1

WELCOME

TO

19TH NATIONAL AWARD FOR EXCELLENCE IN

ENERGY MANAGEMENT 2018

29 – 31 Aug’2018

Presenters

Thejraj B

Nagendra H R

Jafar Husen

VIKRANT TYRE PLANT, MYSURU. KARNATAKA

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1. PLANT / UNIT INTRODUCTION

Late Lala

Juggilal Singhania

Late Lala

Kamlapat Singhania

JK ORGANIZATION

TYRE BUSINESS : JK TYRE & INDUSTRIES

➢ JK Tyre & Industries Ltd is a part of prestigious JK Organization

➢ Pioneered Radial Tyre revolution in India

➢ Technical – Self-reliant.

➢ Capacity – Initial capacity : 55 Tons/ Day (at Kankroli in 1977)

Current capacity : > 2,000 Tons/ Day

Annual Turnover : > Rs 8,500 Crores

➢ 12 Plants – Mysuru (Karnataka) - 3 Plants:

Kankroli (Rajasthan) - 1 Plant,

Banmore (MP) - 1 Plant

Chennai - 1 Plant

Laksar (Uttarakhand) - 3 Plants

Mexico (Tornel) - 3 Plants

Mysuru

Karnataka

3 Plants in MysuruCurrent Capacity

(MT/Day)

Bias Plant 177

Radial Plant 207

OTR Plant 26

TOTAL

410

(8,500 tyres/ day)

4000 Employees

VIKRANT TYRE PLANT, MYSURU

VTP : SYSTEM CERTIFICATIONS (since early 1990s )

3

GREENCO PLATINUM AWARD (29th Jun’2018)

1ST TYRE COMPANY TO WIN PLATINUM AWARD IN INDIA

EE Chapter score : 124 marks out of 150

4

PROCESS FLOW

Mixing

Fabric Dipping

Calendaring

Extrusion

Tyre Building

Tyre Curing

Bead Winding Uniformity testing

Dispatch

Steel Wire Cutting

Tyre X Ray

Tyre Finishing

& Inspection

5

ISO 50001:2011 CERTIFICATE (2013)

ENERGY POLICY

Date : 08.02.2012

6

ENERGY MANAGEMENT TEAM

Energy Auditor & Manager

Plant Coordinators

Members

Total Members : 86

BEE Certified Energy Manager : 2

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BEE - CERTIFIED ENERGY AUDITOR

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2. PLANT ENERGY PERFORMANCE –

SEC FOR LAST 3 YEARS

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ENERGY CONSUMPTION - POWER ( kWh/Kg)

10

ENERGY CONSUMPTION - THERMAL ( KG/KG)

11

OVERALL ENERGY CONSUMPTION (GJ/TON)

12

Data does not have authenticate source

JK VTP : Among Top

4 in the world

GJ

/ T

ON

2. INFORMATION ON COMPETITORS, NATIONAL & GLOBAL BENCHMARK

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3. ENERGY SAVING PROJECTS IMPLEMENTED

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GENERAL PROCEDURE FOR FINANCIAL RESOURCES ALLOCATION FOR

PROJECTS

➢ Identification of Significant energy use

➢ Monitoring of EnPI for identified significant use

➢ Benchmark / target for identified significant energy use

➢ Energy gap analysis & energy loss mapping

➢ Identification of energy projects / kaizens to bridge gap

➢ Prepare Energy Management program with savings & Payback information

➢ Submission of energy projects to HO for budget approval (> Rs 2 Lacs investment)

➢ Review of projects, approval and allocation of resources by Management

➢ Implementation of projects at site

➢ Post Implementation savings audit and reviews

➢ Monthly energy project status review by Unit Head & HO

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FINANCIAL RESOURCES ALLOCATION FOR PROJECTS

1. Communication to Energy team on EnMP

2. Identified EnMP

3. Consolidated report of

EnMP

4. Final submission of EnMP to HO

for Budget approval

16

FINANCIAL RESOURCES ALLOCATION FOR PROJECTS

FYInvestment

Rs lacs

2012-13 55.0

2015-14 96.0

2014-15 120.2

2015-16 154.09

2016-17 191.96

2017-18 179.0

Total 796.25

Investment Summary

5. Justification for EnMP (if any to HO) 6. EnMP review & budget allocation by HO

Savings For

2012-13

(Rs Lacs)

Savings For

2013- 14

(Rs Lacs)

Savings For

2014-15

(Rs Lacs)

Savings For

2015-16

(Rs Lacs)

Savings For

2016-17

(Rs Lacs)

Savings For

2017-18

(Rs Lacs)

Total

Rs Lacs

3.1 61.2 283.1 157.2 147.4 135.4787.40

(122 projects)

Total Savings from past 6 years

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3a. ENERGY SAVING PROJECTS IMPLEMENTED IN FY 2015-16

Sl No Description of ImprovementDate of

Execution

Steam Savings in MT/Day

Investment in Lac Rs/Year

Savings in Lac

Rs/Year

Payback Period in

years

1 Reduction in vent loss in CVL boiler 15.09.2016 15 0 63.9 0.00

2 18 Nos SKODA press Dome insulation 12.03.2016 8 15 34.08 0.44

3 Ball Float traps for Curing Presses18.06.2017 8 8 34.08 0.23

4 Insulation of press valve battery units15.05.2017 12 20 51.12 0.39

5 Insulation of platen press top6.12.2017 2 8 8.52 0.94

6 Insulation of Press Dome Caps24.03.2018 2 7 8.52 0.82

7TLV Traps for all headers of Dome and

Shaping steam01.12.2017 2 5 8.52 0.59

8 Bladder Hot water recovery 28.01.201728 160 120 1.7

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3b. ENERGY SAVING PROJECTS IMPLEMENTED IN FY 2016-17

SlNo

Description of ImprovementDate of

Execution

Savings in

Kwh/Day

Investment in Rs/Year

Savings in Rs/Year

Payback Period in

years

1Simplex ext dewatering with

compressed air eliminated08.05.2016 90 0 163800 0

2carbon handling stopped on

01.06.201601.06.2016 1200 30000 2184000 0.01

3HP-LP interconnection to increase

compressor utilization on 18.07.201618.07.2016 500 100000 910000 0.11

4Leak arrest drive on 15.08.2016, Leak

Terminator Whatsapp group created15.08.2016 1300 0 2366000 0.00

5

Duplex extruder roll cooling with

compressed air replaced with potable

fan, Conversion of HP to LP in U2 and

TR3 Tyre building M/C

6.09.2016 150 1500 273000 0.01

6

Replacement of 10 Nos timer based

moisture drain with float type drains for

air receivers

24.10.2016 200 70000 364000 0.19

7

Major air leak attended in utility and

ash handling system PU tubes

replaced with copper tubes

01.11.2016 150 68000 273000 0.25

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3c. ENERGY SAVING PROJECTS IMPLEMENTED IN FY 2017-18

Project Sr. No Brief Description of projectAmount Approved` in

lacs

Savings For 2017-18 (Lacs Rs)

RemarksAchieved in

Jan‘18

(4) Energy Projects -Phase-VI (Rs 111 Lacs)

RTP.41 Replace 36W conventional tubes with 18W LED tube 6.3 0.27 completed

RTP.42Replace 250 W Metal hallide lamps by 80 W High Bay LEDs

24.8 1.26 completed

RTP.43 Replace125 W streetlight lamps by 36 W LED lights 4.8 0.23 completed

RTP.44 Installation of VFD's for Fume extractors in Mixers 17.5Material received, Installation work under progress, TCD Apr18

RTP.45 Installation of VFD's for Dust Collector in Mixers 10.5Material received, Installation work under progress, TCD Apr18

RTP.46Power factor improvement 0.84 to 0.99 at TS3 station Reduce the MD kVA and KWH impact in billing with retofitment and additonal 500 KVAR APFC panel

9.4 1.12 Complted in Dec 17, Savings starts from Jan 18

RTP.47VFD for the 15 KW AHU blowers of A & C division . Power saving during day and Night times , 14 nos

25.0 PR 3700030192,PO released TCD MAY 18

RTP.48TLV Traps for All header dead ends of Dome and Shaping steam

5.0 0.78Completed in Dec 17 ,Savings Startes from Jan 18

RTP.49

Auto damper control for AHU. This will reduce energy consumption in VAM chillers during cold seasons and also during nights when ambient is equal to or lower than set room temperature.

5.0 Work under progress,TCD : APR 18

RTP.50

Water flow meters for plant water consumption monitoring. Estimated 40 nos water flow meters need to be installed

3.00 Completed

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4. INNOVATIVE PROJECTS IMPLEMENTED

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INNOVATIVE PROJECT : ENERGY

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INNOVATIVE PROJECT : ENERGY

Power generation Kw / hour 100

Power generated Kw / day 2400

Cost of power Rs / Kw Rs 6.50

Cost saved Rs / day Rs 15,600

Cost saved Rs / Year (350 days) Rs 54 Lacs

Cost of Turbo Generator Rs 4 Lacs

ROI < 1 Year

Net impact on Profitability 10 Lacs / annum

Main Steam from

Boiler 19kg/cm2

Hot water

Station

10kg/cm2

Energy

Loss

Main Steam from

Boiler 19kg/cm2

Hot water Station 10kg/cm2

140 Kw TG 10kg/cm2 Out let

19kg/cm2 In let

BEFORE AFTERFeb 2015 Nov 2016

Benefits from the project

➢ Earlier the steam generated from boiler at 19kg/cm2 . This steam passed

through conventional PRS to reduce the pressure as per process

requirement. The Kinetic Energy present in the steam was lost

BEFORE

PRS

➢ Introduced Back Pressure Turbine to in place of PRS to reduce the

steam pressure. During this process Kinetic Energy in the steam

rotates Turbine and generates 2400kW / day. 2% reduction in

purchased power

AFTER

1st Time in Tyre Industry

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ENERGY PROJECT – MOULD CONTAINER INSULATION

PROJECT: Insulation of press mould container for steam saving

OBJECTIVE: To reduce heat loss due to radiation in mould container to save steam

PROCESS:The mould container in press are uninsulated and heat is being lost. The average surface temperature

of the top dome is 130°C. The insulation of mould container is not a general practice

IDEATo develop insulation material & method and insulate the mould container in curing presses so that it

can reduced heat loss due to radiation and reduce steam consumption.

SL NO DESCRIPTION UOM QTY REMARKS

1 Existing surface temperature °C 130Average temperature as measured by

thermal imager

2 Diameter of the dome cavity mtr 1.6 1.5 m dia of cavity considered

3 Surface area per dome cavity (Top only) M2 1.5

4 Ambient temperature at press °C 48

5 Radiation heat loss from Chart w/m2 900 130°C to 50°C as per chart (Sheet 2)

6 Heat loss per cavity W 1357.13

7 Heat loss per cavity Kcal/hr 1167.1

8 Enthalphy of dome steam Kcal/kg 642 4.5 bar considered

9 Steam equivalent of heat per cavity Kgs/hr 1.8

10 Steam loss per cavity per day kgs/day 44

11 Total no of cavity nos 40 20 press

12 Total steam saving per day kgs 1745

13 Cost of steam Rs/MT 1300

14 TOTAL SAVING PER DAY RS/DAY 2,269 Rs 8 Lacs / ANNUM15 Investment Rs 720000

16 Simple Pay Back Days 317 10 Months

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ENERGY PROJECT – MOULD CONTAINER INSULATION

BEFORE AFTER

Radiation heat loss from Mould

container : 1167 Kcal /hr

Radiation heat loss from Mould

container : 150 Kcal /hr

130⁰C 47⁰CUn insulated Insulated

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Interlinking of HP & LP system with control valve to increase HP

compressor utilization.

HP AIR

HEADER

HIGH PRESSURE

AIR

LOW PRESSURE

AIR

PROCESS

BENEFITS•Reduction in power consumption by 1300 KWH/ day

•Total power savings of around 5 lakhs KWH / annum

•Cost savings of Rs 2.7 Million / annum

•1 Nos of 160 kW LP compressor stopped

ENERGY PROJECT – COMPRESSED AIR UTILIZATION

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BEFORE AFTER

▪160 kW X 3 Nos LP compressor in

operation @ 86 % utilization with

avg daily power consumption of

11600 units.

▪90 kW X 3 nos HP compressor in

operation @ 77 % utilization with

average daily power consumption of

3500 units

Avg utilization : 77% / day

▪160 kW X 2 Nos LP compressor in operation

@ 100 % utilization + 37 kW X 1 no small

compressor - with avg daily power

consumption of 8300 units.

▪90 kW X 3 nos HP compressor in operation

@ 100 % utilization with average daily power

consumption of 5500 units

Avg utilization : 98% / day

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5. UTILIZATION OF RENEWABLE ENERGY SOURCE

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Minimum Rs 3.5 crore / Annum for next 10 years (starting from 2017)

Budget allocated for RE power purchase

REC Power Purchase Agreement (wind energy)

5. UTILISATION OF RENEWABLE ENERGY SOURCES

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Type UnitsAnnual

Consumption% of total

power

Unit purchased from IEX Million KWh 27.64 31.85

Unit purchased from Renew Energy Million KWh 52.64 60.64

Unit purchased from CESCOM Million KWh 5.44 6.26

Units generated from Roof Top Solar Million KWh 0.68 0.79

Units generated from recovery Turbine Million KWh 0.38 0.44

Total Power 86.81

5. UTILISATION OF RENEWABLE ENERGY SOURCES

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6. UTILIZATION OF WASTE MATERIAL AS FUEL

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6. UTILIZATION OF WASTE MATERIAL AS FUEL

➢ We do not generate industrial waste which can be used as fuel.

➢ Other waste such as Wood packing scrap material, trimmed

branches, Dry leaves is sent for briquetting & re used in boiler

as fuel. Total coal substitution is around 0.2% per annum.

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7. GHG INVENTORISATION

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7. GHG INVENTORISATION (ISO14064-1:2012)

INTENSITY OF GHG EMISSIONS SCOPE-1,2 (CO2e Ton/Ton)

30%reduction

Verification report & Opinion statement

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8. SUPPLY CHAIN

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8. SUPPLY CHAIN

Green purchase guidelines

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8. SUPPLY CHAIN

Green Procurement Guide lines - VTP

Raw MaterialNon hazardous, eco friendly, Bio degradable, REECH

compliance chemicals

Appliances – AC, Fridges Minimum 3 star

Motors Min IE 3

Paints Low VOC Paints

Taps Push Type

Tube light & Bulbs LED

House Keeping cleaning agents Eco friendly cleaning agents

All material code in SAP updated with Energy performance requirement.

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8. SUPPLY CHAIN – IMPROVEMENT INITIATIVES

➢ Taking measures in Energy management system by being proactive , innovative and cost effective including procurement of energy efficient products & services.

➢ As a Green Responsible company, we have re-sourced / re-organized / re-structured our suppliers close to our manufacturing plants. Suppliers in South cater to south plant & North to North plants

Eg. :- Carbon Black - Earlier supplied from Kolkata to VTP & plant in Chennai supplied carbon black to KTP now the supplies reorganized so that Chennai plant supplies to Mysuru & Chennai Tyre Plant and Kolkata plant supplies to KTP, LTP & BTP. This resulted is overall savings in emission from supply chain .

INVOLVING SUPPLIER IN CII GREENCO JOURNEY

➢ All our major suppliers are involved in Green Supply chapter of GreenCo, couple of them made their Green Initiative presentation during VTP GreenCo assessment.

➢ We are encouraging our suppliers to go for GreenCo certification. Initial assessment done by our team for 2 suppliers in Mysuru. Very soon they may apply for CII GreenCocertification

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8a. SUPPLY CHAIN – Examples – Reduction of Co2 in Supply chain

BEFORE : BEKAERT, Pune

AFTER : BEKAERT, Chennai

SAVINGS : Reduction of 443 Km / trip

CO2 Calculation:

Distance saved : 443 / trip / truck

Number of Truck operating : 15 / month

Total Diesel saved : 17,720 ltrs / annum (@ 4.5 KMPL)

RAW MATERIAL TRANSPORTATION : Steel Wire

Implemented Year- Apr’ 2017

Total CO2 emission reduced

46,780 Kg (@ 2.64 kg /ltr)

Before

After

Total 85 Kaizens / Projects implemented in past 3 years

34% reduction in Scope # 3 emission on supply chain from FY 2015-16

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9. TEAM WORK, EMPLOYEE INVOLVEMENT &

MONITORING

40

STRATEGIES FOR EMPLOYEE AWARENESS & INVOLVEMENT

o Formulate Policy

o Give Direction

• Review Energy

consumption

• Review status of

Energy projects

• Provide resource

o Set target to Reduce

Energy consumption

• Implement Energy

projects

o Benchmarking

o Energy Audits

o Provide resource

o Support & guide plant

team

o Compliance to legal &

other requirements

o Train plant team

o Control / avoid

Energy loss

• Process control

o Monitoring &

measurement of

relevant EnPI

o Train Working group

– Spread awareness

o Participate in

improvement

activities

• Energy Kaizen

o Control / avoid

Energy loss by

adhering to Work

Instruction & SOP’s

Apex Group Core Team Front line Working group

Most Energy Efficient Plant

Avoid Loss , Improved Awareness

41

ENERGY CONSERVATION POSTERS DISPLAYED ACROSS PLANT

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ENERGY CONSERVATION POSTERS DISPLAYED ACROSS PLANT

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STRATEGIES FOR EMPLOYEE AWARENESS & INVOLVEMENT

➢ On the job training is also being imparted to employees in regard to conservation of energy.

➢ Employees have been identified for undergoing training in department where significant energy use

taking place.

➢ Energy conservation tips are being displayed in the prominent places like utility, production hall etc

➢ Employee suggestions on conservation of energy. Suggestions are evaluated & implemented

➢ Employees in CFTs have made many Kaizens to conserve energy.

➢ Energy Management Awareness program for all new recruits

➢ Whatsapp group- “LEAK TERMINATORS” for leak identification, awareness and rectification

44

ENERGY CAMPAIGN – EMPLOYEE INVOLVEMENT IN KAIZEN

Kaizen CompetitionAir Leak Arresting Campaign

Appreciation by Management

Observing air leakage near Curing Press & PCI unit

during air leak arresting campaign during shut days

Curing Press

PCI unit

45

KNOWLEDGE SHARING – JK ORGANIZATION

VTP – Plant II Won Most improved Energy

performance plant – Second year in succession

VTP – Plant I Won Best Kaizen

Award – Group Level

8th Knowledge Sharing Conference on Energy

Conservation –29th & 30th Oct’15 Venue: Kankroli, Rajasthan

Most improved

plant

46

CAPACITY BUILDING PLAN : ENERGY MANAGER / AUDITOR

Plan for capacity building training program for EnMS Team ; Energy Manager /

Auditors training program from NPC / BSI / CII

Plan

Certified Energy

Manger – 1

Certified Energy

Manger – 1

47

10. ENERGY REVIEW, DAILY

MONITORING & VARIANCE ANALYSIS

48

10. ENERGY REVIEW

❖ Daily shop floor review

➢ Plant # 1&3 : At 11:30hrs – By Unit Head & Plant Head

➢ Plant # 2 : At 10:00 hrs - By Unit Head & Plant Head

❖ Monthly review

➢ Energy Performance review - by 1st week of Every Month (Unit Head)

➢ Energy review – 1st Week of every month by Mfg. Director

➢ Business Review Meeting (BRM) – 2nd Week of every month - President

❖ Annual Performance Review – EnMS Management Review Meeting

❖ Annual Performance Review meeting at HO

❖ Benchmarking of Targets w.r.t industry standards - Annually

❖ Review of targets is done based on high impact projects

49

DAILY MONITORING - ENERGY SCORE CARD - EQUIPMENT

Action plan for day to deviation implemented &

effectiveness reviewed in next day meeting

Daily Monitoring Sheet

50

DAILY MONITORING – VARIANCE ANALYSIS

51

DAILY MONITORING – VARIANCE ANALYSIS

PRODUCTIVE POWER - VARIABLE POWER

PRODUCTIVE POWER - SEMI FIXED POWER

NON PRODUCTIVE POWER - FIXED POWER

52

11. AWARDS & ACCOLADES

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NATIONAL ENERGY CONSERVATION AWARD – CERTIFICATE OF MERIT

We participated in the National

Energy conservation award and

received Certificate of Merit

issued by Bureau of Energy

Efficiency , Govt of India,

Ministry of Power on

05.12.2013

54

NATIONAL ENERGY CONSERVATION AWARD – 2nd Prize- Tyre Sector

We participated in the National Energy conservation award and won Second prize under tyre sector

issued by Bureau of Energy Efficiency , Govt of India, Ministry of Power on 14.12.2016

55

GREENCO PLATINUM AWARD (29th Jun’2018)

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FUTURE PLAN

EE Chapter score : 124 marks out of 150

GREENCO PLATINUM PLUS

by 2019

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