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1 st & 2 nd Sep 2010 ENERGY CONSERVATION DRIVE

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Page 1: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

1st & 2nd Sep 2010

ENERGY CONSERVATION DRIVE

Page 2: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

•• Over 49,000 EmployeesOver 49,000 Employees

•• More than 170 Manufacturing FacilitiesMore than 170 Manufacturing Facilities••On 6 Continents and in 24 CountriesOn 6 Continents and in 24 Countries

••Over 35 Tech Centers & 25 Sales offices Over 35 Tech Centers & 25 Sales offices

VISTEON GLOBAL FOOTPRINT

Page 3: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

VISTEON CHENNAI PLANT

Page 4: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

COMPANY NAME VISTEON AUTOMOTIVE SYSTEMS INDIA PVT LTD.

MD KWON TAE CHOI

LOCATION MARAIMALAI NAGAR, CHENNAI

ESTABLISHED MAR 1998

EMPLOYEES 1224

PRODUCTSAIRCON, RADIATOR, INTERCOOLER, BLOSTER, CLUSTERS, COCKPIT ASSEMBLY

COMPANY PROFILE

Page 5: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

VISTEON INDIA – CHENNAI PLANT PROFILE

Company Details

Company Name : Visteon Automotive System India Pvt Ltd

Address : Keelakaranai village,Malrosapuram post,

Maraimalai Nagar,Chengalpattu- 603204

Phone : 044-27416960

Fax : 044-27453858

Email : [email protected] , [email protected]

Contact person : P.Deivabalan , A.Venkateswaran

Designation : Deputy General Manager , Assistant Manager

Plant Engineering

Type of Industry : Automobile

Production Capacity of the plant : 6 lacs carset /year

Annual Turnover of the

Company (2009 – 2010) * : 897 crores

Energy Cost as a % of

manufacturing cost : 2.97 %

Page 6: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

2800+ Employees5 Manufacturing Plants 2 Technical Centers

Chennai

Pune

VISTEON INDIA – PRODUCTS, PLANTS & CUSTOMERS

Compressor

Engine Cooling

ModuleCompact HVAC AC Lines

Inter Cooler

(Tube & Fin)FEM Carrier

Cock Pit

Clusters

VASI Customers

Chennai Plant (VASI) Products

Page 7: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

RADIATORA/C COMPRESSOR

A/C CONDENSER

A/C LINES

ACCUMULATOR

ASSEMBLY

HEATER HOSE

ASSEMBLIES

UNDERBODY TUBE

ASSEMBLIES

REAR COOLER

ASSEMBLY

AIR HANDLING ASSY

AND AIR FILTER

TEMPERATURE CONTROL

OVERHEAD DUCTSAND REGISTERS

I/P ,CLUSTERS,DUCTS

DEFROST-DEMIST

NOZZLES

VISTEON CHENNAI PRODUCT AND LOCATION

Page 8: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

TUBE

MILL

FIN MILL

FIN

MILL

PRESS

CORE

BUILDER

CORE

BUILDER

DEGREASERCAB

FURNACE

LEAK

TESTING

SEAL

FIXING

CASE /FAN

ASSYTANK

ASSY

HEATER

ASSY/COOLING

MODULE ASY

R

A

D

I

A

T

O

R

H

E

A

T

E

R

FLUXING

HEAT EXCHANGER PROCESS FLOW

Page 9: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

GRANULES MOLDING

PAINT

MIXING

PAINT

REGRINDING

BASE

COAT/CLEAR

COAT BOOTH

PRIMER&DENIB

BOOTH

OVENPRIMER

OVEN

SOLVENT

REJECT

COOLING

ZONE

PAINTED

PRODUCT

PLASTICS & PAINT SHOP PROCESS FLOW

Page 10: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

COILBOBBIN

WINDING

IP ASSEMBLY

SOLDERINGFUEL /

TEMP

ASSLY

SPEEDO

ASSEMBLY

CLUSTER FINAL

ASSEMBLY

ELECTRONIC

COMPONENT

(Semi finished

good as raw material)

INSTRUMENT PANEL & CLUSTERS PROCESS FLOW

Page 11: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

We at Visteon Automotive Systems India Pvt Ltd are committed to minimize all forms

of Energy and adverse impact of Environment

Through

• Create awareness amongst employees, encouraging their participation at all levels and recognize such conservation efforts

• Continual up gradation of Energy Efficient and Eco friendly technologies

• Increase the Non Conventional energy usage wherever feasible

• Work an environmental friendly aspects to reduce global warming

• Comply with Energy legislation and regulation

MANAGING DIRECTOR

ENERGY MANAGEMENT POLICY

Page 12: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

DIRECTOR

Manufacturing

Financial Advisory Team

Energy Manager

Energy Champion - CCS Energy Champion - IES Energy Champion - SMD

CFT MEMBERS - CCS CFT MEMBERS - IES CFT MEMBERS - SMD

ENERGY MANAGEMENT PILLAR STRUCTURE

Page 13: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

-6.08 %-29.530.36---37.3110.662006–07

-9.99 %-26.580.42---38.6011.032007–08

-7.4 %0.9424.600.48014451.9LPG41.3311.812008–09

7.964.1 %0.8423.600.5012.9416.0LPG40.8811.682009–10

Carset

in

million

Rs

Milli

on

Tons/K

L

Type

of

fuel

Rs

Million

KWH

*

Million

ThermalElectrical

Thermal

tons or kL

per ton or

unit of

prodn

Electrical

KWH /

Ton or

unit of

prodn

ThermalElectrical

Redn. in Specific Energy

consn. Over previous

year

Specific Energy

Consumption

Prodn.

in tons

or any

other

unit of

prodn.

Annual Energy consumption

Year

(April −−−−

March)

ENERGY CONSUMPTION DATA

Page 14: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

29.53

26.58

24.6 23.6 22.5

0

5

10

15

20

25

30

35

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

0.94

0.840.79

0

0.2

0.4

0.6

0.8

1

1.2

1.4

2008 - 09 2009 - 10 2010-11

SPECIFIC ENERGY CONSUMPTION TREND

Specific Power consumption Specific Fuel consumption

TA

RG

ET

5 %

TA

RG

ET

5 %

Unit

s /

Car

set

m3

/ C

arse

t

Page 15: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

11000132301323037802008Installing Local On / Off switch for Training hall Air conditioner ( 7.5 TR )

8

-136220032975543297554427873TOTAL SAVINGS

24500287442874482132008Installation of Auto On / Off Timer in Street

light ( 90 N0s – 250 W ) circuit

7

112005320053200152002008Switching Off of Cooling tower fan (5 HP) during absence of water flow by installing

flow sensor

6

9750000100170010017002862002008Installation of VFD controls in Material

charging hydraulic motors (200 HP)

5

595000252000252000720002008Introducing VFD in Condenser core builder

instead of Soft starter (13 Kw to 3 Kw per hr)

4

42450000126000126000360002008Reciprocating type drier replaced with Scroll

type air drier.

3

610500226802268064802008Installation of Pull card switch in ( 2 x 36 W )

Tube light fittings ( 300 Nos)

2

15000018000001800000NA2008Improve power factor from 0.93 to Unity by

installing APFC system.

1

RsRsRsUnits

Payback mon

th

Invest Made

Total

Annual Savings

Annual Electrical Savings achieved

Year of

implementation

Title of Energy Saving project implementedSl. No

ENERGY SAVING PROJECTS IMPLEMENTED IN 2007-2008

Zero investment projects – Small drops make big ocean

Page 16: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

-140950014176811417681392829TOTAL SAVINGS

550000131040131040374402009Thermal insulator fixed at outer surface of the barrel

heater in 2500 Injection molding machine

8

124000004808164808161373762009Transparent sheet fixing in shop floor (150 Nos )7

310000217702177062202009Compressor plant lighting on/off control separated from the group control

6

38000183601836040802009Providing sensor in the exit conveyer to control

the blower motor

5

188645005726455726451636132009Replacement of 247 nos MH fittings with T5 fittings

in shop floor --Phase-1,

4

5150006480064800144002009Introducing automatic on/off and speed controller in

GWK Cooling tower motors

3

12000189001890054002009Replace the hydraulic power pack and spindle

with Mechanical lock

2

760000109350109350243002009Introduced VFD to the Hydraulic motor of Crimping

machine

1

RsRsRsUnits

Payba

ck month

Invest Made

Total

Annual Savings

Annual Electrical Savings achieved

Year of

implementation

Title of Energy Saving project implementedSl. No

ENERGY SAVING PROJECTS IMPLEMENTED IN 2008-2009

Zero investment projects – Small drops make big ocean

Page 17: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

1810325006839286839281954082010Replacement of 295 MH fittings with T5 fittings

in shop floor --- Phase-2

8

-155600027811972781197746614TOTAL SAVINGS

1300006240506240501783002010Energy saving in Paint shop Air supply unit by

providing damper & Pulley modification

7

11500109620109620313202010Install auto on /off timer in office air conditioner units 240TR

6

NA0228598228598601572010Replacement of 30hp motor with 10 hp

motor in compressor cooling primary circuit

5

NA06750006750001500002010Reduce the compressor pressure setting

from 7.2 bar to 6 bar

4

NA0241920241920691202010Removal of 16 nos 250w unwanted halogen lamps in shipping area

3

25450000215233215233614952010250W HPSV lamps are replaced with 96w T5

fitting– 90 nos

2

8142000284828488142010Solar light installation in two wheeler stand1

RsRsRsUnits

Payback month

Invest

Made

Total

Annual

Savings

Annual Electrical

Savings achievedYear of

impleme

ntation

Title of Energy Saving project implementedSl. No

ENERGY SAVING PROJECTS IMPLEMENTED IN 2009-2010

Zero investment projects – Small drops make big ocean

Page 18: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

1120000210002100060002010Fixing sun control film in office glass windows4

-170000434280434280124080TOTAL SAVINGS

550000131040131040374402010Compressor air leakage arresting work3

450000151200151200432002010Provide hood between furnace and main fluxer

to avoid heat exit

2

550000131040131040374402010Thermal insulator fixed at outer surface of the

barrel heater in 2500 Injection molding machine

2 and 3

1

RsRsRsUnits

Payback

month

Investment plan

Total

Expected Savings

Annual Electrical Savings Expected

Year of

implementation

Title of Energy Saving project proposedSl.

No

ROADMAP TO ACHIEVE BENCHMARK 2010-2011

Page 19: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

COMPARISION WITH NATIONAL & INTERNATIONAL BENCH MARKS

0.80 MT / carset

( Visteon Global bench mark )

0.84 MT / CarsetTHERMAL

We will be one of the best bench mark practice in

Asia Pacific region

26.7 Units / Carset

( Visteon Global bench mark )

23.6 Units / CarsetELECTRICAL

REMARKSINTERNATIONAL

BENCH MARK

NATIONAL BENCH

MARK

SPECIFIC ENERGY

CONSUMPTION

Page 20: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

BENCH MARK VISIT BY ACMA MEMBERS TO VISTEON

Page 21: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

STRATEGY TO ACHIEVE GLOBAL BENCHMARK

Page 22: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

ROAD MAP TO ACHIEVE GLOBAL BENCHMARK

Page 23: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

PROJECTS LINKED WITH CARBON EMISSION REDUCTION

1 tree consumes 27 Kg of CO2 per annum – Source TNPCB

10.827 Kg CO2400 Nos2009 - 10Tree Plantation

5

2008-09 : 221.7 Kg

2009-10 : 188 Kg

43.81300 GWP33.7 Kg2009 - 10Refrigerant

R134a

4

DG not operated during Peak hours ( 6 hrs , Average power cons: 3000 Units / hr & 3.5 ltr per unit consumed ) , since we have Express feeder from TNEB through Ford.

4236.32.7458

kg CO2/ l

1542.8

KL

2009 - 10Diesel3

5706.1

83.05

1332.2

Total CO2 reduction

In MT

35.95

MT

1567316

Kwh

Annual Savings

LPG

Power

Mode

2009 - 10

2007 - 10

Year of Implementation

TOTAL CO2 REDUCTION

2008 – 09 : 451.92

2009 – 10 : 415.97

2.31 kg CO2/ kg

2

2007 – 08 : 427873

2008 – 09 : 392829

2009 – 10 : 746614

0.85 kg CO2/ kWh

1

RemarksEquivalent CO2

Reduction

Sl No

Visteon India is not registered for CDM/VER however we are contributing towards reduction of CO2 emission through the above listed Encon projects

Page 24: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

ANNEX G :

INNOVATIVE PROJECT

Page 25: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

� PAINTSHOP: AIR SUPPLY UNIT (132

KW)-40% of Air Supply is going waste in the

Primary booth which is not running now.

� To maintain the Air Balancing due to this

unwanted Air Supply, we are forced to run

Exhaust which is another wastage.

� To cool this Air, Chillers are running without

any meaning & Lot of power & money.

PAINTSHOP

AIR SUPPLY UNIT

CHILLERS

3A / 3B

PRIMARY AREA NOT IN USE CLEARCOAT AREA

Main Duct air supply

going to primary &

Clear coar area

1. ENERGY SAVING IN PAINT SHOP AIR SUPPLY UNIT

CURRENT STATUS

Page 26: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

AIR SUPPLY UNIT

CHILLERS

3A / 3B

PRIMARY AREA NOT IN USE CLEARCOAT AREA

PAINTSHOP

Main Duct air supply

going to primary &

Clear coar area

Additional

Damper fixed to

block the air

supply towards

Primary booth

PAINT SHOP AIR SUPPLY UNIT MODIFICATION

Page 27: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

Design Actual

1 Wiping 849.5 859

2 Deionising 1 3907.7 3,921

3 Primer Booth 36528.4 36,399

4 Primer Flash off 3907.7 3,867

5 Cooling Zone 1359 1,200

6 Prep Booth 10194 10,231

7 Deionising2 3907.7 3,918

8 Base Coat Booth 36528.4 36,543

9 Base Coat Flash off 3907.7 3,871

10 Clear Coat Booth 44174 44,169

11 Clear Coat Flash off 3907.7 3,956

12 Rework Booth 9864 8,816

13 Paint Mix room 2718 2,841

Total 161753.8 160591

56,477Total Required air

flow to maintain the

booth balanced is

96123 Cu.m per

hour. We kept some

extra airflow in our

calculation as safety

Note : Capacity of ASU Fan Design - 160,000 cu .m per hour

Actual:160,951cu .m per hour

Air flow ASU AIR DISTRIUTION VOLUMES

Air volume in cu. m per Hour

AreaSno

91,380

PRIMARY BOOTH

91,380 cum/h

CLEAR COAT AREA

56,477 cum/h

1,60,591cum/h

EXISTING VOLUME REQUIRED VOLUME

PRIMARY BOOTH

NOT IN USE

CLEAR COAT AREA

56,477 cum/h

96,123cum/h

VOLUMETRIC AIR FLOW MEASUREMENT

Page 28: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

BEFORE AFTER

EXISTING IMPROVED

NOT AVAILABLE

Air flow supplied to primer

area which is not in use

Now Air flow to primer area

is blocked By providing a

sandwiched damper

ADDITIONAL DAMPER PROVIDED IN AIR DUCT

Page 29: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

BEFORE AFTER

EXISTING IMPROVED

Drive pulley Dia -18.0”.

Static's Pressure – 1650 PascalRated Motor HP -177Motor RPM – 1485

Blower RPM – 1100Present CMH – 1,60,591Actual load – 97 unit/ hour

Annum Power cons – 2,38,300 unitAnnum Power cost – Rs 8,34,050

Drive pulley

Dia :11.1”

Driven pulley

dia:25”

Drive pulley

Dia :18’’

Driven pulley

Dia:25”

Drive pulley Dia -11.1”.

Static's Pressure – 1650 PascalRated Motor HP -177Motor RPM – 1485

Blower RPM – 665Present CMH – 96,123Actual load – 25 unit/ hour

Annum Power cons – 60,000 unit

Annum Power cost – Rs 2,10,000

Net Savings

Rs 6,24,050

Investment

Rs 30,000

ENERGY SAVING BY PULLEY MODIFICATION

Page 30: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

30

Before (With power pack) After (Without power pack) Remarks

Hydraulic power pack is removed

from circuit

ActivityHydraulic motor runs continuously, to clamp the spindle head. Mechanical lock introduced to hold the spindle head

2. SavingsEnergy Cost Savings Remarks

Cost saving 5400 units / annum 4.5 per unit INR 24300 /

annumSavings 540 USD /

annum

Hydraulic Cylinder

Mechanical lock

�� MECHANICAL LOCK PROVIDED TO HOLD THE SPINDLE AT ONE PLACE .MECHANICAL LOCK PROVIDED TO HOLD THE SPINDLE AT ONE PLACE .

�� HYDRAULIC POWERPACK IS ELIMINATEDHYDRAULIC POWERPACK IS ELIMINATED

�� ENTIRE POWER PACK CAN BE USED AS SPARE & SAVE POWER OF 1KW / HOENTIRE POWER PACK CAN BE USED AS SPARE & SAVE POWER OF 1KW / HOUR.UR.

2. ELIMINATION OF POWERPACK IN OPN #50 DISASSY & DEBURRING

Page 31: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

31

3. Before & After

4. Savings• Energy saving of 5400 units per annum ( 540 USD )

• Reuse of removed power pack in other machine .

SINGLE LINE DIAGRAM

Page 32: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

28488140.024Solar street

light

480816137376-Natural

lightings

822465234990-

Roof

Natural

wind

Ventilators

Annual

Savings (Rs.)

Energy

generated in

Kwh

Annual

Savings

(Rs.)

Energy

generated

in Kwh

Annual

Savings

(Rs.)

Energy

generated

in Kwh

2009-102008-092007-08Installed

capacity in

Kw

PictureType of

RES

REPLACEMENT OF ELECTRICAL ENERGY WITH RES

Page 33: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

FUTURE OUTLOOK 2010 - 11

REPLACEMENT OF THERMAL ENERGY WITH RES

App. 15 Kg of LPG /

hr is used for

heating the air to a

temperature of 120

degree C

Existing setup

Reduce the LPG

consumption to

7.5 Kg / hr by

installing solar

air heater in Degreaser

machine

Project to be implemented

21 months22.1 Lakhs270 m2 Solar

Air Heaters

for Reducing

LPG

consumption in the air

drying oven

Solar Thermal

Expected

ROI

Investment

planned

2010-11Proposed Capacity

Type of RES

Page 34: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

UTILISATION OF HAZARDOUS WASTE AS FUEL

Agreement entered with Grasim Cement industries for disposing 32 tons of Oily Rags on or before

Dec 2010

--6317Oily Rags

Planned to dispose

remaining 100 tons of paint waste on or before Dec 2010

2122005764Paint Sludge

RemarksTonnage of

Coal saved

Disposed

Quantity in

Ton

Kcal / KgWaste

UTILISATION OF HAZARDOUS WASTE IN CEMENT INDUSTRIES

1Kg of Coal = 5400 Kcal; Hence 1Kg of paint sludge is equivalent to 1.06Kg of Coal

1Kg of Coal emits approximately 1Kg of CO2 therefore approximately 200 tons of CO2 emission is

saved directly.

Page 35: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

BEST PRACTICES FOLLOWED BY VENDOR - TAFE

Improve the Power factor from 0.95 to 0.98 .

• Installed Natural Wind ventilator ( 20 Nos )

• Planted 50 Nos of trees to CO2 reduction.

• Removal of Halogen lamps ( 250W – 20 Nos ) & CFL

lamps (72W – 20 Nos ) introduced.

• Compressor air leakage arrested ( 75 points )

• Reciprocating compressor changed to Screw

compressor ( 20 HP )

• Transparent sheets ( 25 Nos ) replaced

Page 36: ENERGY CONSERVATION DRIVE Aw… · 12 Rework Booth 9864 8,816 13 Paint Mix room 2718 2,841 Total 161753.8 160591 56,477 Total Required air flow to maintain the booth balanced is 96123

EXTENT OF TEAM WORK IN ENCON

Completed

Units saved : 150000 /

annum

1 Engineer

1 Asst Manager2010Reduce the compressor pressure setting from 7.2 bar to 6 bar

5

Completed

Units saved : 18900 / annum

1 Operator

1 Technician

1 Work group

leader

2009Replace the hydraulic power pack and spindle with Mechanical lock

4

Completed

Units saved : 163613

1 Asst Manager

1 Engineer2009

Replacement of 247 nos MH fittings with T5 fittings in shop floor --Phase-1

3

Completed

Units saved : 69120 / annum

1 Operator

1 Technician2010

Removal of 16 nos 250w unwanted halogen lamps in shipping area

6

Completed

Incentive : 18 Lakhs /

annum

1 Engineer

1 Work group

leader

1 Asst Manager

2008Improve power factor from 0.93 to

Unity by installing APFC system.2

Completed.

Units saved : 72000 / annum

1 Technician

1 Work Group

leader

1 Engineer

2008

Introducing VFD in Condenser core

builder instead of Soft starter (13 Kw to 3 Kw per hr)

1

Progress of Implementation

Manpower involved

Idea originated in

Year

Source of ENCON ideaS.No

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MONITORING / REPORTING SYSTEM

Asia Pacific

Director

Finance

Energy Manager

Energy Manager

Plant engineering

Conducted by

Reviewed MonthlyEnergy Manager &

ChampionsMonthly

Energy conservation Project

status review meeting5

GM –Manufacturing & Finance

MonthlyEnergy Consumption4

All Encon CFT Member

WeeklyEnergy Conservation3

Reviewed dailyEnergy ChampionDailyEnergy Consumption report2

Facility Every 2 hrs / dayEnergy Monitoring1

Photo if anyTeamFrequencyMonitoring ReportS.No

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ROLE OF ENERGY MANAGER

1.Establish energy conservation cell and conduct the meeting as per yearly schedule.

2.Identify the potential saving project ,justify to the management after considering the payback calculation

3.Monitor the power consumption pattern on daily /weekly/monthly basis and take corrective action if any

deviation is there.

4.Fix the bench mark and compare with same industry.

5.Prepare the study material and conduct internal training workshop to all the members

6.Conduct competitions related to encon and motivate the people by proper rewarding during energy

conservation day

7.Interact with BEE or state level designated agency and update the on going energy conservation activities.

8.Support the energy audit firm and implement their recommendation

9.Exchange the information with energy managers of same sector.

10.Ensure proper functioning and calibration of the instruments required for monitoring

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ENCON AWARENESS IN SHOPFLOOR

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ENVIRONMENTAL IMPROVEMENTS

2500002010-2011Providing insulation for cab furnace outer surface 11

2.03 CroresTOTAL INVESTMENT

1850002009-2010Reuse of STP treated water in cooling towers 8

10000002009-2010Green belt enhancement - 150000 Sqft. 7

4000002009-2010Installed electronic flushing system in toilets – 20 nos6

10000002008-2009Installed sprinkler system in green belt area – 200000 Sqft.5

400002008-2009Tree plantation - 400nos4

24000002007-2008Hazardous waste used as a raw material in Cement

industries -200 tons3

10500002007-2008Installed natural roof ventilators – 105 nos2

15000002007-2008Constructed Accelerated solar evaporation pan – 820m21

25000002010-2011Installed Mechanical Evaporator -10kld 10

100000002009-2010Installed Sewage Treatment plant with membrane

technology – 180kld9

Investment madeYear of implementationTitle of project implementedSl. No

ZERO DISCHARGE PLANT

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ENVIRONMENTAL IMPROVEMENTS

STP Plant

Natural

Wind ventilator

Solar Pond

Green

Evolution

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ENVIRONMENTAL IMPROVEMENTS

Green Belt

development

Tree

Plantation

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Mar 1997 Visteon India was founded

May 1998 VASI Plant & Machinery Launch

Dec 1998 Awarded QS 9000 Certificate

Aug 1999 Awarded ISO 14001 Certificate

Sep 1999 Safety Certificate (SHARP Level - 8)

Jul 2001 Awarded TS 16949 Certificate

Sep 2002 CII Energy efficiency Award

Jan 2003 Awarded Hyundai 100PPM Certificate

Mar 2005 Best supplier award from Toyota

Mar 2006 Awarded OHSAS 18001 Certificate

Aug 2006 Tamil Nadu Govt. State Safety award

Feb 2007 Awarded 5 Star from Hyundai

Feb 2007 Golden peacock award for OHS

Aug 2007 Safety Innovation award

Sep 2008 Tamil Nadu Govt. State Safety award

Sep 2009 Tamil Nadu Govt. State Safety award

April 2010 Best Performance award from Hyundai

MILE STONES

Tamil Nadu Govt. State Safety award

OHSAS 18001 Certification

Q1P1 Launch

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ISO 14001 : 2004 CERTIFICATE

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LIST OF NC’s IN ISO 14001 : 2004

4.4.60902AM

Z08

26 Feb 09Operational

control

All the significant aspects related to

their work environment was

communicated to the relevant

contractors.

Annexure 3

The unit was not communicating the

applicable procedures relating to the

significant aspects to the contractors. E.g,

diesel unloading procedures or LPG

unloading procedure to the contractors

doing the job. However noted that the

contractors are given training abut

general EHS briefings.

NewRC

4.3.10902AM

Z06

26 Feb 09Aspect

identification

The environmental impact of related

to the Generation of hazardous waste

was introduced in aspect / impact

register – Annexure 4

That unit may identify and establish

control for environmental impacts related

to ‘generation of Hazardous waste’. The

unit currently has identified

environmental impacts related to

‘disposal of Hazardous waste’.

NewRC

4.4.60902AM

Z03

26Feb 09Operational

control

Training given to the relevant

employees and it was included in the

EHS induction training Annexure - 2

Noted that one of the general waste bins

contained oil soaked cotton gloves.

However noted that in the other areas

waste was found segregated.

NewRC

4.3.20902AM

Z02

26 feb 09Legal and other

requirementsAir and water Consent got renewed

within the time frame.

Annexure - 1

The unit has applied for renewal of water

and air consent on 27.02.09 before the

expiry date. However the unit may

comply to the renewal submission

conditions of the consent and also

communicate with the Pollution Control

board if there are any clarifications.

The plant was waiting for the

communication from Pollution control

board for the fees to be paid.

NewRC

ClauseRefDate

Process /

AspectCorrective action reviewFindingStatusGrade

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ANNEXURE – 1

Renewed within

the time frame

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ANNEXURE – 2 & 3

EHS awareness

among

Employees

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ANNEXURE - 4

Generation of

waste included in

Aspect / Impact

identification

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ENERGY CONSERVATION WEEK CELEBRATION

Welcome Banner

Encon Products Exhibition

Encon Pledge

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ENERGY CONSERVATION WEEK CELEBRATION

Encon awareness in School

Encon awareness

among Children

Encon awareness

Speech

Encon Products donation

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ENERGY CONSERVATION WEEK CELEBRATION

Encon Week Celebration

Encon Policy release

Encon Poster

CompetitionEncon prize distribution

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HERALD INTERNAL MAGAZINE – ENCON WEEK CELEBRATION

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PLEASE CONSERVE ENERGY & KEEP RESERVE FOR ME…

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THANKS