aurobindo pharma limited unit i , hyderabad · energy saving projects implemented in last three...

AUROBINDO PHARMA LIMITED

UNIT I , HYDERABAD

1

mailto:[email protected]





1992

1986

22k+Employees

155+Market presence

29Mfg. Facilities

$2.8BGlobal Revenue

Inception

IPOUSFDA cGMP compliant

33+ Bn

2nd Largest pharma by revenue (India)

10th largest by generic sales (globally)

2020

Brief introduction on Company/Unit

221st CII National Award for Excellence in Energy Management - 2020

3

• Metformin

• Metoprolol

• Bisoprolol

• Gabapentin

• Cefpodoxime

• Ciprofloxacin

• Atorvastatin

Major products :

1. Details of the Products / Processes

Raw material charging

Reaction/ Fermentation

Process

Filtration Process

Drying Process

Milling Process Finished API


4

S No Parameters Units FY 17-18 FY 18-19 FY 19-20

1 Annual Electrical Energy Consumption million kWh/year 78 81 75

2 Annual Electrical Energy Equivalent Million kcal/year 66735 69565 64556

3 Annual Thermal Energy Consumption Million kcal/Year 151093 153501 141300

4 Annual Diesel Consumption KL/Year 398.7 114.6 63.5

5 Annual Diesel Energy Equivalent Million kcal/Year 3727.9 1071.4 594.2

6 Overall Energy Consumption Million kcal/year 221555 224137 206450

7 Overall Energy Consumption MTOE/ Year 21,780 22,303 20,582

8 Annual Production MT/Year 4891.3 4582.4 4905.9

9 Specific Electrical Energy Consumption kWh/Ton of production 0.0159 0.0176 0.0153

10 Specific Thermal Energy Consumption kCal/ Ton of Production 30.8 33.5 28.80

11 Overall Specific Energy Consumption kCal/ Ton of Production 45.3 48.9 42.1

31%

69%

0%

Energy Distribution FY 19-20

Electrical Energy

Thermal Energy

Disel Energy

2. Energy Consumption Overview


5

42%

31%

20%

7%

Steam Distribution

ETP Mfg SRS Support

3. Specific Energy Consumption in last 3 years (FY 2017-20)

13% 14%


6

3. Overall Specific Energy Consumption in last 3 years (FY 2017-20)

45.3

48.9

42.1

38

40

42

44

46

48

50

FY 17-18 FY 18-19 FY 19-20

Overall Specific Energy Consumption

kCal/Ton of Production

An increase in SEC in the FY 2019 was observed due to low production and non linear nature of consumptions

Decrease of SEC in the FY2019-20 due to the implementation of various energy conservation activities

14%


7

DescriptionDesign Temp

(oC)Design SEC

(kW/TR)Operating SEC

(kW/TR)Target SEC (kW/TR)

Reciprocating Chillers (Water

Cooled)

+5 0.86 0.91-1.1 0.90

-20 1.59 1.65-1.72 1.61

-30 1.83 2.1-2.5 1.9

-35 1.95 2.52-2.71 2.0

Screw Chillers +5 0.63 0.68 – 0.82 0.65

Refrigeration Plants :

DescriptionDesign SEC (kW/CFM)

Operating SEC (kW/CFM)

Target SEC (kW/CFM)

Air Compressors 0.16 0.22-0.29 0.18

Description Design SFR (KG/KG)Operating SFR

(KG/KG)Target SFR (KG/KG)

Boiler 4.5 4.8 4.6

4. Information on Internal benchmark - Utility


8

Projects implemented in FY 19-20

S No Project DetailsInvestments(₹ Million)

Annual Savings(₹ Million)

Payback(Months)

1Installation of State -of- Art Oil Free Refrigeration (OFR) Technology and automation of Chilling Plants

7.37 4.53 19.5

2Installation of Molecular Sieve Dehydrator system in Solvent Recovery Plant (SRP) and Eliminating Operation of Chilling Plants

31.06 56.24 6.6

3

Replacement of Liquid Nitrogen Cooling with Mechanical Chillers (-65 oC ,-35 oC) and installation of 500 Nm3 Nitrogen Generation Plant

77.7 17.27 54

4Waste heat recovery form ATFD Flash steam in MEE 2nd Stage for heating for preheating the MEE feed in Group B

0.5 51.1 0.1

5Utilization of waste heat recovery form Stripper Solvent steams for preheating the MEE feed in Group A

0.5 15.3 0.4

5. Energy Saving projects implemented in last three years


9




Payback(Months)

6Replacement of Selected Standard motors of with Premium energy efficiency (IE3) Motors & Optimum size motors

1.71 4.63 4.4

7Installation of voltage stabilizers in the lighting circuit for conservation of energy.

0.05 0.5 1.2

8Installation of IR Motion Sensors based Lighting system at server room & AHU Area for automatic switching off of light during non-occupancy

0.01 0.03 4

9Installation of VFD System for 360TR Chiller primary pump for Conservation of Energy

0.11 0.34 3.8

10Installation of VFD System for 122CFM Compressed Air Plant for Conservation of Energy

0.11 0.31 4.2

11Replacement of old and energy intensive lighting appliances with Energy Efficient LED lights

0.34 0.14 29.1

12Replacement of AHU'S DX coil Cooling Circuit with chilled water at Main Ware house for conservation of energy

0.3 0.69 5.2

13Installation of VFD’s for Pumps, Air Compressors and CT fans for efficient & optimum loading operations

0.42 1.49 3.4



10




Payback(Months)

14Procurement of Energy Efficient (IE3) Motors for both New Projects as well as Replacement of existing low efficiency Motors

0.05 3.52 0.17

15Optimization the operations of vacuum pumps in Solvent Recovery & Production blocks by replacing with suitable utility systems

0.02 0.99 0.3

16Replacing Aluminum Blades by FRP Blades in the Cooling Tower for conservation of energy

0.17 0.49 4.2

17Installation of No Air loss Drain (NAD) Valves in Air Compressors by Replacing Timer/ Mechanical based valves

0.05 0.21 2.8

18Installation of Online Energy Monitoring System for Real time monitoring of Performance of Chilling Plants

2 - -

19Replacement of Condensers and evaporators and Operational Improvements in chilling plants for optimum performance and conservation of energy

3 34.9 1.0

20Installation of Steam traps by Replacing Old non working Traps in the steam Header systems and Arresting Steam Leakages

0.2 1.2 2

Total 125.6 193.9 7.8



11




Payback(Months)

1Installation of Screw Compressor of -20 oC, 90 TR by replacing existing old reciprocating Chilling Plants

1.06 0.87 0

2Replacement of Condensers and evaporators in Chilling Plants and Operational Improvements for Conservation of Energy

1 8.05 1.5

3Installation of No-Air Loss Drain Valves by replacing Timer Control Drain Valve to reduce the compressed air loss in the system

0.5 1.04 0

4Installation of Waste Heat Recovery System at SRS Column for Pre heating Boiler Feed Water

0.51 0.35 0

5Installation of Waste Heat Recovery System for recovering heat from Boiler blow down (CBD) to pre heat the Boiler Feed Water ( BFW)

0.81 0.91 0

6Automatic switching off of Cooling tower fans with respect to return water temperature for Cooling Towers

1.95 1.56 12

7FLP switch for lights near the Operator/ Executive provided to access and control Unwanted lights in Column areas

0.024 0.84 0

8 Street light timer arranged to avoid lights unwanted time 0.0025 0.01 0



12




Payback(Months)

9Installation of electronic ballasts for lights in place of chokes for conservation of energy

0.018 0.02 0

10Installation of Energy Efficient LED lights by Replacement of old and energy intensive lighting appliances

0.76 0.47 0

11Capacitors arranged for power factor improvement from 0.896 to 0.99

0.11 0.4 0

12Installed capacitor banks at load ends/ MCC levels to reduce the distribution losses, avoiding voltage drop

0.04 1.38 0

13 Installation of suitable pumps for RT lines by replacing Old pumps 0.14 0.91 0

14Temperature controller arranged for Cooling Tower fan to avoid unwanted running during low load

0.007 0.15 0

15Optimized the operation of Cooling Tower fan by installing auto cut off system

0.05 0.19 0

16Procurement of Energy Efficient (IE3) Motors for New Projects & Replacement of Motors with New Energy Efficient Motors

1.52 4.09 3

17Installed kVAR Energy Controller for optimizing Power Factor at Load end

0.15 0.29 0



13




Payback(Months)

18Chiller Secondary pumps common line arranged for two loops for optimizing the operation of pump sets

0.1 0.21 0

19Installed interlocking systems between Primary pump and Compressor Unit in Chilling Plants for avoiding running of pumps during off times

1 1.25 12

20Replacement of aged 300 TR VAM and Reciprocating Compressors with New 320 TR Energy Efficient Double Effect VAM

4.15 6.81 8

21Replacement of Old & Energy Intensive Reciprocating Air Compressors with New Energy Efficient Air Compressor of 120 CFM

1.6 0.74 0

Total 15.5 30.5 6



14




Payback(Months)

1Installation of Oil Free Refrigeration (OFR) Technology and automation of Chilling Plant

2.02 2.03 12

2Installation of New +5 250 TR Chilling Plant by Replacing old and vintage VAM System

5.32 2.83 30

3Street light timer arranged to avoid lights unwanted time for conservation of energy

0.01 0.023 0.1

4Automatic switching off of cooling tower fans with respect to return water temperature for Cooling Towers

0.5 1.44 0.1

5Installation of 85 kVAR Capacitor Bank at Load at i.e. 195 HP motor for Improving Power Factor

1.37 0.81 0.1

6Installation of Energy Efficient LED lights by Replacement of old and energy intensive lighting appliances

1.38 2.38 6

7Upgradation of 33 kV to 132 kV by installation of 132 KV Substation dedicated feeder to reduce the power shut down and energy cost

84 36.4 28




S No Project DetailsInvestments

(₹ Million)Annual Savings

(₹ Million)

Payback(Months)

8Procurement of Energy Efficient (IE3) Motors for New Projects & Replacement of Motors with New Energy Efficient Motors

1.3 3.31 4

9Installation of New Level 2 Transformer in Electrical Systems

1.6 0.34 0

10Optimization of Chilling Plants Operations to take benefits of available low atmospheric temperature during Winter Season by suitable Line modifications

0.1 3.9 0

11Replacement of VAMs and Reciprocating Chiller with Energy Efficient Water Cooled Screw Chiller

5.77 8.92 7.5

Total 103.3 62.3 20

15



Replacing compressor oil with Specially Designed oil for better lubrication

VFD to Compressor for Smooth start & Optimum Loading

Magnetic Catalytic Filter with pump to remove NH4OH and generate turbulence in Refrigerant flow

Magnetic Oil Separator to remove oil traces

16

#1 OIL FREE REFRIGERATION (OFR)

START

28/12/19

Start Finish

17/03/20

MOTNHS

19.4

45.3 Lakh/Y

73.68 LakhINVESTMENT:

SAVINGS:

6.96Lakh Units/Year

Solution Implemented

To Improve Energy Efficiency of Chilling plants

OFR Circulation Technology


17

1

#2 DEHYDRATOR IN SRS COLUMN

23/12/18

Start Finish

12/08/19

MOTNHS

6.686.52Lakh Units/Year

Works on the principle of adsorption

Utilizes internal heating and cooling

Very high cooling efficiency with short gas path for heat transfer: reduces cool down time

Eliminated operation of -20 oC, 150 TR Chiller.


Replaced aged energy intensive PSA based Ethanol recovery system

562.4 Lakh/Y

310.6 LakhINVESTMENT:

SAVINGS:

Molecular Sieve Dehydration


18

#3 OPERATIONAL IMPROVEMENTS

Replacement of inefficient Evaporators & Condensers

Decreasing Evaporator Temperature

Descaling, Fills & CT lines cleaning

Swapping of pumps, line size modifications

Reduce the pressure setting in Air Compressors

Finish

31/03/20


MOTNHS

53.47Lakh Units/Year

Optimization of Utilities such as Chillers, pumps and Air Compressors

349.3 Lakh/Y

10INVESTMENT:

SAVINGS: MOTNHS

0.3

01/04/19

Start

Lakh

Arrived Effective Maintenance


19

Installed -65 oC ( 2 Nos) & -35 oC Refrigeration plants

Higher efficient cooling as compared to Nitrogencooling

Installed 500 Nm3/hr Nitrogen Generation plant

17/11/18

Start Finish

15/03/20

172.8Lakh/Y

SAVINGS


#4 REPLACEMENT OF LIQUID NITROGEN

YEARS

776.9

INVESTMENT

Lakh

Eliminated the usage of Liquid Nitrogen (Cost Intensive) for Cooling

applications

YEARS

4.5


20

Installed 4.5 MW & 35 TPH Captive Power Plant

Caters steam to process & Power for production

Reduces the power cost as compared with GRID

Replaces the existing aged Process Boiler


YEARS

Replacing existing aged boiler & to self generation of Power with Cogeneration

Power Plant

#5 CAPTIVE POWER PLANT

648 Lakh/Y

SAVINGS

4000

INVESTMENT

Lakhs

YEARS

6.2

17/11/18

Start Finish

12/03/20


21

1939 Lakh/Y

TOTALELECTRICAL

SAVINGS

TOTALMONETARY

SAVINGS

TOTALINVESTMENT

RESULTS ACHIEVED – 2019-20

167Lakh Unit/Y

MONTHS

8PAYBACKPERIOD

1257Lakh/Y

1271Tons /Y

TOTALCOAL

SAVINGS

Tons of CO2

16,169CO2

REDUCTIONS


22

6. Innovative Projects implemented

I. Utilization of ATFD flash steam for preheating of the MEE feed in Group B Column

Trigger for implementation : Huge flash steam available as 6 kg/

cm2 steam after use converted into condensate

To reduce the steam consumption

To reduce the load on CTs

Replicability :

Yes, huge replication opportunities

All ETP and other waste treatment

SRP and Process Waste heat Recovery

Taken up for implementation

Safety Requirements :

The top recovery from flash tank to

column is about 15- 20 M height

Need fabrication and line

arrangement at that height is risky

Results :

Coal Savings = 823.5 T / Y

Monetary Savings = 51.1 Lakh / Y

Impact on SEC = 12 %

Investment = Nominal

Jan 2019

Time


23


II. Utilization of waste heat form Stripper Solvent steams for preheating the MEE feed in Group A Column

Trigger for implementation :

To utilize the waste heat available in

stripper solvent vapours

To reduce the steam consumption

To reduce the load on CTs

Replicability :


All ETP and other waste treatment

SRP and Process Waste heat Recovery


Safety Requirements : The top recovery from stripper is

about to 25- 30 M height

Need to closer to MEE

Need fabrication and line arrangement at that height is risky

Results :

Coal Savings = 247 T / Y

Monetary Savings = 15.3 Lakh / Y

Impact on SEC = 4 %

Investment = Nominal

Jan 2019

Time


24


III. Utility Automation in Crystallizers for Avoiding loss of energy – 6 Nos

Trigger for implementation : Manual operations are not giving

consistency Product quality enhancement To reduce and optimize the utility

consumption such as Chilled water & RT water

Replicability :


Utility automation in process areas


Safety Requirements :

This implementation required

assurances and approval of QMS

system

Results :

Reduction in Batch Time Cycle

Operational improvement

Reduction on Utility Load

Investment done 15 Lakhs for 6 Nos of crystallizers

2018-19

Time


SNo

Project DetailsProposed

Investment(₹ Million)

Expected Monetary Savings/ Annum

(₹ Million)

Payback(Months)

1Replication of Oil Free Refrigeration (OFR) Technology and Automation of Chilling Plants

12.6 5.02 30.3

2Installation of Screw Chillers by replacing old aged Reciprocating Systems

25.2 45.5 6.6

3Installation of Double effect VAMs (2000 TR) by replacing Air Cooled Chillers and Reciprocating Chiller for +5 oC applications

35 42.4 9.9

4Installation of RO Plant, Cooling Tower and ETP Revamping for Water quality Improvement in CTs - Under Final Stages of Commissioning

127.2 31.54 48.4

5Installation of 4.5 MW Captive Power Plant for self generation of Power & Steam and avoiding the operation of existing aged process boilers

400 64.8 73

6Installation of Energy Efficient pumps by replacing old inefficient pumps

3.6 5.7 7.6

7Installation of Softener System for Water Quality Improvement in Chilling Plants - Under Final Stages of Commissioning

4.5 1.66 32.6

8Installation of Membrane Bio Reactor (MBR) System in Effluent Treatment Plant (ETP) for reducing the Steam Consumption -Under Final Stages of Commissioning

44 19.92 26.5

25

7. Major Encon Projects in FY 2020-2021


26

Finish

01/05/17Installed 30MW Solar Power Plant

4270.50

3926.50

3203.80

2981.302813.30 2749.9

2878.7

3354.33207.4

3292.1 3335.7

3959.4

2000.00

2500.00

3000.00

3500.00

4000.00

4500.00

Apr-19 May-19 Jun-19 Jul-19 Aug-19 Sep-19 Oct-19 Nov-19 Dec-19 Jan-20 Feb-20 Mar-20

MW

h

Generation FY-19-20

Start

13/12/16

YEARSYEARS

5.8339.72Lakh Units/Year

22.6 Crore/Y

130 CroreINVESTMENT:

SAVINGS:

8. Utilisation of Renewable Energy sources

Technology

(electrical)

Type of

Energy

Onsite/Offsit

e

Installed

Capacity

(MW)

Generation

(million

kWh)

% of overall

electrical

energy

Solar PV Solar Off Site 30 33.9729 10.6


27

YEARS

9. Waste utilization and management

S No Type of waste generatedQuantity of waste generated (MT/year)

Disposal method2019-20 2018-19 2017-18

1Evaporation Salt, ETP Sludge, Cooling tower fills and Glass wool

5,353.32 6,201.53 4,880.42Secured land filling to

HWMP

2Mixed Spent Carbon, Liquid Organic waste and Used Filter pads

6,044.32 6,201.53 2,164.85Co-Processing to Cement

Units

3Biomedical waste and

Thermocoal14.82 5.45 26.77

Incineration to M/s Dharma & Co.& M/s

RAMKY

4 Used Oil 16.20 3.80 12.20 Authorised recycler

5 E- Waste 0.24 0.25 - M/s RAMKY

As mentioned above, waste with heat value is not utilised directly in the plant,

Sending to the Cement industry / Co- Processing units where it is used as an alternate fuel


28

YEARS

10. GHG Inventorisation

26000

27000

28000

29000

30000

31000

32000

2016-17 2017-18 2018-19 2019-20

2964228750

31501

28500

kg C

o2/

Ton

Year

Total kgCO2 / Ton of Final Product

S.No Type of system installedInvestment

(Rs in Million)Operating Cost (Rs in Million)

Running Hours

1Continuous Ambient Air Quality

Monitoring Station3.2 0.16 24

Year

Scope 1 emissions kgCO2 / Turn of Final

Products


Products


Products

TotalkgCO2 / Turn of Final

ProductsTons / Turn of final

Product2017-18 15,371 13,161 218 28,750

2018-19 16,790 14,644 67 31,501

2019-20 15,772 12,694 35 28,500

Sustainability report under progress of

preparation

As a part of the continual improvement,

the company has initiated monitoring of

the CO2 emissions for public reporting.

Carbon foot print, reduction targets and

action plans yet to be established.


29

YEARS

11. Green Supply Chain Management

S.NoProjects

ImplementedBenefits Achieved

Description

1Shipper Stuffing Project

Rs 190 Million

Increased loading by 30% to 33% Extra optimization in container with shipper stuffing, Saved freight on additional container had it not been shipper

stuffed. It enabled no dependency on the wooden pallets.

2Double Stacking Injectable Project

Successfully implemented with 50% extra space

3Paperless / Digital Logistics Execution – OTM Project

Decreased Paper consumption and paper less / Digital transactions

First Pharma company in India to adopt OTM. Cloud based Solution Freight Payments linked from OTM to ERP.

4AIR vs SEA – Mode Control

Decreased Carbon Emissions

Increased Sea transportation over Air transportation by pallet systems.

Decreased air Tonnage from 572 Tonnage to 456 Tonnage

5 GST e-Invoicing

Decreased Paper consumption and paper less / Digital transactions

Invoices are authenticated electronically and hence paperless Invoice information will be transferred from the portal in real-

time. Govt. Initiatives for ease of doing business of

exporters/importers


30

YEARS

11. Green Supply Chain Management

S.NoProjects

ImplementedBenefits Achieved

Description

6AEO (Authorized

Economic Operator) Certification

Less paper / Digitalization

Requires limited physical/ hard copy It requires no physical examination for AEO T2 certified

, and hence less paperwork. All documents needs to be upload to ICEGATE through

e-Sanchit. This supports Airlines/ Ocean Liners for the Paperless

transactions

7IMO 2020 Adoption for

less pollution-free marine ecosystem.

Less Pollution Free -Marine eco System

This initiative seek to control airborne emissions from

ships

Limit Sulphur emission to 0.50 percent m/m from

01.01.2020

85.7 % reduction from the current 3.5 percent m/m

limit.


31

11. Teamwork, Employee Involvement & Monitoring

1. Daily Real Time Energy Monitoring System

Implemented across all Refrigeration Systems – 25 Nos

Daily Monitoring, Reporting and Reviewing


32

2. Energy Efficiency / Awareness training program

1. Attended three-days online Training Programme on Advanced Energy Efficiency conducted by CII

2. Organized Engineering Symposium- Engineers Meet within Group Units to share / exchange the best practices

3. Participated in 4th edition National Energy Efficiency Circles Competition by CII and won 2nd runner up

4. Organised Training Programme on Pumps, Motors and Steam System provided by Suppliers



33


3. Summary of Projects implemented through Kaizens 2019-20

With investment (Revenue )

S NoInitiative

departmentInitiatives Completed

To be completed

InvestmentSavings /Annum

Rs.ROI in

months

1 Mechanical 28 9 19 9,09,000 14,66,324 7

2 Utility & Boiler 4 2 2 1,74,300 14,30,005 0

3Electrical &

Instrumentation12 8 4 2,82,360 5,94,571 6

Total 44 19 25 13,65,660 34,90,900

Without investment

S No Initiative department Initiatives CompletedTo be

completedSavings /Annum

Remarks

1 Mechanical 2 2 0 3,04,389 All initiatives are

completed

2 Utility & Boiler 6 6 0 39,23,869 All initiatives are

completed

3Electrical & Instrumentation

0 0 0 - -

Total 8 8 0 42,28,258 closed



4. Projects implemented through Kaizens

34

S No Description of the activity with investment InvestmentEstimated

Savings Rs/ Annum

Achieved Savings

Rs/Annum

1 L&M Utility 1000 TR Cooling Tower Partial loaded 60 HP Motor Stopped - 1,272,896 1,214,467

2 Auto control of -70 sec. pump in F&G utility using VFD and PID controller. 58,860 130,249 122,567

3 CT Fan Motor RPM controlled by Temperature controller(SRP Ceph) 74,000 140,181 133,732

4 Replaced 2X40HP Pumps (100m3/hr,65mH)with 1X50 HP pump (200m3/hr,40 mH) Internal shuffling 1,144,866 1,017,709

6 Auto control of I Block RT Pump(Pressure vs RPM) using VFD and PID Controller 112,000 248,843 3,828.24

8 Auto control of L Block RT Pump(Pressure vs RPM) using VFD and PID Controller 112,000 182,238 151,071

9 Auto control of A Block RT Pump(Pressure vs RPM) using VFD and PID Controller 86,500 239,677 228,640

10 Auto control of B Block RT Pump(Pressure vs RPM) using VFD and PID Controller 76,000 220,560 209,864

11 Auto control of C Block RT Pump(Pressure vs RPM) using VFD and PID Controller 80,000 270,120 251,393

12 Installing VFD to CU General air compressor(ACU022) using pressure transmitter. 61,000 136,910 130,607

Total 660,360 2,713,644 2,111,851


35


5. Type of Projects implemented through Kaizens

Installation of VFD’s for Pumps, Air Compressors and CT fans for efficient & optimum loading operations.

Replacement of AHU'S DX coil Cooling Circuit with chilled water at Main Ware house for conservation of energy.

Optimization of the operations of vacuum pumps in Solvent Recovery & Production blocks by replacing with suitable utility systems.

Replacing Aluminum Blades by FRP Blades in the Cooling Tower for conservation of energy.

Installation of IR Motion Sensors at server room & AHU Area in Lighting system for Automatic Switching off during non occupancy hours.

Utilization of waste heat available from Stripper (Top collection vapours) and ATFD (Flash steam) for preheating the MEE feed in Group A and Group B columns respectively.

Installation of Steam traps by Replacing Old non working Traps in the steam Header system.


36

12. Energy Management System

• Driving Energy Management System

• Approval & Budget Sanctions

• Allocation of all required resourcesSenior Management

• Providing Technical Inputs

• New and Innovative Energy Conservation Ideas

• Review and Submissions to Senior Management

Vice president (Corporate Engineering)

• Energy Assessments with all portable instruments

• Review and of Energy Conservation Proposals

• Coordinating with all stake Holders for ImplementationEnergy Cell (Corporate)

• Support in Energy Assessments ( Allocation of all Resources)

• Prepare and submission of energy conservation

• Seeking approvals at plant level

Engineering Head

(Unit wise)

• Daily data monitoring and reporting on energy projects

• Participate in Energy Assessments along with Energy Cell

• Ground level implementation of energy conservation proposals

Energy Team - PoC

(Unit Wise)


37

S No Instruments Make

1 Power Quality Analysers (2 Nos) Krykard

2 Flue Gas Analyser Kane(NEVCO)

3 Thermal Imager Testo

4 Ultrasonic Flow Meter Eesiflo

5 Ultra Sonic Thickness Gauge Eqinox

6 Pitot tube Nevco

7 Digital Manometer / Pressure meter Comark

8 Hotwire Anemometer Testo

9 TDS / pH Meter Aquisol

10 Stroboscope / Tachometer Extech

11 Humidity, DBT & WBT Meter Testo

12 Digital Pressure Guage Testo

13 Lux Meter Extech

14 Stop watch Extech

15 Psling Psychrometer Dimple

13. Energy Audit Instruments


38

14. Daily Monitoring & Reporting System

• Real Time Parameters

• Loading Pattern

• Manual Data CollectionHOURLY

• Performance Reports

• KPIs

• Overall Consumption

DAILY

• Avg. Monthly Report

• Recommendation for any service / Maintenance

• Inter - Unit Comparisons

MONTHLY


39

15. Long Term Vision on EE

S.No Challenge Long term Vision Present Status Technical/Financial Assistance

1Instrumentation (In-situ)

Highly accurate, precise and consistent data

Instrumentation are obsolete / inaccuracy or erraticism

• Identification of suitable vendors

• Low cost based solution

2IoT based energy monitoring Systems

Continuous real-time data monitoring

Manual / Semi-Real time monitoring systems

• Identification of suitable Vendors

• Low cost based solution

3Implementation of Online Energy Audit Tools

To have in-line data monitoring instruments with MIS

Portable Measuring instruments used which enable Instant Energy Assessment

• Creation of energy audit tools for

all equipment

4Replacement of old Electrical Motors

Phased manneraadopting all Energy Efficient Motors

Motors are old and have low energy efficiency rating

Technical & Financial assistance

5Awareness / Training Programmes

Building effective inter unit relations for knowledge sharing and problem solving

No Structured and training program for Energy Conservation

Periodic Training programs customized for different functional need


40

16. Learning from past CII award programs

i) Procurement (New & Replacements) of energy

efficient motors

Procurement of Energy Efficient Motors yearly around

300 motors with tentative savings of 6 -7 Lakh units in a

year

ii) Replacement of old & Reciprocating Chilling plants with

new Screw Chilling plants

Reciprocating Chilling plant having excess energy

Replaced new screw type energy efficient Chillers

iiI) Implementation of IoT Based (Industry 4.0) Online

Energy Monitoring System

Implemented across all 25 No’s of Chilling Plants –

Daily monitoring and attending the discrepancies


41

17. Awards & Recognitions


42

17. Other Awards & Celebrations

Best Innovative Packaging - IPA ACG SciTech GOLDEN Peacock Award – Environmental Management Value Champions Award – Staff College of India

Energy Week Celebrations Safety Day CelebrationsEnvironment Day Celebrations


43

18. CSR Activities


14 Villages Adopted

48 Water Drinking Plants

350 + Healthcare Programme

21 Educational Institutions

43

Thank You

Aurobindo Pharma Limited,Hyderabad – 500 084Telangana, India

Phone: +91 (40) 6672 5000Fax: +91 (40) 2374 1080 /

+91 (40) 2374 6833,Email: [email protected]


aurobindo pharma limited unit i , hyderabad · energy saving projects implemented in last three...

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