welcome to presentation by rbei · 2018-09-13 · excellence in energy management @ rbei coimbatore...
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EXCELLENCE IN ENERGY MANAGEMENT @ RBEI COIMBATORE
WELCOME TO
PRESENTATION BY RBEI
Represented by
Mr. Ramesh R , Mr.Kandappan D, Mr.Magesh Kumar P 29.08.2018 , 30.08.2018 & 31.08.2018
Excellence in Energy Management @ RBEI/Coimbatore
Internal | RBEI/FCM-COB-SEZ | 09-08-2018
© Robert Bosch Engineering and Business Solutions Private Limited 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.2
Company Overview Bosch since 1886
Headquartered in Germany , operate in over 150 countries, 402,200 associates
Bosch Key business areas : Mobility solutions, Industrial technology, Consumer Goods and
Energy & Building technology
Bosch Business turn over ~ 73.1 billion Euros
Bosch in India : 9 legal entities, 31,330 employees
RBEI is the second largest engineering development centre outside Germany
RBEI turn over : 755 Million Euros, 19000+ associates, existence from 1998
Other RBEI locations: Vietnam and Mexico
E
Excellence in Energy Management @ RBEI/Coimbatore
Internal | RBEI/FCM-COB | 09-08-2018
© Robert Bosch Engineering and Business Solutions Private Limited 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.3
Design Features Plot area : 27.8 acres
Total Built-up Area : 52,858 sqm
Two office blocks + one canteen block cum office area + Utility block
Solar orientation of the buildings
Glazing: Wall to glazing ratio adopted, double glazing and low e-glass
Under deck insulation for the top floor ceiling
Day light harvesting on glazed area by providing light sensors
RCC roof-top solar panels
Floor space design (office area optimized at the center)
Excellence in Energy Management @ RBEI/Coimbatore
Internal | RBEI/FCM-COB-SEZ | 09-08-2018
© Robert Bosch Engineering and Business Solutions Private Limited 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.4
Objectives of Energy Management
Promote energy efficiency and conservation through the use of technology, managing the
natural resources in efficient and sustainable way
Aim at achieving excellence in EnMS system on continual basis considering environmental
impact by reducing carbon footprint
Periodical review of policy and its contents for adequacy
Establish energy objectives and programs
Support in cost effective energy management initiatives
Impart awareness on energy conservation and its impact on environment
Communicate to employees about adopting good energy habits
Excellence in Energy Management @ RBEI/Coimbatore
Internal | RBEI/FCM-COB-SEZ | 09-08-2018
© Robert Bosch Engineering and Business Solutions Private Limited 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.5
Specific Energy Consumption – Trend
89
5 6
Energy Consumption Pattern in 2017
TNEB (in %) DG (in %) RES (in %)
Specific Energy Consumption - Trend
Power
consumption
(in MWhr)
Area (in Sq.m)
SEC(kWhr/Sq.m/year)
2015 7915 47192 168
2016 8775 49087 179
2017 8417 49985 168
Energy Consumption - Trend
Year
Power
consumption
(in MWhr)
TNEB (in %) DG (in %) RES (in %)
2015 7915 84 12 4
2016 8775 87 7.4 5.6
2017 8417 89 5 6
168179
168
0
25
50
75
100
125
150
175
200
2015 2016 2017
kWhr/Sq.m/year
Excellence in Energy Management @ RBEI/Coimbatore
Internal | RBEI/FCM-COB-SEZ | 09-08-2018
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Specific Energy Consumption – Trend
Reasons for Variation
New building operation started in 2015 and stabilisation till beginning of 2017
Implementation of Encon projects
Increase in loading pattern due to business growth
Excellence in Energy Management @ RBEI/Coimbatore
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Information on National Benchmarking (BEE Standard)
0
25
50
75
100
125
150
175
200
2013 2014 2015 2016 2017
kWhr/Sq.m/year
2
3
4
5
1
Specific Energy Consumption (SEC)
YearPower consumption
(in MWhr)Area
(in Sq.m)SEC
(kWhr/Sq.m/year)Star
Rating
2013 5450 29021 188 1
2014 5571 29021 192 1
2015 7915 47192 168 2
2016 8775 49087 179 1
2017 8417 49985 168 2
Specific Energy Consumption (SEC) – Excluding Lab Area
YearPower consumption
(in MWhr) Area
(in Sq.m)SEC
(kWhr/Sq.m/year)Star
rating
2013 3028 26823 113 4
2014 3042 26443 115 4
2015 4353 43762 99 5
2016 4738 45140 105 4
2017 4419 46038 96 50
25
50
75
100
125
150
175
200
2013 2014 2015 2016 2017
kWhr/Sq.m/year
2
3
4
5
1
Excellence in Energy Management @ RBEI/Coimbatore
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Information on National Benchmarking (BEE Standard)
0
6
12
18
24
30
36
42
48
54
2013 2014 2015 2016 2017
AAhEPI (Whr/Hr/Sq.m)Specific Energy Consumption (SEC)
Year Power consumption (in MWhr)
Area (in Sq.m)
Total hours
AAhWhr (Whr/Hr/Sq.m
)Star
rating
2013 5450 29021 8760 21 5
2014 5571 29021 8760 22 5
2015 7915 47192 8760 19 5
2016 8775 49087 8784 20 5
2017 8417 49985 8760 19 5
13% Reduction in SEC from
2014 to 2017
Excellence in Energy Management @ RBEI/Coimbatore
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Bench Marking with other companies and within RBEI
Specific Energy Consumption (SEC) – 2017
LocationsPower consumption
(in MWhr)Area
(in Sq.m)SEC
(kWhr/Sq.m/year)Star
Rating
RBEI – KOR 7193 42721 168 2
RBEI-SEZ 8417 49985 168 2
Specific Energy Consumption (SEC) – 2017
LocationsPower consumption
(in MWhr) Area
(in Sq.m)SEC
(kWhr/Sq.m/year)Star
Rating
IBM 7945 42085 189 1
Benz 4053 24714 164 2
RBEI-SEZ 8417 49985 168 20
25
50
75
100
125
150
175
200
IBM Benz RBEI - SEZ
kWhr/Sq.m/year
1
2 2
0
25
50
75
100
125
150
175
200
RBEI - KOR RBEI - SEZ
kWhr/Sq.m/year
2 2
Excellence in Energy Management @ RBEI/Coimbatore
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Roadmap to achieve benchmark – By DesignSolar orientation,Low e-glass T-5 Fluorescent lamp
Low loss dry type transformer Energy saver for lighting
Occupancy sensor
Centralised BEMS
Excellence in Energy Management @ RBEI/Coimbatore
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Roadmap to achieve benchmark – By DesignHigh COP water chillers Pumps with VFD drives VAV controller for office area
Heat Recovery Wheel unit 2-way valves for AHUs Hydro-pneumatic pumps
Excellence in Energy Management @ RBEI/Coimbatore
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Roadmap to achieve benchmark – OperationEnergy Management System Harmonic Filters Thermography Test
Battery impedance test Awareness for Lab Users Lighting standard adherence
O&M procedures as per OEM
recommendations
Installation and de-
installation programs for
better efficiency
Excellence in Energy Management @ RBEI/Coimbatore
Internal | RBEI/FCM-COB-SEZ | 09-08-2018
© Robert Bosch Engineering and Business Solutions Private Limited 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.13
Energy saving projects implemented in 2015-16
Energy Saving ProjectsCost Benefit
in Million INR
Projector replacement with display units 0.08
Online Energy monitoring 0.10
LED street lights 0.10
VFD Provision for chiller condenser pumps 0.07
Free Cooling during night hour operation 0.24
APFC panel operation automation through PLCNon
quantifiable
DG sets conventional radiator replacement with
coil cooler0.68
Units saving - 64445
Cost saving - 1.26 MINR
Excellence in Energy Management @ RBEI/Coimbatore
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Energy saving projects implemented in 2016-17
Energy Saving ProjectsCost Benefit
in Million INR
140kW solar PV system installed at Phase2
building1.82
115nos of street lights(150W) replaced with
LED(40W)0.52
Lab AC units capacity optimization 0.30
Projector replacement with display units 0.02
Air Compressors capacity optimization 0.01
Units saving - 283418
Cost saving - 2.66 MINR
Excellence in Energy Management @ RBEI/Coimbatore
Internal | RBEI/FCM-COB-SEZ | 09-08-2018
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Energy saving projects implemented in 2017-18
Energy Saving ProjectsCost Benefit
in Million INR
UPS optimization at Cob 101 Building (from
900kVA to 600kVA)0.15
Cooling tower replacement 0.06
Cob SEZ 101 Atrium AC refurbishment 0.16
15kW solar mill (hybrid system of solar and wind) 0.16
1000kVA MD reduction 2.52
BMS upgradation and integration at SEZNon
quantifiable
Units saving - 361227
Cost saving - 5.91 MINR
Excellence in Energy Management @ RBEI/Coimbatore
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Innovative project - 1HVAC system redesign – Primary variable flow system
Background
Energy loss at PHE due to inefficiency of Brine and TES system
Unbalanced cooling effect
Not able to achieve design performance
Increased Hot spots at work area and lab
Energy saving potential in HVAC system
Source of Idea
Data analysis of HVAC system
Internal energy workshop
Excellence in Energy Management @ RBEI/Coimbatore
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HVAC system redesign – Primary variable flow system
Solution
Isolation of PHE and TES
Conversion of brine to chilled water system with variable
primary flow
Benefits
Annual energy saving of 163324 units
Maintenance of design temperature at work area
Design performance improvement in HVAC system
Improvement in chiller COP by 10% (4.8 to 5.2)
CO2 emission reduction of 114 Tonnes / annum
Excellence in Energy Management @ RBEI/Coimbatore
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Energy Saving / Annum : 163324 kWh
Cost Saving / Annum : 1.54 MINR
Investment cost : 3.0 MINR
Payback Period : 1.94 Year
HVAC system redesign – Primary variable flow system
0
2000
4000
6000
8000
Before After
6375 6205
2182 2134
Chiller consumption / Day (kWh)
Working Day Non Working Day
0
1000
2000
3000
Before After
28322430
582 508
Pump panel consumption / Day (kWh)
Working Day Non Working Day
0
5000
10000
15000
Before After
13995 13420
3916 3797
Overall HVAC consumption / Day (kWh)
Working Day Non Working Day
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HVAC system redesign – Primary variable flow system
Excellence in Energy Management @ RBEI/Coimbatore
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Innovative project - 2AHU Blower replacement with EC fans
Background
Energy saving potential in HVAC system
Technology upgradation with precise control
Source of Idea
Acrex Hall of Fame exhibition in 2017
Solution
Replacement of existing AHU blower with EC fans
Excellence in Energy Management @ RBEI/Coimbatore
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AHU Blower replacement with EC fans
Benefits
Annual energy saving of 87703 units
Less spare maintenance / Inventory & less noise
Better operational control with in-built microprocessor
technology
Replication Potential
Rest room Exhaust & ventilation system – implemented in 2018
HRW system – under progress
Fan coil units & Ceiling suspended units
Can be adopted in new and existing firms
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Innovative project - 3Standalone Ac units optimization with VRF and inverter units
Background
Decision of phasing out of R22 refrigerant
Energy saving potential in HVAC system
Source of Idea
Internal energy workshop
Management initiative to phase out of high ODP refrigerants
Solution
Replacement of R22 with less ODP R-410a refrigerant
Enhancement of technology with inverter compressor
Load based optimization of Ac units capacity
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Standalone Ac units optimization with VRF and inverter units
Benefits
Annual energy saving of 68100 units
Increase in system efficiency
Go Green concept - Usage of less ODP refrigerant
Optimization of Ac units from 237.5TR to 205TR
Replication Potential
Can be adopted in new and existing firms
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Renewable Energy sources – Solar PV system
Year 2015 2016 2017
Total Capacity (in kWh) 215 355 367
Total Investment (in Million INR)
21 31.5 32.9
Generation / Annum (in kWh) 316855 493552 512646
Annual cost saving (in Million INR)
2.85 4.44 4.61
Return of Investment(in Months)
88 85 86
CO2 Emission Reduction (in Tons/year)
222 346 359
6.09% of renewable energy
on total energy
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Renewable Energy sources – Solar PV system
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Renewable Energy sources - Solar Mill (Hybrid system of solar and wind)
Installed capacity : 15 kW
(solar 12kW + wind 3kW)
Investment : 1.4 MINR*
Benefits
Production per annum : 17100 units
Annual cost saving : 0.16 MINR
Payback period : 105 months
* MINR – Million INR
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Renewable Energy sources - Solar Thermal Energy
Benefits
Annual energy saving : 23400 units
Annual cost saving : 0.2 MINR
Pay back period : 69 months
Hot water used for dish washing
* MINR – Million INR
Installed capacity : 2 x 2500 Ltrs
Investment : 1.2 MINR*
Old system replacement with solar assisted
heat pump
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Utilization of waste as fuel – Bio gas plant
Year 2015 2016 2017
Quantity of waste as fuel used
(MT/Year)
1.8 1.6 1.7
Waste as Fuel in % of Total
Energy Used
26 23.5 25
Installed capacity : 50 Kg
Investment : 0.2 MINR*
Annual cost saving : 0.3 MINR
Utilisation of food wastage
Bio gas plant - 400Kg is completed in 2018
* MINR – Million INR
New Biogas plant – 400 Kg
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Commitment towards Environment – GHG Inventorisation
Bosch has set itself the following target
values to improve our performance in
environment protection.
o Reduction of relative CO2 emissions by
15% by 2012 (based on 2010)
o Reduction of relative CO2 emissions by
35% by 2020 (based on 2010)
Published in Bosch worldwide news letters
(internal) and forums like CII, IOD, etc.,
111
68
43
75
81 7970
0
20
40
60
80
100
120
2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020
To
ns
CO
2/M
io E
UR
Year
Relative CO2 emission
Target: 202072 Tons CO2
/Mio EUR
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Best practices implemented on energy front in Green supply chain
Utilization of renewable energy
Bio Gas plant
Turbo ventilator for waste yard
Under deck insulation for the top floor ceiling
Thermal & weather proof coating for roof top
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Team work, Employee Involvement & MonitoringDaily Monitoring system and Review
Logs and Trends update, Standard Operating Procedures
Abnormality tracker and History card system
Equipment efficiency mapping
Preventive, corrective and predictive maintenance reports
Daily engineering report and Monthly status report
Review Meeting - chaired by Energy Manager
Top management involvement in Encon
Separate Encon budget allotment for every year
Year 2015 2016 2017
Encon Budget (in MINR)
15.8 17.9 40.8
* MINR – Million INR
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Team work, Employee Involvement & Monitoring
Energy Efficiency / Awareness Training
Energy workshops with technicians
Associate Engagement through various activities
CIP meetings & Brainstorming session
Knowledge transfer from SME’s
In house & external training
Awareness on energy base line
Rewards & motivational programs
0.07% investment on turnover
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Environmental projects
Waste management - segregation at source
Sludge de-watering system and drying bed for STP
Grease trap system for canteen drainage
Introduction of BS IV & ARAI standards for company
transport vehicles
Fuel consumption tracking for all company vehicle
CFC & HCFC free eco friendly refrigerant for Chilling Units
Rainwater harvesting system for Government schools
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Environmental projects Afforestation drive (6000+ tree saplings) around the city
Drive for the conservation of Slender Loris at Coimbatore
and Dindigul
Environmental awareness program for school kids
through “Kovai Green League”
2000+ Volunteering hours have been spent on Swachh
Bharat mission
Implementation of car pooling concept among associates
Restoration of lake at Chinnavedampatty, Coimbatore
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Go Green concept with more green cover
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Way Forward
5 Star Rating by 2020
12% of total consumption from renewable energy source
• Increase in capacity of solar PV system
• Solar car parking
ISO 50001 implementation
Reduction in lab consumption
Reduction in losses through BEMS system analysis
LED Lightings in office area
Purchase of green power
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Awards, Acknowledgements & Achievements
CII awarded “4 star” rating for the commitment in
EHS practices in 2014
CII awarded “Excellent Energy Efficient Building”
for the excellence in Energy Management 2015
IOD awarded “Golden Peacock Environment
Management Award 2016”
CII awarded “Excellent Energy Efficient Building”
for the excellence in Energy Management 2016
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Awards, Acknowledgements & Achievements
Acknowledgement by Coimbatore City Municipal
Corporation for all the initiatives towards “Cleaner and
Greener Coimbatore” in 2017
Acknowledgement by Coimbatore City Municipal
Corporation for campaigning and segregation of waste
at source – towards “Zero waste ward” in 2018
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S e v e n B i l l i o n d r e a m s , O n e P l a n e t
C o n s u m e w i t h c a r e