proper scheduling, Maintenance & Other Conservation Measures in Sand Mixing
Plant
(4) Proper scheduling Maintenance & Other Conservation Measures in Pump House
(5) Proper scheduling, Maintenance & Other Conservation Measures in Compressor
& Compressed Air Lines
(6) Night Working in Fettling Shop & MPV Section stopped, rescheduling of
production activities & other conservation measures
(7) Replacement of 400 W HPSV lamps with 250 W Metal halide fittings in 01
Bldg.
(8) Replacement of 400 W HPSV lamps with 250 W Metal halide fittings in 02
Bldg.
(9) Provision of false ceiling alongwith lighting panel, 80 W Ind. Lamp fittings &
LED Light fittings in CNC Section
196
(10) Replacement of existing underground, basement lights with energy efficient
light fittings in Bldg. No.1
(11) Rewiring & replacement of existing T.L. fitting with Energy Efficient Light
fittings in Store section
(12) Rewiring with replacement of existing light fittings of offices, godown,
passages in 01, 02 & 03 bldgs with energy efficient CFL fittings
(13) Consumption Reduced in Process Heating & in Fork Lifter in HSD Oil in 01
Building Activities
Total annual saving in the year 2010-11 = Rs. 136.80 Lacs
Future Major Plans for Energy Conservation 2011-12
(1) Installation HT APFC panel for power factor improvement & getting incentive.
(2) Installation of solar water heater for process heating
(3) Installation of solar water heater for lunch canteen & factory dispensary
(4) Installation of solar garden lamp near main gate to promote use of solar
energy & for beautification of garden.
(5) Installation of solar garden lamp near administration building for beautification
of garden is under progress.
(6) Implementation of more energy conservation measures in melting shop,
compressor house, pattern shop.
(7) Implementation of more energy conservation measures in melting shop,
compressor house, pattern shop
197
(Installation of solar garden lamps near admin. building)
Grey Iron Foundry, Jabalpur are committed to conserve various forms of Energy
in a cost effective manner for all its products, related operation & ensuring that
production quality, quantity, environment, safety, health of people are maintained.
To meet above goals company will strive for :-
To reduce specific energy consumption in all operations and activities.
To adopt energy efficient technologies/equipment for all new projects.
To replace old and outdated energy inefficient technology/equipment continually.
Conducting energy conservation studies including audits by engaging external
specialists.
Creating awareness among employees through campaigns, publicity about
need for energy conservation.
Recognizing the efforts of employees in energy conservation initiatives and
suitably rewarding them.
To control energy consumption by periodic review and improving plant
processes by motivation & training practices.
To conduct regular management review to ensure continual improvement
and achieve of plant goal.
Reducing specific energy consumption by a minimum of 5% from the present
level by the year 2011-12.
198
Safety & Environment
Safety
Various initiated on safety awareness, including safety audit, risk analysis,
identification of safety hazards, health check up of all employees and in house
training to the employees safety conducted in the factory.
Safety and Environment policy in line of SH & E have been made and display at
various prominent places in the factory for awareness of an employee. 3 tier audit
is being conducted to identify the safety hazards/accident prone operation/
equipment and eliminate of the same to bring better control by adapting the best
practices and to sustain zero accident.
Eudiometry and air pollution tests are carried out periodically in various product
units for minimization of environmental aspects and O.H.S. hazards with the help
of structural reviews to steer plant on going performance. Special type of protective
equipments has been introduced for the betterment of occupational hazard.
Various measures have been taken to avoid the fire hazard like installation of
smoke detector system and fire hydrant system.
Environment
External environment audits through certifying agencies were conducted and various
environmental initiatives including environmental monitoring were implemented to
maintain the ecological balance in and around the company premises and provide
pollution free environment to employees.
199
First Prize General Category
SCHNEIDER ELECTRIC INDIA PVT. LTD.
Unit Profile
Schneider Electric India Pvt. Ltd. has one of their manufacturing facilities located at
Medak road, Hyderabad. The plant is manufacturing electrical equipment like ACB,
contactor, relays etc, having approximately 800 employees and working in two
shifts. State of the art facility with lean manufacturing processes. Hyderabad global
plant produces LVP, MVP and PCP under one roof. Plant will support long term
growth plan by creating low cost manufacturing capacity for new products and
also enhance capacity for existing products to support adjacent regions. The plant
has the distinction of State of the art facility with latest manufacturing techniques.
This plant has seen tremendous growth in volume since 2009 till date. The plant
volume has increased almost 4 times from 112,303 to 374,308 production units
since beginning of 2009. The high pressure on production created the need to
intensify the drive for Energy Efficiency, Save Environment and Health and Safety
of the employees.
200
Brief Description of the Facility is as under:
Land 40,000 Square meter of industrial property
Total facility 11727 square meter of building space
Building Structure The building contains 11,727 square meters,
& Exterior Manufacturing area 4968, Ware house 1550, Others
5210.
Roof The entire facility has its original roof. The roof is a
built up roof with a Metal sheet.
Electrical Power Electrical Power is supplied by Andhra Pradesh Central
Power Distribution Control Board.
HVAC System The Shop floor is cooled with water coolers with
Brand: Voltas, with 300 HP. Support function is
cooled with Package system with Brand: Voltas,
With: 85TR. Some area has a split cooling system
such as: MIS /Server room, IQC, Incoming and
Receiving room.
Fire Suppression The plant is not equipped with sprinkler
System protection. Water tank is located under ground. Two
automated operation pump is equipped to operate
the water pump. The plant has equipped also with
alarm system with audible alarms and automatic fire
department notification.
Back up Power 500KVA Diesel generator and UPS back up power are
available.
Water & Sewer In-house.
Compressed Air The plant operations compressed air is piped
throughout the facility from a central utility room at a
guaranteed pressure of 6.5 kgcm2 at all points. One
unit of compressor is provided with brand of Atlas
Copco to support the production line.
Plant building is a show room for many Schneider products and is a model for
Energy Efficiency.
a. Master pact Circuit Breakers in June-06
b. RN2C Ringmaster in Dec-06
c. RM6 Ring Main unit Jan-07
d. TesysRange of Contactors Dec-06
e. Harmony range of push buttons & pilot lamps : Sept-07
201
f. Kiwi2 contactors production started in July 08
g. Evolis VCB production started in Feb -09
Energy Consumption Detail
The plant is getting power supply from the state electric electricity board. There is
one Transformer of 1000 KVA to step down the voltage from 11kV to 433 V.
Other than state electric electricity board, the facility has a stand by DG set of
500kVA for back up. A quick overview of the energy Consumption distribution is
as under
15%
21%
13%
9%
14%
14%
5%
3%
4%
1%1%
Air Conditioning
Lighting
Raw power
UPS
Air compressor
Ventilation
Kitchen,Dish washer
STP
Water Pumps
Capacitor bank
RO Plant, Server, Garden Lights
202
Lighting: Lighting consumed about 15% and 21% of total load at the facility in
2009-10 and 2010-11. For a normal working day the average lighting energy
consumption per day is 430kWh/day. Facility is having separate lighting feeder to
feed the power to the lighting. Detailed analysis is done every year to find the
energy conservation measures focused mainly on lighting.
Air Conditioning: Air conditioning units are one of the major loads in the plant
consuming about 17% and 15% of total load at the facility in 2009-10 and 2010-
11. An increased focus in 2009-10 led to 2% reduction in consumption.
Air Compressor: Air compressor are one of the major loads in the plant consuming
about 11% and 14% of total load at the facility in 2009-10 and 2010-11. While
couple of energy saving projects were executed and savings realized but overall
consumption has gone up due to the rising production volumes.
Raw Power: It is the energy consumed by the machines on the shop floor. It
contributes to nearly 13% of the total consumption. Continuous application of
lean principles on the production floor by making the product lines more compact
has actually helped in maintaining the consumption in spite of the increasing volume.
Ventilation Units: There are 15 fresh air fans installed to supply the fresh air to
shop floor and other areas. Each unit is having the rated capacity of 25,000 cfm
and 15.5 kW motor capacities. Fresh air units are ducted to supply the air from
one end of the shop floor to other end. It contributes to nearly 14% of the total
consumption.
UPS: There is a 30KVA UPS installed of Schneider MGE make. It consumed about
11% and 9% of total load at the facility in 2009-10 and 2010-11. This reduction
was made possible by Phase balancing.
Energy Conservation Results
While the plant had the unique distinction of having a Green Building with Natural
Roof Lighting during day time, Insulated Roof Top and walls for efficient cooling,
Energy Efficient Compressors, Building Management System for controlling the
temperature centrally and SMS System to monitor Hourly Energy Consumption.
The team has taken up the challenge to further reduce the Electricity consumption
by 5- 10% every year since inception in 2006. Year on year various Energy Saving
Projects are initiated and executed to maintain the target on hand. A total net
saving of 97,568 kWh in 2010- 2011.
203
Energy Consumption VS Production Volume
0
100
200
300
400
500
600
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar
T
h
o
u
s
a
n
d
s
E
n
e
r
g
y
c
o
n
s
u
m
p
t
i
o
n
i
n
K
w
h
0
100
200
300
400
500
600
T
h
o
u
s
a
n
d
s
P
r
o
d
u
c
t
i
o
n
v
o
l
u
m
e
Production ( Units)
Actual Energy (KWH)
Hypothetic Consumption
without EE Projects (KWH)
Key projects/ Initiatives
Arrest the compressed air leakage: Facility is installed with a centralized
compressed air system to supply the compressed air for different applications.
There are two compressors, each having capacity of 200 cfm, out of two
compressors one is running to meet the requirement of compressed air in the
facility. The major usage of compressed air is in the shop floor is for screw
tightening/ loosening, pressing, pneumatic applications etc. Earlier plant air
compressor had 15% leakage which is high, it was planned to reduce the
compressed air leakage to allowable limit of 3 % considering the network.
Detailed analysis was done on the compressors to find the energy conservations
measures. The free air delivery test was carried out for one of the two compressors,
to assess the performance (volumetric efficiency), Pump up test was conducted
and led to annual saving of 7,885 kWh without any investment cost.
Adjusting the control Settings & Controlled through BMS AC temp setting:
HVAC- Target temperature for Air conditioning at 26 deg C & Switch off Air
conditioning during Lunch and one hour before the office closure hours by adjusting
the control Settings & Controlled through BMS with ZERO investment. Increase
Support function Air conditioning set temperature. Presently A/C is working with
set temperature of 22 degree C, it is suggested to increase set temperature to 25
oC1 as per ASHRAE standard leading to annual saving of 7440 kWh.
Regrouping of lights: The existing groups of light were not relevant as per the
gangways, glass windows, roof opening for lights and day or night. A project was
undertaken to do complete regrouping of lights as per the layout of the floor and
daylight available along with load balancing in all three phases.
A graph depicting the Energy Consumption Trend wef April 2009 till March 2011 is
as under:
204
3 phases were created => only 3 groups of lights per busbar. This led to a net
annual saving of 36000kWh.
1 group for day-time lights (always on)
1 group for night-time lights
1 group for lights above gangways (gangway require less light)
Clean Evaporator tubes to reduce specific energy consumption of PAC:
Earlier specific energy consumption of PAC was in the range of 1.7 to 1.8 kW/ TR.
Hence it was suggested to clean evaporator tubes regularly so as to have a better
heat transfer between air and refrigerant and reduce the SEC. Evaporator approach
of all the PACs is 10 degree C, but the allowable approach is in the range of 3 5
degree C. The higher approach was due to the poor heat transfer between air and
refrigerant which is due to the scale formation in evaporator coils. Hence cleaning
the evaporator coils regularly to reduce the approach and thus enhance the PAC
performance, thereby leading to a annual saving of 19620kWh.
Installation of VFD to sewage water treatment plant roots blower to avoid
throttling: In sewage water treatment plant, Roots blower was installed to supply
the air to the effluent water for treatment. The Roots blower sends air to the tank
at pressure of 0.38 kg/cm2. The supply air pipe line from Root blowers Control
valve, just before both tanks are throttled to decrease the air flow rate to the
tank.
While the quantity of effluent collected during the day time is more than that at
night as number of employees working at night is less, Roots blower was operated
at the same speed as in day. Hence it was taken up to install a VFD to avoid
throttling and operate the blower at lower frequency by manual control. This
reduced the energy consumed by the Roots blower motor. This led to a annual
saving of 6307kWh.
Replace 150Watts Halide lamps with 56Watts in Ware house: Earlier 40
halide bulbs of 150 W were operating in storage area and 150-290 average lux
levels were maintained. The average lux level required for store house is 100-150
as per standard. Hence a project was undertaken to replace the 150 W halide
lamps (when these lamps burns out) with 56 W halide lamps to maintain a Lux
level of 150-170 at store house as per standards leading to annual saving of
123967kWh.
Replace garden pump with energy efficient pumps: Rated efficiency of garden
pump was only 46%. Operating efficiency of the pump was much lower than the
rated efficiency (operating efficiency of the pump is not measured as the provision
for measuring head developed is not available. However, actual required is 20
meters, so it was suggested to replace present pump with energy efficient pump.
Plant undertook a project to replace garden pump with energy efficient pumps
(Grundfos, NBG 50-32-160/151) thereby leading to saving of 7920 kWh per
annum.
205
Conclusion: As an organization plant is committed to sustainable development
for the society and our planet. Energy Conservation is one of the most important
pillars of Sustainable development. The unit is committed to deliver 5% saving on
Energy Efficiency year on year. The search for identifying new projects for 2011-
12 has already begun and few have been executed as well. Some of them being
installation of Coolite (energy saving device for the Lighting System), VFD for the
Ventilation Units, VAV for Air-Conditioning Systems and Solar Heating System for
Canteen. The journey continues.
Environmental Policy
206
Second Prize General Category
KULKARNI POWER TOOLS LIMITED
Shirol, Distt. Kolhapur (Maharashtra)
Unit Profile
Kulkarni Power Tools Ltd., [KPT] manufactures Electric Power Tools for a wide
variety of application. KPT was established in the year 1976 and commenced the
production from March 1978. The Company was established as a Joint Venture
with Black & Decker Corporation of USA. It had a financial as well as a technical
collaboration with Black & Decker. This collaboration was terminated in the year
1993 as per original mutually agreed terms.
KPT is a public limited Company being quoted on Mumbai Stock Exchange. KPT is
the only power tool manufacturer in India to have both ISI mark under IS : 4665
(Part 2) - 1984, and ISO 9001 certification from KPT exports its products to
Middle East, East Africa, Nigeria and South Africa, South East Asia and SAARC
countries under a brand name - "Powermaster". KPT products have been also
certified by the Canadian Standards Association (CSA).
KPT started manufacturing a range of basic industrial power tools. It has expanded
the range to cover both professional and artisan (used for the construction and
the housing industry) power tool segments. In the domestic market KPT has
roughly 10-15% market share.
207
KPT Plant at Shirol
KPT manufacturing plant is located at Shirol in the state of Maharashtra. It is about
400 kms; south of Mumbai near Kolhapur. From Kolhapur, it is 40 kms; on the
Kolhapur - Sangli State Highway. From Sangli, it is about 14 kms.
The total land at the factory site is 10.5 acres. The installed capacity of the plant is
dependent on the product mix. However, considering the current product mix and
after the new machines are installed the plant capacity will be 250000 power tools
per year and 4,00,000 motors.
Like any other power tool manufacturer in the world, KPT too has three distinct
shops viz. Machine Shop, Winding Shop and Assembly Shop. KPT also has its own
Power Generation (in case, there is a power failure), a Powder Coating Shop and
a Full Fledged Tool Room. As stated above, to cope up with the Indian customers
requirements, KPT has built a well equipped Reliability Laboratory to conduct all
sorts of tests which power tools and control motors have to go through. The
Motor Testing facility of this lab, is perhaps unique amongst all Indian power tool
manufacturers.
Energy Consumption and savings achieved
1. In year 2010-11, with the new investments in Winding Shop and Machine
Shop of Company, Energy Consumption would have crossed 16 lacs kWh/-
year. With the following steps, Energy Savings achieved is 1,27,228 kWh
a) Use of CFL Lamps
In machine shop there is metal cutting machines. These machines have machine
lamps with incandescent Bulbs and these are in operation in three shifts. These
machine lamps were replaced with the CFL machine lamps. This saved the
direct electrical energy and increased the lamp life.
208
b) Electronic temperature controller for Air conditioner
Plant had window air conditioners for maintaining room temperature. The air
conditioners were equipped with the mechanical thermostats. This thermostat
had slow response for temperature change, which was causing the more time
running of compressor in Air conditioner units. The mechanical thermostat
was replaced with electronic temperature controller. The sensor of electronic
temperature controller has the fast response to temperature change. This
saved the electrical energy of the compressor running.
c)Use of Screw compressor in place of reciprocating compressor
Plant had the reciprocating air compressor for air generation for its machine
shop. The electrical energy consumption for required air generation is more.
The reciprocating compressor was replaced with screw compressor. This new
screw compressor generates the required air with less consumption of the
electrical energy.
2. Besides steps taken in-house, KPT has realised that as a corporate
responsibility, plant sould promote non-conventional energy.
Accordingly, KPT has invested in 2 Wind Mills installed in Maharashtra,
with a capacity of 2.25 M.Watts. Company is currently generating around
30 lacs units per year and giving the same to the State electricity grid.
Plant has maintained the power factor 0.99 since year 2007 as mentioned in
Table no. 2. In year 2010-11 KPT has added one new Automatic Power factor
Correction panel. This led to maintain the power factor unity for the plant in
year 2010-2011.
a) Testing of Blowers with 125 HP & 250 HP motors after 10.00 PM
to consume electricity during off peak period.
KPT also manufacture Industrial Positive Displacement Blowers. These Blowers
are used in STP plants. KPT plan the testing schedule such that the Heavy
209
Blowers which are having 125 HP and 250 HP motors are tested in night time,
i.e. during low peak period. This way plant have saved the electrical energy
and maintained demand.
b) Use of Wind ventilators in new constructed Ware house building to
avoid electrical energy for exhaust fans.
KPT has always focused to use eco friendly devices for energy conservation.
Plant has constructed a new building and in that building instead of using exhaust
fans, it has incorporated the wind ventilators to keep the room temperature
below the ambient temperature.
c) KPT also manufacture the industrial positive displacement blowers
which are required for ETP and STP plants. KPT has installed its
own ETP and STP plant in the factory.
KPT has installed its own ETP/STP plant for factory. The water wastages are
avoided to mix with nature. The treated water is used for gardening. This way,
plant saved the extra water required for gardening. The solid waste generated
is used as a fertilizer for the gardening.
Specific energy consumption mentioned in Table is the overall energy consumption
for the production in plant. KPT has implemented various processes in production
lines and taken corrective actions to reduce the energy per product.
210
Certificate of Merit General Category
REYNOLDS PENS INDIA PRIVATE LIMITED
Sriperumbudur, Distt. Kancheepuram (Tamil Nadu)
Unit Profile
The history of Reynolds dates back to 1927 when it was established by Edmond
Regnault. In 1945, the Company shifted base to Valence in southern France and
took over the Reynolds brand from Milton Reynolds with the name, manufacturing
and selling rights. The Regnault family then sold the unit in 1993 to a group of
investors who christened themselves as Reynolds in 1995 under the same
management.
Reynolds France belonged to the Marine Wendel Group who were the majority
shareholders in Reynolds France before being acquired by the Newell Rubbermaid
Group in late 1999.
211
In India, Reynolds Pens India Private Limited has been promoted as a wholly
owned subsidiary of Reynolds France, which is part of the office equipments division
of Newell Rubbermaid Group of the US. The factory has been commissioned at
Sipcot Industrial Park at Irungattukottai near Chennai for the manufacture of high
technology metallic tips. They are used in the manufacture of ball pens to ensure
smooth writing pleasure throughout its life. Commercial production began in Mar-
2000. Investments upto USD 10 million has envisaged in the Indian factory. The
staff strength of 250 persons handles the production of tips in the state of the art
factory.
G.M. Pens International, their business associates in India, will continue with their
present operations of manufacturing other parts of the pen and also the marketing
of Reynolds branded writing instruments. The ball pens available in India are now a
well known household brand name and are used in offices, schools and home
throughout the country. They source critical parts of the pen including the tips
from Reynolds France and the supply of tips from the factory in India will result in
import substitution.
India is the only place outside of France to have a manufacturing base for ball pen
tips in the Reynolds Group. Their factory in Valence France is a composite writing
instruments manufacturing unit and the products are sold in over 70 countries in
the world today. The range of products comprises writing, marking, drawing and
colouring instruments in the popular and medium priced segments.
Reynolds has arrangements with partners in dozen countries for the manufacture
and sale of ball pens in which brand enjoys leading market position.
Extensive and continuous research and innovation in the area of writing instruments
has been at the core of the success of the Reynolds Group worldwide.
Reynolds now belongs to the Sanford, the top performing Writing Instruments
Division of the Newell Rubbermaid group. The group now is concentrating on
economies of large scale operations from the Indian plant and this in turn has lead
to sourcing strategies including purchase of raw material at affordable prices from
Countries like China, Switzerland, Germany and Belgium.
As Part of the continual improvement process the organization started the activity
of going for an Integrated Management System in the year 2007.
Energy Consumption
By the Energy conservative Initiates taken for the last Two years an eminent
decline in power consumption has been visualized throughout the organizational
activities.
212
Plant Specific Unit Consumption Energy consumption
Description Units 2007-08 2008-09 2009-10 2010-11
Annual Production
(Metallic Ball Point Tips)
Numbers in
Million
1297.8 885.79 684.28 912.938
Total Energy
Consumption per
annum
Lacs kWh 30.46 19.85
17.10 19.25
Kcal ( Kilo calories ) Calories
30.46*860=
26195
19.85*860=
17071
14706 16555
Energy in MTOE
MTOE
(Metric ton
of oil
Equivalent)
26195/
100 = 262.0
17071/
100 = 170.71
14706/100=
147.06 165.55
Specific Energy
Consumption in
MTOE/Actual
production -
Specific
energy
0.20 0.19 0.21 0.18
%Reduction over
2009-10
Percentage
14.28%
Energy conservation measures
Year of Project description Achievement of energy Investment
Commissioning savings per year basis incurred on
of the 2008 -2009 the project
projects Electricity Total (Rs. Lacs)
Lacs (kWh) Savings in
(Rs. Lacs)
2010 Energy saver has been 0.183 0.91 0.53
installed for main Lighting
Board - Avoid Bulb Frequent
Failure, Current consumption
reduced, spare cost reduces.
2010 Installed weekly Time switch 0.418 2.09 0.20
for avoid the Excessive time
run the Air conditioner, water
heater and water dispenser
and Office A/C
2010 Installed the 10 kvar power 0.441 2.2 0.12
capacitor added on the
compressor incomer panel for
reduce load current and
improve the power factor at
individual Equipment
213
Year of Project description Achievement of energy Investment
Commissioning savings per year basis incurred on
of the 2008 -2009 the project
projects Electricity Total (Rs. Lacs)
Lacs (kWh) Savings in
(Rs. Lacs)
2011 Converted from Metal halide 0.152 0.756 1.20
lamp to LED Reduce the
Lighting consumption @ 40%.
Calculation: 0.25 kWhr /Bulb,
after LED Replaced 0.04 Kw
Hr. Total no of lamp 10 no's.
1260 Units saving /month
2011 All multi spindle machines 0.262 1.3 Software
Spindle motor auto cutoff available
provided through PLC. After (0
circuit modified and machine Investment)
got switch off During Ideal
mode. Totally 45 machine we
are provided auto cut off
Circuit
2011 Mulitspindle machines auto 0.137 0.068 0
pneumatic Air cut off During
Ideal time through PLC
2011 All Tube lights in Office areas 0.174 0.852 1.25
converted into LED. After LED
replaced 70% saving each
Tube lights and Conference
hall all 25 W CFL Removed
and provided 12w LED
Provided
2011 Blanking machine VFD 0.156 0.756 0.30
Installed and reduce the
energy consumption
2010 750 W Wall mounting fan 0.021 0.010 0.015
removed By new energy
saving 55 w ceiling fan
provided
2010 Main gate 150 MV lamp 0.090 0.096 0.012
replaced by 18 W and reduce
the Energy
2010 Transvector Nozzle provided 0.013 0.063 0.0125
instead of Air nozzle
Total kWh SAVING /Energy cost 2.047 9.101 3.63
saving /Expenses cost
In Rs. Lacs)
214
Quality, Environment, Occupational Health & Safety Policy
Company manufacture metallic tips for ball point pens to global markets and are
committed to:
(A) EXCEED CUSTOMER REQUIREMENTS ON PRODUCT QUALITY, COST AND
DELIVERY BY ADOPTING ECO FRIENDLY PROCESSES BESIDES PREVENTING
OR MINIMISING RISK TO EMPLOYEES ON OCCUPATIONAL HEALTH & SAFETY.
(B) COMPLIANCE TO APPLICABLE LEGAL AND OTHER REQUIREMENTS
(C) CONTINUAL IMPROVEMENT IN QUALITY, ENVIRONMENT, OCCUPATIONAL
HEALTH & SAFETY MANAGEMENT SYSTEM AND QEHS PERFORMANCE.
(D)IMPLEMENTING PROGRAMMES FOR IMPROVEMENT IN PRODUCT
QUALITY, RESOURCE CONSERVATION, AND PREVENTION OF
POLLUTION, OCCUPATIONAL INJURY AND ILL HEALTH OF
EMPLOYEES.
(E) ENHANCE AWARENESS ON QUALITY, ENVIRONMENT, OCCUPATIONAL HEALTH
& SAFETY AMONGST EMPLOYEES AND INTERESTED PARTIES.
COMPANY WILL ACHIEVE THE ABOVE BY INVOLVEMENT OF EMPLOYEES
AND INTERESTED PARTIES THROUGH AWARENESS, TRAINING AND
MOTIVATION
215
GMR HYDERABAD INTERNATIONAL
AIRPORT LIMITED
Unit Profile
GMR Hyderabad International Airport Limited (GHIAL) is a joint venture company
promoted by the GMR Group (63%) in partnership with Government of India
(13%), Government of Andhra Pradesh (13%) and Malaysia Airports Holdings
Berhad (11%). The Company was incorporated to design, finance, build, operate
and maintain a world class Greenfield airport at Shamshabad, Hyderabad. The
project is based on the Public Private Partnership (PPP) model and is structured on
a Build, Own, Operate and Transfer (BOOT) basis.
216
The Rajiv Gandhi International Airport (RGIA) was inaugurated on March 14, 2008
and commenced commercial operations with effect from 00:01 hrs. on March
23, 2008. The airport which was commissioned in a record time of 31 months
has an initial capacity of 12 million passengers per annum (MPPA) and 150,000
tons of cargo handling capacity per annum. The Project has the flexibility to increase
capacity to accommodate over 40 MPPA and shall be developed in a phased
manner.
The airport provides world-class facilities and infrastructure, in accordance with
ICAO standards and practices to handle large aircraft and international traffic.
Currently, there are 11 passenger airlines flying to 15 international destinations
and 6 domestic airlines operating to around 30 destinations.
GMR Hyderabad Aviation SEZ Ltd, 100% subsidiary of GHIAL is developing GMR
Aerospace Park an Aviation and Aerospace cluster with focus on aircraft aftermarket
services.
RGIA has been rated the best in the world by Airports Council International (ACI)
in the 5-15 million passengers category for its Airport Service Quality for 2009 &
2010. It has also been adjudged as the 5
th
best airport across all categories in
2009, both in the world as well as the Asia Pacific Region.
RGIA is the first airport in Asia to be awarded the Leadership Energy and
Environment Design (LEED) silver rating for its eco-friendly design. It has
also won the Outstanding Concrete Structure of Andhra Pradesh award from the
Indian Concrete Institute.
217
Specific Energy Consumption Trend Chart
Energy Saving Initiatives
1. Replacement of the existing condenser water pumps with suitable
Capacity pumps
There are seven condenser water pumps installed for meeting cooling water
requirement of PTB (Passenger Terminal Building) chillers. The number of pumps
required to be operate depends on the number of chillers in operation. The
performance of the pumps was evaluated based on measured flow rate, head and
current drawn by the motor. The cooling water requirement per chiller is 394.6
m3/h, while the rated Specification of each pump was 380 m3/h at 30m head,
whereas the reuired head as per the actual mesurement was 20-21m. Since
there was a mismatch in the specifications, it was decided to optimize the Capacity
of pumps by suitable replacement.
The specification of the new pumps installed is as given below:
Flow: 400 m3/h
Head: 22 m
Power: 37.0 kW
Pump efficiency: 76%
218
2. Through BAS Operational Efficiency
It was decided to identify and operate Air Handling Units (AHUs) based on the
Flight movement and occupancy. AHU ON/OFF time programme was decided by
discussing along with airport operations team. This resulted in energy saving as
per the details given below:
Saving through AHU'S Time program
AHU's time program
Before After
LOA
D
Total
consumptio
n
Area
Area
LOA
D
(KW)
Operatin
g Time
Total
consumptio
n (kWh) (KW)
Operatin
g Time (kWh)
Saving
in
kWh
per
day
Saving
in Rs
per
month
PTB
AHU'S
PTB
AHU'
S
1050 24 25200 1050 16.5 17325 7875
1,181,2
50
REPLACEMENT OF CONDENSER PUMPS
BEFORE AFTER
LOAD
Total
AREA
LOAD
(KW)
Operating
Time
Total
Consumption
(KWh)
(KW)
Operating
SAVING IN
kWh PER
DAY
SAVING
IN RS
PER
MONTH
PTB
CHILLER
PLANT
135 15 2025 111 15 1665 360 54,000
Consumption
(KWh)
Description Investment Saving per Month Payback period
Original Pumps
After energy saving initiatives -
Pumps with low- head
219
The above picture is the BMS screenshot for time programming of AHUs.
3. Air conditioning system -Cooling Tower Cast Aluminium blade
replaced with FRP blade
REPLACEMENT OF COOLING TOWER BLADES FROMALUMINUM CAST TO FRP
BEFORE AFTER
LOAD
Total
consumption
AREA
LOAD
(KW)
Operating
Time
Total
consumption
(kWh) (KW)
Operating
Time (kWh)
SAVING
IN kWh
PER
DAY
SAVING
IN Rs.
PER
MONTH
PTB
CT'S
42.75 24 1026 26.85 24 644.4 381.6 57,240
Pay back Period
Description Investment Saving per Month Payback period
Cooling Tower Rs.200000 Rs. 57240 3.5 Months
220
Cooling Tower Blade replacement with FRP blades along with hub
4. Lighting System Modification
The details of saving and payback period is given below:
Lighting - System Modification
BEFORE AFTER
LOAD
Total
consumption
Initiative
AREA
LOAD
(KW)
Operating
Time
Total
consumption
(kWh)
(KW)
Operating
Time
(kWh)
Saving
in
kWh
per
day
Saving
in Rs.
per
month
Conversion
of Existing
Lamps to T5
Passenger
Corridors ,
chiller plant,
service
corridors
72 24 1728 56 24 1344 384 57,600
Wash rooms
( 11 nos)
5 24 120 5 12 60 60 9,000
Installation
of Motion
Sensors
Fixed Link
Bridges (
3nos )
5 24 120 5 12 60 60 9,000
Installation
of LED
Lamps
VIP lounges 1 24 24 0.08 8 0.64 23.36 3,504
Power Savers Roof lighting 105 12 1260 94.5 12 1134 126 18,900
Janitor room 1.872 24 44.928 0.936 24 22.464 22.464 3,370
Replacement
of 2x36w TL
fitting to
1x36w
Chiller plant 2.25 24 54 1.12 12 13.44 40.56 6,084
221
Pay Back Period
Lighting - System Modification
Initiative
AREA
Investment
Payback Period
(in months)
Conversion of Existing Lamps to
T5
Passenger Corridors , chiller plant,
service corridors 317000.00 5.50
Wash rooms ( 11 nos) 15950.00 1.70
Installation of Motion Sensors
Fixed Link Bridges ( 3nos ) 4350.00 0.50
Installation of LED Lamps VIP lounges 32000.00 9.00
Power Savers Roof lighting 537026.00 28.00
Janitor room
Nil NA
Replacement of 2x36w TL
fitting to 1x36w Chiller plant
Nil NA
Goal and Energy Policy
Weat GMR Hyderabad International airport are committed to purchase and use
energy in most efficient and effective manner possible. To achieve this company
will strive towards continuous implementation of energy management systems
that supports all its operations and without compromising the ultimate Goal of
providing customer satisfaction at all times.
Sustenance of Energy Saving Initiatives:
This will be achieved by implementing the following action points:
Benchmarking all premises by March 2012.
Reduce energy use per passenger by 5% relative to 2010.
Reduce water consumption by 5% relative to 2010.
Purchase 5% of energy use from renewal sources by 2014.
Developing energy managers and energy auditors
222
BHARAT ELECTRONICS LIMITED
Unit Profile
Bharat Electronics Limited (BEL) is a premier Professional Electronics Company
under Ministry of Defence, Govt of India, engaged in the design and manufacture
of professional grade products, solutions and services. From a modest beginning
in 1954, at Bangalore, under Ministry of Defence, the company has grown into a
multi-unit, multi-product and multi-customer organisation. Growth and
diversification have taken place in line with the advances in Electronics technology.
The Company has grown from a turnover of Rs.100Cr in 1981-82 to Rs. 5550 Cr
in 2010-11.
The Company, in its 57
th
year has been conferred with operational "Mini Ratna" &
subsequently with "Navaratna status" by the government of India. BEL has secured
the top ranking among medium sized aerospace /defence companies in the
prestigious Top performing Companies Study for 2005 carried out by Aviation
Week & Space Technology (AWST), a McGraw-Hill publication for the second
consecutive year.
The Company has two overseas offices - at New York (NYRO) and Singapore
(SIRO) primarily for sourcing components and technologies from other countries.
Two Central Research Laboratories cater to the blue sky research activities - at
Bangalore and New Delhi. Another new laboratory has been established in 2010
to cater for research in the areas of electro-optics and electronic warfare. Three
marketing divisions - National Marketing Division, Central Marketing Division and
International Marketing Division are strategically located to be close to the centres
of power and Customer HQ's at New Delhi and Bangalore.
The Bangalore unit of Bharat Electronics considered the "Flagship" unit, is referred
as Bangalore Complex (Bg Cx), manufactures a full range of Communication
equipments, Radars, Sonars, FCS, Satcoms, EW Systems, Aviation Electronics,
Telecom & Broadcasting equipments and Components. The Customer profile
includes, Military Customers viz. Army, Navy, Air Force; Paramilitary Customers
viz. BSF, ITBP, CRPF, State Police and Civilian Customers viz. AIR, Doordarshan,
ISRO etc., New Business environment with increased global competition and rapid
technological changes necessitated reorganizing Bangalore complex into six
Strategic Business Units (SBUs) in July 2000. Rapid development in the field of
Electronic warfare resulted in new business opportunities, necessitating the formation
of separate SBU for harnessing the same. Thus, Military Communication and
Electronic Warfare (MC&EW) one of the six SBUs was further bifurcated in 2006
223
to create two SBUs i.e. Military Communication (Mil Com) and Electronic Warfare
& Avionics (EW&A). In 2009-10, the Naval Systems SBU was further divided into
two SBUs to address the emerging and diversified needs of the Indian Navy, thus
taking the total number of SBUs to eight. (Fig.O.2)
Fig. 0.2
SBUs of Bg Cx
Military Communication (Mil Com SBU)
Electronic Warfare & Avionics Systems (EW & A SBU)
Military Radar (MR SBU)
Naval systems (NS SS&CS SBU)
Naval Systems (NS-RS&FCS SBU)
Telecom and Broadcast systems (T&BS SBU)
Components (COMP SBU)
Export Manufacturing (EM SBU)
Fig. 0.3
SALES (in Rs. Crores)
YEAR 2008-09 2009-10 2010-11
COMPANY 4611 5235 5550
BANGALORE COMPLEX 2289 2394 2850
Each SBU is an independent operating business entity with its own functions i.e.
Development & Engineering, Manufacturing, Quality Assurance, Marketing, Finance
and HR. All the SBUs get the necessary assistance and guidance from Bg Cx and
Corporate Management.
BgCx, the mother Unit of BEL recorded a turnover of Rs 2850 Cr against last
years actuals of Rs 2394 Cr, thereby recording a growth of 16%. The turnover of
the Unit with respect to BEL (Company as a whole) is shown in Fig.O.3.
Energy Consumption Profile
Sources of Energy
The plant uses Electricity as the primary source of energy from State Electricity
Board. Electricity is used for driving the motors of refrigeration compressors, air/
gas compressors, air handling units, process related equipment and lighting. HSD
is being used in DG sets for Captive consumption.
224
The energy consumption profile of the plant during the last five years is as shown
in the graph below:
Electrical energy consumption of BGCX
3
5
6
.
8
3
4
2
.
3
3
1
6
.
8
3
0
8
.
0
2
9
0
.
3
0
50
100
150
200
250
300
350
400
2006-07 2007-08 2008-09 2009-10 2010-11
Year
E
l
e
c
t
r
i
c
a
l
E
n
e
r
g
y
i
n
L
a
k
h
K
W
h
r
s
Specific Energy Consumption of major product DMRR (Digital Mobile
Radio Relay)
Energy Consumed for Design, Development, Testing of Digital Mobile Radio Relay
and associated products is considered for Specific Energy consumption of the
product and the last three year data per production of Equivalent Vehicle DMRR
unit (KWH per Equivalent Vehicle-DMRR unit) is shown below:
Specific electrical energy consumption
1
6
0
1
0
1
3
2
5
4
1
0
5
1
6
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
2008-09 2009-10 2010-11
Year
K
W
H
p
e
r
E
q
u
i
v
a
l
e
n
t
V
e
h
i
c
l
e
-
D
M
R
R
u
n
i
t
225
Energy Conservation
The Company has made conscious efforts to reduce the consumption of electrical
energy from 48 million units in 1988-89 to 29.0 million units in 2010-11 even
though production has increased several times. The consumption of fuel has been
drastically reduced from 942 kiloliters to 485 kiloliters during the same period.
Company has set up a Standing Committee on Energy Conservation and Energy
Audit (EC&EA) at corporate level during 1988-89 to monitor, review and implement
energy conservation solutions in the company.
The standing committee meets every quarter during the year at different Units
and conducts walk through energy audits and share the best practices. The progress
is reviewed during the standing committee meetings. The best practices followed
also are shared with other industries in Bangalore.
The organization has increased its share in renewable sources of energy by
installing 51,500 Litres capacity solar water heating system for use in the canteens.
Various activities added to enhance the awareness level are as mentioned below:
The following have been implemented as a measure of Energy conservation
1. Replacement of old centrifugal chiller with new energy efficient screw chillers.
2. Day light harvesting and Turbine Air ventilation system
3. Incorporation of LED street lights in place of conventional street lights
4. Installation of demand based pumping system in place of conventional constant
feed pumping system for supply of chilled water to AHUs.
5. Conversion of CADDS & PCB Dx plant to Split AC
6. Replacement of old condensor unit of 60TR DX type AC plant with Energy
efficient condensor unit
7. Replacement of old window AC units with new 5 star rated split AC units
8. Replacement of old reciprocating compressors with new energy efficient screw
compressors.
9. Providing variable feed controller in the compressed air network.
10. Integrating VFD to Cooling Tower fan motor
11. Resizing of borewell pumpsets.
226
227
First Prize General Category
(Subsectors of EC Award)
KIRLOSKAR FERROUS INDUSTRIES LIMITED
Distt. Koppal (Karnataka)
Unit Profile
Kirloskar Ferrous Industries Limited is a registered Public Limited Company.
M/s. Kirloskar Ferrous Industries Limited is currently engaged in the manufacture
of Pig Iron and Ferrous Castings at its plant located at Bevinahalli Village, District
Koppal in the State of Karnataka. The company was promoted by the renowned
Kirloskar Group of Companies in 1990 with a view to undertake Iron, Steel and
Castings manufacture. The Kirloskar Group is well over 65 years old and is well
known for its manufacturing excellence.
228
All through the growing years, the Kirloskar Group has had a long close relationship
with the Foundry business with several group units specializing in the manufacture
of high quality ferrous and non-ferrous castings.
229
Commissioning of New 4.5 MW Power Plant
Excess CO gas generated by MBF production process
after upgradation of blowing system was being burnt
before releasing the burnt gas to the atmosphere. The
power plant was installed to make use of excess CO
gas which was released as wastage to the atmosphere.
Energy cost savings: Rs 3,90,38,263/-
Total investment: Rs 22,00,00,000/-
Installation of Hot Blast Stoves
Hot air is required in Mini Blast Furnace for combustion
of coke which in turn will reduce iron ore to pig iron.
Earlier plant had metallic blast pre-heaters and
maximum air temperature obtained was 750 C.
Thermal efficiency of metallic blast pre-heaters was
55% and coke consumption was 788 kg per MT of
Hot Pig Iron metal. Hence unit installed Hot Blast Stoves
(Air Pre-heaters) of JSC Kalugin Russia Technology and
now are achieving a temperature of 1100 C. Coke
consumption in Mini Blast Furnace has reduced from
812 kg to 783 kg per MT of Hot Pig Iron metal.
Energy cost savings: Rs 8,91,00,000/-
Total investment: Rs 22,25,00,000/-
Increasing the Cooling Tower Capacity in
Power Plant
Cooling tower capacity increased from 600 cubic
meter to 1000 cubic meter & additional load of 200
KW was achieved.
Energy cost savings: Rs 30,62,400/-
Total investment: Rs 34,00,000/-
Replacement of Cooling Water Pumps at TG 1 & 2
200 KW, 10 UPH3 High Pressure pumps replaced by
90 KW, UP 300 / 34 pumps in each TG.
Total investment :Rs 6,00,000/-
Energy cost savings: Rs 24,71,040/-
230
Installation of HP Fans with Energy
Efficient Motors at MBF1 & 2
The Pig Iron production target is achieved by
running 4 blowers instead of earlier 5 blowers
[before installation of HP blowers].
Total investment :Rs 1,37,00,000/-
Energy Savings: Rs 1,86,20,000/-
Installation of Solar Street Lights at
Water Reservoir
Solar street lights were installed at plant water
reservoir to utilize solar energy.
Energy cost savings :Rs 74,844/-
Total investment: Rs 3,04,000/-
Installation of Wind Driven Fans
Electric Power driven exhaust fans replaced by
wind driven fans for Ventilation purpose. In
addition to the energy conservation, noise level
in the working area is minimized.
Total investment :Rs 4,90,000/-
Installation of dedicated Compressor Air Line for Power Plants
Centralised air receiver system replaced by dedicated Compressor Air line to avoid
abnormal usage of the compressed air which was leading to TG trips. Unit used to
draw power from grid from tripping time to TG loading time.
Energy cost savings : Rs 72,00,000/-
Total investment : Rs 5,00,000/-
Drawing of Power from grid (Govt. of
Karnataka) at a power factor of 0.98 to
avoid penalty on low power factor
Earlier KFIL were drawing power at a power
factor of 0.83 to 0.84. Power factor was
improved to 0.97-0.98 by installing capacitors and harmonic filters. KFIL were
paying a penalty of Rs. 4 to 5 Lacs per month
Energy Bill savings : Rs 48,00,000/-
Total investment : Rs 21,00,000
231
Installation of Transparent Roof Sheets
Replaced metal roof sheets with 125 transparent
roof sheets in MBF shop floor to utilize natural day
light for illumination.
Energy cost savings : Rs 1,60,000/-
Installation of Sensor water taps at canteen to conserve water
Installation of Drip irrigation System for gardening by recycling waste water
Installation of Sprinklers in Raw Material Yard to reduce Air Pollution by recycling
waste water
Environment and Safety Policy
232
(Subsectors of EC Award)
INORBIT MALLS (INDIA) PVT. LTD.
Malad (W), Mumbai, Maharashtra
Unit Profile
Inorbit is a group company of K Raheja Corp, one of the leading names in the field
of real estate and retail in the country. Since its inception, the Group has constantly
set new benchmarks for quality, performance and service and has a success story
that spans across decades, and across industries from real estate to hospitality to
retail.
233
Inorbit Mall India Pvt. Ltd. started as a mission to create celebratory environments
for retail with the launch of Inorbit Malad in 2004. Located between Mumbais
most prolific commercial hub, Mind Space at Malad Link Road & a huge residential
base in Malad (West) & surrounding areas, the mall has a total built-up area of
7,20,000 sq. ft. Inorbit, Malad is conceptualized by M/s. Chapman Taylor Partners
- UK, one of the worlds best architectural firms.
Committed to setting benchmarks in the Indian Retail Industry, its success is due
to its unique positioning as a true one-stop lifestyle destination. Inorbits core lies
in understanding that shopping is a multifaceted experience. The constant endeavour
of Team Inorbit to create a million experiences has helped it bag 20 awards thus
far.
Inorbit believes in living with the planet and not living off the planet. It adopts
green habits at every stage of its lifecycle and employs an array of green initiatives
likewater & sewage recycling, sensor taps & urinals, solar power, occupancy &
motion sensors, energy friendly, CFL, T-5 & LED lighting, use of high efficiency
pumps & motors amongst others.
For this, Inorbit Malad has tied up with Johnsons Control Inc. under the aegis of
Clinton Foundations Climate Initiative to audit, recommend and implement energy
conservation and energy optimisation retrofit measures. This was the first such
tie-up across the world under this programme.
Energy Consumption and Savings Achieved
Specific energy consumption mentioned in Table 1 is the overall specific energy of
common area electrical consumption & mall HVAC system.
Table 1: Reduction Achieved in Specific Energy Consumption kWh/kW Load
Year kWh in Million LOAD IN kW SPECIFIC ENERGY
CONSUMPTION
kWh (unit) / kW(load)
FY 2005-2006 80.33 1834 4380
FY 2006-2007 82.31 1879 4381
FY 2007-2008 76.68 1750 4382
FY 2008-2009 68.72 1568 4383
FY 2009-2010 67.14 1532 4382
FY 2010-2011 63.75 1455 4381
234
Year kWh kWh kWh Saving Reduction in CO
2
without energy by emission
efficiency implementing Million Kilo Gram
Energy Saving (1 kWh = 0.85 kg
measures of CO
2
emission
(Lacs Units) (Lacs Units) (Lacs Units) (ESTIMATED ONLY)
FY 2005-2006 80.33 80.33 NA NA
FY 2006-2007 82.31 83.95 1.64 0.139
FY 2007-2008 76.68 79.96 3.28 0.278
FY 2008-2009 68.72 75.22 6.50 0.552
FY 2009-2010 67.14 68.34 1.20 0.102
FY 2010-2011 63.75 69.92 6.17 0.524
Energy Savings Since 2005-06 18.79
Energy Savings Since 2009-10 7.37
Table 2: Energy Savings Achieved By Implementing Energy Efficiency
Measures in The Mall
Table 3: Total kWh Consumption Trend For FY 2005-06 To 2010-11
Energy Conservation: Major Projects Implemented
The following projects were implemented to save lighting power consumption &
HVAC power consumption:
1. Replacement of 660 nos. of Fluorescent Light Fittings (FTL) with
T-5 Light Fittings at Basement Car Parking:
- From the time the mall got operational in 2004, the basement parking had 36
/ 40 W with Electronic Ballasts. They were partially switched on around 10:30
am. 100% lights were on during 4:00 pm. to 10:30 pm. Some of the lights
were turned off after 10:30 pm. Most of the parking lights were kept on till
235
the last show ended at around 02:00 am at the Fame Cinema Multiplex. The
then installation of the FTL at the basement parking area was not uniform and
dark patches were observed in some of the areas.
- The Energy Efficient T-5 FTL was considered in the basement parking area.
The average burning hours considered for savings was 11 hours. The re-
orientation of the FTL with Energy Efficient T-5 FTL 28W tuned to 21W in the
basement car parking area gives uniform illumination and allows for de-lamping
of approximately 10%. Installing occupancy/movement sensors at strategic
locations including the Entry/Exit ramp further reduced the consumption by
10%.
T-5 Light Fittings at Service Yard Area:
- Single T-5 28W fixtures were recommended in place of Dual T-8 fixtures.
Accordingly, the energy efficient T-5 28W tuned to 21W was recommended
for Service yard area.
- The average burning hours considered for savings was 11 hours. Existing
36W fluorescent light fittings were replaced with 28W T-5 fluorescent light
fittings at service yard area.
T-5 Light Fittings for all Backlit Signage:
- 58 nos. of backlit signage are installed on the building facade. 36W/ 40W FTL
were used for signage and hadcopper ballasts. These could be replaced by
Energy Efficient T-5 28W tuned to 21W.
- The luminance efficacy of T-5 is 104 lm/ and it gives 25% more light than the
conventional 36W/ 40W FTL. Therefore, de-lamping of up to 25% was
considered.
- Accordingly, all the 36W tube light fittings were replaced with 28W T-5 tube
light fittings.
4. Replacement of 179 nos. of Halogen (1X50W) Light Fittings with
8W LED light fittings:
- The common area passages of Mall was illuminated with 50W halogen spot
light fittings which were replaced with 8W LED light fittings having equal
illumination & lux level.
236
5. Replacement of 47 nos. of 400W Metal Halide (MH) Fittings with
T-5 street light fittings:
- Outdoor Lighting areas typically consist of open parking area, landscape lighting
like Garden light and facade lighting. 400W MHs were used for open parking
space.
- All the outdoor lights are switched on during the night time and hence, the
average burning hours considered for the calculation was 4 hrs.
- The 400 MH for illuminating the outdoor parking were replaced by the 4x24W
T-5 streetlight fixtures which would give around 40-60% savings.
6. BMS Facility Improvement Measure for night load reduction:
- During the night time i.e. after Mall hours, only few types of equipment like
emergency lightings, some pumping systems, sewage treatment plant loads
were kept on.
- Information was obtained from Reliance Energy (the utility company then)
over two months. It indicated that more than 150 kVA to 200 kVA load was
being consumed between 02.00 am to 09.30am.
- Here, the actual minimum load during night time was found as 144kVA. This
indicated that a considerable amount of night load can be reduced by better
control & monitoring through BMS.
- Accordingly, minimum night load requirements of Mall were identified & remaining
unnecessary loads& equipments were switched-off automatically by BMS to
avoid human error.
7. BMS Facility Improvement Measure for Reduction of Max Demand
in kVA:
- As per the Electricity Tariff Structure for Billing Demand, the highest value of
the following three conditions is considered for the Billing Demand calculations:
a) Actual established demand recorded in the month during the period of
0600 hours to 2200 hours.
b) 75% of the highest billing demand or Contract Demand, whichever is
lower, during the preceding eleven months.
c) 50% of the Contract Demand as defined in the Supply Code. (Contract
Demand means demand in kilo Watt (kW)/kilo Volt Ampere (kVA),
mutually agreed between Reliance Energy and the consumer as per the
agreement).
Hence, peak load management is very crucial in order to reduce the annual
billing demand & demand cost.
237
- The following measures were adopted for the Peak Demand Control Strategy:
a) The critical & non-critical connected loads and running loads were identified
and based on this, the non-critical running loads were de-selected from the
total running loads for peak load control.
b) The two main pre-existing energy meters provided the entire building energy
consumption details. These meters were owned by Reliance Energy, the utility
company then. Two additional meters were installed parallel to the existing
meters. These additional meters were connected to the BMS system for
demand monitoring.
c) Major electrical motors ON/OFF status was connected into the BMS system
for monitoring
d) The monthly peak kVA demand value based on historical & future monthly
loads estimation was calculated and this value was used as a set point in the
BMS system.
e) BMS start / stop was provided for the identified equipments as per Table 5
f) A BMS alarm system for operator was also installed that is triggered if the
demand exceeds the set value as determined above.
BMS Facility Improvement Measure for Reduction of Max Demand in kVA contd....
- Accordingly, it was identified that Maximum Demand for Mall is 2100 kVA with
necessary & critical equipments operational. Through this a saving of about
demand load of 250-339 kVA was achieved in various months (at 0.99 Power
Factor).
8. Providing Variable Frequency Drives (VFDs) for Common Area
Air Handling Units (AHUs):
- There are twenty one 21 nos. AHUs in the common area with different
capacities ranging from 22 TR to 45 TR. These AHUs were normally operating
between 10.45 am to 11.45 pm i.e. about 13 hrs per day with constant flow.
Even though the mall occupancy varied during the day and on weekends, the
AHUs were operated at constant speed.
- Accordingly, VFDs were installed in 10 nos. of selected AHUs to optimize AHU
fan power during low occupancy periods of mall operation. Also, replacement
of the non-working two-way valve was done and further these were all
operated through BMS. Installation of temperature sensor was also done and
these, too, were connected with the BMS system.
9. Upgradation of Primary Chilled Water Pumps:
- The chilled water system consists of primary & secondary circuit. Seven (7)
primary pumps at 11kW each with capacity of 172 m
3
/hr were supplying the
return chilled water to the Chillers. Two secondary pumps @ 45 kW each with
capacity of 640 m
3
/hr and each with VFDs were supplying the chilled water to
the various air handling units.
238
- The above primary circuit was originally designed to supply return chilled water
to four air-cooled Chillers of 365TR each & to two water-cooled Chillers of
700TR & 300TR. The installation of a new 800TR water cooled chiller had
modified the pumping requirements and therefore the pumps existing then
were not completely suitable.
- It was identified that each primary pump is operating around 150 m
3
/hr flows
with 11m head and power consumption in the range of 10.5 to 10.8 kW.
- Five existing primary pumps & motors were removed. The suction & discharge
pipelines for new energy efficient pumps were modified. Installation of pump
accessories - Base Plate, Coupling, Coupling Guard, Set of Foundation Bolts,
and Rubber Expansion Bellow was done. Necessary electrical connections for
new pump system with existing cable and starter wads done. Proper insulation
for new pumps was done and it was connected with new piping.
- Accordingly, all 7 nos. of 15HP primary pumps were redesigned and replaced
with 10HP pumps. Efficiency of each primary pump existing previously was
around 50%. The efficiency of the new energy efficient pumping system was
delivered in the range of 68% to 70% as per the planned design.
10. Replacement & Re-design of 800TR Condenser Pumps:
- The cooling water requirement for 800TR Chiller is supplied through three (3)
cooling waterpumps. Capacity of each pump is 230 m3/hr and 30 m head.
Normally three pumps are running with throttled condition in suction & discharge
side to meet the condenser cooling water requirement. One cooling tower of
900 TR capacity is provided for the 800TR Chiller.
239
Table : Onsite Measurement of 800 TR Condenser Pumps
- Efficiency of the condenser pumps existing then was around 32%. It was
identified that each condenser pump is operating with 11m head and the
power consumption is in the range of 30 to 30.5 kW each. From the existing
pump curve it was identified that these pumps are running outside of their
optimum curves.
- The 3 existing condenser pumps were replaced with 2 new pumps (one
standby& one working) designed with proper head and flow that suited the
site requirements. The new energy efficient pumps operate in the range of
68% to 70% efficiency, which increased the existing pump efficiency by 40%
(see Table below).
Table : Parameters of Present & New Condenser Water Pumps
11. Installation of Solar Power LCD TV at Mall Main Entrance
- A fully solar powered LCD display was strategically installed at the main mall
entrance just before the central atrium. For this a solar cell panel was installed
at the terrace level.
- This was installed with a view of showing the energy conservation initiatives
taken by the Mall through an audio-visual medium for Consumer Awareness
and Education amongst the numerous people visiting the Mall (approx. 0.9 -
1.0 crore visitors come to the mall on an annual basis).
240
Other Major Conservation & Optimisation Measures Implemented Over
the Years
1. Installation of Automatic Power Factor Controllers for all capacitor banks
was undertaken in 2006 so as to maintain Unity power factor thereby
optimising consumption and availing of the incentive offered by the electricity
supplier.
2. Replacement of two Air Cooled Chillers with a 800TR water cooled chiller
was done in 2007 as water cooled chillers IKW is less than that of the Air
Cooled Chillers. This resulted in a major reduction in consumption as well.
3. Re-setting of chilled water set-points was done to achieve 25 degree C ambient
temperature thereby reducing energy consumption significantly.
4. Installation of Air Curtains and Automatic Sliding Doors at all entry & exit gates
was done from day one itself so as to avoid Air Conditioning losses.
5. Running of smoke extraction fans in reverse direction during early morning
hours to fill cool, fresh air inside the Mall is being done regularly as a pre-
cooling measure.
6. The poly carbonate roofing in Atrium Dome & Food Court Dome was covered
with a PVC coated, heat resistant dome cover in order to avoid direct heat
gain from sun rays thereby reducing and optimising the air-conditioning load
(and thereby reducing electricity consumption) as well as improving the ambient
conditions for the Malls customers.
7. Sun Control Film was installed on the entry & exit glass doors and major
windows. Again, this was done to both improve the ambient conditions as
well as to reduce electricity consumption.
8. to optimise and reduce electricity consumption, replacement of 24-hour /12-
hour running 36W fluorescent tube lights was done with 28W T-5 tubes at
various staircases and back of the house areas.
9. Installation of motion sensors in stairwells to conserve electricity consumption
10. Timers were provided for automatically switching ON/OFF common area lighting
& facade signage lighting so as to optimise consumption by removing errors
on account of manual operation.
11. Use of open parking during non-peak hours was done so as to avoid lighting
power consumption at Basement Parking area during day time.
12. Upgradation of STP plant was done in order to improve the treated water
output level.
13. Installation of additional grease traps was done and dosing of chemicals post
the passage of sewage water from the grease trap was undertaken in order
to improve the treated water quality supplied as make-up water thereby
improving HVAC efficiency and reducing consumption of electricity.
14. Regular cleaning of chillers and regular chemical dosing & monitoring of make-
up water is performed to optimise chiller performance.
15. Installation of LED-based brand signage was done in 2011 so as to reduce the
power consumption in comparison to the consumption of the earlier Cold
Cathode-based signage.
241
(Subsector of EC Award)
AIR INDIA LTD
Unit Profile
Air India Ltd is the largest Airline in India. Air India ltd is a Public Sector Company
formed after the Merger of erstwhile Air India and erstwhile Indian Airlines. Air
India's Headquarters is in Mumbai. It has a Fleet of varied type of aircraft consisting
of the latest state of the art Boeing 777 and Airbus 330 aircraft for International
Operations. It has Airbus A319, A320 and A321 for Domestic Operations. Air India
strongly believes that a company can grow only when it includes all sections of the
society in its development. It offers a work culture where every employee gets an
opportunity to grow with the company.
242
Air India has a business vision to become recognized as an Energy efficient,
competitive and premium International Airline.
Air India is confident that with the optimal use of resources and the latest
technology, forthcoming years will take the company to even higher level of glory
and it will live up to the rising expectation of all the stake holders in its future
journey.
Energy Consumption at Air India
Energy Management of Air India recognizes that safety is of the paramount
importance and that any fuel conservation procedure is only undertaken when
consistent with safety.
On the part of Air India, managing fuel efficiency is resulting from:
Additional attention to planning
High accuracy of the flight planning system and in the execution of the flights
Increased situational awareness
Crew discipline to follow the flight plan
Availability of appropriate analytical tools and statistics
Adequate training to Pilots and other operational personnel
A feedback mechanism to inform employees as airline policy,
Setting efficiency targets and measurement of performance data within specified
timelines.
By accurately managing fuel, AIR INDIA can:
Exercise proper risk management by ensuring that sufficient fuel is carried to
the high-risk airports and less fuel to airports where it is not necessary
Minimize the risk of unplanned fuel diversions
Ensure that flights land with adequate fuel reserves
Ensure that Crew and Flight Dispatchers maintain a safe and efficient approach
to fuel management
Monitor the use of fuel reserves for purposes other than intended, such as the
surplus carriage of fuel while catering for fuel to an alternate airport. Ensure
Fuel Management Information System tracks the fuel intended for usage and
monitoring deviations in the flight plan fuel.
Energy Consumption
The following is a bar chart of the fuel consumption for the Air India fleet. The Air
India Green Initiatives team has achieved a 12.2% fuel reduction.
243
The fuel consumption is monitored on a monthly base per aircraft type. The following
is a list of the fuel consumed per aircraft type and year.
Fuel Savings Chart
244
Energy Conservation
The Chairman and Managing Director (CMD) has constituted a Steering Committee
for Operational Efficiency, Fuel Management and Emission Reduction. The Steering
Committee monitors all matters of operational efficiency, fuel management and
reduction of fuel costs. The Steering Committee is headed by the CMD and consists
of the Nodal Officer and Executive Directors of various Departments. Sub-
committees have also been formed to ensure implementation of all projects
determined by the Steering Committee and help in the introduction of new
processes and procedures for Fuel Efficiency.
The Air IndiaGreenInitiatives Steering Committee runs the company wide saving
program and sets targets and actions for all departments.
Energy Conservation Methods
The Air India Ltd Green Initiatives Steering Committee runs the companywide
saving program and sets targets and actions for all departments. The following
shows a breakdown of the achieved savings per department based on the 2010-
2011 data.
Energy Saving Initiatives Department wise
Flight Operations
APU usage Reduction: Significant progress has been
achieved in reduction of Auxillary Power Unit (APU) usage.
Flight crew and ground personnel continued sensitization is
done. Ground Power Unit (GPU) is being used to maximum
usage.
245
Flight Operations: Flight Operations has introduced
a training / sensitizing program to all pilots for the
improvement of fuel efficiency and reduction of the
environment impact.
Pilot Technique: Air India has increased pilot
technique in fuel efficiency by providing more fuel
information to pilots via a company fuel efficiency
chapter in the Flight Operations Manual and with the
introduction of a dedicate fuel training program.
Landing Flap Settings: A systematic review of
landing flaps to optimized settings.
Use of Idle Reversers on Landing: Air India Ltd
has initiated the use of idle reverse thrust on landing.
The use of idle reverse thrust minimizes fuel
consumption, reduces engine maintenance and
decreases noise and pollution at airports.
Low Noise Low Drag Approaches: Decelerated
Approach Procedure (Low Noise Low Drag Approach) procedures have been
introduced for most of the flights in Air Indias current operation.
Reduced Acceleration Altitude: Air India Ltd has reduced the acceleration
altitude to 1,000 AGL for most flights.
ACARS: Air India will expedite the activation of ACARS
on all the aircraft that are presently equipped. In
addition, all new aircraft acquisitions will be fully
equipped with ACARS. The ACARS menus supports
Flight Operations, Dispatch, IOCC and Maintenance
requirements. Direct communications between the
Company Operations Departments and the aircraft
will be instantaneous during all phases of flight.
Flight Planning and Dispatch Section
Flight Planning: The Air India has purchased a new flight planning system and
it has started with the implementation phase for the
new Flight Planning system.
Cost Index: Air India has converted from Mach flying
to Cost Index flying.
Contingency Fuel: Air India has reduced it from 5%
to 3% on some types and 10% to 6% on other
aircraft types.
246
Additional Fuel: Air India has reduced the amount of fuel being uplifted by
Pilots and Dispatcher based on statistical data.
Alternate Selection: Air India has changed the practice to adopt an alternate
airport policy based on:
JAR-OPS alternate airport requirements
Designate the closest suitable alternate airport in good weather
Designate second alternate airport under conditions as specified in JAR-OPS
Apply a takeoff alternate as required by JAR-OPS
Centre of Gravity: Centre of Gravity
is always optimised to decrease the
drag on the aircraft
Zero Fuel Weight Error: A reduction
of the error between the Estimated
ZFW and the Actual ZFW has been
achieved to produce a more accurate
EZFW for the flight.
Fuel Management Information: Air
India has created an in-house
statistical fuel management
information system.
Centralized Dispatch: Air India has established a centralized dispatch center
that is concentrating on flight planning and flight following. A centralized dispatch
group plays a major role in supporting the flight. When Mission Management is
required to either speed up or slow down a flight for economic reasons the
dispatch group is available to support the mission on required basis.
Maintenance & Engineering Department:
Engine Core Wash : Engineering has
introduced the engine core water
wash program to the most effective
interval for each engine type, Fan-
blade and IGV. Air India recently
became the first and sole provider of
Pratt & Whitney EcoPower Engine
Wash Service in India. It is designed
to clean aircraft engine fuel path and
turbine blades so as to improve
aerodynamic characteristics. It has
proven to be one of the most
247
effective methods of reducing fuel burn and reduce Carbon Dioxide emissions.
It uses non-toxic chemicals and collects all effluents after cleaning the engine
core. The effluents are recycled through a filtering process and reused in
subsequent washes, thus minimizing water consumption. It results in an
effective and faster engine wash and offers an eco-friendly innovative solution
resulting in better Engine Gas Temperature margin and fuel burn improvement.
Till January 2011 Air India has washed 124 Engines using Eco Power system,
saving 540,000 gallon of fuel worth 1.9 million US$ while reducing its Carbon
dioxide emissions by approx 5300 metric tonnes. It is estimated that about
2.6 m gallons worth approximately 9 million US$ will be the annual recurring
saving while eliminating 25,000 metric tonnes of carbon dioxide emission.
Airframe: New procedures have been established which
take into consideration deteriorating aircraft performance,
uneconomical use of aircraft systems and unnecessary
carrying of weight.
Maintenance: Reduced the amount of drag each aircraft
is generating due to dirt and rough surfaces especially in
the critical zones of the fuselage, wings and empennage.
Weight Management: All unnecessary weights have
been removed from the aircraft. Carrying un-needed
weight (such as unnecessary parts, dirt, and moisture) is
inefficient.
Reporting and Monitoring: Formal meetings between M&E and Flight
Operations concerning weight management have been established and a
person nominated to monitor the results of corrective actions and follow up
on the status of agreed programs.
Replacing old aircrafts with the new generation fuel efficient aircrafts :
Air India has reduced its B747-400 & A310-300 fleet and increased its B777
& B737, A320 & A330 aircraft in its operations.
Corporate Environment Policy
Air India Limited, covering all its AOPS, subsidiaries and SBUs, as a part of its
corporate social responsibilities, is committed to address all environment issues
with particular regard to preserving and protecting the environment. Air India,
through its Environment Management System, will abide by all applicable laws
and regulations and try to exceed the requirement by periodically reviewing its
policy for improvement in its environment related performance.
248
Air India is committed to implement Green Initiative measures through effective
implementation of programmes that :
Reduce carbon emission, reduce noise and other pollution, reduce fuel
consumption, reduce consumption of natural resources.
Provide sufficient resources to meet environmental objectives by continual
measuring, monitoring, reporting and improving upon environmental
performance.
Set performance targets wherein objectives are achieved through training
and the implementation of work instructions and practices.
Air Indias goal is to be an organization whose practices make it one of the most
environmentally sensitive company in the aviation industry through an approach
that safeguards and enhances the quality of life of its employees, customers and
protects the environment.
249
First Prize Glass
HNG FLOAT GLASS LTD.
Andheri East, Mumbai (Maharashtra)
Unit Profile
HNG Float Glass Limited (HNGFL) is the group company of Hindustan National
Glass Industries Limited. HNGFL is in the business of Float glass manufacturing
with the installed glass melting capacity of 600 TPD. The plant at Halol is built over
121 acres of land with provision for second line. HNGFL has tied up with M/s
Toledo Engineering Company (TECO), USA for basic engineering, design services,
project engineering and complete project management including procurement
management, engineering management, project services and onsite job assistance
during the installation, commissioning and start-up of the Float Plant. TECO has
the expertise of making long lasting and energy efficient float furnaces. Plant is
having capability to manufacture glass between 2 mm to 12 mm thickness, 715mm
to 3680mm width and 900mm to 6100mm length.
HNGFL is ISO 9001:2008, EMS 14001 and OSHAS 18001:2007 certified company.
HNGFL annual turnover is Rs. 2890 Million. Company is one of the major producers
of float glass in India and capturing around 20% market share. Company is having
state of the art glass producing technology with highly automated plant. Company
is coming up with new Mirror plant in near future.
250
Company believe in the continuous improvement and following the same strategy
for energy conservation in our plant. Company has started our journey of energy
conservation with the installation of energy management system in the plant for
monitoring and controlling power consumption. Plant is monitoring and controlling
power consumption on shift basis and fuel consumption on day basis.
Plant has captured area wise energy consumption data and identified major energy
consumption areas. Plant has focused on electrical heating; compressed air
consumption and water pump house area and identified some scope of
improvement in these areas. Plant has made some cross functional team to work
on different projects and start achieving our targets. Plant also identify where
major variation occurs due to change in our process.
Plant has started optimization of our thermal energy used for glass melting. This
task is having different variable involve in this and some of this are not in our
control. Plant is measuring CO and O2 value in flue gas with the help of analyser to
minimize the natural gas consumption. Plant has installed online oxygen analyser
for the same. Plant has also insulated regenerator body to reduce heat loss from
the surface.
251
Monthly consumption graph is the evidence of continuous reduction in specific
electrical energy consumption due to plant sustained effort towards finding energy
conservation projects and implement the same. Energy conservation drive is
continuously going on company is achieving targets and set new targets for the
future and going to create best industrial bench mark for float glass industries
Company has implemented many energy conservation projects throughout the
year. Out of that major projects detail are given below.
Power Unit Saved = 1179096 Before
Saving in Lacs Rupees = 61.077
Investment in Lacs Rupee = NIL
We were running 3 nos main plant cooling water pump each of 160 Kw. These three pumps were
running 24 hours continuously due to process cooling requirement. We have studied the process
requirement. We found that the entire coolers were having parallel connection from main header. We
measure the temperature deference between inlet and out let temperature of the water and found it was
coming just around 1.5 Deg C. So We have converted parallel connection of the cooler to series
connection. After this modification we are able to stop one 160 Kw pump.
After
Stop one Main plant cooling water pump by optimization of cooling water requirement in process.
252
Power Unit Saved = 1716595
Investment in Lacs Rupee = 74.557
We were usingFO as a fuel for the furnace. Than we change over to NG system. By changeover to NG
We can reduce our compress air consumptionas well as power consumptionin Oil heater and Heat
treasure.
Change the furnace fuel to NG from FO
After
We are having four cullet crusher of 15Kw in cutting line. These cullet crushers are used to crush the
rejected glass. Crusher no # 4 was running continuously. We have modified its circuit. Now this crusher
is started when rejected glass reach to this crusher.
Reduce the running hours by automation of cullet crusher # 4 to run only when glass is rejected.
After
Install VFD for Main plant Hot water pump motor to reduce speed
and save energy
Install VFD for Lehr blower motors to reduce speed and save
energy
We were running Main plant hot water pump of 90 Kw capacity with soft
starter, We were controlling Hot well level by throttling discharge valve of
pump. We have installed new VPD and reduce RPM of the pump to save
energy.
We were using blower for cooling glass in the F zone of annealing
lehr. We were controlling temperature of glass ribbon by throttling
discharge damper of blower. We have installed two new VFD
drives for two F zone Blowers (37KW & 55KW) and reduce RPM
of the blower to save energy.
Power Unit Saved = 145416 Power Unit Saved = 105120
Saving In Lacs = 7.533 Saving In Lacs = 5.445
Investment in Lacs = 3.234 Investment in Lacs = 5.040
253
Before
After
We were having two booster pumps of 18.5 Kw for tin bath area. One booster pump is unable to match
our pressure requirement and so we were running tow booster pump to maintain our process. We have
design new pump with the help of M/S KSB and replace old pump with new pump of 30 Kw. After
replacing the pump we are able to maintain required pressure with the help of one pump only.
Replacement of two under design booster pump with two properly design booster pump. After
that we run only one booster pump instead of two.
Natural Gas Saved ( Lacs Nm3) = 42.48
Reduce the Specific Thermal Energy Consumption through different energy conservation
measures..
After
1. We have provided insulation to regenerator wall to reduce heat loss from that wall
2. We have provided waist cooler to improve current inside the furnace and reduce fuel requirment.
3. Pull enhancement to reduce specific energy consumption
Energy Policy
Plant at HNG Float Glass Limited manufacturing float glass are committed to
reduce total energy consumption and save natural resources in all our process
and activities with continual improvement approach.
Company shall achieve this by:
Optimization of our process through innovative ideas, creativity and focused
improvement approach.
Reduce usage of various form of energy by up gradation of our equipment,
infrastructure and supply chain.
Increase people awareness, communication, and knowledge enhancement.
Implementing proper energy monitoring and controlling system.
Investing in projects for energy conservation and renewable energy through
systematic investment plan.
Minimize additional energy consumption and running cost for new capital
investment.
254
First Prize Integrated Steel
TATA STEEL LIMITED
Jamshedpur (Jharkhand)
Building Profile
Established in 1907 at Jamshedpur, India and one of Asia's first integrated private
sector steel companies, the Tata Steel group is among the top-ten global steel
companies with an annual crude steel capacity of over 28 million tons per annum
(mtpa). A Fortune 500 company, it produces a spectrum of steel products and
mainly feeds the market sectors of construction, automobiles and engineering.
The Tata Steel Group, with a turnover of US$ 26.63 billion in FY'11, has over
80,000 employees across the five continents.
Post its globalization initiatives that established its presence in Europe and South
East Asia, Tata Steel is the world's second-most geographically-diversified steel
producer, with operations in 26 countries and a commercial presence in over 50
countries. Tata Steel possesses and operates iron ore and coal mines in India and
has made investments in Africa, Canada and Australia to ensure long-term raw
material security for its global operations.
255
Tata Steel is increasing its crude steelmaking capacity at the Jamshedpur Works
from 6.8 mtpa to 9.7 mtpa via a 2.9 mtpa brown field expansion project. The
project comprises setting up:
i) One 6 mtpa Pellet Plant,
ii) Two coke oven batteries, each with 0.7 mtpa capacity,
iii) One 2.9 mtpa Blast Furnace and
iv) LD Shop and a Thin Slab Caster and Rolling Mill (TSCR) of 2.4 mtpa to produce
hot rolled coil (HRC).
The company has on the anvil three Greenfield steel projects in the states of
Jharkhand, Odisha and Chhattisgarh in India.
The 6 mtpa Greenfield Integrated Steel Plant at Kalinganagar, Odisha, will make
hot and cold rolled flat products and will be built in two phases, each of 3 MTPA.
The first phase of the project is expected to be commissioned by January 2014.
This phase will have a 3 mtpa crude steel capacity feeding hot and cold rolling
mills. The second phase, with an additional 3 mtpa crude steel capacity, is scheduled
to be completed by March 2015.
The Groups vision is to be the worlds steel industry benchmark in Value Creation
and Corporate Citizenship through the excellence of its people, its innovative
approach and overall conduct. Underpinning this vision is a performance culture
committed to aspirational targets, safety and social responsibility, continuous
improvement, openness and transparency.
Energy Consumption
The energy consumption figures for the last three is as shown below :-
Sl. Particulars Unit 2008-09 2009-10 2010-11
a. Light Diesel Oil Tonne 4019 3384 3808
b. Coking Coal Tonne 2983335 3119669 3231927
c. Coal for injection in Blast furnaces Tonne 554261 847359 837942
d. Boiler/Middling Coal Tonne 133527 127334 94745
e. Electricity 103 KWh 2261560 2479930 2381671
f. Plant Specific Energy Consumption Gcal/tcs 6.587 6.125 6.006
g. Total Manufacturing Cost Rs. Crores 8525.19 9429.69 10649.39
h. Total Energy Bill Rs. Crores 3328.45 4156.68 4672.54
i. Energy as% of total cost of % 39.04 44.08 43.88
production
256
Energy Conservation Commitment, Policy & Set up
Sustainability and environment friendliness is at the core of every business. Tata
Steel is fully aware of the fact that the energy supply is mainly supported by fossil
fuels, whose reserves are limited and emission of carbon dioxide is caused by
energy combustion. Hence it is committed to energy conservation efforts.
With the introduction of the "Energy Conservation Act", Tata Steel has reaffirmed
its commitment to rationalization of energy use, matters relating to the recovery
and waste utilization. To meet the commitment concrete measures for efficient
use of energy, its recovery and waste utilization have been formulated.
In order to secure a stable energy supply and reduce cost, as well as preserve the
environment, Tata Steel has implemented a variety of energy conservation
measures. The measures implemented in the last 11 years have yielded good
results and the specific energy consumption has reduced from 7.401 Giga calories
per ton of crude steel to 6.006 Giga calories per ton of crude steel. This reduction
in Specific Energy Consumption has been achieved mainly by various phases of
modernization, phasing out of energy inefficient process, improving operational
practices, and adopting innovative technologies. The trend of specific energy
consumption is depicted below.
Energy Conservation achieved through introduction of new technologies,
optimization of operational practices and process intensification during the last Six
years are :
Plant Sp. Energy Consumption (Gcal/tcs) 6.959 6.717 6.655 6.587 6.125 6.006 FY'06 FY'07 FY'08 FY'09 FY'10 FY'11 Plant Sp. Power Consumption (KWh/tss) 402 388 400 421 385 356 FY'06 FY'07 FY'08 FY'09 FY'10 FY'11 Boiler Coal Consumption ( MT) 0.598 0.329 0.189 0.134 0.127 0.095 FY'06 FY'07 FY'08 FY'09 FY'10 FY'11 By_product Gas Utilization (%) 91.45 93.32 98.28 94.03 95.70 96.73 FY'06 FY'07 FY'08 FY'09 FY'10 FY'11
Plant Sp. Energy Consumption (Gcal/tcs)
6.959
6.717
6.655
6.587
6.125
6.006
FY'06 FY'07 FY'08 FY'09 FY'10 FY'11
Plant Sp. Power Consumption (KWh/tss)
402
388
400
421
385
356
FY'06 FY'07 FY'08 FY'09 FY'10 FY'11
Boiler Coal Consumption ( MT)
0.598
0.329
0.189
0.134 0.127
0.095
FY'06 FY'07 FY'08 FY'09 FY'10 FY'11
By_product Gas Utilization (%)
91.45
93.32
98.28
94.03
95.70
96.73
FY'06 FY'07 FY'08 FY'09 FY'10 FY'11
257
Energy conservation Measures, Plans & Target
During the decade Tata Steel has implemented a number of measures to improve
energy efficiency to sustain reduction in specific energy consumption which are
depicted below :
A journey started with (A) Implementation of best practices for energy
conservation such as Utilization of by product gases for Steam and Power
generation, Phasing out old and energy inefficient Units, Enhancing by product gas
recovery and optimization of operating practices. With the above efforts reduction
in Specific Energy Consumption was felt at a very low pace. An effort was than
redirected towards (B) Adopting best available technologies to reduce Sp.
Energy Consumption such as Waste heat recovery from waste gas of Blast Furnace
stoves, Installation of Top Recovery Turbine, Use of Regenerative Burners, Coke
dry quenching and application of V/F drives. This has resulted in significant reduction
in Specific Energy Consumption.
Currently no single breakthrough technology is available in the Iron and Steel
sector that could reduce the Specific Energy consumption drastically. Hence
challenges are to improve energy efficiency by adopting (C) New and emerging
technologies such as Combined Cycle Power Plant on by product gases, Thin
Slab Caster & Rolling, Use of Pellets and shift on alternate fuel (ie gas mixing) for
utilizing lean by-product gases.
258
6.721
6.198
5.920
5.997
5.626
5.400
6.587
6.125
6.006
5
6
7
FY-09 FY-10 FY-11 FY-12 FY-13 FY-15
G
c
a
l
/
tc
s
Plan Actual
Environment
Tata Steel Group puts emphasis on minimizing the environmental impact of its
operations and its products by adopting sustainable practices and continuous
improvements in environmental performance. Manufacturing steel unavoidably
produces carbon dioxide (CO2). However, Tata Steel products are part of the
solution to climate change as steel has inherent environmental advantages of
being durable, adaptable, reusable and recyclable. CO2 emissions in steel production
are off set by reductions in emissions through the life cycle of steel products,
achieved through effective product design and through recycling at end of life.
It is this abiding involvement with the environment which has earned the company
recognition for its achievements.
4
th
On-line Ambient Air Quality stations commissioned in Steel Works
11 On-line Stack Monitoring Systems installed at Steel Works.
Highest ever solid waste utilization of 94.40% was achieved for the year
2010-11.
Environment Clearance and NOC (i.e. Consent to Establish) obtained for 9.7
MTPA
Expansion Plan for Jamshedpur Steel Works.
Successful re-certification of Steel Works for OHSAS-18001: 2007 standards.
Successful surveillance audit of EMS: ISO 14001:2004 standards for Steel
Works.
Participated in Carbon Disclosure Project (CDP 2010). Tata Steel achieved
Carbon Disclosure Leadership Index (CDLI) score of 71% based on CDP 2010
response (63% scored in 2009) to secure highest amongst Indian Steel sector.
259
Tata Steel has implemented a variety of control measures to improve the working
environment at the shop floor. The objective has been to create an atmosphere
that respects both nature and community at the same time. The Jamshedpur
works is the first in the world to be conferred the SA 8000 for work conditions and
improvements in workplace. All its operations have achieved the ISO-14001
certification for Environment Management.
260
Second Prize Integrated Steel
ROURKELA STEEL PLANT, SAIL
Rourkela (Odisha)
Unit Profile
Rourkela Steel Plant (RSP), the First Temple of Modern India is the pride of Odisha.
The state's glorious heritage of initiative, enterprise and entrepreneurial brilliance
finds its modern expression in the Steel Plant. Rourkela Steel Plant is located in the
north-western tip of Odisha and at the heart of a rich mineral belt.
A major producer of diversified range of sophisticated steel products, RSP is an
integral part of the Steel Authority of India Limited (SAIL) - a Navratna Company.
Built in the late 50's with West German collaboration, RSP was the first integrated
steel plant to be set up in the public sector. RSP also pioneered the adoption of the
sophisticated LD process of steel making in Asia.
261
The Plant, initially designed to produce half a million ton (MT) of crude steel per
annum, was upgraded to produce 1 million ton of crude steel. The production of
hot metal commenced at RSP with the lighting up of its first Blast Furnace Parvati
by the then President of India, His Excellency Dr. Rajendra Prasad on 3rd February,
1959. The other units at the 1 MT stage were commissioned by the early part of
1962.
In order to meet the additional demand for flat products in the country, the capacity
of the steel plant was further expanded to 1.8 MT. Commissioning of the
expansion units commenced in 1965 and was completed by 1969. In order to
overcome technological obsolescence and to continue to remain competitive in
the market place, RSP went for further modernization in 1988. The modernisation
of the Plant was completed in two phases from 1994 to 1999. With this
the production capacity of the Steel Plant was augmented to 2 million tons
of Hot Metal and 1.8 Million tons of Crude Steel. Rourkela Steel Plant has
carved a name for itself as a unique producer of special purpose steels in the flat
steel segment. Plates, Hot Rolled Coils, Cold Rolled Sheets and Coils, ERW Pipes,
Spiral Weld Pipes and Silicon Steel Sheets and Coils are the products in RSPs
repertoire.
RSP has many firsts to its credit. It was the first plant in India to incorporate LD
technology of steel making. It is also the first steel plant in SAIL and the only one
presently, where 100% of the slabs rolled are produced through the cost effective
and quality centered continuous casting route. RSP is the only plant in SAIL to
produce silicon steels for the power sector, high quality pipes for the oil and gas
sector and tin plates for the packaging industry. Another uniqueness of RSP is that
it does not produce semis.
The use of its Plates in ship building & high pressure vessels, Silicon Steel in the
electrical machine manufacturing industries, corrugated galvanized sheets for roofing
including industrial roofing, pipes in the oil & gas sectors, tinplates in packaging
industry and Special Plates in the defence of the nation is well known.
RSP is further undergoing massive expansion to augment Hot Metal
Production from 2.0 to 4.5 MT and Crude Steel Production from 1.9 to 4.2
MT with introduction of state of art technology and energy efficient
processes.
262
SL SHOP/UNIT Production ratio GCal/TCS
No. GCal/TP Actual Balanced Actual Balanced
1 Coke Ovens 1.6075 0.6900 0.7174 1.1092 1.1533
2 Sinter Plant - I 0.5566 0.6702 0.5378 0.3730 0.2993
3 Sinter Plant - II 0.5305 0.9234 0.7410 0.4899 0.3931
4 Blast furnace 2.8663 1.0658 1.0573 3.0549 3.0306
5 SMS - I 0.9264 0.1936 0.1936 0.1794 0.1794
6 SMS - II 0.1526 0.8064 0.8064 0.1231 0.1231
7 Plate Mill 0.7213 0.2159 0.2146 0.1557 0.1548
8 Hot Strip Mill 0.5892 0.7354 0.7299 0.4333 0.4300
9 Pipe Plant 0.2574 0.0279 0.0353 0.0072 0.0091
10 Cold Rolling Mill 1.2801 0.1413 0.1790 0.1808 0.2292
11 Silicon Steel Mill 2.0210 0.0371 0.0468 0.0751 0.0945
12 CPP - I (Boiler) 0.0944 1.5181 1.5181 0.1432 0.1432
13 CPP - I (Power) 1.1207 0.1876 0.1876 0.2103 0.2103
14 MP Boiler 0.1265 0.3693 0.3693 0.0467 0.0467
15 Oxygen Plant 0.9415 0.0931 0.0931 0.0877 0.0877
16 RMP 0.9318 0.1197 0.1197 0.1115 0.1115
17 Auxiliary 0.1561 1.0000 1.0000 0.1561 0.1561
18 Losses 0.1221 1.0000 1.0000 0.1221 0.1221
19 Total 7.0591 6.9740
Rourkela Steel Plant 2009-10
SL SHOP/UNIT Production ratio GCal/TCS
1 Coke Ovens & CCD 1.5858 0.6986 0.7044 1.1079 1.1170
2 Sinter Plant - I 0.5615 0.6466 0.5201 0.3631 0.2920
3 Sinter Plant - II 0.5369 0.9091 0.7312 0.4881 0.3926
4 Blast furnace 2.8663 1.0661 1.0532 3.0558 3.0190
5 SMS - I 0.9656 0.1855 0.1855 0.1791 0.1791
6 SMS - II 0.1877 0.8145 0.8145 0.1528 0.1528
7 Plate Mill 0.7230 0.2135 0.2120 0.1543 0.1533
8 Hot Strip Mill 0.5805 0.7283 0.7309 0.4228 0.4243
9 Pipe Plant 0.2022 0.0392 0.0505 0.0079 0.0102
10 Cold Rolling Mill 1.2515 0.1334 0.1701 0.1670 0.2129
11 Silicon Steel Mill 2.0068 0.0358 0.0457 0.0719 0.0917
12 CPP - I (Boiler) 0.0484 1.4788 1.4788 0.0715 0.0715
Rourkela Steel Plant 2010-11
263
Sl. SHOP/UNIT Production ratio GCal/TCS
13 CPP - I (Power) 1.2162 0.1836 0.1836 0.2233 0.2233
14 MP Boiler 0.1673 0.3936 0.3936 0.0659 0.0659
15 Oxygen Plant 0.6274 0.0950 0.0950 0.0596 0.0596
16 RMP 0.9559 0.1146 0.1146 0.1095 0.1095
17 Auxiliary 0.1346 1.0000 1.0000 0.1346 0.1346
18 Losses 0.1608 1.0000 1.0000 0.1608 0.1608
19 Total 6.9960 6.8702
Energy Conservation Measures Taken In RSP, Rourkela During
2010-11
1. Installation Of VVVF Drives In Hot Air Dryer Of Tandem Annealing Line
of Silicon Steel Mill: Hot air dryer motor is used for delivering hot air which is
subsequently used to dry the sheet treated in TA Line. VVVF drive has been
installed in the above mentioned motor of capacity 30 KW by M/S Danfoss
Industries Pvt. Ltd. resulting in benefit of about 9 KW. Current drawn by the
motor has been considerably reduced from a level of 45 to 30 Ampere. Besides
this it has also resulted in ease of maintenance and reduction in down time.
Total Investment: Rs. 1,50,000
2. Oxygen enrichment in Blast furnace 2 & 3: Hard coke is the main energy
input to Blast Furnaces. It acts as reducing agent; acts as fuel for maintaining
temperature to keep the iron in molten condition and it also take the burden
load of the furnaces. Oxygen enrichment in B.F. 2 & 3 of RSP has been done
by utilizing the in-house facilities by 1 1.5 % to increase the coke burning
rate and productivity. Productivity of the furnace has improved by about 2
2.5 %. Subsequent reduction in energy consumption by way of reduction in
coke rate shall be quantified after stabilization of the process.
Total Investment: Rs. 4.53 Crores
3. Automatic operation of Electrical fields of ESP in Sinter Plant-II on
Energy Saving mode/Charge ratio mode: Automatic operation of the
electrical fields of ESP of waste gas, SP-II in energy saving mode. Electronic
controller unit for ESP with firing card & other accessories were procured from
M/S Ador Powertron Pvt. Ltd., Pune and commissioned with in-house resources
resulting in a saving of about 30 kWh.
Total Investment: Rs. 3.5 Lacs
4. Installation of VVVF drives in all the running equipments of Batt-IV of
Coke Oven: Analog drives of all the running equipments (20 nos. of motors)
Battery-IV of Coke Oven have been replaced with VVF drives during re-building
of battery-IV. This has resulted in substantial reduction of power consumption
besides other benefits like ease of maintenance and reduction in incidents of
break-downs.
Total Investment: Rs. 100 Lacs
264
5. Introduction of mixed gas firing in MP Boiler as a retrofitting project:
Mixed gas firing was introduced in MP Boiler-2 after suitable modification to
enable utilization of by-product fuel gas & substitute the boiler coal. This has
resulted in a saving of about 1.5T coal per hour, besides other benefits like
case of maintenance reduction of carbon in bottom ash and prevention of fire
slippage during monsoon.
Total Investment: Rs. 10 Lacs
6. Commissioning of energy efficient new 700 TPD ASU-III of TOP-II:
Obsolete and highly energy intensive TOP-I of RSP has been stopped and
substituted by one of the most energy efficient and state-of-the-art 700 TPD
ASU-III of TOP-II. This has resulted in substantial saving of power consumption.
Total Investment: Rs. 340 Crores
7. Conversion of traditional tube-lights to CFL: About 1000 nos. of 40 Watt
tube-light in Offices and corridors have been converted to CFL of 18 watts,
resulting in substantial saving in power consumption. This scheme will be
extended in subsequent years to all the office buildings of RSP as a part of
energy conservation measures.
8. Conversion of HPSV to LED in Street lights of RSP: 50 nos. of 250 watt
HPSV lamps in street lights of RSP were replaced by 90 watt LED, resulting in
substantial saving in power consumption. This scheme will be extended in
subsequent years as a part of energy conservation measure
9. Conversion of Aluminum to FRP blade in five nos. of cooling tower of
TOP-II: There are numbers of Cooling Towers in the plant for recycling the
water in cooled condition. The temperature of water controls the efficiency of
the process where cooled water is used. In plant most of the Towers were
having Aluminum blades which are highly energy intensive. By using FRP blade
electricity consumption can be brought down by 25 %. Now we are replacing
Aluminum blades with FRP blades in a phased manner. In 2010 we have replaced
5 such blades
10. Thyresterization of mill run out table and approach table, entry and
exit manipulator of Plate Mill: Thyresterization has been introduced in mill
run out table and approach table entry and exit manipulator, wherein the
Analog drives and have been converted to digital drives. This has helped in
reducing power consumption as well as other benefits like ease of maintenance
and reduction in incidences of break downs.
265
11. Introduction of coal tar fuel injection in Blast furnace I: Coal tar injection
through tuyers has been commissioned in Blast furnace-I of RSP with a capacity
of 100 kg Tar/THM, as a partial replacement of coke. This project is under
stabilization. It is expected to replace coke at 1:1 ratio after stabilization.
Exact amount of saving will be quantified after stabilization of the system.
Total Investment: Rs. 6.6 Crores
12. Thermal insulation of steam pipe lines: About 2000 m
2
of damaged thermal
insulation on steam lines have been replaced, which has increased steam
temperature at consuming end and reduced condensate formation down the
stream. This has resulted in availability of steam required by plant unit. Steam
saved has consequently resulted in saving of boiler coal.
Energy & Environmental Policy
266
Second Prize Mining
MOIL LIMITED
UKWA MINE
Ukwa, Distt. Balaghat (Madhya Pradesh)
Unit Profile
Ukwa Mine is an underground Mine of MOIL Limited situated about 243 Kms. from
Nagpur. There are 673 employees including Executives, staff and workers. The
Mine is operated in two shifts.
The Ore body at Ukwa Mine is flat which poses difficulty in Mining. The underground
Mine at present is being excavated from 70 Meter level to 110 Meters below
ground. Company has embarked on new vertical Shaft project for improvement
in productivity and to enhance safety.
The heavy rainfall in Ukwa Mine poses inundation problem as the Mine is located in
remote area and failure of power is always imminent during monsoon. A 1000 KVA
DG set has been proposed to be installed to improve the existing power position as
well as to replace old and inefficient DG sets. Energy conservation measures by
providing VFD for Compressor has been already implemented and provisions are
being made for other equipments such as pumps, ventilation fans etc.
267
DESCRIPTION 2009-10 2010-11
Total energy consumption in Lacs of kWh 11.091 9.837
The existing Mining methodology uses multi level haulages to haul ore from different
levels of Mine. Installation of new vertical shaft will have access to all the levels
through one vertical shaft and transportation of men and material will save time
end energy and improve production and productivity of Mine as well as improve
working condition and safety environment. Power is being distributed from a 33
KV substation and main electrical installations are air compressors, Haulages at
surface as well as in underground, Centrifugal Pumps and ventilation fans.
Energy Consumption
As it has been already stated major energy consuming units are pumps, Air
compressor and haulages. The total energy consumption during the period of
2009-10 & 2010-11 is as below:-
The percentage of energy consumption for major Energy consuming units are as
below :-
DESCRIPTION 2009-10 2010-11
% Total Energy Consumption % Total Energy
Consumption
Haulage 12.62 14.03
Underground Pumps 17.76 19.32
Compressor 27.14 29.29
Ventilation 12.08 12.81
Company has already started sinking a new vertical shaft at Ukwa Mine to improve
production, productivity as well as energy conservation. Presently, plant is using 5
Haulages for hauling ore from underground mine. However, after installation of
vertical shaft only one winder shall be used for transportation of men, material
which will significantly reduce energy consumption by improving the productivity
as well time required for transportation of man in underground mine. Company is
also procuring a 1000 KVA DG set for replacement of 2 Nos. of existing 500 KVA
DG set which are old and inefficient as a energy savings measure.
Ukwa Mine is an underground mine having flat ore body. Flat ore body of mine
posses severe mining constraints for wining ore from mine. The major equipment
installed in Mine are as below :-
1. Air Compressors.
2. Water pumps in underground mine.
268
3. Haulages for hauling Manganese Ore.
4. Ventilation Fan for ventilation of mine.
5. Sand stowing plants for filling voids.
6. D.G. Sets.
The Ukwa Mine is an underground mine and drilling, blasting, mucking, hauling
Manganese Ore from underground mine are main activities.
1. Energy conservation through variable frequency drive compressor
Pneumatic drill machine are required for drilling as electrical drill machine cannot be
used due to low torque. Pneumatic machines operating at 90 Lbs /Sq. inch are the
only suitable equipment to perform faster drilling in hard rocks.
Plant has introduced VFD operated compressor which regulates its operating speed
automatically depending on requirement of compressed air. The automatic
operation of compressed air through VFD results in savings of energy. Earlier unit
was using two compressors each of 150 HP capacity however, after installation of
250 HP VFD the operation of twin compressor has reduced drastically and it has
resulted in energy saving.
2. Energy Conservation by using Smaller HP Pumps for dewatering
The underground pumps are operated throughout the year for dewatering to save
mine from inundation.
250 HP Compressor at Ukwa Mines with Variable Frequency Drive
269
35 HP submersible pump and 30 HP centrifugal pump
The inrush of water reduces other than monsoon season. Considering the
requirement of monsoon season plant had installed 150 HP and 167 HP centrifugal
pumps for dewatering purposes. These pumps were also used for dewatering
other than monsoon season. As an energy conservation measures plant has
installed 35 HP submersible pump and 30 HP centrifugal pump to operate other
than monsoon season which has resulted in energy saving.
3. Energy Conservation Measures in Sand Stowing Plant
After wining ore in underground voids are created in mined area. It is necessary to
fill these voids using filling material for stability of mine. Plant is using sand mixed
with water for filling these voids known as sand stowing.
Water tank for sand stowing & recirculation of water for plant
As a measure of energy conservation new water tank has been constructed to
store water and water is allowed to flow through gravity for sand stowing. Earlier
a 75 HP pumps was operated continuously for sand stowing plant. This has resulted
in conservation of not only energy but water too. In another measure a tank has
been constructed at ground level to re-circulate water in plant which otherwise
was allowed to flow out in drain. Earlier a 7.5 HP pump was used continuously to
feed water to plant. In current scenario in place of 7.5 HP pump plant is using 3 HP
pump for recirculation of water and 7.5 HP pump is being used intermittently
270
Certificate of Merit Mining
BEACH MINERALS COMPANY PVT. LTD.
Kuttam, Distt. Tirunelveli (Tamil Nadu)
Unit Profile
Beach Minerals Company Pvt Ltd (BMC) is the early bird in Garnet production in
the private sector in India. BMC is a 100% export Oriented Unit and the leading
Miners & Exporters of wide varieties of minerals such as Garnet, Ilmenite, Rutile,
Zircon. Its core competence exists with Mining, Processing and Refining of these
beach placer Minerals, with the sizable production capacity. The mineral processing
plant is located at 132, Tiruchendur Road, Kuttam, Tiruneveli District. Currently,
company has been successfully exporting these minerals for various industrial
applications to the market in the Europe, America, Middle East, Far East and
Australian Countries. In Garnet and ilmenite production, it occupies a leader position
in India and in the Globe, it has a major share in the market.
It has in its employment more than 1000 workers including skilled and engineers
and mineral-processing technologist.
271
Year Total Production of Total Electrical Energy Specific Electrical
Garnet & ilmenite Consumption Energy Consumption
per annum Lacs kWh /year in kWh/tonne
2010-11 1,59,754 tons 61,39,125 units 331 kWh/tonne
Energy Consumption
Annual Energy One Time Electrical Energy Furnace Oil
Savings Investment Saving in Savings in
in Rs. Lacs in Rs. Lacs Lacs kWh Lacs KL
1,10,52,864 32,80,000 24,55,692 NIL
Energy Conservation measures adopted by BMC
BMC has implemented the energy conservation measures in various areas of its
unit.
In the mining area, to increase the feeder and water pipe line of Feeder III, it has
to increase the motor KW rating. But, instead of that, to reduce the energy
consumption, it has changed the plan and installed a new CUP III plant in the
mining area as a small unit nearby the main plant.
Mine has removed 220KW capacity feeder III pump motor and 55 Kw capacity of
feeder III water line motor. And also, we mine has reduced the capacity of Cup
plant AC Drive motor capacity from 250kW to 185 kW.
1. The capacity of the feeder pump motor - 220 KW. The energy consumption of
the motor is 181 Units / hr. So, the savings by eliminating the above pump
motor per annum 181 x 24 x 349 days = 15,16,624 units.
So, Total investment incurred - Rs. 26,80,000
First year energy cost savings - Rs. 68,24,800
2. The capacity of feeder III water line motor is 55 kw. The Energy consumption
of the motor is 31 units / hr. So, the savings by eliminating the above motor
per annum - 31 x 24 x 350 days = 2,60,846 units.
So, Total investment incurred - nil
3. The cup plant AC drive motor capacity is 250 kw pump motor. Now, mine has
reduced it to 185 kw pump motor. Energy savings per annum of the unit -
6,78,722 units.
So, Total investment incurred - Rs. 6,00,000
272
BMCs Energy Management Policy
BMC has distinctive policy to save cost towards its energy requirements.
1. Bulk of the Energy Consumption is based on a low cost biomass resources
which not only reduces our energy cost, but also is very light on the atmosphere
with minimum carbon intensity.
2. Monitoring and control of consumption of Energy through effective energy
management systems and regular energy audits. Constantly endeavoring to
reduce energy cost by optimal consumption and economical practices.
Spreading this awareness among all the employees and staff.
273
First Prize Paper & Pulp
BILT GRAPHIC PAPER PRODUCTS LIMITED
(Unit - Bhigwan)
Distt. Pune (Maharashtra)
Unit Profile
Bilt Graphic Paper Products Limited Unit Bhigwan, India is the largest coated paper
manufacturing plant of the country. Each employee of the unit is committed for
efficient use of energy, efficiency and best utilization of resources right from the
inception of the plant.
Capacity utilization of the Paper Machine has increased tremendously over the
last two years due to innovative measures like debottlenecking of the refining
constraint by use of Bio-refining enzyme, use of micro-particle for higher drainage
& installation of the Polyurethane covered roll in the vibration prone fourth press
position. Specific Energy Consumption for the Paper plant has reduced by 7.5 %
due to path breaking initiatives taken by employees without any investment like
drying after the coating by only hot air & cylinder drying. Energy consuming Infrared
dryers have been stopped permanently after taking various printing trials with the
paper produced without radiation drying in some grade of papers.
BGPPL specific electrical energy consumption is only 667.7 kWh /T which is at par
in paper industry at international forum.
The success story of Bilt, Bhigwan is due to the continual improvement done by
the company employees under the umbrella of strong management systems.
274
2009-10 2010-11
Finished Production (Ton/annum) 248515 272741
Capacity Utilization (%) 81.48 89.42
Electrical Energy Consumption (Lacs kWh) 1794.77 1821.07
Steam Consumption (Ton) 553638 552546
Specific electrical energy consumption (kWh /T) 722 667.7
Specific thermal energy consumption (Ton/T) 2.23 2.03
Energy Performance of the unit is visible from the following trends. The trends are
for Specific Energy consumptions of both machines put together. The trend is
compared on finished Paper
Through its consistent efforts in effective energy utilization & energy conservation
Graphic Built is excelling past efficiency targets year after year.
Energy Consumption
BGPPL journey of excellence is visible from the table below :
275
Energy Conservation Initiatives taken
During 10-11 mill has implemented following Energy Conservation Initiatives,
resulting into saving of Rs 482.25 lacs.
Project Description
(Lakhs
KWH)
Stea
m
(MT)
Total
fuel
In
MTOE
Total
Savings
(Rs .Lakhs)
Investment
incurred on
the project
(Rs. Lakhs)
2010-11
Replacement of old
inefficient Secondary Air
conditioner Pump 1with
energy efficient p ump-1
in PM1
1.01
4.15 2
2010-11
Replacement of old
inefficient Secondary Air
conditioner Pump 2 with
energy efficient pump in
PM1
1.01
4.15 2
2010-11
Replacement of old
inefficient Condenser
Pump 1 with energy
efficient pump in PM1
0.24
0.97 0.9
2010-11
Replacement of old
inefficient Condenser
Pump 2 with energy
efficient pump in PM1
0.24
0.97 0.9
2010-11
Temperature control of
pm2 VAM Cooling basis
fan resulting into energy
saving in fan and
additional pump (22kw)
both.
0.59
2.44 0.01
2010-11
Stoppage of Pre -coat(1
&2) IR Drying system
during all 180 GSM and
above board paper in
Off Machine coater
(Average10
days/month)
7.2
29.66 0
2010-11
Provided interlock to
stop the Dust blower
when machine is not
running
0.0729
0.30 0
276
2010-11
Installation of Titon
Aerator in ETP-1 No 2.92
12.02 8.26
2010-11
Use of B CTMP in Furnish
in PM1 to reduce KWH
and steam
2.96
1666
6
1050 140.34 0
2010-11
Optimizations of IRCON
Drying system in PM2
coater 1 and coater 2
10.5
43.26 0
2010-11
Stoppage of NBKP Soft
wood Refiner motor in
pm2 by optimizing the
process like reduc ing
the soft wood from 20%
to 12%.
45.36
186.88 0
2010-11
Stoppage of 1 No of
Supply blower in coater
1 and coater 2 in PM2
10.75
44.30 0
2010-11
Stoppage of 1 No of
Exhaust blower in coater
1 and coater 2 in PM2
1.01 4.15
0
2010-11
Installation of VFD at
cooling water pump 2
motor in pm2
2.10 8.65
5
Grand Total 85.94 16666 1050 482.25 19.07
Project Description
(Lakhs
KWH)
Stea
m
(MT)
Total
fuel
In
MTOE
Total
Savings
(Rs .Lakhs)
Investment
incurred on
the project
(Rs. Lakhs)
277
278
Energy Policy
279
First Prize Petrochemicals
RELIANCE INDUSTRIES LIMITED
Hazira Manufacturing Division
Distt. Surat (Gujarat)
Unit Profile
Reliance Industries Limited, Hazira Manufacturing Division is an India's largest
integrated Petrochemicals, Polyester site located near Surat in Gujarat state
spreaded over 1000 acres.
Naphtha is cracked at high temperature to produce ethylene and propylene. Benzene
and toluene are extracted from the cracked products. Butadiene plant adds value
to the C4 stream from cracker. Ethylene is polymerized to LLDPE/HDPE in the
polyethylene plant. Propylene is polymerized to PP in the polypropylene plant.
Ethylene is chlorinated to ethylene-di-chloride, which is cracked to vinyl chloride
and, in turn, polymerized to PVC in the PVC plant. Ethylene is oxidized to ethylene
oxide, which is hydrolyzed to MEG in the Mono Ethylene Glycol plant. Paraxylene
is oxidized to produce PTA. MEG and PTA is reacted in polycondensation lines to
make POY, PSF, Polyester Fibre Fill and PET. The complex has 350 MW of captive
power generation capacity based on gas and naphtha. Hazira has its own jetties
and a single buoy mooring five km. off the coast for the large tankers to transfer
the main raw materials Naphtha and Paraxylene directly to the tank farms.
280
Specific Energy Consumption Trend
Sustained effort of Hazira Manufacturing Division, over the years to reduce energy
consumption in its energy intensive petrochemical operations has resulted into
3.58 % reduction in Energy Index over last 3 years.
Achievement: Energy Conservation
During last 3 years, Energy Conservation Drive was pursued with high level of
commitment and enthusiasm across all levels of the organization. This is manifested
by implementation of 224 nos. of ENCON projects resulting in the energy
saving to the tune of 93,315 kSm
3
NG and 63,660 MWh with investment of
more than 80 Cr. Rs. during the period.
281
Major Energy Conservation Projects implemented during FY 2010-11
1) Installation of additional motor driven BFW Pump (B-900) and
stoppage of BFPT at Cracker plant to achieve energy savings.
Project Background
At Hazira Manufacturing Division, complex level there are four level of steam grids
viz 110 ata, 40 ata. 17 ata and 4.5 ata. The complex steam system is mainly
governed through steam generation and export by cracker plant, lower level waste
steam recovery from various process plants and steam generation at CPP to
cater to the power demand and process steam requirements. The steam grid of
mother plant cracker interacts with all levels of complex steam grid and thus has a
significant impact on CPP steam demand and thus fuel consumption at CPP.
Within cracker, there are three boiler-water feed pumps (BFP) installed. In normal
operation 2 nos. pumps are operated, one of which is turbine driven and the other
is motor driven. The turbine for BFP is a small capacity back pressure turbine
which due to its size and vintage has lower efficiency than extraction cum
condensing turbines installed at CPP. Considering seamless integration of complex
grid with cracker grid at all level of steam grid, there is an opportunity to cater to
the crackers process power and steam needs more efficiently.
Brief description of the project / initiative implemented
Considering the opportunity for energy conservation and GHG reduction, a de-
novo review of the cracker CPP steam grid was carried out by an in-
house cross functional team.
After an intense deliberation and in-depth review it was decided to install a motor
driven pump at cracker for BFP supply so that two BFPs can be operated through
motor as prime mover.
282
The entire project has been executed within the schedule and in-line with the
management of change (MOC) process taking utmost care for process safety
and reliability. This has resulted in export of additional 45 TPH of 40 ata steam
from cracker to CPP.
The additional power and lower level steam demand at cracker are catered through
efficient extraction at CPP which demanded lesser steam to fulfill the process
energy need at cracker. Thus, it resulted in net reduction of about 11 TPH of
110 ata steam (SHP Steam) at CPP.
Key innovations
The key innovativeness is the change in the process design provided by
the licensor.
This is the First of its kind process design change in the Licensee
plants.
Project Benefits
Energy Saving : 61,376 Gcal per annum
Energy Cost-savings : Rs. 821.4 Lacs
Emission reduction : 12,938 MT CO
2
/ Annum
2) Replacement of bowed Superheater modules of Heat Recovery
Steam Generator (HRSG) #1 and 2 with drainable type super
heater modules at CPP&U.
Background of the Project
Heat recovery steam generator (HRSG) -1& 2 out of total 9 HRSG are in
service since commissioning (FY 1991-92). HRSG-1 &2 was designed to supply
SHP steam with supplementary firing to maintain of 117 kg/cm
2
pressure and
of 512 deg C Temperature. To maintain this steam parameter minimum SHP
generation required was 65 tph irrespective of Steam and Power scenario.
During an annual inspection distortion was observed in superheater (SH)
modules of HRSG-1 & 2. It necessitated the replacement of excessive
buoyed SH modules due to reliability concerns.
Brief description of the project / initiative implemented
Instead of one to one replacement of SH modules, it was decided to tackle
the issue with an innovative approach.
In view of the energy loss due to the condition of SH modules and original
design, RIL-Hazira selected the Energy efficient design of SH Modules with
283
upgraded metallurgy of tube based on the recommendation of Task-Force
consisting of Cross-functional team members This measure can reduce HRSG
minimum steam generation to 50 tph in unfired mode along with
achievement of steam parameter, 117 kg/cm
2
and temp 512 C.
As this measure removes the constrain of higher SHP steam generation
irrespective of Steam and Power scenario, ultimately results in optimized CPP
operation. Metallurgy of the SH-2 modules was upgraded to alloy steel
T22 and T91 with optimized tube fin configuration.
With the implementation of above design changes in SH module configuration,
HRSG#1 & 2 steam generation in unfired mode was achieved resulting in 0.9
ksm
3
/hr NG savings.
Execution of the modified SH modules were a challenging task since it was
implemented in operating plant. Moreover, the task was implemented ahead
of schedule without any safety incident.
Project Benefits
Energy saving : 61,236 Gcal/Annum
Energy Cost-savings : Rs. 705 Lacs
Emission Reduction : 12,909 MT CO
2
/Annum
3) Uprating Gas Turbine Capability of GT-3 and GT-5 by change of
components for increased firing temperature.
At HMD CPP, there are 9 nos. gas turbines (each of about 30 MW capacity at
site condition) and 2 nos. extraction cum condensing turbines (40 MW capacity
each). The complex power demand is catered through operating GTs at about 25
- 27 MW considering spinning reserve of 3 MW to keep the complex operating
without grid synchronization in-case of any inadvertent machine trip. Balance of
the power demand is met through loading STGs through extraction and
condensation modes.
This project was taken-up to increase the capacity of Gas Turbines by change of
the combustion components to allow higher firing temperature in combustion
process. This has provided about 3 MW more capacity in uprated machines. The
increased GT capacity has been employed to reduce condensation load of STGs.
This ENCON measure resulted in savings of about 19 TPH of 110 ata steam
(SHP Steam).
Project Benefits:
Energy saving : 1,06,013 Gcal/Annum
Energy Cost-savings : Rs. 1,419 Lacs
2
/Annum
284
4) Reduction in steam consumption by reducing the water/Aqueous
EO Ratio in glycol reactors at MEG plant.
At HMD, in EO-EG plant, Mono-ethylene Glycol (MEG), Di-ethylene Glycol (DEG)
and Tri-ethylene Glycol (TEG) is produced through the reaction of Ethylene oxide
(EO) and Water. The proportion of Ethylene Oxide and water in the feed determines
the proportion of MEG, DEG and TEG in the final product. Higher Water to EO ratio
in feed results in higher MEG in final product mixture. The subsequent purification is
achieved through evaporation of excess water using steam as energy source.
Conventionally, MEG, DEG and TEG prices movements are in harmony with one
another and also MEG prices are significantly higher than DEG and TEG prices.
Thus EO-EG plant was operated at Higher Water / EO ratio to produce more MEG
compared to DEG and TEG. Since June 10 the appreciation in DEG prices were
higher than MEG prices thus providing an optimization opportunity for Water / EO
ratio to minimize energy consumption in evaporation unit. In order to arrive at the
optimum value of Water / EO ratio a constrained optimization model was developed
keeping water / EO ratio as variable and minimization of steam consumption as
part of objective function. Through the optimization model it was established that
Water to EO ratio of 7.5 is optimum.
Plant scale implementation of this scheme resulted in reduction of 6 TPH of HP
steam and 180 KW of pumping power.
Project Benefits
Energy saving : 26,063 Gcal/Annum
Energy Cost-savings : Rs. 354 Lacs
2
/Annum
285
Energy Policy
286
Certificate of Merit Petrochemicals
CONTINENTAL CARBON INDIA LIMITED
Ghaziabad (Uttar Pradesh)
Unit Profile
Continental Carbon India Limited (CCIL) was formed in October 2000 upon
the acquisition by Continental Carbon Company (CCC), USA of the carbon black
assets of Oriental Carbon & Chemicals Ltd. Since then the carbon black
manufacturing facility in Ghaziabad, Uttar Pradesh, has been substantially
refurbished and production capacity is doubled to 65,000 MT PA. A 15 MW Waste
Heat Recovery Power Plant, commissioned in 2008 is co-located with the
manufacturing unit and supplies power to the Uttar Pradesh grid.
Continental Carbon Company (CCC), USA which is recognized as a leader in the
development and manufacture of furnace grade carbon blacks has licensed leading
edge and environmental friendly manufacturing technology to CCIL.
287
CCIL has received a steady flow of capital over the years and is now a subsidiary
of CCCs parent company; CSRC, a Taiwan based listed company. The CSRC
group is the worlds 5th largest manufacturer of Carbon Black.
Carbon Black an engineered carbon is primarily used as a reinforcing filler in
rubber compounding. The end products like tires, profiles, hoses and V-belts are
mostly consumed by the automotive industry.
CCIL ranks third amongst the manufacturers of Carbon Black in India with FY
2010 net revenues of Rs. 362 crores and a headcount of 212 of regular employees.
It operates from a single location in Ghaziabad. A second plant is planned to be
built in Vishakhapatnam (AP) for which land has been procured and preliminary
activities are in progress.
In the next 5 years CCIL is set to grow organically and in areas of acquired
expertise faster than average Industry growth rates by pursuing a four pronged
strategy.
Human Resource Development.
Innovation and Technological Leadership.
Energy efficiency and Environment Sustainability.
Leveraging of Information Technology and Automation for driving cost
reduction.
Details about the innovative projects implemented in last 3 years
15MWH Waste heat recovery Plant (Year 2008)
Purpose of the project activity
The purpose of the project activity is to utilize the process waste gases
and waste heat, by installing a 60 TPH boiler and 15 MW turbine to generate
steam and electricity. The related energy savings and environmental benefits
are the main drivers for initiating the project activity. The energy content
in the waste gas is utilized to produce steam which in turn will be used to
generate electricity. The electricity generated by the project activity using
waste gas is used to meet the in-house energy demand of CCIL
manufacturing plant and surplus electricity were fed into the Northern
regional electricity grid of India. The project is contributing positively towards
Greenhouse Gas emission reduction, conservation of natural resources
and sustainable development of the community.
288
Description of the project:
CCIL produces carbon black from carbon black feedstock through the oil
furnace process. In the oil furnace process followed by CCIL, an aromatic
liquid hydrocarbon feedstock is heated and injected continuously into the
combustion zone of furnace where it is decomposed to form carbon black.
The furnace can operate on fuel oil as well as natural gas. The carbon black
so produced is then conveyed through the reactor, cooled and collected in
bag filters in a continuous process. In this process a residual waste gas
gets generated that contains a significant volume of combustible gases
which can be used to produce heat.
Since March 2005, CCILs production plant capacity has been 65,000 tons
per annum. CCIL has a 35 tph, 4.4 MW waste gas recovery cogeneration
plant for meeting its captive electricity and steam requirements. This 4.4
MW plant was not connected to the grid. The captive electricity and thermal
requirements of the plant are expected to remain the same and the baseline
plant has sufficient capacity to satisfy CCILs captive thermal and electricity
demand. The process steam requirements were being met by steam
through PRDS (Pressure Reducing De-superheating Station) and small
amount of residual steam through PRDS is exported to the nearby
industries. However the old Power plant was using only a portion of the
available waste gas, a significant amount of waste gas is flared off without
yielding any useful energy. In addition there are also waste heat losses in
the old plant due to inefficiency of the existing turbine, excessive steam
consumption in the air pre heater, losses in the steam distribution network
and heat losses associated with the PRDS system. In other words there is
waste energy in two forms (a) previously flared waste gas (b) previously
unused waste heat. CCIL has therefore decided to implement a higher
capacity boiler of 60 tph and energy efficient 15MW turbine that would
utilize the entire waste gases - including the waste gas which was being
flared as well as utilize the previously unused waste heat (in the form of
waste heat losses) to generate steam and electricity. The higher capacity
boiler utilizes the entire amount of waste gas including the previously flared
waste gas. Electricity generated is being used to meet the captive
requirements of the carbon black plant and surplus electricity being supplied
to the state electricity utility (Uttar Pradesh Power Corporation Limited)
which forms part of the Northern Region electricity grid of India.
CO2 emission reduction due to this project is 45840 MT/Year.
High Temperature APH 950 Deg C First of its kind in India ( Year
2009)
Pre-project Scenario
In the pre-project scenario, the existing less energy efficient air pre-heaters
was installed with carbon black process reactors. In the carbon black process
289
feed stock (heavy petroleum oil) is cracked in reactor under controlled
condition to produce the carbon black. For carbon black reaction total amount
of heat per volume of air should be maintained constant. A fixed Flame
temperature is maintained inside the reactor. The required heat is supplied
from two sources.
1) By complete combustion of fuel oil (furnace oil) with pre-heated air (from
existing APH)
2) Sensible heat of pre-heated air used for above combustion.
With low temperature APH hot air temperature of 580C only can be
achieved.
The flue gas of the process, quenched with the pre-decided quantity of
water to ascertain the quality of the product. The hot flue gases at
temperature of 1300-1100C exit from the carbon black reactor. The existing
air pre-heaters were designed for the smoke temperature at APH inlet was
670C. To bring down smoke temperature from 1300C/1100C to 670C,
lot of water quenching was being done which killed the available sensible
heat in smoke.
Post-project Scenario
In the post-project scenario 950C Air Pre Heaters are installed in all the
four TR-175 Tread reactors. These new 4 high temperatures Air Pre Heaters
(APH) replaced the old low temperature APH. By putting High Temperature
APH hot air temperature of 950C was achieved. This hot air is supplying
more sensible heat to the reactor than pre-project case. To maintain required
total heat load in reactor heat supplied by fuel oil combustion is less.
Therefore, fuel oil consumption is less for the same process. Hence, there
is substantial saving of fuel oil. Smoke temperature at APH-inlet is maintained
up to 900-1000C thereby amount of water quenching is also reduced.
The total CO2 emission reduction = 17000 MT/Year from this project.
290
Projects implemented in 2010-2011
Installed new design rector for the production of carbon black ( PC84). This
new reactor helped us to reduce the oil consumption per ton of Carbon
black production. The saving of oil per year is 2025MT
Installed the quench boiler in the process to make steam from the process
waste heat. This is unique development in carbon black industry. We saved
5.27lakh kWh/year with this installation.
Unit replaced the old oil charge pump. 1.08 lakh kWh/ year energy saved
due to this project.
Transparent sheet provided at ware house roof. After this change unit
switched off all lights in ware house during day time. Energy saving from
this project is 0.5lakh kWh per year.
Energy Consumption
291
Second Prize Plastics
JAGDAMBA POLYMERS PVT. LTD.
Balasore (Odisha)
Unit Profile
Jagdamba Polymers Pvt. Ltd. an ISO 9001-2008 Company was established as
a SSI Unit in 1999. The company is a pioneer unit in plastic injection moulding in
the state of Odisha and has its credit to introduce several new products for the
first time in the State, including plastic moulded house hold and furniture products,
ABS Plastic Bobbins (for jelly filled and optic fiber telephone cable manufacturers),
Television Cabinets etc. This is the largest plastic injection moulding plant in the
State and at present, manufacture range of House hold and furniture products in
Plant own brand. Company is growing rapidly with the vision to become a dominant
player in plastic processing in the region. The company has setup energy efficient
microprocessor controlled injection moulding machines supported with adequate
testing facilities for quality assurance. Continuous development in design and process
through in house Research and development activities.
The company is a market leader for its quality, durability, vibrant models and vivid
colors and designs, aesthetic excellence for all its products. The Company is a two
times National Award winner for being out standing SME, for the year of 2006 &
2009. The award is given by Govt. of India, through the Ministry of MSME.
Description Unit 2009/10 2010/11
Ref. year
Current year
Specific Electrical Energy Consumption KWH/ MT. 761.69 617.11
Specific % Reduction Over Base Year 2009/10 % 0 18.9
Total Energy Bill Rs. Lakhs 35.40 48.87
Connected Load KW 536 723.53
Average Plant Power Factor 0.98 - 1.00 0.99 - 1.00
292
Specific Power Consumption Reduction in Specific Electrical
Energy
761.69
617.11
Achieved Comparison of Power Factor
Energy Conservation Activities
Energy conservation is being continual activity. The management supports and
gives huge importance for continuous improvement in energy conservation.
Substantial saving has been achieved in specific energy consumption, plant energy
performance and energy cost vis--vis manufacturing cost. Some of the focus
areas have been on:
(a) Utilisation of Optimum load factor to avail lower tariff rate at higher load
factor.
(b) Optimum capacity utilizations of plant & machinery and reduction of waste.
(c) Technology up-gradation etc.
During the previous several years, unit has been able to maintain continuously
Power Factor almost to 1.00. By this achievement, we have not only been
293
benefitted by substantial earning in PF incentives, but also saving by maintaining
lower demand load and in zero breakdowns of motors.
Energy Conservation Achievement
Ref. year Current year
Production MT. Processing 1409.87 1999.99
Production Factor (current year _ 0 1.42
production/ref. year production)
Ref. year equivalent= (ref. year Lakh KWH/Year _ 15.25
energy use X production factor)
Current year energy Lakh KWH/Year _ 12.34
Energy performance= (ref. year % 0 19.08
equivalent - current year energy)
X 100/ Ref. year equivalent.
Plant Energy Performance
Energy Efficient Plant & Machinery
Plant is fully equipped with PLC controlled, energy efficient, most modern plant and
machinery supported with auxiliary equipments with the aim to enhance the
productivity and energy efficiency, better working environment etc. to become
cost competitive.
Training & Development
Training & Development, workshops and awareness programs are plant regular
activity involving all the workmen & other employees. Energy conservation
awareness programs are organized every Saturday and focus is made on smallest
conservations of power. During the workshops several newer ideas come up on
the energy savings and implemented.
294
Energy Conservation Measures taken by the Company
Unit has taken several measures for conservation of energy commensuration to
plant size and operations. As a result substantial saving has been achieved during
the year vis--vis earlier years. The measures adopted by the company in the
conservation of energy areas;
a. Use of electrical servo drive & hydraulic proportionate controlled in all new
injection moulding machines saving demand load and power consumption by
over 30%.
b. Complete recycling of water used for cooling of moulds and machines.
c. Increase in the tank size of hot water returned from machine and mould for
natural cooling. This has resulted in desired level of water cooling with
substantial reduction in running hours of cooling towers.
d. Modified the water supply system and reduced energy consumption by
reduction of electrical motor quantity.
2 Nos Cooling
Towers.
Before After
COMMON
TANK
To system
Fromsystem
HOT WATER
TANK
COLD
WATER TANK
COLD
WATER TANK
From
System
To
System
SINGLE &
e. Prevention of mineral scaling in molds, machine & all other water lines for
effective cooling during production.
f. Use of translucent sheet in the roofing of factory shed to maximize the use of
day light.
Before After
295
g. Use of energy efficient/saver CFL lamps and other low cost lightings of proper
size.
h. Use of only star rated BEE marked equipments.
i. Use of energy saving ceramic heaters in the injection molding machines and
Insulation of pipes to reduce heat loss and atmospheric temperature
Before After
j. The company has been maintaining power factor nearly 1.0 by using shunt
capacitors resulting in reduced contract demand and improvement in the life
of motor and substantial earning of incentive in the energy bill for the same.
k. Installation of voltage stabilizer for the plant to prevent stoppage of machines
due to low/high voltage resulting in energy saving in restart time.
l. Continuous monitoring and preventing leakages of hydraulic oils from machines.
m. Online purification and cleaning of hydraulic oil has resulted in substantial saving
in downtime of machines and in loss of energy in restarting of the machines.
n. Installation of energy efficient air compressor and preventing leakage in the
compressed air line.
o. Focus on smaller saving in electricity; i.e. complete switching off/ reduction in
number of lights, fans, air-conditioners etc. in the office and other areas
according to the number of people.
p. Focus on use of natural lights instead of electrical energy wherever possible in
the office and plant.
296
Project Gain Description
Sl. Projects On Year of Annual Energy Investment
No. project energy cost in Rs.
implement- saving in saving
ation KWH in Rs.
1 Modification in water reservoir 2010/2011 30,835.20 1,22,104.00 20,000.00
system for enhanced water
cooling
2 Installation of additional power 2010/2011 69,988.60 2,77,154.92 60,000.00
factor panel
3 Changing the plant lighting system 2010/2011 3,425.75 13,566.00 5,100.00
4 Change of barrel hearer 2010/2011 1,13,529.60 4,49,577.22 30,000.00
5 Modifying air compressor supply 2010/2011 7,708.80 30,526.85 1,000.00
line
6 Installation of translucent 2010/2011 1,401.60 5,550.34 6,000.00
roofing sheets.
7 Modification in water delivery 2010/2011 38,544.00 1,52,634.24 25,000.00
system (individual to header
system) in pump house
8 Replacement of fixed pump by 2010/2011 1,16,800.00 4,62,528.00 75,00000.00
electric servo drive for hydraulic
system.
Total 382233.55 1513641.57 7647100.00
Energy Conservation Commitment and Policy
Energy conservation activities were started about 4-5 year ago. However the
momentum in the awareness and conservation took in 2008. Gradually, awareness
and the conservation activities increased as reflected in the several of the
conservation projects taken up by the company. The company follows following
energy conservation policies;
Adoption of energy conservation as a Mission.
Reduce specific energy consumption in all plant operations.
Recycle of energy wherever possible.
Adoption and installation of energy efficient technologies, equipments and
accessories.
Continuous enhancement of awareness level among the employees for energy
efficiency through workshops and awareness programs organised by
professionals, industry associations and govt. organisations.
Weekly meeting of the employees and the groups have enriched the company
to have a balanced focus on all the area of Energy Conservation, Quality and
productivity Improvement.
297
Review and monitoring of energy conservation skill and performance periodically.
Observation of Energy conservation week.
Observation of legal requirements relating to energy conservation.
Environment Policy
We are committed to the cause of the conservation of environment through
various initiatives. We are committed to achieve;
Zero emission and Reduction of process waste.
Recycling of process waste generated during the process of production.
Comply with the applicable environmental legislation and standard.
Promoting the cause of environmental preservation amongst employees
Applying continual improvement philosophy throughout the organisation.
298
Certificate of Merit Plastics
RAYCHEM RPG PVT. LIMITED
Vasai, Distt. Thane (Maharashtra)
Unit Profile
Raychem RPG Pvt Limited was incorporated in 1984. Raychem RPG is a 50:50
joint venture between Tyco Electronics, USA and RPG Group, India. Tyco Electronics
is a US $13 Billion global provider of engineered electronics components for
thousands of consumer and industrial products, network solutions and energy
markets: wireless systems for critical communications, radar and defense
applications, They design, manufacture and market products for customers in
industries ranging from automotive, appliance, aerospace and defense to
telecommunications, computers and consumer electronics.
RPG Group is one of India's leading business group with presence on Sectors like
Power, Tyres, Retail, IT, Transmission, Carbon Black, Specialty and Entertainment.
Vasai Plant
Vasai Plant is a 100% EOU unit, which facilitates manufacturing of Injection and
Compound Moulding of Polymeric Accessories for Power and Telecommunication
Cables.
299
Products
Products Application
End cap termination High voltage joint Low voltage joints
Medium voltage joint
Energy Consumption
(Specific energy consumption per tonne)
3.7%
Reduction
19%
Reductio
n
300
Sr. Description Unit 2009-10 2010-11
No
1 Specific energy consumption kWh/Tonne 11119.37 8963
2 % reduction of SEC %age 3.7 19.39
3 Energy Utilized Lacs/year 50.43 48.05
4 Maximum Demand reduction KVA 940 746
5 Energy cost as %age of sale %age 3.6 3.4
Projects Executed
301
Energy Conservation
Raychem RPG Pvt. Ltd is an organization that largely focuses to meet todays
requirement of the Nation, its various CSR activities and the steps taken in the
area of energy conservation showcases the managements interest to serve the
nation.
Considering the huge potential in the area of energy conservation, the management
has left no stone unturned to invest in this area. The reducing trend in SEC since
last 3 years depicts the hard work and efforts put by every individual in the
organization towards energy saving, Further these results are sustained and
monitored at every step to keep track of its sustenance. We have achieved these
results through
Up-gradation, New Designs
Use of Latest Technology, Management tools
Optimization of Energy utilization
Energy Policy
302
Certificate of Merit Plastics
THE SUPREME INDUSTRIES LTD.
Khuskhera, Distt. Alwar (Rajasthan)
Unit Profile
Founded in 1942, Supreme is an acknowledged leader of India's plastics industry.
Handling volumes of over 100,000 tonnes of polymers annually, effectively makes
us the country's largest plastics processors. Not surprisingly, Supreme Industries
also offer the widest and most comprehensive range of plastic products in India.
Company 19 advanced plants are powered by technology from world leaders,
and complement its extensive facilities for R & D and new product development.
In fact, Supreme is credited with pioneering several products in India. These include
Cross- Laminated Films, HMHD Films, Multilayer Films, SWR Piping Systems, PP
Mats and more. Supreme Industries is seeking to perform strongly internationally
as well.
303
Exports remain a focal area of company operations, even as company add newer
markets to its list worldwide. 2010-11 will see The Supreme Group turnover
touch a projected Rs. 25,000 million.
Specific Energy Consumption Comparison of Last 3 Years
DESCRIPTION YEAR(08-09) YEAR(09-10) YEAR(10-11)
UPSEB KWH 2738150 3085850 3595064
(PURCHASED)
CAPATIVE KWH (DG) 127375 320668 194599
TOTAL KWH 2 8 6 5 5 2 5 3 4 0 6 5 1 8 3 7 8 9 6 6 3
SALES TURN OVER 1497.1 2469.7 3816.9
(Rs . IN LAC)
PROD. IN TONS 1408 1866 2674
ENERGY COST/ 9.24 7.08 5.05
SALES TURN OVER
(%a ge)
Specific En er gy 2.04 1.83 1.42
(KWH/ Kg. )
Specific En er gy 2040 1830 1416
(KWH/ t on n e)
2.04
1.83
1.42
0
0.5
1
1.5
2
2.5
2008-09 2009-10 2010-11
Energy unit/kg
9.24
7.08
5.05
0
1
2
3
4
5
6
7
8
9
10
1st Qtr 2nd Qtr3rd Qtr
Energy cost/Sales
turn over(%)
304
Measures taken to reduce specific energy consumption
1. In injection molding machine the typical energy demand throughout the cycle
varies continuously despite this varying energy demand. The conventional AC
operated fixed displacement, vane or Gear type of Hydraulic pump will be operated
at fixed speed. This fixed speed is designed to deliver the required hydraulic fluid
for the maximum demand. At that times other than that of maximum demand
that excess hydraulic fluid will be diverted back to the sump via relief valve and the
pump energy use will be largely wasted. It means that pump motor delivering
excess hydraulic fluid through out the cycle. In Industrial product cooling time is
more so that at this period no Energy is required.
So by Installing the VFD or Servo controlled drive will give the hydraulic
flow as per requirement at each activity of a cycle thus plant can save
energy.
2. Due to heat radiation loss in conventional barrel heater in injection molding
machine contactor on-off frequency is very high resulting more energy consumption
and increase in environmental temperature.
To reduce the energy consumption by reducing the contactor on-off
frequency the insulated pad and insulated heaters were used.
3. The operational life of current white LED lamps is 100,000 hours. This is 11
years of continuous operation, or 22 years of 50% operation. The long operational
life of an LED lamp is a stark contrast to the average life of an incandescent bulb,
which is approximately 5000 hours. If the lighting device needs to be embedded
into a very inaccessible place, using LEDs would virtually eliminate the need for
routine bulb replacement.
Main advantage of LED lights are low energy consumption, reduce cost of
replacement, low labor cost, low maintenance cost.
4. Water pressure for heat exchanger pump was 3.5 bar & flow was 80 cu. M /hr.
with 15 kw motor. When plant analyze then it conclude that heat exchanger
requires low pressure & high flow rate. Unit select the pump which has 2 bar
pressure & 120 cu.m flow with 7.5 kw motor.
Unit review the performance of pump then it been observed that m/c oil
temperature has also reduced from 41'c to 39'c which again helps to reduce
breakdown.
305
Motor direct control Motor control through VFD
Barrel heater without insulated
jacket
Barrel heater with insulated jacket
Energy conservation measures implemented 2010-11
1. Project-Installation of VFD drive on injection molding m/c 550T
By installing VFD induction main motor will reduce its RPM upto 70% during idle
condition of m/c i.e.during cooling time/mold open/mold close.
2. Project - Installation of barrel insulation
By installing insulation on barrel heater, heat will not emit from barrel results heater
on time will reduce which save energy.
Intangible benefit: Reduce environment temp. during summer which increase
operator efficiency.
Before After
Before After
306
Induction AC motor Servo controlled motor
3. Project -Servo drive install on 3 Injection molding m/c's
By installing servo drive, motor will reduce RPM to "0"/reduce during idle condition
of m/c i.e cooling time/mold open / mold close time.
Intangible benefit: Because fluid pressure does not remain all time of m/c cycle
thus reduce m/c oil temp. Ultimately water is also required less to cool down m/c
4. Project -LED light installed on plant road
The operational life of current white LED lamps is 100,000 hours. This is 11 years
of continuous operation, or 22 years of 50% operation.
Main advantage of LED lights are low energy consumption, reduce cost of
replacement, low labor cost, low maintenance cost.
Before
After
Before After
307
5. Project-Power saver installed on slow speed grinder using
Pokayoke techniques
Power saver is a mechanism when motor runs without load continuously up to
preset time, then motor will stop after preset time. It helps to reduce power
consumption. It requires to set as per current drawn during no load condition.
Intangible benefit: It increases equipment life
Before After
6. Project-Cooling tower pump replaced with low head/high flow
Water pressure for heat exchanger pump was 3.5 bar & flow was 80 cu. M /hr.
with 15 kw motor. When plant analyze then it conclude that heat exchanger
requires low pressure & high flow rate. Plant select the pump which has 2 bar
pressure & 120 cu.m flow with 7.5 kw motor
Intangible benefit: Plant reviewed the performance of pump then it has been seen
that m/c oil temperature has also reduced from 41'c to 39'c which again helps to
reduce breakdown.
Motor controlled through
DOL starter
Motor controlled through
energy saver
15 KW motor with high head/
low flow rate
15 KW motor with low head/
high flow rate
Before After
308
7. Project - Induction motor of higher capacity replaced with lower
capacity in capacity in Injection molding m/c 1150
Initially m/c was having main motor of 75 kW. After studying process for our mold
then it has been seen that plant was using only 60 % of flow of pump. Unit took
help of m/c manufacturer, they also analyzed process & concluded that it is possible
to reduce pump size hence reduced motor size. Plant took trial with lower capacity
pump & it has been seen that there is no problem in product & monitor continuously
for 1 month & found there is no problem. Power consumption reduced drastically.
To reduce further company is thinking to install VFD.
Intangible benefit: It reduces maximum demand helps to increase m/c without
increasing maximum demand.
Summary
75 KW induction motor on
IMM m/c
55 KW induction motor on
IMM m/c
After Before
S.No. ENERGY SAVING MEASURES Annual Saving Investment
(Rs. Lacs) (Rs. Lacs)
1 Installation of VFD drive on injection molding
m/c 550T
3.07 2.06
2 Installation of barrel insulation 0.217 0.22
3 Servo drive install on 3 Injection molding m/cs 21.13 18.6
4 LED light installed on plant road 0.522 1.86
5 Conventional lights replaced with T5 light inside
plant
0.619 0.65
6 Power saver installed on slow speed grinder 0.109 0.05
7 Cooling tower pump replaced with low head/high
flow
3.63 0.55
8 Induction motor of higher capacity replaced with
lower capacity in Injection molding m/c 1150
3.016 00
9 Process optimization of molds in injection
molding m/c
2.402 00
Total 34.193 23.99
309
First Prize Refinery
INDIAN OIL CORPORATION LIMITED
(ASSAM OIL DIVISION)
Digboi Refinery, Distt. Tinsukia (Assam)
Unit Profile
Digboi Refinery of Indian Oil Corporation Limited (Assam Oil Division) is the oldest
refinery in the country and is the only refinery of such vintage in the world today.
The original refinery at Digboi came up in 1901 and was rebuilt in 1923. It had an
installed capacity of 0.5 MMTPA. After nationalization in 1981, Digboi Refinery
Modernization Project was taken up and accordingly a new Crude Distillation unit
of 0.65 MMTPA operating capacity was commenced in 1996 replacing the age-
old/outdated two Crude Distillation units of 0.25 MMTPA capacity each.
The refinery had a large number of secondary processing units which were based
on outdated technology and highly labour intensive. These units came up in a
piecemeal manner from early thirties till 1954. Almost all of these units have been
replaced by energy efficient new technologies.
These modernization projects and other ENCON measures have resulted in a
quantum improvement in the energy performance of the refinery. With various
ENCON measures and monitoring of plant operations, the specific energy
consumption (MBN) has been reduced from a level of 152 in 2003-04 to a level of
65 now.
Digboi Refinery manufactures conventional petroleum products like LPG, Naphtha,
Motor Spirit, Superior Kerosene (SKO), High Speed Diesel (HSD), Furnace Oil (FO)
and Raw Petroleum Coke. It also produces one of the best quality of Paraffin Wax
besides other products like Aromex, Jute Batching Oil (JBO), Mineral Turpentine Oil
(MTO), Solar Oil etc.
Although the installed capacity of Digboi Refinery remains at a low level, it has
taken many steps for improvement of operational efficiency ever since 1981
(after nationalization of erstwhile Assam Oil Co.) specially in the field of energy
conservation, pollution control and safety.
The refinery is a ISO-9001, ISO-14001, OHSAS-18001 and ISO - 17025 Company.
310
Several projects on modernization and replacement/augmentation of its old
secondary units and auxiliary / facilities was completed in 2003/04. The CRU
was commissioned in Aug., 1997 and a new Delayed Coker Unit was
commissioned in Aug, 1999. Wax Hydrofinishing Unit was commissioned in
June, 2001. Solvent Dewaxing Unit & Hydrotreater unit projects completed
and commissioned in May, 2003 & December, 2003 respectively. Commissioning
of these new units have replaced the old labour/energy intensive units. The
new units have contributed significantly to energy conservation, increase in
secondary processing capacity and product quality improvement. While CRU
has already contributed to production of unleaded petrol, the Hydrotreater
project has improved HSD quality by producing ultra low sulphur and high
cetane HSD. A new unit MS Quality Upgradation Unit (MSQ) was commissioned
on December 2010 to produce BS - III quality MS.
Energy Consumption
The refinery's fuel requirement is met by refinery off-gases generated from the
various process units and also the purchased natural gas from M/s Oil India Limited.
The purchased natural gas is used in Captive Power Plant in Gas Turbines to produce
power while the refinery off-gases / natural gas is used in the various furnaces of
the process units and also supplementary firing in HRSGs. Only in case of failure of
Natural Gas supply, HSD is used in Gas Turbines. The refinery is self-sufficient in
electrical power and does not have to import power from the state grid for refinery
operations.
311
1. Optimization of pre-heat at HDTU :
In the present scenario of BS-III HSD production, the reactor effluent temperature
has increased further due to increase in the reactor severity. Considering the fact
that the higher heat content of the reactor effluent has larger potential to preheat
the combined feed, the combined feed preheat temperature was increased by
gradual throttling the control valve at Hot Combined Heat Exchanger bypass line
on the feed preheat train.
With continuous effort, the heater delta "T" has been minimized to 11-12 Deg C
and one main FG burners was shut off. FG flow to burners has also come down to
about 57-58 kg/hr from 142-145 kg/hr at the same t'put level of the unit which is
more than 58% of the original fuel gas consumption.
2. Replacement of metallic blades with FRP of Fin Fan Coolers (CRU-
7.5 KWx2 ; DCU-22.5 KWx8 & 5.5 KWX2 ; HDTU-14.5 KWx6 ; HGU-
7.5 KWx2) :
In order to conserve energy (power) the metallic blades in the fin fan coolers of
the above units were replaced with energy efficient (power saving) hollow FRP
blades. This has resulted in power saving to the tune of 30 - 35 %.
3. Application of Anti corrosion coating in cooling water pump :
In one no. Cooling Water Pump, anti corrosion coating (Corrocoating) have been
made in top casing, bottom casing and impeller. This has resulted in efficiency
improvement of the pump to the tune of 8 % with power savings of 0.78 lacs
kWh.
4. Replacement of existing feed pump Motors at WHFU with energy
efficient Motors (2 nos.) :
2 nos feed pumps motors at Wax Hydro-finishing Unit of rating 18.5 KW, 415 V,
50 Hz were replaced with energy efficient EFF1 type motors. This has saved
power to the tune of 12 %.
5. Optimization of Bench-G operation (Slop Oil Drying System):
Replacement of Steam Driven pumps with Centrifugal pumps on
Feed and Tower Bottom duty :
Two nos Crude Distillation Unit namely Bench - C and Bench - G were commissioned
in the year 1932 & 1936 respectively. Following the installation & commissioning
of a new Crude Distillation Unit in 1996, Bench - C has been scraped while Bench -
G is now being used (with limited facilities) for drying of slop oil generated in the
refinery to knockout water content to make it suitable for processing along with
312
the crude. The pumps available here were steam driven pumps which consumed a
lot of energy (steam). In order to conserve energy, 4 nos of steam pumps on
feed & tower bottom duty were replaced with centrifugal pumps which saved NG
to the tune of 2.13 Lacs Nm3/year.
6. Supply of LP steam ex. MP steam to WHFU from nearby area
instead of distant VRSD area :
Earlier LP steam to Wax-Hydro-finishing Unit was supplied from a distant area
(near VRSD Unit) about 300 meters away from the unit. In order to save energy
(steam), this supply was discontinued and the same was made available from the
lights & fans in Refinery workshop and canteen was converted into single switch
operation. This has resulted in the power saving of 0.17 lakh kWh / Yr.
7. Installation of Lighting Transformer at AVU / CRU / Utility :
Earlier no independent lighting transformer was available to cater lighting power to
AVU, CRU & utility area. Three new transformers of capacities 200, 100 and 100
KVA respectively have been installed and commissioned. This has resulted in
reduction of energy consumption by 20%, in addition to reduction in maintenance
cost.
8. Replacement of existing conventional Street Light (250W) system
with CFL (56W T-5) in the Township right from Main Gate to
Muliabari Bihutoli (160 nos., phase - II) :
In order to conserve energy, the conventional street lights (250 W) in few locations
of the refinery township as mentioned above were replaced with energy efficient
CFL lights (56W). A total of 160 Nos. were replaced in 2010-11 thereby saving
power to the tune of 1.71 Lacs kWh /Yr.
9. Condensate recovery from offsite (Phase-II ex. AVU, CRU & DCU) :
Earlier the condensate generated from above units was drained to the storm
water drain. As an energy conservation measure, the condensate ex above units
is now being collected in a centralized tank and pumped to DM plant for use as
Boiler Feed water. This has resulted in savings of around 3 m3/hr of DM water.
10. Condensate recovery from HDTU, HGU & SRU :
Earlier the condensate generated from above units was drained to the storm
water drain. As an energy conservation measure, the condensate ex above units
is now being collected in a centralized tank and pumped to DM plant for use as
Boiler Feed water. This has resulted in savings of around 2 m3/hr of DM water.
313
11. Installation and Commissioning of Solar Street Lights in few
locations of the refinery township (30 Nos.) :
With a mission to use renewable energy, a total of 30 nos solar street lights have
been installed and commissioned in few locations of refinery township/installations
(Guest House, AOD Hospital, New Tank Farm and Effluent Treatment Plant) replacing
the conventional street lights. This has resulted in power saving to the tune of
1.09 Lacs kWh /Yr. Digboi Refinery has also taken up a no. of solar power schemes
for implementation.
12. Single switch operation for lights and fan in the workshop and
canteen to save power during lunch period :
In order to reduce power consumption, the multiple switch operation of all the
lights & fans in Refinery workshop and canteen was converted into single switch
operation. This has resulted in the power saving of 0.17 lakkh kWh / Yr.
13. Installation of Proximate Sensors (100 Nos.) in General Office
Complex (75 Nos.) and Refinery (25 Nos.) :
Proximate Sensors have been installed in Administrative office complex and Refinery
offices to ensure the automatic switching-off of fans, lights and AC during absence
of person from the respective offices. This has reduced the power consumption
on above area about 0.41 Lacs kWh/Yr.
14. Recovery of steam condensate ex. Deaerator drain at DCU. :
Earlier the condensate generated from above location was drained to the storm
water drain. As an energy conservation measure, this condensate has been routed
to a centralized tank and pumped to DM plant for use as Boiler Feed water. This
has resulted in savings of around 1 m3/hr of DM water.
15. Steam Trap management in the Refinery :
In order to reduce steam consumption in the refinery, Steam Trap Management in
the refinery was taken up by a dedicated team which includes rationalization of
steam trap network, repairs and maintenance of the same, immediate replacement
of defective steam traps etc. This has resulted in steam savings of 3.0 MT/hr.
16. Operational improvements at AVU & DCU (FG saving) :
With continuous monitoring in the furnace operations and subsequent optimization
in excess air and furnace draft, optimization in preheat train etc., a considerable
quantity of energy could be saved at Atmospheric Vacuum Distillation Unit and
Delayed Coking Unit. In addition to above, class room training on furnace
optimization to the operating personnel was also conducted to achieve the above
goal.
314
Environment:
Digboi Refinery is meeting all the environmental stipulations w.r.t Air, Water etc. A
'Dissolved Air Floatation' unit has been installed and commissioned in May, 2009
in its Effluent Treatment Plant to meet the revised CPCM norm for oil & grease (5
ppm max.).
Digboi Refinery has been placed at the lowest level amongst 88 clusters of industries
in an environmental assessment of industrial clusters across the country based
on Comprehensive Environment Pollution Index (CEPI) carried out by Central
Pollution Control Board along with IIT, New Delhi in October, 2009.
A CDM project titled 'GHG emission reductions through crude pre-heat train
optimization in the CDU & VDU of Digboi Refinery' was registered by UNFCCC on
04-12-2008, the CER verification of which, however, is in progress.
Digboi Refinery has also achieved ISO: 14064 certificate w.e.f. 28th July, 2011.
Digboi Refinery has been declared the winner of Gold Award in Petroleum Refining
Sector for outstanding achievement in Environment Management under 11th Annual
Greentech Environment Excellence Award-2010.
Safety:
Safety is one of the major thrust areas at Digboi Refinery. In order to strengthen
safety aspects, Digboi Refinery has introduced Safety Marshals in its safety cell.
Apart from various zonal safety meetings, quarterly Management Safety and
Occupational Health Meetings are held.
315
Second Prize Refinery
RELIANCE INDUSTRIES LTD.
SEZ Refinery
Distt. Jamnagar (Gujarat)
Unit Profile
Reliance Industries Limited (RIL) is India's largest private sector company with
footprints in exploration & production of oil & gas, petroleum refining and marketing,
petrochemicals (polyester, fiber intermediates, polymers and chemicals), textiles,
retail and special economic zones (SEZ).
RIL commissioned the SEZ refinery (having the capacity of 580 KBPSD), yet
another high capacity cum complex grass root refinery, in Dec 2008 adjacent to
existing Jamnagar complex. Select streams are exchanged between the two refining
complex creating value synergy. With both the refineries operational and processing
over 1.24 million barrels per day of crude, RIL is the largest refiner at any single
location in the world. The addition of the new refinery has transformed 'Jamnagar'
into the 'largest refining hub of the world'. Further, company is among the Top 10
private sector refining companies, globally, owning 25% of world's most complex
refining capacity.
316
While SEZ refinery caters clean fuels (less than 10 ppm S gasoline and diesel
meeting Euro IV & beyond) to the world market, the earlier refinery operating
under DTA (Domestic tariff area) regime refinery caters cleaner fuels (Euro III and
IV) to both domestic and export market.
The complex consists of Crude Distillation, Hydro Treaters, FCC, Coker, PRU,
Alkylation, Clean Fuels complex, Reformer and Polypropylene units. The complex
has dedicated Offsite & Utility facilities like Desal unit, ETP, Cooling Towers and
Captive Power Plant to produce 710 MW of power.
Year MBTU/BBL/NRGF
2009-10 63.3
2010-11 56.26
Overall Energy Index for the Refinery is normally calculated as Total energy
consumption (MBTU) per ton or barrel of Feed (Crude oil) per Refinery complexity
factor ie MBTU/BBL/NRGF. NRGF is the Refinery Complexity factor. Refinery
Complexity factor indicates how much complex is that Refinery. It takes into
consideration the type and number of primary / secondary / treating units in the
refinery. Therefore, the Overall Energy Index in terms of MBTU/BBL/NRGF gives
the true picture of refinery.
Zero Main Flare Achievement in year 2010-11.
Zero main flare was achieved in the year 2010 on continuous basis (Reduction of
20 TPD of hydrocarbon flaring) by arresting the leakages in Hydrogen Complex as
well as by implementation of En-con schemes in Alkylation Unit (Refrigeration
compressor seal modification), Flare Gas Recovery Unit (Additional 30" suction
piping for the flare gas recovery compressor) & Propylene Recovery Unit ( PRU
regeneration gases to LLP flare). The amount of gases flared are monitored on
daily basis. The trend shows the reduction in flaring after implementation of En-
Con schemes as mentioned above.
317
Substantial improvement in SEZ furnace thermal efficiencies (by 0.5%)
by operational excellence, continuous monitoring & target setting.
Following actions were taken to improve the furnace efficiencies:-
Stoichiometric Air Requirement (SAR) calculation correction in Crude 3 & 4
DCS.
Lead Lag status of all furnaces was checked and emphasis was given to take
lead lag in line.
Furnace efficiency and other parameters monitoring and weekly reporting
started. CTS Energy Cell raises the alarms where ever the efficiencies are
lower than design.
Furnace excess oxygen target setting was done to 2.0% for all balanced draft
furnaces.
Furnaces were audited regularly.
The gaps observed were presented to management& action taken there off.
Reduction of LP Steam dumping from 84 TPH to 50 TPH
Following actions were taken for reduction of LP Steam dumping:-
NG pre-heating to Aux-Boilers/HRSG by LP Steam to 60 deg C in CPP Complex.
Stopping of the turbine-driven pumps & keeping as stand by in process units.
Changed the governor logic of same to start the turbine quickly.
Provision of new 8" line bypass to LP Steam Generator (S18) in VGO HT Unit
(Bypass line provided in VGO HT-3 Unit in return FCC feed temp also increased.
Hot feed going to Tankages were completely stopped
Increasing pipeline economic thickness (Process as well as Steam Lines)
was taken as ENCON project due to increased Crude pricing.
Focused Energy Audit study was initiated by renowned consultant KBC to
bring down the specific energy consumption further.
The salient Energy conservation schemes implemented in the year 2010-
11 as follows:
318
S. Project description Achievement of Annual energy Investment
N. savings in 2010-11 incurred
Electricity Fuels* Total on the
(Lacs Total savings project
kWh) (fuel) in in Rs. Rs. (Lacs)
(MTOE) (Lacs)
1 Reduction of LP steam dumping from 16857.89 2150.2 6.0
84.0 to 50.0 TPH
2 Zero Main Flare achievement after 11315 1443.2 151.4
implementation of schemes in
Alkylation Unit (Refrigeration
Compressor Seal Modification) &
Flare Gas Recovery Unit (Additional
30"suction piping for the Flare Gas
Recovery Compressor)
3 Implementation of Hydrogen load 6898.5 879.9
control to avoid hydrogen flaring &
Degradation to fuel in SEZ Refinery
4 Improvement in Flare Gas Recovery 766.5 97.8 14.0
Compressor HC Recovery after the
implementation of modification i.e.
Routing of Propylene Treater
Regeneration Gases to LLP Flare
5 Running only 3 air compressors in 262.8 368.7 3.0
place of 4 in Utility Complex.
TOTAL: 262.8 35837.89 4939.8 174.38
Energy Conservation Commitment and Policy
Reliance has a comprehensive policy on energy conservation. Innovative energy
conservation practices are practiced all throughout the site. Better operating
practices, improved operating efficiencies, optimum utilization of resources
increased automation, introduction of advanced control systems, new techniques
and technologies, higher capacity utilization are the various methods used which
aim at the corporate goal or commitment to conserve / optimize energy
consumption. The companys Energy Management policy is given below :
Reliance Industries Limited plays a leading role in the national and global economy
by providing quality goods and services in the materials and energy value chain.
Our Mission is:
To become the lowest specific consumer in the industry.
To widen options for energy sources and
To minimize the adverse impact of operation on the environment.
319
We plan to achieve the above within the framework of sustaining the business by:
Integrating energy management with the business objectives and estab-
lishing performance driven goals.
Upgrading hardware, deploying state-of-the-art technologies and improving
practices to increase the energy efficiency, reduce greenhouse gas emissions
and minimize environmental impacts.
Supporting scientific research and technological efforts to deliver new sources
of energy and materials including renewable and alternate fuels.
Carrying out regular audits and training employees to promote energy con-
servation as a culture across the entire business functions.
Continuously benchmarking energy efficiency and energy productivity against
others.
Promoting awareness on energy conservation among all the members of
Reliance family and the community at the large.
Safety and Environment
At Reliance Jamnagar, clean environment for sustainable development is of prime
concern, and is an important business objective, achieved by every employees
contribution and responsibility towards environmental performance.
Reliance Jamnagar is committed to the protection of environment. The design of
state of the art effluent treatment plant, low NOX burners in Furnaces and zero
liquid effluent discharge ensure the safety of the environment. Treated sewage,
industrial effluent and stack emissions are extensively monitored to ensure no
harm is done to the environment. Reliance is committed to transform the arid
land in and around the complex into a lush green belt.
320
321
Certificate of Merit Refinery
INDIAN OIL CORPORATION LTD. -
Gujarat Refinery
Vadodara (Gujarat)
Unit Profile
Gujarat Refinery, the flagship Refinery of Indian Oil, was born after discovery of
crude oil in Ankleshwar in South Gujarat. Late Pt. Jawaharlal Nehru, then Prime
Minister of India laid the foundation stone of this Public Sector Refinery at Koyali,
situated on the outskirts of Vadodara, on 10
th
May, 1963, with the technical
assistance of the then USSR. Initially, the Refinery was set up with a capacity of
2.0 million metric tonnes per annum (MMTPA) for processing Ankleshwar Crude.
The first Crude Distillation Unit (AU 1) of 1.0 MMTPA was commissioned in October
1965. Gujarat Refinery has been in the forefront of productivity, quality, safety,
environment protection and its strong commitment to customer delight and national
service since then. The Refinery has been expanded, revamped and modernized
from time to time and today, the refining capacity of Gujarat Refinery stands at
13.7 MMTPA. Gujarat Refinery has 5 nos. of Primary Distillation Units, Secondary
Processing facilities like Visbreaking Unit (VBU), Fluidized Catalytic Cracking (FCC)
Unit, a Hydrocracking Unit (HCU). The refinery has also appropriate product
treatment units like Diesel Hydro-De-Sulphurization Unit and associated Hydrogen
and Sulphur Recovery Units etc.
Gujarat Refinery is designed to process i) Indigenous Crudes, viz., South Gujarat
& North Gujarat crudes, Bombay High ii) High Sulphur Imported crudes and iii)
Low Sulphur Imported crudes. The South Gujarat & North Gujarat crudes are
received through a dedicated crude pipelines and the Imported and Bombay High
crudes are received from Vadinar in Gujarat Coast through a countrywide crude
oil pipeline.
Gujarat Refinery manufactures petroleum products / petrochemical feedstock /
specialty products like LPG, Naphtha, Motor Spirit (MS), Superior Kerosene Oil
(SKO), Aviation Turbine Fuel (ATF), High Speed Diesel (HSD), Light Diesel Oil (LDO),
Benzene, Toluene, N-heptane, Food Grade Hexane, Fuel Oil, Low Sulphur Heavy
Stock (LSHS), Bitumen and Sulphur.
The Petro-chemical plant (Linear Alkyl Benzene) with production capacity of 120
TMT/year was commissioned in Aug04. This plant utilizes Kerosene as a feed
stock and produces LAB products used for detergents manufacturing.
322
MS Quality Upgradation project for production of Euro-III grade MS was
commissioned successfully in October, 2006.
Under Resid upgradation project (Hydrogen, DHDT, ISOM, SRU, VGO-HDT and
DCU units) for production of Euro-III and Euro-IV grade HSD and MS for further
environment commitment and Government regulation were commissioned
successfully in 2010 and 2011.
During the year 2010-11, Gujarat Refinery achieved crude throughput of 13.56
Million Metric Tonnes. And achieved 62.7 MBN ( MMBTU/BBL/NRGF) which was
the lowest against previous year best of 65.8 in the year 2009-10.
Energy Consumption
Gujarat refinery, since its inception, has always accorded highest priority towards
energy conservation. Sustained efforts are made for continual reduction in energy
consumption in the refinery through various energy conservation measures and
close monitoring.
The specific energy consumption in terms of MBN for the last five years are
presented in the following graph :
Gujarat Refinery made significant efforts in the areas of Energy conservation right
from the beginning and a dedicated Technical Audit Cell was formed in 1971 to
over-view the energy consumption activities and control of the same. Besides
the above, Energy Conservation Cell under Senior Manager was constituted in
1990 to act as a focal point for energy conservation activities. Currently, the TA
and Encon cell of Gujarat Refinery is headed by a Chief Manager who reports to
DGM (TS). There is total involvement and commitment of top management with
323
regards to energy conservation and formal monthly reviews of Energy performance
are done where the Executive Director chairs the meeting and the same is attended
by all Head of Departments, Deputy General Managers and General Managers.
The Energy Conservation schemes implemented during 2010-11 have yielded a
saving of around Rs. 6125.64 lacs
A brief description of the major energy conservation measures implemented during
the year 2010-11 are given below :
a. Flare gas recovery system
The flare system is available for the safe disposal of inflammable gases, released
from system pressure controller and safety relief valves. In Gujarat refinery the
flare loss for the year of 2008-2009 was 1353 Kg/hr. In order to minimize flare
loss and reduce CO
2
emission to atmosphere, a flare gas recovery system was
installed by M/s GARO in the month of June 2010. The FGRS has a single
compressor capable of compressing 1400 NM
3
/hr (min) to 1604 NM
3
/hr (max)
of flare gas whose molecular weight varies from 9 to 50 and it compress the flare
gas to a pressure of about 6.5 Kg/cm
2
g. This recovered flare gas is utilized in
refinery fuel gas system.
324
Savings : 7650 SRFT/ Yr.
b. Installation of Magnetic Resonator in GTs
Gujarat Refinery is having five nos. of Gas Turbines, each with a capacity of 30.0
MW. Natural Gas is the primary fuel used in these Gas Turbines. The average NG
consumption in each GT is 10 KSM3 /Hr for generating 30 MWH. In order to
increase the efficiency of Gas Turbines magnetic resonators were installed in GT-
1, GT-2 and GT-3 in the month of September 2011.
The fuel dipoles in motion when resonated with Magnetic field get electrically
polarized in phase perpendicular to the magnetic field. The polarized fuel readily
reacts with air, enhancing the air, fuel ratio, thus improving the combustion efficiency
and has resulted in savings of 2278 SRFT/Yr.
Savings : 2278 SRFT/Yr, Monetary : Rs. 575.56 Lacs
325
c. Stepless control in makeup compressor in HCU
Two out of the three Make-up Gas Compressors normally run in Hydro-cracker
Unit to meet H
2
demand of the unit. These reciprocating compressors can operate
with fixed step loads only and thus discharge a fixed quantity of H
2
at any given
combination of load. The excess H
2
thus compressed is spilled back to the
compressor suction through spillback control valve on a continuous basis, thereby
wasting substantial amount of energy.
In the month of November 2010, Stepless Capacity control was commissioned in
Make Up Gas compressor of Hydro-cracker unit. Stepless capacity control system
for reciprocating compressors allows operation in a range between 25-100 % so
it gives the control over gas volume per working stroke. This has resulted in
savings of 2000 SRFT/ Yr.
Savings : 2000 SRFT/ Yr, Monetary : Rs. 505.32 lacs
d. Foggy Cooler in GT-1
The average power demand of Gujarat Refinery in 2008-09 was 84/85 MW
(Approx) and Max power load was 88 MW (Approx). It was observed that base
load capability of Gas turbine decreased to 2-3 MW during summer as compared
to winter. To overcome this problem Foggy Cooler was installed by M/s Mee
industries Inc. in GT-1 of Gujarat Refinery in the month of December 2010.
Foggy Coolers reduces the combustion air temperature by generating fine droplet
size water fog at the air duct of GTG (of the order of 15 to 20 m). The water
326
mist evaporates taking latent heat from the air and by evaporating billions of
micro fine droplets in the gas turbine inlet duct, adiabatic cooling is attained and
the evaporation effect results in drop in inlet temperature, resulting in gas turbine
power augmentation and an increase in gas turbine efficiency.
The implementation of foggy cooler has incurred saving to the tune of 7416
SRFT/Yr.
Investment : Rs. 136.4 Lac
Savings : 7416 SRFT/Yr. Monetary : Rs. 1873.73 Lacs
e. Corrocoating at Cooling water pump
Corrocoating of wetted pump internals was done by M/s Kirloskar Corrocoat Pvt.
Ltd. which improved the smoothness and we achieved low coefficient of friction
of the pump internal surface, and resulted in increase in the pump efficiency.
This coating was done in all the cooling tower pumps of Gujarat Refinery in the
month of January 2011 and resulted in savings of 491 SRFT /Yr
Photograph of before and after corro-coating pumps:
Savings : 491 SRFT /Yr Monetary :Rs. 124.06 Lacs
327
f. Online Cleaning of fire-side furnaces of FPU 1, FPU 2, AU 1, AU2
and AU5
With heavy residual oil as fuel, some degree of incomplete combustion is inevitable
which leads to formation of carbon deposits on heat transfer surfaces. Due to
these deposits there is high bridge wall temperature which affects the efficiency of
the furnace. In Gujarat Refinery it was observed that For AU1, AU2, AU 5, FPU 1,
FPU 2 Furnace Arch, Box and Stack temperature were higher than design
temperatures. To reduce these temperatures online cleaning of furnaces was
done which has resulted in savings of 1025 SRFT /Yr.
Investment, Rs. 13 Lacs
Savings: 1025 SRFT /Yr. Rs. 258.98 Lacs
g. Replacement of 250 nos, 40W tube light fitting with 28W
At Gujarat refinery In 2010, illumination in the office rooms WAS being catered by
light fittings that comprise fluorescent lights of 12/40W/36W each; with copper
ballast for each tube which itself records a watt loss of ~12W. Hence it was
replaced by lights with High efficiency TL-5/28W/ 865, in which there are two
tubes each of 28W capacity and single electronic ballast which records watt loss
of ~6W. This has resulted in savings of 4SRFT / Yr.
Investment, Rs. 2Lacs
Savings: 4SRFT Rs. 1 Lac
h. Modification in 18 nos Lighting Transformer
In Gujarat refinery the area lighting and plant lighting in the Refinery is fed through
the lighting transformers which provide the lighting circuit voltage level near to
220 Volts with different voltage Levels of the LT bus.
In 2010 some of the lighting transformers secondary voltage level was high (238
to 250 Volts) as compared to desired voltage level of 220 Volts even after adjusting
the tap position/ link for minimum secondary voltage. Due to this high voltage the
electrical energy consumed for same level of illumination was proportionally high.
This wastage of electrical energy could be saved by reducing the secondary voltage
level of lighting transformers. Additionally, the rate of failure of electrical
components in lighting fixtures is increased due to high voltage.
Thus, in the Endeavour of energy conservation and minimizing maintenance cost,
the lighting transformers were modified to suite the requirement which has resulted
in savings of 36 SRFT / Yr.
Total investment, Rs. 15 Lacs
Savings: 36 SRFT / Yr., Rs. 9 Lacs
328
Energy Policy
Gujarat Refinery has a well defined Energy Policy as under
To be a World Class Performer in Energy Management by
Adopting Energy Efficient and Environment Friendly Technologies
Benchmarking IOCL Performance with the Best in the World and endeavoring
to be ahead
Promoting use of Renewable Sources of Energy
Fostering a culture of participation and innovation amongst stake holders
for continual improvement in Energy Conservation
Propagating the message of avoiding wastage of energy to the community.
329
Second Prize Sponge Iron
WELSPUN STEEL LTD.
Taluka-Anjar (Gujarat)
Unit Profile
M/S Welspun Steel Ltd. has commissioned manufacturing of Sponge Iron, TMT
bars & Billets in Kutch. The capacity is 120000 TPA, 70000 TPA & 70800 TPA
respectively.
Sponge Iron Plant
In this Plant iron ore, coal & dolomite are used as raw material. These three
materials are passed through rotary Kiln in which it is passed through 7 different
zones of temperature which ranges from 800 deg C to 1070deg C depending
upon properties of Raw material. Finally the product is sponge iron (Fe) which is
passed through cooler & then to magnetic Separator where Magnetic & non
magnetic parts are separated.
330
Steel Melting Shop
Scrap/sponge iron, fluxes, Ferro alloys are melt in electric arc furnace. The molten
metal from electric arc furnace is taken in a ladle for refining. The metallurgy of
Steel in terms of carbon, phosphorous content, alloy element etc, is controlled in
this stage. The charging is through top of furnace. The furnace are tilted for tapping
or removal of slag. The liquid steel is cast into semi finished products such as
billets, blooms, slabs etc. This process is called continuous casting.
Rolling Mill
Billets are the raw material for making TMT bars. Billets are heated in preheating
furnace with the help of Gasifire at 1200 deg c to make metal malleable and then
rolled into finished products.
Captive Power Plant
12 MW power is generated in Power Plant. Out of these 12 MW approx 7 to 8 MW
is generated with help of waste heat recovery boiler which uses the waste heat of
rotary Kiln. The remaining 4 to 5 MW is generated with the help of FBC boilers.
Energy Conservation Measures Taken
Sponge Iron
(A) By Using VFD Drives
In sponge iron plant Welspun has replaced conventional starters with VFD drives
for shell air fan (High speed blowers). By doing this plant has saved energy worth
Rs 14.23 lacs / year.
(B) Blending Of Coal
In this process two different types of coal are blended according to process
requirements. By doing this optimum use of GVC of coal is obtained which eventually
results in saving of coal and Plant achieved a saving of 32728512 Rs / Year.
Steel Melting Shiop
(A)Change Of Crucible Size
Plant has replaced the 7 MT crucible with 9 MT crucible. By doing this the production
has increased but the power consumption is not increased in that proportion. So
ultimately power is saved and plant achieved a saving of Rs 3551149/year.
331
Sponge Iron
Financial Sponge Iron Coal Consumption
Year MT MWh SpEn/Ton MT Ton/Ton
2009-2010 116982 7156.884 61.17 165796 1.41
2010-2011 107516 6288.34 58.48 139699 1.29
116982.0
7156.9
61.2
165796.0
1.4
107516.0
6288.3
58.5
139699.0
1.3
0
20000
40000
60000
80000
100000
120000
140000
160000
180000
MT MWh SpEn/Ton MT Ton/Ton
Sponge Iron Coal Consumption
2009-2010
2010-2011
Steel Melting Shop
Financial Steel Melting Shop
Year MT MWh SpEn/Ton
2009-2010 29068 23403.56 805.13
2010-2011 27099 20952.12 773.16
29068.0
23403.6
805.1
27099.0
20952.1
773.2
0
5000
10000
15000
20000
25000
30000
35000
MT MWh SpEn/Ton
Steel Melting Shop
2009-2010
2010-2011
332
Other energy conservation measures taken by company
a) Minimizing the breakdown by implementing the Preventive maintenance
schedule to save the power.
b) Charging / shifting the material by help of transfer trolley rather manually
c) Managing ON / OFF time of street light by help of security guards.
d) Using clear roof shed sheet to save the power to avoid shed light in the day
time
e) Using soft starter instead of conventional starter
f) Switching off the machine / pump power if not in use to save energy
Health, Safety & Environment Policy
333
Certificate of Merit Sponge Iron
VANDANA GLOBAL LIMITED
Siltara, Raipur (Chhattisgarh)
Unit Profile
M/S Welspun Steel Ltd. has commissioned manufacturing of Sponge Iron, TMT bars
& Billets in Kutch. Vandana Global limited is a part of the Vandana Group of Industries.
The Vandana group of industries is one of the leading, reputed, financially sound multi
products and professionally managed group of industries in Iron and Steel Sector of
Central India based at Raipur & its Surrounding area of Chhattisgarh State. The Group
is existing since 1941. Over 67 years of strong track record. Vandana Group is in Iron
334
& Steel trade as well as in manufacturing business. It has earned very good name,
reputation and credibility due to its professionally managed team, modern
manufacturing technology and quality products. At present, the Group is manufacturing
and marketing Sponge Iron, Ingot, Mild Steel Billet, Ferro Alloys, Steel Rollings, Heavy
Structurals. TMT Bars, Wire Roads and Bar, Wire drawing, Wire Galvanizing with a
strong hold on Electro Power generation. As a diversified business house. The Group
is also in HDPE bags & Poly Hydro Carbon manufacturing business. The group has a
strong network for international business in the global market. The Group has an
annual turn over of more than 100 Billion Indian Rupees and going to set an example
for its achievement within a short span of time. Apart from Vandana Global Limited
the group has following other companies too-
Vandana Vidhyut Limited, Bilaspur (C.G.)
Vandana Industries Limited, Urla, Raipur (Plastic Div.) C.G.
Vandana Rolling Mills, Urla, Raipur (C.G.)
Vandana Udyog Limied, Raipur (C.G.)
Vandana Ispat Ltd., Urla, Raipur (C.G.)
Shivalik Udyog (I) Limited, Urla, Raipur (C.G.)
Vandana Plantation, Raipur (C.G.)
Vandana Global Limited
The company having annual turn over of Rs. 500 Crores is one of the highest
business contributory in the group, based at Siltara Industrial Area with ISO
9001:2000 Certified. It has 4 divisions viz -
1. Captive Power Plant Division
2. Steel Division
3. Sponge Iron Division
4. Ferro Alloys Division
1. Captive Power Plant Division:
The company has a very modern Capacity Power Plant which is a state-of-the-art
of its own. The technology used for the Power Plant are from SIEMENS. This
power plant has a capacity to generate 38 MW power based on Waste Heat
Recovery from Rotary kiln, Washery Rejects and Coal. The Company is also
authorized to trade power to other industries. In future company will be interested
to add some new power users for power supply.
2. Steel Division:
(A) Induction Furnace : to form liquid metal from Sponge Iron. The company
has 4 different sizes of furnaces (2 x 12 Ton capacity and 2 x 6 Ton capacity)
(B) Continuous Casting Machine (CCM): The company has 02 stand modern
continuous casting machine to produce high quality mild steel billets from liquid
metal. The company produces different sizes & specifications of M.S. Billets as per
market requirement. It is likely to be expended in near future.
335
3. Sponge Iron Division:
The company has 2 Coal Based rotary kiln (1 x 200 TPD & 1 x 500 TPD) to
produce high grade sponge iron under Direct Reduced Iron Technology. The Sponge
Iron produced by company is well demanded in the market for its quality & Grade.
4. Ferro Alloys:
The company produces high as well as export grade Ferro Alloys such as "Silico
Manganese & Ferro Manganese" with the help of very modern and high technology
based submurzed Arc Furnaces each of 9 MVA capacity. Within a very short span,
VGL has registered itself as a quality manufacturer of Ferro Alloys and as a result,
VGL is regularly suppling its Ferro products to leading bulk buyer of Indian Markets
like " Steel Authority of India Limited" which is the highest steel manufacturing unit
of the World and many others reputed concerns.
VGL is also engaged in the process of acquiring raw material mines like - Iron Ore,
Manganese Ore, Coal Mines both in India and abroad and also for the setting up of
2 MW Solar Power Plant at Saraipali (Chhattisgarh).
Energy Consumption
S. No. Particular Unit FY2009-2010 FY2010-2011
1. Energy Input
1.1 Total Solid fuel consumption i.e.
Coal, Coke & CPC
Gcal
2331758 1981482
1.2 HSD Consumption Gcal 541 563
1.3 FO Consumption Gcal - -
1.4 Electricity Purchase from Grid Gcal 7 -
2. Energy Output
2.1 Electricity Export to the Grid Gcal 814878 516516
2.2 Dolachar sold to the market Gcal 47952 47074
3 Total Energy Consumption Gcal 1469476 1418454
4. Total Equivalent Sponge Iron
Production
MT
159411 161084
5 Gate to Gate SEC Gcal/MT of Sponge Iron 9.218 8.806
6 Gate to Gate SEC MTOE/Ton of Sponge Iron 0.9218 0.8806
7 Gate to Gate SEC Kcal/kg of Sponge Iron 9218 8806
336
Energy Conservation Measures (FY 2010-2011)
Achievement of annual energy savings in 2010-2011
Electricity Fuels*
Description
(Lacs
kWh)
Coal (T) F. Oil
(KL)
Gas
(lacs
Nm )
3
Total
(fuel)
MTOE
Total
Saving in
(Rs. ) Lacs
Investment
incurred on
the project
R. (Lacs)
(A) Electrical
1. Down sizing of belt conveyor
motor from 22 KW to 15 KW
0.09537 - - - 0.8 0.28611 0
2.Down sizing of belt conveyor motor
from 15 KW to 11 KW
0.02442 - - - 0.2 0.07326 0
3. Down sizing of belt conveyor
motor from 55 KW to 37 KW
0.12768 - - - 1.1 0.38304 0
4.Installation of steam injector (30
MW TG Set condensor unit)
0.00070 - - - 0.006 0.00210 0
5. Throttling of Dilivery valves of 2 x
260 KW (HT) RCW pump motor (30
MW TG Set)
3.96000 - - - 34.06 9.9 0
6.Throttling of Dilivery valves of 2 x
110 KW CW pump motor (8 MW TG
Set)
0.87120 - - - 7.5 2.178 0
7. Optimization of Ash Handling
pneumatic System resulted in the
stoppage of one compressor driven
by 132 KW Motor.
7.75698 - - - 66.71 23.27 0
8. Raising of SAF Shell Height by
300 mm
49.99778 - - - 91.9 150 6
(B) Thermal
1. Generation of power by hot flue
gases
- 55715 - - 23010.3 1113 4800
2. Generation of power by dolachar - 14518 - - 5995.93 290.7 12400
TOTAL 62.83413 70233 - - 29208.506 1589.7925 17206
Downsizing of 22 KW motor to 15 KW
337
Raising of SAF Shell height by 300 mm shown by arrow
Energy & Environment Policy
Vandana Global is committed to sustainable development, healthy environment,
efficient use of natural resources, pollution prevention, energy conservation, waste
eradication, eco-friendly and recycling measures.
Optimum use of energy.
Reduction of specific energy consumption.
Reduction of carbon foot print.
To identify, assess and manage impacts.
To prevent water, air, noise and soil pollution.
To follow 3R Principle Reduce, Reuse & Recycle.
To train and educate employees for maintaining clean and green environment.
To preserve Bio-diversity through plantation in and around plant premises.
338
Second Prize Steel Re-rolling
JSL STAINLESS LTD.
Hisar (Haryana)
Unit Profile
JSL Stainless Ltd. is the ISO 9001:2000, ISO 14001:1996 and OHSAS
18001:1999 certified Flagship Company of the $ 2.0 billion Jindal Organization.
Today JSL are the largest stainless steel producer in India.
The company today has come a long way from a single factory establishment,
started in 1970 by Late Sh O P Jindal. As the numero uno it has taken on the task
of making stainless steel a part of everybody's life by taking a 360 degrees approach
from production of raw materials to supply of architecture and lifestyle related
products.
339
JSL Product
Hot rolled coils transported to Cold Rolling division for Re-Rolling.
Cold Rolled Products
Cold rolled coils and sheets are produced after being processed in the 20 Hi Mill,
continuous annealing & pickle line, skin pass mill slitting line and cut to length lines.
Absolute flat sheets are produced after being put through the Voss leveler. Sheets
& cold rolled coils are available in different finishes 2D, 2B, No.3, No.4 and BA.
Company also produces coin blanks from re-rolled cold product.
Customized Products
JSL Stainless Ltd. has developed the capability to supply customized products for
critical applications such as nuclear application 304L, 321 grade steel.
Duplex Stainless Steel 2205, a ferritic-austentic stainless steel having a high chloride
pitting resistance is the new entrant in the product mix. Cold Rolled annealed strips
find extensive application as tubular material in sea water, chemical and paper &
pulp plants.
Energy Consumption
Energy Conservation remains top priority at JSL Stainless Ltd. Hisar. Company is
regularly participation in various energy conservation activities and developed a
strong energy Managers team inside the plant.
Cold Rolled Strips MT 115080 200177 198938
(Production)
Total Elect. Energy Lac kWh 589.58 881.44 826.7
Consumption
Money Value Rs Lacs 2549.81 3649.16 4009.3
Specific Elect. Energy kWh / Ton 512.32 440.33 415.54
Consumption
Sustainable Growth (Energy Consumption)
440.33
415.54
400
410
420
430
440
450
2009-10 2010-11
Year
K
W
H
/
T
o
n
340
Energy Conservation
Measure Project Taken in year 2010-11
S.No
Title of Energy Saving project
implemented
Investment
(Rs. Lacs)
Actual Annual
Savings (Rs
Lacs)
1
Optimizing strip cooling through Jet
cooling Blower speed control
0.50 81.91
2
Optimizing Pressure of cooling
chamber through Jet exhaust
blower speed control
0 43.56
3
Fuel Saving in boiler no 1and 2 by
online monitoring & control of
oxygen % in Flue Gas
0.6 32.4
4
Compressed air Energy Saving &
Water Quality improvement in
dynasand filters in CRD-1 & 2
0.3 1.30
5
Replace WBA Cooling Water pump
with lower flow and pressure pump
0 13.16
8
Circulation Cooling tower fan
in auto control of CRD-2
0.35 0.46
9
Changing cooling tower
fan motor from 18.5Kw to 9.3Kw
0 0.33
10
Automation of fan motor w.r.t. C.W.
temp at Z-3.
0.2 0.59
11
Optimum utilization of water in AP-3
line
0 3.54
12
Replacement of 250W street light
with 24x2 W
0.7 0.37
13 Z#2 Mill POR DC Motor Blower
remaining stop during Sub Passes Nil 0.31
14 Reduction in Package AC
consumption by arresting cooling
leakage.
0.6 2.56
15
Replacement of motors rewind(3 to
4 Times) with high efficient new
motor
8.35 6.80
16
Energy Saving by Replacement of
over rating motor at brushing
machine-2 top toll at AP2 line
0.25 1.13
TOTAL 11.42 188.44
341
Energy Policy
JSL Stainless Ltd Hisar are committed towards energy conservation through
optimal utilization of various forms of energy in a cost effective manner.
For achieving this, JSL devote itself to:-
Promote use of energy efficient processes, equipments, devices and systems
in the manufacturing of steel and sustain continuous reduction in specific energy
consumption year-on-year.
Maintain sound and efficient energy management system to continually monitor
and improve the energy usages in the processes.
Constantly identify the area of improvement and work for its implementation.
Benchmarking with the global best in the industry.
Create awareness for efficient use of energy & its conservation and make
energy conservation integral to JSL work culture & personal habit.
Adhere to all applicable statutory requirements.
This will be achieved by dedicated team work and active participation & commitment
from employees at all levels. Since, it is an ongoing process; JSL, try to continually
achieve the best and further keep on improving.
342
Certificate of Merit Steel Re-rolling
REMI EDELSTAHL TUBULARS LIMITED
Tarapur, Boisar (Maharashtra)
Unit Profile
REMI Edelstahl Tubulars Ltd. is one of the leading manufacturers of Stainless Steel
Tubes and Pipes in India, listed on Bombay Stock Exchange since 1986.
It was established in 1970 as Rajendra Mechanical Industries Ltd. In the year
2009, company name was changed to its present name 'REMI EDELSTAHL
TUBULARS LTD'. It is a one of the Group Companies of REMI Group, promoted by
Saraf & Family.
Under the very dynamic management it is making steady progress by increasing
capacity, installing latest equipment, and latest quality techniques.
Now REMI Edelstahlis making its strides in a big way in Oil sector and are getting
approvals such as - API, PDO and other international Oil sector and Power sector
companies.
REMI's Strengths
1. Single Stop for all stainless steel tubular requirements.
2. Spread over 14 acres of land with cover area of 5 Lacs Square feet at, Tarapur,
an industrial Township in Maharashtra (160 Kms from Mumbai).
3. Manpower: 300, Turnover: USD 31 Million in 2010-11
4. Installed capacity is 18000 MT / annum.
5. Catering to all types of process industries in India and abroad.
343
Electrical Energy Consumption
2008-2009 2009-2010 2010-2011
Month
Energy
Consumption
Final
Production
kwh /
kg
Energy
Consumption
Final
Production
kwh /
kg
Energy
Consumption
Final
Production
kwh /
kg
(Kwh) (Kg) (Kwh) (Kg) (Kwh) (Kg)
April
161655 437976 2.71 124954 246004 1.97 162663 234897 1.44
May
171300 409614 2.39 141906 256524 1.81 164282 261592 1.59
June
157410 440665 2.80 153879 324853 2.11 194303 392259 2.02
July
180930 452426 2.50 179111 348830 1.95 186317 374397 2.01
August
248020 513596 2.07 162969 353647 2.17 199192 406425 2.04
September
199459 407199 2.04 146507 292170 1.99 218835 347989 1.59
October
175473 309467 1.76 124319 207492 1.67 233876 472724 2.02
November
144052 232426 1.61 114968 252287 2.19 160454 415649 2.59
December
137355 175435 1.28 154855 291526 1.88 237200 494876 2.09
January
155283 270907 1.74 161117 294709 1.83 198225 530836 2.68
February
153561 143376 0.93 154921 326862 2.11 191773 564655 2.94
March
156317 271220 1.74 170449 330411 1.94 212100 556210 2.62
Total 2040815 4064307
1.99
1789955 3525315
1.97
2359220 5052509
2.14
The efforts made in the past are listed below:
1) Replacing T 8 (40 W) tube light fixtures with T 5 (28 W) with electronic
ballast.
Investment Rs. 100,000
Saving 21097 KWH = Rs. 137,000
2) Replacing magnetic ballast of 250 W HPSV Lamps with Electronic ones.
Saving 76650 KWH = Rs. 498,000
3) Installing Soft starter on Compressor (30 HP)- avoided mechanical loading/
unloading
Saving 38106 KWH = Rs. 247,000
4) Installed auto stops on all machines during idle times.
Energy savings Rs. 300,000
344
5) Replaced rectifier based welding machines with Inverter based Welding machines
saving
Investment Rs. 400,000 per machine
Energy savings Rs. 360,000 per welding machine
6) Installed Eleven such Welding machines
Total savings Rs. 3960,000
7) Made provision of Sky lights to avoid switching on lights during day time.
Saving 191625KWH = Rs. 1,245,000
Energy Conservation efforts taken last year
1) Replaced old Room Air conditioners with Energy efficient ones
Energy saving Rs. 112,250
2) Replaced existing Electric Motors above 5 HP with Energy Efficient EFF 1 motors
Energy Savings Rs. 611,742
3) Installed Recuperators in furnaces and used hot exhaust gasses to pre heat
air input
4) Replaced floor level compressed Air line with over head and PPR special grade
pipes
345
Other measures being taken for Energy Conservation
1. Redirecting the hot exhaust flue gasses through chemical baths for heating
these to 50 C
2. Installing LPG fired Drier for drying chemically coated tubes and replacing Air
blowers
3. Replacing electric motors 3 to 5 HP with Energy efficient ones.
4. Installing Servo motors for operating Tube feed and rotation in Pilger machines
by replacing the hydraulic system at present.
5. Installing automation for feeding / loading and exiting of tubes at various
operations in the plant, thus decreasing the idle time and increasing the
operational time of equipment and reducing human fatigue.
6. Up grading operating equipment with more efficient ones
7. Improving insulation of Hot pipes and conserves heat loss and energy.
Improved safety.
8. Installing auto Shut off Valves in all LPG lines a safety measure.
9. Installing improved Fire fighting measures.
346
Second Prize Sugar
K.C.P. SUGAR AND INDUSTRIES
CORPORATION LIMITED
Lakshmipuram, Distt. Krishna (Andhra Pradesh)
Unit Profile
K.C.P SUGAR AND INDUSTRIES CORPORATION LIMITED is one of the oldest sugar
factories of India. The organization is a public limited company and also one of the
largest producers of sugar in India, manufacturing nearly 1.7 million tones of sugar
from cane. With the recent liberalization of sugar industry and the increase in
demand of sugar, the unit is poised for tremendous growth.
M/s. KCP SUGAR AND INDUSTRIES CORPORATION LIMITED has set up their Sugar
plant at Lakshmipuram, Krishna district of Andhra Pradesh in the year 1996 for
manufacturing of White Sugar with a capacity of 2500 TCD. The unit has been
performing consistently well, through periodic up gradation and modernization of
the production facilities.
This unit is producing the following products and by products.
1. Sugar - Main product, 2500 TCD
2. Molasses - By product
3. Bagasse - By product
4. Filter cake / Press mud - By product
5. Fly ash - By product
6. Power - Co generation - By product
This is an Agro based industry and Sugarcane is the raw material. The crushing
operation of this mill will be for about five months, between November and April
and the remaining period will be utilized for overhauling of the machineries.
Main features of the Unit
Crushing Capacity : 2500 TCD
Power generation Capacity : 7.25 MW
Boiler Capacity : 64 TPH at 42 kg/cm2 & 20 TPH at 21 kg/cm2
The bye product, bagasse obtained after crushing the sugarcane is used as fuel for
the boilers. Unit have captive power generation of 5 MW capacity. The exhaust
obtained from the power turbines is used for boiling the sugar juice to produce
sugar.
347
Energy Consumption
In an on going continuous effects of energy conservation plant has implemented
many energy conservation steps and there by the specific thermal and electrical
consumptions were reduced by 23.4% and 18.6% respectively over last year.
Description Units 2009-10 2010-11
Specific Electrical Energy Consumption MTOE / tonne 0.0234 0.0190
Specific Thermal Energy Consumption MTOE / tonne 0.229 0.175
TREND GRAPH OF REDUCTION IN ENERGY CONSERVATION
Functions of EC cell
1. Implementing steps to reduce the power consumption and saving energy.
2. Analyzing the energy consumption every year.
3. Planning for usage of waste heat.
4. Plans to increase saving of fuel.
5. Innovating the scope for recycling of process rejects.
6. Implementing the pinch technologies for reduction in water consumption.
7. Creating awareness to employees in the field of energy conservation measures.
0
.
2
2
9
0
.
1
7
5
0
0.05
0.1
0.15
0.2
0.25
2009-10 2010-11
Specific Thermal Energy Consumption
MTOE / tonne
0
.
0
2
3
0
.
0
1
9
0
0.005
0.01
0.015
0.02
0.025
2009-10 2010-11
Specific Electrical Energy Consumption
MTOE / tonne
348
Technology Absorption for Energy Conservation
Introduction of condensate flash recover system with once used tanks, thus
eliminating existing 6 No's of condensate pumps.
Creation of positive head to the existing 200HP injection pump and installation
of VFD, resulting in pump operation at lower RPM most of the times.
Trails were conducted with sugarcane planter and sugarcane harvester towards
partial mechanization of sugarcane cultivation.
Elimination of process pumps at different stations by suitable modifications.
Exhaust and vapor condensate separate monds with pumps thus avoiding
number of pumps.
Installation of VFD in various systems in place of star delta starter to achieve
power saving.
Replacement of incandescent bulbs with CFL lamps.
Isolation of crystallizers cooling water pumps by interconnecting the delivery
lines of the pumps.
Modification done for pumping of exhaust condensate directly from boiling
house to de-aerator by isolating feed water receiving tank to achieve reduction
in steam and power consumption.
Introduction of flash recovery system for boiler blow down water to achieve
energy conservation.
Successful introduction of implements like planters, rotovator, mini tractors,
fertilizer applicators suitable to plant conditions for total mechanization in
future.
Modifications carried out to utilize 2nd vapors for sulphited juice stage-ii heating
continuously to achieve steam economy.
Modifications of B-Heavy liquor feeding system to continuous vacuum pan
with gravity flow to avoid double pumping in order to achieve reduction in
power consumption.
Installation of AC drives for mill tandems in place of steam turbines to achieve
energy conservation.
Sugar plant automation (batch pans) to achieve easy operation and minimize
manpower utilization.
349
Measures Taken For Energy Conservation
The company has embark on several measured to minimize energy consumption,
some of the measures undergone in the crushing season 2010-11 are highlighted:
1. Replacement of star delta starter with VFD for several pumps:
Unit has replaced star Delta starter with
VFD for A,B,C grain pumps, A-heavy
molasses pump, B-magma pump,
exhaust condensate mond pump, vapor
condensate mond pump.
Investment in Rs: 9.0 Lakhs
Electrical Savings: 0.64 lacs kWh
Annual Savings in Rs. 3.2 Lacs
2. Diversion of batch Pan condensate to continuous Pan condensate
mond:
Batchpan condensate diverted to
continuous pan condensate mond and
for pumping with single pump and
avoided one pump.
Investment in Rs: 0.35 Lacs
Electrical Savings: 0.418 Lacs kWh
3. Liquor to A-CVP by avoiding pump:
Modified the liquor line to feed the
liquor under vacuum and avoided the
pump.
Electrical Savings:0.418 Lacs kWh
"A" CVP LIQUOR FEED LINE WITHOUT PUMP
BATCH PAN CONDENSATE DIVERTED TO
CONTINUOUS PAN CONDENSATE MOND
350
4. Clarifier liquidation through closed
loop mond:
Clarifier liquidation kept in closed loop to avoid
heat loss.
Thermal Savings: 105.70 MTOE
5. Modification of flash recovery system:
Modified the self designed Flash recovery unit
by increasing the depth of syphon for vapour
condensate water by pumping with single pump
and avoided seven numbers of pumps.
Annual savings in Rs. 1.49 Lacs
6. Modification of evaporator scheme from devc + quad to modern
quint:
Evaporator scheme runned as modern
quint instead of DEVC + quad by installing
existing lines and valves.
351
7. Diversion of pan condensate to flash recovery :
Pan condensate partially diverted to flash
recovery system which increased the temp
raise in raw juice by duplex.
8. Common pump for B & C seed pump:
Eliminated c-seed pump by using common
pump for B-seed & C-seed with
arrangement of gutter.
Annual Savings in Rs.2.09 Lacs
9. A-light magmising for B-seed and Dry seed:
Hot condensate was replaced with A-Light
liquor for magmising.
10. New PCC arrangement on alternator:
New PCC was added on 3 MW BHEL
alternator for load sharing there by avoiding
to run all the three alternators.
352
Certificate of Merit Sugar
DALMIA CHINI MILLS
Unit - Nigohi
Unit Profile
Dalmia Chini Mills - Nigohi, is a unit of Dalmia Bharat Sugar and Industries Limited -
one of the leading sugar producers in the country with total cane crushing capacity
of 22500 TCD, 79 MW of cogeneration capacity & a distillery of 80 KLPD. The
Nigohi plant with a crushing capacity of 7500 TCD and cogen of 27 MW was set up
during 2006-07 which was also the first crushing season of the unit.
353
The plant has state-of-the-art facilities serving as a role model for the industry. It
has consistently achieved excellence in plant operational metrics and occupies a
technological leadership position in the industry. The unit has robust quality systems
and has also embarked upon several initiatives such as TPM, 5S, ISO 14001 and
OSHAS 18001 to create world-class systems & processes.
It is also credited with pioneering achievements in registration of cogeneration
power project under CDM (Clean Development Mechanism). The plant is registered
under this mechanism and helping in global efforts to mitigate impact of greenhouse
gas emissions.
The plant was designed to be energy efficient and is already amongst one of the
best in the industry. However, with continuous effort, experimentation, innovation
& teamwork, the specific electrical and thermal energy consumption were reduced
in 2010-11 by 16.5% and 11.28% respectively from last year (2009-10) which
resulted in an increase in power export.
Graphs showing energy consumption reduction over last year:
354
Energy consumption figures of last two years
Year Electrical energy Thermal energy
consumption consumption
kWh/ton of % reduction Mkcal/ % reduction
sugar over last year ton of sugar over last
year
2009-10 416.34 6.54
2010-11 347.40 16.5% 5.80 11.28%
Major electrical energy conservation projects implemented in the year
2010-11
1. Installation of VFDs on injection water pumps for constant vacuum
in Pans
Motor rating: 200 kW
Electrical Units Saved : 4.08 Lac kWh
Annual Savings : Rs 16.68 Lacs @ Rs 4.09/ kWh
Investment : Zero (used standby VFDs)
2. Installation of VFD drives in Fluidized Bed Drier (FBD).
Motor rating: ID Fan - 55 kW, Hot Air Blower - 37 kW, Cold Air Blower - 37 kW
Annual Savings : Rs 14.60 Lacs @ Rs 4.09/ kWh
Investment : Rs 6.50 Lacs
3. Reduction in feeding depth of Mill Cane Carrier and increase in
RPM of Cane Chopper
Motor rating: Cane Cutter - 4 x 450 kW, Shredder - 2 x 1000 kW
Annual Saving : Rs 40 Lacs @ Rs 4.09/ kWh
Investment : Rs 5 Lacs
4. Replacement of HPSV lamps (250 W) with CFLs (65 W)
Annual Saving : Rs 2.41 Lacs @ Rs 4.09/ kWh
355
5. Reduction in power plant auxiliary consumption by optimization of
energy saving equipment & VFD drives.
Investment : Zero
6. Reduction in power consumption by maintaining the average cane
crush, consistent operations & general awareness
Investment : Zero
Hence, total annual electrical energy savings in 2010-11 were 47.6 lac
kWh which resulted in a savings of Rs 195 lacs with an investment of Rs
12 lacs.
Major thermal energy conservation projects implemented in the year
2010-11
Modification in Boiler SA Air system by providing additional SS Nozzles
in panel wall for efficient combustion of bagasse.
Thermal energy saved :
Bagasse saved : 22224 MT
Annual Saving : Rs 356 Lacs @ Rs 1600/ MT
Hence, total annual thermal energy savings in 2010-11 were 50936 which
resulted in a savings of 22224 MT of bagasse valued at Rs 356 lacs with
an investment of Rs 0.50 lacs.
356
Certificate of Merit Sugar
K.C.P SUGAR AND INDUSTRIES
CORPORATION LIMITED
Vuyyuru, Distt. Krishna (Andhra Pradesh)
Unit Profile
K.C.P Sugar and Industries Corporation Ltd., Vuyyuru is a conglomerate with
divergent activities and multi company with Rs 300 crore turnover and its
manufacturing units are located in Andhra Pradesh and Tamilnadu states. The
company has been manufacturing sugar since 1941 and established itself as a
leader in the Indian sugar industry.
The sugar plant is 75 year old and was under different managements. Company
acquired a sick unit under scheme of amalgamation in 1941 and has taken up
various development activities in phased manner. Presently the sugar division is
operating 7500 TCD sugar plant, 15 MW co-generation power plant and 50 KLPD
distillery in the same complex. Today, the plant is one of the foremost energy
efficient plants in the country with new benchmarks in energy conservation. It has
received national awards for Excellence in Energy Management consecutively from
CII since 2005.
This is one of the best Indian sugar industry which recorded 32% steam on cane
during 2010-11 crushing season.
Energy Consumption
In sugar industry, electrical and thermal energy consumptions do play vital role.
With continuous efforts and successful experiments, the specific thermal and
electrical consumptions were reduced by 10.5% and 17% respectively over last
year and also resulted in increase of power export to 48 KW from 34 kW per ton of
cane.
Trend showing energy consumption reduction over last year:
kWh/tonne of sugar Million Cal/tonne of sugar
357
Energy Consumption Figures of Last Two Years
Electrical energy consumption Thermal Energy consumption Year
kWh /tonne
of sugar
% Reduction
Over Last year
Mkcal/tonne
of sugar
Reduction
Over Last year
2009 -10 209 3.9
2009 -10 174 17 3.5 11
Technologies Adopted For Energy Conservation
1. Replaced raw juice and imbibitions water batch weighing scales with mass
flow meters.
2. Fully automated continuous pans for A, B and C massecuites.
3. Auto star delta starters for all applicable motors.
4. Flash heat recovery from condensate for evaporators, juice heaters and
pans.
5. PLC based automation aided by AC VF drives.
6. Extensive use of energy efficient motors.
7. Replacement of all inefficient worm gears with planetary gears and helical
gearbox.
8. Replacement of standard tube lights with CFL.
9. Automation of all batch pans.
10. Common condensate pumping.
11. Mechanical seals for all applicable pumps.
12. Usage of wind driven turbo ventilators and day lighting system.
13. Installation of effective cooling and condensing system with automation
14. Replacement of cyclone dust collector with Ventury type wet scrubber for
Boiler.
Following are the trend setting energy conservation projects implemented in the
plant:
1. Installation of AC motors with VFDs for sugar cane Mills.
358
2. Use of Quintuple evaporator 3
rd
vapor for all batch and continuous pans.
Major Electrical Energy Conservation Projects Implemented in the Year
2010-11
1. Energy efficient Boiler feed water
transfer pump
Two nos. of low efficiency pumps and motors are
replaced with a single higher capacity high efficiency
pump and motor.
Electrical units saved : 0.34 Lacs kWh
Annual saving : Rs. 0.93 Lacs
2. Molasses lubrication for C-Massecuite
Adding molasses to the feed of cont.
centrifugals reduced the viscosity of
massecuite resulted in improvement
of machine capacity utilization and also
resulted in reduction of operating hours.
3. Installation of VFD for GRPF
KCP Sugar have replaced Gear system
with Variable Frequency Drive for
G.R.P.F. drive unit
Major thermal energy conservation projects implemented in the year
2010-11
1. Moisture % bagasse was controlled by
the suitable modification in KCP old
conventional mills of size 30" X 60".
Fuel saved : 2307 MT
359
2. Installation of 1300 Sq. M. Evaporator Body :
Installed one number of 1300 Sq.M. heating surface
evaporator body to handle high rate of crushing
with higher imbibition with minimum steam %cane.
Fuel saved : 3846 MT
3. Installation Of Auto Control Valve In
Film Type Sulphur Burner Steam Line:
Auto control valve installed in the steam line
of film type sulphur burner.
Fuel saved : 34 MT
4. Modification of liquor feed lines for pans
For effective distribution of liquor in batch
pans instead of single feed line, multiple feed
lines were provided. This helped us in
reducing steam consumption.
Fuel saved : 400 MT
360
Energy and Environment Policy
361
Second Prize Tea
HINDUSTAN UNILEVER LTD.
Instant Tea Plant
Etah (Uttar Pradesh)
Unit Profile
Hindustan Unilever Limited (HUL) is India's largest fast moving consumer goods
company & owns a 52% majority stake in FMCG market in India. HUL is the
market leader in Indian consumer products with presence in over 20 consumer
categories such as soaps, tea, detergents and shampoos amongst others with
over 700 million Indian consumers using its products.
Instant tea unit Etah is strategic site for Unilever & one of 3 factories worldwide
Unilever has for instant tea manufacturing. Instant Tea Etah Unit was established
in year 1996 with a capacity producing Hot water and Cold Water soluble Instant
tea powder. This unit is a 100% Export Oriented Unit & recognized by Export
promotion council, Government of India in 2007.
362
Process Flow Chart for Manufacturing Process
Energy Consumption Trends
363
Energy Conservation measures taken in 2010-11
The Instant Tea Unit Etah now has always been cognizant of the need for
Conservation of energy and has been steadily making progress towards this end.
HUL tradition has always been to encourage its employees to actively participate
in continuous improvement of business operations, which includes reduction in
Energy & Operation loss. Following this tradition, Management decided to introduce
a Suggestion Scheme for taping creative thinking / ideas for improvement in
Energy Efficiency & reduction in energy cost in Steam, Electricity, Refrigeration,
Water, Air Process etc. The Suggestion scheme channelized creative potential of
all Employees by creating an environment for employees involvement and reap
the benefits of improvements in terms of operating costs (including Energy saving),
safety and Quality. Energy Conservation measures have been implemented in all
Manufacturing sections, Utilities & offices, of the plant and special efforts are being
put on undertaking specific energy conservation Some of the Encon measures
mention here under :
A. Modification in steam airpreheater
1. Basic design change to increase the air contact surface area. Earlier it was
small fins of tube with wide gap, in the new preheater aluminum fins with
narrow cross section and all fins of different header are fixed at 90 degree
angle to each other hence contact time increases, resulted in high outlet
temperature.
2. Steam is passed through multiple headers to have maximum recovery, Steam
condensate of last header is also being passed through one more header to
preheat the inlet air before entering into main header.
3. Total investment- Rs. 3.7 Lacs Energy, cost savings - Rs. 21.95 Lacs per year.
B -Use of Multistage PHE for liquor cooling
Plant has 2*5 T Ammonia based chilling plant, the capacity of each main
Compressor motor is 55 KW, for company Evian bright (Cold Instant Tea) product
plant need to run both compressor load was app. 62 TR. After implementing
below mention kaizen unit is able to reduce the chilling requirement 63 TR to app.
55 TR & plant reduce the load on compressor, which is resulted in saving of 36800
kWh by below mention kaizen. Procured 3 passes Plate heat Exchanger in place
to two pass. Earlier Tea liquor directly cooled from Chilling from 55 to 7 degree
Celsius was first cooled 55 to 45 degree Celsius from existing cooling tower water
(without any further investment) & then by chilling. This will help in reduction
around app. 8 ton load on ref. system.
Total investment-Rs. 1.5 Lacs, First year energy cost savings- Rs. 3.12 Lacs
C. Installation of Closed loop condensate recovery system
Plant has Installed the closed loop steam condensate recovery system in 2010.
Earlier unit had open loop condensate recovery system in which all the condensate
coming from the plant was getting collected in one tank (open to atmosphere) &
364
from which condensate was getting transfer to boiler feed water tank with help of
electric driven pump.
With the new introduced closed loop recovery system all the condensate get
collected in flash vessel from which flash steam & condensate gets separated.
After this condensate goes to boiler with help of PPPPU (Pressure Powered Pump
Package Unit) system in which no electrical supply is needed & pump is driven with
the help of steam itself. Moreover separated flash steam is utilized in process with
the help of motive steam.
Advantages of Closed loop recovery system over Open loop recovery
system:
Better heat transfer.
Gain in feed water temp at boiler resulting in reduction in fuel.
Utilization of Flash steam in process, resulting in reduction in specific steam
consumption in process.
No electricity investment as condensate is getting transferred with the help of
steam driven pump.
D. Use of VFD for 90 KW Suction blower
In tea spent drying system 90 KW suction blower is installed to suck the hot air
from spin flash dryer, in before status the inlet air damper was controlled manually,
motor run on full RPM, the running load was app. 90 amps with variation, the
output is also non liner plant installed a VFD system & control the air by setting the
frequency as per desired output, the load is came down to app. half of the before
condition, same time the starting problem also avoided. The product quality also
improved.
Total investment - Rs.1.45 Lacs
First year energy cost savings- Rs.4.87 Lacs
Other Energy Conservation measures taken to reduce the energy
consumption
1. Use of Dissolved Oxygen meter to reduce electrical consumption.
2. Reduction in the steam consumption in the Falling Film Evaporator unit by
using efficient vacuum system.
3. Provision of Isolation Valve to avoid loss in chiller.
4. Modification in condenser design.
5. Automation of pumps by using laval switch & PLC.
6. Use of efficient lighting system.
7. 20% reduction in water consumption in last year.
8. Reduction in idle running hours of some equipment.
365
First Prize Textiles
ZENITEX PVT. LTD.
Surat (Gujarat)
Unit Profile
Zenitex Pvt. Ltd. is a textile process and dyeing Industry under the leadership of
Zenith Silk Mills. Zenitex is ISO 9001:2000, ISO 14001:2004 and OHSAS
18001:2007 certified company. Zenitex (Sachin) unit was established in the year
2003 in Sachin (GIDC) Surat.
Since 2007 Zenitex has taken exemplary measures in Energy Conservation and
Environmental protection. Zenitex become the proud Recipient of the Best Industry
Award 2009 (Quality and Environmental Protection) by Govt. of Gujarat. The
Director of Zenitex Mr. Viral Desai won the National Award (2010) as an outstanding
Entrepreneurship.
366
Energy Consumption
This year mill installed a brand new Energy Efficient Stenter with direct gas firing
instead of radiators. It also installed Variable frequency drives for all motors and
pumps thus saving the energy and wear and tear maintenance. A new high efficiency
Steam boiler was also introduced.
In last three years mill specific energy consumption figure are shown below, which
depicts continual reduction in specific energy consumption over last two years due
to plant's sustained efforts with the implementation of various energy conservation
measures and ideas to increase efficiency of equipments.
The continuous implementation of various energy conservation measures being
ongoing practice, there is steady decline of specific energy consumption.
Electrical Consumption
Gas Consumption
367
Coal Consumption
Major Projects Implemented for Energy conservation at Zenitex.
Stenter Machine After Modification
This year mill installed a brand new Energy Efficient Stenter with direct gas firing
instead of radiators.
Measures :
Annual Savings in Rs. 17.069Lacs
Investment in Rs. 45Lacs
Simple Payback in Months 32
Stenter Machine Percentage kWh Consumption Compared To Total Annual Electricity
Consumption
Stenter Machine Percentage kWh Consumption Compared To Total
Annual Electricity Consumption
368
Windmill (Renewable Energy)
The mill has reduced carbon emissions and carbon print by investing in low carbon
energy options such as renewable energy i.e. Windmill.
Insulation
At Zenitex mill has insulated all the Vessels (Jet, Drum, Boiler)
Mill also insulated all the steam lines including the exhausted de-pressure waste
recovery steam lines and boiler feed water tank, APH, condensate recovery system
and HRU.
Measures :
Investment in Rs. 2.84 Lacs
Simple Payback in Months 2.86
Reuse DE pressure Steam of Drum Machine in Steam Boiler After
Modification
Measures :
VFD In Factory
Variable Frequency drives installed on all the machines and utilities in the factory.
Due to installation of all the Energy Saving measures we have excess windmill
based power generation compared to our units which are exempted.
Street Light
Special Metal Halide (70 W) lamps street lights were installed at Zenitex replacing
Old mercury lamps
Polycarbonate Roof Sheets
Exclusive heat resistant, U.V. proof poly carbonate roof sheets installed at zenitex
plant premises eliminate 200 No's of T5 tube light, CFL bulbs in the day hours.
The rest of the roof in the plant premises at zenitex cement roof sheets were
replaced by galvanium (powder coated) sheets jindal profile providing more
illumination
369
Factory Lighting
Measures :
Lighting Management and Replacement of conventional Tube light by T5 Tube
lights.
Compressor
30 Hp screw compressor is replaced by 20 HP reciprocating compressor with VFD
Measures :
Condensate Water Collection After Modification
At Zenitex mill has installed float trap to collect condensate water
Measures :
Environment Policy
Protection of environment is of prime concern and an important business objective
at Zenitex. With a leading role in providing quality fabrics and services to our
esteemed customers.
Zenitex is conscious of its responsibility towards creating, maintaining and ensuring
a safe and clean environment for sustainable development.
In particular, Zenitex is committed to continually improve the EHS management
and EHS performance by focusing on :
Striving to go beyond legal compliance wherever applicable.
Conserving natural resources like water, oil, wood and raw materials
370
Reduce, recycle and reuse of wastes and its proper disposal.
Reduce emissions to air.
Reducing Incidents that relate to OH & S hazards.
Follow a systematic approach to environmental management plan in order to
achieve continual performance improvement.
Conserve natural resources by their responsible and efficient use in all our
operations.
Plant trees, develop green belts and promote lush green surroundings at our
manufacturing location to be in harmony with nature.
Comply with relevant laws and regulations as well as take any additional
measures considered necessary.
Creating awareness in all employees on environmental issues.
This policy shall be communicated to all employees and shall be made available to
the public on request.
371
Second Prize Tyre
BALKRISHNA INDUSTRIES LIMITED
Bhiwadi, Distt. Alwar (Rajasthan)
Unit Profile
The success story of BKT, begun in 1995 when it entered into production of cross
ply off-highway tyres, With the help of persistent & intensive market research
coupled with ever expanding production capabilities, BKT has made its mark in the
niche segments like Agricultural, Construction, Industrial, Earthmover, ATV (All Terrain
Vehicle) and Turf care applications.
BKT is continuously developing its production base and has expanded its product
range significantly. With three manufacturing plants and one In-house Hi-tech
Mould-manufacturing facility at different locations in India, BKT is very well equipped
to feed the ever-growing demand of its worldwide customers.
372
About 95% of tyre production is exported, out of which 70% is sold in Europe,
where farms are large and scientific methods of farming, requiring tractors with
different tyre types for agribusinesses. Other major markets for BKT are North
America & Middle East followed by South America, Africa, Australia& Asia. Talking
about OEMs, BKT supplies its products to major OEMs across the globe in
construction segment & has also been successful in making inroads to the
Agricultural OEM-market. Today BKT has presence in more then 100 countries
across the globe with a vision to attain global leadership in off highway tyre solution.
Energy Consumption
The Balkrishna Industry strives to reduce energy consumption; The Company
adopted and implemented new energy saving technology & practices for reduction
of its energy consumption in terms of electrical, thermal & water as a continuous
improvement. It installed number of Variable frequency drives in plant equipments
& replaced energy efficient lights in plant and also gone for energy efficient thermal
equipments for reduce steam consumption in plant. This reveals in the energy
consumption figures. Data of last two years show in table that follows:
Annual Production Tons 32346.20 44164.00
Total Electrical Energy Lacs Kwh 215.59 258.28
Consumption/ Annum
Specific Energy Consumption Kwh /Ton 666.50 584.8
(Electrical)
Total Thermal Energy MKcal 75325.20 81614.60
Consumption
Specific Energy Consumption MKcal /Ton 2.33 1.85
(Thermal)
373
BKT is committed to total Energy management and prevention of energy
wastage.
BKT insist for energy conservation features in the design stage it self.
Continuous monitoring of various energy consumption and continuous efforts
to reduce the energy consumption from time to time.
Reduce energy cost continuously every year by adopting effective Energy
Management System
Benchmark specific energy consumption with national & international standards
and set up system to achieve them.
Maintain the implemented conservation measures at every time.
Each and every employee was trained for their maximum knowledge to utilize
the various energies in an economical way& aware to stop the wastage.
Conduct weekly energy conservation cell meeting for continuous improvement.
374
Energy Conservation projects implemented during 2010-2011
(A). Saving Of Electricity
Sl. Description Saving in Saving Investment
No. Lac Kwh / (r-in Lac) (r-Lac)
Annum Annum
1. One Air washer made permanently 0.94 4.32 0.00
switched off by reroute the
parallel A/W duct for plant human
comfort cooling.
2. Transparent sheet provided on 0.30 1.38 2.50
remaining plant shed for natural
light during day time.
3. Admin Block air conditioner package 0.84 3.86 0.60
units replaced with split A/C.
4. Reduce the operation hrs of 0.40 1.84 0.40
condensate transferred pump by
providing magnate level indicators
on storage tank at boiler house.
5 One pump made permanently 0.27 1.24 0.10
stopped by providing one piston
valve & modification of pipe line in
DCC pre make up line in H/W 1st.
6 Electrical energy saved by 0.18 0.81 0.15
reducing RPM of Air washer blower
through pulleys replaced.
7 Cooling tower fan blades of aluminum 0.40 1.84 0.25
alloy replaced with FRP material.
8 Old & many times re winded motors 1.90 8.74 14.8
replaced with new energy efficient
motors at various locations in plant.
9 One water supply pump provided 0.60 2.76 0.00
in place of two pumps for same
application so saved electricity.
10 Plant light replaced with 2x28 w 0.20 0.92 0.50
energy efficiency light
11 One dust collector motor stopped 0.30 1.38 0.40
during any two mixers operates at
a time.
12 Over all water consumption reduced 1.20 5.52 1.50
in process by improving of recovery
system of steam condensate &
circulation of process water from
plant equipments, so reduced bore
well running hours, due to this saved
electricity.
13 Reduced motor kW of water pump for 0.75 3.45 0.20
same application by replacing low
kW motor.
Total 8.28 38.10 21.40
375
(B). Saving Of Thermal Energy
Sl. Description Fuel Saving Investment
No. Saving (r-in Lac) (R-lac)
(Tons)/ Annum
Annum
1 Hot water (temperature around 120C) 200 15.00 8.00
directly recovered from separate
header from main drain of 45 nos.
tire curing presses & reused in hot
water generator
2. No. of Steam leakage observed & 150 11.25 1.80
rectified of plant equipments during
year by conducting energy
management program.
3 Hot Insulation on bare hot surface, 180 13.50 4.60
hot water tank & steam pipe lines to
reduce heat loss & improved in
quality of steam
4 Hot water reused which is sucked by 120 9.00 1.20
vacuum pumps from tire curing
presses at end of cycle
5. Gain more condensate water from 80 6.00 1.20
flash steam from tire curing presses
by providing separator box at
main drain
6 Defective steam condensate traps 120 9.00 2.20
replaced or repaired during energy
management program
7 More steam condensate recovered by 120 9.00 6.00
replaced new condensate collection
tank at ground floor from high at
boiler house
8 Belt conveyor installed for pet coke in 135 10.13 15.00
bunker of boiler so save carpet &
other losses
Total 1105 82.87 40
Total Absolute Saving Of Year 2010-2011
YEAR ELECT. ELECTRICITY FUEL FUEL FUEL TOTAL
(LAC (r-LAC ) (MT) PET Mkcal (r- LAC ) INVESTMENT
KWH) COKE (PET COKE) (r- LAC)
2010-11 12.14 55.84 1430 11726 107.25 84.35
376
Energy Policy
377
Certificate of Merit Tyre
TVS SRICHAKRA LIMITED
Vellaripatti, Madurai (Tamil Nadu)
Unit Profile
TVS Srichakra is one of the leading two and three wheeler tyre manufacturer in
India rolling out over 11 million tyres per annum. Part of US $ 2.2 billion largest
Auto Ancillary group TVS, founded by Sri. T.V.Sundaram Iyengar, TVS Tyres lives
upto the rich heritage and strong value system of the parent company.
Incorporated in 1982, the company manufactures a complete range of Two and
Three wheeler Tyres and Tubes for the domestic market and Industrial Pneumatic
tyres, Farm & Implements Tyres, Skid steer tyres, Multipurpose tyres, Floatation
tyres etc. for the export market, at its state-of-art manufacturing facility at Madurai
in Tamil Nadu. Spread over an area of 2.5 lakhs sq. mts, the manufacturing unit at
Madurai employs over 2000 people. TVS Tyres is one of the major suppliers to all
leading original equipment manufacturers namely TVS Motors, Hero Honda, Bajaj
Auto and Yamaha Motors The company is a global player, exporting to USA, Europe,
Africa, South America and South East Asia.
378
Energy Consumption
ELECTRICAL ENERGY
2009-10
2010-11
S1
579.78
548.95
420.00
440.00
460.00
480.00
500.00
520.00
540.00
560.00
580.00
SPECIFIC ELECTRICAL ENERGY
kWh / Tonnage
B
e
t
t
e
r
Installation of Screw Compressor
Status: Reciprocation compressors running in the plant
Observation: Efficiency is low due to long service and wear & tear
Action Taken: Screw compressor installed. Noiseless operation, oil leak free and
efficiency is good.
Payback : 3 months
Before Now
379
Installation of Condensate Recovery System
Status: Condensate Recovery system
installed in export plant for fire wood
boiler
Observation: Feed water temperature
increased from 65 deg to 90 deg
Action Taken: Octane pump installed
Payback:
VFD Installations
Status: Mirco boiler ID, FD, FW pumps - 2 nos are provided with conventional
starters.
Observation: Motor drive systems running with full speed all the time which results
in energy loss
Action Taken: Suitable rating VFD installed with proper feed back
Payback:
Payback : 1.5 years
Before Now
380
Online Efficiency Monitoring of Boilers
On Line Efficiency Monitoring - 6 TPH Juliflora Fired boiler
The system accepts input from oxygen analyzer, Feed water TDS, Feed water
temperature sensor, stack temperature sensor, ambient temperature sensor,
steam flow meter to calculate & indicate the following parameters :
Boiler efficiency %, Individual losses of boiler i.e. : Radiation loss, enthalpy loss &
stack loss, Steam flow rate & total consumption, blow down rate & totalisation,
excess air %, feed water temperature, steam temperature & steam/fuel ratio.
The control loop automatically controls the TDS ppm in boiler & minimizes blow
down loss.
The system incorporates SCADA SOFTWARE to indicate and display all relevant
parameters to user and generate reports accordingly. This data is acquired into a
PC which can be at 900 meters max of cable distance.
Energy Policy
TVS Srichakra Limited itself committed and motivated towards Total Energy
Management and prevention to energy wastage through:
Continuous Implementation of Energy Efficient Technologies for producing
World Class Automobile Tyres and Tubes with optimum Specific Energy
Consumption
Continuous education & training to all employees for updating their Energy
conservation awareness.
Implement and practice Energy efficiency throughout the plant operation &
its utility functions.
Continuous monitoring and conduct of regular audits for conserving energy
to wards optimum.
381 381
OFFICE & BPO OFFICE & BPO
OFFICE & BPO OFFICE & BPO OFFICE & BPO
BUILDINGS BUILDINGS
BUILDINGS BUILDINGS BUILDINGS
OFFICE & BPO OFFICE & BPO
OFFICE & BPO OFFICE & BPO OFFICE & BPO
BUILDINGS BUILDINGS
BUILDINGS BUILDINGS BUILDINGS
382
LED Bulb
383
First Prize Office Buildings
COGNIZANT TECHNOLOGY SOLUTIONS
(GVC), Bangalore (Karnataka)
Building Profile
Golf view campus is 15 year old facility which was occupied by Cognizant in 2004.
Its total area is 1,66,000 Sq feet and hosting about 1250 associates. Automation
is limited to scheduling and building MD is 1500KVA.
Cognizant (NASDAQ: CTSH) is a leading provider of information technology,
consulting, and business process outsourcing services, dedicated to helping the
world's leading companies build stronger businesses. Headquartered in Teaneck,
New Jersey (U.S.), Cognizant combines a passion for client satisfaction, technology
innovation, deep industry and business process expertise, and a global, collaborative
workforce that embodies the future of work.
384
With over 50 delivery centers worldwide and 130,000 employees as of September
30, 2011, Cognizant is a member of the NASDAQ-100, the S&P 500, the Forbes
Global 2000, and the Fortune 500 and is ranked among the top performing and
fastest growing companies in the world.
1
Electricity Energy Consumption in the Office Building
Energy used Units 2009 - 10 2010 - 11
2 Electrical Consumption
(a) Electricity Purchased
Lacs
kWh
32.7 25.41
(b) Self generated
Lacs
kWh
1.51 1.01
(c) Total Electricity Consumption (a+b)
Lacs
kWh
34 26.42
3 Achievement of energy savings fromimplementation of new Energy Efficiency Projects for the current
year
Year
Electricity (Lakh
kWh)
Any Other
2010-11 7.8 Nil
4 Specific Energy Consumption (SEC) Reduction during the period 2009- 2011
Year
Total electricity consumption/ Total bui lt-up area
(kWh/m
2
)
% Reduction over
2009 - 2011
2009 - 2010
222 18
2010 - 2011
171 23%
5 Absolute Savings
Elect. Saving (Lacs kWh) in
2010-11
Elect. Consumption (Lacs kWh) in
2009-10
% Elect. Saving (savings achieved/
electricity consumption of previous year)
(i) (ii) (i) / (ii) x 100
7.8
34 23%
Achievement of Annual energy savings in 2010-11
Electricity Year of Commissioning
of the projects
Project description
(Lacs kWh)
Total savings in (Rs. Lacs)
Overall Annual saving 7.80
39.00
HVAC 3.22
16.10
UPS 4.26
21.30
Lighting 0.19
0.95
20010-2011
Elevator & Utilities 0.13
0.65
Energy Conservation Measure implemented in 2010-11
Year: 2010-11 HVAC power saving measure
Description of the energy conservation measure:
Pre cooling effectively used during winter days by turning ON the units based
on requirement
385
In the weekends and off business hours AC is turned ON only if the occupancy
is high or fans are provided
Increased the data centre temperature from 18 deg to 22 +/- 1 deg
Provided cooling for servers instead to the entire volume of the data centre
by creating hot aisle and cold aisle thereby reducing the cooling losses
Arresting the below false flooring and above false ceiling plenum cooling
leakages.
Location of the temperature sensor is changed to achieve the optimized and
accurate supply air temp.
Arrested all the leakage points in the precision air conditioning room.
Re-oriented the return and supply air grills so as to optimize the air movement
for optimized cooling and minimum losses in the work station.
Rectified the insulation of the AHU rooms.
Scheduling of the AHU start and stop time, making the same as a workspace
policy and religiously implementing the same
Increasing the work station set temp from 22 deg to 24 +/-1 deg.
Replaced 2nos AHU star-delta starters with variable speed frequency drive
and cooling the area as per requirement.
Decreasing the cooling of the workspace during the lunch period
Picture/ sketch/ drawing after
modification
Chiller secondary pump VFD
frequency is changed
386
AHU Plenum & duct air leakage
arrested applying sealant
In data center below raised floor
made asperse sheet partition to
avoiding supply air waste of
40Sq.ft, toward the end wall of
D/C
Year of implementation: 2010 11
First year energy cost savings, Rs. 21,30,368
Year: 2010-11 UPS Power saving measure
Software was developed in-house and installed in every PC to push the unit
into sleep mode during the non-business hrs. The unit will go to sleep mode
after 7 PM if it is idle and every half an hour it checks for the PC which is in ON
condition and pushes to sleep mode.
System monitor is replaced CRT to LCD
Turning on emergency lamps only during the power change over period (EB to
DG and vice versa)
Energy audit on UPS to check the condition of the system.
Emergency light UPS power supply draw only during EB/DG changeover
NO/NC contacts has been integrated with breaker
387
PC ON/OFF Status
Floor Wing Total seat ON Standby OFF
X 140 23 36 70
Y 132 13 29 0
Ground
Z 58 5 31 0
X 38 9 23 43
Y 65 20 36 52
1st floor
Z 196 29 29 40
X 89 13 14 61
Y 89 19 15 55
2nd floor
Z 163 19 15 109
X 16 1 4 7
Y 58 11 17 27
3rd floor
Z 270 36 67 69
Academy W 191 27 43 124
Power management Template
The initiative by company for running a script to switch off PCs when in idle condition
has given us benefits, below is the data related to the status of PCs during night.
Sticker pasted on all PCs quoting shutdown Pc before leaving office and formation
of green brigade team
Year : 2010-11 Power saving measure in Lighting
In the floor light fitting the acrylic sheet was removed to increase the LUX
level.
Emergency lights will turn only during the power change over (EB to DG and
vice versa) by reconfiguration the circuit with the contactors.
Natural lights are effectively used during winter season and hence extra lamps
which are located near the glazing were switched off
388
Dedicated lighting switches are provided in the unmanned area like AHU rooms,
Electrical rooms, Hub rooms, machine rooms etc.
Orientation of the CFL lamps is changed to optimize the Lux level
Basement emergency lights 60W
incandescent lamp
Replaced to 18W tube light
modification
Picture/ sketch/ drawing after
modification
Year of implementation: 2010 - 11
First year energy cost savings, Rs. 95,000
Year: 2010-11 Elevators and utilities
Lift operation was scheduled based on the need
Running minimum elevators during week ends
Installation of thermostat for all the vending machine to control heat &
consumption.
Formation of the go green team & implementing the same.
Initiating the code 001 policy which says
Zero breakdown
Zero downtime
One efficiency ( 1 KWH per Sft per month)
Energy audit of the facility.
389
Second Prize Office Buildings
BHARAT SANCHAR NIGAM LTD.
Telephone Exchange, Palarivattam, Ernakulam (Kerala)
Unit Profile
BSNL is one of the largest Public Sector undertakings, fully owned by Central
Government, engaged in providing World class Telecommunication services. BSNL
has always been in the forefront of energy conservation ever since the Energy
Conservation Act 2001 was enacted. Testimonies to this are the National Energy
Conservation Awards that have come BSNL's way since 2005. In 2010, under
Office Building category, all the four awards were garnered by BSNL, which was
specially appreciated during the function on Energy Conservation Day 2010.
With 37885 Telephone Exchanges and around 70000 Base Trans Receiver Stations
(BTS) across the country, BSNL has a reach over every nook and corner of the
country. The energy bill during 2010-11 was Rs. 2210 crores. With BSNL sustained
390
energy conservation programmes to meet a target of 10 % energy saving
compared to the previous year, it tried to contain it to the barest minimum.
BSNL Kerala Circle also has given special emphasis on energy conservation. Three
National and 4 State level Energy conservation awards received for various buildings
in Kerala are the outcome of the initiatives taken by this Circle in the energy
conservation front, including the first prize at National level and in Kerala state,
during 2010. BSNL has already embarked on tapping renewable energy in a big
way. Solar water heaters are provided with a total capacity of 9800 LPD in 15
sites of Kerala, where there is scope for such a system, ie for Inspection Quarters,
hostels and canteens. Moreover, Solar PV system of 4.29 kWp capacity were
installed in two BTS sites in Kerala and three more sites have been identified for
providing solar PV system of 5 kWp in this year. Bio- Gas plants and rain water
harvesting systems were also provided in selected sites.
Building Profile - Palarivattam
Established in the year 1992, this telephone exchange building has been playing
host to a variety of switching equipments ranging from old technology to the
most modern digital technology. At present the building houses different types of
switching equipments to meet the demands of landline, WLL, GSM, TAX, OFC, Wi-
max, Broad Band etc, apart from many Administrative offices and a Customer
Service centre.
This building complex comprises a technical block of G+ 2 Floors and an
administrative Block of G+ 3 Floors. Floor wise profile of the building is given
below.
Technical Block :
Ground Floor : First Floor :
Battery Room, Power plant, MDF, OF Station & STR
2 x 400 kVA indoor Transformer Broad Band DSLAM
Substation,
2 x 380 kVA DG set Room
Second Floor : Admin. Block :
EWSD, AXE, GSM BTS, Customer Service Centre &
WLL BTS, (5+1) x 7 TR PAC Plant other Administrative offices.
True to the traditions of BSNL, this building can boast of a variety of energy
conservation features, some built in and the rest adopted by design. It has a
distinct feature of a double wall envelope, meant to keep the heat ingress minimum.
Least amount of glass area was another built in feature to contain the heat gain,
thereby reducing the demand on air conditioning. In other words, 'Green' concept
was very much there at the design stage itself. As most of the main switches are
located in the top floor of the building, in order to minimize the heat ingress
391
Specific Energy Consumption and Graphical Representation
Specific Energy Consumption UNIT 2009-10 2010-11
Details
Total Electrical Energy kWh (lakhs) 13.386 11.104
consumption per annum
Self Generated per annum kWh (lakhs) 0.29 0.25
Total Energy Consumption kWh (lakhs) 13.676 11.354
Total Area Sq. mtrs 4075 4075
Specific Energy Consumption KWh/Sqmtr 335 278
through exposed ceiling and thereby to reduce the AC load, lime concrete covering
has been provided on the terrace.
All conceivable energy conservation measures have been adopted in this building,
which are giving saving potential to BSNL.
392
Details Of Fuel Used and Annual Consumption For Last Two Years.
2009-2010 2010-2011
Total annual Energy Cost in 67.10504 58.00424
Rs. (lakhs)
# Fuel used for Electricity Type of fuel 6.81 5.87
Generated in Ton HSD
*Total Thermal Energy
Consumption in Ton (Except fuel
used for power generation) NA NA
Major Energy Conservation Projects Implemented In the Building.
1. Replacement of inefficient AC Packages:
Old Air Conditioning System New Air Conditioning System
The old plant was of 2 Nos. 5 x 7 TR water cooled AC unit (100 % standby),
whose life was expired and inefficient. This was replaced with (5 + 1) x7 TR Air
cooled PAC Units, with only 1 No. 7 TR PAC as standby. New Air cooled package
AC plant is of high static air pressure, which does not require air handling unit.
These new PAC units are highly energy efficient with twin compressors and high
sensible heat factor capacity. As the condensors are air cooled, usage of water
also has been totally eliminated.
2. Saving in water consumption due to change of PAC units from
Water cooled to air cooled units:
Air conditioning system for the smooth working of existing exchange equipments
were done with 2 x 5 Nos. of 7TR water cooled package AC plants for which
considerable quantity of water was required for cooling the condensers. With the
replacement of water cooled AC plants by air cooled AC plants, the usage of
water for AC plant could be totally dispensed with.
393
3. Downsizing of air conditioned area and AC plant room by providing
partition:
During the replacement of PAC plant, layout of the AC plant room was totally
redesigned and the air conditioned area was reduced drastically. Due to the
replacement and rearrangement of AC plants, an area of 71.5 sq. mtrs was
recovered in the plant room. An area of 36 sq. mtr was reduced in the switch
room.
4. Switching off standby modules of power plant:
The main power plant is of SMPS type which is energy efficient and with much
advantages. The standby modules of power plant, which is conventional type,
were normally in the connected position so as to cater the load in case of an
emergency. Arrangements have been made to switch off the standby conventional
power plant and it is connected in such a way that this will be included in the circuit
only when it is needed, thereby avoiding the continuous losses.
5. Replacement of 2x40 W Fl. fittings with energy efficient 2 x 28 w
T5 lamps in places where continuous operation is required:
The old 2x 40 W decorative type Fluorescent fittings with copper ballast, provided
in Customer Service Centre, STR Transmission Room
and Broad band D slam room were replaced with
2x28W energy efficient T5 fittings with electronic
ballast, where they work longer hours.
6. Replacement of 2x40 W fl fittings with
energy efficient CF lamps at corridor.
The old 2x 40 W decorative type Fluorescent fittings
provided in the corridors were replaced by 2x11W
energy efficient fittings, leading to considerable energy
savings.
7. Replacement of HPSV street lights with
energy efficient CF lamps:
70 W/ 150 W HPSV lamps were replaced with 18 W
energy efficient CF lamps in the existing street light
fittings. 70 W damaged HPSV post top fittings were
replaced with 11 W CF lamp fittings. These lights were
working roughly 12 hours daily.
394
8. Savings on account of providing LED
lamps on various equipment and panel
boards:
Indication lamps of all the panels were filament type,
the power consumption of which was higher (6 watts
against 1 watt LED lamp). As these lights are in ON
position 24 hours a day, even a meagre energy
saving would result in considerable annual savings.
Hence, the Filament type indication lamps were
replaced with LED type indication lamps.
9. Making use of natural light & ventilation:
To take the full advantage of abundant natural light and ventilation, arrangements
are made in such a way that use of A/C units and some light fittings are completely
eliminated in 2 office rooms.
10. Optimisation of switch room Temperature :
Switch room temperature is invariably maintained at an optimised value of 24
O
C.
By resetting the temperature at 1
O
C above the previous setting of 23
O
C,
considerable energy savings could be realised.
11. Vigorous awareness & poster campaign:
Energy conservation slogans and measures are displayed in the prominent places.
Energy conservation campaigns are conducted at all levels to bring awareness
among staff. Large numbers of general public are also visiting this site, at the
customer service centre and the awareness is also spread among the public,
through posters.
12. Maintaining power factor at unity: Incentive received for
monitoring and maintaining PF at unity in each monthly electricity
bill.
An APFC panel of 120 kVAr capacity was installed in this site during 2000. The
power factor of the system could be maintained at unity thereby maximum incentive
in each monthly Electricity bill could be realized from KSEB. The highest PF in the
system reduces losses in the distribution line and therefore is an energy conservation
measure in the electrical distribution system.
13. Keeping the building Eco friendly:
Lush greenery is maintained all around the building to reduce the ingress of heat
and to reduce the carbon content in the atmosphere.
395
14. Life expired inefficient AC units are replaced with 5 star rated split
type AC units.
Life expired inefficient AC Units in the building were replaced with 5 star rated split
AC units.
Energy Policy of BSNL.
BHARAT SANCHAR NIGAM LTD., IS COMMITTED TO CONSERVE ENERGY IN ALL
ITS OPERATIONS. WE HAVE ADOPTED ENERGY CONSERVATION AS A STRATEGIC
BUSINESS GOAL AND MAKE IT AS A WAY OF LIFE
Goal & Objectives
Make Energy Conservation a Mass Movement with involvement of all our
employees.
Monitor and Control consumption of energy through Energy Management
Groups.
To reduce Specific Energy Consumption in all our operations and activities, to
bring down the energy cost.
Recognise the efforts of our Staff in Energy Conservation.
Share and enrich experience on Energy Conservation with SSAs/Circles.
Quarterly Energy Core meeting at Circle level constituting of the following
1. CGM Chairman 2. PGM/ GM Member
3. PCE (E)/CE(E) Member 4. PGM/ GM (Finance) Member
Quarterly Energy core meeting at SSA level constituting of the following
1. GM Chairman 2. DGM Member
3. IFA of SSA Member 4. Concerned EE (E) Member
All new construction to be Green Bldg.
Implementation of Low Cost Measures, No Cost Measures and High Cost
measures.
Use of Energy Efficient Products, Free Cooling System and Non-Conventional
Energy Sources.
396
Second Prize Office Buildings
BHARAT SANCHAR NIGAM LIMITED
(Canada Corner Telephone Exchange)
Nashik (Maharashtra)
Building Profile
Canada Corner Complex is located at Sharanpur Road, Nashik and accommodates
various Telephone Exchanges and Administrative Offices of BSNL. It is having one
main R.C.C. Building of composite type having (G+2) - Technical Block and (G+3)
- Administrative Block. Area per floor is about 1149 sq.mtr with a total building
height of 14.85 Meters.
397
Sr. Floor No. Type of Exchange / Load
No
1 Ground common Transmission Room, MDF Room, Four Nos.
Power Plants, Sub-Station Room and DG Set
Room having 4.95 Mtr. Floor Height
2 First Tech. & Admn. OCB Exchange with capacity 10.9k and E-10-B
Exchange with capacity 13k, NIB Equipments,
Broadband, 2Nos. AC Plants having 4.95 Mtr.
Floor Height & various Offices accommodated in
Admn. Section
3 Second Tech D-TAX Exchange with capacity 30k and WTR
& Admn. Transmission Centre, DOT SOFT Equipment
Room, 1 No. AC Plant having 4.95 Mtr. Floor
Height and TRA Section having 3 Mtr Floor
Height
4 Third Admn. 4 Nos. Inspection Quarters Having 3 Mtr.
Floor Height.
This Complex is fed by 2 x 400 KVA Transformer Sub-Station having Contract
Demand of 380 KVA with supply back-up provided by Diesel Generating Sets of 1
x 500 KVA + 2 x 320 KVA capacity. The energy is consumed in various types of
loads in the main building and various offices in the campus. There is major
consumption of electricity in Power plants and AC plants. The actual consumption
has been derived by recording readings of all types of loads are tabulated below.
Details of Loads :-
Sr. Capacity INPUT (KVA)
No.
1. Power Plant
1. OCB Local, 1000 Amps (100 X 10) 28.18
2 600 A (D- Tax) 20.38
3 400 A (NIB) 8.58
4 i) 600 A - FR -I (E-10-B) 79.98
ii) 600 A - FR -II (E-10-B)
iii) 600 A - FR -III (E-10-B)
Total 137.12
Say 140KVA
398
Sr. Capacity INPUT (KVA)
No.
2. A.C. Plant
1 (1 + 1) x10 TR for Transmission 16.53
2 (3 + 1) x7 TR for OCB Exchange 27.31
3 (5 + 1) x7 TR for E-10-B Exchange 40.97
4 (2 + 1) x10 TR for Transmission & (3 + 1)
x10 TR for D-TAX 66.13
Total 150.94
Say 150KVA
3. E.I. and Misc
A) Pumps
1 (1 + 1) x 5 HP Monoblock for staff quarters 5.02
2 (1 + 1) x 5 HP Monoblock for E-10B Building 4.69
3 1 x 2 HP Submersible for Garden 0.81
Total 10.52
Say 10KVA
B) Compound Light
1 58x36 Watt CFL 2.20
Total 2.20
Say 2KVA
C) E.I. & Fans
1 E-10-B building 28.45
2 Campus and staff Quarters 43.80
Total 72.25
Say 75KVA
Total of E. I. & Misc. Load Say 90KVA
Total 377KVA
399
The energy conservation measures are carried out in the main E-10-B Building
and Campus to save optimum electrical consumption. Mainly Two measures are
carried out which are explained below:
A) Replacement of old Sodium Vapor/Mercury/Fl. Type Compound
Light Fittings by 36 watt CFL.
Building has replaced existing 70watt HPSV, 125 watt HPMV, 150 watt HPSV
lamps with 36 watt CFL with slight modifications in the existing fittings and
achieved substantial energy saving with bare minimum investment.
Energy Saving = 17976 kWh
Energy Saving in Rs. = 23200
400
B] Replacement of old life expired Package A C units having poor
EER.
The 14 to 16 years old life expired Package AC units which were working with
poor EER about 6 due to ageing, wear & tear. By replacing old package A.C.
unit with new Package A C units having energy efficient motors, compressors
the EER was improved up to 8. Total 23 Nos. old package A.C. units were
replaced and maximum saving was obtained.
C] Saving by using free cooling concept.
One or Two dismantled Life expired Package units are used in Four A/C plants
to implement the concept of Free Cooling. Only blower of existing scrapped
A.C. unit was utilized to feed the outside cool air in A.C plant room when ever
the ambient temperature is suitable by providing suitable fine filter, volume
control damper and suitable ducting and opening in outer wall of A C Plant
room. The operation of the blower was atomized by providing a controller
having temperature sensor and RH sensor to operate the blower at suitable
time. The blowers of other package A. C. unit were operated as per CFM
requirement.
Energy saving is obtained by reducing the operating hours of compressor while
maintaining the inside temperature to the required range.
401
Certificate of Merit Office Buildings
INDIAN RAILWAYS
DRM Office, N. E. Railways
Izatnagar, Bareilly (Uttar Pradesh)
Building Profile
Indian Railways are a major department of the Central Government with a presence
throughout the length and the breadth of the country. Apart from heavy electrical
energy usage for the purpose of electric traction, Railways utilises large amount of
electrical energy in its installations like administrative and service buildings, stations,
residential colonies, pumping installations etc. With the growing demand for
improved passenger and staff amenities, the energy bill has been continuously on
the rise. However, the Railway have embarked on a mission to reduce the energy
demands through the use of energy efficient devices and practices and tapping the
unconventional/renewable sources of energy. Under the 'Vision 2020' document
and the '28-point. Energy Action Plan', all Zonal Railways are working towards
reduction in the total energy bill by 15% by 2020.
Building in Day
402
The DRM office building came into existence in 1969 and houses the chambers of
the DRM and other officers of Izatnagar division, sections for staff, Divisional Control
Centre, various control rooms, conference halls and public utility spaces. The building
has a built-up area of 16640 sqm with an air-conditioned area of 1068 sqm.
The total connected load of the building is 467.3 KVA and the power supply is
provided by a 2x500 KVA, 11/0.4 KV transformer substation with a 250 KVA
generator backup for emergencies.
The building boasts of a variety of energy conservation measures, some of which
were as suggested by an energy audit conducted in 2009-10 and some of which
have been installed under Railway Board's initiative.
Energy Consumption
The Divisional Control Centre as well as various departmental control rooms
(including the FOIS-Freight Operating Information System, which necessitates 24-
hours air-conditioning) and Telephone Exchange work round the clock. These are
unavoidable energy utilisation centres essential for the Railway operation and no
disruption in these services is acceptable. This leads to an increase in the specific
energy consumption vis-a-vis say an office with a normal nine - to - five working.
Specific Energy Consumption and Its Graphical Representation
Specific Energy Consumption UNIT 2009-10 2010-11
Details
Total electric purchased per annum kWh (Lacs) 4.756 4.043
Self generated per annum kWh (Lacs) 0.513 0.442
Total energy consumption kWh (Lacs) 5.269 4.485
Total area Sq. m. 16640 16640
Specific energy consumption kWh /Sq.m. 31.67 26.95
34
32 31.67
30 26.95
28
26
24
22
S
E
(
k
W
h
/
s
q
m
)
20
2009-10 2010-11
YEAR
Specific Energy Consumption (kWh/sqm.)
403
Energy Conservation Measures in DRM Office, Izatnagar
A. The DRM office building came into being in 1969 on Nainital Road, at Izatnagar,
Bareilly (U.P.). The building has a built-up area of 16640 sqm with an
airconditioned area of 1068 sqm. The building includes officerss chambers,
staff sections, various Control rooms, Conference room and Public utility
spaces. The total connected load of the building is 467.3KVA and the power
supply is provided by a 2x500 KVA, 11/0.4 KV transformer sub-station with a
250 KVA generator backup for emergencies.
B. Various energy conservation measures have been adopted in the office which
are enlisted below:-
1. Replacement of 706 no.T-12, 40W FL fittings by T-5, 28 watt fittings
giving an annual saving of about 30922 units. Replacement of all 20W/
40W/60W Incandescent bulbs in the office by 11 W/14 W CFLs mostly in
public utility spaces. There are no incandescent bulbs remaining in the
building.
2. Rationalisation of existing light fittings and their removal/relocation as
required. 16no. of 28 W FL fittings in the office have been removed
resulting in an annual saving of 701 units.( One fitting each, as an example,
has been taken out from the double tube fittings in the Conference room
without any adverse effect on required lux level.)
3. 336 no. old 90 W fans have been replaced by 60W fans giving an annual
saving of about 36288 units.
4. 110 no. 15 W indicator lights for officers chambers have been replaced
by 1W LED lamps giving an annual saving of 6745 units.
5. 9 no. 150/250W Metal Halide lights on poles in front of the office have
been replaced by 30W LED sreet lights giving an annual saving of 3942
units.
6. Occupancy Sensers which switch off the ACs and the lights within 10
minutes if no movement is detected have been provided in various
chambers/rooms/sections. This will result in an expected saving of about
60000 units annually.
7. A 99 KVA Electronic Energy saver connected to the light and fan circuits in
the office has been tested to give a saving of about 14% which works
out to approximately 20000 units annually.
8. As a policy, from 16
th
of October to 15
th
of April, every year, all the Air
conditioners (excepting 2 nos. for Control Server Room) are switched
off permanently. Similarly, the use of halogen heaters during the cold
404
season has been restricted to a minimum by providing them only when
the temperature drops to 8 C. These measures, through not quantified,
result in substantial energy savings.
9. 3no. 1.5t ACs has been replaced by their 5 star rated version giving an
annual savings of about 6000 units.
10. Energy Audit for the DRM office building was carried out by an energy
audit firm and all the measures suggested during the audit have been
implemented :-
S.No. Recommendation Status
1 Avoiding cold air loss in Control room's
Air duct by repairing the same. Completed
2 Providing proper insulation on each split type
AC's outdoor unit copper tube. Completed
3 Use of Energy saver for the office. Completed
4 Replacement of 40W FL tubes with 28W,
T-5 FL fittings in the offices. Completed
5 Use of Occupancy sensors for ACs. Completed
11. 200 KVAR APFC panel has been provided at the substation which while
improving the pf to above 0.95, results in reduced useful energy losses. The
main 250 KVA backup GenSet is the canopy covered, environment friendly
type.
12. In addition to the activities mentioned in the preceding paras, the following
works are in pipeline :-
(i) 10 KW Solar panel (grid connected) for the building, the tender for which
is due to open in Dec, 2011. This will reduce the existing load on UPPCL
supply by about 7 to 8 KW.
(ii) Replacement of all ACs by star-rated ones on age-cum-condition basis.
Vision 2020 document of Indian Railways envisages saving up to 15% of energy
through energy efficiency measures in both traction as well as non-traction use.
The year 2011-12 has also been declared as The year of green energy.
After enactment of the Energy Conservation Act, 2001, there is thought for adopting
energy efficiency measures in various sectors of economy. Railway Board vide
letter no. 2007/Elect(G)/152/2 Dt- 06.07.2007, advised all Zonal Railways to
conduct energy audit of areas like major GM/Divisional administrative buildings,
405
hospitals, pumps, loco sheds, major railway stations and workshops as a one-
time exercise.
A 28-point Action Plan drawn by Railway Board serves as the guidelines
for energy conservation for all zonal railways. These points are enumerated
below
Segregating of 70/30 lighting circuits at platforms.
Use of CFL fittings at corridors, staircases, toilets & bathrooms in place of 60/
40 watt incandescent lamps.
Use of T-5 fluorescent tube lights in place of T-12 FTL fittings.
Use of Automatic Power Factor Correction panels in HT/LT substations.
Replacement of 90 watt ceiling fans by 60 watt ceiling fans.
Use of electronic fan regulators in place of conventional fan regulators.
Provision of LED based station name board in place of neon sign board.
Timer switch on high mast towers-yard lighting/street lighting.
Use of electronic ballast in place of conventional ballast in FTL circuits and
metal halide circuits.
Automation of pumps.
Use of energy efficient pumps in place of old inefficient pumps.
Efficiency measurement of pumping installation and implementation of action
plan.
Use of solar panels at stations.
Use of solar panels at LC gates.
Replacement of conventional geysers in rest houses/lobbies/retiring rooms/
hospital/running rooms/canteens/base kitchens by solar geysers.
Use of solar street light for (a) colonies (b) training institutes.
Use of electronic kWh meters in place of conventional kWh meters for
residential quarters.
Use of energy saver for: (a) pumps (b) lighting circuits (c) Air conditioning
circuits (d) machine in workshops.
406
Use of quick coupling socket for air distribution in workshops and sheds.
Use of occupancy sensors for light control in (a) officers chambers (b)
conference rooms (c) waiting halls.
Use of copper wiring for quarters.
Setting of optimum voltage for transformers in substations for lighting circuit.
Replacement of HPMV lamps with metal halide lamps.
Use of VVF control for cranes, lifts and escalators.
Use of 3 star and above labelled electrical products and equipments.
Energy audit conducted in past two years and short term & long term
recommendation implemented or not.
De-stocking of incandescent lamps.
Any other item proposed by the Railway/PUs.
407
Second Prize BPO Buildings
INFOSYS BPO LIMITED
IBPO-1, Tal-Mulshi, Distt. Pune (Maharashtra)
Building Profile
Infosys Pune Phase II has nine software development blocks, one IBPO development
block including a food court on the top floor, a 1000 room ECC and three food
courts totaling to approx. 42,00,000 plus sq ft. Totally there are a 25000 plus
strong work force in Infosys Pune campuses.
Infosys BPO is a subsidiary of Infosys Limited and operated out of the Hinjewadi,
Pune campus. BPO-1 building commenced business operation from September
2007 and currently is fully functional. BPO-1 has a capacity for 3000 employees
with an area of 2.75 Lacs square feet and operations run 24*7. It consists for
ground + 3 floors. The third floor has a food court for its employees
408
Electrical Consumption Pattern -2009 -10
Electrical Consumption Pattern -2010-11
409
Energy Conservation Measure
Removed of existing PL fitting and
installed LED fittings.
Removed Excess lights (36 watt
Fluorescent Tube light ) from existing
fittings
Movement Sensors - For all Rest
Rooms & Cabins
Street light fitting replaced with lower
wattage fittings.
TITLE Energy Energy Total Energy
Consumption Consumption Saving Saving
Before (KWh) After (kWh) (kWh) Cost (Lacs)
Removed of existing PL 18973 2108 16865 1.0119
fitting and installed LED fittings.
Removed Excess lights (36 watt 404352 269568 134784 8.0870
Fluorescent Tube light) from
existing fittings
Movement Sensors - For all Rest 11824 7390 4434 0.2660
Rooms & Cabins
Street light fitting replaced 45000 27000 18000 1.0800
with lower wattage fittings.
Energy Saving Details
410
Health, Safety and Environmental Policy
Infosys as a corporate citizen is committed to demonstrating a high standard of
environmental protection, sharing of best practices and provision of a safe and
healthy work place.
To achieve this, Infosys shall work towards:
Conservation of resources
Prevention of pollution
Adherence to all applicable legislations
Eliminating accidents, occupational illness and injuries at work
Infosys will work with various stakeholders towards continual improvement of its
Environmental, Health and Safety Management System.
Infosys BPO shall meet mandated health and safety requirements as a minimum
and strive to go beyond regulatory limitations to become a leader in environment,
health and safety management.
411
Second Prize BPO Buildings
INFOSYS BPO LIMITED
BPO-Building 48, Bangalore (Karnataka)
Building Profile
Infosys Limited Bangalore campus is spread over 71.3 acres with 50 buildings,
There are many noteworthy features within the campus. It has a "Customer
Care" building, Five Non air conditioned Food Courts and apart from this there are
8 conference rooms with attached dining rooms for the use of individual customers,
a large lobby, a recruitment center, a breakfast lounge (Ideal for breakfast and
lunch meetings) to seat 100 people which comes with a video wall 4 x 4 squares
to enable meetings and presentations over a meal. There is the grand Management
Council Room to seat a hundred people. A large APLCD based video wall enables
state of the art corporate presentation & VC facilities. The wall has 7x3 squares
and is one of the largest video walls in the country.
412
Brief about Infosys Limited BPO Building No. 48
Infosys BPO Limited, a subsidiary of Infosys Technologies Limited, provides business
process management services to Global 2000 companies. Leveraging the benefits
of service delivery globalization, process redesign and technology, drives efficiency
and cost effectiveness into clients business processes. Infosys BPO Limited and
Infosys work closely together to provide a complete outsourcing solution to the
client, addressing the clients technology as well as business process outsourcing
needs. Within this campus all the buildings are numbered from Building No.1 to 50
and Building No. 48 is one of the building. Like other buildings B -48 which operates
and provides 24 X 7 process support, enclosed brief technical information.
Built up area of the Building NO. 48 :- 1,95,000 sft.
Orientation of the building :- East West.
Type of Glass used :- SS20 with clear lamination inside and blue tint outside.
Construction materials used :- Steel and RCC composite materials.
Number of floors :- Ground Floor + 5 ( totaling to Six Floors ).
Number of Workstations :- 2208.
Number of PL & Cabins :- 299.
Number of Server rooms :- 5.
Energy Consumption
Installed dedicated indoor type dry cast resin transformer is fed from dual 11KV
Ring main system, having internal LT power distribution system, power being
distributed internally by using bus rising mains and tap-off boxes for tapping power
at floor levels, multiple bus raising mains used to distribute Raw power & UPS
power.
a) Brief about installed & operating capacity of electrometrical
equipments in this building :-
Operating demand :- 620 KVA to 820 KVA
Operating voltage :- 405 Volts.
Installed UPS capacity for work area :- 3 X 160 KVA UPS Systems, which
are operating in Parallel redundant mode, all the three UPS systems are
operating at 48 % load.
413
Installed Data Center & HUB room UPS capacity :- 2 X 60 KVA UPS
Systems 21 % loaded
Installed chiller capacity :- 3 X 250 Tr.
Baby chillers : - 36 Tr.& 2 X 24 Tr.
Total number of Air handling units :- 13 numbers, all the AHU are connected
to VFD
Make of Light Fixture : Thorn - Suspended 3 X 36 Watts composite light
fixture which provides Illumination both Direct & indirect ways.
Annual Energy consumption for the year 2010 -2011
Energy Consumption in percentage of total building energy
consumption
414
Implemented Energy Conservation Practices:
Installed Energy Management Software and Building Management system
software installed in all Infosys campuses which are working at Ten different
location in India.
Daily energy reports are generated on daily basis and monitored by concerned
Electrical engineer at each location.
Across our development center around 1200 Digital Energy Meters installed
and monitored centrally.
Energy meters installed at building mains level and at distribution levels.
In Building No. 48 around 22 energy meters installed and energy consumption.
First time in industry all the VFDs are enabled on Modbus protocol in getting
the energy data on EMS soft ware - Note : all the 13 number AHU energy
consumption is monitored without installing the energy meters.
Energy Conservation Measures Implemented
a) Air Conditioning systems :-
Chillers will be switched on depending on the process requirement and on
basis of environment condition.
Floor temperature maintained at 24 degree C.
Depending on process timings AHU switch timings are preset to switch ON /
OFF the AHU.
VFDs installed in all the AHUs.
VFD will take the feedback from the return air temperature & varies the motor
speed.
All the AHU motors are operating between 85 to 90 % efficiency.
Motorized actuators installed in all the chilled water circuit.
415
b) UPS System :-
All the desk top systems installed in work area and in data center are energy
star rated.
After process hours awareness created to all the users to keep the desk top
in turn off mode.
c) Illumination :-
Installed energy efficient electronic ballast & lamp light fixtures with latest
technology reflectors.
Installed occupancy sensors in Cabins, meeting rooms and in rest rooms.
Illumination levels are maintained between 350 to 400 Lux at work area.
All the cabins and meeting rooms are facing towards glass faade, wherein
during day time all the users are using day light illumination who are sitting
towards North & South direction.
Monthly energy Consumption pattern of Building No. 48
416
Health, Safety and Environmental Policy
Infosys as a corporate citizen is committed to demonstrating a high standard of
environmental protection, sharing of best practices and provision of a safe and
healthy work place.
To achieve this, Company shall work towards:
Conservation of resources
Prevention of pollution
Adherence to all applicable legislations
Eliminating accidents, occupational illnesses and injuries at work.
Company will work with various stakeholders towards continual improvement of
our Environmental, Health and Safety Management System. Company shall meet
mandated health and safety requirements as a minimum and strive to go beyond
regulatory limitations to become a leader in environment, health and safety
management. Various Energy Conservation and Water Conservation initiatives
are taken on annual basis and energy saving and water savings targets are set
annually by management. All the conservation activates are reviewed by top
management on monthly basis.
417 417
HO HO
HO HO HOTELS TELS
TELS TELS TELS
HO HO
HO HO HOTELS TELS
TELS TELS TELS
418
419
First Prize Hotels
ROYAL ORCHID CENTRAL
Icon Hospitality Pvt. Ltd.
Hotel Profile
Royal Orchid Central is a division of ICON Hospitality Pvt. Ltd, Manipal Centre,
Bangalore. It's a 4 star hotel located at the center of the garden city. The hotel
was built on 1990 & the Built up area is 9816 sq mtr.
It's a 21 year old hotel taken up by Royal orchid central and the hotel operation
started on 02nd Feb 2003. Hotel has Basement, Ground floor & +12 Floors, total
130 rooms in which having 108 club rooms, 18 studio rooms & 4 Executive
suites.
420
Energy Consumption Chart with 2009-10 & 2010-11 Comparison as
below :-
Electrical units saved 6.24% compare to last year
Total Units saving is 1.26 Lacs units compare to last year
Electrical Units Comparison
Months 2009-10 2010-11 Units
Total Total Saved
Electrical Units Electrical Units
April 161503 196124 -34621.0
May 173326 203226 -29900.0
June 182784 182515 269.0
July 176447 181112 -4665.0
August 175621 177281 -1660.0
September 168354 170574 -2220.0
October 163776 150605 13171.0
November 167116 126965 40151.0
December 157169 125244 31925.0
January 156688 122817 33871.0
February 156820 125888 30932.0
March 188686 154296 34390.0
Total 2028290 1916647 111643.0
Average 169024.2 159720.6 9303.6
Daily 5634.1 5324.0 310.1
MONTHS 2009-10 2010-11 2009-10 2010-11
ELECTRICAL UNIT / ELECTRICAL UNIT / ROOM ROOM
ROOM OCC ROOM OCC OCC OCC
APRIL 106 88 1523 2219
MAY 167 118 1035 1723
JUNE 102 90 1793 2032
JULY 86 80 2059 2257
AUGUST 92 79 1910 2238
Electrical Units / Room Occupancy:-
421
MONTHS 2009-10 2010-11 2009-10 2010-11
ELECTRICAL UNIT / ELECTRICAL UNIT / ROOM ROOM
ROOM OCC ROOM OCC OCC OCC
SEPTEMBER 91 62 1858 2755
OCTOBER 98 58 1676 2607
NOVEMBER 66 49 2535 2601
DECEMBER 88 51 1781 2478
JANUARY 77 49 2036 2521
FEBRUARY 64 40 2469 3142
MARCH 81 51 2333 3027
AVERAGE 93 68 1917 2467
S Electrical Energy Conservation Details Units/ Total Investment
No year savings / done on the
year in project
(Rs. Lacs) (Rs. Lacs)
1 HVAC Systems Chiller temperature 87600 6.132 0
setting as per the load and weather
condition (condencer pump , CT Fan,
Chiller pump , etc)
2 Secondary chiller pump operation 87600 6.132 0
Saving in chiller power
3 Guest rooms defective AC Thermostats 23725 1.66075 1.5
replaced & room standard Temp
setting done
4 Guest rooms out dated 21 no FCU 7300 0.511 6.3
Units have been replaced
5 Guest rooms light control defective 29200 2.044 0.2
20 no key tag units replaced
6 Lobby, Coffee shop & public area 115340 8.0738 1
55w Halogen has been replaced by
11 W CFL
7 Movement sensor for toilet lights & 29200 2.044 0.5
Timers for Fountains, Exhaust, etc
8 40 W Tube lights has been 8760 0.6132 0.5
replaced by 28w T5 Electronic
Tube lights
379965 26.5976 10
422
Picture of De-Super Heater before
Installation
Picture of De-Super Heater after
Installation
1. Project Achievement
Hot water generation was done from HVAC system rather than Hot Water Boiler
which is resulting in the huge quantity of HSD saving:
This project was started in May 2010, as the CIAT make 75 TR Screw chiller had a
defective De-super heater system for Hot water generation, then Hotel started
the processing and replace the new De-Super heater but due to the natural hardness
of water Hotel unit could not feed the Raw water into the De-super Heater to
Generate Hot water. Because, it will block the system which will effect the operation
of chiller plant and it may spoil the chiller compressor. Again Hotel took up new
challenge to solve the problem planned to incorporate PHE system for primary
soft water circulation and hence the natural raw water can be circulated on the
Secondary side for the user end to get Hot water. So on the Project has been
completed by Technical studies & financial implementation and achieved goal by
Energy Conservation on HSD for Hot Water generation. From Nov 2010 onwards,
90% of hot water Boiler usage was reduced which resulted of 100 ltr HSD saving
per day . Hence, Cost saving per Month is 3000 ltr x Rs.42/- = 1,26,000/-
PHE system
423
2. Boiler HSD Consumption Chart
HSD saved 26.73% compared to last year
HSD saving for hot water generation is 12,520 ltr / year
MONTHS 2009-10 2010-11
TOTAL BOILER TOTAL BOILER HSD
HSD CONSUMED HSD CONSUMED SAVINGS
APRIL 2736 3000 -264.0
MAY 3720 2784 936.0
JUNE 3480 2712 768.0
JULY 3648 2760 888.0
AUGUST 3792 2140 1652.0
SEPTEMBER 3360 2040 1320.0
OCTOBER 3240 2200 1040.0
NOVEMBER 3792 2300 1492.0
DECEMBER 3552 3100 452.0
JANUARY 3072 1080 1992.0
FEBRUARY 2496 1680 816.0
MARCH 3120 1400 1720.0
AVERAGE 3334.0 2266.3 1067.7
TOTAL 40008 27196 12812.0
DAILY 111.1 75.5 35.6
3. Water Consumption / Room OCC :-
All Urinals sensors provided to save water.
Air filters provided for all guest rooms taps.
PM of Plumbing fittings & flush system
Pressure guns usage in kitchen pot wash area to avoid water wastage.
Sofner plant & floor cleaning water store & used for gardening plants.
During 2009-10 water consumed 1.27 kl/ room which reduced to 1.04kl /
room night during 2010-11
That is approximately 20% saving on water / room night occ
424
Environment Policy
Royal Orchid Central on Dickenson road, Bangalore, Pledge to protect its
environment , In doing so, it will comply with all applicable legal & other requirements
which relates to its environmental aspects.
Royal Orchid Central, Bangalore shall endeavor to :-
Optimize the consumption of Electricity, HSD, Water & other Energy resources.
Minimize waste operations.
Handle and dispose waste in responsible manner.
Hotel shall identify, Monitor, Control Key environmental impacts & continually improve
environmental performance.
It will communicate its environmental policy to all persons working for and on
behalf of organization.
This policy shall be made available to the public on request
425
Certificate of Merit Hotels
ADITYA PARK
A Unit of Manjeera Hotels and Resorts Ltd.
Hotel Profile
A premium property from the well-known Sarovar chain of hotels, Aditya Park
welcomes guests to everything luxurious that comes with the convenience of
being close to the major areas in town. Aiming to be the best host for the class
business travelers to the city, the hotel brings the best possible facilities and
amenities to make it a convenient stay for them.
Rooms in Aditya Park :
Total Rooms : 88
Superior Room : 65
Executive Room : 10
Suites : 02 and Junior Suites : 11
426
2. Electric Units Consumed from April 2010 to March 2011
3. Gas Consumed from April 2010 to March 2011
4. Total Water Consumed from April 2010 to March 2011
Energy Consumption
1. Diesel Consumption from April 2010 to March 2011
427
Major Project Implemented During 2010 2011
Fitch Fuel Catalyst Saving of diesel 3 ltr per hour
Fitch Fuel Catalyst is the new introduction Hotel has done in order to enhance the
saving by the principle of arresting the carbon formation on the coil which increases
the heat exchange efficiently. This helps in reduction of HSD consumption. The
total investment is Rs.1,20,000/- by installing this Hotel has saved 3 ltr per hour
for running boilers and the total investment was recovered in 4 months.
Energy Conservation Committee, Policy and Set up
As Aditya Park has started working towards energy conservation. To be more
effective in making itself as a hotel that takes cares of environment.
Green team will be functioning with the objectives as follows:
1. To create awareness
2. To train people to follow energy conservation practices
Waste Management
Garbage Disposal
Waste Separation
Minimization of waste
Material Conservation
3 R System
1. Reduce
2. Reuse
3. Recycle
Guest Education and involvement
Sustainable Purchase systems
428
1. Water Saving Taps
2. STP plant 70 kl per day
3. Air Scrubber for the kitchen exhaust- Filters the oil
and grease content will be filtered in the filter, and will
exhaust only the air without pollutants in to the
atmosphere
429 429
HOSPIT HOSPIT
HOSPIT HOSPIT HOSPITALS ALS
ALS ALS ALS
HOSPIT HOSPIT
HOSPIT HOSPIT HOSPITALS ALS
ALS ALS ALS
430
431
First Prize Hospitals
DIVISIONAL RAILWAY HOSPITAL
Western Railway
Sabarmati, Ahmedabad (Gujarat)
Hospital Profile
The Divisional Railway Hospital Sabarmati, Ahmedabad was started in 1962 as 20
bedded sub-divisional hospital under Baroda Division. At present it has grown to
65 bedded referral hospital. It provides secondary health care services to all
beneficiaries of the Ahmedabad Division.
The hospital has matched the growth of Ahmedabad Division and has become one
of the very well equipped hospitals of the Western Railway. All basic specialties like
Medicine, General Surgery, Gynecology & Obstetrics, Ophthalmology, Orthopedics,
Pediatrics, Pathology, Radiology, Sonology and Dental clinic are available. Division
has tie up with Apollo Hospital for emergency cardiac treatment for heart diseases.
432
The Power supply for this Hospital building is fed through Railway own supply
system and has built up area of 3339 square meters. With the adoption of all
possible energy conservation measures and vigorous and continuous monitoring,
Divisional hospital could achieve a remarkable saving in energy consumption by
10.4 % despite connected load of the offices have been increased in 10-11 by
101KW. This was possible only with the Vision 2020 and Energy conservation
action plan of Indian Railway.
Energy Consumption Pattern
Sr No Energy used Units 2009-10 2010-11
1 Electricity purchased LackWh 3.97 3.55
2 Self generated Lac kWh 0.0012 0.008
3 Total Electricity Consumption Lac kWh 3.9712 3.558
4 Energy saving Lac kWh 0.413
5 Saving over previous year %age 10.4 %
Energy Consumption in Building
Consumption per built up area-
Item 2009-10 2010-11
Connected load in kW 220 321
Consumption in lackWh 3.97 3.56
Built up area in sqmtrs 2984 3339
Consumption per built up area 133 107
433
Item 2009-10 2010-11
No of beds 47 65
Consumption in lackWh 3.9712 3.558
Consumption per bed in kWh 8449 5473
Consumption per bed-
Energy conservation action plan for Hospitals
1. Use of T-5 fluorescent lamps in place of T-12 FTL lamps.
2. Use of CFL fittings in corridors, staircase, toilets and bath rooms in place of
60/40w ICLs.
3. Use of automatic power factor corrector in HT/LT substation.
4. Use of electronic ballasts in place of conventional ballasts.
5. Use of electronic fan regulator in place of conventional fan regulator.
6. Provision of LED based name board in place of neon board.
7. Automation of Pump.
434
8. Use of energy efficient pumps in place of old pumps.
9. Replacement of conventional geysers with solar geysers.
10. Use of electronic kWh meter in place of conventional kWh meters.
11. Use of energy saver for pumps, AC circuits & lighting circuits.
12. Use of occupancy sensors in Officers chambers, waiting halls & conference
rooms.
13. Use of 3 star and above rated electrical products.
14. Use of Building energy management system
Major projects implemented during the year 2010-11
1. Provision of Solar water Geyser :
One no. 500 LPD capacity Solar Water Heater has been provided with total cost of
Rs.69600/-. It is feeding hot water to various wards. The annual saving achieved
with this solar heater is Rs.35000/-
Solar Water Heater GSM technology
2. Pump operation through GSM based technology:
Submersible pump which supplies water to Divisional hospital building has been
provided with GSM technology which not only controls its operation and reduces
the wastage of energy but monitor the pump performances and gives feedback
through SMS.
3. Provision of 3 star and above rated Air conditioner units:
14 nos without star rated AC units have been replaced 3 star and above rated AC
units.
4. Electronic fan regulator:
100 nos conventional fan regulators have been replaced electronic fan regulator.
5. Replacement of 36 w FTL with CFL in corridor:
69 nos 2x11 w CFL fittings provided in place of 36 w conventional fittings in
corridors.
435
6. Replacement of 36 w FTL fitting with 28 w T-5 fittings:
244 nos 36 w FTL fitting have been replaced with energy efficient 28 w T-5
fittings.
7. Replacement of old refrigerator with 5 star rated refrigerators:
10 nos refrigerators of old type replaced with energy efficient star rated refrigerators.
8. Replacement of HPSV fittings with 70W MH fittings :
15 nos HPSV 150 w fittings were replaced with 70W MH fittings in 2010-11.
Star rated Refrigerator MH fittings
9. Replacement of Conventional ceiling fan with star rated fans:
24 nos conventional ceiling fans were replaced with star rated fans in 2010-11.
10. Provision of Electronic energy meter:
Conventional Energy meter is replaced with Electronic energy meter in 2010-11.
11. Provision of LED Indication lamps in the distribution panels:
30 nos LED indication lamps provided in the panels in place of conventional lamps
in 2010-11.
LED indication lamps
436
12. Provision of Flow restrictor in toilets & bathroom:
Flow restrictor has been provided in water taps in Operation theatre.
Water flow restrictor LED display & TV
13. Provision of LED display board and TV in OPD:
01 no LED display board and 01 LCD TV was placed in OPD in year 2010-11.
14. Provision of energy conservation slogan boards:
50 nos slogan boards which educate and give message for energy conservation
have been placed in all the offices and corridors.
Slogan posters LCD monitor
437
15. Replacement of conventional CRT monitors of computer with LCD
monitors:
04 nos conventional CRT monitors were replaced with LCD monitors for PCs.
16. Observation of Energy conservation Day:
14 December, 2010 was observed as Energy conservation Day. An exhibition
was arranged on that day. This has created a sense of responsibility towards
energy conservation among energy users in the building.
17. Plantation around Division building:
Environment friendly surroundings with trees and plants were developed which
now gives a cool and pleasant atmosphere all around. It helps toward energy
conservation.
Energy policy of Indian Railway
1. Saving up to 15 % of energy through improved energy efficiency in both
traction as well as Non traction use.
2. Sourcing at least 10% of energy used from Renewable energy sources such
as Solar power and Biomass.
3. Energy audits to improve energy efficiency on thousands of its Stations and
offices and adoption of LED lighting and Energy conservation Building Code
(ECBC).
4. Procurement of only 3 star and above higher rated products for achieving
energy efficiency.
5. Annual reduction of 0.14 million tones of CO2 emissions through free
distribution of 4 CFLs per family of Railway employees in replacement of energy
inefficient incandescent lights.
6. Massive plantation drives along the railway track, Railway colonies and buildings.
438
Second Prize Hospitals
FORTIS HOSPITAL
Noida (Uttar Pradesh)
Hospital Profile
Fortis Hospital, Noida, was established in 2004. It is built in 5 acres of land in an
institutional area in sector 62 of Noida. This Hospital is focused on super specialities
Neurosciences, Gastro, Liver Transplant, Oncosciences, Cardiac Sciences, Renal
Transplant and Orthopedic sciences. Complex procedures like Knee and Hip
replacement, spinal fixations, head surgery, renal transplants, laparoscopic surgery,
cardiac surgery, stenting, neurointerventions are routinely being done here.
Hospital also has fully functional departments of Cardiology, Cardiac Surgery, and
Nephrology with a Dialysis Unit, Urology, Minimal Access surgery, Gastroenterology,
Plastic surgery, Medical, Surgical and Radiation oncology. These are backed by
fully equipped Anesthesia services, radio diagnosis services, critical care services,
Emergency medicine department with 2 fully equipped ACLS ambulances and
provision for air rescue, in house 24 hour SRL pathology lab and an in house
Blood Bank. The hospital also offers Stem Cell Treatment, Bone Marrow Transplant
and a PET CT.
Hospital has 7 fully equipped state of art Operation rooms. The ORs have 2
operating microscopes, endoscopic systems for all the surgical disciplines, multi
modality monitors, intraoperative video recording systems for training and teaching
439
purposes, intraoperative C Arm with DSA facility, and intraoperative ultrasound
facility. The Hospitals diagnostic wing has a double slice CT scanner, a 1.5 T MRI
scanner, 3 D ultrasound and digitized X ray system.
Energy Consumption
Hospital has 11 KV supply in the hospital with an independent feeder from the sub
station and have a 2000 KVA transformer with an AVR with 2 DG sets of 750 KVA
rating each. In 2011, Hospital has added another DG of same capacity as a stand
by.
The consumption for the year 2009 10 and 2010 -11 has been as under:
In 2009 10: Electricity consumed from the grid was 39.6 lacs KVAH with an
average Power factor of
96% OR 38.01 kWh
Units generated through the DG sets = 60600 X 3.7 =2.24 Lacs kWh
Total energy consumed in the year: (38.01 + 2.24) = 40.25 lacs kWh
In 2010 11: Electricity consumed from the grid was 36.01 KVAH with an average
Power factor of 99%
OR 35.65 lacs kWh
Units generated through the DG sets: 32400 X 3.7 = 1.20 lacs kWh
Total energy consumed in the year : (35.65 + 1.20) = 36.85 lacs kWh
Electricity consumed per bed per annum has been as under:
2009 10: 22.75 K kWh
2010 11: 19.81 K kWh
The brief annual comparison is as under:
(Power and Fuel (budgetted vs Actual)
(in Rupees lacs)
Month / Budgeted Actual Electricity Diesel Units Units
Year (Rs/unit) oil Rs/liter consumed Budgeted
2008 - 09 277.44 4.54 32 43.34
2009 -10 289.82 209.93 4.3 35.5 39.6
2010 - 11 221.66 192.74 4.75 39 36.01 40.68
440
The Engineering and bio medical services have been outsourced to a Malaysian
company, M/S Faber star since March2008 and they are still a part of hospital
and working in a thorough professional manner
The energy bill for the year 2008 (Jan08 till Dec08) was observed to be around
270 lacs INR which seemed to be on a very high side. Subsequently, we decided
on conducting an in-house energy audit and few of the observed points with
action taken are reproduced below.
Points observed
The overall actual airflow of the
AHUs is 75% of the designed
CFM
Modulating chilled water valves and
the temperature controllers not
working on the AHUs
VFD of secondary chilled water
pumps not working
Power factor at 0.93-0.95
Sanctioned load of 1834 KVA
never utilized over the last 05
years and MDI never exceeded
1000 KVA
High quantity of cool air being
exhausted
High illumination
Ineffective air conditioning in many
areas exposed to sunlight
Action taken
Improved the CFM by
completely
overhauling the AHUs
Set them right
Set it right
Installed additional
capacitors to bring up
the PF to 0.995
Got the load reduced
to 1300 KVA
Provided dampers in
each exhaust duct and
control the air flow
through speed control
using VFDs
Installed T5 (28 W)
having electronic
chokes
Sun control films
installed on the
windows exposed to
sunlight.
Sr. No.
1
2
3
4
5
6
7
8
441
A few other major steps were as under
Hospital was being billed under HV2 category by UPSEB and got it revised to
HV 1 tariff category. With a saving of around 0.30 paisa per unit.
In-house laundry operations were observed to be around Rs.14 a Kg and the
same was outsourced at Rs.9 per Kg.
Timers installed for lightings / Heaters installed in Auto claves to ensure the
stoppage of steam boilers / HT Incomer thoroughly maintained by UPSEB /
Condenser and cooling towers thoroughly cleaned and maintained the delta T
by replacing the fills in the CT etc.
The combined efforts / results of the complete audit actually surprised us as
well since the energy cost was substantially reduced.
Something or the other is always being done to bring the energy consumption
lower each month.
Going forward, Hospital is in discussions with few of the LED manufacturers to
convert all lightings into LED under the ESCO mode and are even trying to get
this project registered with UNFCCC under the CDM project in order to gain
CERs, which shall bring the nation a good name internationally.
With the implementation of the above project, Hospital shall be in position to
conserve at least 15 to 20% of its energy consumption.
442
443 443
MUNICIP MUNICIP
MUNICIP MUNICIP MUNICIPALITIES ALITIES
ALITIES ALITIES ALITIES
MUNICIP MUNICIP
MUNICIP MUNICIP MUNICIPALITIES ALITIES
ALITIES ALITIES ALITIES
444
445
Second Prize Municipalities
VADODARA MUNICIPAL CORPORATION
Street Lighting Department
Vadodara (Gujarat)
Municipality Profile
Vadodara Municipal Corporation was formed in 1966. Vadodara Municipal
Corporation has implemented Energy Conservation measures in Street Light Service
since 1992-93. The measures have been implemented as a part of day to day
activities of the streetlight department. Total area of coverage of Vadodara Municipal
Corporation is 160 Sq. Kilometers and total population of the municipal is 18 Lacs
(2010-2011). 1745 kilometers of street lighting is covered in vadodara (2010-
2011). Vadodara Municipal Corporation is the first in the country to implement
international level lighting, lowest life cycle cost of the entire project & GSM based
intelligent street light controller.
REDUCTION ACHIEVED IN SPECIFIC ENERGY
CONSUMPTION kWh/KW LOAD
YEAR KWH IN LOAD IN SPECIFIC ENERGY
Million KW CONSUMPTION
kWh (unit) / KW(load)
1999-00 15.8 3650 4329
2000-01 17.8 4160 4279
2001-02 18.8 4370 4303
2002-03 17.1 4500 3800
2003-04 17.5 4680 3740
2004-05 18 4960 3630
2005-06 18.9 5160 3663
2006-07 19.7 5380 3662
2007-08 20.5 5610 3655
2008-09 22.21 6400 3471
2009-10 23.48 7200 3262
2010-11 23.83 8100 2942
Specific energy consumption mentioned in table is overall specific energy of the
streetlight installations of entire city. The load connected with intelligent streetlight
controller with dimming facility has specific energy consumption 1686kWh/kw/
annum. VMC intends to implement intelligent streetlight controller with dimming
facility for entire street lighting load within three years, it will help to achieve
further energy savings and will result into reduction in specific energy consumption
much below 3000 kWh/kw/annum and reduction in associated carbon emission.
446
447
Summary of Energy Conservation Measures Implemented
1. Design based Lighting with dimming technology during off peak hours. [58%
Energy efficiency by Improving 300% service delivery compared to
conventional installations]
2. Conversion of T12 FTL(40W) into T8 FTL(36W) &Procurement of low watt
loss (9W) Ballast. [Energy savings 1.513 million kWh during 2010-2011]
3. Conversion of HPMV into HPSV (Lamp selection based on lumen efficacy) &
Procurement of low watt loss Ballast.
[Energy savings 1.624 million kWh per every year &2.125 million kWh
during 2010-2011]
4. Material procurement and testing as per relevant Indian standard with
Government approved lab ERDA. [Material Procurement cost decreased
from Rs. 111.00 per luminary in the year 2005-06 to Rs. 71.05 per
luminary in the year 2010-11].
5. Streetlight Installation policy is based on IS 1944 (part I & II), 1970, sanctioned
by General Board of the Corporation. (VMC is the only city in the country to
implement this policy)
6. Time management. (7% to 10% saving potential)
7. Installation of Microprocessor Based Intelligent Street Light Controller with
GSM technology for data transfer (SCADA). (VMC is the first city in the country
to implement SCADA in street light service.)
8. VMC has implemented decorative lighting during the year 2010 which improves
daytime aesthetic value of the city.
Pictures of Important Tourist Places of Vadodara city & Energy
Initiatives taken
1. Design based v/s Conventional lighting:
448
2. Design based lighting:
3. Lighting Effect of Design based Central lighting:
449
4. GSM based Annual Programmable Energy Saver Unit:
Energy & Environment Policy
The energy efficiency measures have been implemented as a part of day to day
activities of the streetlight department with the involvement of Executive Engineer,
Dy. Executive Engineer, Additional Assistant Engineer and Foreman (Head of the
maintenance team). Energy efficiency is considered before project planning phase,
which avoids additional investment for energy efficiency after project implement.
Most of the energy efficiency measures are NO Cost measures.
450
Certificate of Merit Municipalities
SURAT MUNICIPAL CORPORATION
Hydraulic Department
Surat (Gujarat)
Municipality Profile
Surat Municipal Corporation is presently supplying 760 MLD potable water through
four Water Treatment Plant (also known as Water Works) and 17 numbers of
Water Distribution Station. Surat City has population of 45 Lacs. 82 % of population
is covered under piped network.
Water is taken from River Tapti through Intake well / French well. Water Treatment
Plant mainly consist Cascade Aeration Unit, Stilling chamber, Partial Flumes, Flash
Mixtures, Clarifier Inlet channel, Sludge Blanket Lamella Clarifier, Rapid Gravity
Sand Filter Bed etc. With these various units treatment of raw water is done by
Pre-Chlorination, Primary treatment and Filtration up to the standards of safe
drinking water. Transmission of treated water is done from Water Works to various
Water Distribution Stations located in different parts of the city via Transmission
pipelines and from Water Distribution Station to consumer through Piped Water
Distribution Network.
451
Sarathana Water Works is supplying 300 MLD and Head Water Works is supplying
50 MLD every day which meet 46 % of Surat need of Water Supply. Head Water
Works is oldest Water Works of Surat established in 1898. Both Water Works
consume 201 Lacs KWH per annum which is 26.42% of energy consumption of
entire water supply system.
Water is the basic need for human being and hence it is inevitable need. Water
Supply is consuming 54 % of total electricity need of SMC. Also around 55 % of
total operation and maintenance expense for water supply system is consumed
by electricity. Wind Energy is renewable energy and practically no fuel cost and
hence if Electricity generated from Wind Energy is used for Water Supply, it will
make Water Supply more economical and environment friendly which shall help
Surat City to make it Self Sustainable City.
Specific Electricity Consumption
Sarathana and Head Water Works are supplying water in Surat City. The reduction
in specific energy consumption is calculated below:
General Description 2009 - 10 2010 - 11
1 Total Area of Coverage Water Supply
(in Sq. kms) 267.74 280.80
Total Area of Coverage of Water Supply
by SWW & HWW (in Sq. kms) 53.28 53.85
2 Population (in Lacs) 42.60 44.50
Population (in Lacs) Covered by SWW & HWW 16.15 16.32
3 Quantity of drinking water pumped in 260.27 272.67
Million m3 /year
Quantity of drinking water pumped by 122.73 125.22
SWW & HWW in Million m3 /year
5 Electricity Purchased at SWW & HWW 201.26 209.29
(Lac kWh)
6 Energy Produced by Wind Machine ----- -21.30
(In Five Months)
7 Net Electricity Consumption (5-6 ) 201.26 188.00
(Lac kWh)
8 Electricity consumption at SWW & HWW 201.26 188.0
(Lac kWh)
9 Electrical Energy Consumption in drinking 0.03078 0.02788
water pumping / Quantity of water supplied/
area of coverage [{6 (e) / 5 (iii)} / 5 (i)]
Lac kWh / million m
3
/km
2
452
2009 2011
Year Electrical Energy Consumption in % Reduction over
drinking water pumping / Quantity of 2009 - 2010
water supplied /area of coverage
(Lac kWh/million m
3
/km
2
)
2009 - 2010 0.03078 --
2010 - 2011 0.02788 9.41%
As the machines were commissioned on 2
nd
Nov. 2011, the energy generated
till March -2011 is 21 lacs KWH. Now energy consumption of both Sarathana
Water Works and Head Water Work in year Year 2009 10 is 201.26 Lacs
KWH. Hence compare to Year 2009-10 energy saving of 10.58 % is achieved.
However in span of one year (irrespective of financial year period). The energy
generated in span of one year from the date of commissioning is 70 lacs kWh.
Hence, from that perspective energy saving in the tune of 34 % per
annum is achieved.
Measure :
Use of Wind Energy for Water Supply System in Surat City.
453
Objective behind the Measure
Surat Municipal Corporation is committed to achieve the long term goal of
making Surat City as Self Sustainable City from energy perspective.
Therefore, SMC has made focus on promotion of energy efficiency and renewable
energy in all areas.
Water is the Most Important Basic Need of Human Beings and first priority for
Municipal Corporation to provide quality water supply to every citizen of Surat in
time and in required quantity. In Surat, Water Supply System consumes around
54% of total electricity consumption of Surat Municipal Corporation. 76 million
KWH is consumed in water supply, sewage system consume around 21% energy
i.e. 31 million KWH and Street light consume 17% of energy i.e. 25 million KWH.
Hence SMC has decided to take path breaking step in Water Supply System by
establishing Wind Power Project. SMC is the first corporation in India who has
established 3 MW Wind Power Project for Catering the electricity need of
Sarathana Water Works and Head Water Works.
Whatever energy is generated at Wind Power Plant is being wheeled to User
Facility i.e. in case of SMC it is Sarathana Water Treatment Plant and Varachha
Water Treatment Plant. As per Gujarat Electricity regulatory Commission order,
10 % of Electrical Unit Generated is being deducted towards wheeling losses.
454
Wind Power Plant Details
There are Two Numbers of 1.5 MW Wind Machines installed at Adodar site, Village
Gosa, Dist Porbandar. Land of around 1 hector is taken on lease basis near the
sea bank of above location. The Wind Machines are numbered as ADO 22 & 24.
Each Wind Machines has 78.5 m hub height having Rotor diameter of 82 m.
Length of three blades is 40.25 m. It starts to produce generation of electricity at
Wind Speed of 4 m/s and it produces its rated output of 1500 kW at 12 m/s. It
gets stops when wind speed is going beyond 20 m/s. These wind machines are
supplied, erected, commissioned and operated by Suzlon Energy Ltd. (Model: S
82, 1,500 kW).
Energy is generated at 690 V (3 phase, 50 Hz) and it is converted to 33 kV
through Transformer located in vicinity to WTG. 33 kV transmission lines is laid
from WTG to Adodar Substation and their it is convert from 33 kV to 66 kV and
fed into GETCO Grid.
SMC has also undertaken the process of availing CDM benefit for this project.
Important Financial Aspect of Project
Total capital expense: 18.46 Crores (for 3 MW)
Total O & M expense up to 10 years: 3.76 Crores (for 3 MW)
Present transmission charges for 3 MW: 29.48 lacs per annum
Insurance charges for 3 MW: 2.86 lacs per annum
Other charges for 3 MW (GEDA, Electrical Inspection etc.): ~ 1.00 lac per
annum
Total Expected Effective Average Energy Generation (at Meter) per annum:
64.03 Lac kWh
Wheeling Charges: 10% of energy generated at Wind Farm
Total Expected Net Energy Available for Use (For 3 MW) per annum: 57.63
Lacs kWh
Expected reduction in electricity bill at prevailing energy rate: 2.83 Crores
per annum
455
Second Year Total O & M expenses: 36.75 lacs per annum
Escalation in O & M expenses per annum: 5 %
Consultancy Fees: 6.75 lacs
Expected simple payback period: 7.10 years (W/O CDM Benefits)
Expected payback period with 8% interest rate per annum: 10.09 years (W/
O CDM Benefits)
Actual Performance of Project:
The Wind Power Project was commissioned on 2
nd
Nov. 2011. Recently it has
completed one year of operation. Hence revised data are produced here:
Energy Generated in 12 months: 78.34 Lacs kWh (against expectation of
64.03 Lacs KWH)
Energy Used at Sarthana & Varachha WW: 70.50 Lacs KWH (against expectation
of 57.63 Lacs kWh)
Gross Amount Saved : 350.78 Lacs, Net Amount Saved: 316.15 Lacs
Other Important Energy Conservation Measures ( Year 2010 -11)
SMC has generated renewable energy of 68.73 Lacs kWh through four number
of Bio Gas Based Power Plant installed at various Sewerage Water Treatment
Plant in year 2010 -11
SMC has installed 3200 numbers of energy efficient street light system in new
area which has saved 2.51 Lac kWh in year 2010 -11.
50% Light are kept OFF on 155 major road during low traffic hours i.e. from
12:00 AM to morning which has resulted in energy saving of 15.38 Lacs kWh.
With the help of 17 numbers of Energy Conservation Feeder Pillar based on
Voltage Reduction Principal which reduces voltage during low traffic period
resulted in energy saving of 2.73 Lacs kWh in street light system.
LED based traffic system has saved 2.76 Lacs kWh in year 2010-11.
456
EEC Goals Towards Energy Efficiency
To promote the Energy Efficiency through identifying various energy
conservation projects and to carry out the feasibility of energy conservation
project.
To promote the use of renewable energy in various Municipal Services.
To do feasibility study for own power generation through conventional and
non conventional sources of fuels.
To conduct Energy Audit of all electrical facility having contract demand load
more than 75 KW as per Gujarat Use of Electrical Energy (Regulation) Act
1999 through external Energy Auditor approved by Government of Gujarat.
To conduct in house Energy Audit through own Team.
To find out sources for procuring power at lowest possible price.
To monitor the usages of electricity of corporation.
457 457
ST ST
ST ST STA A
A AATE TE
TE TE TE
DESIGN DESIGN
DESIGN DESIGN DESIGNA A
A AATED TED
TED TED TED
AGENCIES (SD AGENCIES (SD
AGENCIES (SD AGENCIES (SD AGENCIES (SDA A
A AAs s
s ss) )
) ))
ST ST
ST ST STA A
A AATE TE
TE TE TE
DESIGN DESIGN
DESIGN DESIGN DESIGNA A
A AATED TED
TED TED TED
AGENCIES (SD AGENCIES (SD
AGENCIES (SD AGENCIES (SD AGENCIES (SDA A
A AAs s
s ss) )
) ))
458
459
First Prize State Designated Agencies (SDAs)
PUNJAB ENERGY DEVELOPMENT AGENCY
Chandigarh
SDA Profile
Punjab Energy Development Agency (PEDA) was formed in Sept. 1991 as a State
Nodal Agency for promotion and development of New & Renewable Energy sources
in the State of Punjab under the guidelines of Ministry of New & Renewable Energy,
Govt. of India.
The Government of Punjab has also declared PEDA as the State Designated Agency
(SDA) to co-ordinate, regulate and enforce the Energy Conservation Act-2001 in
the State of Punjab in April, 2005 as per clause 15(d) of the Act under the guidelines
of Bureau of Energy Efficiency (BEE), Ministry of Power, Government of India.
PEDA has contributed various important initiatives / projects for the promotion of
Renewable Energy & Energy Efficiency in the State of Punjab. PEDA has been
conferred with National Energy Conservation Award in appreciation of their efforts
in energy conservation in the State Designated Agency sector for the year 2008.
460
PEDA has also become the State Agency for the Renewable Energy Certificate
(REC) accreditation in the state of Punjab under the recent notification dated 30
th
November, 2010 by Punjab State Electricity Regulatory Commission (PSERC) in
accordance with the REC Regulations of Central Electricity Regulatory Commission
(CERC).
Power Scenario in Punjab
Punjab is aggressively pushing for major capacity addition of power generation to
cover the current and anticipated shortages due to the growth of the economy.
POWER SCENARIO OF PUNJAB
INSTALLED CAPACITY 6510.1 MW
TOTAL ENERGY SALES 30682.97 MU
PEAK DEMAND 8672 MW
PEAK MET 7340 MW
PEAK DEFECIT/ SURPLUS -1332 MW (-15.4 %)
ENERGY DEFECIT/ SURPLUS -3577 MU (-8.4%)
State NRSE Policy-2006 (Targets)
To add generation capacity of 1000 MW by the year 2020 bringing the share
of NRSE to the level of 10% of conventional power.
To motivate all sectors of the economy to ensure conservation of energy to
the extent of 20% within the next 20 years.
461
Major Projects
Solar Passive Complex - An Excellent Energy Efficient Building.
Bureau of Energy Efficiency has labelled PEDA Solar Passive
Complex (office building), Chandigarh as "BEE 5 Star" on 1st
October, 2010 under the office building category in the composite
climatic zone. This building is unique both in terms of energy
efficiency and environment friendly.
It is the centre of Excellence of a solar building integrating natural
light and air with built in light vaults, solar photovoltaic power
plant, water bodies and environment friendly landscaping.
Mini Hydel Power (30 projects) - 36.90 MW Solar photovoltaic power (7 projects) -2.375MW
Waste to Energy (1 project) - 1 MW Biomass power (4 projects) - 40.5 MW
Cogeneration (27 projects) - 278.85 MW Solar Water Heating Systems - 15.50 lacs LPD
462
Energy Consumption & Energy Saved In 2010 - 11
Electricity Consumption in MU in the state 32,231.72 MU
Energy saved in MU by carrying out EC activities 778.02 MU
% Saving 2.41 %
State Govt. Notifications / Regulations
20.1.2006 Mandatory use of Solar water heating systems in buildings having
area of more than 500 sq yds, Compact fluorescent lamps (CFLs), BIS marked
pump-sets in govt. & private sector, Promotion of Energy Efficient Building
Design.
6.12.2007 Mandatory use of CFLs on Agri-pump set sites
22.8.2007 - State Govt. directive to replace incandescent bulbs with CFLs in
all govt. Buildings and offices.
17.3.2008 State Level Energy Conservation Action Plan Team (ECAT)
463
11.9. 2009 For creation of Energy Conservation Cells in all departments.
9.10.2009 Containing instructions to all the departments for implementation
of notification regarding mandatory use of CFL, SWHS, BIS Pump-sets and
promotion of energy efficient buildings.
22.2.2010 For constitution of Punjab State Energy Conservation Fund
(PSECF) Rules.
5.7.2010 For constitution of State Level Steering Committee (SLSC) to
provide guidance and support for the operation of PSECF.
7.10.2011 Mandatory use of minimum BEE 4 star labeled and ISI marked
motor pump sets, Power capacitors, Foot/Reflex valves in Agriculture Sector
Energy Efficiency Demo Projects
Municipal Street Lighting (LED Based) at MC, Majitha, 170 LED street lights
(30W & 40W) having annual energy saving potential of 0.79 lacs Units (80%).
Revamping of drinking water supply pumping system at Mai Bhago Polytechnic
College for Women, Amritsar having annual energy saving of 48.7%.
Five government buildings Pb. Mini Secretariat, DAC Ludhiana, Patiala, Sangrur
and Bathinda having annual energy saving potential of 9.59 lac units with
payback period of 26 months.
Five Municipal Corporations Amritsar, Bathinda, Jalandhar, Ludhiana and Patiala
having annual energy saving potential of 57 MU with payback period of 5
years.
SME clusters steel re-rolling mills, Mandi Gobindgarh and textile mills, Ludhiana
under USAID / IRG ECO-III project having annual energy saving potential of
15% to 20% with payback period of 1.5 to 2 Years.
Area light / street light (LED based) of Sirhind Mandi, Punjab.
Other Important Energy Conservation Activities
Formulated five year Energy Conservation Action Plan (2007-2012) and
substantive activities undertaken with financial assistance from BEE i.e. IT
support, Technical assistance / consultancy / survey, workshops / training
programs / manuals, Publicity / awareness and Demo projects.
PEDA conducted Investment Grade Energy Audit (IGEA) of 24 Govt. / Public
buildings for implementation of energy efficiency projects.
PEDA conducted Investment Grade Energy Audit of two big institutions i.e.
Punjabi University, Patiala and National Institute of Pharmaceutical Education
& Research (NIPER), Mohali covering all areas such as buildings, water pumping,
464
street lighting, sewerage pumping etc. having saving potential of 1.21 MU &
0.51 MU respectively.
PEDA has established Energy Information Centre (EIC) at Solar Passive
Complex, Chandigarh.
Painting competitions for school children of 4th, 5th & 6th standard have been
organized during 2009-10 & 2010-11.
Brochures (Folders) on energy conservation in Punjabi & English were
distributed among various stake holders during the meetings, seminars,
conferences, trainings and workshops
Note-book stickers, car stickers and time tables on the theme of energy
conservation were distributed in the schools.
Survey of Commercial Buildings as Designated Consumers in the State of
Punjab which fall under Energy Conservation Act, 2001.
Report on Impact of Energy Conservation Act-2001 in the State of Punjab.
Survey, Compilation & Analysis of data of Rice Shelling Mills in Punjab.
Survey conducted for identification of Designated Consumers as per guidelines
of the Bureau of Energy Efficiency, MOP, GOI.
Prepared and published Annual Year Book on Energy Conservation Measures
in the state of Punjab.
Motivate the industrialists for energy efficiency and to participate in National
Energy Conservation Awards. 72.65 MU were saved in the Energy Intensive
Units in last two years.
Awareness of energy conservation created among the people through press
advertisement, school lectures through field staff, display of Mobile Exhibition
Van, bus panels and radio jingles.
State Level Energy Conservation Day has been celebrated in association with
PSPCL on 14th December, 2010.
Interactive meeting with Certified Energy Manager / Accredited Energy Auditors
and Designated Consumers has been organized.
PEDA in association with PSPCL initiated the implementation process of Bachat
Lamp Yojna (BLY) CDM based CFL scheme launched by BEE, GOI. PSPCL
being the utility is in the process of finalization of distribution of CFL in domestic
sector in the state and it is expected the distribution will start in the month of
November / December, 2011.
465
Initiated the process of implementation of Pilot Agricultural Demand Side
Management (Ag-DSM) Project of 2186 agriculture pump-sets in district
Muktsar and Tarn-Taran, Punjab. Estimated annual energy saving potential of
7.38 MU with payback period of 2 to 3 years.
Organized one day workshop on Sustainable Building Design at Chandigarh.
Organized Training Programmes for Designated Consumers for Annual
Reporting of Energy Data.
PEDA in association with CII organized International Conference & Exposition
on Renewable Energy Agenda for the North New Approaches for Green Energy
and Energy Efficiency.
State Level Energy Conservation Awards were distributed during a function.
Organized state level conference / meeting on energy conservation to discuss
joint progress with certified energy managers, certified energy auditors and
designated consumers on 16 March, 2010 and 5th October, 2011 at PHD
Chamber of Commerce & Industry, Sector 31-A, Chandigarh.
PEDA in association with PHD Chamber of Commerce and industry organized
a seminar on Energy Conservation and Management on 30.7.2010 at
Ludhiana for SMEs
Organized State Level Conference on Energy Conservation in Various Sectors
of the Economy on 18.01.2011 at Chandigarh, inaugurated by Dr. Ajay Mathur,
Director General, BEE, MOP, GOI. The aim of this conference was to bridge the
information/knowledge gap on energy conservation / energy efficiency activities
being carried out in the state, role and responsibilities of SDA and different
departments/organizations.
Awards & Appreciations
PEDA has been awarded commendation certificate on national energy
conservation day celebration i.e. on 14th December, 2008 by Ministry of Power,
Govt. of India, in appreciation of their efforts in energy conservation activities
in the State Designated Agencies Sector for the year 2008.
PEDA has been awarded with Second Prize on National Energy Conservation
Day celebration i.e. on 14th December, 2010 by the Ministry of Power, Govt.
of India in appreciation of their efforts in the energy conservation activities in
the State Designated Agencies Sector for the year 2010.
Honble Chief Minister, Punjab conferred State Award to Senior Manager (Energy
Conservation), PEDA on the occasion of State Level Independence Day
Celebration Function held on 15
th
August, 2011 at Amritsar recognizing his
services in the field of energy efficient building design and energy conservation
activities in the state.
466
Second Prize State Designated Agencies (SDAs)
RENEWABLE ENERGY DEPARTMENT, HARYANA
& HARYANA RENEWABLE ENERGY
DEVELOPMENT AGENCY (HAREDA)
Chandigarh
SDA Profile
The Department of Renewable Energy, Haryana is mandated to plan, formulate
policies and implement following programmes in the State:
1. Renewable Energy Programmes including generation of Power from
Renewable Energy Sources
2. Implementation of Energy Conservation Act, 2001.
3. Demand side management
HAREDA has been set up under the administrative control of the Department to
assist it in speedy implementation of the programmes. An Energy Conservation
Cell has been created in the Department /HAREDA for implementation of EC
Programmes in the State.
Energy Consumption in Haryana State
Sector Total Savings In MW Savings
Consumption Potential Potential
(Million Units) (Million Units) in %
Agriculture 7168 2150 352 30
Domestic 3772 754 123.5 20
Industrial 5440 1360 222.9 25
Commercial 1181 236 38.6 20
Others 1709 256 41.9 15
Total 19290 4756 779.5
(Source : Haryana Statistical Abstract 2008-09)
467
Various Energy Conservation Measures in the State have resulted in avoiding of
capacity addition of conventional power of approx. 86 MW during 2010-11 in the
State. Sector wise initiatives are listed below:-
Energy Efficiency In Lighting
About 25% of the Energy Consumption in the State is for the lighting purposes
and the Govt. offices are a major consumer of electricity for this purpose. Haryana
is the first State in the country to have decided to replace the ordinary bulbs
and conventional tube lights with energy efficient lights by 1.1.09 in all Govt.
offices & buildings.
Accordingly, the Department of Renewable Energy, Haryana/ HAREDA finalizes a
rate contract of energy efficient lightings ( including CFLs and T-5 tube lights)
to enable the Govt. Departments / Boards & Corporations to carry out the purchase
of CFLs & T-5 tube lights.
During 2010-11, 10205 CFLs and 16271 T-5 tube lights were replaced in
Govt. buildings resulting in saving of 2.09 million units of electricity annually. So
far 1, 22,705 CFLs & 1, 30,771 T-5 energy efficient tube lights have been
got replaced in the state in Govt. buildings.
Energy Efficiency In Agriculture Sector
Agriculture sector is the most energy consuming area (40%) in the State.
Inefficient agriculture pump sets while consume more electricity and draw less
water on one hand, they increase the burden on the State Govt. in the form of
power subsidy. Haryana was the first State in the country to mandate use of ISI
marked pump sets and accessories in 2005.
Now, Haryana has become the only State in the country where use of BEE star
rated pump sets (with minimum 4 star rating) has been made mandatory for new
tubewell connections as an agriculture DSM measure with effect from 7
th
October 2010. During the year 2010-11, 27901 star rated/ISI marked pump
sets were installed by the power utilities which resulted in saving of 219.31 MU of
electricity translating into a saving of Rs. 919.00 crores in the electricity bills
annually and reduction of 164263 tones of CO2 emission.
Energy Audit & Energy Efficiency In Buildings
1) Energy audit of 10 Govt. buildings completed indicating a potential energy
saving of 26,484 kWh per year. Suggested action plans were implemented
by the concerned departments on their own. Energy audit of Haryana Raj
Bhawan completed and implemented resulting in saving of 1.20 Lacs units
of electricity amounting to Rs. 3.60 lacs with an investment of Rs.16.16
lacs. Energy audit of CM residence completed and implemented with an
468
investment of Rs. 6.67 lac which has resulted in annual savings of 60000
units of electricity amounting to Rs. 2.70 lac annually with a payback period
of 3 years.
2) Investment grade Energy Audit study of 41 large Govt. Buildings
completed at a cost of Rs. 15.84 lac & is under implementation by the
building owners. These projects will result in saving of 2.41 million units of
electricity per annum with an investment of approx. Rs. 9.65 cr. with a
back period of about 18 months.
3) Realizing the potential for Energy Conservation in the building sector, the
Energy Conservation Building Code (ECBC) has been circulated to line
departments for adoption.
4) The Haryana Govt. has taken an in principle decision to adopt the Energy
Conservation Building Codes (ECBC) launched by the Bureau of Energy
Efficiency Govt. of India in July 2007.
5) A Handbook on Energy Conservation in Building Sector in Hindi & English
both has been printed for creating awareness and has been distributed among
the general public.
6) In an initiative to develop replicable prototypes of energy efficient
buildings, HAREDA has got modified the standard building designs of
following Govt. buildings by experts like TERI :
a) Mini Secretariat Complex
i. Admn. Block
ii. Judicial Block SDO Civil Comple (Admn. Block), Hansi
b) Community Health Centre (CHC)
c) Standard House of 1220 Sft. Type-IV
d) Community Centres of HUDA
These modified building designs are being used by the Architecture Deptt./
PWD for construction of above categories of buildings.
7) Haryana is the first State in the Country where new scheme for energy
audit has been introduced in the financial year 2009-10 for promoting
investment grade energy audit in private, Govt., Semi-Govt., industrial,
Institutional and commercial buildings. Under the scheme, owners of
the buildings shall be provided financial assistance @ 50% of the investment
grade energy audit cost with maximum limit of Rs. 50,000/- provided,
they undertake to implement the energy audit report. Under this scheme,
financial assistance has been provided to 19 industries/ institutions/
commercial buildings.
469
8) The Department has organized a Two days Training on ECBC & Green
Buildings on 15
th
and 16
th
July, 2010 at Retreat Gurgaon. This training
was attended by 51 participants. Another training programme on ECBC was
organized on 16-17 February, 2011 at Faridabad which was also attended
by 51 participants from the NCR region.
9) To crosscheck / verify the drawings of the Department of Architecture, Haryana
as per ECBC through BEE empanelled architects/ consultants, BEE, GOI /
HAREDA shall provide a sitting fee of Rs. 10,000/- per day to that
Architect / Consultant. Accordingly, the Deptt. of Architect, Haryana has
been informed for taking necessary action in the matter.
10) State Level Technical Committee (STC) has been constituted to recommend
the amendments in the building bye-laws and revision of the HSR to
incorporate Energy Conservation Building code (ECBC) and notified in the
Gazette of Haryana Govt. on 28.01.2010.
11) On the request of the Department, the BEE, GOI has provided the services
of TERI for amending the building bye-laws. The recommendations
regarding the specific modification of Municipal Building Byelaws and HUDA
received from TERI have been forwarded to Stakeholders Departments
for their comments so that same may be examined and discussed by Sub
Committee.
12) Haryana is the first State in the country to incorporate the energy
efficient building material, Electrical items, and Solar Water Heating System,
in the Haryana Scheduled of Rates (HSR) to implement ECBC in the
state. The meeting of the Direction Committee held on 14.10.10 has
approved them, in principle, and accordingly the same have been included in
HSR through Notification dated 4
th
November 2010.
13) For demonstration of designing & construction of 5 star GRIHA rated /
ECBC compliant building, Deptt. is constructing its office building Akshay
Urja Bhawan at Sector -17, Panchkula.
14) On the occasion of celebration of State Level Energy Conservation Day on
18
th
December, 2009 Honble CM, Haryana has announced to award Rs.
2.00 lac & Rs. 1.00 lacs to the architect for designing 4 star & above
and 3 star rated building respectively.
Energy Conservation in Industrial Sector
Haryana has six clusters of various industries where there is a potential of improving
energy efficiency through heat recovery. These clusters are:
a) Faridabad - Light Engineering
b) Rewari Aluminum and Brass Industry.
470
c) Panipat Textile Industry
d) Yamuna Nagar Plywood & Steel Rolling
e) Karnal Rice Mills
f) Gurgaon- Auto ancillary
In the first step, willing and potential industrial units in four of the six SME
clusters namely, Faridabad, Gurgaon, Rewari, Panipat & Karnal were identified
for energy efficiency campaign with financial assistance of Rs.2.0 crore from the
BEE under the State Energy Conservation Fund(SECF). The potential industries
were identified through interaction meets and thereafter preliminary Walk Through
Energy Audit (WTEA) was conducted in 40 identified units in each of the five
clusters. Walk through Energy Audit involves preliminary investigations about the
process, fuel consumption and assessment of the energy saving potential.
Interactive meet at Faridabad, Karnal, Gurgaon and Rewari organized with
expenditure of Rs.3.00 Lacs. Sanction of financial assistance of Rs.19.2 Lacs has
been given to 200 industries of Faridabad, Gurgaon, Karnal, Rewari and Panipat.
WTEA report of 179 industries of Faridabad, Gurgaon, Rewari and Panipat have
been received. Analysis of WTEA reports of Faridabad, Rewari and Gurgaon district
have been done.
In the second step, 30 potential industries were to be selected for detailed
energy audit on the basis of their response, scope of energy efficiency gains,
expert recommendations and participation. The detailed energy audit is proposed
to be conducted with 75:25 cost sharing basis with HAREDA support limited to
Rs.1.5 lac per unit provided the units undertake to implement the techno-
economically feasible recommendations. Sanction of financial assistance of
Rs.12.75 Lacs has been given to 12 industries of Faridabad and Gurgaon.
In the third step, two best detailed energy audit reports (total eight) will
be selected for developing them as demonstration projects on waste recovery
through WHRB, Recuperators, Economizers, Automatic voltage Regulators, Power
capacitors etc. with 75:25 cost sharing basis. The financial assistance to the
SMEs will be limited to Rs.7.50 lac per unit.
In the fourth step, HAREDA shall prepare a demonstration manual based
on success stories of the demonstration projects and shall disseminate the results
of the demonstration projects through interactive workshops so that similar
projects may be replicated. Detail of these activities has been included under
SECF activities.
DSM Measures
Solar water heating technology is a viable commercial technology for water
heating applications. The State Govt. is promoting solar water heating systems
as a DSM measure also. The installation of 1000 solar water heating systems
(SWHS) of 100 lpd capacity contribute to peak loading saving of 1 MW and each
100 lpd system contributes to 1.5 tons CO
2
emission reduction. To promote
SWHS following schemes have been initiated in the State:
471
1. Rebate in electricity bills for domestic users Rs.1200/- per year for 100
lpd system, Rs.2400/- for 200 lpd system & Rs.3600/- per year for 300 lpd
system or more for three years.
2. On domestic solar water heater Capital subsidy upto Rs.8000/- for all
Haryana residents and Haryana Govt. employees living in Chandigarh.
3. Haryana is the only state in the country where 70% financial assistance
is provided on installation of solar water heating systems in social sector
charitable institutions like Working Women Hostel, Destitute Childrens
Home, Deaf & Dumb Rehabilitation Centers, Sports Hostels, Hostel for the
SC students etc.
During 2010-11, solar water heating systems of approx. 500000 LPD
capacity were installed in the state which is the highest capacity installed in the
state in a year. So far, approx. 2342 systems of approximately 21,00,000
lpd have been installed ( as on 31/3/11) in the State resulting in a saving on
31.5 Million kWh of electricity annually translating to a peak load shaving of 21
MW and reduction of CO2 emission by 31,500 metric tonnes annually.
ESCO Projects
Haryana is the first State in the Country where ESCO projects have been
conceptualized, designed and implemented by the State Designated Agency
on its own. HAREDA has implemented ESCO projects in the Municipal Council,
Hisar & the HUDA, Panchkula successfully in 2008-09.
1) In MC, Hisar 5405 street light points have been replaced with energy
efficient lighting fixtures resulting in 59.30 % saving in the energy
consumption and over all saving of Rs.18.00 lacs due to reduced electricity
bills and avoided O&M costs.
2) In HUDA, Panchkula, 5273 street light points have been replaced with
energy efficient lighting fixtures resulting in 66.15 % saving in the energy
consumption and over all saving of Rs. 61.77 lacs due to reduce electricity
bills and avoided O&M costs.
3) An impact assessment study of the Hisar project, carried out by M/s NITCON
in 2009 indicates that the implementation of the project has resulted in
saving of 13.41 Lacs KWH of energy per annum and a monitory benefit
of Rs.67.00 Lacs per annum.
4) In Panchkula, 16.96 Lacs units of electricity could be saved annually
after implementation of the project.
472
Implementation of EC Act 2001
1) Survey of 19 designated consumers in the state completed and the survey
of 715 other probable designated consumers and commercial buildings is
under process. Lists of 119 Energy Managers and 136 Energy auditors
of the state prepared. The study shows that out of these, only 12 energy
managers and 41 energy auditors are active in the area of energy
conservation. The study conducted by M/s NITCON shows that 6 energy
audit firms and 3 energy service companies are located in the State. The
study also identified 114 commercial buildings with load above 500 kW in
the State out of which 77 are in the Gurgaon region.
2) Trainings for designated consumers on e-filing of annual energy returns
organized on 11.06.10 and 22.06.10 at Murthal (Sonepat) and Gurgaon
respectively. Director, HAREDA also participated in a training programme for
the SDA personnel of UPSDA on 23.8.09 at Lucknow as key resource person.
3) During 2009-10 sale of 25,560 Star Labeled refrigerators and 7,310
Star Labeled air conditioners was reported from 5 districts contributing to
saving of 23.2 MUs of electricity annually. During 2010-11 sale of 55000
Star Labeled refrigerators and 15500 Star Labeled air conditioners
was reported contributing to saving of 49.92 MUs of electricity annually.
4) Impact assessment study of EC measures taken up for the year 2009-
10 conducted by the HAREDA shows a saving of 165 MW through various
energy conservation measures in the State. During 2010-11, energy savings
of about 86 MW was achieved due to implementation of various energy
conservation measures.
Publicity & Awareness
In order to create awareness among the masses an interactive radio programme
called HAREDA Urja Mantra is being aired from the AIR FM, Chandigarh twice a
week since 4.11.08 and the programme is receiving very good response.
In addition to this, publicity campaign through press advertisements, radio
jingles, wall paintings, hoardings, workshops and seminars, brochures,
pamphlets, electricity bills and T.V films is being carried out regularly.
School Outreach Programmes
An innovative Bal Urja Rakshak Mission (BURM) was launched on the occasion
of state level energy conservation day function on 18.12.08 at Gurgaon by Honble
Power Minister, Haryana with an objective to sensitize students of 8
th
and 9
th
standard in the areas of energy conservation, Renewable Energy, climate change
and sustainable development. Under this programme, following activities are
being undertaken:
473
1) Activities like essay writing, slogan writing, painting, quiz, working
models/projects and competitions on various forms of energy and its
efficient use, climate change and global warming.
2) Development of a team of dedicated volunteer students known as Urja
Rakshak who shall undertake to organize these activities in their schools/
homes and neighbourhood/community.
3) Training of Urja Rakshaks in conducting energy audit of their schools/homes
and community and developed a habit of energy saving while learning.
4) Celebration of festivals like Baisakhi, Holi, Diwali, Raksha Bandhan etc. as
Urja Utsavs with awards and recognition to best performers on the themes
of Renewable Energy and Energy Conservation and related issues.
5) Urja Rakshaks to act as energy warriors to create awareness against
energy theft.
During 2010-11, the BURM programme was extended to Panchkula and
Faridabad and in 2011-12, it has been extended to Hisar district.
A State Level Rajiv Gandhi Renewable Energy Education Park has been set
up at the City Centre, Sector-29, Gurgaon at a cost of Rs.2.5 crores to provide
information to the general public and students in particular about renewable energy
sources & Energy Conservation and their uses in day to day life.
In an innovative initiative, HAREDA has set up an Energy Information Centre
(EIC) in the Rajiv Gandhi Renewable Energy Education Park, Gurgaon to
provide advisory services on energy conservation and related issues. The Bureau
of Energy Efficiency (BEE), Ministry of Power, Govt. of India has provided
financial assistance of Rs.7.3 lac for the project and the technical support is being
provided by the French Government. This EIC will be the first such advisory
centre in the country. At the EIC, the visitors will be able to know their energy
efficiency and carbon footprints through interactive exhibits. An exhibit on ECO
Home will demonstrate design of an energy efficient home. The exhibits are being
prepared by M/s Biodiversity Conservation India Ltd.(BCIL)-Alternative Technology
Foundation (ATF), Bangalore who have been associated by the French Government
for such projects. The EIC continued its energy conservation popularization activities
through interactive meets, workshops and students friendly events.
Initiatives by Power Utilities
1) During 2010-11, 824656 CFLs/ T-5 tube lights were distributed/ installed by
the power utilities under general programme/BPL families programme/ Bachat
Lamp Yojna. Resulting in energy saving of 99.21 MUs.
2) During 2010-11, 27901 tube well connections with energy efficient ISI
marked/ star rated motor pump sets were released resulting in energy saving
of 219.31 MUs of annually.
474
Sr Activity Numbers Total Energy
No. Installed/Sold Savings in MU
1 EC measures by HPGCL at Panipat
Thermal Power Station
i. 8799 T-5/LED lamps
ii. VFD for 55kW/75HP condensate
transfer pump 87991 1.83
2 Distribution of CFLs by
a. UHBVN 1,72,554 nos 17.00
b. DHBVN 1,20,144 nos 11.84
3 Number of BPL families given two
20W CFLs while releasing the
connections
a.UHBVN-2725 5450-nos 0.72
b.DHBVN- 61226-nos. 8.09
4 No. of Star labeled transformers
purchased by UHBVN/ DHBVN 22000 43.36
5 Number of CFLs distributed by
UHBVN under Bachat Lamp Yojna 4,54,483 nos 59.72
3) In 2010-11, 22000 star labeled transformers were procured and installed
contributing to energy saving of 43.36 MUs annually.
4) Use of CFLs for new connections made mandatory.
5) Regarding implementation of the State Govt. Notification dated 25.6.08
on energy efficient lighting in consumers with connected load of 30 KW and
above & all Central Govt./CPSU offices in the State, the Uttar Haryana Bijli
Vitran Nigam has reported that during 2010-11, the premises of 3554 such
consumers were converted to energy efficient lighting premises thereby saving
of about 97.29 MUs of electricity annually. In addition, the Dakshin Haryana
Bijli Vitran Nigam (DHBVN) also reported replacement of 213796 CFLs/T-
5 and 590 LED lamps in their area of operation thereby saving of about
16.45 MUs of electricity annually.
6) For information dissemination, information technology is the most effective
tool. HAREDA initiated redesigning of its website in 2010-11 using
latest web technology. The new website was launched on 25.4.2011 and
is user friendly. An amount of Rs. 2.05 lac was incurred for the purpose.
During the year 2010-11, energy savings of about 643.4 MUs of electricity
equivalent have been quantified as per the detail given at table which
translates to about 86 MW capacity addition avoided.
Quantifications of energy saving in 2010-11 in Haryana
475
6 Number of tubewell connections
released with ISI mark/ Star label
a. UHBVN 20199 nos 158.77
b. DHBVN 7702- nos. 60.54
7 1000 T-5 installed to replace 900 no.
55 watt FTLs and 100 GLS, 50 no.
of 250 watt streets lights replaced
with 45 watt CFLs by HVPNL 0.01
8 Number of premises of consumers
with connected load 30 kW and
above converted in to energy efficient
lighting premises by
a. UH 3554 nos 97.29
b. DH (approx.) 213796
CFLs/T-5, 590 16.45
LED,
9 Energy saving by sale of star labeled 55000
products refrigerators,
15500 ACs 49.92
10 Energy saving by replacement of energy
efficient lighting fixtures in Govt. buildings CFLs 10205, 2.09
T-5 16271
11 Decentralized RE Applications for DSM 0
a. Solar street Lights- 74 Watt each 8663 0.09
b. Solar Power packs-250 kW 3 0.32
12 Installation of Solar Water Heating
Systems as DSM 5.00 Lacs lpd 7.5
13 Biomass co-generation projects 5 80.47
of 10.45MW
14 Small Hydro Projects- 2 MW Sep 2010 1 4.4
15 Biogas based Power Projects : 4 MW 2 23
643.41
LED village project at Shimla Molana, Panipat
The Bureau of Energy Efficiency, Ministry of Power, Govt. of India has provided
funds to the tune of Rs. 15.00 Lacs for converting conventional bulbs & tube
lights of the village Shimla Molana, district Panipat. Under this project, 272
incandescent bulbs of 40W have been replaced with 7 W LED Lamps, 158
incandescent bulbs of 60W have been replaced with 10 W LED Lamps and 466
flurosecent tubelights of 40 W/ 100 W incandescent bulbs have been replaced
with 16 W LED Tube lights. In addition to this, 7 LED street lights of 9 W have been
installed. This has resulted in peak load reduction by about 33 kW and shall result
in estimated annual savings of 72000 units of electricity. The project has been
completed on 20.8.2011.
476
LED Street Lighting Demo Project
HAREDA had developed a Detailed Project Report for LED based municipal street
lighting in the Kalka Town in March, 2009. The Project aims at replacement of
900 nos. of 40 watt tube lights with 24 watt LED street lights, replacement of
150 no. of 250 watt HPSV lamps with 120 watt LED street lights with 7 Micro
processor timers at a total cost of Rs. 70.16 lacs. The project is under
implementation and is likely to be completed by 15.11.2011.
Cogeneration Power Projects
To meet the captive power and steam requirements of the industries, biomass
based cogeneration is being promoted in the industries. During 2010-11, following
five Biomass cogeneration projects of 10.45 MW capacity were commissioned in
the following industries.
Sr. No. Site Capacity
1 M/s Shri. Vishnu Overseas Pvt. Ltd.,
Kaithal 1.5 MW
2 M/s R.P Basmati Rice Ltd, Karnal 0.5 MW
3 M/s Sunstar Overseas Ltd, GT Road,
Behlgarh, Sonepat 1.95 MW
4 M/s REI Agro Ltd, ( Unit-II) Bawal
Growth Centre, Jaliawas, Rewari 2.5 MW
5 M/s Best Food International (P) Ltd,
Village Norata, Tehsil Indri, Karnal 4.00 MW
TOTAL 10.45 W
Haryana Govt. is committed to meet the demand for energy sustainable growth
through clean and green technologies. On one hand new conventional power
generation capacity is being added with the latest technologies, on the other the
Government is promoting energy efficiency and renewable energy. The State
Government has announced renewable energy power policy in November, 2005
which aims at to harness at least 10% of the total capacity addition from
Renewable Energy Sources.
Haryana Govt. has also formulated of 5 year State Energy Conservation Action
Plan in December, 2007 which aims at to achieve energy savings of 500 MW
through energy conservation and energy efficiency measures in the State out of
which approximately 470 MW has been achieved so far. The state has adopted
regulatory measures, awareness and incentives approach to mainstream energy
conservation.
477
Second Prize State Designated Agencies (SDAs)
NAGALAND STATE DESIGNATED AGENCY
Department of Power, Government of Nagaland
Kohima (Nagaland)
SDA Profile
Nagaland State Designated Agency (NSDA) has been set-up under the
Administrative head of Chief Electrical Inspector with a separate Energy Conservation
Cell for effective implementation of Energy Conservation Programmes in the State.
Category 2007-08 2008-09 2009-10 2010-11
(MU) (MU ) (MU) (MU )
Domestic 231.22 213.86 224.16 234.81
Commercial 30.83 28.52 31.7 33.87
L.T .Industrial 12.33 11.41 12.06 13.26
Public lighting 9.25 8.55 8.61 9.16
Public water works 6.17 5.20 6.27 6.30
H.T. bulb 18.50 17.11 17.26 19.33
Total : 308.29 285.15 300.06 316.73
Category-wise energy consumption year-wise :
Power Scenario of Nagaland
a) Installed Capacity 28.5 MW
b) Power through other source 80.5 MW
c) Peak Demand 100 MW
d) Peak met 80 MW
e) Peak deficit 20 MW
f) Total Energy Sales 517.00 MU
Consumption of coal in the State is negligible. Though the consumption of HSD,
LPG, Kerosene, motor gasoline is considerably high, the profile could not be
projected due to non-availability of statistics. On the whole, Electricity accounts
for the major share of Energy Consumption in the State.
478
Brief Note on Activities of Nagaland State Designated Agency up to
2010-11
Publicity / Awareness:
1. An awareness campaign on Energy Conservation was held at the Longkumer
Kilem, Mokokchung town with the Chief Electrical Inspector Er. K.T.Wabang
Ao giving the introductory speech and power point presentation on Energy
Conservation Act 2001 was also made. Er. S.K.Gupta, Superintending Engineer,
Department of Power, Mokokchung delivered a speech on Measures on
Energy Conservation followed by interactions. Stickers, pamphlets and
Booklets were circulated among the participants and the general public. Towards
encouraging the public on Energy Conservation, C.F.L. was also distributed to
all the public of Mokokchung Town.
2. An awareness & publicity seminar-cum- awareness campaign on Energy
Conservation was conducted at the Don Bosco Youth Centre, Wokha. The
programme was primarily aimed on Energy Awareness for the public in General
and the students in particular. Introductory speech and Power Point presentation
on Energy Conservation Act 2001 was delivered by Er. K.T.Wabang Ao, Chief
Electrical Inspector, Nagaland State Designated Agency. Measures on Energy
Conservation was made by Er. N.Mozhui, Executive Engineer (E) Wokha
followed by discussion. Students from many schools participated in the
campaign for Energy Conservation. Prominent citizens / Dignitaries from various
fields attended the programme.
3. As part of the Energy Conservation drive, a three day long awareness- cum-
publicity along with seminars on Energy Conservation was held along with the
premier State Road Show held at Mon Town, Nagaland from 7
th
8
th
April
2010. Advertisements were made to promote Energy Conservation through
local print media. Banners were displayed and large hoardings with Energy
Conservation slogans were erected at prominent location. Wall hanging type
flex banners with energy conservation message were displayed at the energy
conservation stall, Nagaland State Designated Agency (NSDA). LED bulb and
street light were demonstrated on the stall. Promotional materials like folders,
leaflets, Pamphlets, Stickers were distributed to the General public for creating
awareness.
4. During 2009-10 similar promotional materials numbering around 1.50 Lacs
were translated to a few local dialects and distributed through churches and
Local Student Organization. Also 500 Nos of Bill Board were made and placed
along Dimapur Kohima Mokokchung Road and Towns.
5. A Comprehensive Five years Nagaland State Designated Agency Action Plan
was published during the period. Annual Book of Energy Conservation Measures
in Nagaland was also produced in 2009-10. Quantification of Energy
Conservation of Nagaland was also prepared during the same period.
479
6. A Seminar on dissemination of Energy Conservation Act 2001, and Standards
& Labeling was held with various stakeholders, Students etc in Mokokchung
town.
7. Promotional materials like leaflets, Brochures, tracts and through print &
Electronic media campaigning were taken-up during 2009-10 & 2010-11.
8. A seminar on awareness and dissemination of Energy Conservation Act 2001
was held amongst the Nagaland State Designated Agency officials.
9. As part of the Energy Conservation drive, a three day long awareness- cum-
publicity along with seminars on Energy Conservation was held along with the
premier State Road Show held at Mon Town, Nagaland from 7
th
8
th
April
2010. Advertisements were made to promote Energy Conservation through
local print media. Banners were displayed and large hoardings with Energy
Conservation slogans were erected at prominent location. Wall hanging type
flex banners with energy conservation message were displayed at the energy
conservation stall, Nagaland State Designated Agency (NSDA). LED bulb and
street light were demonstrated on the stall. Promotional materials like folders,
leaflets, Pamphlets, Stickers were distributed to the General public for creating
awareness.
10. Seminar on Energy Conservation Techniques in Industries was held in
Collaboration with Petroleum Conservation Research Association (PCRA) on
23
rd
Nov. 2011. The programme was a huge success with different
Departments, Organizations, Entrepreneurs and University Students attending
the Seminar.
11. District / State level Essay writing competition for school children studying in
classes 6th 8
th
is conducted yearly by the Nagaland State Designated Agency
( NSDA ) in order to equip the children with the awareness on Energy
Conservation.
12. Advertisements were made to promote Energy Conservation in all the leading
dailies on National Energy Conservation Day. Large hoardings with Energy
Conservation slogans and pictures were erected in prominent location. Banners
were displayed and promotional materials like folders, leaflets, stickers and
Brochures were distributed on all occasions.
13. Materials in English language concerning Energy Conservation and Efficient
use of Energy as supplied by Bureau of Energy Efficiency (B.E.E) have been
translated into local vernacular to create awareness and disseminate
information for efficient use of energy and its conservation and for undertaking
awareness programme for consumers, Schools, Industrial & Commercial
Sectors and the General Public.
14. Design, printing of posters, Stickers, Pamphlets, Leaflets, Promotional Materials
for printing of more numbers of copies for wide circulation to the public.
480
Preparation of Recommendation for Streamlining State Level Policies
Concerning Energy Conservation.
Notification issued by the State Govt. for mandatory use of C.F.L. and Electric
choke in Govt. Buildings, promotion of Energy Efficient Building Design and
Mandatory use of Solar Water Heating Systems in Hotels / Hostels, Hospitals,
Schools, Colleges etc. on the recommendation of State Designated Agency (SDA).
Demonstration Projects
As part of the Demonstration Project the Nagaland state Designated Agency (NSDA)
in coordination with the Bureau of Energy Efficiency (BEE) has implemented high
impact value Energy Efficient street lighting at Dimapur flyover. This achievement
has made a mark in the power sector as first of its kind leading to the appreciation
and demand for such demo projects.
Demonstration Project on Space Heating through solar energy was conducted at
the Nagaland Civil Secretariat building in about 20 rooms covering the Chief Ministers
Chamber and Conference Hall, all Cabinet Ministers Chamber, Chief Secretarys
Chamber and Conference Hall and the Chamber of Principal Secretary (Home )
Implementation of high Impact value Energy Efficient street lighting in Mokokchung
Town, Nagaland which resounded with a positive impact on the public.
With the Bureau of Energy Efficiency (BEE) launching a nationwide LED Village
Campaign and proposing the SDAs to convert one village with LEDs, the Nagaland
State Designated Agency (NSDA) has identified ROTTOMI Village for implementing
the LED Village Campaign. Three (3) to Four (4) light points of each household
has been replaced with LEDs and the existing street luminaries of the village have
been converted with LEDs.
Green Village Initiatives
An aggressive Energy saving plan coded Green Village Initiatives in few Villages
is being taken up to create awareness for conservation of Energy while at the
same time promote the usage of eco- friendly materials.
The Govt. of Nagaland is committed to meet the demand of sustainable energy
growth through Green & Clean Technologies while the State is implementing capacity
addition through conventional means in the other hand the Govt. has announced
to harnessed at least 10% of total capacity addition from New & Renewable
Source of Energy.
481
Certificate of Merit State Designated Agencies (SDAs)
UTTARAKHAND RENEWABLE ENERGY
DEVELOPMENT AGENCY (UREDA)
Dehradun (Uttarakhand)
SDA Profile
The State of Uttarakhand since its existence
is trying to harp on Non-Conventional and
renewable energy sources in order to
achieve sustainability in the energy sector.
The Uttarakhand Renewable Energy
Development Agency (UREDA) has been
established in July, 2001 exclusively to
promote Renewable Energy Sources, for
which the state has tremendous potential.
Govt. of Uttarakhand, vide its order No.
632/576/AS(E)/Camp/2008 dated 27
th
August, 2008, has nominated UREDA as
State Designated Agency (SDA) in the
State of Uttarakhand for Energy
Conservation Programmes and awareness..
An Energy Conservation Cell has been created in the UREDA for implementation
of EC Programmes in the State.
UREDA functions under the administrative control of Department of Renewable
Energy, Govt. of Uttarakhand and basically implements the following programmes
in the State:-
1. Renewable Energy Programmes including generation of Power from
Renewable Energy Sources
2. Implementation of Energy Conservation Act, 2001.
3. Demand side management
4. Accreditation of RE Projects under REC (Renewable Energy Certificate)
Mechanism.
In addition, UREDA designs and implements its own programmes which are specially
suited for the state of Uttarakhand, and in many ways, has evolved systems,
which are now accepted under the national programme.
482
Sector Total Consumption (MUs) Saving Potential (MUs)
Agriculture 300 90.00
Domestic 1160 232.00
Industrial 2729 191.00
Commercial 712 10.20
Municipalities 262.61 54.65
SME Cluster 180.07 MU & 2169 TOE 27.17 MU & 434 TOE*
Total 5343.68 MU & 2169 TOE 605.12 MUs & 434 TOE
(Source: Study Conducted by NPC in October, 2009)
TOE = Tons of Oil Equivalent
Various Energy Conservation Measures in the State have resulted in avoiding of
capacity addition of approx 31.04 MUs in the state during 2010-11. Sector wise
initiatives are listed below:-
Demonstration Projects:
Under this project total 172 Nos. based Energy Efficient Street Lights have been
installed in place of 150W HPSV Street lights at Chakrata Road, Dehradun. The
project has been implemented by Municipal Corporation, Dehradun. The saving of
34840 units of electricity has been observed from Sept 2010 to March 2011.
LED Village Campaign:
Under this project 1000 incandescent bulbs of 100 Watt each replaced with LED
bulbs of 8 Watt each. The saving of 178812 units of electricity has been observed
from Aug 2010 to March 2011.
Solar Water Heating Systems:
Solar Water Heating systems of 139800 Liters per Day (LPD) capacity have been
installed during 2010-11. The saving from the installation of these systems has
been observed to be 2.097 MUs of electricity.
483
Other DSM Project:
Under this project distribution of CFLs/replacement of incandescent bulbs with
CFL of 18 Watt capacity each has been made. The saving of 28.73 MUs of electricity
has been observed by the execution of the project.
Constitution of State Energy Conservation Fund
Govt. of Uttarakhand has notified The Uttarakhand Energy Conservation Fund
Rules, 2010 vide its notification No. 2754/I/2010-1(3)-20/06 Dt. 3rd December,
2010 for the utilization of EC Fund in the State. For the administrative and financial
control of the fund, a committee with the Chief Secretary as its Chairperson has
been formed.
The fund shall be constituted with the grant and loans received from the Central
Government, State Government and any organization or person and share of
income of the electricity fee of every year shall be transferred to the fund by the
State Government.
Funds shall be utilized by UREDA with the prior approval of the State Government
for the following activities:-
1. To organize trainings for the employees and experts for the proper utilization
and conservation of energy and survey technique.
2. To take all necessary steps for ereating awareness and making the available
information and technical knowledge easily accessible to the common man.
3. To modify ECBC conforming to the local requirement of the State and in
context to the above make rules for proper utilization of power in the buildings
and to direct the building owners covered by the rules of the Act to follow the
provision of ECBC.
4. To direct the designated consumers notified by the Central Government, to
inform with prescribed process after follow the recommendation of the audit
report and to make rules for this purpose, and
5. To conduct Energy Conservation Day and Energy Conservation Week.
484
Certificate of Merit State Designated Agencies (SDAs)
CHHATTISGARH STATE RENEWABLE ENERGY
DEVELOPMENT AGENCY (CREDA)
Raipur (Chhattisgarh)
SDA Profile
Chhattisgarh State Renewable Energy development Agency (CREDA) has been
registered on 25.05.01. CREDA has been constituted under Department of Energy,
Government of Chhattisgarh for implementation of various schemes pertaining to
Renewable Energy sources and Energy Conservation activities. Controlling body of
CREDA is the governing body with Ministry of Energy, Chhattisgarh, headed by Honble
Chief Minister Chhattisgarh as Chairman and Principal Secretary (Energy) as Chief
Executive Officer (CEO). CREDA is established as nodal agency by state government
on 25th May 2001 with the main objective of development and popularization of
non-conventional & renewable sources of energy and energy conservation activities
in the state.
Within a short span CREDA has done a pioneering job in various Energy Efficiency
activities in Chhattisgarh. In last 10 years, since its establishment CREDA did
extensive work in the field of Renewable Energy and Energy Efficiency. CREDA has
implemented projects in the field of generation of power from Renewable energy
sources and environment friendly resources. To undertake this onerous
responsibility, CREDA has positioneditself as an organization with enough financial
and human capabilities having aprofessional organizational structure.
Energy Consumption of the State during the year 2010-11
As per the data received from Chhattisgarh State Power distribution company
Ltd. total consumption of electricity within the State is 1207.70 Crore units during
the year 2010-11.
485
Energy Conservation Activities done by CREDA in the State
Established an internet platform for communication among CREDA (SDA),
various stakeholders, consultants etc.
Prepared a list of Designated consumers of Chhattisgarh as per EC- Act.
Prepared a list of buildings at state level which falls under energy conservation
Act.
Design, printing and distribution of promotional materials to all stakeholders,
certified energy manager, accredited energy auditors, designated consumers
& general public.
Collect the data of concerning manufacturing as well as sales of energy
efficient households appliances and other equipments at state level falling
under the energy conservation Act.
Annual survey and analysis of impact of Energy conservation Act, based on
report of accredited energy auditors as well as energy manager and other
sources of information in the state.
CREDA organized training programme for designated consumers for annual
reporting of energy data, e-data filing/analysis.
Completed Energy Audit of 40 government buildings under investment grade
scheme of B.E.E. and also completed energy audit of 09 water works, 05
industries, 02 rice mills through state energy conservation fund.
CREDA has completed the electricity Bill analysis of 98 Govt./Semi Govt.
Buildings.
Incorporated an elective course of Energy Conservation and Management
in the curriculum of all engineering colleges.
C.G. Housing Board has made policy for mandatory installation of SWHS in
buildings having area 1500 sq.ft. or more and is in process to install SWHS
in 3000 HIGs as motivated by CREDA.
Under DSM demo project the Airport road of 9.5 KMS has been illuminated
by replacing 300 W sodium vapour lights with solar powered T-5 lamps
and saving @ 3.79 lacs units of electricity per year.
486
Project Description Replacement of Street Light fittings
at VIP Road, Raipur
Lighting fittings originally 306 Nos. of HPSV Lights of 250
Watts each
New Light fittings installed 306 Nos. of T-5 fittings of 14 watt
Replacing 250W, HPSV Lights each
Reduction in connected load 86.6 KW
Annual Electricity Consumption 306 x (250 + 50) x 12 x 365
Before replacement of light 1000
fittings (50 watts for Ballast) 402084 kWh
Annual Electricity consumption 306 x (14+3) x 12 x 365
After replacement of HPSV lights 1000
with T-5 lights (3 watts for Ballast) 22785 kWh
Annual Electricity Savings achieved 3,79,299 kWh
Annual Saving in Energy Cost @ Rs. 15.17 Lacs
Rs.4.00/kWh
Replaced 2000 Nos. sodium vapour lamps in street lights with 4 x 24W, T-
5 luminaries from:
1. Shastri Chowk to Tatibandh Chowk
2. Kutcheri chowk to vidhansabha
3. Bhagatsingh chowk to VIP colony, etc.
Saving @8.00 lacs units of electricity per year
CREDA also replaced 750 Nos. of 250Watt HPSV lamp with T-5 (4x24
Watt) luminaries in 08 industrial area of Chhattisgarh. It saves @5.00 lacs
units of electricity per year.
CREDA has installed 15 KW SPV power plant for lighting in Vivekananda
Sarover, Raipur.Total 280 Nos. LED street lightening luminaries are installed.
CREDA has installed 15 KWatt Solar Photovoltaic Power Plant at Collectorate
Building, Bilaspur with replacement of GLS lamps with CFL, Old fans with
energy efficient fans of 60 Watt and conventional tube lights with T-5.It
saves approximately Rs.2.00 lacs/year.
CREDA has installed the Energy saver panel with Auto switch near Astha
Petrol Pump, Jail Road, Raipur. The total load of street lights under Nagar
Nigam Raipur, is about 1892 kW with 159 switching points. Hence the total
potential of Annual Energy savings through street light is Rs.90.00 Lacs
with the onetime expenditure of Rs.95.00 lacs, which will be paid back
487
within 13 months. The percentage of energy saving would be appox. 30-
35%
Announced Energy efficiency in agricultural pumps with the approval of
cabinet of ministers through order no.1437/F-21/08/NSVY/09/13/2/DE/
2009 dt. 25/09/2009
Notification has been issued for appointment of inspecting officers, their
powers and functions as per the Energy Conservation Act vide letter No.
4132/382/2009/13/1 Raipur Dtd. 22-08-09.
Installed automatic power factor corrector panels in medical college hospital
Raipur & CIMS, Bilaspur, having capacity approx. 850 KVAR with an
investment of approximately Rs.18.00 lacs and envisaged saving of
approximately @ Rs. 24.00 lacs per year in their electrical bills.
CREDA has implement High impact demo project in Jagdalpur city by
replacing 340 nos. HPSV/MH Street lights with suitable LED luminaries. It
saves @2.5 lacs units of electricity per year.
Also replaced 337 Nos. conventional tube lights with T-5 (28 Watt) Energy
Efficient light in central Jail, Raipur.
108 Nos. of LED street lights are installed in Energy Education park, Raipur.
Installed 20 KW SPV Power Plant with energy efficient lighting in Maa
Bamleshwari mandir, Dongargarh, Distt: Rajnandgaon.
Installed 15 KW SPV Power Plant with energy efficient lighting in Maa
Mahamaya Mandir, Ratanpur, Distt: Bilaspur.
CREDA has completed a project of LED village, Vill: TOR, Block: Dharsiva,
Distt: Raipur is totally electrified by LED lighting:
Description is as follows:
1. LED street lights : 45 Nos.
2. LED bulbs 10 Watt : 700 Nos.
3. LED bulbs 1 Watt : 100 Nos.
CREDA has awarded the task for preparation of sector specific energy
saving plan for the State of Chhattisgarh to Energy Efficiency Services Ltd,
vide letter No. 2914 Dtd. 04-08-2010. The sectors selected under this
task are:
1. Agriculture Sector.
2. Municipal Sector.
Work almost completed a draft report has been submitted by EESL.
488
CREDA has awarded work for preparation of report on present status and
future scope of waste heat recovery and implementation plan & policy for
the WHR in state. (Work almost completed, a draft report is submitted by
the consultant.)
CREDA provides assistance of Rs.1.00 Lacs for DPR preparation of WHR in
the state. (02 Nos. of industries has been benifited)
Successfully implemented energy conservation awareness and publicity
campaign through Posters, Pamphlets, Brochures, Booklets, T.V., Radio,
print media etc., in the state of Chhattisgarh.
Established 07 Energy Conservation clubs in Engineering Colleges.
An awareness publicity clipping is aired with voice of Honorable Chief Minister
through Zee 24 Ghante NEWS Channel.
CREDA has been celebrating Energy Conservation Day/Week since last many
years in the state of Chhattisgarh through many campaigns like debate,
painting, quiz, slogan etc. competitions among school children, awareness
rallies, media publicity.
In this year we also organized classroom awareness programme for school
children, Total 1006 Nos. of classes have been benefited.
CREDA replaced Approx. 98000 CFLs and T-5 tube lights in all tribal hostels
of Chhattisgarh.
CREDA is providing necessary coordination to CSPDCL and EESL for
implementing Bachat Lamp Yojna in Chhattisgarh.
CREDA has installed approx. 1.00 lac CFLs in remote villages under RVE
scheme.
Replaced 700 CFLs in Central Jail Raipur.
CREDA is in process to amend the ECBC (Energy Conservation Building
Codes) framed by BEE, to suit the regional & local climatic conditions as
per the provisions of the Act. and seeking comments of PWD, CGHB, RDA,
NRDA, Urban Admn.etc.
As an impact of Energy Conservation measures approx.20.00 lacs of
electrical units have been saved in the year 2010-11 as per the reports
received from ULBs, Govt. Offices, Hotels, industries etc.
489
Details of Notifications/regulations issued by State Government
1. Issued order to mandatory use of Energy Efficient appliances in govtt. Offices,
Buildings, Industries etc. vide Govt. of Chhattisgarh department of Energy
order No.f 11-1/2010/13/1, Raipur dtd:07.01.2011.
2. Issued order to distribute only BEE star rated pumps set for agriculture vide
Govt. of Chhattisgarh department of Energy order No.f 08/Urjavibhag/
CREDA/starratedpumps/T-5/09 dtd:05.04.2010,
3. Issued order for B.E.E. approved pump sets with appropriate capacitors,
PVC suction and delivery pipe, frictionless foot valves and CFLs upto 20
Watts in all new pump connections under Krishak Jeevan Jyoti Yojana
vide Govt. of Chhattisgarh Department of Energy, order No. 1437/F-21/08/
NI.E.Y/09/13/2/E.D/2009 Dtd. 25-09-09.
4. Issued notification for appointment of Inspecting Officers, their powers and
functions as under Section 17 (1) to17 (4) of E.C. Act-2001. vide No. 4132/
382/2009/13/1 Raipur Dtd. 22-08-09.
5. Issued notification for use of CFLs,T-5, Electronic Choke Regulators, Energy
efficient fans in all industrial commercial, institutional as well as all Central/
State Govt. and their PSU offices/Establishments. It also states use of CFL,
T-5 / LPSV/Induction Arch Energy Efficient Street light fittings for all new and
existing colonies/townships of Govt. / Private / Autonomous bodies vide
No. F1-21/2005/13/1, 14049 Dtd. 18-08-09.
6. CREDA has also been entrusted the implementation of Bachat Lamp Yojana
of B.E.E. in nine districts of Chhattisgarh vide No. 594/2009/13/1 Raipur
10-07-09.
7. Issued government order for providing electric connection to agricultural
pump sets having ISI mark only. Providing capacities for pump sets and rural
feeders.Promoting energy efficient foot valves. Vide letter No.1552/13/2/
ED/EC/2008 Dt.28-07-2008.
8. Issued circular by Chief Secretary on implementation of E.C. measures in
state vide 388/CS /2008 dtd. 29-04-08.
9. Issued Govt.Circular for Replacing bulbs with CFLs & Magnetic chokes with
electronic chokes and mandatory of Solar Water Heating System. Switching
off lights at Govt. offices by employees on leaving.Awarding of Govt. of
departments for outstanding energy savings. Vide Ltr. No. 166 Dtd. 12-01-
07 of Collector, Janjgir Champa.
10. Issued Govt. Circular for Replacing bulbs with CFLs & Magnetic chokes with
electronic ones. Solar Water Heating System mandatory. Switching off lights
490
at Govt. offices by employees on leaving. Awarding of Govt. of departments
for outstanding energy savings.Vide D.O.No. 5381 Dtd. 22-02-06 & Letter
No. 2240/C.S./N.S/200 Dtd. 01-09-2006 of Chief Secretary C.G. Govt.
11. Issued Govt. order to Govt. press and Public Relation Department of Govt.
of Chhattisgarh for printing Energy Conservation Slogans on all office
stationery / Brochures, Applications & all official correspondence vide letter
No. 2126/C.S/N.S/200 Dtd. 28-08-06
12. Govt. D.O. letter for design of Energy Efficiency Govt. Buildings by Principal
Secretary. (Energy) Vide D.O. No. 5235-39 Dtd. 15-02-06.
13. Issued Government order for installation of Solar Photovoltaic Dusk to Dawn
System in Municipal Corporations vide Principal Secretary (Energy) letter No.
1513, 14/SED/EC/2005 Raipur Dtd. 15-07-05.
14. Government order for -
A) Providing automatic ON/OFF switches for street lights in Municipal
Corporations. Making of alternate street lights after midnight. Supply
savings fixations hoardings and promoting use of solar hoardings.
Prohibiting Neon lights and light mast lights in urban areas. Vide letter No.
1804/13/ED/Electric supply/2005/Raipur Dtd. 13-06-2005 of Secretary,
Energy Dept.
15. Constitution of State level committee for Energy Conservation (ECAT) vide
letter No. F1-21/05/13/1 Raipur dtd. 31-12-2005.
16. Order for prohibiting electric geyser in all Govt./Semi Govt. buildings
establishments and replacing it with Solar Water Heating Systems. Vide No.
11457/E.D/CREDA/2004 Dtd. 04-12-04.
17. Constitution of State level Energy Conservation fund of Rs.1 Crore. vide
letter No. 835/CN-1258 Dtd. 30-10-06 of finance department Govt. of C.G
18. Proceedings of ECAT (Energy Conservation Advisory Team) vide No. 5504/
CREDA Raipur Dtd. 28-02-07, 1513 Dtd. 19-07-06 and on dates 10-04-06
& 13-01-06.
491 491
THERMAL PO THERMAL PO
THERMAL PO THERMAL PO THERMAL POWER WER
WER WER WER
ST ST
ST ST STA A
A AATIONS TIONS
TIONS TIONS TIONS
THERMAL PO THERMAL PO
THERMAL PO THERMAL PO THERMAL POWER WER
WER WER WER
ST ST
ST ST STA A
A AATIONS TIONS
TIONS TIONS TIONS
492
493
First Prize Thermal Power Stations
ADANI POWER LIMITED
Tal - Mundra, Distt. Kutch (Gujarat)
Unit Profile
Adani Power Mundra, is having 4x330MW of units and 5x660 MW units. In the
year 2010-11 all four units of 330 MW commissioned and one unit of 660 MW
commissioned successfully.
Subcritical units of 330 MW comprises of boiler which is designed and manufactured
by B& W company and meets the standard of ASME, turbine is designed by Beijing
BEIZHONG steam turbines generator Company Ltd. The boiler adopts the standard
arrangement of natural-circulation coal fired boiler. It adopts single drum with
subcritical parameters, single reheater, wet bottom slag, semi- outdoor single
furnace, balance draft, full suspension arrangement. Design fuel is Indonesia
bituminous coal. It adopts medium speed direct firing pulverizing system under
positive pressure with opposite combustion mode. The coal burner is the latest
DRB-4Z type super low NOx double air adajustement of rotational flow burner.
494
Turbine is tandem compound, reheating, condensed steam with three cylinders
and two exhaust pipes. There are 7 extraction stages in the turbine. High pressure
rotor is of 11 stages, Medium pressure rotor is having 12 stages, low pressure
rotor is having 2X5 stages.
Technical specification of subcritical turbine:
Rate capacity 330 MW
Main steam pressure 17.75 Mpa
Main steam Temperature 540 degC
Reheat temperature 540 deg C
Technical specification of supercritical turbine:
Rate capacity 660 MW
Main steam pressure 24.2 Mpa
Main steam Temperature 566 deg C
Reheat temperature 566 deg C
Plant Performance and Energy Consumptions
PARAMETER FY2009-10 FY2010-11
GENERATION (MU) 1570.268 7241.203
PLF (%) 81.59 85.13
AVAILABILITY (%) 86.72 93.27
S.O.C.(ML/KWHR) 4.24 1.23
S.C.C.(GMS/KWHR) 438 448
DEEMED PLF (%) 93 88.05
HEAT RATE (KCAL/KWHR) 2358 2268
AUX. POWER CONS.(%) 10.38 8.9
THERMAL EFFICIENCY (%) 36.47 37.92
495
Adani Power Limited has created the history in power sector by commissioning
1320 MW in a single calendar year. This milestone company have achieved because
of effective monitoring of the projects and commissioning activities. Company
have not only commissioned the units but also operated efficiently.
Adani Power Limited also created history of synchronizing first supercritical unit
(660 MW) of India within 36 months from zero date.
Heat rate and auxiliary power consumption reduced in the year-2010-11 due to
efficient way of operation and adapting energy efficiency programs.
Thermal efficiency improved in the year 2010-11 mainly due to optimum usage of
primary fuel viz. Imported Indonesian and South African coal and also concentrated
on the proper usage of secondary fuel.
APL has achieved monthly highest station PLF of 91.5 % with total station
generation of 673.7 Million Units in the month of Oct-2010.
Lowest monthly DM water consumption 0.88 % achieved with total station
generation of 447.4 Million Units by APL in the month of July-2010.
APL has achieved lowest station heat rate of 2215 Kcal/KWh with total
generation of 888.9 Million Units in January-2011
496
Energy Conservation
The following benefits have been accrued to APL as a result of innovations
and best practices without any investment in the year 2010-11.
1) Interconnecting Instrument and service air compressor:
In the year 2010-11 one no of service air compressor and instrument air
compressor stopped in each unit of Phase I and Phase II. In Phase I company
has stopped IAC & SAC since Ist January -11 and in Phase II company has
stopped IAC and SAC since February-11 respectively, this company could
able to achieve by loading/unloading pattern study and interconnecting the
service air and instruments air lines. Earlier company used to run two instrument
air compressor and two service air compressors for each units.
Energy Saved in the year 2010-11 = 1.93 Million Units
Saving is monetary terms = Rs. 43.06 Lacs
2) Reducing the pressure set points in instrument air compressor:
Loading and unloading pressure set points modified in Instrument air
compressors and service air compressors. Normally for all control valves
required pressure of 5-6 kg/cm2 hence to cater this plant has reduced the set
497
point of all instruments air compressor from 8.2kg/cm2 to 6.5 kg/cm2.
Resulted in saving of power without affecting the process.
3) Regulated Cooling tower fans operation:
Last year during the season of winter plant has regulated the Cooling tower
fans as per the cooling water temperature and condenser vacuum. Plant has
20 nos of cooling tower fans are available, normal operation 19 CT fans are
running and one is standby. During the month of November, December and
January company stopped 3 nos of CT fans during the night shift (5hrs)
Energy Saved in the year 2010-11 = 0.39
Million Units Saving is monetary terms = Rs. 8.77 Lacs
4) Stopping of One Circulating water pump during winter :
In 4x330 MW Units, each unit is having three circulating water pumps running
in normal operation and one Circulating water pump standby between two
units. Each circulating water pump having flow of 18000 m3/h. In the year
2010-11 plant has stopped one circulating water pump in each unit since 20th
Dec till 15th March
498
5) Oil consumption reduced in 4x330 MW :
Phase I and II boilers are front and rear fired and having five and six vertical
grinding mills. Normally four mills in operation and one standby. While taking
fifth mill in operation plant used to take three nos of oil guns to satisfy the
ignition system. Later on to save oil consumption company have modified
operation procedure. Whenever the flame intensity is above 80 % of all other
running mills and fire ball in good condition unit starts fifth mill.
Secondary Fuel Saved in the year 2010-11 =144 KL
6) Oil consumption saving during the Commissioning of Unit 3 and 4 :
By optimising the process, people and technology the commission group has
saved the 1801 KL of oil. This was achieved with proper co-ordination, keen
monitoring during the chemical cleaning and by adapting the technique of "Do
it right first time". Unit-3 full load achieved within 72 hrs from 1st
synchronisation.
Secondary Fuel Saved in the year 2010-11 =1657 KL
499
Second Prize Thermal Power Stations
CAPTIVE POWER PLANT
VEDANTA ALUMINIUM LIMITED
Bhurkamunda, Jharsuguda (Odisha)
Unit Profile
M/s Vedanta resources Plc is a company Listed in London stock exchange operating
it business throughout the globe and in to Copper, Aluminium, Zinc, Iron ore and
Commercial Power Business.
It is operating its copper business through M/s Sterlite Industries (I) Ltd having
plants at Tuticorin and Silvasa in India, KCM (Konkola Copper Mines) in Zambia
and Copper mines in Australia.
It is operating its Aluminium Business through MALCO (The Madras Aluminium
Company Ltd) at Mettur, Tamilnadu, BALCO (Bharat Aluminium Company Ltd)
at Korba, Chattisgarh, Vedanta Aluminium Ltd at Jharsuguda and Lanjigarh,
Orissa.
It is operating its Zinc and Lead Business through HZL (Hindustan Zinc Limited),
Chanderia, Rajastan and at Vizag, Andhra Pradesh.
It is operating its Iron ore Business through M/s Sesa Goa
It is operating its Commercial Business through Sterlite Energy (I) Ltd (2400
in operational at Jharsugudain Orissa and 3x660 MW is under construction in
Punjab)
500
The 1215 MW Captive Power Plant (CPP) of Vedanta Aluminium Limited at
Jharsuguda (Odisha) is the largest CPP of India. Situated about 5 KM away from
the bustling town of Jharsuguda, this coal-based thermal power plant of Vedanta
Aluminium Limited has been built alongside one of India's largest deposit of coal at
IB Valley and Asia's largest non-brackish reservoir - 'Hirakud Reservoir'.
Commissioning of its first unit started in Aug'08 and last i.e. 9th unit commissioning
completed in March'10. The plant has 9135 MW sub critical, direct pulverized
coal fired, corner tangential firing, natural circulation boiler, single reheat, double
cylinder, double flow, single shaft, extraction and condensing steam turbine of
'Shanghai Electric' Make. The plant has adopted the state-of-art Digital distributed
Control System, High Concentration Slurry Disposal (HCSD) of fly & bottom ash,
counter-flow forced Cooling Towers, and multi-flue Stacks. It sources water from
Hirakud Reservoir over a distance of 33 kilometers. Coal is transported from
Mahanadi Coal Fields through bottom discharge wagons and also by road from
some of the mines. The firm strives to be at the forefront of technological innovation
and establish itself as a leading player in both the domestic and global Aluminium
industry.
Plant Performance and Energy Consumption
S. No. Operating Parameters Unit Year
2009-10 2010-11
1 Actual Generation MU 5639 7954
2 Plant Load Factor % 70.69 75
3 Plant Availability Factor % 84 81
4 Aux. Power Consumption % 9.82 10.14
5 Specific Coal Consumption gm/kWh 910 893
6 Specific Oil Consumption ml/kWh 3.67 0.8
7 Heat rate kcal/kWh 2730 2678
Energy Measures & Conservation
1. Provision of Both phase interconnections in compressor line.
This plant has total 16 nos. compressor, 8 nos. compressor for each phase, with
separate headers for instrument & service air.
Purpose: for instrument air and Service air. Earlier 7 Compressors were running
for each phase. Instrument & service air headers of both phases were
interconnected through a pneumatic valve. After modification one compressor
stopped without disturbing the system.
Total Investment: Rs 82500.
First year energy cost savings: Rs 42.26 Lacs
501
2. CW Pump Optimisation:
As per design two nos. circulating water pumps are to be in running condition. As
Plant is able to get more than rated vacuum in winters, stopping one pump during
winter season.
Total Investment: NIL.
First year energy cost savings: Rs. 686.76Lacs
3. CT fan blade replacement from GRP to FRP
For each unit 5 CT cell are there for maintaining desired parameters, blade material
Glass reinforcement plastic, blade weight is more than FRP blade, power
consumption rated motor is 132 KW. Plant replaced blade from GRP to FRP blade
for 5 CT fans and saved power consumption. Plant also changed fan blade with
gear box assembly, but motor was not changed
Total Investment: Rs. 2.65 Lacs.
First year energy cost savings: Rs. 25. 46 Lacs
4. Both phase HFO & LDO interconnection
Pump Operation before modification:
HFO: Total 6 nos pumps. Three pumps for each phase. For each phase two
running, one standby.
LDO: Total Four pumps. Two pumps is for each phase. For each phase one running,
one standby.
Total Investment: Rs. 0.2Lacs.
502
5. Change in Operation philosophy for turbine drains.
For turbine drains OEM has provided pneumatic valve as well as manual isolation
valve in drain line, during normal operation pneumatic valve is to be in closed
condition and manual valve is to be open. It was found that pneumatic valve was
passing. The operation practice was changed and rather depending on only
pneumatic valve power plant is now closing the manual valve also during normal
operation, thus saving steam from direct dumping to condenser. Due to same the
specific steam consumption reduced from 3.6 to 3.3 kg/kWh.
Total Investment: Rs. 15Lacs.
6. Optimization of Service water & ICW pumps
For both phases service water requirement two service water pump in running
condition and one standby (total three service water pump).
Plant has service water to industrial cooling water interconnection line in which
one manual isolation valve and one NRV was there. Plant had taken out NRV from
that line. Thus it was able to stop one service water pump and to maintain same
header pressure plant run extra four ICW pump.
Total Investment: NIL
Energy Management at VAL 1215 MW Power Plant:
Plant has certified Energy Auditors. There is organization with in organization to
monitor and take up the energy management initiatives. Vedanta has divided the
plant in to various sub section like ash handling, coal handling etc where specific
consumption is monitored. Example: The team working in Coal handling plant
takes care and monitor the specific consumption i.e. power consumption per ton
of coal handled. The optimization and new initiatives comes from the bottom line
people in this way. The same is discussed in monthly meeting and any of the
503
financial approval is required is given then and there itself based on the payback.
Usually less than 3 years payback items are taken on immediate basis.
On thermal side plant have one dedicated team to measure the performance of
individual equipment like air pre-heaters etc and quantify the losses. The appropriate
list of actions always kept ready before any unit goes for shut down.
Other than internal resources, Plant also takes external agencies help and in this
year plant has taken the help of CII to identify the potential savings. Also NPC and
BEE base line data audit is completed and the same is taken for bench marking.
Plant also take the guidelines and findings from other group companies having
similar power plant where audit is done by different party.
504
Certificate of Merit Thermal Power Stations
GMR VEMAGIRI POWER GENERATION LIMITED
East Godavari (Andhra Pradesh)
Unit Profile
The Vemagiri project of GMR Vemagiri Power Generation Ltd., promoted by GMR
Group of consists of one advanced class industrial heavy-duty type Gas Turbine
with generator, one steam turbine with generator, one triple pressure heat recovery
steam generator (HRSG) all capable of operating in combined cycle mode.
The plant has achieved Commercial Operation (CoD) on 16th September 2006.
505
Energy Conservation Programs
Projects implemented by GVPGL
1. Instrument Air Compressor optimization
Total savings is 0.67 Mu * 3 nos = 1.97 MU/year
2. Multistage Pressure reduction valve.
- Thermal images shows passing from the Automatic Pressure Reduction valve
Valve of HP/IP boiler feed pump.
- By Installing multistage pressure reduction drag valves Pressure is reduced in
many stages (13 40) avoiding the high pressure difference across the valve
and thereby reducing the erosion of its seat.
3. Gas turbine inlet filter Replacement Cycle.
HP/IP Feed Water Pump
506
- By replacing GT inlet filters before the pressure drop across the fil-tration
system is, 4 in. H2O. A delta DP of 4 in. H2O translates to about a 1.4% loss
in output and about half a percent loss in heat rate.
- Best O&M practice to maintain the GT inlet filter healthiness & periodic
monitoring of Inlet pressure losses about a 1.4% increase in output
4. Plant Lighting Load Optimization
- By optimizing the lighting voltage of the dedicated lighting transformer power
savings has been achieved.
o Before Lighting Voltage was 240-250 V
o Now Lighting Voltage is 210V.
- Also by switching off unnecessary Lights at unmanned and less used areas in
the plant, saving around 20kWh.
5. Plate Heat Exchanger
- In plant for CCW and ACW heat exchange, 2 PHEs are available but before
only one PHE was in service by taking both the PHEs parallel in operation,
pressure drop in the across the PHEs has been reduced and better Heat
exchange noticed between the Fluids.
- PHE parameters Comparison
507
6. Gas Turbine Compartment Fan modification
- The approximate loss that occurs because of the improper closing of the
damper
o 33.9%
o Past power consumption for TK fan - 85 kW
Reverse rotation of the stand pump is arrested by modifying the command damper.
- Power Savings is 23 kW
- Power savings per year is 2X23X24X365 = 0.42 MU
- Annual Savings Rs.10.12 Lacs.
Apart from the Above mentioned Projects
Variable Frequency Drive (VFD) has been installed for Condensate Extraction
Pump (CEP) in the Month of October.
- Frequency has been reduced to 43.4 Hz from 50Hz
- CEP motor rating 431 kW
508
- By varying the frequency power consumption of the motor is reduced to 305
kWh.
- Annual Energy Saving 1095 MWh.
- Annual Savings 2* 1095000= Rs. 20.93 Lacs
Specific Fuel Consumption for the year 2010-11
Month Energy Fuel Consumption Specific Fuel
Generation SCM Consumption
kWh
April-10 268302000 50358283 0.187692537
May-10 244225000 45913742 0.187997715
June-10 192316000 35857850 0.186452765
July-10 272880396 50979699 0.186820672
August-10 261671604 49180753 0.187948376
September-10 260114000 48553503 0.186662398
October-10 255284000 47703455 0.186864257
November-10 205600000 39123172 0.190287802
December-10 205883000 38461837 0.18681405
January-11 220702000 41538085 0.18820892
February-11 200129000 36706106 0.183412229
March-11 227749000 39650005 0.174095188
Total 2814856000 524026490 0.186164582
509
Auxiliary Power Consumption
Saving by Reduction in Aux. Power
2010-11 2009-10
Plant load Factor, % 82.9 88.68
Gross generation, MU 2814.86 3011.23
Auxiliary power, % 2.98 3.12
Auxiliary power, MU 83.88 93.95
Total savings in aux power, MU 10.07
(93.95-85.29)
Designed Heat Rate (Kcal/kWhr) 1730
Heat Rate (Kcal/kWhhr) 1710.26 1700.82
GCV (kcal/Scm) 9187 9003.5
Gas Consumption, MMSCM 524.06 568.8
Calculation (1730-1710.26)*
2814.86MU (generation) 55565.3364 Kcal
Gas savings Million (55565.3X %82.9 PLF) 46063.6639 Kcal/Year
EHSQ Policy at GMR VPGL
Adopting prudent utility practices to generate reliable and Quality power
complying with the requirement of all the stake holders.
Providing clean, healthy and safe work environment through the prevention
of human ill health & injury and prevention of environmental pollution arising
out of GVPGL activates.
Ensuring compliance with applicable legal and other requirement to which GVPGL
subscribes.
Optimum utilization of resources and reducing waste generation.
IMS in to every activity of GVPGL with a focus on continual improvement and
sustainable growth.
Involvement of employees at all levels to inculcate Total quality culture.
Improving the quality of Neighboring community through Corporate social
responsibility
510
Certificate of Merit Thermal Power Stations
THERMAL POWER PLANT
MARAL OVERSEAS LTD.
Goyal Nagar, Distt. Indore (Madhya Pradesh)
Unit Profile
MARAL OVERSEAS LIMITED (MOL) is a group Company of renowned LNJ Bhilwara
group. The LNJ Bhilwara group( Graphite, Textiles and Power Generation) founded
by Shri Laxmi Niwas Jhunjhunwala has a global presence. MOL plant was set up in
the year 1989 as 100% Export oriented, vertically integrated Textile manufacturing
Unit (An ISO 9001, 14001 & 18001 accredited Co.).
The Thermal Power Plant of 8.5 MW was set up in the year of November 2007 for
to cater its captive power and process steam requirement both.
The Thermal Power Plant has been set up with latest state of the art technology
with complete automation incorporating DCS system of ABB. The plant was set
up on EPC basis by reputed manufacturer Thermax. The plant has all environmental
protection system like three field ESP back filter on all junction point of coal
conveying system. The Thermal Power Plant is comparable with any of the world
511
class plants in respect of house keeping, efficiency, standard operating practices
and green environment.
TPP has atmospheric fluidized bed combustion (AFBC) steam Boiler capacity 50
TPH and is designed to fire F grade coal 100%.
Energy Consumption and Plant Performance
The TPP since its commissioning has improved performance in energy consumption
and Plant operating parameters year on year basis. A dedicated team of qualified
engineers have been involved in optimizing plant performance by monitoring its
parameters (Condenser vacuum, O2 level, Boiler exhaust gas temperature and
Boiler efficiency) and consumption (Auxiliary power consumption, Specific coal
consumption, Specific heat rate and Plant load factor etc.). The efficiency of boiler
has been constantly maintained its design efficiency of 82 +/-2%. The efficiency
levels achieved for the past two year have been 82.5% and 83%.
Sl. Operating UOM Year
No. Parameters 2009-10 2010-11
1 Actual Generation M U 70.24 65.97
2 Plant Load Factor % 80.2 88.6
3 Deemed PLF % 99 98
4 Auxiliary Consumption % 10.31 10.13
5 Sp. Coal Consumption Kg/kWh 0.955 0.89
6 Heat Rate Kcal/kWh 3441 3205
7 Thermal Efficiency % 26.4 27.2
Auxiliary Power Consumption in Lacs Units
512
This pump now
isolated & stopped
Auxiliary Power Consumption in %
Energy Conservation Measure implemented in 2010-11
1. Stopping of Side Selection Filter (SSF) Pump
Technology : Optimizing equipment use
As per plant design SSF Pump is used for filtration / circulation of water of cooling
tower. By modification in cooling water line the same flow in SSF achieved. By this
modification from cooling water pump line header, SSF pump (30 KW) has been
isolated & stopped.
Agency that executed the project : In house
Energy saving Yearly : 183823kWh
Energy tariff per KWh : Rs. 4.25
Total Investment : NIL
Yearly cost savings : Rs. 781248
Pay Back Period : Immediate
513
2. Modification in stage casing of Boiler feed water Pump 2
Technology : Modification
Replaced the entire stage casing in Boiler feed water Pump by modified casing &
complete overhauling and alignment.
Modified
stage casing
Energy saving Yearly : 255024kWh
Energy tariff per KWh : Rs. 4.25
Total Investment : Rs. 1100000
Pay Back Period : 12 Months
3. Waste heat recovery from hot water
Technology : Waste heat recovery
Installation of heat exchanger in DM feed water line to recover heat of waste hot
water from process.
This heat exchanger is
installed in Boiler feed
water line.
514
FD Fan Running in Auto
mode now
Energy saving Yearly : 91 Ton
Coal Rate per Ton : Rs. 3800
Pay Back Period : 5 Months
4. Automation of FD FAN operation
Technology : Automation
FD Fan was Running in Manual Mode. By Engineering Changes in DCS Logic it is
Running in Auto Mode Now.
Total Investment : Nil
5. Condenser Cleaning by bullets
Technology : Preventive maintenance
Bullets cleaning of condenser were performed to clear the minor scaling in
condenser tubes.
515
6. Cleaning of APH & Economizer
Technology : Preventive maintenance
During annual shutdown the economizer & APH tubes were thoroughly cleaned.
516
Total Investment : Rs.120000
517 517
ZON ZON
ZON ZON ZONAL AL
AL AL AL
RAIL RAIL
RAIL RAIL RAILW W
W WWA A
A AAY Y
Y YYS S
S SS
ZON ZON
ZON ZON ZONAL AL
AL AL AL
RAIL RAIL
RAIL RAIL RAILW W
W WWA A
A AAY Y
Y YYS S
S SS
518
519
First Prize Zonal Railways
SOUTH CENTRAL RAILWAY
Secunderabad (Andhra Pradesh)
Zonal Railway Profile
South Central Railway(SCR)formed in October 1966,is one of the most promising
Zonal Railways on Indian Railway network. During the year 2010-11, it carried a
total of 357 million passengersand 96.2 million tons of freight, with gross originating
earning of `7345 Crore, registering 15.61% growth over previous year. SCR is
striving its best to fulfill the passenger's aspirations and demands. The SCR comprise
of overall six divisions viz.Secunderabad, Vijayawada, Guntakal, Guntur, Hyderabad
and Nanded with route kilometers of 5634.06on Broad Gauge and 175.930on
Metre Gauge & three workshops i.e., Carriage Repair Shop, Lallaguda, Tirupati and
Wagon Workshop, Guntupalli. SCR covers entire Andhra Pradesh and part of
Maharashtra, Karnataka, Madhya Pradesh and Tamilnadu.
Overview of Infrastructure and other salient Features
Route Kilometers : 5809.99
Track Kilometers :7805.251
Electrified Route Kilometers : 2111
Electrified Track Kilometers : 5149
No. of stations : 733
No. of Divisions : 6
No. of Carriage and Wagon Repair Workshop : 3
No. of Electrical Loco Sheds : 3
No. of Diesel Loco Sheds : 4
No. of Traction Substations : 34
No. of sub stations (Non-Traction) : 209
No. of TL coaches : 3146
No. AC coaches : 514
No. of staff quarters : 36344
No. of Electric Locomotives including 73 WAG9 and 20 WAP7): 455
No. of MEMUs : 109
No. of Passengers (in millions) : 357.002
Goods loading (in million tonnes) : 96.200
Total earnings (in crore of `) : 7348.05
No. of passenger trains run : 196704
No. of goods train run : 248078
520
Energy Consumption
521
The following energy conservation measures are actively implemented during the
year 2010-11:
Traction (Electric):
1. SCR is having 34 Traction Sub-Stations (TSS) consisting of 21 nos. of 12.5/
13.5 MVA and 44 nos. of 20/21.6 MVA transformers. By switching off stand
by transformers no load losses of 37.15 lakh units are reduced every year.
This is 0.3% of annual traction energy consumption of 1257 Million units.
2. Power factor of all the TSS of SCR is maintained at 0.96 i.e. above minimum
of 0.95, without penalty.
3. Provision of coasting boards and power boards enroute for trains to regulate
power on falling and raising gradients.
4. OHE voltage is maintained at 27.5 KV by suitable operation of tap position
during day & night, minimising OHE current & I
2
R losses.
5. Switching off yard lights to required minimum at traction sub stations.
6. Shifting of metering point from grid substations to traction sub stations at
Kadapa & Pakala Traction Sub-stations.
7. Yearly calibration of Trivector meter by AP DISCOMs & Railways jointly and
the accuracy of meters is 0.5 class.
8. 12 Nos. of 5 KVA Auxiliary transformers were provided at L.C.Gates and IB
locations instead of 10 KVA Auxiliary transformers minimising iron losses.
Sparkless Current collection testing with OLIVER G
OLIVERG regularly used for attending spark location and
maintaining spark free current collection.
522
9. To ensure sparkless current collection, GPS base recording system OLIVER G
is regularly used for attending spark location and maintaining spark free current
collection.
10. Energy audit of Traction sub-station at Krishna Canal has been done by energy
audit consultant and the major recommendations are implemented. 100 kVA
Auxiliary transformer was replaced with 10 kVA saving 2500 units per year.
11. Shutting down off the locomotives in trip-sheds, freight sheds, yards &
enrouteidling for more than 30 minutes.
12. Switching off traction motor blowers whenever the train is stopped for more
than 15 minutes.
13. Improving driving skills for negotiating gradients and undulating terrain without
frequent braking and notching up.
Intensive use of Loco Simulator for training of Loco Pilots and their monitoring by downloading energy data
523
14. Right powering of trains to attain higher average speeds.
15. Switching OFF trailing loco in case of MU while working light load trains.
16. By extensive usage of regenerative braking for trains working with three phase
locos 33.56 million units saved amounting to 14.9 crore.
17. Fixing section wise, SEC target, for Goods train and also monitoring the SEC
data through Energy cum Speed Monitor (ESMON).
18. The Specific Energy Consumption (SEC) on Electric Traction has been reduced
from 5.20 Unit/1000 GTKM to 4.32 Unit/1000 GTKM effecting a saving 27.39
Crore.
Traction (Diesel):
Consumption of diesel for traction purposes is being monitored by adopting following
conservation measures:
1. Fuel consumption Trials for different types of trains are conducted regularly to
monitor and to improve upon their performance. Appropriate action is initiated
to check the consumption of HSD Oil if any increase is noticed in trip Ration
and also improve the Engine manship of the crew, various aspects like load,
gradient, imposed speed restrictions from time to time or taken into account
while assessing the Trip ration. Strict watch is maintained to ensure issuing of
HSD Oil to the diesel locomotive and also maintaining the infrastructural facilities
in good condition to ensure proper accountal of HSD Oil. Loco Pilots and
shunters are regularly counselled by the nominated Loco Inspectors to be
responsible and to account correct fuel balances while handing over and taking
over of locomotives in Traffic Yards and in Diesel Sheds.
2. Instructions are reiterated through lobbies to counsel Loco Pilots by ensuring
correct loads are projected by the Guards while writing CTRs.The Loco Pilots
and Guards have been educated to indicate the correct load/tonnage of the
train in the Trip Sheet/Combined Train Report (CTR).
3. Timely submission of CTRs by the Loco Pilots in evaluating the detailed contents
in CTR is ensured. Strict and stringent action is initiated against the erring staff
in failure to submit CTR in time. In this connection, a JPO No. CTR/08 has
been issued for Numbering of CTRs serially to avoid missing of CTRs.
4. The Handling Loss at the time of decanting HSD Oil from Road Tankers and at
HSD Oil Issuing Points is fixed at 0.1%. SCRly has achieved an average of
0.003% which is well within the target fixed and the net in saving is to the
tune of 255 kLs per annum valued at `101.65 lakh.
5. Leakages are not permitted on Pipelines, Pipe Line Joints/Valves at RCDs.
524
Non-Traction:
17,227 Nos.of T-5 lamps were provided at stations and service buildings in
2010-11, reducing load by 345 kW leading to saving of 7.56 Lakh units
amounting to 40.45 Lakh per annum.
1264 Nos. CFLs were provided in place of ICLs of 60W leading to saving of
1.66 lakh units amounting to 8.9 lakh per annum.
43 Nos. of energy efficient pump sets have been provided, reducing load of
32kW leading to saving of 0.47 lakh units amounting to 2.5 Lakh per annum.
1,564 Nos. of energy efficient ceiling fans were provided,reducing load of 31
kW leading to saving of 0.91 lakh units amounting to 4.84 lakh per annum.
1,526 Nos. of electronic fan regulators were providedleading to saving of
0.44 lakh units amounting to 2.34 lakh per annum.
539 Nos. LED luminaries were provided,reducing load of 14 kW leading to
saving of 0.41 lakh units amounting to 2.19 lakh per annum.
108 Nos. of 3W LED Reading lamp cum Cell phone charging points commissioned
at stations to facilitate reading and mobile charging leading to saving of 0.04
lakh units amounting to 0.2 lakh per annum.
2 Nos. of Traversers & 4 Nos. of EOT cranes and 1 No of air compressor are
provided with VVVF drives leading to saving of 0.94 lakh units amounting to
5.01 lakh per annum.
Extensive use of Energy efficient Fittings (T-5 fittings)
525
Traversers with VVVF drives E.O.T.Cranes with VVVF drives
32 Nos. of occupancy sensors were provided in Guntur division, reducing load
of 32kW leading to saving of 0.58 Lakh units amounting to 3.12 Lakh per
annum. Working of timers is being ensured in 350 high masts having connected
load of 1514 kW.
Occupational sensors in officers chambers
32 nos. of Energy savers have been provided in High Mast lighting systemleading
to saving of 1.69 Lakh units amounting to 9.06 Lakh per annum.
At 5 stations energy savers are provided for light circuits on platforms leading
to saving of 0.04 Lakh units amounting to 0.2 Lakh per annum.
In 589 Stations Platform lighting load is segregated into 70% and 30%. 30%
of lighting is always in "ON" condition, 70% lighting load is controlled by ASM
either manually or through remote whenever required as per the train
movement. It's working has been ensured.
21 nos. of timers were provided for 70% & 30% lighting circuits at railway
stations leading to saving of 0.15 Lakh units amounting to 0.78 Lakh per
annum.
526
70% (part night) & 30% (all night) lighting system on platform
16 Nos. of Induction lamps were provided leading to saving of 0.12 Lakh units
amounting to 0.62 Lakh per annum.
6 Nos. Level Crossing gates have been electrified using solar power leading to
saving of 0.06 Lakh units amounting to 0.31 Lakh per annum.
3 Nos. of solar water heaters were provided leading to saving of 0.15 Lakh
units amounting to 0.78 Lakh per annum.
Solar water heating system
527
3 Nos. of timers were provided for controlling pumps leading to saving of
0.08 Lakh units amounting to ` 0.43 Lakh per annum.
Timer control for pumps
Pumping system has been modified at Dhone station duly avoiding double
pumping at SR pump house (GLR). It has resulted in a net saving of 72120
units per annum. As a result 47.81, kW load had been reduced leading to
saving of 4.22 Lakh per annum.
To minimize specific energy consumption.
To identify locations over divisions and workshops having potential of saving
of electrical energy in different areas such as train operation, Railway stations,
service buildings, workshops, Loco sheds, hospitals, colonies etc.
To organize energy audits and implement the recommendations.
To work out action plans for divisions and workshops regarding energy
conservation measures to be adopted and to monitor its implementation.
Standardize & adopt use of appropriate energy efficient design/innovative
technology.
Promote use of renewable energy.
Create awareness & motive all employees & their family members for energy
efficiency & energy conservation initiatives and recognize their efforts.
528
Second Prize Zonal Railways
CENTRAL RAILWAY
Mumbai occupies pride of place on Indian Railways map. This is the place from
where the 1
st
Railway train India began its journey from Boribunder to thane on
16
th
April 1853. Since then Central Railway has achieved the following land marks.
Overview of Infrastructure and Other Salient Features of Central
Railway (as on 31.3.2010.)
Route Kilometers 3905
Track Kilometers 5975
Electrified Route kilometers 1856.606
Electrified track kilometer 5282.575
No. of stations 484
No. of Divisions 05
No. of Carriage & Wagon Repair Workshop 03
No. of Electric Loco Sheds 03
No. Diesel Loco Sheds 08
No. of coaching Depots 12
No. of Traction Sub stations 78
No. of Sub stations (Non traction) 232
No. of TL coaches 3022
No. of AC coaches 654
No. of staff quarters 44411
No. of passengers (in millions) 1685.30
Goods loading (in million tones) 124.12
Total earnings (in crores of Rs.) 6909.08
Operating Ratio 106.47
529
Traffic Dealt by Central Railway
The breakup of freight under the plan heads as well as major commodities
handled during 2009-10 are as under :
Sr. Item Tonnes Originating
No (millions)
1 Coal 27.73
2 Finished products (steel plant) 0.45
3 Cement 6.24
4 Ores for exports 0.02
5 Miscellaneous goods
a. Food grains 0.90
b. Mineral Oil 2.95
c. Fertilizers 2.45
d. Other goods 3.96
6 Railway stores/material 0.17
7 Container services 11.68
Total 56.55
Energy Consumption
530
531
Energy Conservation: Major Projects Implemented during the year
2009-10 & 2010-11
In Traction power, the following measures have been taken during the year
2009-10.
Reduction in SEC by using capacitor banks at TSSs by maintaining good power
factor at TSSs
In Non-traction power, an approximate amount of Rs.674.21 lakhs per year
is saved due to following measures taken during the year 2009-10.
5699 nos. of energy efficiebnt T-5 tube fittings (28W) have been provided at
station and service buildings in place of 40W FTL fittings.
532
86146 nos. of CFL lamp have been provided in place of incandescent lamps in
staff quarters of Central Railway under CDM project.
Solar heaters have been provided at 15 locations of running rooms and retiring
rooms.
1229 nos. of energy efficient fans (60W) have been provided in place of 90 W
fans.
238 nos. Timer switches provided on High Mast lighting towers for yard lighting.
200 nos. planned to provide during the year 2010-11.
26 nos. energy efficient pump sets have been provided.
At 26 stations LED station's name board have been provided.
162 nos. three star and above graded equipments have been procured.
1055 nos. of staff quarters have been rewired with copper wiring.
4 nos. solar panels have been provided at stations for emergency stand by
power supply
Total Savings achieved by Electrical Department (Genl) due to implementation of
various measures in 2009-10 is Rs. 674.21 lakhs
Energy policy
Guidelines regarding energy conservation are being received from time to time
from the Railway Board. These are being advised to the divisions and being
monitored. Energy Conservation week is celebrated from 14th December to 21st.
December of every year by conducting seminars, distributing booklets on energy
conservation measures.
Objectives
To have lowest specific energy consumption.
To maximize the use of renewable energy resources wherever feasible.
To identify the areas of excessive energy consumption and avoidable loss of
energy and to initiate measures to arrest the same.
533
Certificate of Merit Zonal Railways
NORTHERN RAILWAY
New Delhi
Northern Railway is one of the sixteen zones and the northernmost zone of Indian
Railway. Its headquarters is in New Delhi located at the palace site of the erstwhile
rulers of Vododara, Gujarat, called Baroda House.
Northern Railway is one of nine older zones of Indian Railway and also the biggest
in terms of network having 6807 kilometres of route. It encompasses the states
of Jammu and Kashmir, Punjab, Haryana, Himachal Pradesh, Uttarakhand, Uttar
Pradesh, Delhi and the Union Territory of Chandigarh.
The Zone was created on 14th April 1952 by merging Jodhpur Railway, Bikaner
Railway, East Punjab Railway and three divisions of the East Indian Railway north-
west of Mughalsarai (Uttar Pradesh). It includes the first passenger railway line in
north India, which opened from Allahabad and Kanpur on 3rd March 1859. As
mentioned above, the Zonal Headquarters office of Northern Railway is at Baroda
House, New Delhi. Divisional headquarters of its five divisions are located at Ambala,
Delhi, Firozpur, Lucknow and Moradabad.
534
Electric Traction 2009-10 2010-11
Energy consumed for Traction ( Lacs kWh / year ) 6083 5980
Electric bill paid for Traction ( Rs.Lacs / year ) 26488 28270
GTKM for Goods ( in '000) 37740018 37802128
GTKM for Passenger( in '000). 14725409 15021970
Total GTKM( in '000). 52465427 52824098
Specific Energy Consumption Reduction
SEC for Goods ( kWh / 1000 GTKM ) 5.44 4.64
SEC for Passenger ( kWh / 1000 GTKM ) 19.30 19.30
% SEC reduction during 2010-11 for
(Passenger) w.r.t. preceding year 0.00 0.00
% SEC reduction during 2010-11 for (Goods) -1.45 -14.71
w.r.t. preceding year
Non Traction Energy
Electricity consumed for Non-Traction 3243 3013
(Lacs kWh / year)
Electricity bill Paid for Non-Traction ( Lacs / year ) 13890.00 13776.21
Connected load in ( KW ) 222255 228513
Specific Energy Consumption Reduction
SEC for Non Traction in kWh / kW i.e. 1459.13 1318.52
Electricity consumed in kWh / connected
load in kw of current year.
% SEC reduction during the period -2.74 -9.64
2010-2011 w.r.t. preceding year.
(Current year SEC-previous year SEC) /
previous year SEC x 100 )
Diesel Traction
Diesel Quantity purchased for Traction (KL/year) 413756 430852
Diesel cost in Lakh Rs 137283.82 135502.99
SFC for Goods ( Litres / 1000 GTKM ) 1.96 1.92
SFC for Passenger ( Litres / 1000 GTKM ) 3.62 3.55
% SFC reduction during 2009-10 for
(Passenger ) w.r.t. preceding year. -2.69 -1.93
% SFC reduction during 2009-10 for
(Goods) w.r.t. preceding year. -1.51 -2.04
Energy Consumption
535
Energy Conservation: Major Projects Implemented during the year
2010-11
The following energy conservation measures are actively implemented:
Traction (Electric):
1. Northern Railway have 19 Traction sub-stations consisting of 6 Nos. of 12.5/
13.5 MVA and 25 Nos of 21.6 MVA Transformers. By switching off stand by
transformers no load losses of 17.94 Lacs kWh are earned every year. This is
0.3% of annual traction energy consumption.
2. According to present tariff order of PSERC minimum power factor to be
maintained is 0.95. During the year 2010-11 all the TSS of N.Rly have
maintained power factor above 0.95 and rebate amounting to Rs 6.06 Cr is
received for maintaining Power Factor above 0.95.
3. At Ballabgarh Traction sub-station capacitor bank upgraded from 1600 KVAR
to 2400 KVAR for improvement in power factor.
4. Provision of coasting boards and power boards enroute for trains to regulate
power on falling and raising gradients.
5. OHE voltage at 27.5 kV maintained by suitable operation of tap position during
day & night.
6. Switching off yard lights to required minimum at traction sub-stations.
7. Calibration of Trivector meter is conducted yearly to maintain the accuracy of
meters 0.5 class.
8. To ensure sparkless current collection, OLIVERG is regularly used for attending
spark location and maintaining spark free current collection.
9. Continuous efforts are being made by N.Rly with SEBs to reduce traction
tariff.
10. SEC (Specific Energy Consumption) on electric traction of this Railway
has been reduced from 5.44 (March10) to 4.64 (March11). This resulted
into a saving of 103 Lacs units and a saving Rs 4.86 crores during the year
2010-11.
11. Authorized Energy Audior, accredited consultant by M/s. BEE, conducted energy
audit of Narela Traction Sub-Station and the recommendations are
implemented.
536
Non-traction:
Initiatives on Energy Conservation Measures
1. Distribution of 172417 Nos CFL in Railway Colonies under CDM project during
which 120230 Nos. of 60 W incandescent lamps replaced by 14W CFL and
52187 Nos of 100 Watt incandescent lamps replaced by 20 W CFL, which has
resulted into reduction of 9704 KW in connected load.
2. 30613 Nos T-5 fittings were provided in place of T-12 / T-8 fittings at stations
and service buildings
3. 8299 Nos CFLs have been provided in place of 60 / 40 watt incandescent
lamps in service buildings.
4. 48 Nos of modular chilled drinking water plants were provided.
5. 73 Nos Solar Water Heaters in place of electric geysers were provided.
6. 6337 Nos 60 Watt Ceiling fans have been provided in place of 90 watt ceiling
fans
7. 1743 Nos Electronic fan regulators have been provided in place of conventional
regulators.
8. 35 Nos Timer switches have been provided on high mast towers / street
lighting circuits.
9. Automation of 76 Nos pumps have been done.
10. 48 Nos Automatic Power Factor Correction Panels have been provided in HT
and LT sub-stations for improvement of power factor.
11. 19 Nos LED based station name board have been provided in place of neon
signboards.
12. 9812 Nos electronic KWH meters have been provided in place of conventional
KWH meters for residential quarters and vendors premises
13. Use of copper wiring for 6799 Nos quarters.
14. Replacement of 14 Nos HS / VS / Energy inefficient pumps by mono-block
submersible pumps.
15. 13 Nos Microprocessor based Automatic Platform Lighting Management System
with segregation of 70% / 30% circuits have been provided for Railway
Platforms
16. Use of 3 stars and above labeled electrical products and equipments, which
are mandatory.
537
Initiatives on Green Energy:
1 163 Nos Solar based lighting system (Home light + Street Light) have been
provided for Level Crossing Gates
2 73 Nos Solar Water Heaters in place of electric geysers were provided.
3 Manwal Railway Station of Ferozpur Division, Gill and Daunkalan Railway Stations
of Ambala Division developed as Green Energy Stations with the help of solar
modules for reliable 24X7 hrs power supply to station load such as lighting
and fannage, UTS reservation.
4 To provide un-interrupted power supply for proper functioning of Computerized
" Unreserved Ticketing System" (UTS) and minimize the use of Portable Gen
Set during power supply interruptions, it was planned to provide "Solar
Photovoltaic Hybrid Power Supply System" for UTS at Kathua Railway Station.
It was installed and commissioned departmentally on 11.11.2010 by providing
8 Nos 12Volt, 70W Solar Panels
5 To generate onboard renewable energy through solar panels and to provide
Solar based power supply system for lights and fans, one Narrow Gauge
Coach has been provided with 20 nos Solar Power Panels (Each 12 V, 70 Wp)
in two groups in series of 10 panels each. One series group of 2 solar panels
can give an output of 4-5 Amp, thereby making total output to 45 Amp
Traction (Diesel):
1 Providing Microprocessor based Governors on Diesel locomotives, which control
the consumption of HSD oil minutely and as per demand, quantum of HSD oil
will be decided. Excess burning of oil is minimized to a great extent.
2 Monitoring of diesel consumption locomotive wise and loco pilot wise
3 Trip rations are fixed for different trains and are regularly monitored for
adherence. Any increase in Trip Ration, appropriate action is initiated to check
the consumption of HSD Oil by locomotive or Engineman ship of the crew.
However load, gradient, restriction of speeds are also taken into account
while assessing the Trip Ration. It is also ensured that there is no discrepancy
while issuing HSD Oil to the diesel locomotives at the time of handling over
and taking over charge by the loco pilots and shunters.
4 Loco pilots and Guards have been educated to assesses the correct load/
tonnage of the trains in the Trip sheet/combined Train Report (CTR)
5 Crew controllers must ensure that no CTR is lost or improperly accounted.
The CTR document is also a base for calculation of the mileage etc, of the
Loco pilots/guards. JPO has been issued regarding numbering of CTRs to avoid
missing of CTRs
538
6 The handling loss at the time of decanting HSD Oil from Road Tankers/Rail
Tank wagons and at HSD fuelling points is fixed at o.1%. Handling losses of
Northern Railway in each RDIs is much better with in the permissible target of
0.1%.
7 Leakage are not permitted on Pipe line Joints/Valves at RCDs.
8 Special attention of locomotives during scheduled maintenance to arrest
leakage of fuel and lubricant.
9 When the locomotives are idling in yard for more than 30 minutes, instructions
are issued to shut down the locomotive to avoid excess consumption of HSD
oil.
10 When running the trains in empty condition (empty wagons), the rear diesel
locomotive in Multiple unit (MU) is shut down to avoid excess consumption of
HSD oil.
11 Weak loco pilots are identified and they are educated/counseled. In case of
need, the loco pilots are also directed for simulator training to improve their
skills.
Energy Conservation Initiatives
Fittings
In an effort to reduce load for energy conservation without jeopardizing illumination
level energy efficient 1x28W T-5 fittings are being provided in the Zonal Railway.
539
Microprocessor Based Energy Management Automatic Platform Lighting
System
At Chandigarh Railway Station, lights are on two circuits having 70% and 30%
lighting respectively. The system ensures that 100% lighting is maintained only
when train is present on the platform.
Replacement Of Conventional Geysers In Rest House/Hospitals/Running
Room By Solar Geysers
Use Of Occupancy Sensors For Light Control In Officers' Chambers/
Conference Rooms/ Waiting Halls
Automation Of Submersible Pumps
Provision Of Power Factor Corrector
1.0 Northern Railway has taken several measures to perform its responsibility
towards climate protection. Some of these mesures are as under:
1.1 Free distribution of CFLs to Railway employees under CDM Project.
1.2 Saving up to 3.6% of energy through a improved energy efficieny in both
traction as well as non-traction use.
1.3 Induction of new generation 3 phase locomotives with regeration facility on
rolling stock that use less energy and less material.
1.4 Energy audits to improve energy efficiency of its stations, offices & major
load centres and adoption of LED lighting and Energy Conservation Building
Code ( ECBC ).
1.5 Sourcing of energy used from Renewable Energy sources such as solar power,
biomass.
1.6 Procurement of only 3-star or higher rated products for achieving energy
efficiency.
540
Certificate of Merit Zonal Railways
EAST COAST RAILWAY
Bhubaneswar (Odisha)
East Coast Railway was inaugurated on 8th August'96 by the then Hon'ble Prime
Minister of India and it has been carved out of South Eastern Railway with jurisdiction
comprising of Khurda Road, Visakhapatnam and Sambalpur divisions.
Operationalization of East Coast Railway had started from 1st April, 2003.
Overview Of Infrastructure And Other Salient Features Of East Coast
Railway (As On 31.3.2011) -
Route Kilometers 2646.40
Track Kilometers 5167.21
Electrified Route kilometers 1548
Electrified Track Kilometers 3500
No. of Stations 288
No. of Divisions 03
No. of Carriage and Wagon Repair Workshop 01
No. Electrical Loco Sheds 02
No. of Diesel Loco Shed 01
No. of Coaching Depots 04
No. of Traction Substaions 32
No. of Substations (Non Traction) 181
No. of TL coaches 1690
No. of AC coaches 375
No. of Staff Quarters 25246
No. of Passengers (in millions) 79.37
Goods loading (in million tonnes) 109.13
Total Earnings (in Crores of Rs.) 5082.00
Operating Ratio 42.82
541
Main Electrical Assets (As on 31.3.2011) -
Holding of locos of Electric Loco Shed, Visakhapatnam 171
Holding of locos of Electric Loco Shed, Angul 94
No. of Central AC plants 26
No. of Air conditioners 1166
No. of Electrical Pumps 578
No. of Water Coolers 280
No. of Refrigerators 111
No. of Transformers 282
Diesel Generator sets 282
Energy Consumption
2.1 Traction Energy Details
2009-10 2010-11
1. Energy consumption and cost of
purchased energy for Electric Traction
(i) Energy consumed for Traction 6928.89 7669.35
(Lacs kWh/year)
(ii) Electric bill paid for Traction (Rs Lacs /year) 27309.95 34445.92
(iii) Contracted demand (MVA) 291.4 309.4
2. High Speed Diesel use for Traction and
Purchased Diesel for traction
(i) Quantity purchased for Traction (kL/Year) 96690 98468
(ii) Diesel cost in Lakh Rs. 36141 42136.00
3. Total Energy Cost [ 4.1(ii) + 4.2 (ii) ] 63450.95 76581.92
in Rs Lacs/year
4. GTKM on Electric traction
(i) GTKM for Goods (in '000) 42522496 49226589
(ii) GTKM for passenger (in '000) 8943382 11098688
(iii) Total GTKM (in '000) 51465878 60325277
5. Specific Energy Consumption Reduction -
Traction (Electric)
i) SEC for Goods (kWh/1000GTKM) 9.85 8.19
(ii) SEC for Passenger (kWh/1000GTKM) 25.1 24.79
6. Specific Energy Consumption Reduction -
Traction (Diesel)
(i) SFC for Goods (Litres/1000GTKM) 2.22 2.09
(ii) SFC for Passenger (Litres/1000GTKM) 4.55 4.48
542
2.2 Non Traction Energy Details
2009-10 2010-11
1. Electricity Consumption and cost of
Purchased Electricity for Non-Traction
(Lacs kWh/Year)
(i) Electricity consumed for Non-Traction
(Lacs kWh/Year) 842.2 810.0
(ii) Electricity Bill paid for Non-Traction
(Rs Lacs/Year) 3227.47 3787.5
(iii) Contracted Demand (KVA) with Utility 24423 24803
(iv) Connected load in (KW) 52680 52702
2. Specific Energy Consumption
(i) SEC for Non-Traction in kWh / kw, i.e.
Electricity consumed in kWh / connected
load in KW of current year. 1598.7 1537
543
GTKM ON TRACTION
42522496
8943382
51465878
49226589
11295688
60325277
0
10000000
20000000
30000000
40000000
50000000
60000000
70000000
2009-10
2010-11
2009-10 42522496 8943382 51465878
2010-11 49226589 11295688 60325277
GTKM for Goods (in
'000')
GTKM for
passenger (in '000')
Total GTKM (in '000'
SEC FOR GOODS AND PASSENGERS TRAINS
FOR ELECTRIC TRACTION
9.85
8.19
25.1
24.79
0
5
10
15
20
25
30
2009-10 2010-11
SEC for Goods
(kWh/1000 GTKM)
SEC for
Passenger
(kWh/1000 GTKM)
544
DIESEL PURCHASED FOR TRACTION AND
COST OF THE DIESEL
96690 98468
36141
42136
0
50000
100000
150000
2009-10 2010-11
Diesel purchased
for Traction
(kL/Year)
Diesel cost for
Traction in Lakh Rs
NON TRACTION-ENERGY CONSUMPTION AND AMOUNT PAID
842.2
3227.47
52680
810
3787.5
24803
52702
24423
0
10000
20000
30000
40000
50000
60000
Electricity
Consumed
(Lakhs kwh/year)
Electricity Bill paid
(Rs. Lakhs/year)
Cotract Demand
(KVA)
Connected Load
(KW)
2009-10
2010-11
545
NON TRACTION-INVESTMENT MADE,SAVING ACHIEVED AND
ENERGY COST
53.04
75.55
287.48
3227.47
50.63 40.76
199.58
3787.76
0
500
1000
1500
2000
2500
3000
3500
4000
Investment
made (Rs
Lakhs/year)
Saving achieved
(Lakhs
kwh/year)
Saving achieved
(Rs. Lakhs
/year)
Energy Cost
(Rs. Lakhs)
2009-10 2010-11
Energy Conservation
3.1Energy Conservation Achievements During The Year 2010-11
In Traction Power, the following measures have been taken during the year
2011-12 :
Reduction in SEC by using capacitor banks at TSSs by maintaining good
power factor at TSSs.
In Non-traction Power, an amount of nearly Rs. 200 Lacs has been saved
due to following measures taken during the year 2010-11.
1469 nos. of T-5 fittings (28 W) were provided in place of 40 W FTL
fittings/MH fittings/HPSV fittings/incandescent lamps.
1607 nos. of energy efficient fans (50 W) were provided in place of
conventional fans (60 W).
1 nos. LC gate was electrified through solar energy. Total 66 nos. LC
gates have been electrified on ECOR through solar energy.
14 nos. of energy efficient pumps provided in place of old inefficient pumps
10 nos. Occupancy censors have been provided.
65 nos. of Timer switch to control street lights / Yards have been provided
during 2010-11.
LED type Name Board has been provided at DRM office, Sambalpur.
546
Lights circuits were segregated into 70% / 30% lighting circuits at 16
stations during 2010-11.
Segregation of Domestic & Non-Domestic Loads has been done at 02
Stations over ECo. Railway during the year 2010-11.
In Loco Operation, an approximate amount of Rs 485.12 Lacs saved per year
(at current electricity tariffs) due to following measures taken during the year
2010-11 -
As an energy conservation measure, empty rakes are being run with one
locomotive in switched off condition in multiple and one/two in switched
off condition in triple head units in Visakhapatnam division. This has resulted
in saving of 51 lakh units amounting to Rs. 229 Lacs per year.
Energy saved by shutting down of Light Engines when idle for more than
15 minutes and train engines for more than 45 minutes. Because of this
practice Rs 256.12 Lacs per year saved.
Total Savings achieved by Electrical department due to implementation of
various measures in 2010-11 is:
2009-10 2010-11
(i) Annual Electric energy savings achieved
(Lacs kWh/Year)
(a) Current year GTKM for passenger X
[(SEC of previous year - SEC of
current year in kWh/1000GTKM) x 1000] Nil 34.4
(b) Current year GTKM for goods X
[(SEC of previous year - SEC of current
year in kWh/1000GTKM) x 1000] 642.09 817.16
(c) Total annual electric energy saving
(Lacs kWh/Year) [ 6(i)(a) + 6(i)(b) /
100000] 642.09 851.56
(ii) Annual Diesel savings achieved
(Kilo Litres/Year) 2009-10 2010-11
(a) Current year GTKM for passenger X
[(SFC of previous year - SFC of current
year in kWh/1000GTKM) x 1000 ] 3125 330.48
(b) Current year GTKM for goods X
[(SFC of previous year - SFC of
current year in kWh/1000GTKM) x 1000 ] 4174 2958.55
547
2009-10 2010-11
(c) Total annual HSD (Kilo Litres/Year)
[ 6(ii)(a) + 6(ii)(b)] / 1000] 7299 3289.03
(iii) % saving 2008-09 & 2009-10 for Electric 2009-10 2010-11
Traction
(a) For passenger [(savings in current year/
electricity consumption of previous
year)] X 100 Nil 0.49%
(b) For goods [(savings in current year/
electricity consumption of previous
year)] X 100 11.07% 11.79%
(iv) % saving 2008-09 & 2009-10 for Diesel 2009-10 2010-11
(a) For passenger [(savings in current year/
diesel consumption of previous year)] X
100 17.57% 24.76%
(b) For goods [(savings in current year/
diesel consumption of previous year)]
X 100. 6.71% 12.21%
Implementation of Energy Conservation Measures & Investment
1. Traction (Electric) 2009-10 2010-11
(i) Total No of measures implemented 2 2
(ii) Total Investment made (Rs Lacs/Year) Nil 8.68
(iii) Total Saving achieved (Lacs KWH/Year) due
to implementation of EC measures/projects. 105.50 105.50
(iv) Saving achieved (Lacs KWH/Year) due to 642.09 851.56
improvement in SEC
(v) Saving achieved (Lacs Rs/Year) due to 2529.83 3823.5
improvement in SEC.
(vi) Electricity cost (Rs Lacs/Year) 27309.95 34445.92
(vii) % Saving of electricity cost 10.80% 14.0%
2. Traction (Diesel) 2009-10
(i) No. of measures implemented 1 Nil
(ii) Investment made (Rs Lacs/Year) Nil Nil
(iii) Savings achieved (KL / Year) due to
implementation of EC measures / projects 2512 Nil
548
2009-10 2010-11
(iv) Savings achieved (KL / Year) due to
improvement in SFC 7299 Nil
(v) Savings achieved (Rs Lacs/Year) due to
improvement in SFC. 2728 Nil
(vi) Diesel cost (Rs Lacs/Year) 36141 42136
(vii) % Saving of diesel cost 6.35% Nil
3. Non-Traction (Electric Energy) 2009-10 2010-11
(i) No. of measures implemented 08 08
(ii) Investment made (Rs Lacs/Year) 53.04 50.63
(iii) Savings achieved (Lacs kWh/Year) 75.55 40.76
(iv) Savings achieved (Rs Lacs/Year) 287.48 199.58
(v) Energy Cost (Rs Lacs) 3227.47 3787.26
(vi) % Saving of energy cost 8.91% 5.27 %
Policy and Plan of action to achieve the energy conservation
Energy Policy - Guidelines regarding energy conservation are being received from
time to time from the Railway Board. These are being advised to the divisions and
being monitored. Energy Conservation week is celebrated from 14th December
to 21st December of every year by conducting seminars, distributing booklets on
energy conservation measures.
Objectives of East Coast Railway
To have lowest specific energy consumption.
To maximize the use of renewable energy resources wherever feasible.
To identify the areas of excessive energy consumption and avoidable loss of
energy and to initiate measures to arrest the same.
549 549
MANUF MANUF
MANUF MANUF MANUFA A
A AACTURERS CTURERS
CTURERS CTURERS CTURERS
OF BEE ST OF BEE ST
OF BEE ST OF BEE ST OF BEE STAR AR
AR AR AR
LABELED LABELED
LABELED LABELED LABELED
APPLIANCES APPLIANCES
APPLIANCES APPLIANCES APPLIANCES
MANUF MANUF
MANUF MANUF MANUFA A
A AACTURERS CTURERS
CTURERS CTURERS CTURERS
OF BEE ST OF BEE ST
OF BEE ST OF BEE ST OF BEE STAR AR
AR AR AR
LABELED LABELED
LABELED LABELED LABELED
APPLIANCES APPLIANCES
APPLIANCES APPLIANCES APPLIANCES
550
551
First Prize BEE Star Labeled Appliances
(Air Conditioner)
SAMSUNG INDIA ELECTRONICS PVT. LTD.
Unit Profile
Samsung Electronics Co., Ltd., the parent Company of Samsung India is a global
leader in semiconductor, telecommunication, digital media and digital convergence
technologies with 2010 consolidated sales of US$ 135.8 billion. Employing
approximately 190,500 people in 206 offices across 68 countries, the company
consists of eight independently operated business units. Samsung India Electronics
Ltd. commenced its Indian operations in December 1995 and is a leading provider
of high technology consumer electronics, IT, Home appliance and Telecom products
in the Indian market. India is the hub for Samsung's South West Asia operations.
The Company provides employment to around 8200 plus employees; with around
5000 employees being involved in the R&D area. The Company achieved a sales
turnover of over US$3.5bn in 2010.
552
The Samsung manufacturing complex housing manufacturing facilities for Colour
Televisions, Mobile Phones, Refrigerators, Washing Machines & Air conditioners are
located at Noida (UP). In November 2007, Samsung commenced the manufacture
of Colour Televisions and LCD Televisions at its state-of-the-art manufacturing
facility at Sriperumbudur, Tamil Nadu. The Company is also manufacturing Fully
Automatic Front Loading Washing Machines, Colour Monitors, Refrigerators and
ACs at its Sriperumbudur facility.
The company's thrust on Product Innovation and R&D has given the company a
competitive edge in the marketplace. Samsung has two R&D Centers, located at
Delhi and Bangalore. The focus of the R&D Centre is to customize both Consumer
Electronics and Home Appliance products to better meet the needs of Indian
consumer
Samsung Air Conditioners
The interior design of home adds a lot personal comfort & appeal. Since the air
conditioner is a large part of that interior, Samsung provides a variety of air
conditioners with stylish, sophisticated designs. While paying attention to high
performance & healthy freshness in everybody living Samsung Air Conditioners
provide utmost comfort in the hottest of weather. Samsung Air Conditioners bring
a cool, refreshing wave & make everyday living a delightful & rejuvenating affair.
553
Star-rated Samsung Air Conditioners
India's Star performers - Samsung Air Conditioners are engineered to consume
minimum energy In fact, the BEE Star Rated Samsung Air Conditioner range is one
of the most energy efficient range in India.
The Advantage of Star*rated ACs
The performance of Star*rated ACs doesn't just have an impact on the
environment, it benefits saving money also. Firstly Star*rated product save the
energy consumption which reduce the electric bill. In addition better performance
from AC, which conforms to international standard on power consumption
Samsung Air Conditioners - Benefits - Energy saving
Samsung Air Conditioners are powerful, exact control to reach the desired
temperature quickly and maintains precise temperatures, so there's less fluctuation
and less motor run-time. This ensures quieter operating noise and less energy
waste. Therefore reduce the energy consumption.
In Samsung Air Conditioner, used UTR Compressor with its high torque motor
has the reliability to maintain superb performance even in severe temperatures of
up to 54C for a long time. The latest UTR succeeded in saving energy
consumption and increased energy efficiency by 10%. Samsung also used Stabilizer
free compressor which withstands voltage fluctuations as low as 135V to as high
as 290V and reduces the need for an additional stabilizer during power fluctuations
554
Samsung Implemented Latest Technology by using PFC (Parallel Flow Condenser)
which increase the Energy Efficiency of the product by maximize the heat transfer.
Design of these PFC is such that Louvered fins and multichannel tubes eliminate
maximum heat. By Multi flow Section structure the refrigerant passes at once
through several tubes, increasing the surface area of heat dissipation, which gives
better performance and reduce the power consumption
There are 3 main components in a PFC coil:
Header
Parallel Flow Al Tubes
Enhanced Al Fins
Features of PFC
More efficient than traditional copper Tube condensers, therefore smaller in
size.
Uses about 40% less refrigerant than copper Tube condensers
Greatly reduced brazed connections - less chance for leaks
The smaller coil allows for a smaller cabinet, less metal, less refrigerant, less
freight, and less warehouse space
Approx 5 times more heat transfer than Cu Fin Tube Condenser
555
Second Prize BEE Star Labeled Appliances
(Air Conditioner)
Company Profile
LG Electronics India Pvt. Ltd., a wholly owned subsidiary of LG Electronics, South
Korea was established in January, 1997. The trend of beating industry norms
started with the fastest ever-nationwide launch by LG in a period of 4&1/2 months
within the commencement of operations in May 1997. LG set up a state-of-the
art manufacturing facility at Greater Noida, near Delhi, in 1998, with an investment
of Rs 500 Crore. This facility manufactured Color Televisions, Washing Machines,
Air-Conditioners and Microwave Ovens.
LG AC Factsheet
Launched in 1998, LG Electronics India's Air Conditioning business provides an
integrated package from key components to business solutions. The company's
offerings include residential and commercial air conditioners, home solutions
and compressors.
LG AC residential and commercial products create a refreshing and healthy
indoor atmosphere, using advanced technology and stylish design, while also
addressi ng envi ronmental concerns. LG has devel oped a range of
environmentally-friendly components for its air conditioners. This increases
efficiency and performance, using less energy and thus minimizing environmental
impact.
In creating its products, LG looks closely at its customers, conducting extensive
research and incorporating the findings into products that reflect consumer
needs. One result of the consumer insights LG has gained is the introduction of
products with health-conscious features that respond to people's increasing
concern over their health. Such features have made LG the leading company
in air conditioners.
LG AC Company has secured its position as the number one brand of residential
air conditioners since 2005. LG AC is the number one manufacturer of air
conditioners in India, achieving accumulated sales of 5 million units in 2010.
556
Energy Saving Projects
Multi Flow Condensers:
MF condensers provides up to 10% added efficiency compared to conventional
fin and tubes design
Environmentally friendly as smaller refrigerant charge is needed
Fin & Tube Multi Flow Condenser
Capacity
Comparison Multi Flow Vs Fin & Tube
.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2
1500
2000
2500
3000
3500
4000
4500
Air velocity (m/s)
Heat capacity (kcal/h)
Fin&Tube P7
Multi Flow 6Path
Main Products
Split Air Conditioners
Window Air Conditioners
Floor Standing
Hot And Cold
Cassette
Multi Split
557
BLDC Motors:
Brushless DC Motors have 8~12% better
efficiency than AC Motors
Capable of Operating in Wide Temperature range
Brushless DC Motors have high torque to inertia
ratio so less power consumption
Scroll Compressor:
High efficiency due to less moving parts
High efficiency due to Asymmetric Scroll Profile & Sub-
bearing Structure
10~20 % more efficiency in comparison to Rotary
Compressor
Cross Flow Indoor Fan :
Skew Type Fan Application for Optimized Air Flow
Air Flow Pattern Change for less power & noise
558
Innovative and
Sustainable
Products
Inverter Air
Conditioner:
559
Certificate of Merit BEE Star Labeled Appliances
(Air Conditioner)
HITACHI HOME & LIFE SOLUTION (INDIA) LTD.
Distt. Mehsana (Gujarat)
Company Profile
Founded in Japan in 1910 by Namihei Odaira with the aim of promoting technology
developed in Japan, Hitachi is now one of the most respected Japanese business
powerhouses and a technology leader with well diversified activities worldwide in
the areas as diverse as consumer products, information system, electronics, power,
industrial system, materials, services etc. Hitachi Limited is ranked among top
companies in fortune 500 with a global turnover exceeding $100 Billion.
Hitachi Home & Life Solutions (India) Limited (HHLI), a subsidiary of Hitachi
Appliances Inc, Japan, is a listed company at BSE & NSE exchanges. HHLI came
into existence in 1984. Since its inception HHLI has focused on developing and
supplying high-quality products and technology that contribute to the overall
prosperity of the society.
560
Headquartered in Ahmedabad, Gujarat, the companys manufacturing facility at
Kadi, Gujarat, is among the ten Hitachi air conditioner facilities worldwide. With a
total installed capacity of 400,000 units a year HHLI is amongst the top air-
conditioning companies in India. HHLI offers the most sophisticated and advanced
air conditioning products designed and engineered especially for the diverse Indian
climate of high ambient temperatures. The Indian plant also exports Hitachi room
air conditioners to the SAARC, Middle East and other tropical countries in addition
to catering to the Indian market.
HHLI has a wide range of products which include Room air-conditioners (Window
& Split type), Ductable air-conditioners, Telecom segment cooling solutions,
Rooftops, Chillers, SET FREE (Variable Refrigerator flow) Systems and
Refrigerators.
Development of Energy efficient product
Development of next generation window air conditioner in 1.0Tr/1.5Tr & 2.0Tr
range. Star rating upgraded from 3 star to 5 star in 1.0Tr/1.5Tr range which leads
to reduction of power consumption by 3.36KWh/month.
Development of next generation Split air conditioner in 1.0Tr/1.5Tr & 2.0Tr range
with self-cleaning technology. As per define logic, filter clean itself after some
running hours. So no dust will accumulate in filter. And even after some month
running, there will be no drop in airflow or efficiency which leads to saving of
power consumption.
Star Rating
Feature of Advanced Hitachi Air Conditioners
Most of Hitachi ACs are having highest Energy Efficiency Ratio (EER) in its
category
79% of Hitachi sold split ACs are 5 star rated
The turbo fans with lesser number of blades make the most silent AC as air
cutting is less
The sound level is much more lower( 34dB) for 1.5 Tr split AC.
The innovative air delivery mechanism enables spiral airflow creating a whorl
effect ensuring no hot air pockets in the room
561
(Refrigerator)
VIDEOCON INDUSTRIES LTD.
Gurgaon (Haryana)
Company Profile
Videocon Industries Ltd is India's foremost manufacturer of Home appliances
products with production capacity millions of refrigerator CTV, LCD, washing
Machine. The cost effectiveness of the manufacturing process at Videocon's
manufacturing plants state of art technology near zero wastage technology
resulting in reduce manufacturing costs, total quality control, vertical integration
and complete control over the industry.
The Videocon group emerges as a USD 2.5 Billion global conglomerate continuing
to set trend in every sphere of its activities from a conference room sized assembly
line in 1979.
562
Today the group operates through 4 key sectors:
Consumer Electronics and Home Appliances
Videocon Industries Limited manufacture, assemble and distribute a comprehensive
range of consumer electronics, products and home appliances, including finished
goods such as television,
Home entertainment
systems, refrigerators,
Washing machines, Air
Conditioners and other
small household
appliances and
components such as
glass shell (panels &
funnels), compressors,
motors etc.
563
Certificate of Merit BEE Star Labeled Appliances
(Refrigerator)
SAMSUNG INDIA ELECTRONICS PVT. LTD.
Company Profile
Samsung India Electronics Private Limited (SIEL) is the Indian subsidiary of the US
$55.2 billion Samsung Electronics Corporation (SEC) headquartered in Seoul,
Korea. It is the hub of Samsung's South West Asia Regional Operations, and looks
after its business in Nepal, Bangladesh, Maldives & Bhutan besides India. SIEL
commenced operations in India in December, 1995. Initially, a player only in the
Colour Televisions segment, it later diversified into colour monitors (1999) and
refrigerators (2003). Today, it is recognized as one of the fastest growing brands
in the sphere of digital technology, and enjoys a sales turnover of over $ US 1
billion in a just a decade of operations in India.
564
The Manufacturing Function
SIEL has its manufacturing facility at Noida, U.P. This is the state-of-the-art, high-
tech facility for manufacturing Color Televisions, Color Monitors, and Washing
Machines & Refrigerators. This manufacturing unit consists of sophisticated facilities
with latest Auto Insertion Machines, Auto PCB Tester, High Efficiency Module
Conveyor, and all modern machines geared up for High Speed, High Volume &
Very High Quality Production. Samsung firmly believe that continuous innovation is
the key to making path-breaking improvements in its products & processes and
achieve productivity goals beyond imagination. Samsung uses many tools for
innovation such as Reduced 7 Type of Wastage & Six Sigma. Samsung
commitment to grow through continuous innovation has helped us improve its
productivity by 200% in the last 5 years.
Samsung India is also instrumental in carrying out Hardware Research &
Development at its Noida R&D Centre. The focus of the R&D Centre is to customize
both Consumer Electronics and Home Appliances products to better meet the
needs of the Indian customer.
"What makes Samsung Refrigerator so Efficient"
Many fridges made by Samsung are Energy Star compliant, which means that
they are meant to save you money on utility bills since they take less energy than
older fridges do. This type of appliance often even includes an alarm that goes off
when the fridge door is left open too long, further saving you money on electricity
bills. Another Samsung refrigerator aspect is the Twin Cooling System, which creates
air for the fridge and freezer separately. This is helpful since the freezer needs to
stay dry, while having some moisture in the refrigerated space can help produce
stay fresh for as long as possible.
COMPRESSOR SERIES : Samsung is using the EQ Series that is an upgrade to
the existing model, BK Series that has been produced from 1999, and is currently
utilizing this technology in its Samsung Brand premium refrigerator and other
facilities for major customers. The household refrigerators that have adopted the
EQ Series have won the best Prize of Energy Winner in 2005 in the domestic
(Korea) market and the excellence of the product was verified by domestic
consumers. The Energy Winner Prize is awarded to the most efficient product that
was launched in the year.
Distinguished excellence of the EQ Series is proven by the fact that the variable
speed type of BLDC Motor has replaced the existing constant (single) speed type
of AC Motor and saved 30% of electric power consumption, EQ Series has
dramatically improved the system operation efficiency by both the BLDC Motor of
high efficiency and Inverter Controller. The increased efficiency has been estimated
as a worlds best level in the same displacement of inverter Compressor.
565
Introduction of Innovative and Sustainable Products in Future and
their Efficiency Levels
SIEL will propose various energy efficient measures to achieve annually average
7% energy efficient improvement goal throughout the project period such as:
Optimization of refrigeration cycle with high efficient heat exchanger
- Switching previous refrigerant (HFC-134a) to more energy efficient refrigerant
(ex. R-600a
1
etc.), etc
- This is meant to reduce the CFC emission as well as enhancing the efficiency
of the refrigerator. His mainly targeted to reduce the energy consumption of
the refrigerator. This change is associated with change in compressor which
would be more efficient and will hold all safety measures required for
introduction of new refrigerant.
Improvement of compressor EER (energy-to-efficiency ratio)
- Switching previous AC compressor to inverter compressor, etc
- The inverter type compressor will reduce the time lapsed by the compressor
to regain its momentum after completing a particular defrost cycle. This would
means lower power required to regain the original RPM and thus this would
bring the compressor energy lapsed. This energy lapse elimination would
decrease the energy consumption of the compressor thus, would be beneficiary
for the energy saving.
Improved thermal properties of insulation foam
- Switching previous foam blowing agent (HFC-134a) to advanced blowing agent
(ex. cyclo-pentane
2
etc.) Existing blowing agent is cyclo-pentane (Another
name of blowing agent is R141b)
- Switching previous polyurethane foams to vacuum insulation panels or vacuum
insulation panels with polyurethane foams, etc (No plan of VIP as on now)
- Foam plays an important role. The change in foaming would provide better
insulation thereby bringing down the heat losses across the condenser pipes
spread across the cabinet of the refrigerator.
Design of high efficient fan-duct system
- Switching previous AC fan motor to DC fan motor, etc
- This is mainly done in the freezer section so as to reduce the time lapsed for
varying the cooling speed. This would help in achieving the freezer desired
temperatures in a shorter time thus, thermostat would reduce the compressor
work done.
Advanced system control algorithm with sensors
566
- The sensors used plays a vital role in detection of temperature and collaborating
as per the PCB attached to them as well the compressor. The inputs from
these sensors determines the run time for the compressor. Better the PCB
functioning better and accurate compressor run time.
Reduction of heat losses, including optimization of door gasket design,
etc
- This activity is mainly for reduction in heat losses through the refrigerator
door.
- Better is the sealing across the gasket lesser the cooling loss.
- In addition to the energy efficiency improvement measures above, SIEL may
include state-of-the-art technologies through making a continuous effort to
improve the energy efficiency of refrigerators.
567
(Tubular Fluorescent Lamp)
SURYA ROSHNI LIMITED
Malanpur, Distt. Bhind (Madhya Pradesh)
Company Profile
Surya Roshni Limited is a Public Limited Company with Board of Directors, headed
by the Chairman cum Managing Director. Surya Roshni Limited, has come a long
way since its inception in 1973 when it set up its Steel Tubes Division at Bahadurgarh
(Haryana). Surya Roshni Limited started its first Lighting Division in 1984 at Kashipur
(Uttrakhand) with technical know-how from world renowned OSRAM GEC of U.K,
Teison Furnace of U.K, Cristaleries De Mataro of SPAIN, Ferro of U.S.A, Falma of
Switzerland, Tungsten of Hungary and to manufacture lamps and its major
components.
568
Surya Roshnis range of products include Fluorescent Lamps, Incandescent (GLS)
Lamps, Decoration lamp, High pressure Sodium and Mercury Vapour Lamps,
Compact fluorescent lamp and their Components which include Filaments, Glass
shells, Tubular shells, Aluminium Caps and Lead Glass Tubings. It has built up a
country wide sales organisation with 30 Branches spread all over the country.
The second Lighting Division of Surya Roshni Limited, was set up at Malanpur
(Distt. Bhind) M.P. about 300 Kms. away from Delhi and 25 Kms. from Gwalior, in
the year 1991. Besides manufacturing Fluorescent Lamps, Incandescent (GLS)
Lamps, Compact Fluorescent Lamps ( GE Europe) and Decoration Lamps, this
unit also manufactures Glass Shells and Lamp Caps on state of the art Ribbon &
Danner machines and Cap manufacturing machines supplied by Dema Technologies,
U.K. and PCB Assembly.
Today Surya Roshni Ltd., is the second largest manufacturer of both GLS &
Fluorescent Lamps in India besides producing large quantities of High pressure
sodium & Mercury vapour lamps, Compact fluorescent Lamp, Components etc.
Further to above manufacturing activities, Surya markets an extensive range of
Luminaries, accessories to meet the requirement of every segment of the market.
Surya light fitting reach out to a wide & varied clientele. The application includes
domestic and area lighting beside LEDs. These luminaries are designed for optimum
use of light as well as to ensure that the aesthetics, energy efficiency & environmental
needs are met. After extensive in-house research, products are marketed there
by ensuring high quality standards. Surya also markets high mast lighting systems
& octagonal poles
The products manufactured by the organisation meets all Indian and International
Quality Specifications.
It exports its products to almost all countries of the world. The organisation has
extensive facilities and is playing a leading role in the Lighting Industry all over the
globe.
Impressive Credentials
Leading manufacturer of lighting products in India
Surya's 36 W Super Bright Fluorescent Tube Lamp has been given FIVE STAR
Rating by Bureau of Energy Efficiency
US$6 million to US$150 million in less than 10 years
Attained no 1 position in India in fluorescent tube lights in less than 10 years
569
(Agriculture Pump Set)
CRI PUMPS PRIVATE LIMITED
Saravanampatty, Coimbatore (Tamil Nadu)
Company Profile
Last decade saw C.R.I. Pumps redefining its position from one of the leading
names in India's water pump market to a widely recognized brand in the global
segment. The company's success mantra is made of just three words:
"commitment, reliability, innovation", represented by the name of the organization
itself, C.R.I. Each and every line of the inspiring story of C.R.I. Pumps' growth
underscores the company's focus on staying committed, reliable and innovative.
570
The inception of C.R.I. Pumps was in 1961. Though it was a humble attempt, back
then, to produce just a few irrigation equipments with the limited infrastructure of
a small foundry and supporting machinery, it didnt take too many years for C.R.I.
to show the signs of a big promise, by means of its constant efforts to meet the
customers expectations.
C.R.I. had successfully built a huge sales network throughout India and abroad. It
was made possible by maintaining consistent synergy between the production
facilities and the demand from the customers. The expansion process of sales
network was executed in such a manner that the company will always have direct
access to the market response and customers requirements. 29 branch offices
directly run by the C.R.I. group stay in touch with various categories of customers
as well as with four thousand dealer outlets.
The C.R.I. team frequently interacts with farmers, other customers, plumbing
contractors, builders et al. through surveys and conferences organized at regular
intervals. Since agricultural sector played a major role in the phenomenal growth
of the brand, the company is always keen on closely studying irrigation related
issues, land conditions etc. and delivering innovative, timely solutions as well.
Several models of submersible pumps with exceptional technology (that ensures
more water discharge than the ordinary ones) stand testimony to C.R.I. Pumps
commitment to the farmers community. On the other hand, when it comes to
domestic and other applications, C.R.I. has got a wide range of water pumps with
great energy-saving features to the customers delight. Apparently, the much
visible trust factor associated with the brand isnt incidental. It was built over
years, by means of dedicated efforts with a vision as the driving force.
Agriculture Pumps
100 mm (4")
Borewell Submersible
Pumps - SR, SM, SH,
S4H, S4D & S4G
Series
150 mm (6")
Pumpsets - SR, S6G,
S6E, S6S & SM Series
175 mm (7") Borewell
Submersible Pumps -
CM Series
571
200 mm (8 inch)
Pumps - CR & CM
Series
Horizontal Openwell
Submersible Pumps -
CSS & CSM Series
Vertical Openwell
Submersible Pumps
Centrifugal Monoblock
Pumps - CH, CS & BP
Series
250 mm (10 inch)
Pumps - CM Series
Key Energy Saving Projects
Maharashtra AgDSM pilot project at Sholapur through MSEDCL
Installation of energy efficient pumpsets through AP Agro scheme
Installation of energy efficient pumps for new connections through Tamilnadu
Govt Scheme
Successful execution of Tamilnadu AgDSM scheme (Phase 1)
Western railway project for supplying of energy efficient pumps
Supplying of energy efficient pumps for Chhattisgarh Gram Panchayat
Scheme
572
Energy Conservation Achievements and their contribution to the overall
efficiency market
Energy Savings in MWh
Introduction of Innovative and sustainable products in future and their efficiency
levels.
C.R.I is very much committed in providing of energy efficient products through
innovative design and technology which would result in benefiting to the
customer, environment and the society. C.R.I will be launching Solar Pumps
suitable for Agriculture and Domestic Application within short period
C.R.Is Commitment for being energy efficient and to keep Safe
Environment:
Effective System comprising the Quality Management System and
Environmental Management System
Continually improve the environment performance by reducing emissions to
air and solid wastes and improve the methods of manufacturing
Optimize use of resources like water, power and fuel
Maximize the use of eco-friendly materials
Train and motivate human resources to be Quality and environmentally
responsible
Encourage suppliers and contractors to become Quality and environmentally
responsible
573
(Ceiling Fan)
HAVELLS INDIA LTD.
Haridwar (Uttarakhand)
Company Profile
Havells entered the fans business in mid-2003 and soon, with its consistent quest
for innovation and customer satisfaction, became an enviable competitor and a
player- revered for capturing strong market through its wide range and pioneering
designs. Havells has developed India's most modern and integrated manufacturing
plant for fan in the country located in Hardwar (Uttrakhand) with capacity of more
than 5 million fans annually. Factory is equipped with state of art technology including
automated CNC machines for motor winding, CNC machines for end covers
machining, conveyorised painting plant with electrostatic painting systems &
conveyorised assembly lines with computerised testing facilities. Other facilities
include- Fully integrated automation system air delivery measurement for ceiling
fan.
574
Energy Saving projects implemented with respect to the product, and
what made this product so efficient
The ceiling fan is a product whose efficiency relies on a number of factors e.g.
aerodynamics of the blade, winding, quality of material being used, tolerances in
the assembly, etc. Each and every factor is equally important as the slightest
mistake in any of these results in huge efficiency losses. Automated CNC controlled
winding, CNC machining of the motor covers, close tolerancing in startor and
rotor grinding, use of best raw materials, etc have resulted in a highly efficient
product.
As there are a large number of factors influencing the efficiency of the motor it
requires an extensive testing facility and quality control system. HAVELLS, committed
to delivering the best quality product to its customers, has installed a fully automated
Air Delivery chamber for testing and quality control.
Energy Conservation Achievements and their contribution to the overall
efficiency market
In February 2009, HAVELLS was the first one to register for the Standards and
Labeling Programme of BEE for Ceiling fans. Soon after HAVELLS initiative in
promoting the cause of energy efficiency all the industry players took notice and
followed us. HAVELLS has started a trend in the industry and is leading the market.
The overall efficiency market trend is very positive with the average customer
getting more and more conscious about the urgent need to switch to energy
efficient products not only for his own benefit but also for the common benefit of
the nation as a whole.
Introduction of Innovative and sustainable products in future and their
efficiency levels
HAVELLS has always been committed towards energy efficiency and thoroughly
believes that there is always scope for more efficient products. HAVELLS has
setup The Centre for Research & Innovation with a vision of continually improving
the quality and efficiency of the existing products. At the same time stress is laid
on new innovative products to be delivered for the future. The stress is always
upon the future needs and demands of the consumer and how Havells can
efficiently meet them. Havells look forward to a better future building out of Havells
present endeavors in conceptualizing products that are far more efficient than are
presently available.
575
(Colour Television)
Company Profile
LG Electronics India Pvt. Ltd., a wholly owned subsidiary of LG Electronics, South
Korea was established in January, 1997. The trend of beating industry norms
started with the fastest ever-nationwide launch by LG in a period of 4&1/2 months
within the commencement of operations in May 1997. LG set up a state-of-the
art manufacturing facility at Greater Noida, near Delhi, in 1998, with an investment
of Rs 500 Crore. This facility manufactured Color Televisions, Washing Machines,
Air-Conditioners and Microwave Ovens.
During the year 2001, LG also commenced the home production for its eco-
friendly Refrigerators and established its assembly line for its PC Monitors at its
Greater Noida manufacturing unit. The beginning of 2003 saw the roll out of the
first locally manufactured Direct Cool Refrigerator & Compressor from the plant at
Greater Noida.
576
Standby Power Consumption Reduction
Circuitry modify & additional circuit incorporated to reduce power consumption
in Standby Mode
STR operation mode change in STDBY Mode
Relay circuitry added to cut OFF unused parts (eg DEG coil)
Regulators change to LDO margin type with less Iq
In 2004, LGEIL also up its second Greenfield manufacturing unit in Pune, Maharashtra
that commences operations in October this year. Covering over 50 acres, the
facility manufactures Color Televisions, Air Conditioners, Refrigerators, Washing
Machines, Microwave Ovens, Color Monitors and GSM phones.
LG has been able to craft out in nine years, a premium brand positioning in the
Indian market and is today the most preferred brand in the segment
Recently, LG Electronics India Pvt. Ltd. crossed a record $100 million export turnover
figure. This achievement is a major milestone for the Company and has
consolidated LG's position not only in the domestic but the international markets
as well. The company has achieved a turnover of Rs. 10,455 crore in 2009-10
and Rs. 11,777 crore in 2010-11
Specific Energy Consumption Color Television FY2009-10 &
FY 2010-11
Total Energy Saving 274879 MWH
Technology Advancement focused by LG in Consumer Electronics (to name
a few)
1. Standby Power Consumption Reduction
2. Picture Tube Design Changes
3. LED TVs
577
LED LCD TVs
Power Consumption
CCFL LCD TV VA LED TV IPS LED TV
90W
W
160W
42 Screen size comparison
25%
``
15%
``
40%
CCFL LCD TV
LED
Impact
150 W ~90 W
ON Mode
CCFL Lamps require High Less operating Voltage
LED Backlight Further Improvements
Innovation
Local Dimming driving introduced in
42LCD Vs LED
*LG standard test conditions
120
Energy Environment Policy & Impact
Our aim is CO2 Reduction target : 75K ton by 2012 & 150K ton by 2020
Technological & Economic Benefit
Green business creation under mitigation of climate change
Technological Advantage
LG focus will always be on improving the technology in much faster way and it
will give LG an edge over its competitors.
Environmental & Social Benefits
Annual Saving through Star
Conserve fossil fuel and other
Units Saved (KWH) Per
annum*
2200 Millions
* For 2009-2010 , 2010-11 produced Qty of star rated products as compare to non
star models (Approx)
Help in reducing Global
578
(Storage Water Heater)
RACOLD THERMO LIMITED
Chakan, Distt. Pune (Maharashtra)
Company Profile
Racold Thermo Ltd, an ISO 9001:2008 company, is a fully owned subsidiary of
Ariston Thermo Spa, Italy and is part of The Ariston Thermo Group which has a
global presence in 150 countries. The Indian operations include India's largest and
fully integrated water heater plant in Chakan near Pune, Maharashtra that has
been operational since 1999. The plant is located at Chakan in Pune having a
capacity to produce over 5,00,000 units/year and employing approx. 500
employees. Please find attached the photograph of the factory. With a complete
range of Electrical, Gas and Solar water heaters, Racold Thermo Ltd.- The Hot
Water Specialist, is now providing integrated water heating solutions to all the
sectors i.e. domestic, commercial and industrial.
579
Ever since its inception, Racold Thermo Ltd. has been the technology leader in the
Indian Market, setting standards for the water heating industry with many firsts to
its credit like Rustproof polypropylene body, PUF insulation for better energy
efficiency, product with highest pressure rating suitable for high rise buildings and
pressure pump applications, imported thermostat, cut-out and safety valve
conforming to the best international standards, to substantially improve the safety
of the product.
Racold has always strived to bring in new technology, enhance the aesthetics,
quality, durability and performance of the product. The products are constantly
upgraded with a view to giving consumers a better product. In these endeavors,
the "standing loss" of storage water heater products has been improved
considerably to make the products more energy efficient. Racold has introduced a
New Tank Technology - SPHP with Polymer Coating, to reduce the heat dissipation
and consequentially the standing losses.
Racold has increased the thickness of PUF and glass wool which has improved the
insulation. Also, company has changed the geometry of the heating element,
making the sensitivity of the thermostat more efficient for cutting IN & OFF
operations.. The combined effect of more insulation and change in the geometry
of the heating element has enabled us to achieve the desired energy saving and
better standing loss (which is less than before).
Racold as a brand is synonymous with breakthrough innovation, premium quality
and complete customer satisfaction. The company is working on a new product
platform which is to be launched soon. This will establish new standards in
sustainability and energy efficiency in water heaters in the future. Racold is the
largest manufacturer and seller of water heaters in India, both in the domestic &
export segments, exporting more than 4,00,000 water heaters in the past.
The design of the components used in company products are of international
standards (having ROHS compliance ). For example, Racold unit do trivalent chrome
plating which is costlier instead of the normal chrome plating.
Company endeavour always has been to have products which are environment
friendly and keeping the end user in mind.
580
NATIONAL ENERGY CONSERVATION AWARD 2011
AWARDS COMMITTEE MEMBERS
1. Shri P. Uma Shankar - Chairman
Secretary (Power)
Ministry of Power
Shram Shakti Bhawan
Rafi Marg, New Delhi.
2. Shri A. S. Bakshi - Member
Chairperson
Central Electricity Authority,
Sewa Bhavan, R.K. Puram
New Delhi.
3. Shri Devender Singh - Member
Joint Secretary (EC)
Ministry of Power
Shram Shakti Bhawan
4. Dr. Ajay Mathur - Member
Director-General
Bureau of Energy Efficiency
4th Floor, Sewa Bhawan,
R.K. Puram, New Delhi-110066
5. Shri Rakesh Jain - Member
JS & FA
Ministry of Power
Shram Shakti Bhawan
6. Shri S.K. Chakraborty - Member-Secretary
Dy. Director General (TS) &
Chairman, Technical Committee
National Productivity Council,
Utpadakta Bhavan, Lodi Road,
New Delhi.
581
NATIONAL ENERGY CONSERVATION AWARD 2011
TECHNICAL SUB-COMMITTEE MEMBERS
1. Shri S.K. Chakraborty - Chairman
Dy. Director General (TS)
2nd Floor, Utpadakta Bhawan,
Lodi Road, New Delhi-110 003
2. Shri Amarjeet Singh - Member
Chief Engineer (C&E)
Central Electricity Authority,
Sewa Bhawan, R.K. Puram, New Delhi
3. Shri D. Goswami - Member
Scientist E
Bureau of Indian Standards,
Manak Bhavan, Bahadur Shah Zafar Marg,
New Delhi
4. Shri D. Pawan Kumar - Member
Director & Group Head (EM)
Utpadakta Bhawan, Lodi Road
New Delhi-110 003
5. Prof. Neelima Risbud - Member
Dean of Studies
Department of Architecture
School of Planning & Architecture
4, Block-B, I.P. Estate, New Delhi-110 002.
6. Shri Sushil Kumar - Member
Director Electrical Engineering (PS)
Ministry of Railways
Railway Board
Rail Bhawan, New Delhi-110 001
582
7. Shri A.K. Asthana - Member
Sr. Technical Expert
GIZ, BEE
4th Floor, Sewa Bhawan,
R.K. Puram, New Delhi-110 066
8. Shri K.K. Chakarvarti - Member-Secretary
Energy Econonmist,
Bureau of Energy Efficiency,
Sewa Bhawan,
R.K. Puram, New Delhi-110 066
583
The responsibility for the authenticity and correctness of
statistical/data and opinions expressed in this document
rests solely on the participating Industries, Office & BPO
Buildings, Hotels & Hospitals, Municipalities, State Designated
Agencies, Thermal Power Stations, Zonal Railways, and
Manufacturers of BEE Star Labeled Appliances/Equipment of
National Energy Conservation Awards - 2011.
This publication does not constitute an endorsement by
the Government of India on the opinions expressed in it.

Award Book2011

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Award Book2011

Uploaded by

Copyright:

Available Formats

NATIONAL AWARDS

You might also like