th national award for excellence in energy management … 11th national award for excellence in...
TRANSCRIPT
1
11th National Award for Excellence in Energy Management 2010
Kirloskar Oil Engines Ltd., Khadki
Contents
Introduction
SEC Reduction in last three years
SEC – How close to Global best?
Innovation in Project Implemented
ENCON Project (2007-10)
Projects linking to Carbon Emission Reduction & Environment
Employee Involvement & Methodology
Utilization of Renewable Energy Sources
Waste to Energy Projects
Inputs from ISO 14000/9000 & OHSAS
Replication of best practices
CSR initiatives
Award & Accolades
Way ahead
Introduction of KOEL
KOEL - Company Profile
Self Certification by Indian Army -2001
ISO 14001 -> 1998
ISO 9001 -> 1992
Plants at Khadki Kagal, Rajkot, Nagar, Nashik
Incorporated in 1946.
EN 16000 & SA 8000 -> 2012
OHSAS 18000 & FM
Approval 2009
TPM, KAIZEN, CE 2006
Zero water discharge company
TS16949 2004
2
Products
Diesel engines ranging from 3 hp to 11000 hp.
Biggest : 11,000 hp
Smallest : 3 hp
Engine Bearings
The Kirloskar Green Genset
‘KIRLOSKAR GREEN POWER IDEAS’
World’s largest selling Genset Brand
Product Applications
Off Highway Tractors
Defence & Power Generation Agriculture
SEC Reduction in
last three
years
3
Achievement - Specific Energy Consumption
Year KWh/ BHP KWh / Bearing (HSD)Litres /BHP
2007 - 2008 3.66 0.081 0.38
2008 - 2009 3.54 0.074 0.36
2009 - 2010 3.32 0.064 0.33
15% Reduction
in SEC
Benchmark Line
34% Reduction
in SEC
Benchmark Line
29% Reduction in SEC
Benchmark Line
Achievement - Specific Energy Consumption
Absolute Reduction in Energy Resources
Energy / Utility Resource 2007-08 2008-09 2009-10Absolute % Reduction
wrt Previous Year
Electrical Power in MkWh units
22.39 15.46 14.1 8.80
HSD in KL X 102 20.40 13.23 11.02 16.70
Water in KL X 10⁴ 12.89 9.82 7.92 19.31
Compressed Air in MkWh
3.58 2.49 2.36 5.07
Product 2007-08 2008-09 2009-10
Engines (Electrical Energy) 5.9 % 3.27 % 5.0 %
Bearings (Electrical Energy) 17.3 % 9.13 % 13.5 %
Engines (Thermal Energy) 19 % 5.2 % 8.33 %
% Reduction in SEC w.r.t. Previous year’s SEC
Target & Performance - SEC
2
2.4
2.8
3.2
3.6
4
2006-07 2007-08 2008-09 2009-10
3.8
3.66
3.4 3.4
3.89
3.663.54
3.32
KW
h/B
HP
Year
Engine - Specific Energy ConsumptionTarget Vs Performance
Target PerformanceBenchmark = 3.2 kWh/BHP
4
0
0.02
0.04
0.06
0.08
0.1
0.12
2006-07 2007-08 2008-09 2009-10
0.11
0.087
0.075
0.065
0.096
0.081
0.0740.064
KW
h/B
ea
rin
g
Year
Bearing - Specific Energy ConsumptionTarget Vs Performance
Target PerformanceBenchmark = 0.061 kWh/BRG
Target & Performance - SEC
SEC – How close to
Global best?
KOEL, Khadki
MNC Competitor
A
MNC Competitor
B
3.32 KWh/BHP
5 KWh/BHP4.2
KWh/BHP
External Benchmark
Product – Engines
External Benchmark
Product – Bearing
KOEL, Khadki
Competitor A
0.064 KWh/Brg
0.12 KWh/Brg
Internal Benchmark
Product – Engines
KOEL, Khadki
KOEL, Kagal
KOEL, Rajkot
3.32 KWh/BHP
3.85 KWh/BHP
3.2 KWh/BHP
Internal Benchmark
Product – Bearings
KOEL, Khadki
KOEL, Nagar
0.064 KWh/Brg
0.072 KWh/Brg
Data source – www.energymanagertraining.com MEDA Competition CD
SEC –External & Internal Benchmark
Innovation in Project
Implemented
5
Green Technology Cell
The goal of GTC is to develop commercial &sustainable business models based on variousgreen and renewable energy technologies & as wellas energy management solutions to meet theenergy needs of each consumers in an environmentfriendly manner.
Innovative Project No. 1 In-house Research Facility
Pilot Scale Research Facility
Field Scale Biogas plants
Lab Scale Research Facility
Biogas to Power & Fuel
Biogas plants H2S Scrubber
Storage
Biogas Gensets
Compressor
Cylinder Cascade
Vehicle Application
Rural Energy Solutions (Biogas)
Biogas plantsH2S Scrubber Storage Biogas
Genset
Street Lighting / Community Application
House Lighting
Storage
Cooking Gas
6
Innovative Project No. 2
Renewable Energy Supply for Rural Area (RESRA)
GTZ initiated project
Under this project 24 Greengensets are installed at 24 villagesof Korba District of Chhattisgarhstate.
Energy will be produced throughstraight vegetable oil (SVO) andbiogas (Local resources)
Energy for tribal peoples for 6 to 8hours per day.
Similar project is also undertakenby KOEL at Kolwan village of Punedistrict.
After
Regenerative Panel
Total Investment : ` 30 Lakhs
Annual Savings in Rs. : ` 5 Lakhs
Payback period : 6 Years
Description After
• During Genset testing, energy waswasted in resistive load banks.
• We have developed UPS & testingpanel to use generated energy forinternal application.
• Use of double conversion gridinteractive Device consist of IGBTbase front-end rectifier andinverter.
• Regenerative test bed for Genset
• First of it’s kind in industry
• Greater replication potential
Use of Grid Synchronizing UPS & Panel for Genset Testing
Innovative Project No. 3
After
Furnace after modification
Total Investment : ` 2 Lakhs
Annual Savings in Rs. : ` 8 Lakhs
Payback period : 3 months
Description After
• In Heat Treatment plant, there arefour numbers of diesel fired meltingfurnaces. Melting of Al-metal is takeplace at 6600 C.
• Flue gases from these furnaces aregenerally released to theatmosphere through scrubber.
• We have installed small unit onfurnaces through which flue gasesare diverted to the charge.
• We observed that cycle time isreduced by 45 minutes. This hassaved 13.5 lit of diesel per charge.
Waste Heat Recovery from Al-Foundry
Innovative Project No. 4
Exhaust compressed air stored and reused for low pressure application
Reused exhaust air for cleaning
Total Investment : ` 0.25 Lakhs
Annual Savings in Units:108576 kWh
Annual Saving : ` 5.97 Lakhs
Payback period : 15 days
Before After
Air was wasted through exhaust
Exhaust pressurized air in continuousproduction line is used for low-pressureapplications. Due to this activity overallpressurize air consumption is reduced ofACBG shop.
Innovative Project No. 5
7
Replaced the Age Old MG Set Induction Motor Generator by Static Converter
Static Convertor Panel
Total Investment : ` 21 Lakhs
Annual Savings in Rs. : 7.3 Lakhs
Payback period : 34.5 months
Before After
Motor Generator
Innovative Project No. 6
On Induction Hardening M/c No. 8106,earlier motor generator set is used. Thiswas replaced by Static Converter which isswitched On/Off only when the heatingprocess actually occurs. Also theefficiency of MG Set is only 60% ascompared to static converter.
Reduce idle running of 18hrs
of 26 KW load
First to approach BEE to initiate star ratings for engine driven pumpsets .
Our newly developed VARSHA pumpsets are 25 to 30% more fuel efficient
compared with Chinese pumpsets.
This will help our country to reduce the penetration of inefficient Chinese
pumpsets and improve nation’s energy security.
30,000 Varsha pumpsets sold in 2009-10 and it reduces the CO2 emission by
about 12,000 tons per year.
KOEL’s Digvijay engine of 500 KVA rating is also most energy efficient among its
category. These engines can also be run on 100% biodiesel.
Our 4R810 engines are having highest energy efficient in the world –
Comments given by OEM JCB.
Launched higher fuel efficient gas engines also resulting into 50% reduction in
emissions
Innovation in Products
Response from Customers Response from Customers
KOEL has developed the super silent Genset.
The first super silent Genset is installed at residence of Ministry
of Power, GoI, New Delhi.
This Super Silent Gensets meeting the requirement of less than 65dBA sound pressure level for 15 to 62.5 kVA rating as per measurement guidelines given in ISO 8528-10 .
8
ENCON Project
(2007-10)
Summary of ENCON Projects
Sr.
No.
Year No. of
measures
Implemented
Investment
Made
( ` Lakhs )
Annualized
Saving (`
Lakhs )
Energy
Cost
( ` Lakhs
per Yr)
% saving (saving
achieved /Energy
cost of previous
year)
1 07-08 25 33.55 72.80 1133.04 6.51 %
2 08-09 107 56.77 169.65 843.60 14.97 %
3 09-10 37 73.10 98.35 777.17 11.65 %
Total 169 163.42 340.8
ENCON Projects are always having top priority at Management level.
No budget restriction for the ENCON projects having payback period less than 3 years
ENCON Project CAPEX approval by top Management is within 24 hrs – lowest in any industry.
Particular No. of Projects
Investment in Rs Lakhs
Savings in Rs Lakhs
Avg. Payback Period
Zero Investment Projects 69 0.0 90. 5 Nil
Low Investment Projects (< Rs 5 Lakhs)
59 37.5 110.48 6 Months
Summary of ENCON Projects
Zero Investment Projects
Eliminating the idle running of Hydraulic /Spindle/ Chilling Units by using PLC/ Timers on SPMs and CNCs
Spindle motors run ion Star-Delta-Star as per grinding requirement on Grinding machines
Spindle motors switched off in Logic as per Component variety
Optimization of Compressor operation using EMS System
Casting forged camshaft instead of Steel Camshaft for Ha series eliminated Induction Hardening Operation
Modification in water piping at Admin Bldg sprinkler
Spindle run in Star when not grinding
Total Investment : Nil
Annual Savings : 114504 kWH
Annual Savings in : ` 6.29 Lakhs
Description After
• Start to delta configuration
• Spindle motors of Grindingmachines were run in delta onlyduring grinding operation, in starwhen retracted in cycle
• Horizontally deployed on allGrinding machines in all Mfg.Plants throughout Khadki Location
ENCON Projects
Zero Investment Projects
9
Zero Investment Projects
Hydraulic switched off when idle
Total Investment : Nil
Annual Savings in Units : 14.60 Lakh kWh
Annual Saving in : ` 80.32 Lakhs
Description After
• Stop the idle running of HydraulicPumps, Spindle motors, Oil andcoolant chilling units and pumpsby modifying PLC Logic, ElectricalLogics or Limit switches.
• Horizontally deployed on allSPMs, GPMs, CNC machines,Conveyors, Press machines in allMfg. Plants throughout KhadkiLocation
ENCON Projects
Motor with Belt drive and VFD
Total Investment : ` 20 Lakhs
Annual Savings in Rs. : ` 52Lakhs
Avg. Payback period : 5 Months
Before After
Gearbox Assembly
Replaced Gear box assembly by VFD andMotor- Belt drive horizontally deployedon 27 machine in all Mfg. Plantsthroughout Khadki Location
ENCON Projects
Low Investment Projects
Energy Efficient Pump
Total Investment : ` 9.0 Lakhs
Annual Savings in Rs. : ` 27.5 Lakhs
Payback period : 4 Months
Before After
Conventional Pumps
Replaced conventional induction Pumpsby Energy Efficient pumps –
As per our KBL water pumping auditreport, we have replaced conventionalinduction pump-motors 23 nos total 85kW by 38 kw in all Mfg. Plantsthroughout Khadki Location
ENCON Projects
Low Investment Projects After
Washing Machine
Total Investment : ` 0.1 Lakh
Annual Savings in Rs. : ` 2.34 Lakhs
Payback period : Immediate
Description After
• On Paint booth Washing zoneengine was being washed withheated effluent more than 600 C.
• Now the effluent is replaced bysolution containing Prototex-2,which retains all qualityparameters and requires
• NO HEATING. Hence we havesaved electricity required to heatthe effluent.
Use of Special Type Washing Liquid For Engine Cleaning
ENCON Projects
Low Investment Projects
10
Total Investment : ` 0.8 Lakhs
Annual Savings in Rs. : ` 0.62 Lakhs
Payback period : 10 Months
Description After
At our R & D center, hot water wasgenerated by using electrical heaters forcanteen applications. We have installedsolar water heating system for replacingthe electrical geysers. Size of the solarwater heating system is 375 Lits.
Annual Energy Savings = 12840 KWh
Installation of Solar Water Heating System for Canteen
ENCON Projects
Low Investment Projects After
Total Investment : ` 3 Lakhs
Annual Savings in Rs. : ` 2 Lakhs
Payback period : 1.5 years
Description After
For improving the internalenvironment & day light level, wehave installed turbo ventilators &transparent sheets at HeatTreatment shop. Turbo ventilatorsare wind driven eco-friendlysystems. To maintain sameenvironmental condition we haveinstalled 36 units instead of 24 fans.
Wind driven turbo ventilators for HT shop
ENCON Projects
Low Investment Projects
Total Investment : ` 6 Lakhs
Annual Savings in Rs. : ` 8 Lakhs
Payback period : 9 Months
Description After
Installation of Godrej Make Control AirSystem to reduce the pressure dropacross the plant and saving theelectrical energy. This system is workedon the basis of demand sidemanagement (DSM) for airconsumption.
Avg. energy consumption before installation = 10200 KWh/Day
Avg. energy consumption after installation = 9626 KWh/Day
Annual Energy Savings = 1,79,088 KWh
Control Air System For Central Compressor HouseDemand Side Management
ENCON Projects
Total Investment : ` 6 Lakhs
Annual Savings in Rs. : ` 10.7 Lakhs
Payback period : 7 Months
Description After• Installation of VFD for 1000 CFM screw
compressor.
• Benefits of this project are as follows.
• Avoid high starting torque
• Increased the life of motor & compressor
• Reduction in breakdown & maintenance cost
Avg. energy consumption before installation of VFD = 6854 KWh/Day
Avg. energy consumption after installation of VFD = 6162 KWh/Day
Annual Energy Savings = 2,15,904 KWh
VFD For Screw Compressor
ENCON Projects
11
Replacement of old motors by EE Motors
EE Motor
Total Investment : ` 3.5 Lakhs
Annual Savings in Rs. : ` 2.9 Lakhs
Payback period : 19 Months
Before After
Old Motor
95% EE,
(NEMA Premium)
Make – Baldor Electricals, USA
Motors of old reciprocatingcompressors were very much old,inefficient & consuming high energy.We have replaced two motors of rating90 KW & 55 KW by NEMA premiumhigh-energy efficiency motors of M/sBaldor Electrical, USA.
ENCON Projects
Waste Heat Recovery from Al-Foundry
Washing Machine
Total Investment : ` 10 Lakhs
Annual Savings in Rs. : ` 2.30 Lakhs
Payback period : 4.3 years
After After
Scrubber
For improving the environmentalconditions of HT shop, we have installedwater scrubber at the exhaust of meltingfurnaces. Hot water available from thisscrubber is used for component washingmachine. Due to this, we can remove theelectrical water heaters of the washingmachine.
ENCON Projects
Total Investment : ` 10 Lakhs
Annual Savings in Rs. : ` 16Lakhs
Payback period : 7 Months
Description After
Earlier we were using the heatless dryersfor removing the moisture fromcompressed air. This type of dryers arenot energy efficient & also perform verypoor. Therefore, we have installedrefrigerated air dryer (RAD) of 2000 CFMin place of heatless air dryer (HD).
Annual energy consumption before installation = 336960 KWh
Annual energy consumption after installation = 7270 KWh
Annual Energy Savings = 3,29,690 KWh
Installation of Refrigerated Air Dryer
ENCON Projects
Projects linking to Carbon Emission
Reduction & Environment
12
Projects linking with Carbon Emission Reduction
Sr. No
Title of project implemented
Year of Implementation
Total CO2
Reduction
Total Annual Savings
Invest. Made Payback
monthsNo of CERs /
VERsRs Million Rs Million
1Wind Power Project of 5.6 MW capacity
2007 9100 52.0 280 64
2.Manufacturing of biodiesel at OEM (Program of Activities)
2010 4500 30 100 40
Other Projects linking with Carbon Emission Reduction
• Waste heat recovery project at Al foundry
• Use of canteen waste for biogas generation
• Reduction in engine testing cycle time & use of cold testing
• Use of bio-LDO in place of HSD for melting furnaces
• Use of bio-diesel for in-house power generation
• Engines running on biogas
• Utilization maximum day light
• Elimination of TCE (trichloro ethylene)
• Waste heat recovery from compressors
Employee Involvement
&
Methodology
ENCON – The Kirloskar Way
Our approach is two pronged. One, we will continuously keep minimizing use of energy in ouroperations. Two, we will develop economically viable green products. - Chairman Speech 2007
13
Policies & Strategies
Singed in 2007
• Energy PolicyPublished in
2002
• CII – Code for Ecologically Sustainable Growth
Revised in 2009
• EHS Policy
In Process
• Policy for procuring EE equipments
Energy & EHS Policies
KIRLOSKAR OIL ENGINES LTD.
ENERGY POLICY
Achieving optimum use of energy in our operation and bringing
about improvements in the energy efficiency of our processes and
products will form an important components of the continuous
improvement efforts in our organization.
We shall strive to reduce energy consumption per unit of value
added by :-
• Minimizing wastages using Energy Efficient processes and equipment.
• Conducting periodic Energy Efficiency improvement studies and implementing improvement measures.
• Involvement of employees of all levels in the energy conservation efforts.
• Effective dissemination of information
• Establishing norms and initiating programmes to reach these norms.
• Promotion to renewable Energy resources within & Outside KOEL.
In achieving these, we shall utilize the knowledge and expertise
available from various sources including sister organization,
collaborators and outside experts.
We shall make efforts to bring continuous improvement in the energy
efficiency of our products.
Atul Kirloskar
Reviewed :- 10-May-2005 Chairman & Managing Director
EHS policy Energy Policy
Being Cognizant of the need of sustainable growth as dwindling stock of natural capital, we commitourselves to attainment of the following Ten – Natural Capital Commandments.
1. Reduce specific consumption of energy and water by 3-5% every year over next ten years.
2. Reduce specific generation of waste and reduce the quantum of waste going to land fills by 3-5%every year over next ten years.
3. Increase use of renewables, including renewable energy by 5% every year in place of non-renewableover next ten years.
4. Reduce greenhouse gases emissions and other process emissions by 3-5% every year over next tenyears.
5. Increase use of recyclable and enhance recyclability of resources embedded in the product.
6. Increase the share of harvested rainwater in the overall annual use of water by 5% every year overnext ten years.
7. Incorporate life cycle assessment criteria for evaluating new and alternative technologies andproducts.
8. Strive to adopt green purchase policy and incorporate latest clean technologies at design stage
9. Take lead in promoting and managing product stewardship program, by forging partnership withbusiness and communities.
10. Reduce depletion of natural capital, which is directly attributable to company’s activities by 5% everyyear over next ten years.
We also commit to demonstrate attainment of these commandments in our pursuit to certifications such asISO 9001, ISO 14001, OHSAS 18001, SA8000, Green Buildings, Eco-labels and the like.
Aug 15, 2007 Atul Kirloskar
Chairman & Managing Director
CII- Code for ecologically sustainable growthENCON Culture
(Four Main Pillars)
Data Monitoring
Data Recording
Data Analysis
Data Comparing
Capacity Building
Promotional Programs
Society Awareness
Product improvement
Production process
improvement
Green Technology Cell
Green Energy Product
Use of renewable
Green Promotion
• Energy AOP
• Allocation of Cost
Centers
• Target Setting
• Waste & Losses
Identification
• ENCON Projects
• Data Controlling
• Training &
Awareness
• Energy week
• Information
sharing &
Results &
Achievements
• K-Group Utility
Meeting
• New machines &
Process improvement
• Design, develop and
mfg energy efficient
products
• Implementation of
EURO Stage III
• Procurement of EE
equipments
• Wind power project
• Use of bio-diesel
• Bio-gas based
engine
• Solar water heating
for canteen
• Waste elimination &
recycling
ENCON Cell
• Monthly review by ENCON Cell Head
• Bi -Monthly review by Director (ENCON Mentor for K-Group Companies)
• Annually assessment by K-Group ENCON Competition Assessors
Centralized Energy
Monitoring System
Knowledge
building
Technology up-
gradation
Green Energy &
Green Products
ENCON Achievements
14
ENCON MENTOR
Mr. R.R. Deshpande
Executive Director
ENCON LEADER
Mr. S.B. Gosavi
Sr. G .M. – Utilities
ENCON MANAGER
Mr. Milind Deore
Energy Manager – KOEL
KHADKI PLANT
ENCON TEAM MEMBERS 19
NAGAR PLANT
ENCON TEAM MEMBERS 8
KAGAL PLANT
ENCON TEAM MEMBERS 19
RAJKOT PLANT
ENCON TEAM MEMBERS 9
NASIK PLANT
ENCON TEAM MEMBERS 14
Utilities Mainteninance Mfg. Engg. Production
Heat Treatment R & E FinancePersonnel &
Safety
KOEL ENCON Cell
• Monitoring & Verification
• Record & Result Review
• OFI – Continuation
• Review & Target
• Revise / update Action Plan
• Set & Compare Benchmark
• Start the Cycle
• Resource Collection
• Project Implementation
• Monitoring Progress
• Capacity Building & Training
• Energy Audit
• Action Plan
• Target Setting
• Short Term & Long Term Action Plan
Plan Do
CheckAct
Methodology - PDCA Cycle
KOEL
ENCON
Management
ENCON team regular meetings
ENCON annual budget & projects
K-Group Utilities Meeting
Monthly review by company Director
Small improvements through employees suggestion scheme
Internal Energy Audit
ENCON annual assessment k-group
interplant competition
Implementation of suggestions from
k-group ENCON assessors
External Energy audit
Routine monitoring of energy
conservation and feedback of same
KOEL
ENCON
Management
Productivity improvement programs like TQM, Kaizen 5S, TPM etc.
ENCON Management Process
Inputs from ISO, TS & OHSAS internal &
external Audit
Centralized Energy Monitoring System
KOEL has undertaken the project for Centralized Energy Monitoring System in 2008-09.Under this system we have installed more than 125 digital energy meters. We aremonitoring following resource consumption using this system .• Electrical Energy• HSD & Biodiesel• Air Consumption• Water Consumption
15
Competition --> Slogans Poem Poster Suggestion KAIZEN ENCON Projects
Location
Khadki 248 22 52 70 27 5
Kagal 465 65 122 105 16 0
Nashik 48 13 14 30 3 3
A'Nagar 22 3 10 5 16 0
Rajkot 224 9 33 65 4 23
Total 892 112 225 247 70 31
Response to ENCON Week
Celebration of EC Week Celebration of EC Week
16
ENCON ACTION PLAN 2009-10 Training Programs
Half-day training program onEnergy Efficient Motors –
With the help of InternationalCopper Promotional Council ofIndia (ICPCI), KOEL Khadki hasorganized half training programon Energy Efficient Motors.
Training Program for Energy AuditProcess
Workshop on Green Building Technologies
UTILITY HIGHLIGHTS
17
ENCON at Employee’s Home
During last financial year KOEL has won the K-Group level ENCON awards. The prize moneyis used for purchasing energy efficient CFL lamps and these lamps were distributed to eachemployee of KOEL. More than 2500 CFLs are distributed to KOEL employees.
• No. of CFL distributed = 2500 Nos. of 15 W
• Energy Savings through these CFLs = 246000 KWh of worth Rs 14.78 Lakhs.
• Reduction in emissions = 210 Ton of CO2
We have also organized exhibition cumdiscounted sale of EE lamps & RE devices forKOEL employees.
Prize distribution function
Year 2008-09
6 Kaizens/person
8 Kaizens/person
Year 2009-10
22 Kaizens/person
BenchmarkTOYOTA
Employee Involvement… Strategy……
18
KAIZEN (Year 2009-2010)
BG (Engines)-----Location
Monthly
target
APR MAY JUN
E
JULY AUG SEPT OCT NOV DEC JAN FEB MAR CUMM
Khadki 600 603 614 616 624 607 613 604 731 630 608 583 628 7461
Kagal 335 322 364 454 304 260 243 192 174 193 269 143 342 3260
Nasik 165 164 165 167 163 165 165 191 87 137 86 88 48 1626
Rajkot 65 60 63 67 65 60 61 00 27 25 52 50 38 568
Bearings -----Location
Khadki 45 09 11 11 15 36 54 24 50 100 69 70 51 500
Nagar 45 39 38 40 48 49 83 20 47 33 15 03 08 423
Sourcing
125 127 129 130 126 128 131 132 128 152 127 130 130 1571
Utilization of Renewable
Energy
Sources
Green Energy Profile
Contribution of Green Energy 31.5%
Total Connected Load 15246 KW
Total no. of Transformers 16 Nos.
Constant Power factor recorded 1.0
Total Energy Consumption (MSEDCL) 141.03 Lakh kWh
Total standby Generation capacity 9320 KVA
Power generation on DG set 1.19 Lakh kWh
Wind Energy Generation 99.14 Lakh kWh
Fuel Consumption (HSD) 1090 KL
Green Fuel Consumption (Bio-diesel) 30 KL
Gas Consumption (LPG) 60000 Kgs
Green Gas Consumption (Bio-gas) 6840 Kgs
Wind Power Project
• Installed Capacity = 5.6 MW
• Energy Generation in 2009-10 = 99.20 Lakhs kWh
• Emission reduction = 9100 Ton CO2
Canteen Waste based Bio-Gas Generation
• Waste to Energy Project
• Bio-gas Generation : 360 cylinder/year
• Cost Saving = Rs. 2.88 in Lakhs
Bio-diesel based Power Generation
• Bio-diesel is being used for In-house Power Generation
• Bio-diesel based Power Generation in 2009-10 = 1.19 Lakhs kWh
• Cost Saving = Rs. 3.2 in Lakhs
• 60% Reduction in emission
Solar Water Heating System
• Two Solar Water Heating System installed for Canteen application
• Energy Saved = 18,000 units/year
Renewable Energy Initiatives
19
Use of Day light
• Incorporated transparent sheets to improve day light
• Day light level is more than 1000 lux
• Energy Savings = ` 11. 30 Lakhs
Use of Turbo vent to improve the air circulations
• Use of Natural Air
• Improvement in Environmental Conditions
• Energy Savings of worth = ` 5. 23 Lakhs
Solar Street lights
• Use of solar energy for street illumination
• Green Energy Promotion
• Energy Savings = ` 0.3 Lakhs
Biogas based power generation
• Gensets are run on Bio-gas at GTC
• Testing Energy is used for canteen application
• Energy Savings in 2009-10 is = = ` 1. 1 Lakhs
Renewable Energy Initiatives
Waste to Worth
Projects
Waste to Worth Projects
Canteen Waste based Bio-Gas GenerationWaste to Energy Project Reduce 15 % LPG consumption of
Canteen Bio-gas Generation : 360 cylinder/year Cost Saving = ` 2.88 Lakhs
Reduction in Carbon Emission -
Recovery of AL from waste Dross Project Investment - ` 0.5 LakhsMetal Saving of Worth - ` 9.54 Lakhs
Payback is only 1 Month. Reduction in hazardous waste
Dross Before recovery
Dross After Recovery
Waste to Worth Projects
Utilization of waste heat for washingWaste heat recovery project Project Investment - ` 10 Lakhs Annual Cost Saving = ` 2.30 Lakhs
Improvement in Environmental conditions
Recovery of waste heat from Flue Gases Waste heat recover project Project Investment - ` 2.0 Lakhs HSD Saving of Worth - ` 8.0 Lakhs
Payback is only 3 Months Improvement in Environmental
conditions
After Recovery
Before recovery
20
Inputs from ISO
14000/9000
& OHSAS
Elimination of TCE from BRG plantReduction in testing cycle & cold testing Elimination of water heating Use of green energy i.e solar, wind Energy efficient procurement program Green sourcing program
ProcessReplacment of asbestos sheetUpgardation of ETP plants Use of maximum day lights Use of turbo vents Adoption of Green building concepts
Infrastructure
Green technology centere Intergation of product with green energy sources like bio-diesel, biogas, SVOAdoption of upgarded emission normsFule efficient engines & pumpsetsBEE labelling program
Awareness campaign for schools, Residential colonies etc.Corporate sustainability reporting
Society
Inputs from ISO 14001/9000 and OHSAS 18000
During the internal & external audit of ISO 14001/ 9000 and OHSAS 18000, we havereceived OFI. With respect to these OFIs, we undertake objectives, targets & programs.Some of the environmental initiatives are as follows.
Products
Replication of best
practices
21
FRP Fan Blade
• Reduction in Energy Consumption by 25%
• Better Air Flow due to Aerofoil Shape
Fan less Cooling Tower
• Use of Natural Draft
• Removal of Electric Fan
• Reduction in maintenance cost
Unity Power Factor
• Power Factor Benefits by MSEDCL
• Reduction in Line Losses
• Increase in Efficiency of Electrical System
Replication of Best Practices
Use of T5 Lighting in Office Areas
• Reduction in Energy Consumption up to 30%
• Improvement in Lux Level
Occupancy Sensors
• Avoid idle running & wastage of Energy
• Switch ON lights & Fans only when required
Solar Water Heating System
• Use of Natural Resources
• Use in Canteens & process applications
• No need of Electrical Energy
Replication of Best Practices
VFD Application for ENCON Projects
• Significant Reduction in Energy Consumption
• Highly Efficient
• Used in Compressor, Electric Motors, Pumps etc.
Use of Energy Efficient Motors
• Energy Reduction from 15% to 20%
• Long Life
• Less Pay Back Period
Use of Turbo-Ventilators
• No Need of Electrical Energy
• Zero Maintenance
• Cost Effective
Replication of Best Practices
Improvement in Insulation
• Reduction in thermal energy losses
• Reduction in Fuel Consumption
• Improve working conditions
Replacement of Old & Inefficient A/C’s by BEE Star Labeled A/C’s
• Promote Use Efficient BEE Star Labeled Products
• Saving in Electrical Energy
• Reduce the maintenance cost
Replacement of Oversize Pump & Motors
• Conduct Audit by K.B.L.
• Replaced Inefficient Pumps by EE Pumps
• Process Improvement
• Significant Saving in Electrical Energy
Replication of Best Practices
22
Electronic Ballast
• Energy Saving of 60-70 %
• Improvement in PF
• Increase the life of lamp
Use of Natural light
• Avoid the use of artificial lighting
• Energy saving
• Improve the working conditions
Energy Saving Devices for Street lighting
• Maximum use of day light
• Reduce the energy wastage
• Lower maintenance cost
Replication of Best Practices
CSR initiatives
Awareness Program for Women
23
Award
& Accolades
KOEL receiving the ‘National ENCON Award’ from Hon. Minister of Power Mr. Sushilkumar Shinde.
KOEL bagged First Award in the competition of “State Level Award for Excellence inEnergy Conservation and Management-2007” organized by Govt. of Maharashtraand MEDA.
K-Group ENCON Awards
KOEL, Khadki has bagged First Award in the“K-Group Interplant ENCON Competition2007-08” into large unit category.
KOEL, Khadki has bagged Second Award in the“K-Group Interplant ENCON Competition2008-09” into large unit category.
KOEL, Khadki has bagged Second Award in the“K-Group Interplant ENCON Competition2006-07” into large unit category.
24
Other Awards & Accolades
CII EXIM Bank Award for BusinessExcellence 2009 – KOEL receivedCommendation Certificate for StrongCommitment to Excel.
KOEL received DSK Energy Award -2007
Way
Ahead
BEE Star labeling for pumpsets & engines 2
1 IGBC Green Factory Rating system
3 Green Sourcing program for suppliers
Long Range Plan for ENCON (up to 2015) 4
Energy purchasing from Power Exchanges 6
5 Publishing first Corporate Sustainability Report & carbon foot print
7 Increase the % contribution of green energy through renewable
EE Procurement Policies / Standard Guideline Manuals 8
9 Celebration of ENCON for full Month instead of week
EE & Environment Check for new Equipment or CAPEX projects. 10
Way Ahead : 2010-11
25
On Our Way to Sustainable Development …
Thank you
Questions