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Garware Polyester Ltd. Aurangabad
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Company Profile
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⇒ Garware Polyester Limited is the pioneer in the field of polyester film. The Company has developed different types of films and is exporting to 57 countries in World. The company has excellent infrastructure and strong commitment to Safety, Quality, Energy Conservation , Environment preservation and R&D.
⇒ Winner of Highest Export Award-Plex council (Govt of India, Ministry of Commerce) since last 20 years.
⇒ Winner of 1st award in 2009 in “Plastic Category” on National Level (NECA)
⇒ Winner of 2nd award for excellence in Energy Conservation and Management in 5th Maharashtra State Level Award competition in year 2008 in category “Other Industries“.
⇒ The company has set up cross functional Energy Conservation Cell, which focuses on energy management and improvement.
⇒ The company recognizes the importance of energy conservation, not only to improve the bottom line but also to help the environment and society at large for sustainable growth.
Company Profile11/10/09
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Process Flow Diagram
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Feeding
Slitting
Packing & Despatch
Re-cycling
Aux. Winder
Chill Roll
Extrusion
Drying
TDO
MDO
Film Process 11/10/09
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ENCON Efforts
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Energy Conservation Summary
8.285025.71416.52360.71102009-2010
10.175216.91530.97178.00132008-2009
8.324730.70393.7065.7082007-2008
% Savings of Energy Cost (iii/iv x100)
Energy Cost
(Rs. Lakhs/ year)
(iv)
Savings achieved
(Rs. Lakhs/ year)
(iii)
Investment made
(Rs. Lakhs)(ii)
No. of Measures
implemented (i)
Year
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ENCON Projects (2007-08)
0.2042.78231.520.00Conversion of Boiler from F O to Biomass firing. C U, Waluj.
4.0020.91313.60- 10.58Commissioning of 40TR & 60TR VCC Chiller, C.U. Waluj..
60.00207.551123.12
0.00Conversion of VAHP m/c to double effect. C U, Waluj.
0.201.810.000.52Provision of VFD for VAHP C/T Fan. C U, Waluj.
Total Savings (Rs. Lacs)
F O (MT)
Elect. (LkWh)
Investment incurred. (Rs. Lacs)
Achievement of energy savings per year basis
Project Description
Cont’d
5
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65.70393.702194.2- 3.48Sub Total
0.004.200.001.20*Higher cap reci. compressor operation stopped by taking portable compressor in line. Film Plant, Chikalthana.
0.301.230.000.35Palletizing return water pump replaced by high efficiency pump. Film Plant, Chikalthana
0.5017.640.005.04Optimization of ejector C/T, Poly Plant, Waluj.
0.5097.575280.00Provision of cooling water to Poly Plant cutter instead of chilled water Waluj.
Total Savings (Rs. Lacs)
F O (MT)
Elect. (LkWh)
Investment incurred (Rs. Lacs)
Achievement of energy savings per year basis
Project Description
Operational tuning
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ENCON Projects (2008-09)
0.0010.580.002.85*Optimization of compressed air system and stopping one compressor, C U, Waluj.
0.005.290.001.43*Provision of VFD to Boiler No.2, FD Fan, C U, Waluj.
0.0010.580.002.85*Optimization of chiller water and stopping one chilled water pump. C U, Waluj.
70.00265.281069.20-13.464Installation of cost effective Screw Chiller, C U, Waluj.
80.00144.92584.10.00Provision of HP ejectors to Poly Plant ,Waluj.
Total Savings (Rs. Lacs)
F O (MT)Elect. (LkWh)
Investment incurred. (Rs. Lacs)
Achievement of energy savings per year basis
Project Description
Cont’d
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10.008.9336.000.00EIL heater efficiency optimization. C U, Waluj.
1.002.350.000.63Provision of VFD to Cooling water return sump pump, Poly Plant, Wlj.
0.12.060.000.55Aeropeq blower motor pulley replaced by smaller dia. pulley ETP (speed red-30%) Waluj.
0.12.350.000.63Installation of VFD on Biopeq feed pump. ETP, Waluj.
0.002.350.000.63Replacement of 150 HP blower motor with 75 HP motor, Film Plant, Waluj.
Total Savings (Rs. Lacs)
F O (MT)
Elect. (LkWh)
Investment incurred (Rs. Lacs)
Achievement of energy savings per year basis
Project Description
Cont’dUse of available material
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178.00530.971883.37.05Sub Total
0.005.0001.35*Optimization of air compressor operation in Chikalthana Plant
15.0035.5509.58Installation of high efficiency screw chiller in Chikalthana plant
0.0035.731440.00Briquette firing to Boiler
Total Savings (Rs. Lacs)
F O (MT)Elect. (LkWh)
Investment incurred (Rs. Lacs)
Achievement of energy savings per year basis
Project Description
7
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ENCON Projects (2009-10)
0.009.690.002.38Stopping of MDO chilled water system and hook up from C U, Waluj.
332.4191.261800.000.00Commissioning of Biomass fired Boiler in C.U.Waluj.
0.0011.3751.040.00Direct transfer of condensate from Glycol Recovery & eco-recir to De-aerator in Waluj.
15.0029.380.007.2Polyplant cutter cooling tower-Waluj.
11.0015.4369.30.00EIL heater efficiency optimization. C U, Waluj.
Total Savings (Rs. Lacs)
F O (MT)Elect. (LkWh)
Investment incurred. (Rs. Lacs)
Achievement of energy savings per year basis
Project Description
Cont’d
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1.500.970.000.24Provision of VFD to TDO oven blower in Chikalthana plant
360.71416.521974.349.92Sub Total
0.100.4000.10Secondary hot oil pump impeller trimming in Chikalthana plant.
1.5012.03540.00Use of emulsified F.O. for Thermic fluid heater in Chikalthana plant
0.0076.690.000.00*P.F. incentive at Chikalthana0.00169.300.000.00*P.F. incentive at Waluj.
Total Savings (Rs. Lacs)
F O (MT)Elect. (LkWh)
Investment incurred (Rs. Lacs)
Achievement of energy savings per year basis
Project Description
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Specific Energy Consumption For Chips Production 11/10/09
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Specific Energy Consumption For Film Production
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Global norms / Benchmark
Garware Polyester Limited is producing specialty Polyester Film and hence the specific energy consumption of our product can not be compared with other Film Producers.
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Innovative Projects
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332.4191.261800.00.00Commissioning of Biomass fired boiler-Waluj.
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1.02.3500.63Provision of VFD to C.W. return sump pump-Waluj.
4
0.0011.3751.040.00Direct transfer of condensate from Glycol recovery & economizer recirculation to De-aerator-Waluj.
2
15.0029.380.007.2Polyplant cutter cooling tower-Waluj.
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Investment incurred on the project Total
savings F. Oil (MT)
Elect (L kWh)
Achievement of energy savings / year basis
Project descriptionS.N.
Innovative Projects (2009-10)
Rs. Lacs
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ENCON Project No. 1 Title : Poly Plant Cutter Cooling Tower
Background of the project : To reduce chilled water load.Observation made :o Chilled water is used for Polyplant cutter for cooling of chips from 280°C
to 40°C.o Cooling water can also be used for cutter cooling.Technical and Financial AnalysisInvestment : Rs. 15 Lacs Implemented : Aug. 20091st year cost Saving : Rs. 29.38 LacsImpact of implementation : Reduction in chilled water load by 200 TR/Hr.
Innovative projects
2.61Energy consumption after9.81Energy consumption before
Electricity cons. (Lacs kWh)On annual basis
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Before
After
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ENCON Project No. 2Title : Direct transfer of condensate from Glycol Recovery and Economiser recirculation to Deaerator
Background of the project : To reduce Furnace oil consumption for Boilers
Observation made : Glycol recovery steam is collected in tanks and then transferred to De-aerator. We can also use economizer recirculation for De-aerator heating.Technical and Financial AnalysisInvestment : NIL Implemented : Aug. 20091st year cost Saving : Rs. 11.37 LacsImpact of implementation :Improvement in Deaerator temp. by 20 Deg. C and reduction in Furnace Oil consumption by 51.04 MT per annum.
Innovative projects
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Before
After
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ENCON Project No. 3Title : Commissioning of Briquette Fired Boiler
Background of the project : To reduce Furnace oil consumption for Boilers.Observation made : Use of standby boiler can be made by installing external furnace for biomass firingTechnical and Financial Analysis :Investment : Rs. 332 Lacs Implemented : Jan. 20101st year cost Saving : Rs. 91.26 LacsImpact of implementation :Reduction in Furnace Oil consumption. Thereby reduction in SO2 by 210000 Kg/annum and estimated reduction in CER by 11000 per annum
Innovative Projects
1800Energy consumption before MT-F.O.Furnace Oil cons. (MT/Annum)On annual basis
CDM Status : Process of PIN, PDD completed. HCA awaited
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Briquette Fired Boiler
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ENCON Project No. 4Title :Provision of VFD to C.W.return sump pump.
Background of the project :C.W. sump receives C.W. water flow ranging from 70 M3/Hr to 130 M3/Hr.
Observation made : If we provide VFD to pump with impulse to pump speed thro LT on
sump, we can save pump power and loss of water.Technical and Financial Analysis :Investment : Rs. 1.0 Lacs Implemented :-Mar.-2009.1st year cost Saving : Rs. 2.35 LacsImpact of implementation :Reduction in power cons and water cons.
Innovative Projects
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Environmental Projects
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• Separate EMS teams (Chikhalthana and Waluj) are formed for maintaining and improving environmental norms.
• Monthly EMS presentations are organized in a meeting chaired byDirector of the company.
• Effluent treatment plants in both the locations viz Chikhalthana and Waluj are managed by highly experienced managers to maintain MPCB norms.
• Ambient air and stack analysis are carried out and maintained within norms every month.
• Company has won 16 no's of awards in different categories of safety competition.
• Internal safety competitions are arranged every year.
• Energy Conservation Week is organized every year.
Safety and Environment Management System
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Environmental Projects
• Conservation of water through ENCON projects
• Optimization of DM Plant, Cooling water system
• Ideas through suggestion.• Use of C.W. blow down and • treated effluent to Gardens
Reduction over 07-08Wlj Plant:
23.89%Chk Plant:
16.98%
Reduction inWater Consumption
2008-2009
Estimated reduction in CER by 11000 / Annum
The IAEC make horizontal tubular boiler provided with external furnace for firing briquettes.
Reduction in emission of SO2 By 210000 kg / annum.
Commissioningof Biomass Fired Boiler
2009-2010
Sludge purchased from M/s. Sanjivani Sakhar Karkhana, Sangamner, M.S.
Improved quality of
treated effluent
Anaerobic reactor sludge renewed
Actions takenEffectProjectYear
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4833.249.1211000Jan. 10Biomass fired boiler
1
Rs. Million
Rs. Million
No. of CERs/ VERs
Payback (Months)
Invest. Made
Total Annual savings
Total CO2reduction
Year of implem-entation
Project titleSN
Clean Development Mechanism (CDM) Project
16
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31
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17
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Reduction In Ammonia Consumption 11/10/09
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Reduction In Water Consumption (M3)
18
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GPLFirst Award in Plastic Sector.
2009BEENational Energy Conservation Award-2009
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GPL2nd Award in Other Industries
2008MEDA5 th State Level For Excellence in Energy Conservation and Management
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Film, Chkl
A Plaque & Certificate of Merit
2008NSC –MC
Maharashtra Safety Awards –2008
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Film, Wlj
3rd Hindi – Mr.DKGhodke
2009NSC –MC
Safety Slogan Competition –2009
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Batch, Wlj
Certificate of Merit2008NSC –MC
Maharashtra Safety Awards – 2008
3
Film, Wlj
Certificate of Merit2008NSC –MC
Maharashtra Safety Awards – 2008
2
Film, Chkl
A Plaque and Certificate of Merit
2008NSC –MC
Maharashtra Safety Awards – 2008
1
PlantWinner CategoryYearOrganized by
Awards TitleNList of Awards 11/10/09
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Energy Monitoring
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Garware Polyester Limited plays vital role for producing variety of products with high level of quality standard and prioritizes energy value for the final product.Our mission is :
To produce products with minimum use of energy. Use of cleaner technologies wherever possible and ensuring efficient and uninterrupted supply of utilities to plants.
This, we plan by following ways.Efficient energy generation, utilization and distribution. Continuous evaluation of performance of plant equipments and processes to achieve most efficient, high standard quality products. Targeting the under-performance equipments and processes for improvement.Monitoring and targeting the specific energy consumption to achieve best possible as compared to past performance.Use of internal and external expertise to achieve targeted performance. Train employees and implement ideas of energy conservation thorough small ENCON teams.
M S AdsulDirector-Technical
Energy Management Policy11/10/09
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Director -Technical
Head Engineering
General ManagerCentral Utility &
“Energy Manager”
ENCON TeamFilm Waluj
ENCON TeamPoly &
Batch, Waluj
ENCON TeamCentral Utility
Waluj
ENCON TeamChikalthana
ENCON Team Structure
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Percentage Break up of Time Spent by Senior Executives
15Energy Conservation Measures.7.10Quality Management.6.5Analyzing Competitors Profile.5.15Marketing coordination activities.4.15Materials Management3.25Manufacturing Excellence.2.15Technology Implementation1.
Percentage Time SpentFunctionSr.No.
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3 % Reduction over 2009 – 2010
1% Reduction over 2009-2010
2010 - 20111.211262.81Chips0.9991032.6Film
ThermalElectricalYear
• In line with the proposed energy conservation future energy projects are already identified and out of 2 identified projects implementation in progress.
• Daily ENCON meetings are organized to identify potential areas of Energy Conservation.
• Weekly meetings are organized for discussion on areas of energy savings.
• Interaction with external agencies for conservation of energy.• KRA to operating staff to conserve energy in their own area of
working.
2009-10 (Base year)
Benchmarking of Energy Consumption Norms
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1. DailyEnergy report is generated by Central Utility on daily basis.•Energy Report is checked by Dept Head and corrected if reqd.•The report is then circulated to concerned Dept Heads for corrective actions to control energy consumption.
2. Monthly•Based on daily energy consumption, monthly energy report is prepared and circulated to all concerned. Comparison of energy consumption is done with previous months and deviations are studied for reduction in Energy Bill.
3. Yearly•Yearly reports generated from data collected as above.•Specific energy consumptions are calculated and targets are set for future.•ENCON projects are identified and budgeted in annual budget.•Major ENCON projects are listed in annual report.
Energy Monitoring.11/10/09
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868686%Efficiency10.21.99.9MT/DayFurnace Oil cons.3.80.743.9MKcal/HRFired Heat3.270.653.39MKcal/HRDistributed Heat255100252T/HrFlow
300.0310.0299.0°CReturn Temp.320.0320.3320.3°CSupply Temp.PolyBatchFilm UnitItemsE
IL -HEATER
1226439186230781Total208071049610311Poly1242175624859Batch894157380415611FilmTotalPlantCen. UtilityPlant
Power Distribution (kWh)
Daily Monitoring & Reporting Formats
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Steam Balance
0.0MT/DayFurnace oil cons.32.0MT/DayBriquette Cons.73.0%Boiler efficiency
0.2MT/Hr.Losses0.4MT/Hr.FO / Tank Farm0.4MT/Hr.Deaerator1.5MT/Hr.Film Plant0.4MT/Hr.Jumbo Heater1.4MT/Hr.Poly Plant0.8MT/Hr.Batch / Gly. Rec.5.1MT/Hr.Consumption by users5.1MT/Hr.Generation thru’ boiler
UnitItem
23GIL619Total
167Poly179Batch250FilmCons.Plant
Water Cons (M3/Day)11/10/09
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0.732.311.211262.811.22269.04Chips 416.5212.366.540.9991032.61.141104.89Film
Rs. lacsThermalElectricalMillion Kcal/ton
kWh/Ton
Million Kcal/Ton
kWh/Ton
Plant
Money saved during
2009-10
% Reduction (+) or Increase (-)
(a-b) / a* 100
Actual achieved in
2009-10(b)
Planned target for2009-10
(a)
Energy Conservation target setting and monitoring of the same
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Implemented6.0 MT F.O.-Rs 1.48 Lacs per Month
Rs. 2.0 Lacs
Arch pressure transmitter changed to higher pressure range transmitter to tune outlet oxygen percentage.
1
Present Status
Saving (Rs. Lacs)
InvestmentObservationsSr. No
1. EIL New Delhi
External Energy Audit Observations (2009-10)
2. CHEMBOND, Mumbai
Under implementation
Rs. 0.68 Lacs per Month
NilChilled water flow measurement to Pre-Poly condenser done and decided to install Booster Pump
1
Present StatusSaving (Rs. Lacs)
InvestmentObservationsSr. No
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Implemented6.0 MT F.O.-Rs 1.48 Lacs per Month
_ID/F.D fans speed tuned through drives to maintain oxygen percentage in stack 5-6 percentage
2.
ImplementedImproved productivity and product quality
Rs 10-lacsPut burner firing oil pressure control on return header temp.
1.
Present Status
Saving (Rs. Lacs)
InvestmentObservationsSr. No
1. EIL New Delhi
External Energy Audit Observations (2008-09)
24
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2. Kaeser Compressors (India) Pvt Limited, Pune
Dropped due to process constraints.
Rs 0.95 Lacs per Annum
Rs 5.0 LacsReplacement of Nitrogen blower with energy efficient blower in Batch Plant.
2.
Will be considered for project.
Rs 0.95 Lacs per Annum
Rs 5.0 LacsReplacement of system blower with energy efficient blower in Film Plant Waluj.
1.
Present Status
Saving (Rs. Lacs)
InvestmentObservationsSr. No
3. Atlas Copco, Pune
Will be considered during project.
Rs 18 Lacs per Annum
Rs. 0.30 Lacs
Air flow measurement of various systems, and calculation of present specific power consumption.
1
Present Status
Saving (Rs. Lacs)
InvestmentObservationsSr. No
External Energy Audit Observations (08-09) 11/10/09
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1 Day3MEDA / FICCI
Energy Conservation, Renewable Energy & Energy Audit (2010-11)
1
1 Day2TAACT, Nasik
Seminar on Reducing energy bill for lighting (2008- 2009)
71 Day1MEDAENCON MEDA (2008-2009)6
2 Days1Power line, New Delhi
Managing Energy Cost (2008 -2009)
5
2 Days2CIISeminar on rotating equipments (2008-2009)
4
3 Hours17In HouseEnergy conservation in electrical by Mr. A.A. Bugdani. (2009-2010)
3
3 Hours15In HouseEnergy conservation in utility by Mr. V.S.Saraf. (2009 - 2010)
2
DurationNo of Participants
Organized By
Program name & DetailsSr. No
Awareness Creation in Employees
25
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Rs/M318.75MIDC-Water13)Rs/Unit4.5Power12)Rs/MT25000.00F.O.11)Rs/M326.61Soft Water10)Rs/Tr6.63Chilled Water9)Rs/M31.49PSA Nitro8)Rs/M30.56Instr. Air7)Rs/M30.43Compr. Air6)Rs/M31.37C.W.Water5)Rs/M347.10D.M.Water4)Rs/MT1142.50Steam (Briq.)3)Rs/MT1912.60Steam (F.O.)2)
Rs/MKcal/Hr.3381.67Hot oil1)Unit RateCostUtilitySr. No
Utility cost for month …..11/10/09
50986.16Grand Total89.78246.04203.09173.06140.65133.54Total
20.1917.4113.8811.989.67Mar1221.2717.8814.1611.7710.12Feb1122.8215.3214.2114.2911.20Jan1023.3715.1714.5614.5610.48Dec921.3017.9614.9815.9510.80Nov821.6418.1614.858.7610.31Oct718.5418.6814.7011.3111.70Sep620.9218.6215.178.3112.29Aug5
21.1919.0717.5014.7910.5411.37Jul422.6919.4616.8914.9511.2012.02Jun321.8818.7914.3114.6311.1611.28May224.0218.6815.1912.1710.8312.30Apr.1
Year (10-11)
Year (09-10)
Year(08-09)
Year (07-08)
Year (06-07)
Year (05-06)
PF Incentives (Rs. Lacs)MonthSN
Power Factor Incentive Benefit:
26
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Renewable Energy Utilisation
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Renewable Energy Sources, Utilization of Waste
⇒ Biomass fired boiler commissioned in Jan. 2010. Thereby, replacement of 1800 MT of furnace oil by agriculture waste.
⇒ Waste wooden material is burned in boiler to reduce furnace oil consumption.
27
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Best Practices Implemented On Energy Front Amongst Associates.
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ENCON Projects Implemented in Garware Industries Limited, Waluj, Aurangabad.
1 Month0.101.090.27Primary Therminol circulation pump impeller trimming.
3
_0.305.651.41Total4
1 Month0.101.80.45Primary Therminol circulation pump impeller trimming.
2.
1 Month0.102.760.69H-line blower speed reduction 15 %.
1.
Simple payback months.
InvestmentRs-lacs
Annual Saving Rs-Lacs.
Annual Saving Power –Lac-kWh
ENCON ProjectSr. No
28
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Corrective Preventive Action
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ISO 9001:2008Product Name :1484113Re-CertificationJob Description/Code:
221.35GARWARE POLYSTER AURANGABAD
Company Name/Code
MinorType of findings
R.S.JamdadeContact(s) :
Omprakash ModakTeam Member (s) :
Engg-Film - WalujDepartment :Dattatray WaghmareTeam Leader8.4 Analysis of DataClause :DWA/02Number :24/12/2009Date(s) :
29
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Requirement of the clause: As Per standard ISO 9001-2008 Clause No - 8.4 Analysis of data The organization shall determine, collect and analyze appropriate data to demonstrate the suitability and effectiveness of the quality management system and to evaluate where continual improvement of the effectiveness of the quality management system can be made. This shall include data generated as a result of monitoring and measurement and from other relevant sources. The analysis of data shall provide information relating to characteristics and trends of processes and products, including opportunities for preventive action Non -conformity-A. Process Engg film plant Waluj- Vibration analysis Dtd 24/Sept 2009 for line 4 specifies various alarms like inspect the bearing, insufficient contact area at motor base etc, data observed to be not analyzed for necessary actions.
Non Conformity 11/10/09
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Corrective Action Report (to be completed by the company) :J V DeshmukhCompany
Representative :30/12/2009Proposed Completion
Date
A) Variance analysis carried out for the Last three Quarters and wherever required Corrective actions taken in order to achieve the Target.B)Short shutdown was taken on 27.12.09 and actions taken on vibration analysis report dated 24/11/09.Motor was removed to inspect the base. Following actions taken.1)Cleaning of foundation plate .2)Realignment of the motor.3)Re-Tightening of blots with torque wrench.Root Cause : (1) The status of recommendation for vibration report was ALERT, which required monitoring the trend, however corrective action could not be taken as shutdown was required. Corrective Action : (1) Tightening of blots on monthly basis for such kind of machines as per status of recommendation. (2) Action plan for observations and action recommended by outsourced NDT activities now implemented in preventive maintenance schedule. (Format F /ENG/023/05).
Corrective Action
30
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V.S.SARAFG.M. (UTILITY) & “ENERGY MANAGER”
MOBILE NO. +919822557093