national award for excellence in energy management -2016
TRANSCRIPT
1
National Award for Excellence in
Energy Management -2016
22nd - 24th Aug’2016
Haridwar Singh
National Award for “Excellence in Energy Management – 2016 2National Award for “Excellence in Energy Management” – 2016 2
Hero Honda Motors Ltd.
Incorporated
1985
First motorcycle "CD 100" rolled out
from Dharuhera Plant
Gurgaon plant
inaugurated
1997
2001
Hero Honda become World No.1
Two Wheeler manufacturing
2008
Haridwar plant
inaugurated TPM Kick Off at HMCH
2009
2011
Name changed to Hero
MotoCorp Ltd.
1984
Journey Started
20132013
Company Profile
Start of 1st overseas plant at Columbia Inauguration of CIT at Jaipur,
Rajasthan
20152016
50 Million bikes Sold
2014
Various milestones during Hero MotoCorp’s Journey
Start of 4th plant & GPC at
Neemrana, Rajasthan
2
National Award for “Excellence in Energy Management” – 2016 3
Description – HM3H Supply Chain
Suppliers - Uttarakhand (Nos.) 42
Suppliers - Non Uttarakhand (Nos.) 126
Description – HM3H Manufacturing facilities
Manufacturing Lines (Nos.) 04 Equipments (Nos.) 1234
Employees (Nos.) 4500 Avg. Age of Equipments (Years) 7
Avg. Age of Employees
(Years)28
Minimum Education of
EmployeesITI
Supply chain – Flow & Details
Unidirectional Material Flow
Machine Shop
Engine Assembly
Frame Assembly
Final Inspection
Weld Shop
Paint Shop Dealer
Customer
Supplier
Haridwar
Supplier
NCR
Disp
atch
Disp
atch
75%
25%
0%
20%
40%
60%
80%
% P
art
s
Parts Buying
Production Processes
Decentralized Supply Hubs
Decentralized Supply Hubs
National Award for “Excellence in Energy Management” – 2016 4
Total 31 No’s Zero investment projects Implemented and conserved 14 Lacs kwh and cost
saving of Rs 73 Lacs/year
EnCon Projects – Electrical (Zero Investment)
Sr.
No.Top 10 Energy Saving Projects
Annual Savings
Kwh in
Lacs
Rs in
Lacs
1Switching off Steel & Aluminium Phase FDV's in Lunch , Dinner & C-shift to reduce energy
consumption.1.52 7.67
2Reduce kwh consumption on Non Working Days by clubbing separate lines maintenance activity
in similar shifts.1.47 7.60
3Reduction of kwh consumption in Engine Assembly by using 1 common washing machine in Line-
4 & 3 by re-lay outing & trolley arrangement.1.50 7.58
4Gun drill machine coolant circuit modify to run 2 pumps in place of 4 to save energy in Machine
Shop.1.17 5.92
5 Optimize the process in Lacquer Paint shop to run 2No's Water pump place of 3No's. 0.84 4.27
6Reduction in kwh consumption by delay in switching on chillers' after running AHU (Air Handling
Unit) from different power source.0.75 3.79
7 Power Transformer switched off on alternate week to reduce iron losses in one transformer. 0.58 3.42
8 Reduction in kwh by stopping of motor in Dia 5.5 drill station (OP70) in Cylinder Head. 0.54 2.73
9 Reduction in kwh consumption by intermittent stopping of flushing motor in Machine Shop. 0.49 2.45
10Save energy consumption by process synchronizing with ACED predegreasing heating and
circulation pump 0.40 2.01
Total Saving (Top 10 Projects) 9.26 47.44
Total Projects Saving (31 Nos) 14 73
3
National Award for “Excellence in Energy Management” – 2016 5
EnCon Projects – Electrical (With Investment)
Sr.
No.Top 10 Energy Saving Projects
Annual Savings
Kwh in
Lacs
Rs in
Lacs
1Energy Conservation Engine Assembly washing machine by modification in Coolant, Heating and
Air circuit line.4.71 23.62
2 Resource conservation in ACED Paint shop by provision of 3 frame Body loading in one hanger 3.89 19.63
3Reduction in power consumption of Sheet Metal & ACED paint shop exhaust blowers through
VFD 2.59 15.40
4Save Energy by decreasing cycle time 76.5sec/Line to 72Sec/Line in Aluminium phase (Crank
Case).1.96 9.91
5 Reduce energy consumption by improving productivity in Aluminum Phase Cylinder Head. 1.86 9.40
6 Reduction of power consumption in engine assembly washing machines by heater modification . 1.56 9.25
7Save energy by eliminating Chiller in Dry off Oven in SM Paint Shop by extending conveyor length
for natural component cooling. 1.73 8.74
8Optimisation of 1500 CFM Air compressor auto mode VFD (Variable Frequency Drive) to reduce
energy consumption.1.39 7.01
9Reduction in power consumption of paint shop pumps by installation of VFD in place of star delta
starters.1.25 6.49
10Power saving by installing 4No’s VFD in FDV’s Blowers by balancing of velocity at FDV drops at
work station1.23 6.22
Total Saving (Top 10 Projects) 22.17 115.67
Total Projects Saving (27 Nos) 31 163
Total 27 No’s Investment Projects Implemented and conserved 31 Lacs kwh and cost saving of
Rs 163 Lacs/year
National Award for “Excellence in Energy Management” – 2016 6
EnCon Projects – Natural Gas savings
7 Projects implemented & Conserved 469 Ton SCM Natural Gas and resulted cost saving of Rs.
178 Lacs /year
Sr.
No.Gas Saving projects
Annual Savings
Gas Saving
Ton ( SCM)
Rs in
Lacs
1 Shift operation reduction in ACED Paint shop by provision of 3 frame Body loading in one hanger 210 73
2 Natural Gas uses in Plant in place of Propane and optimized burner setting and air fuel ratio. 140 59
3 Hot Water Generator Burner nozzle setting optimisation 60 23
4 ACED Paint Shop burner setting optimisation 24 9
5 SM Paint Shop burner setting optimisation 21 8
6 Lacquer Paint Shop burner setting 8 3
7 New Paint Shop burner setting optimisation 7 3
Total Saving 469 178
4
National Award for “Excellence in Energy Management” – 2016 7
Plant specific Resource consumption
Achieved Continual improvement in resource conservation
Resource Unit
Start Year Achieved Target
FY
08-09
FY
09-10
FY
10-11
FY
11-12
FY
12-13
FY
13-14
FY
14-15
FY
15-16
FY
16-17
Electricity Kwh / Veh 24.61 17.31 16.37 15.61 15.72 14.74 15.79 15.12 14.68
Fuel Kg / Veh 0.714 0.609 0.474 0.428 0.427 0.447 0.476 0.368 0.330
Water KL / Veh 0.350 0.178 0.154 0.145 0.155 0.142 0.124 0.111 0.106
Increased due to installation of comfort cooling on expansion
lines along with new models commissioning and trials.
24.61
17.3116.37
15.61 15.72
14.74
15.7915.12
14.68
14
16
18
20
22
24
26
2008-09 FY
2009-10
FY
2010-11
FY
2011-12
FY
2012-13
FY
2013-14
FY
2014-15
FY
2015-16
FY
2016-17
Target
Kw
h/V
eh
Specific Power Consumption
39%
0.714
0.609
0.474
0.428 0.4270.447
0.476
0.368
0.330
0.30
0.35
0.40
0.45
0.50
0.55
0.60
0.65
0.70
0.75
2008-09 FY
09-10
FY
10-11
FY
11-12
FY
12-13
FY
13-14
FY
14-15
FY
15-16
FY
16-17 Target
SC
M/V
eh
Specific Fuel Consumption
48%
Extensive efforts made in FY 15-16 to bring down SFC by 24%
National Award for “Excellence in Energy Management” – 2016 8
Theme Selection
Resource optimization in ACED Paint Shop Project: 1
Understanding Situation & Setting Targets
Conveyor Details
SR.
NO.DESCRIPTION SPECIFICATION Current
1 Conveyor Speed 3.5 m/min to 4.1 m/min. 4.1 m/min
2 Hanger Pitch 1200 mm 1200 mm
3 Load Capacity Optimum 65 Kg / Hanger 42.5 kg
4 Drive Unit 2 nos. 2 nos.
5 Conveyor Length 560 meter 560 meter
6 Total no of Hangers 466 nos. 466 nos.
7Process time loading
to unloading131 min. 131 min
8 Hanger Envelope size950mm x 900mm x
1250mm
900mm x 800mm x
1200mm
9 Part per HangerAs per Envolpe size and
within weight limit
2 frame body , 3
main stand,3 side
stand
Hanger loading to be increased to utilize the capacity of
conveyor
Theme : To reduce Power & Fuel consumption and to increase Productivity by C shift elimination
Innovative
800mm
300 mm
Hanger needs modification
Frame Assembly Demand -8500
A- Shift
6:30 AM to 3:00PM
B –Shift
3:00PM to 11:30PM
.
Cycle Time/frame body needs to be reduced from 8.92
sec to 6.16 sec to eliminate C shift
8.92
6.16
0
2
4
6
8
10
ACED Cycle Time Takt Time
Se
c
Takt Time Vs Cycle Time
3100 4250
3100
42502300
0
2000
4000
6000
8000
10000
ACED
Production -
3- Shift
Frame assly
Requirement-
2 Shift
No
s
8500 8500
Frame Assembly Demand
/ Supply
ACED Frame Body Supply -8500
A- Shift
6:30 AM to 3:00PM
B –Shift
3:00PM to 11:30PM
C – Shift
11:30PM to 6:30AM
Extra Running
5
National Award for “Excellence in Energy Management” – 2016 9
Analyzing the factors
5260
36
6072
83
50
83
0
50
100
Hot Water Pre Degreasing Degreasing Elec Deposition
Heat Exchanger Plates (Nos)
Current Required
Component
Anode Cathode ratio (2
frame body,2 main &
side stand)
Anode Cathode ratio
(3frame body,3 main &
side stand)
Anode Cathode ratio
(3frame body, 3 main &
side stand)
SA(m2) PPH TSA(m2) SA(m2) PPH TSA(m2) SA(m2) PPH TSA(m2)
Frame Body 1.5 2 3 1.5 3 4.5 1.5 3 4.5
Main Stand 0.14 2 0.28 0.139 3 0.42 0.139 3 0.42
Side Stand 0.018 2 0.036 0.0175 3 0.053 0.0175 3 0.053
Total 1.6969 3.32 4.97 4.97
Total Surface Area
for painting
Cathode(m2)
9× 3.32= 29.88 9× 4.97= 44.73 9× 4.97= 44.73
Total Area of
Anodes(m2)30× 0.27= 8.1 30× 0.27= 8.1 36× 0.27= 9.72
Anode
:Cathode ratio1 : 3.94 1 : 5.52 1 : 4.60
Anode Cathode Ratio Study – Limit (1:5)
Resource optimization in ACED Paint Shop
Confirming Effectiveness
8.92
5.95
0
5
10
Before After
Reduction in cycle time
(Sec)
31004840
3100
37822300
0
2000
4000
6000
8000
Before After
Elimination Of C Shift
(Nos)8500 8600
Implementing countermeasures
Project: 1Innovative
9224
7928
7000
7500
8000
8500
9000
9500
Before After
Energy Saving (KWH/Day)
6000
5300
4800
5000
5200
5400
5600
5800
6000
6200
Before After
Fuel Saving (SCM/Day)
Projects Implemented and conserve of 3.89 Lacs kwh and 210 Ton SCM Natural Gas and resulted saving of
Rs 93 Lac/year
14% 12%
National Award for “Excellence in Energy Management” – 2016 10
76.5
72
68
70
72
74
76
78
Crank case Required Cycle Time
Sec/LineCycle Time/Line Difference On Robotic cell
1005 1005 1005300 100
1005 1005 1005
300
845 845 845
0500
10001500200025003000
Nos SHIFT & MODULEWISE
PRODUCTION AT CURRENT SITUATION
Shift A Shift B Shift C
GAP – 4.5 2 Shift
Stopped
Previous Condition
Target Setting
Improvements Done:
Results:
KAIZENS
S. No.
Machine Before Condition After Condition
1Rotary
Milling
(RM)
Table rotating on lower speed 24 SecSpeed shifted on Higher
speed and controlled by VFD22 Sec
2 OP10A
High Air Cutting time
25 Sec
Air Cutting time reduced
22 SecSeparate Operation of dia. 8.8 and
dia11.6 mm
Combination Drill
implemented for dia 8.8/11.6
mm
3 HM High Air Cutting time 25 Sec Air Cutting time reduced 23.6 Sec
4 WMHigh IDLE time during Door opening
and Closing30 Sec
IDLE time reduced by Logic
modification24 Sec
5Robotic
Cell
High Machining time (65.5) due to dia.
6.6drilling from Cover and joint face65.5 Sec
Single shot drilling provided
form cover face only60 Sec
6Cross robot Loading and Unloading
time high
Single point unloading to 3
point unloading done
940 940 940300 550
100
940 940 940
300550
814 814
200
0
500
1000
1500
2000
2500
3000
Module-1 Module-2 Module-3 Vigel Expansion Hunk
Nos SHIFT & MODULEWISE
PRODUCTION AT CURRENT SITUATION
Shift A Shift B Shift C
Total Out Put -9265 VPD
Total Manpower – 129 Nos(Base)
Total Out Put -9268 VPD
Total Manpower – 138 Nos (base)
25.5/comp
24.0/comp
76.5 72
607080
Crank case
Before
Crank case
After
Sec/Lin
e
Cycle Time/Line Difference
25.5/comp 24.0/comp1 Shift
Stopped
Started
running
Saving of 1.96 Lac kwh/year and Rs 10 Lac/year by reduction of cycle time
Optimizing Resource in Aluminum Phase Project: 2Innovative
Theme : To save energy consumption by decreasing cycle time of Aluminum phase Crank Case robotic cell
6
National Award for “Excellence in Energy Management” – 2016 11
Previous Condition
Methodology/Approach Adopted: -
Improvements Done
Results:
High Use of Resources ( Air, Water, Electricity) in
Engine Assembly Washing Machines.
1575
0
1000
2000
3000
4000
Before After
ElectricityKWH /day
Benefit:
1. Energy Saving of 4.72 KWH/Year
2. Water Saving of 375 KL Annually
� Heater Elimination & Heater tank volume
reduction
� 1 Pump elimination through interconnection
� Elimination of compressed Air with blowers.
125
0
100
200
300
400
500
600
Before After
Water Litres /day
23.9 Lacs
160
170
180
190
200
210
Before After
Energy Cost Rs (Lacs)
Energy Reduction
� Study of system requirements
� Step by Step elimination & quality
check.
� Resource optimization
Energy Usage reduction in Washing Machine
Optimization of Energy Usage resulted in Net Saving of Rs 23.9 Lacs per annum
AfterBefore
Project: 3Innovative
National Award for “Excellence in Energy Management” – 2016 12
Previous Condition
Methodology/Approach Adopted: -
Improvements Done
Results:
All food preparation processes done through use
of natural gas & gas burners .
Benefit:
1. Natural Gas saving of 100 Kgs per day.
2. Thermal cost reduction of 4000 Rs/day.
100
0
100
200
300
400
500
600
Before After
Natural GasKgTechnology Upgradation
1. Study of all the types of cooking processes.
2. Segregation & determination of high
energy consuming processes.
3. Looking for alternate efficient & proven
technology.
4. Adapting to requirements.
� Boiling processes (Rice & dal cooking)
replaced with steam cooking
� Easy to use equipment – Convotherm
combi-oven
� Reduction in food preparation time
� Reduction in Natural gas usage
Total Propane consumption (For Cooking in
kettles & Open burner-321/Day
Hours Operation-5.30Hrs
Kitchen Operation
Fuel Consumption reduction in Canteen
Cooking by Convotherm resulted in reduction of thermal energy cost of Rs 1.2 Lacs
per annum
Cooking by Convotherm resulted in reduction of thermal energy cost of Rs 1.2 Lacs
per annum
Project: 4Innovative
7
National Award for “Excellence in Energy Management” – 2016 13
Previous Condition Improvements Done
Results:
Benefit:
AfterBefore
Methodology/Approach Adopted: -
Conveyor
Total Conveyor Length – 23Mtr.
Fast Cooling Zone (With
Chiller)
Tag Rag
Inspection
Conveyor
Tag Rag
Inspection
Extended
Conveyor Track
Total Conveyor Length – 23Mtr.
Cooling Thru Air Shower in
extended conveyor
1. High Running electricity cost of chillers
eliminated.
2. Maintenance cost & use of CFC gases reduced.
Sheet Metal Paint Conveyor cooling
being done through forced cooling by
operating chillers Paint
Dry Off OvenFast Cooling
Through Chillers
Tag Rag AreaPainting Booth
Forced Cooling Convert into
natural cooling
Energy/Loss Reduction
• Idea collection and feasibility study
• Brainstorming done among team for
infrastructure optimization
• Convert forced cooling into natural cooling
0
10
Before After
Power Cost
0.87
Rs (LPA)
Paint Shop Process Flow
Elimination of High Energy Consuming- Chillers
SM Paint shop process change resulted in Electrical Saving of Rs. 0.87 Lac/year
Project: 5Innovative
National Award for “Excellence in Energy Management” – 2016 14
Benefits :
Before After
Modified circuit.
Continuous
supply
TIMER
PLCElectrical
PanelElectrical
Panel
Continuous running of FDV’s Stoppage of FDV’s for 60 Mins/Day
Saving of 1.5 Lac kwh/year through timer control in FDV
Auto operation of FDV of Aluminum & Steel Phase
FDV stoppage of Aluminum & steel Phase during lunch & dinner time resulted saving
Rs. 7.7 Lac/year
Kaizen-1
8
National Award for “Excellence in Energy Management” – 2016 15
Benefits :
Before After
VFD installation in Paint Shop Exhaust Blowers
System (Without VFD) System (With VFD)
Variable Frequency Drive (VFD) installed in all 7 No’s Pumps for regulating power as
per flow /Pressure requirement: Saving of Rs. 6.25 Lac /year
Saving of 1.25 Lac kwh/year
O/p Pressure – 0.9 Kg/cm2
Power = 11 .1 Kw
0.9
Kg/cm2Valve opening = 100 %
0.9
Kg/cm2
O/p Pressure – 0.9 Kg/cm2
Power = 16 .2 Kw
Valve opening = 66 %
Induction
Motor &
Pump Set
Induction
Motor &
Pump Set
MotorMotorVFD
MainsMains
Kaizen-2
National Award for “Excellence in Energy Management” – 2016 16
Benefits :
Before After
Conventional light installed
in Plant
Convention Tube light
Conventional light with High
Power consumption
Shop floor Light on after
shift end
Shop floor Light control with
timer T5 light installation
Conventional light replaced
with led light in PlantHigh Power cons. Light
replaced with sky light
Lighting power consumption reduced using timer, alternate sources and low rating
lights resulted saving of 5 Lac kwh/year
Lighting power consumption reduced using timer, alternate sources and low rating
lights resulted saving of 5 Lac kwh/year
Efficiency Improvement Projects - Lighting
1 Lac kwh/year
Less maintenance cost of lighting system
1
3
1 2
3 4
Total 4 No’s Kaizen done in Lighting system
4
2
Kaizen-3
9
National Award for “Excellence in Energy Management” – 2016 17
Benefits :
Before After
BEFORE
Stoppage of Dust Collector and
Fume Exhaust for 60 Mins/Day
Power
PanelMOTOR
5. Developing & Implementing Countermeasure
Power
Panel
Timer installed to stop
operation during Lunch/
dinner ,Tea Time &
Planned stoppage
Auto operation of Dust Collector
Continue Supply
Modification done to switch off motors by Timer during Lunch/Dinner breaks:
Saving Rs 3.8 Lac/year
Continuous running of Dust
Collector and Fume Exhaust
Saving of 0.74 Lac kwh/year
Kaizen-4
National Award for “Excellence in Energy Management” – 2016 18
Major Environmental Projects & Initiatives
S.No. Environment Projects
1 1MW Solar Plant installation to use natural resource power
2 Tree Plantation: Project - "Laksh Vraksh" : To plant One Lakh Trees.
3 Zero Discharge plant and lake renovation (Water Harvesting)
45KL per Day solar plant water generation installation for Cooking and Dishwashing in
Canteen
5Up-gradation of Robotic Painting in Primer Booth of SM Paint shop for improvement
in paint transfer efficiency and becoming more environment friendly
S.No. Environment Initiatives
1 Celebrating Earth Hour every year.
2 Waste Management: Co-processing technology for disposal of Hazardous waste
3 Paint sludge incineration burnt outside plant (Incinerator stop)
4 Regular operation of organic waste converter .
5 Regular Operation of Thinner Recovery System.
Efforts to reduce CO2 emissions by implementation of various projects
10
National Award for “Excellence in Energy Management” – 2016 19
GHG Emission Inventorisation
CO2e (MT) FY 15-16
Scope –I
5,420 CO2e (MT)
Scope-II
53,999 CO2e (MT)
Scope-III
38,770 CO2e (MT)
GHG Inventorisation
43,50451,881 53,940 53,999
10,1797,655 8,891 5,420
53,68359,536 62,831 59,419
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
2012 - 13 2013 - 14 2014 - 15 2015 - 16
Year
CO2 Emissions (MT)
Scope 1 emissions
CO2e (MT)
Scope 2 emissions
CO2e (MT)
Total CO2e MT
60007000 7519 8028 8325 8526 8739 8941
0
2000
4000
6000
8000
10000
12000
20
08
-09
20
09
-10
20
10
-11
20
11
-12
20
12
-13
20
13
-14
20
14
-15
20
15
-16
No
’s o
f T
ree
Cumulative Nos of Tree (Inside Plant)
Better
Maintaining 8941 trees inside plant which reduced 348.7 Ton CO2 emission/year
23.77 23.4024.05 23.69 23.35
20.00
21.00
22.00
23.00
24.00
25.00
2012-13 2013-14 2014-15 2015-16 2016-17
Target
Kg
/Ve
h
Year
CO2 Gas Emission (kg/veh)
Better
National Award for “Excellence in Energy Management – 2016 20National Award for “Excellence in Energy Management” – 2016 20
Environmental Unique Feature
Sustaining environmental initiatives in HM3H
Green Technology –Fluidized Bed hanger
burning
Rain Water HarvestingSLF (Secured Land Fill)
for waste disposal
Green Manure
Generation for Guarding
Thinner Recovery SystemGreen Technology –ACED Paint Shop for Frame Body Painting
Green Compliance by
Incinerating paint sludge
Green Compliance by
treating water through ETP
11
National Award for “Excellence in Energy Management” – 2016 21
.
• .
• .
.
• .
• .
Environmental Promotional & Participation activities
Tree plantation activity to conserve environmentTree plantation activity to conserve environment
.
• .
• .
.
• .
• .
Number of Trees :- 8941
Green Park:- 25.75 acre
Green Roof:- 11.15 acre
Garden maintained by
Manure
Tree Plantation : Project -
"Laksh Vraksh" : To plant
One Lakh Trees
Hariyal iPhir Se –
Tree Plantation Initiative:-
Out side the plant 440
Tree planted
National Award for “Excellence in Energy Management – 2016 22National Award for “Excellence in Energy Management” – 2016 22
Energy Conservation
Efficiency
Improvement
Loss Reduction /
Elimination
Improvement/ Innovative Technology
Management Control
Energy Conservation Methodology based upon 4 major categories with scope
Sr.
No.Scope
1Using efficient
lighting LED/CFL
2Installing Efficient
Motor/Pumps
3
Compressor
Pressure
Optimizing
4
Reducing Pressure
Setting at Local
Machines
5Standardization of
Pneumatic fittings
Sr.
No.Scope
1 Power Factor
2Air Leakage
Arresting
3
Remote & Auto
systems for timely
switching off
4Removing Over
Rated Equipment
5Use of Transvector
Nozzles
Sr.
No.Scope
1 Renewable energy
2 Installation of VFD
3Install Regulators
and automatic valve
4
Using Local
compressor for Non
Working Day
5DC tools in place of
pneumatic
Sr.
No.Scope
1Online
Monitoring
2 Auditing
3Auto Timer
Control
4
Conservation
awareness
Programs
5Fortnightly
review
Methodology/ApproachResource Conservation
12
National Award for “Excellence in Energy Management – 2016 23National Award for “Excellence in Energy Management” – 2016 23
PLANT HEAD
HOD
PRODUCTION
ENGINEERING
SECTION HEAD
PRODUCTION HEAD
TEAM
MANAGER
HOD
QUALITY
ASSURANCE
SECTION HEAD
QUALITY ASSURANCE
TEAM
MANAGER
HOD
MAINTENANCE
( FACILITATOR)
RCT
LEADER/ENERGY MANAGER
TEAM
MANAGER
HOD
PRODUCTION
SECTION HEAD
PRODUCTION
TEAM
MANAGER
HOD
HUMAN
RESOURCE
SECTION HEAD
HUMAN RESOURCE
TEAM
MANAGER
Resource Conservation driven from Top management with involvement of all
sections employees
Resource Conservation CellResource ConservationF
OR
TN
IGH
TLY
RE
VIE
WM
ON
TH
LY R
EV
IEW
PLANT HEADPLANT HEAD
MANUFACTURING HEADMANUFACTURING HEAD
National Award for “Excellence in Energy Management” – 2016 24
Monitoring & Reporting Systems
DG online Monitoring System Substation online monitoring Auto KWH report Auto KWH report
Generation
Transformer online monitoring
Online Monitoring system deployed to identify and analyze Abnormalities
Resource conservation
project registration format
& sample calculationEnergy Monitoring Energy Monitoring
Format shop wise
13
National Award for “Excellence in Energy Management” – 2016 25
Benefits :
Before After
Solar Power Synchronization with existing Double Bus bar Panel to utilize the solar
power
Renewable Energy: 1MW Solar Power PlantRenewable Energy: 1MW Solar Power Plant
Power Utilization only through Grid Solar Power Utilization
Double Bus
Bar
( Grid/ DG)
Plant Load
132/11 KV
Transformer
HT Cable
Reduction of 1347 Tons of Co2 in Environment ( Considering 1412 MWH per year)
1. Utilization of natural solar power
2. Less maintenance activity
Double Bus
Bar
( Grid/ DG)
Plant Load415 V / 11 KV
Transformer
LT Cable
LT Cable
National Award for “Excellence in Energy Management” – 2016 26
Benefits :
Before After
Layout derived to accommodate the
system without compromising the
Green Roof
Total Energy saving cost of Rs 4.7 Lac/Year
1. Carbon Footprint Saving = 54 MT/Yr
2. Saving of 0.80 Lac Kwh/Year
Water heating through electrical
heaters
Renewable Energy: 5KLD Solar Hot Water Plant for CanteenRenewable Energy: 5KLD Solar Hot Water Plant for Canteen
14
National Award for “Excellence in Energy Management” – 2016 27
Projects Planned in next 3 Years
Sr.
No Description Year Resource UOM
Energy/
Resource
Saving Per
Year
Proposed
Savings in
Lac Rs.
1Street Lights -Sodium Vapor
conversion into LED lights.FY 16-17 Power KWH 96,000 5.0
2 Zero Liquid Discharge FY 16-17 Water KL 73 -
3
Solar Based 200 KW Power
Plant.(20% Expansion in
existing Capacity)
FY 17-18 Power KWH 255,000 12.8
4 Solar light installation. FY 17-18 Power KWH 102,000 5.0
5Solar Based Hot Water
Generating System.FY 18-19 Fuel Ton SCM 240 58.0
6Solar Based Cooking in
Canteen .FY 18-19 Fuel Ton SCM 30 7.2
Total Saving Expected - 88.0
Various projects are in pipeline in our journey to enhance renewable resource
utilization