cii national award for excellence in energy management 2018

a

8 / 3 0 / 2 0 1 8

CII National Award for Excellence in

Energy Management 2018

EICHER TRUCKS & BUSES, PITHAMPUR

Manish Kandu Upendra ShrivastavaSanjay Dangi

2

To be recognized as the industry leader driving modernization in

commercial transportation in India and the developing world

VECV (A Volvo group & EICHER Motors joint venture) - VISION

3

TRUCKS, BUSES AND ENGINES

Eicher Trucks and Buses

EICHER ENGINEERING COMPONENTS

Volvo Trucks

Bus Body andApplication Manufacturing

Engines

VECV Business Areas

Methodology for Energy Conservation

At VE Commercial Vehicles we follow Volvo Production System It has 10 Management & 11 Technical Pillar Environment Pillar aims to Green manufacturing approach

Envi

ron

me

nt

6

VPS Environment Pillar aims to Green manufacturing approach..

Waste

reduction and

management

World class

energy

efficiency

Water

conservation

GHG

mitigation

Material

ConservationGreener

Supply chains

Renewable

energy

Product

Stewardship/

Toxicity

Going Green…

Countermeasures

Selection of areas (perspective) : Based

on highest power consumption

Identification of possible solutions for reduction of energy lossses (7 kinds)

Investigation Measurement Analysis

Standardization Horizontal Expansion

Step 2 Step 3 Step 4


Production process analysis on Energy perspective

Measure Energy Consumption and losses

Done countermeasure projects for energy conservation

- Projects results measurement

- Training programs

Horizontal deplyoment of project for same type of losses at plant level

Identification

Step 1

The 7 step approach for energy conservation

VPS -Environment Pillar Methodology for Energy Conservation

Energy conservation Methodology – EnCon project : Heat Pump instead of electrical water heaters

Analysis Root Cause

30kWt Heat pump installed on Differential washing machine ( 2016-17)& saving potential per annum :1.27 MINR.

Identification Investigation Measurement

Countermeasures Standardization Horizontal Expansion

Washing machine uses hot washing fluid to

clean parts , hot fluid temp. maintained by

heating electrical heaters

Electrical heaters uses 1 kW electrical power for 1 kW heat output

Electrical heaters are inefficient & takes

more power to convert hot water

Energy Efficient Heat pumps can be used for washing fluid heating

Step 1 Step 2 Step 3 Step 4


As Horizontal deployment 3nos. X 65 kW Heat Pumps

are installed on balance machines (2017-18)

Additional saving potential:

5.3 MINR/annum

9

Energy Consumption per unit of production

KPI 2014-15 2015-16 2016-17 2017-18Target

2018-19Benchmarking

Variable power (KWh/Vehicle)

576 518 459 460 450995 (Nearest competitor)

Water (m3/Vehicle)

8.57 8.28 6.45 6.15 6.12 NA

LNG(mMBTU/Vehicle)

1.32 1.22 0.97 0.98 0.95 2.2 Durr (OEM)

Specific Energy consumption & Benchmarking

• Overall Sp. Energy consumption is on decreasing trend .• 2017-18 power consumption increased due to new projects trials (Engine

test bed, BIW line, new ware house , paint shop capacity expansion ).

Benchmarking data not available

BenchmarkingkWh/vehicle

* All benchmarking data taken from CII presentation

0

1000

2000

3000

4000

5000

6000

7000

8000

2014-15 2015-16 2016-17 2017-18

10

42

96

3

99

5

57

6

51

8

45

9

47

5

Global

National

VECV

RemarkBenchmarking is very difficult as plant to plant process, product, outsourcing is different.

Energy Conservation Projects - Zero fund investment projects (2015-18)

SN Title of Project YearAnnual Electrical Saving (kWh)

Total Annual Savings(Rs million)

1Robotic Paint booth- re-program VFD for blower & install VFD on pump.

2015- 16 66154 0.43

2Manuel switching off( air cooler, lights, fans etc)

2015- 16 147692 0.96

3 Hydel Power purchase 2016- 17 0 1.05

4Manual switching off( air cooler, lights, fans etc)

2016- 17 23503 0.15

5Operation of process pumps & fans linked with position of cabin into their zone.

2017- 18 158571 1.11

6Spot repair machine frequency optimized from 50Hz to 40Hz during non working time

2017- 18 172857 1.21




7ASU on/off controlled by a real time timer & shut off during non-working hours

2017-18 205714 1.44

8

Work deck ASU speed control with temperature & humidity in Day/night. (Consider 4 hr motors run in 50% frequency so 232+200 units will be saved)

2017-18 121429 0.85

9

Optimization of Top coat Booth ASU supply & Exhaust blowers running interlock with cabin sensing. ( 132 Kw -02 blowers will be saved at least 03 hr at low frequency)

2017-18 58571 0.41

10Manual switching off( air cooler, lights, fans etc)

2017-18 99785 0.7




11 Hydel Power purchase 2017-18 0 2.15

12Sealer oven circ. Fan frequency optimized from 50Hz to 25Hz during Post Purge Time.

2017-18 1080 0.008

13ASRS Lighting on/off controlled by a real time timer & shut off during Day Time.

2017-18 42000 0.3

14Zero investment EnCon project -Thermal

2017-18 88 mMBTU 0.068

Total Electrical Energy Savings (MWh) 1097

Total Thermal Energy Savings (mMBTU) 88

Total Cost Savings (MINR) 11

Zero fund investment projects (2015 -18) - Highlights

SN Other Energy conservation projects Annual Savings

MWh MINR

1Operation of process pumps & fanslinked with position of cabin intotheir zone.

159 1.11

2Spot repair machine frequencyoptimized from 50Hz to 40Hzduring non working time

17 1.21

3ASU on/off controlled by a realtime timer & shut off during non-working hours

206 1.44

9Robotic Paint booth- re-program VFD for blower

66.15 0.43

Frequency 50Hz Frequency 40Hz

Throttled v/v

Full open v/v



MWh MINR

4All process dip tanks level reduceby 200 mm in depth & saved LNGas heat load reduced

88 mMBTU/annum

0.79 MINR/annum

5Sealer oven circ. Fan frequencyoptimized from 50Hz to 25Hz during Post Purge Time.

1.08 0.008

6Working area ASU fan frequencyoptimized at low frequencyaccording temperature.

121 0.85

7Top coat ASU & Exhaust FanFrequency optimized from 50 HZ to25 Hz at break time .

59 0.41

Before After



MWh MINR

8ASRS Lighting on/off controlledby a real time timer & shut offduring Day Time.

42 0.3

10Manual switching off ( air cooler, lights, fans etc.)

271 1.81

11Hydel Power purchase (2016-17to 2017-18)

- 3.2

Total saving (zero investment projects) 11 MINR

Hydel Power

List – Funded Energy Conservation projects (2015 -18) -

SN Title of ProjectAnnual Savings Investment

Kwh MINR MINR

1Plant cooling tower (10 nos.) fan operation -control by temp. controller

143590 0.93 0.056

2Replacement of conventional lights by energy efficient LED lights

147692 0.96 1.26

3 Automation in street lights 43446 0.28 0.035

4EDC Utilities- Cooling tower pipe line modification & pumps interlocking

446154 2.90 0.14

5 Arrest compressed air leakages in plant 258462 1.68 0.12

6 VFD installed in 1000 cfm compressor 125538 0.82 0.025

7Engine test Beds-Integration of exhaust blower with engine test cycle

25846 0.17 0.05

8Automation in ADU ( air dryer units ) at shop floor

153231 1.00 0.14

9VFD installed in 200 cfm compressor at Paint shop

27692 0.18 0.3

List – Funded Energy Conservation projects (2015 -18)


Kwh MINR MINR

10 Machine shop Air Line Separation 332308 2.16 0.25

11Heat recovery system for ED oven in paint shop- LNG saving

3961 mMBTU 2.16 2.4

12Energy conservation by VFD installation on paint shop pumps & compressor

20769 1.62 0.48

13HVAC booth pump replaced ( 0.75 kw to 0.37 KW,6 nos)

1538 0.12 0.03

14Plant LED Light conversion Total 3184 nos. LED lights installed

582335 5.89 6.47

15Energy conservation by VFD installation on plant pumps, compressor & blowers as horizontal implementation of energy savings

22106 1.72 1.12

16 Heat Pump in Axle line washing machine 15385 1.20 1.18

17 Compressor Automation 23077 1.80 0.35



Kwh MINR MINR

18 AC convertor at Reliability lab Air conditioner 209 0.02 0.02

19 Helical Pump on bore well no. 06 1282 0.10 0.1

20Heat recovery system for Top coat oven in paint shop- LNG saving

1971 mMBTU 3.00 2.4

21Energy conservation by VFD installation on paint shop pumps & compressor

231429 1.62 0.48

22Energy efficient Air cooler at CMS2 building –78 nos.

485714 3.40 5

23Modification in pneumatic valve actuation system

36285 0.25 0.036

24Heat Pump in Axle line washing machine phase-2

575714 1.69 3.35

25 Plant LED light conversion 467286 3.27 2.934



Kwh MINR MINR

26 Flux maxiox system on Oven LNG pipeline 929 mMBTU 0.72 0.45

27 30 kVA Solar plant at CMS2 44902 0.31 1.5

Total Electrical Energy Savings (MWh) 4518 MWh

Total Thermal Energy Savings (mMBTU) 6861 mMBTU

Total Cost Savings (MINR) 40.0 MINR

EnCon. Project Description

SavingPotential/annum

Investment

kWh MINR MINR

Energy efficientheatingHigh COP Heat Pump onAxle washing machineeliminated electricalheating (225 kWt)

757142 5.3 8.42

Energy efficient helicalpump for bore well11.2 kWh centrifugalpump replaced by Helicalpump 3.7 kWh

14285 0.1 0.1

Compressor operation automation to eliminate unloading hours

23077 1.8 0.35

Funded Energy Conservation Projects (2015-18) - Highlights

Helical rotor

Automation to control

unload power

Specialized supervisory to monitor and

control compressors

operation

(Heat PumpTotal : 4 nos.)




Investment

kWh MINR MINR

Variable Frequency Drives : All the motors above 5.5 KW are now operated through VFD

630372 4.33 1.92

LED lights3876 conventionallights replaced byenergy efficient LEDlights Phase 1 to 4(2015-16 to 2017-18)

1197313 10.1 10.6

Power reduction Per fixture :- 250W to 80W - 36W to 18W etc

250 W

36 W 18 W

80 W

http://www.google.co.in/url?url=http://www.ebay.com/bhp/high-bay-lights&rct=j&frm=1&q=&esrc=s&sa=U&ved=0ahUKEwiy1tewkr7PAhUMQo8KHZLlCUIQwW4IHzAF&usg=AFQjCNFCDZAjJVn1EC72FI5KbkiY56ET0A

http://www.google.co.in/url?url=http://www.ebay.com/bhp/high-bay-lights&rct=j&frm=1&q=&esrc=s&sa=U&ved=0ahUKEwiy1tewkr7PAhUMQo8KHZLlCUIQwW4IHzAF&usg=AFQjCNFCDZAjJVn1EC72FI5KbkiY56ET0A



Invest-ment

kWh MINR MINR

Modification in pneumaticvalve actuation systemAt CED paint shop,compressor is nowswitched –off during nonworking hours

36285 0.254 0.036

High COP heat pump eliminated electrical heating for dish washer at canteen

20000 0.14 0.3

AC converter operatestwo air conditioners withone out door unit 1857 0.013 0.024


Bypass line with valve

stop compressor

running during non

working hours

Canteen heat pump system

Before After



Investment

kWh MINR MINR

Solar hybrid ACHybrid AC made of Solarcollectors which superheatsthe refrigerant & therebyreduce energy use

9072 0.063 0.165

Air cooler at CMS2 building Evaporative air cooler has high efficiency then Centralized cooling system (ASU)

485714 3.4 5

LED lights installations in2018-19 YTD total 275 nos.In all new projects installed LEDoverhead & process Tube lights

248271 1.74 1.95


Evaporative Air Cooler 10K CMH @1.1 kWh

LED light installed in plant also improves lux level



Investment

kWh MINR MINR

Nano-fluid for compressorUse of POLYTRON MTC – OilAdditive into compressor toimprove compressor efficiency

27648 0.19 0.045

Nano-fluid for chiller – (water)Improvement in heat transferby use of Nano fluid(Hydromx) at Cab weldcooling system

35714 0.25 0.51

Variable Refrigerant flowA/Cinstalled energy efficient VRFAC instead of DX AC unit atnew ME office

37706 0.26 1.5


VRF A/C Unit

Polytron MTC to Comp. oil


SavingPotential/annum Investment

kWh MINR MINR

Compressor Heat Recoverysystem Successfully installedheat recovery system oncompressor to generate hotwater from exhaust hot air &reuse at washing m/c

312840 2.19 2.3

Indoor nature switch forhighbay lights Successfullytrail taken of in-door luxsensor for gangway lights(24nos.), Automatic switch on atlow lux level & Automaticswitch off at required lux level

2304 0.016 0.0165

Energy Conservation Projects (2015-18) - Highlights

Light Control by Nature Switch

EnCon. Project DescriptionSavingPotential/annum

Investment

LNG conservation byReuse of waste heat byheat pipe on ED & Topcoat Oven at CED Paintshop

5799

mMBTU

5.04

MINR

4.8

MINR

Burner efficiencyimprovement bystreamlining LNG flow atCED Paint shop

929

mMBTU

0.7

MINR

0.45 MINR

Hot exhaust air for HWGCompressor exhaust use on Hot water generator to preheat the suction air before combustion

639.36

mMBTU

0.53

MINR

0.023MINR

LNG molecules gap increases after passes through flux maxiox device


Heat Recovery system

Other Process improvement projectsSavingPotential/annam

Investment

LT Room energy meterInstallation Installedefficient & commonenergy meter at main LTroom for effective powermonitoring

It improves right data

collection with same type of

energy meter which is also

compatible to automatically

send data remotely

Day light harvesting210 nos. roof sheets arereplaced by transparentpoly carbonate sheets

171429

kWh

1.2

MINR

1.17

MINR

Compressed air leakagearresting Continuously airleakage arresting done atplant & reported monthlybasis

24576

kWh

0.17

MINR

0.038MINR


Old to new

Funded Energy Conservation Projects (2015-18)

SNEnCon Projects

(2015-16 to 2017-18)Savings/annum Investment

MWh mMBTU MINR MINR

1 Zero fund investment project 1097 88 10.81 0

2 ROI < 1 year 2654 2900 25.32 10.37

3 ROI > 1 year 1864 3961 14.68 20.30

Total savings 2015-16 to 2017-18

5615 6949 50.81 30.67

CO2 emmission reduction 5329 tons

29

Results

Savings – by heaters elimination Investment Other savings

312 Mwh/annum2.19

MINR/annum2.3 MINR

Reduction in hot air exhaust Compressor cooling improves

Innovation project 1: Hot water generation by Compressor waste heat

Before – Compressor heat exhausted to Ambient

Compressor 72% of energy (hot air)exhausted to atmosphere , for compressedair generation & Compressor cooling

Oil

hea

t re

ject

ed

to A

mb

ien

t

After – Hot water by Compressor exhaust

Exhausted heat recovered by “CompressorHeat Recovery System” & used to washingm/c for washing fluid heating

Schematic “Compressor heat recovery system” Eliminated

washing m/c fluid heaters

Methodology: Brainstorming , VPS 7 step approach

30

Innovation project 1: Hot water generation by Compressor waste heat

• Washing machine using hot water generated from

“compressor heat recovery system” to heat up washing fluid

• Electrical heaters switched off & used as standby

Engine line Washing machine Compressor heat recovery system

Water

Water

Hot

Cold

Compressor

Heat Exchange system

In Future same EnCon activity horizontally deploy on other compressor & use recovered heat at paint shop/Canteen etc.

31

Results

Savings Investment

892 MWh/annum10 MINR/annum 0.128 MINR

6048 mMBTU/annum

Innovation project 2 : Dip Skid Commonization for PT-CED & Ro-Dip process

Before – Different skid for diff. model

Old skid with adaptor plates, need touse adaptors for diff. cab model & takesfitment time

After – Common skid for diff. models

Common skid for 12 different models,eliminate the adaptor plates fitmenttimes, & Saving of 3.5 min in each cycle

32

Existing System/Current Mechanism – CED Paint shopLD Legacy & 2.0 m upgrade Cabin

No Adapter

HD Legacy Cabin

No Adapter

2.1 m Condor – Day

2.1 m Condor – Sleeper

2.3 m Condor – Day

2.3 m Condor – Sleeper

LD Face Cowl

MAV cowl

VE 5100 MAV cowl

Approx. weight of Adaptors 40 Kg

33

Uniqueness & Creativity Content 12 Different models can be accommodated on single skid without any adapter.

Accurate Interfacing in skid exchange from cab weld to Dip skid & dip skid to paint skid .

Smooth interfacing of modified dip skid with Ro dip system in PT/CED process where cabin rotate with skid in high byoncey force and eliminate chance of cabin & adapter falling inside the tanks.

Prove out dip skid performance in all chemicals / Paint / Oven high temperature.

3

3

Old Skid with Adapter Plates New Modified Dip Skid

34

Results

Savings Investment

326 MWh/annum 2.4 MINR/annum ZERO

Innovation project 3 : CED Paint shop – Booth ASU & Exhaust blower optimization

Before – Blowers running continue After– Optimization Blowers running

Booth ASU & Exhaust interlock with cabinpresence sensor during running production.In case of cabin absence supply & exhaust fan willrun @ 25 (Hz) frequency .Horizontal deployment in Axle & Engine booth.

Booth ASU & Exhaust running continue @ 50 Hz.System runs continue irrespective of cabinavailability.Daily cumulative (small slots) approx. 4 hr idlerunning including break hours.

25HZ

25HZ

50HZ

50HZ

35

Results

Savings Investment

148 MWh/annum 1.06 MINR/annum ZERO

Innovation project 4 : Cab weld– Chiller running optimization

Before : Chiller running continues After– Optimization of Chiller running hrs.

60 TR chiller & 90TR cooling tower required for maintain spot welding guns temp i.e. 20 to 25 deg.

Both system were continues run in all 03 shifts round the year.

During winter & Rainy season desired tempcan be achieved only by cooling tower.

Additional demister filter introduced toimprove circulation water quality.

06-08 months chiller power saved

36

Energy management structure

Energy Conservation Cell

Plant head

Energy Manager(Pillar owner)

Co

re T

eam

Pillar coordinator

Plant maintenance

FinancePaint shop

HR Safety Utility

Sup

po

rt

Team

Cabin group( Cab weld - Paint

shop)

TEAM group(Transmission-Engine-

Axle-Machine)

TCF group( Trim- Chassis-

Final)

Energy Monitoring Smart Sense+ meters

Total Energy

Fixed CostVariable Cost

Line wise Area wise

Energy Recording & Monitoring

Electrical Power Head

• Energy Consumption per annum trend


Electrical Energy consumption –(GWh)

Thermal Energy (LNG) consumption –(mMBTU)

• Power consumption increasing year by year with increase in production volume but specific power consumption in decreasing trend as shown earlier

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

0

10000

20000

30000

40000

50000

60000

70000

80000


Monthly Power data monitoring

Separate monitoring on Sunday/non-production day power consumptions

40

Energy saving Budget allocation

Comparison with Energy saving budget allocation

Description 2014-15 2015-16 2016-17 2017-18 2018-19

Budget (MINR) 2.6 3 33 10 48

Power bill (MINR) 241 269 214 269 306

Budget (%) 1.08% 1.12% 15.42% 3.72% 15.6%

More then 3% provision for energy conservation projects last & current year of total energy bill.

Projects recommended by energy management cell & approved by FI (finance) pillar are

funded through this budget.

* Present year budget includes special sanction of 38 MINR for 1 MW roof top solar plant

Employee envolvement

No of Kaizen Received

Kaizen award distribution

Suggestion Scheme

Employee envolvement - People Development Process

PEOPLE DEVELOPMENT

People involvement to ensure continual improvement organization.

• Stringent recruitment process w.r.t. category wise eligibility.

• PACT – Permanent and company trainee

• Permanent• Apprentice (APP)• Technical

operation trainee (TOT)

• Indo – German Tool Room Trainee (IGTR)

1

• Induction training of newly joined operator followed by assessment.

• Classroom training• Hands on training - OJT

• WCQ and VPS training of existing workforce

2

34• Team and individual recognition for morale.

• Best Managed Shop competition to enable competitive spirit among teams

Employee envolvement – Detailed practical training

11 SystemsDetailed Practical Training

10 Standard Documents - Detailed

Practical Training

People envolvement – Energy Conservation week celebration

Awards & ISO Certifications

“GreenCo Bronze Rating”

ISO 50001

LEED Certification

for VECV

Headquarters @ Gurgaon

One of the top 50Platinum

rated green buildings in India

“National Energy management award 2017”

ISO 14001

2013-14

Option Evaluation• Bio Mass• Mini Hydel• Solar

2014-15 & 2015-16• Solar Power Purchase 17 GWh

• Roof top solar 10 kWp

• Solar Pump 5 kWp

• Solar hybrid air conditioners

2016-17 & 2017-18

• Total Solar Power Purchase 27 GWh

• Roof top solar 50 kWp new installation

Renewable Power & percent share

2014-15 2015-16

29.58% 38.48%

2016-17

45 %

2017-18

45 %

Projects implemented to reduce hazardous waste generation

Use of waste as Alternate Fuel/Raw Material

SN

Details of Project Year% of waste disposed as alternate fuel /

raw material

1Exhaust fumes of ED oven reused as fuel & preheat the oven fresh air

2015Total 2485 mMBTU LNG as fuel saved &

total 2.16 MINR cost savings achieved

2Exhaust fumes of Top coat oven reused as fuel & preheat the oven fresh air

2016Total 3314 mMBTU LNG as fuel saved &

total 2.88 MINR cost savings achieved

3 Solvent recycling 2016 100% used solvent recycling

4 Food waste conversion in compost 2016 20% Food waste conversion into manure

5M/C shop washing m/c filter paper Reuse Of Filter Press cloths

2017100% filter clothes are reused for chips segregation.

6Use of compressor waste heat as fuel to generate hot water for axle line

2017

Total 312840 Kwh electricity &

Total 2.19 MINR cost savings per annum

generated

Utilization of Waste as Energy source

48

GHG Emission inventorization

Scope Unit 2014-2015 2015-2016 2016-2017 2017-18

Scope 1tCO2e / Annum 42539 39499 43222 57535

tCO2e / per eq. vehicle 1.03 0.79 0.86 0.88

Scope 2tCO2e / Annum 21341149 23355043 18746926 24710441


Scope 3tCO2e / Annum 4377 4804 5839 7696


Total Scope 1, 2 & 3

tCO2e / Annum 21388065 23399345 18795657 24775672

tCO2e / per eq. vehicle 518 467 374 378

FUEL COMBUSTION

GHG emission Sustained this year due to multiple projects and new products trial Overall 3 year GHG emission in reducing trend

49

GHG Emission inventorization

Scope 2016-2018 2018-2020

Scope 1

Installation of heat recovery in paint shop –Completed

Installation of flux maxiox device for LNG reduction

2 to 5 % reduction

Sealer oven elimination by process layout modification.

Scope 2

33 % Solar Power Purchase of total energy consumption - achieved

14 % Hydel Power Purchase of total energy consumption - achieved

Installed 50 KW roof top solar plant in CMS2

Install 1MW roof top solar plant

Day light harvesting (light pipe)

Scope 3

Haz. waste disposal alternate location started.

Inward Logistics - Premium flight reduction 10 %

Trip Reduction by introducing bigger size of vehicle for local delivery

10 to 20 % Reduction GHG

Green supply chain

EEC– Dewas1. LED lights into expansion shed of plant2. Air cooler to replace air conditioner in Gear grinding m/c3. VFD at compressor4. Energy on ventilation system5. Installation of energy efficient VRF air conditioning system

As green supply chain energy conservation initiatives done at supplier end

EEC - Thane 1. Improvement in lighting system by

LED lights conversion

VEPDC - Pithampur1. Plant LED Lights conversion2. Installation of energy efficient VRF

air conditioning system3. Air cooling of training room & rest

area at place of air conditioning.

Vehicle dispatch :1. Centralized Vehicle distribution

center created from Pithampur to save transportation fuel & energy

Other suppliers - Pithampur1. Improvement in lighting system

by LED lights conversion of process & street lights

51

Water conservation

• Water consumption increasing year by year with increase in production volume but specific water consumption in decreasing trend

7.06

8.57 8.28

6.45 6.15

0.001.002.003.004.005.006.007.008.009.00

SWC - Kl/vehicle

Kl/vehicle

288186

353407

417000

365206403134

0

50000

100000

150000

200000

250000

300000

350000

400000

450000

Water Consumption (kL)

WaterConsumption(kL)

52

Water sustainability• For continues water availability in plant COMPREHENSIVE GROUNDWATER

ASSESMENT FOR SUSTAINABILITY STUDIES conducted for ETB plant • In assessment done the Geophysical Investigations, Hydro-geological studies, Study of

Geomorphology, and Land use & recommended to recharge ground water

Water recharging points created for water sustainability Done in Sep’17

Water conservation

Existing Water Extracting Points at plant (Bore wells 09 nos.)

53

Water conservation

Rain water harvesting done to sustain ground water table at 18 locations

2016-17 : Water purchased from outside of 6.8 MINR through tankers.

2017-18- NIL water purchasing

Water Con. projects

Water Con. Project Description


Investment

Kilo Liter MINR MINR

Utilization of RO waste water by installation of secondary RO on reject water line

7200 0.30 0.6

Eliminate wastages and reuse DM water in process

7839 0.32 0.1

Use of ETP treated water to process 60000 0.6 0.1

Water Con. projects

Water Con. Project Description


Kilo Liter MINR

Water taps aerator installed to reduce water consumption(It gives 40% water savings)Water consumption reduced from 7 lpm to 4 lpm

1764 0.073

Digital Water level sensor at main pump house water tank to stop water overflow & safe water level monitoring

5.5 0.0002

Use of Eco friendly chemical to conserve water (CORN BASED POLYMER FORMING CHEMICAL)

360 0.015

Manual water level indicator

Digital water level indicator & water consumption totalizer

Water Conservation

Usage of ETP treated water for gardening – step towards zero discharge

Green belt at Plant by

use of ETP water

Design initiatives for energy conservation

• Skylights in shop floor for natural lighting to save energy in day time.

• Energy efficient LED light fittings for all new projects.

• Occupancy Sensors in Meeting rooms & wash rooms.

• Ventilation – Air changes in non AC area through modular coolers

• Use of energy efficient EFF1 Motors in machine.

• Sleep mode for machine screen & auto shut off during idle running of machine.

• Chiller with eco friendly gases R134a.

• VRF AC for new office areas

• Water conservation – RO water is supplied in closed loop system to Engine test beds dyno cooling, and cooling tower is fed through raw water reducing overall water consumption.

Saving Potential per annum : 11428 kWh (0.083 MINR) Investment : 0.5 MINR


Day lighting system trial in progress, Light pipe installed & performance under observation


Way

ah

ead

1 MW roof top solar power plant

Day lighting system for buildings

Phase 5 Plant LED light conversion

Heat pump at Guest house

Airtron AC power saver

Saving Potential per annum :1500 MWh (10 MINR )Investment : 38 MINR

58

Way ahead : Electrical power savings 2935 MWh


Saving Potential per annum :195429 kWh (1.4 MINR) Investment : 2.05 MINR

Saving Potential per annum :316667 kWh (1.9 MINR )Investment : 3.8 MINR

Way

ah

ead

Control air system to control plant compressed air pressure

RTPFC for real time power factor controlling

Plant VFD conversion

Use of POLYTRON MTC – Oil Additive into all compressor to improve compressor efficiency

Saving Potential per annum :240000 kWh (1.68 MINR )Investment : 1.69 MINR

59

Way ahead : Electrical power savings 2935 MWh

Status of Encon projects committed last 3- years

• Projects : 14

• Savings 14.62 MINR

2015-16

• Projects : 11

• Savings:16.67 MINR

2016-17 • Projects : 17

• Savings : 19.52 MINR

2017-18

Last 3 Year

EnCon

Journey

• 42 Encon projects implemented • 5615 MWh savings achieved• 6949 mMBTU savings achieved• 50.81 MINR savings achieved • 5329 ton of Co2 reduction achieved

Cost saving through EnCon projects : 15.45 MINR

Investment : 17.90 MINR

38 MINR - Solar

Business Plan 2018-19

YTD Savings : 4.64 MINR

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