cii - 11th national award for award-2010... · cii - 11th national award for “excellence in...

1

1

CII - 11th National Award for

“Excellence in Energy Management - 2010”

1 & 2 Sep10

Delphi-TVS Diesel Systems Ltd

Presented by

1.P.Premkumar

2.S.Murugesan

3.S.Ramesh

2

• The company was established in 1990 and a part of TVS Group.

• TVS group is the largest auto component manufacturer in India.

• Delphi TVS is a joint venture between Delphi USA and TVS India.

• Delphi USA is the largest manufacturer of automotive systems.

• Delphi TVS manufactures Diesel Fuel Injection Systems and

the Products are fitted in the Cars and Utility Vehicles.

Corporate Profile

2

3

Delphi-TVS Factory

PLANT II – UTTARAKHAND, PLANT III – ORAGADAM, CHENNAI

PLANT I MANNUR,CHENNAI

4

Largest Indian Manufacturer of Rotary Fuel Injection Equipment

Pump Car Pump Van Pump Tractor

Injector TractorInjector Filter

3

5

Escorts

Our Valued Customers

6

HARD STAGE HARD STAGE

SOFT STAGE SOFT STAGE

HEAT TREATMENTHEAT TREATMENT

INJ.ASS & TESTPUMP.ASSY&TEST

INJECTORFILTERDIESEL PUMP

VENDORS VENDORS

VENDORS

Process Flow Chart

Filter Cell

4

7

8

Electrical Electrical Kwh/ Ton or unit of prodn

Electrical

- 2.06273.1273181122.97 19.97 2006-07

1.25 68.71 329798 147.35 22.67 2009-103.57 69.58261213131.3 18.18 2008-091.29 72.16 291981 134.62 21.07 2007-08

Rs Million

Kwh Million

Redn. in Specific Energy

consumption over previous

year

Specific Energy

Consumption

Prodn in tons or any other unit of prodn

Annual Energy consumption

Year(Apr-Mar)

Specific Energy Consumption

5

9

Benchmarking

§ Difficult to Fix Benchmark (National&International)

due to Variation in Process (Competitors &Collaborators).

§ Internal Benchmark arrived to Plan Improvements.

10

68.71Internal Benchmarking

(Based on Encon Policy)

66.9Units ( KWH/FIE)1

ManufacturerRecommendations

(Cummins )

ManufacturerRecommendations

(MAN B&W)

Basis

3.503.60SFC(HSD)3

4.014.05SFC(HFO)2

Current Level

Bench MarkParameterNo

Benchmarking

6

11

7020426

Annual Cost Savings achieved (Lakhs)

4110232009-1035823202008-09495192007-08

Investment (Lakhs)

Annual Energy Savings

Achieved(Lakhs)

No of Projects Implemented

Year

35.84.1672009-109.91.6552008-097.41.1642007-08

Annual Cost Savings achieved (Lakhs)

Annual Energy Savings achieved (Lakhs)

No of Projects Implemented

Year

SUMMARY OF ENCON PROJECTS FOR PAST THREE YEARS

Projects with no Investment

12

2007

2007

2007

2007

2007

2007

2007

Year of Implementation

-0.480.08To switch off hydraulic motor when m/c is idle for more than 10mins(23 nos)

7

0.020.130.003Replace standalone panel coolers with panel mounted coolers (6nos)

3

0.020.10.023Solar water heater for ultrasonic washing m/c at HT shop

6

0.162

0.15

0.824

0.17

Investment (million)

0.170.04Install 99KVA (coolite energy saver) for factory and street lighting part 1.

4

0.030.007Replace inefficient AHU at Nozzle and Barrel hard stage (EE motor, EE Fan, Flat belt).

5

0.040.01Replace the inefficient air drier and optimize the size

2

0.120.027Replace the inefficient pumps with energy efficient pumps(2nos.)

1

Cost Savings

(in million)

Units savings

(in million)

Energy Project Implemented No

Projects Implemented (2007-10)

7

13

-0.220.032007Plc logic modified to run hot air blower during washing only.

8

2.50.60.1520071500KW HT AVR in place of inefficient 750KVA Transformer.

12

0.0180.060.0142007Replacing indirect oil heating by direct heating at Parco lubrication.

13

2007

2007

2007


0.0960.0360.006Automation of Chiller operation for Match Grinding AHU

11

-

-


0.020.003Level sensor Introduced for coolant motor for micromatic m/c(Nozzle)

10

0.020.003Logic introduced to switch off feed motor and coolant motor when main motor is stopped (Nozzle-Wick man)

9

Cost Savings

(in million)

Units savings

(in million)



14

0.60.420.072007Optimization of compressor operation (400CFM in place of 680CFM during Lean hours)

14

0.090.0780.0182007Use of VFD for AHU (VCO Nozzle).15

0.050.01-2007Optimization of steam lines in kitchen considering additional requirements.

16

2007

2007


0.10

0.023


0.0160.004Solar street lights(4nos)18

0.02-Install magnetic resonators to improve combustion efficiency in 1.9MW HFO DG set.

17

Cost Savings

(in million)

Units savings

(in million)



8

15

0.060.190.0352008Use the spare capacity available in AMS make CNC(15kva) machining centre to machine pump housing and achievea.Cycle time reduction(120sec to 20sec).b.Eliminate 2nos of HMT Milling m/c (2*12.5 HP Motor)-Innovative Project

21

0.590.270.0452008Replacement of inefficient air driers and optimize the size (1500CFM instead of 3nos of 600CFM).

20

0.0250.250.0422007Combining coolant tanks to use singlecoolant motor instead of two motors and optimizing motor Sizea.Zusaman&micromatic (small parts)b.Paragon&micromatic

19



Cost Savings(in million)

Units savings (in million)



16

228.81.462008Install 375 TR Vapour Absorption Machine using Waste heat from Flue gas and Jacket Water from 1.9MW HFO DG(Switch off 2nos of 70TR and 2nos of 100TR Vapour Compression Chillers)

22

0.0040..0050.0012008Replacing 36 w lamps by T5 28w lamps (50nos).

23

0.160.140.022008Lub oil separator (to utilize waste heat from Separator and decrease auxiliary consumption of HFO generator). –Innovative Project

24

0.590.540.092008Replacement of Split A/C (33TR) in BAY-6 (Hard Stage) with AHU and using VAM.

25

1.140.7520.1362008Replace inefficient compressors at CR(2nos of 240 CFM &1no200 CFM with vary Feed capacity 632 CFM(sullair)

26




Units savings

(in million)

Energy Project Implemented

No


9

17

0.0990.140.0252008Install 50KVA Coolite Energy Saver for canteen and office lighting and street lights

27

0.0160.042-2008Improve combustion efficiency - canteenboilers and multistage evaporator by adjusting burners

28

2008

2008


6.9

1.15


5.25-Installation of 1MW HFO DG Set to replace rental DG sets (1000KVA & 500KVA)) by providing infrastructure (sharing the infrastructure of 1.9MW)

30

0.720.13Optimization of compressed airEnergair for automatic control of air compressors (Supply side)Control air to meet the Peak Demand (Demand side)

29

Cost Savings

(in million)

Units savings

(in million)



18

-0.820.152008Process change at Gas Nitrating area:-Eliminate Preheating using Activation process(650 deg C) before processing at GNF by using manual cleaning (Added Benefit Ammonia Saving)

31

0.510.610.112008Install VFD for AHU’s at BSH, 6th bay, Nozzle VCO operating them in closed Loop(3nos)

32

2008

2008


2.3

-


0.210.036Implementation of Up flow anaerobic sludge blanket reactor schematics in place of aerobic synthetics.

34

0.0140.022Automatic Switching off motors when idle-intermittent usage (Pump Sub assembly)

33

Cost Savings

(in million)

Units savings

(in million)



10

19

0.0040.0590.0092008Productivity Improvement(20%) in Scroll plate in CNC Voumard by modifying the fixture for Machining 5 pieces in a cycle instead of 4

35

0.0700.0460.0082008Productivity Improvement(15%) in Cam roller Shoe ID grinding by Automation of Component loading & unloading

36

0.060.190.0322008Modifying the grinding wheel grade and improving the Dia role in BLOHM M/C to reduce cycle time out of two M/C one M/C become Surplus

37

0.100.41-2008Installation of magnetic resonators to reduce the fuel consumption in 1MW HFO

38



Cost Savings

(in million)

Units savings

(in million)



20

-0.090.0132009Downsizing of Hydraulic Motor in a.) Barrel Soft Stage – 3HP to 1HPb.) Rotor (line 3) – 2HP to 1HP

42

2009

2009

2008


0.0010.1620.027Combining the chiller10TR for oil for CAM roller ID grinder (2 M/Cs into a single one)

41

-

0.002


0.0090.0015Removal of redundant motor in thefollowing M/Cs after replacing theConveyor with Gravity Chutea.Cam valve Reaming (1 no)b.Centre less Grinding (1no)c.Mobile core assembly motor (1no)

40

0.0140.002Modifying the filtration system in ImecoWASHING M/C and removing the redundant motor Before: 2 Nos of 2 HP pump After : 1 no of 2 HP pump

39

Cost Savings

(in million)

Units savings

(in million)



11

21

0.050.0220.042009Replace conventional metallic blade of man cooler fans with FRP Blades.

46

0.020.2160.0362009Closed loop arrangement for New small parts (A/c area)

47

2009

2009

2009


0.040.040.007Up gradation of Inefficient obsolete 400 CFM drier with Energy Efficient eco-friendly drier to achieve reduction of pressure drop to 0.18 bar from the existing 0.33 bar

45

-

0.002


0.060.01PLC Programming for Radiator for automatic switching on/off radiator fans based on water temperature.

44

0.0060.001Automatic Control of Conveyor using Sensor in Aluminum Cell

43

Cost Savings

(in million)

Units savings

(in million)



22

0.0960.080.0132009Replace VAM chiller water pump with energy efficient Pump (Before:30KW :After :22KW)

48

0.0800.110.0182009Install high efficiency pump for Heattreatment Cooling tower

49

0.50.230.072009Use roots blower instead of Compressed air for phospating Plant -50CFM

53

2009

2009

2009


0.50.230.07Replace the existing reciprocating compressor with new screw compressor(400cfm)

52

0.19

1.1


0.150.025Install VFD for screw Compressor (ENGGCentre)- 22KW

51

0.1080.018Heater modification in SQF to increase the availability (to reduce MTTR)-Reduce Shutdown and Start up losses

50


Units savings (in million)



12

23

0.270.320.0542010Replace the conventional motor withEnergy efficient motor(7.5HP in the Following areas)parisudh-4nosmicromatic- 3nos

54

-

-

0.3

1.2

0.04

0.17

2010

2010

Interlock :a.Hydraulic pump to be interlocked with the Cycle start in vacuum Hardening Furnaceb. Provided between the cooling cell temperature and Lid fan I GNF .

55

2010

2010

2010


-

-

-


1.69

0.25

0.15

0.14

0.035

0.02

c.Cooling cell fan to be interlocked with Load Sensor in HT Furnaced.Chiller and Quench motor to be interlocked with cycle start in ELVA-2e.Coolant pump to be interlocked with level sensor in ID Grinding


Units savings(in million)



24

0.030.540.072010Reduce the no of Operations for Parco Plant 18hrs instead of 24hrs by suitable Queuing of Jobs

56

0.040.1450.0212010Replace existing SQF Cooling tower pumps with new Energy Efficient pump(Before:15KW ,After:7.5KW)

57

-0.3010.0432010Coolant tank filtration modification in Blohm Coolant Tank System –Innovative Project

58

0.050.1450.0212010Optimize Common Rail Chilled waterpump with new Energy Efficient pumpIn UPCR Area (Before:9.3kw,After:7.5kw)

59



Cost Savings

(in million)

Units savings

(in million)



13

25

0.0150.3890.062010Interlock provided between the low temp tempering furnace and the post washing (sqf-3) and optimize the usage of Furnace to avoid rejection

60

0.0200.100.0142010Automatic switch off by timers for Office Airconditioners

61

-0.0450.0062010Level sensor to be provided for Alkali spray pump in SQF-1 &2 Post Washing

62

44.7030.053.91Total



Cost Savings

(in million)

Units savings

(in million)



26

Jun10

Apr10

Aug10

Aug10

May10

Target

0.08

0.003

0.005

-

0.05

Investment

(million)

3

Immediate

1

Immediate

1

Payback Period

(Months)

0.32-Installation of water level controller for RO water tank in remote location.

4

0.170.02Water pump, cooling tower fan to be interlocked with water temperature

3

0.300.04Chiller’s Temperature sensor location to be changed (80 numbers )

5

0.230.04Idle /Sleep timer for CNC and PLC machines

2

0.600.09Common coolant tank for OD and surface Grinders in cam ring cell

1

Cost Savings

(in million)

Units savings

(in million)

Energy Project Planned for 2010-11

No

Projects Planned for 2010-11

14

27

30.050.280.04Jun10Installation of pressure booster for Chiron and Mikrosa m/c.

6

70.050.0980.014Jun10Installation of Wind Ventilators in Heat Treatment area and Contactor Shed.

7

Aug10

Aug10

Target

0.168

0.20

Investment

(million)

2

8

Payback Period

(Months)

1.134-Reducing the room temperature of 1.9MW HFO Genset by providing Exhaust duct to alternator

9

0.320.046Reduction of Intake air in Compressed Air Room (from 32ºc to 26ºc)by providing suitable Exhaust Ducting.

8

Cost Savings

(in million)

Units savings

(in million)


No


28

20.0200.20.03Aug10One transfer pump instead of three pumps in BSH Area (Before:3x2.2kw,After:2.2kw)

10

3.50.250.850.12Aug10Thermal insulation between hard stage machines and washing machines to reduce heat load in AC area

11

30.0820.432-Sep10Optimizing HFO Consumption by feeding non-essential auxiliary loads in TNEB

12

220.220.120.02Sep10Install new efficient pump for chiller pumping operation (Before:1x9.3,1x5.5,2x7.5,After:15kw)

13

Target Investment

(million)

Payback Period

(Months)

Cost Savings

(in million)

Units savings

(in million)


No


15

29

110.91.00.14Oct10To maintain the intake air , and cooling water temperature of HFO Gen set ( as per mfg recommend)

14

480.680.1680.024Under Progress

Installation of 168 nos of light Fitting instead of 2*36w Light Fitting in MFG area.

15

400.040.0280.004Under Progress

Replacement of 250W MHL by 4*54w t5 Light Fitting in heat treatment gangway(20nos) .

16

1816.510.8-Nov10Reduction of Fuel Consumption by installing 500KVA UPS and fed critical manufacturing loads with TNEB

17

18.9817.210.62TOTAL

Target Investment

(million)

Payback Period

(Months)

Cost Savings

(in million)

Units savings

(in million)


No


30

No of Encon Projects

17232019

05

10152025

2007-08 2008-09 2009-10 2010-11

Annual Energy Savings (Lakhs)

710

23

5

0

5

10

15

20

25

2007-08 2008-09 2009-10 2010-11

72.16

69.5868.71

66.9

64656667686970717273

2007-08 2008-09 2009-10 2010-11

2007-082008-092009-102010-11

Sp.Energy Consumption

Target

Investment (Lakhs)

41

358

49

189

0

100

200

300

400

2007-08 2008-09 2009-10 2010-11

Sp.Energy Consumption- Target (2010 – 2011)

16

31

Machine tank

Coolant transfer pump

COOLANT RETURN PUMP

0

0

BEFORE MODIFICATIONAFTER MODIFICATION

COOLANT PUMP

TANK TO MACHINE

M / C

Project-1:Coolant Tank Filtration System Modification

Coolant filtration tank

B (2500 L)


B (2500 L)

Clean Coolant tank

A (2500 L)

32

Machine tank

COOLANT RETURN PUMP

0

Clean Coolant tank

AFTER MODIFICATION


COOLANT PUMP

TANK TO MACHINE

M / C


17

33


By modifying Coolant tank filtration system ,we eliminated one 7.5HP Pump.

• Energy Saved - 120kwh/day

• Annual Energy Savings - 43,200 kwh /day.

• Annual Cost Savings - Rs. 3.1Lakhs

34

After: We use ONLY ONE AMS for cover face millingCycle time is 20 sec/component/machinewith the help of 100 dia cutter our team saved 100 secsTwo machines costs - Rs. 5.8 lakhs

Reduced by 78%10 mins / day45 mins / dayM/c cleaning timeReduced by 74%Rs 0.10 / compRs 0.38 / compTool costReduced by 15%52 secs60 secsTake time for aluminum cell

Power cost reduced by 93 %Rs 0.097 / compRs 1.444 / compPower cost

Manual work eliminatedNot requiredRequiredLoading for millingTime reduced by 85%15 secs100 secsCutting time

Space reducedAMS BT 30HMT MILLING M/CCover face milling

BENEFITSAFTERBEFOREOPERATION

Before: We are using TWO HMT MILLING M/C’ sfor cover face milling in De coupled turning centresCycle time is 120 sec / component / machine

AMS BT 30

Project-2: Process Improvement

NET COST SAVING 2.0 LAKHS /ANNUM

18

35

Project-3 Lube Oil Circuit Energy Economiser

• Lube oil temperature required for effective Separation - 85ºC

• Optimum temperature required for bearing lubrication - 65ºc-75ºC

Requires purified lube oil to be cooled by water.

Resulting in the process of heating and cooling.

WASTE OF ENERGY• Lube oil going to Separator - 60ºC

• Lube oil coming From the Separator - 88ºC

We can utilize this heat to heat the incoming lube oil to the separator there

by reducing the load on the heaters.

36

GENERATOR

L.O SEPARATOR

ECONOMISER

24 K.W OIL PRE HEATER

BEFORE MODIFICATIONAFTER MODIFICATION

60°C 88°C

85°C62°C

POWER CONSUMPTION. 5.85 KW 3.1 KW

HEAT RECOVERY FROM LUB OIL SYSTEM

Traditional Method Lub Oil Economizer

Lube Oil Circuit Energy Economiser

Lube oil Temp before heater - 60° C

Lube oil Temp after separator - 88º C

Temperature raise in the circuit - 28º C

Heater consumption per hr - 5.85 KW

Lube oil Temp to PHE - 60º C

Lube oil Temp out of PHE - 74º C

Temperature raise - 14º C

Energy saved per hr - 2.70 Kw

Annual Savings - Rs. 1.36Lakhs

19

37

Energy Management -Organization Structure

Sr.GM(MFG)

Energy Leader

Utility Manager

Utility Team Encon Team

EVP(Opns)

DGM(WED)Energy Manager

Electrical Mechanical

38

Extent of Team Work in Encon

In progressExpected savings -2Lakhs/annum.

Supervisor - 1noOperator- 2nosTechnician -1no

2010Supervisor Install pressure booster for Mikrosa machine and reduced pressure setting to 5.8bar from 6.3bar from the main compressor house.

4

In progressExpected Savings of 14000/annum.

Supervisor -1noJunior Engineer -1noElectricians -4nos

2010SupervisorReplacing 250 w MHL Lamp in heat treatment gangway by 4*54w T5 Light Fitting (10nos).

3

ImplementedSavings of 1lakh/annum was obtained.Savings Planned-1.2 Lakhs /Annum

Supervisor -1noOperator-1no

2009OperatorHeater modification( SQF) to increase availability (to reduce MTTR)Shut Down &Startup Losses

2

Implemented Savings achieved -1.1 lakhs/annumSavings Planned -2Lakhs/Annum.

Technician -1noOperator -1noSupervisor- 1no

2009TechnicianSwitching of the fuel pump motor in pump testing machine when testing is not taking place. small group activity.(25machines)

1

Progress of implementation

Extent of man-power involved

Idea originated in

Year

Source of Encon idea No

20

39

Extent of Team Work in Encon

DTVS received 23 Encon ideas(2009-10) and after implementation team members are Suitably rewarded.

Suggestion Form SGA Presentation(Encon)

Small group Association consisting of Workmen facilitated by a Supervisor formed to focus on Energy conservation activities.

40

Monitoring & Reporting Systems

2

1

No

Team Comprising Finance ,WED

MonthlyMonthly Power Cost

Daily

Energy Manager

DailyReview Specific Fuel Consumption of DG and HFO,Energy Consumption in Various Feeders andEnergy Balance

Reviewed by

FrequencyPicturesMonitoring& Reporting

DTVS Power cost for Nov 09 1.12.09

Amount/month monthRs. Rs.

Fixed cost

DG rental cost 1000KV 214200DG rental cost 750K V 127500O&M Payment 1.9MWP owerica 1MW 337080

V AM 2247201000KV 70000

78652Total Fixed cost 1052152 1052152 1052152.00

V ariable costE .B Bil l 2722760 2722760 2722760.00

A rkay engery 1.11.09 TO 15.11.09A s Per s tore 16.11.09 to 30.11.09

Diesel cost ( LZZ9XH1000) 7988 l tsOpening 40000 lt s 12292lt sP urchase 12292 lt s 60000lt sClos ing 35696 lt s 38587lt sConsumpti on during month 33705 lts

28591 lt sWED 7105 l ts 26850 lts 989148.53 928916.03 1918064.56

E &D, Canteen, others 6855lts 245808.13 237159.01 482967.141.11.09 TO 15.11.09

Furnus oil (HFO) (LZZ900B 0000) 82.72 MT 16.11.09 to 30.11.09Opening 118.52 MT 52.65 MTP urchase 52.65 MT 189.41 MTClos ing 148.59 MT 97.48MTConsumpti on during month 144.58 MT 3780263.33 3789572 7569835.25

627 lts @Rs120/ lt s

Lub. Oil (L00900B1052) [email protected]/ lts 75240 37200 112440.00

Total variable cost 12806066.95

P ower cost ( including of E&D, Canteen, other d iesel usage) 13858218.95

A) Diesel E&D, canteen and others 482967.14

B) After adjusting diese l used by others 13 375251.81

Total uni ts for the month 1924547 units

P er uni t cost - aft er adjus t ing the di esel used by other dept Rs.6.95/unit

Rotary 1898042 unit s Rs13191391.9

Comman Rial 26505 unit s Rs.184209.75

1924547** Diesel & furnus oil rate taken from Nov 09 purchase order** EB Amount as per last month actual

21

41

Carbon Emission Reduction

4321.35.91405 T of CO2/

annum

Jun2008

Implementation of vapour absorption machine for air conditioning using waste heat recovery from exhaust flue gas(genset)

1

Rs Million

Rs Million

No of CERs / VERs

Payback months

Invest Made

Total Annual Savings

Total CO2Reduction


Title of project implemented

No

42

Renewable Energy

Utilization of solar energy for street

Lights(23nos) around the plant

Total Installed Capacity - 6600LPDhot water

Factory Power House

TotalWind

Ventilators installed - 220nos

22

43

Waste Utilization as a Fuel

507kwh6020kcalFlue gas from Fluid thermfurnace to replace air heaters.

270152kwh131250kcal

Excess heat from Jacket water

b

50589kwh507253kcalFlue Gas from 1.9MW HFO DG

1.a

Waste fuel as % of

total energy

Equivalent of Conventional energy used

(kWh of electricity or Ton

/ kL of fuel)

Quantity of waste fuel

used (Tons or any other Eq

Unit)

Type of Waste Fuel used

No

44

Best Practices

v Sharing of Practices with Vendors, Customers,

Contactors.

v Energy awareness through posters, training program

for Contractors, Operators

PCRA Awareness program

BPCL Awareness Program on Oil Conservation Week

23

45

Installation of Anaerobic Treatment Plant

• In the UASB reactor the inlet COD levels can be reduced upto 70% due to the anaerobic degradation of microorganisms in the sludge blanket at the bottom.

• No electromechanical equipment required, hence we can save the power up to 70units per day.

Environmental Project

46

1.Internal audit NC’s now reopened and the effectiveness verification is carried out using the modified NCR format. 2.NCR format modified to include why, why for root cause analysis &also a separate space provided for recording corrective action.

nc-3Internal Audit NC’s closed with-out effectiveness monitoring and review of effectiveness Towards recurrence and occurrence pertaining to Operation Control and Legal Evaluation of Compliance.

1.The emergency preparedness and response plan revised to include mitigation action and subsequent follow up action forall the identified emergency situation2.Emergency plan (EMS/P-09) revised to ensureadequacy of ISO14001:2004 requirement.

nc-2EMS /P09 (Emergency Preparedness and Response) not addressing the mitigation plan and the subsequent follow-up actions for all the identified emergencysituation(Ammonia Storage, LPG Storage, HSD/HFOStorage, Hydrogen Storage, Chemical Storage, CaptivePower Plant).

1.Process scrap is Stored and segregated ,hazardous waste is stored separately.2. The audit frequency for critical operational areas now increased to once in 15 days.

nc-1Operational Control not effective as per procedure for Storage and Segregation of Process scrap and Storage of hazardous waste

Corrective/Preventive action takenDescription ofNon-Conformities

Certified for ISO14001:2004 and TS16949:2007ISO 14001:2004 Surveillance audit on Feb 2010

TS16949:2007 Re-Certified on Jun2010

24

47

Environmental improvements in periphery

§ About 3,400 trees (40

varieties of trees and saplings)

have been planted in 15 schools

in the villages near Mannur.

Peripheral Improvements

48

• Many Rain Water Percolation Pits have been installed at the site to catch rainwatercollection and storage of rain water during the monsoons.

Rain Water Harvesting

25

49

Environmental Communication &Awareness

Environmental happenings and activities are shared through Posters, Communication boards in shop floors to increase environmental knowledge and awareness among Employees and Interested Parties.

50

Sewage Treatment Plant Eco Friendly Scrap Yard

ETP

Environmental Improvements

26

51

No. of Schools involved - 15,

No. of Students involved - 3600

Awareness Campaign on Global Warming3Days Programme:

(09.12.09 - 11.12.09)

Awareness Programme beyond the Plant

Environment day

Tree Plantings

No. of Schools involved - 15

No. of Students involved - 2500

No. of Trees Planted - 300

52

Awards and Recognitions

Lean Challenge Competition -2009CII- National Award for Excellence

in Energy Management 2007

NCQC 2009- TPM Circle Competition Excellence Award

NCQC 2009- Poka Yoke Competition Excellence Award

NCQC 2009- Quality Circle Competition Excellence Award

CII- National Award for Excellence

in Energy Management 2009

27

53

Encon Journey Continues …..

54

28

55

56

SQF-3 TEMPERING FURNACE UNLOADING

Process

Before

Tempering Furnace Always ON but used only for 3hrs/day .

Out of 6 Varieties only one Variety require Tempering

AfterFurnace switched on during tempering process and

switched off immediately after Tempering Process.

Furnace Capacity - 36kw

Savings in hrs/day - 19hrs.

Savings in Cost /year - 8200hrs*31kw*6.5= 16Lakhs

Calculation-SQF3

29

57

GNF furnace Cooling cell Kanbon

Processes time 36 hours Processes Time 4 hours

Cooling fans 2.2 +2.2 KW

Before

The cooling cell cooling fan continuously running After

The cooling cell cooling fan 2.5 hours/cycle running . Approximately 20 Hours / month (idle time = 8200 Hrs – app )

Savings = 8200 hrs x 4 KW = 32400 KWH

For 6 furnaces = 194400 kwh

Cost Savings= 194400 x 6.5 = 1263300 Lakhs

Savings = 12 L ( app )

Calculation -GNF

58

• Flow of Exhaust Flow gas- 14703 Kg/hr• Inlet Temperature -339deg c• Outlet Temperature - 189 degc• Diff in Temp - 150deg c• Specific Gravity-0.23kj/kg • Q- 14703*150*0.23 - 507253kcal• Kw - 589.

• Jacket Water Volume -52.5m^3/hr• Difference in Temp - 2.5 deg c• Q- 52.5*1000*2.5*1 - 132500Kcal• Kw - 152

Waste Fuel Calculation

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