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

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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)

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Minister of Power

Government of India

New Delhi-110 001

MESSAGE

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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

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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)


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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)


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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)


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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 14th

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


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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

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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

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Director General

Bureau of Energy Efficiency

Government of India

Ministry of Power

New Delhi - 110 066

(DEVENDER SINGH)

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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

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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

YEA

R W

IS

E EN

ER

GY

S

AV

IN

GS

A

CH

IEV

ED

BY

P

AR

TIC

IP

ATIN

G U

NITS

IN

M

IN

IS

TR

Y O

F P

OW

ER

’S

N

ATIO

NA

L

EN

ER

GY

C

ON

SER

VA

TIO

N A

WA

RD

S

CH

EM

E

(1

99

9, 2

00

0, 2

00

1, 2

00

2, 2

00

3, 2

00

4, 2

00

5, 2

00

6,

20

07

, 2

00

8, 2

00

9, 2

01

0 &

2

01

1)

Year

No. of

An

nu

al

On

e Electrical En

erg

y S

avin

gFu

rn

ace O

il

Co

al

Gas

GH

G Em

ission

Particip

atin

gS

avin

gs in

tim

e&

O

th

er

Savin

gs

Savin

gs

red

uction

,

un

its

Rs. C

rores

in

vestm

en

tM

illion

Eq

uivalen

tliq

uid

fu

el

in

Lakh

in

Million

in

kW

havoid

ed

Savin

gs, in

Metric

Lakh

cu

bic

tC

O2

Rs. C

rores

cap

acity in

Lakh

s kL

Ton

nes

metres

MW

2011

644****

2390

2201

3421

504

3.29

33.21

4085

9.236

2010

592****

2138

5457

2422

357

3.41

23.42

8338

7.810

2009

558***

2377

3180

2451

359

5.65

12.4

4274.9

6.125

2008

368**

1859

2493

2216

325

1.85

3.47

15729

5.620

2007

384*

1843

2923

1620

308

1.25

5.86

15379

5.287

2006

388*

1135

1266

1288

245

1.19

5.17

29044

7.404

2005

343

993

1319

1327

252

2.4

7.58

13122

5.257

2004

297

763

1364

814

155

2.49

5.37

18585

5.531

2003

191

539

1071

542

103

2.21

12.65

73181

16.220

2002

174

594

691

641

122

1.7

7.4

35588

8.547

2001

157

587

659

485

90

2.21

4.79

3929

2.409

2000

120

366

630

524

100

1.327

0.64

707

1.012

1999

123

205

940

205

45

1.62

2.15

2444

1.365

Total

15789

24194

17956

2965

31

124

224406

81.82

13

years

*Participating units include Industrial units, Buildings and Zonal Railw

ays

** Participating units include Industrial units, Buildings, Zonal Railw

ays, State D

esignated Agencies and M

unicipalities

*** Participating units include Industrial units, Buildings, Zonal Railw

ays, State D

esignated Agencies, M

unicipalities and

Manufactures of Star Labelled Appliances (Energy savings of star labelled appliances not included)

**** Participating units include Industrial units, B

uildings, Zonal Railw

ays, State D

esignated Agencies, M

unicipalities,

Manufactures of Star Labelled Appliances and Therm

al Pow

er Stations (Energy savings of star labelled appliances not included)

9

ALUMINIUM

2nd

Prize : 1. Hindalco Industries Ltd, Renukoot unit,

Distt. Sonebhadra (Uttar Pradesh)

2. National Aluminium Company Limited,

Smelter Plant, Distt. Angul (Odisha)

AUTOMOBILE MANUFACTURING

1st

Prize : Mahindra & Mahindra Ltd., Zaheerabad,

Distt. Medak (Andhra Pradesh)

2nd

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

1st

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

2nd

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

1st

Prize : The Andhra Sugars Limited, Saggonda,

Distt. West Godavari (Andhra Pradesh)

CONSUMER GOODS MANUFACTURING

1st

Prize : Carrier Airconditioning & Refrigeration Limited,

Gurgaon (Haryana)

2nd

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

1st

Prize : Mother Dairy, Patparganj, Delhi

2nd

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

1st

Prize : USV Limited, Unit - 1, Baddi (Himachal Pradesh)

Certificate of Merit : Orchid Chemicals & Pharmaceuticals Ltd.,

Alathur, Distt. Kancheepuram (Tamil Nadu)

EDIBLE OIL / VANASPATI

2nd

Prize : Ruchi Soya Industries Ltd., Buti Bori,

Distt. Nagpur (Maharashtra)

FERTILIZERS

1st

Prize : Rashtriya Chemicals & Fertilizers Ltd.,

Trombay Unit,Chembur, Mumbai (Maharashtra)

2nd

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

2nd

Prize : Marico Limited, Kanjikode, Palakkad (Kerala)

Certificate of Merit : Glaxo Smithkline Consumer Health Care

Limited, Nabha (Punjab)

FOUNDRY

2nd

Prize : Grey Iron Foundry-Indian Ordnance Factories,

Jabalpur (Madhya Pradesh)

GENERAL CATEGORY

1st

Prize : Schneider Electric India Pvt. Ltd.,

Hyderabad (Andhra Pradesh)

2nd

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)

1st

Prize : Kirloskar Ferrous Industries Limited,

Distt. Koppal (Karnataka)

2nd

Prize : 1. Inorbit Malls (India) Pvt. Ltd., Malad (W),

Mumbai (Maharashtra)

2. AIR INDIA LTD, Mumbai (Maharashtra)

GLASS

1st

Prize : HNG Float Glass Ltd., Andheri East Mumbai

(Maharashtra)

12

INTEGRATED STEEL

1st

Prize : Tata Steel Limited, Jamshedpur, (Jharkhand)

2nd

Prize : Rourkela Steel plant, SAIL, Rourkela (Odisha)

MINING

2nd

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

1st

Prize : BILT Graphic Paper Products Limited,

(Unit- Bhigwan) Distt. Pune (Maharashtra)

PETROCHEMICALS

1st

Prize : Reliance Industries Limited, Hazira Manufacturing

Division, Distt. Surat (Gujarat)

Certificate of Merit : Continental Carbon India Limited, Ghaziabad

(Uttar Pradesh)

PLASTICS

2nd

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

1st

Prize : Indian Oil Corporation Limited (Assam Oil

Division) Digboi Refinery, Distt. Tinsukia

(Assam)

2nd

Prize : Reliance Industries Ltd., SEZ Refinery,

Distt. Jamnagar (Gujarat)

Certificate of Merit : Indian Oil Corporation Ltd. - Gujarat Refinery,

Vadodara (Gujarat)

13

SPONGE IRON

2nd

Prize : Welspun Steel Ltd., Taluka- Anjar (Gujarat)

Certificate of Merit : Vandana Global Limited, Siltara, Raipur

(Chhattisgarh)

STEEL RE-ROLLING

2nd

Prize : JSL Stainless Ltd., Hisar (Haryana)

Certificate of Merit : Remi Edelstahl Tubulars Limited, Tarapur,

Boisar (Maharashtra)

SUGAR

2nd

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

2nd

Prize : Hindustan Unilever Ltd. Instant Tea Plant,

Etah (Uttar Pradesh)

TEXTILE

1st

Prize : Zenitex Pvt. Ltd., Surat (Gujarat)

TYRE

2nd

Prize : Balkrishna Industries Limited, Bhiwadi,

Distt. Alwar (Rajasthan)

Certificate of Merit : TVS Srichakra Limited, Vellaripatti, Madurai

(Tamil Nadu)

14

OFFICE BUILDINGS

1st

Prize : Cognizant Technology Solutions (GVC),

Bangalore, (Karnataka)

2nd

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

2nd

Prize : 1. Infosys BPO Limited, IBPO-1, Tal-Mulshi,

Distt. Pune (Maharashtra)

2. Infosys BPO Limited, BPO-Building 48,

Bangalore (Karnataka)

HOTELS

1st

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

1st

Prize : Divisional Railway Hospital, Western Railway,

Sabarmati, Ahmedabad (Gujarat)

2nd

Prize : Fortis Hospital, Noida (Uttar Pradesh)

MUNICIPALITIES

2nd

Prize : Vadodara Municipal Corporation, Street lighting

Department, Vadodara (Gujarat)

Certificate of Merit : Surat Municipal Corporation,

Hydraulic Department, Surat (Gujarat)

15

STATE DESIGNATED AGENCIES (SDAs)

1st

Prize : Punjab Energy Development Agency,

Chandigarh

2nd

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

1st

Prize : Adani Power Limited,Tal.- Mundra,

Distt. Kutch (Gujarat)

2nd

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

1st

Prize : South Central Railway, Secunderabad

(Andhra Pradesh)

2nd

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)

1st

Prize : Samsung India Electronics Pvt. Ltd., Noida

(Uttar Pradesh)

2nd


(Uttar Pradesh)

Certificate of Merit : Hitachi Home & Life Solution (India) Ltd.,

Distt. Mehsana (Gujarat)


(Refrigerator)

1st

Prize : Videocon Industries Ltd., Gurgaon (Haryana)

Certificate of Merit : Samsung India Electronics Pvt. Ltd., Noida

(Uttar Pradesh)


(Tubular Fluorescent Lamp)

1st

Prize : Surya Roshni Limited, Malanpur, Distt. Bhind

(Madhya Pradesh)


(Agriculture Pump Set)

1st

Prize : CRI Pumps Private Limited, Saravanampatty,

Coimbatore (Tamil Nadu)


(Ceiling Fan)

1st

Prize : Havells India Ltd., Haridwar (Uttarakhand)


(Colour Television)

1st


(Uttar Pradesh)


(Storage Water Heater)

1st

Prize : Racold Thermo Limited,Chakan Distt. Pune

(Maharashtra)

1717

INDUSTRIALINDUSTRIALINDUSTRIALINDUSTRIALINDUSTRIAL

SECTSECTSECTSECTSECTOROROROROR

INDUSTRIALINDUSTRIALINDUSTRIALINDUSTRIALINDUSTRIAL

SECTSECTSECTSECTSECTOROROROROR

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.MgrInst. Maint.MgrMech 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 PowerPlant

Electricity AC toDC Conversion

Anode Baking

Al2O3 Green Anode

Fume TreatmentPlant

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 NALCO’s 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 ProductSpecific Electrical

Energy Consumption

kWh/ Eq. Veh

% Reduction over2009-10

Specific ThermalEnergy

ConsumptionMKcal/ Eq. Veh

% Reduction over2009-10

2009-2010 Utility Vehicles, lightCommercial Vehicles, 3 Wheeler

188.34 -- 0.8673 --

2010-2011Utility Vehicles, lightCommercial 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 no’s of VFD’s 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 80-95O

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

Slno.

Energy conservation measures ( ENCON)planned

Anticipatedsavings in

energyin Rs Lacs

Approx.Investmentin Rs Lacs

Projectcommencement

& completionyear.

1 Installation of natural draft cooling tower 1.65 3 2011-12

2 Installation of Compressor Heat Recovery System 3.25 162011-12

3 Replacing 50 no’s existing lamps with induction lamps 3.5 152011-12

4Providing mechanical auto shut off taps for adminbuilding

1.8 22011-12

5 Providing Solar Heating Systems for Canteen 4 10 2011-12

6 Providing Solar Heating Systems for LPG vaporizer 2.6 52011-12

7 Provision of street light energy savers 0.85 0.52011-12

With the implementation of the above Energy Conservation measures, plant would

achieve the following targeted results.

YearElectrical

(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 ENCON’s

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 Investment : 0 Lacs 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 EnergyConsumption per annum

Lacs kWh 949.42 1079.41

Specific Electrical EnergyConsumption

kWh / Eq.Veh. 531.31 508.33

Total Fuel Consumption perannum

MKCal 61740 66834

Specific Fuel Consumption MKCal / Eq.Veh. 0.3455 0.3147

Electrical & Thermal Energy Consumption

949.421079.41

Co

nu

mp

tio

nin

La

kh

KW

H

2009-10 2010-11

Electrical Energy consumption in

Lakh KWH

61740 66834

Co

ns

um

pti

on

inM

Kc

al

2009-10 2010-11

Thermal Energy Consumption in

MKCal

Electrical & Thermal – Specific Energy Consumption

531.31508.33

KW

Hp

er

Eq

.Ve

.

2009-10 2010-11

Specific Electrical Energy

consumption (KWH / Eq. Vehicle)

Reducion

4.32%

0.3455

0.3147

MK

Ca

l/E

q.V

eh

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 CO2

Reduction in 205.8 tCO2

;

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

tCO2

;

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 tCO2

;

Investment in Rs. 0.2 Lac.

Engine Jacketwater circulationpump 18.5KW.

Before

Engine Jacketwater 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 tCO2

;

Investment in Rs. 2.4 Lac

Display ofambient

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

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 CapacityClinker: 0.55MTPACement: 1.0MTPA

65

Clinker and Cement Production

354731

403354

454447478099

0

50000

100000

150000

200000

250000

300000

350000

400000

450000

500000

550000

Pro

du

cti

on

inM

T

20

07

-08

20

08

-09

20

09

-10

20

10

-11

Year

Clinker Production

539197597486

675744

760629

0

85000

170000

255000

340000

425000

510000

595000

680000

765000

850000

935000

Pro

du

cti

on

inM

T

20

07

-08

20

08

-09

20

09

-10

20

10

-11

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.

98.1395.62

90.18

78.38

0

20

40

60

80

100

120

KW

H/T

of

cem

en

t

20

07

-08

20

08

-09

20

09

-10

20

10

-11

Year

Specific Electrical Energy Consumption

788.04754.52

785.7770.86

0

100

200

300

400

500

600

700

800

Kcal/kg

of

clin

ker

20

07

-08

20

08

-09

20

09

-10

20

10

-11

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 PowerConsumptionkWh/MT Cement

109.04 92.85

Specific Heat ConsumptionKcal/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 CementProduction (excludes

cement producedfrom grinding unit at

split location inGujarat)

LTPA 36.63 36.02 34.12

Clinker Sale(excludes clinker

exported to grindingunit at split location

in Gujarat)

LTPA 3.21 4.17 4.19

Total CementProduction including

clinker saleLTPA 39.84 40.19 38.31

% utilization % 94.91 95.75 92.46

Coal consumption Tonnes 359799 391631 373544

Electricityconsumption

Lac kWh 3153.82 3366.35 3268.84

Specific electricalenergy consumption(excluding crusher)

kWh/Tonof cement

80.25 80.66 80.55

Specific thermalenergy consumption

Kcal/kgclinker

768 763 746

Coal consumptionKg/ton ofcement

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

Un

it/T

on

(ce

men

t)

Sp. Elect.EnergyConsumption

76

Sp. Thermal Energy Consumption

768

763

746

739

744

749

754

759

764

769

774

2008-2009 2009-2010 2010-2011

Year

Kc

al/K

g(c

lin

ker)

Sp. Thermal EnergyConsumption

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 m3

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

kWh1236 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 ofManufacturing

% 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

FuelsS.No.

Project Description PowerLacsKWH

CoalMT

Total fuel(MMKcal)

Saving(Rs. Lacs)

Investment(Rs. Lacs)

1

Energy Conservation by hightemperature refluxing in distillationcolumns of MPP plant

1460.31 5114 50 25

2

Energy Conservation by hightemperature refluxing in distillationcolumns of P&P plant

1168.24 4091 40 5

3

Installation of Thermo compressor tocreate additional steam extractiondemand by 3 TPH @8 Kg/cm2

1460.31 5114 50 60

4

Installation of Desuperheater to recoverthe superheat of extraction steam of TG#5

1460.31 5114 50 6

5Reduction in steam consumption byproviding Decantor in Ethyl Acetate plant

730.15 2557 25 8

6

Reduction in Power consumption byproviding additional cooler in Ketenefurnace gas

36 3071 85 69

7

Reduction in steam consumption inAcetic Anhydride plant by vacuumdistillation

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 VFD’s Installation:

� 4 Pumps Consumption: 9,50,400 kWh

� 3 Pumps Consumption: 3,56,400 kWh

� Total Consumption : 13,06,800 kWh

After VFD’s installation

� Power Consumption : 7,92,515 kWh

� Power Saving in KWH : 5,14,285 kWh

� Saving in power after

installation of VFD’s : Rs. 18 Lacs/ Annum

� Investment for the VFD’s : 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

9.538.38

0

2

4

6

8

10

12

2009 2010

12

Specific Electricity Consumption kWh/Box

0.000520.00044

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 Cost Saving – Rs. 2.1 Lacs

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 ElectricityConsumption

Lacs kWh 417 390.94

Annual Prod Quantity Lacs 86.02 90.68

Specific EnergyConsumption -Electrical

kWh/product 4.84 4.31

Total Thermal Energy M Kcal 13,558 10483

Specific EnergyConsumption -Thermal

MKcal/product

0.0016 0.0012

Electrical Thermal

Year Specific EnergyConsumption -Electrical

%Reductionover 2009

Specific EnergyConsumption -Thermal

% Reductionover 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

37.2°C36.7 °CAmbient Temp.

203°C264°CFlue Gas Temp.

646%52%Excess Air

713CO ppm

2.29.3% CO2

18.36.8% O2

Baking OvenDry OvenParameters

44.3%80.3%Efficiency

37.2°C36.7 °CAmbient Temp.

203°C264°CFlue Gas Temp.

646%52%Excess Air

713CO ppm

2.29.3% CO2

18.36.8% O2

Baking OvenDry OvenParameters

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

Otherconversioncost

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

3333.233.433.633.8

3434.234.434.6

2009 - 2010 2010 - 2011

Years

Sp

.E

l.E

n.in

KW

H/T

on

ne

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

Sp.T

h.E

n.C

onsp

.MK

cal/Tonne

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 Nm3

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 MillionKcals

6208.77 6414.72

Specific energy consumption – Thermal MillionKcals

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








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








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. Title 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.

Plant 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

Saving for boilers

Energy Installed VFD on Purified Water 2.25 1.65 0.6

Saving 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

ENERGY POLICY

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 : 230°c

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 : 170°c

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 no’s of 20 HP vacuum pump

which saved energy in full as well as part load of capacity utilization. (No of

driers – 6 No’s). 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 expander’s chute which was supplied by the

supplier reduced the running of one conveyor.

� Plant has installed 2 no’s 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 tank’s 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

no’s of flakers out of 10 No’s 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.

BIRD’S 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

AMMONIA V

1045 MTPD

AMMONIA-I

350 MTPD

AMMONIA TO SUPHALA, A.B.C.,

NITRIC ACID, ANP PLANT

STEAM

PRODUCT UREA

CO2

FUEL

GAS

NH3 METHANOL

220 MTPD

HIGH

PRESSURE

RIL GAS

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- 260o

C) per MT in 2009-10 to 1.42 MT (Pressure – 40 atm abs, Temp-

400o

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 12-15O

C against ambient

temp 30-35O

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. Stamicarbon’s

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 May’09 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

7.327.45

7.717.78

7.85

7.88

7.85

7.817.97

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

91

-92

92

-93

93-9

4

94

-95

95

-96

96

-97

97

-98

98-9

9

99-0

0

00

-01

01

-02

02

-03

03-0

4

04-0

5

05

-06

06

-07

07

-08

08

-09

09-1

0

10

-11

Year

Mk

cal/M

TU

rea


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.

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

65000006

-07

07-0

8

08-0

9

09-1

0

10-1

1

Years

7.800

7.900

8.000

8.100

8.200

8.300

8.400

06-0

7

07-0

8

08-0

9

09-1

0

10-1

1

Years

Pro

du

cti

on

(MT

)

Sp

.E

ne

rgy

(Gc

al/

MT

)

700000

800000

900000

1000000

1100000

06-0

7

07-08

08-0

9

09-1

0

10-11

Years

Pro

du

cti

on

(MT

)

5.400

5.500

5.600

5.700

5.800

5.900

06-0

7

07-0

8

08-0

9

09-1

0

10-1

1

Years

Sp

.E

ne

rgy

(Gc

al/

MT

)


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 company’s 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 CO2

emission reduction. Major schemes

implemented in the last three years are as under:-

S.N. Plant Name of SchemeYear of

ImplementationResulted Saving(Rs Lacs/annum)

InvestmentDone

(Rs Lacs)

1

Isolation valve provision in 14''CD vapor line from process

condensate stripper ( F 1321 toE-1322 air cooler

FY2008-09 16.77 1.20

2

Installation of AmmoniaProduct Heater in the ammonialine going to urea plant

FY2009-10 48.31 13.03

3

PAC Discharge line sizeincreased from 10'' to 12'' for

reduce pressure drop andincreasing air flow rate.

FY2009-10 107.36 17.92

4FD/ID Fan duct modification by

using CFD AnalysisFY2009-10 41.17 140.33

5Provision of Primary Reformer

Fuel NG preheatingFY2009-10 4.75 20.90

6

Am

monia

Pla

nt

Installation of New Plate type

heat exchanger in synthesisloop.

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 plant’s 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


SM3

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 SM3

/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, Fiancée, 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 ProductQuantity

(MT)

Total UnitsConsumed

(kWh)

Total FOConsumed

(Liters)

SpecificPower

Consumption(kWh/MT)

Specific FuelConsumption

(L/MT)

2008 - 09 CopraProcessed

229782428774.6

314798.6 105.7 13.7


19896.8 2032199.5 268606.8 102.1 13.5


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

SlNo Key Process Indicators

Actual (10 -11)

Target (11 -12)

1 Reduction in Specific Fuel Consumption 12.22 10.75

2Reduction in Specific Power Consumptionin OilMill 83 80

3 Increase in Rainwater usage 1825

Sl Projects Identified Units saved LitersSaved

Savings( Lacs)

Investment( Lacs)

1Solar System for Administration blocklighting & PC 12500 0.5 10

2 Solar streetlights 12500 0.5 4

3Energy efficient motors for Super AExpellers 52000 2.08 5

4PID controller for Oilmill Conditioners toreduce steam usage 2130 0.64 1.95

5Replacing UG oil heating sump with newinsulated sump 15000 4.5 2.5

6Utilization of First stage ExpellerCondensate 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.


ProductionVolume

MT 41623 40639 46533

EnergyConsumption

kWh 110974012 105068922 107882648

SpecificEnergy

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

Total Investment : 1020 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 2-3ºC 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 2008-09 200 9-10 2010 -11

Annual Pr oduction MT 3705 4311 3639

Total electrical ener gy

consumption/ annum

Lacs

KWh9445274 8992843 6892996

Speci fic electrical ener gy

consumptionkWh/MT 2549 2086 1894

ELECTRICITY

Consumption % reduction overYEAR

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

20861894

0

500

1000

1500

2000

2500

3000

Sp

.E

ne

rgy

Co

ns

um

pti

on

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 employee’s 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

Th

ou

san

ds

En

erg

yc

on

su

mp

tio

nin

Kw

h

0

100

200

300

400

500

600

Th

ou

san

ds

Pro

du

cti

on

vo

lum

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

oC±1 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 blower’s 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 inMillion

1297.8 885.79 684.28 912.938

Total EnergyConsumption per

annumLacs kWh 30.46 19.85 17.10 19.25

Kcal ( Kilo calories ) Calories30.46*860=

2619519.85*860=

1707114706 16555

Energy in MTOE

MTOE

(Metric tonof oil

Equivalent)

26195/100 = 262.0

17071/100 = 170.71

14706/100=147.06 165.55

Specific EnergyConsumption in

MTOE/Actualproduction -

Specificenergy

0.20 0.19 0.21 0.18

%Reduction over2009-10

Percentage14.28%

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 5th

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 (AHU’s) 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

AreaArea

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

PTBAHU'S

PTBAHU'

S

1050 24 25200 1050 16.5 17325 78751,181,2

50

REPLACEMENT OF CONDENSER PUMPS

BEFORE AFTER

LOAD

TotalAREA

LOAD

(KW)

Operating

Time

Total

Consumption(KWh)

(KW)

Operating

SAVING IN

kWh PERDAY

SAVING

IN RSPER

MONTH

PTB

CHILLER

PLANT

135 15 2025 111 15 1665 360 54,000

Consumption(KWh)

Description Investment Saving per Month Payback period

Original PumpsAfter 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 FROM ALUMINUM CAST TO FRP

BEFORE AFTER

LOAD

Total

consumption

AREA

LOAD

(KW)

Operating

Time

Total

consumption

(kWh) (KW)

Operating

Time (kWh)

SAVING

IN kWhPER

DAY

SAVING

IN Rs.PER

MONTH

PTBCT'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

LOADTotal

consumption

InitiativeAREA LOAD

(KW)

Operating

Time

Total

consumption

(kWh)(KW)

Operating

Time

(kWh)

Saving

in

kWh

per

day

Saving

in Rs.

per

month

Conversionof ExistingLamps to T5

PassengerCorridors ,chiller plant,servicecorridors

72 24 1728 56 24 1344 384 57,600

Wash rooms( 11 no’s)

5 24 120 5 12 60 60 9,000Installationof MotionSensors

Fixed LinkBridges (3nos )

5 24 120 5 12 60 60 9,000

Installationof LEDLamps

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 3,370Replacement

of 2x36w TLfitting to1x36w

Chiller plant 2.25 24 54 1.12 12 13.44 40.56 6,084

221

Pay Back Period

Lighting - System Modification

InitiativeAREA

InvestmentPayback Period

(in months)

Conversion of Existing Lamps toT5

Passenger Corridors , chiller plant,service corridors 317000.00 5.50

Wash rooms ( 11 no’s) 15950.00 1.70Installation 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 NAReplacement of 2x36w TLfitting 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 57th

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 BGCX35

6.8

34

2.3

31

6.8

30

8.0

29

0.3

0

50

100

150

200

250

300

350

400

2006-07 2007-08 2008-09 2009-10 2010-11

Year

Ele

ctr

ica

lE

ne

rgy

inL

akh

KW

hrs

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

16

01

0

13

25

4

10

51

6

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

2008-09 2009-10 2010-11

Year

KW

Hp

er

Eq

uiv

ale

nt

Ve

hic

le-D

MR

Ru

nit

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 AHU’s.

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.

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 750º 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 1100º 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 Mumbai’s

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 world’s 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. Inorbit’s 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 Foundation’s 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 CO2

without energy by emission

efficiency implementing Million Kilo Gram

Energy Saving (1 kWh = 0.85 kg

measures of CO2

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 m3

/hr were supplying the

return chilled water to the Chillers. Two secondary pumps @ 45 kW each with

capacity of 640 m3

/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 m3

/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 Mall’s 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 India’s 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 AOP’S, subsidiaries and SBUs, as a part of it’s

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 India’s 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 Group’s vision is to be the world’s 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

6.1256.006

FY'06 FY'07 FY'08 FY'09 FY'10 FY'11

Plant Sp. Power Consumption (KWh/tss)

402388

400

421

385

356

FY'06 FY'07 FY'08 FY'09 FY'10 FY'11

Boiler Coal Consumption ( MT)0.598

0.329

0.1890.134 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

94.0395.70

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

5.6265.400

6.587

6.125

6.006

5

6

7

FY-09 FY-10 FY-11 FY-12 FY-13 FY-15

Gcal/tcs

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.

� 4th

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 RSP’s

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 m2

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

BMC’s 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

2010-11Installation 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

2.961666

61050 140.34 0

2010-11Optimizations 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

2010-11Stoppage 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)

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 kSm3

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 cracker’s 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 CO2

/ 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/cm2

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/cm2

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

ksm3

/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 CO2

/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


/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


/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 CCC’s parent company; CSRC, a Taiwan based listed company. The CSRC

group is the world’s 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, CCIL’s 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 CCIL’s 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 580°C 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 1300-1100°C exit from the carbon black reactor. The existing

air pre-heaters were designed for the smoke temperature at APH inlet was

670°C. To bring down smoke temperature from 1300°C/1100°C to 670°C,

lot of water quenching was being done which killed the available sensible

heat in smoke.

Post-project Scenario

In the post-project scenario 950°C 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 950°C 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 900-1000°C 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 ElectricalEnergy

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-à-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-à-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 No’s CoolingTowers.

Before After

COMMON

TANK

To system

From system HOT WATER

TANKCOLD

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%Reduction

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 today’s

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 2865525 3406518 3789663

SALES TURN OVER 1497.1 2469.7 3816.9(Rs.IN LAC)

PROD. IN TONS 1408 1866 2674

ENERGY COST/ 9.24 7.08 5.05SALES TURN OVER(%age)

Specific Energy 2.04 1.83 1.42(KWH/Kg.)

Specific Energy 2040 1830 1416(KWH/tonne)

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/c’s 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

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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.

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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.

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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 company’s 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 employee’s

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 10th

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 Aug’04. 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 CO2

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 NM3

/hr (min) to 1604 NM3

/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/cm2

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 H2

demand of the unit. These reciprocating compressors can operate

with fixed step loads only and thus discharge a fixed quantity of H2

at any given

combination of load. The excess H2

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 μm). 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 no’s, 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 no’s 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

7156.961.2

165796.0

1.4

107516.0

6288.358.5

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

2009-20102010-2011

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

2009-20102010-2011

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 FY 2009-2010 FY 2010-2011

1. Energy Input

1.1 Total Solid fuel consumption i.e.

Coal, Coke & CPC

Gcal2331758 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

MT159411 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 KW0.02442 - - - 0.2 0.07326 0

3. Down sizing of belt conveyor

motor from 55 KW to 37 KW0.12768 - - - 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 by300 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


KW

H/T

on

340

Energy Conservation

Measure Project Taken in year 2010-11

S.NoTitle of Energy Saving project

implementedInvestment(Rs. Lacs)

Actual AnnualSavings (Rs

Lacs)

1Optimizing strip cooling through Jet

cooling Blower speed control0.50 81.91

2Optimizing Pressure of coolingchamber through Jet exhaust

blower speed control0 43.56

3Fuel Saving in boiler no 1and 2 by

online monitoring & control ofoxygen % in Flue Gas

0.6 32.4

4Compressed air Energy Saving &

Water Quality improvement indynasand filters in CRD-1 & 2

0.3 1.30

5Replace WBA Cooling Water pumpwith lower flow and pressure pump

0 13.16

8Circulation Cooling tower fan

in auto control of CRD-20.35 0.46

9Changing cooling tower

fan motor from 18.5Kw to 9.3Kw0 0.33

10Automation of fan motor w.r.t. C.W.

temp at Z-3.0.2 0.59

11Optimum utilization of water in AP-3

line0 3.54

12Replacement of 250W street light

with 24x2 W0.7 0.37

13 Z#2 Mill POR DC Motor Blowerremaining stop during Sub Passes Nil 0.31

14 Reduction in Package ACconsumption by arresting cooling

leakage.

0.6 2.56

15Replacement of motors rewind(3 to

4 Times) with high efficient newmotor

8.35 6.80

16Energy Saving by Replacement of

over rating motor at brushingmachine-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

EnergyConsumption

FinalProduction

kwh /kg

EnergyConsumption

FinalProduction

kwh /kg

EnergyConsumption

FinalProduction

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.

0.229

0.175

0

0.05

0.1

0.15

0.2

0.25

2009-10 2010-11

Specific Thermal Energy Consumption

MTOE / tonne

0.023

0.019

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 consumptionYear

kWh /tonne

o f sugar

% Reduction

Over Last year

Mkcal/tonne

o f 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 3rd

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 OEM’s, BKT supplies its products to major OEM’s 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 120°C) 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

Better


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.

381381

OFFICE & BPOOFFICE & BPOOFFICE & BPOOFFICE & BPOOFFICE & BPO

BUILDINGSBUILDINGSBUILDINGSBUILDINGSBUILDINGS

OFFICE & BPOOFFICE & BPOOFFICE & BPOOFFICE & BPOOFFICE & BPO

BUILDINGSBUILDINGSBUILDINGSBUILDINGSBUILDINGS

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 PurchasedLacskWh

32.7 25.41

(b) Self generatedLacskWh

1.51 1.01

(c) Total Electricity Consumption (a+b)LacskWh

34 26.42

3 Achievement of energy savings from implementation of new Energy Efficiency Projects for the currentyear

YearElectricity (Lakh

kWh)Any Other

2010-11 7.8 Nil

4 Specific Energy Consumption (SEC) Reduction during the period 2009- 2011

YearTotal electricity consumption/ Total bui lt-up area

(kWh/m2)

% Reduction over2009 - 2011

2009 - 2010 222 18

2010 - 2011 171 23%

5 Absolute Savings

Elect. Saving (Lacs kWh) in2010-11

Elect. Consumption (Lacs kWh) in2009-10

% 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

ElectricityYear of Commissioningof 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 0Ground

Z 58 5 31 0

X 38 9 23 43

Y 65 20 36 521st floor

Z 196 29 29 40

X 89 13 14 61

Y 89 19 15 552nd floor

Z 163 19 15 109

X 16 1 4 7

Y 58 11 17 273rd 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 24O

C.

By resetting the temperature at 1O

C above the previous setting of 23O

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

SE

(kW

h/s

qm

)

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 officers’s 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 16th

of October to 15th

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 8º 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) officer’s 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 client’s business processes. Infosys BPO Limited and

Infosys work closely together to provide a complete outsourcing solution to the

client, addressing the client’s 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

equipment’s 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.

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� 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 VFD’s 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.

� VFD’s installed in all the AHU’s.

� 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 façade, 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.

417417

HOHOHOHOHOTELSTELSTELSTELSTELSHOHOHOHOHOTELSTELSTELSTELSTELS

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.

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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

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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

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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

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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

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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.

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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.

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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 Officer’s 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

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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 Hospital’s 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

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The Engineering and bio medical services have been outsourced to a Malaysian

company, M/S Faber star since March’2008 and they are still a part of hospital

and working in a thorough professional manner

The energy bill for the year 2008 (Jan’08 till Dec’08) 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

AHU’s is 75% of the designed

CFM

Modulating chilled water valves and

the temperature controllers not

working on the AHU’s

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 AHU’s

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 VFD’s

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

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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

CER’s, 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.

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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.

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 m3

/km2

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 m3

/km2

)

2009 - 2010 0.03078 --

2010 - 2011 0.02788 9.41%

� As the machines were commissioned on 2nd

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 2nd

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.

457457

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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 30th

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 SME’s

� 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.

� Hon’ble Chief Minister, Punjab conferred State Award to Senior Manager (Energy

Conservation), PEDA on the occasion of State Level Independence Day

Celebration Function held on 15th

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 7th

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 15th

and 16th

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 4th

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

18th

December, 2009 Hon’ble 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.

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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 CO2 emission reduction. To promote

SWHS following schemes have been initiated in the State:

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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.

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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 Hon’ble

Power Minister, Haryana with an objective to sensitize students of 8th

and 9th

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.

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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.

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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.

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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.

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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 7th

– 8th

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 7th

– 8th

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

23rd

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 – 8th

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.

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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 Minister’s

Chamber and Conference Hall, all Cabinet Minister’s Chamber, Chief Secretary’s

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 SDA’s 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 27th

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.

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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 Hon’ble

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.

491491

THERMAL POTHERMAL POTHERMAL POTHERMAL POTHERMAL POWERWERWERWERWER

STSTSTSTSTAAAAATIONSTIONSTIONSTIONSTIONS

THERMAL POTHERMAL POTHERMAL POTHERMAL POTHERMAL POWERWERWERWERWER

STSTSTSTSTAAAAATIONSTIONSTIONSTIONSTIONS

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 9×135 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 no’s = 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 PHE’s are available but before

only one PHE was in service by taking both the PHE’s parallel in operation,

pressure drop in the across the PHE’s 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



517517

ZONZONZONZONZONALALALALAL

RAILRAILRAILRAILRAILWWWWWAAAAAYYYYYSSSSS

ZONZONZONZONZONALALALALAL

RAILRAILRAILRAILRAILWWWWWAAAAAYYYYYSSSSS

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 & I2

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’

OLIVER’G’ 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 1st

Railway train India began its journey from Boribunder to thane on

16th

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

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, OLIVER’G’ is regularly used for attending

spark location and maintaining spark free current collection.

9. Continuous efforts are being made by N.Rly with SEB’s to reduce traction

tariff.

10. SEC (Specific Energy Consumption) on electric traction of this Railway

has been reduced from 5.44 (March’10) to 4.64 (March’11). 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 forPassenger(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 40.76199.58

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.

549549

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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 54°C 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

addressing environmental concerns. LG has developed 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 2.21500

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 company’s 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 world’s 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-600a1

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-pentane2

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 Roshni’s 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 Tubing’s. 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 didn’t 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 isn’t 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.I’s 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 TV90W

W

160W

42” Screen size comparison

25% `1̀5%

``40%

CCFL LCD TV LED

Impact

150 W ~90 W

ON Mode

• CCFL Lamps require High • Less operating Voltage

LED Backlight Further Improvements

• InnovationLocal Dimming driving introduced in

42”LCD 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 nonstar 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

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