garware polyester ltd. aurangabad - ciigbc award...⇒ garware polyester limited is the pioneer in...

1

11/10/09

1

Garware Polyester Ltd. Aurangabad

11/10/09

2

Company Profile

2

11/10/09

3

⇒ 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

4

Process Flow Diagram

3

11/10/09

5

Feeding

Slitting

Packing & Despatch

Re-cycling

Aux. Winder

Chill Roll

Extrusion

Drying

TDO

MDO

Film Process 11/10/09

6

ENCON Efforts

4

11/10/09

7

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

11/10/09

8

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

11/10/09

9

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.


F O (MT)

Elect. (LkWh)

Investment incurred (Rs. Lacs)


Project Description

Operational tuning

11/10/09

10


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.


F O (MT)Elect. (LkWh)



Project Description

Cont’d

6

11/10/09

11

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.


F O (MT)

Elect. (LkWh)



Project Description

Cont’dUse of available material

11/10/09

12

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





Project Description

7

11/10/09

13


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.





Project Description

Cont’d

11/10/09

14

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.





Project Description

8

11/10/09

15

Specific Energy Consumption For Chips Production 11/10/09

16

Specific Energy Consumption For Film Production

9

11/10/09

17

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.

11/10/09

18

Innovative Projects

10

11/10/09

19

332.4191.261800.00.00Commissioning of Biomass fired boiler-Waluj.

3

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.

1

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

11/10/09

20

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

11

11/10/09

21

Before

After

11/10/09

22

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

12

11/10/09

23

Before

After

11/10/09

24

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

13

11/10/09

25

Briquette Fired Boiler

11/10/09

26

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

14

11/10/09

27

Environmental Projects

11/10/09

28

• 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

15

11/10/09

29

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

11/10/09

30

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

11/10/09

31

11/10/09

32

17

11/10/09

33

Reduction In Ammonia Consumption 11/10/09

34

Reduction In Water Consumption (M3)

18

11/10/09

35

GPLFirst Award in Plastic Sector.

2009BEENational Energy Conservation Award-2009

7

GPL2nd Award in Other Industries

2008MEDA5 th State Level For Excellence in Energy Conservation and Management

6

Film, Chkl

A Plaque & Certificate of Merit

2008NSC –MC

Maharashtra Safety Awards –2008

5

Film, Wlj

3rd Hindi – Mr.DKGhodke

2009NSC –MC

Safety Slogan Competition –2009

4

Batch, Wlj

Certificate of Merit2008NSC –MC

Maharashtra Safety Awards – 2008

3

Film, Wlj

Certificate of Merit2008NSC –MC


2

Film, Chkl

A Plaque and Certificate of Merit

2008NSC –MC


1

PlantWinner CategoryYearOrganized by

Awards TitleNList of Awards 11/10/09

36

Energy Monitoring

19

11/10/09

37

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

38

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

20

11/10/09

39

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.

11/10/09

40

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

21

11/10/09

41

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

42

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

22

11/10/09

43

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

44

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

23

11/10/09

45

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)


11/10/09

46

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)


1. EIL New Delhi

External Energy Audit Observations (2008-09)

24

11/10/09

47

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)


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)


External Energy Audit Observations (08-09) 11/10/09

48

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

11/10/09

49

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

11/10/09

51

Renewable Energy Utilisation

11/10/09

52

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

11/10/09

53

Best Practices Implemented On Energy Front Amongst Associates.

11/10/09

54

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

11/10/09

55

Corrective Preventive Action

11/10/09

56

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

11/10/09

57

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

58

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

11/10/09

59

V.S.SARAFG.M. (UTILITY) & “ENERGY MANAGER”

MOBILE NO. +919822557093

garware polyester ltd. aurangabad - ciigbc award...⇒ garware polyester limited is the pioneer in...

Documents