a
8 / 3 0 / 2 0 1 8
CII National Award for Excellence in
Energy Management 2018
EICHER TRUCKS & BUSES, PITHAMPUR
Manish Kandu Upendra ShrivastavaSanjay Dangi
2
To be recognized as the industry leader driving modernization in
commercial transportation in India and the developing world
VECV (A Volvo group & EICHER Motors joint venture) - VISION
3
TRUCKS, BUSES AND ENGINES
Eicher Trucks and Buses
EICHER ENGINEERING COMPONENTS
Volvo Trucks
Bus Body andApplication Manufacturing
Engines
VECV Business Areas
Methodology for Energy Conservation
At VE Commercial Vehicles we follow Volvo Production System It has 10 Management & 11 Technical Pillar Environment Pillar aims to Green manufacturing approach
Envi
ron
me
nt
6
VPS Environment Pillar aims to Green manufacturing approach..
Waste
reduction and
management
World class
energy
efficiency
Water
conservation
GHG
mitigation
Material
ConservationGreener
Supply chains
Renewable
energy
Product
Stewardship/
Toxicity
Going Green…
Countermeasures
Selection of areas (perspective) : Based
on highest power consumption
Identification of possible solutions for reduction of energy lossses (7 kinds)
Investigation Measurement Analysis
Standardization Horizontal Expansion
Step 2 Step 3 Step 4
Step 5 Step 6 Step 7
Production process analysis on Energy perspective
Measure Energy Consumption and losses
Done countermeasure projects for energy conservation
- Projects results measurement
- Training programs
Horizontal deplyoment of project for same type of losses at plant level
Identification
Step 1
The 7 step approach for energy conservation
VPS -Environment Pillar Methodology for Energy Conservation
Energy conservation Methodology – EnCon project : Heat Pump instead of electrical water heaters
Analysis Root Cause
30kWt Heat pump installed on Differential washing machine ( 2016-17)& saving potential per annum :1.27 MINR.
Identification Investigation Measurement
Countermeasures Standardization Horizontal Expansion
Washing machine uses hot washing fluid to
clean parts , hot fluid temp. maintained by
heating electrical heaters
Electrical heaters uses 1 kW electrical power for 1 kW heat output
Electrical heaters are inefficient & takes
more power to convert hot water
Energy Efficient Heat pumps can be used for washing fluid heating
Step 1 Step 2 Step 3 Step 4
Step 5 Step 6 Step 7
As Horizontal deployment 3nos. X 65 kW Heat Pumps
are installed on balance machines (2017-18)
Additional saving potential:
5.3 MINR/annum
9
Energy Consumption per unit of production
KPI 2014-15 2015-16 2016-17 2017-18Target
2018-19Benchmarking
Variable power (KWh/Vehicle)
576 518 459 460 450995 (Nearest competitor)
Water (m3/Vehicle)
8.57 8.28 6.45 6.15 6.12 NA
LNG(mMBTU/Vehicle)
1.32 1.22 0.97 0.98 0.95 2.2 Durr (OEM)
Specific Energy consumption & Benchmarking
• Overall Sp. Energy consumption is on decreasing trend .• 2017-18 power consumption increased due to new projects trials (Engine
test bed, BIW line, new ware house , paint shop capacity expansion ).
Benchmarking data not available
BenchmarkingkWh/vehicle
* All benchmarking data taken from CII presentation
0
1000
2000
3000
4000
5000
6000
7000
8000
2014-15 2015-16 2016-17 2017-18
10
42
96
3
99
5
57
6
51
8
45
9
47
5
Global
National
VECV
RemarkBenchmarking is very difficult as plant to plant process, product, outsourcing is different.
Energy Conservation Projects - Zero fund investment projects (2015-18)
SN Title of Project YearAnnual Electrical Saving (kWh)
Total Annual Savings(Rs million)
1Robotic Paint booth- re-program VFD for blower & install VFD on pump.
2015- 16 66154 0.43
2Manuel switching off( air cooler, lights, fans etc)
2015- 16 147692 0.96
3 Hydel Power purchase 2016- 17 0 1.05
4Manual switching off( air cooler, lights, fans etc)
2016- 17 23503 0.15
5Operation of process pumps & fans linked with position of cabin into their zone.
2017- 18 158571 1.11
6Spot repair machine frequency optimized from 50Hz to 40Hz during non working time
2017- 18 172857 1.21
Energy Conservation Projects - Zero fund investment projects (2015-18)
SN Title of Project YearAnnual Electrical Saving (kWh)
Total Annual Savings(Rs million)
7ASU on/off controlled by a real time timer & shut off during non-working hours
2017-18 205714 1.44
8
Work deck ASU speed control with temperature & humidity in Day/night. (Consider 4 hr motors run in 50% frequency so 232+200 units will be saved)
2017-18 121429 0.85
9
Optimization of Top coat Booth ASU supply & Exhaust blowers running interlock with cabin sensing. ( 132 Kw -02 blowers will be saved at least 03 hr at low frequency)
2017-18 58571 0.41
10Manual switching off( air cooler, lights, fans etc)
2017-18 99785 0.7
Energy Conservation Projects - Zero fund investment projects (2015-18)
SN Title of Project YearAnnual Electrical Saving (kWh)
Total Annual Savings(Rs million)
11 Hydel Power purchase 2017-18 0 2.15
12Sealer oven circ. Fan frequency optimized from 50Hz to 25Hz during Post Purge Time.
2017-18 1080 0.008
13ASRS Lighting on/off controlled by a real time timer & shut off during Day Time.
2017-18 42000 0.3
14Zero investment EnCon project -Thermal
2017-18 88 mMBTU 0.068
Total Electrical Energy Savings (MWh) 1097
Total Thermal Energy Savings (mMBTU) 88
Total Cost Savings (MINR) 11
Zero fund investment projects (2015 -18) - Highlights
SN Other Energy conservation projects Annual Savings
MWh MINR
1Operation of process pumps & fanslinked with position of cabin intotheir zone.
159 1.11
2Spot repair machine frequencyoptimized from 50Hz to 40Hzduring non working time
17 1.21
3ASU on/off controlled by a realtime timer & shut off during non-working hours
206 1.44
9Robotic Paint booth- re-program VFD for blower
66.15 0.43
Frequency 50Hz Frequency 40Hz
Throttled v/v
Full open v/v
Zero fund investment projects (2015 -18) - Highlights
SN Other Energy conservation projects Annual Savings
MWh MINR
4All process dip tanks level reduceby 200 mm in depth & saved LNGas heat load reduced
88 mMBTU/annum
0.79 MINR/annum
5Sealer oven circ. Fan frequencyoptimized from 50Hz to 25Hz during Post Purge Time.
1.08 0.008
6Working area ASU fan frequencyoptimized at low frequencyaccording temperature.
121 0.85
7Top coat ASU & Exhaust FanFrequency optimized from 50 HZ to25 Hz at break time .
59 0.41
Before After
Zero fund investment projects (2015 -18) - Highlights
SN Other Energy conservation projects Annual Savings
MWh MINR
8ASRS Lighting on/off controlledby a real time timer & shut offduring Day Time.
42 0.3
10Manual switching off ( air cooler, lights, fans etc.)
271 1.81
11Hydel Power purchase (2016-17to 2017-18)
- 3.2
Total saving (zero investment projects) 11 MINR
Hydel Power
List – Funded Energy Conservation projects (2015 -18) -
SN Title of ProjectAnnual Savings Investment
Kwh MINR MINR
1Plant cooling tower (10 nos.) fan operation -control by temp. controller
143590 0.93 0.056
2Replacement of conventional lights by energy efficient LED lights
147692 0.96 1.26
3 Automation in street lights 43446 0.28 0.035
4EDC Utilities- Cooling tower pipe line modification & pumps interlocking
446154 2.90 0.14
5 Arrest compressed air leakages in plant 258462 1.68 0.12
6 VFD installed in 1000 cfm compressor 125538 0.82 0.025
7Engine test Beds-Integration of exhaust blower with engine test cycle
25846 0.17 0.05
8Automation in ADU ( air dryer units ) at shop floor
153231 1.00 0.14
9VFD installed in 200 cfm compressor at Paint shop
27692 0.18 0.3
List – Funded Energy Conservation projects (2015 -18)
SN Title of ProjectAnnual Savings Investment
Kwh MINR MINR
10 Machine shop Air Line Separation 332308 2.16 0.25
11Heat recovery system for ED oven in paint shop- LNG saving
3961 mMBTU 2.16 2.4
12Energy conservation by VFD installation on paint shop pumps & compressor
20769 1.62 0.48
13HVAC booth pump replaced ( 0.75 kw to 0.37 KW,6 nos)
1538 0.12 0.03
14Plant LED Light conversion Total 3184 nos. LED lights installed
582335 5.89 6.47
15Energy conservation by VFD installation on plant pumps, compressor & blowers as horizontal implementation of energy savings
22106 1.72 1.12
16 Heat Pump in Axle line washing machine 15385 1.20 1.18
17 Compressor Automation 23077 1.80 0.35
List – Funded Energy Conservation projects (2015 -18)
SN Title of ProjectAnnual Savings Investment
Kwh MINR MINR
18 AC convertor at Reliability lab Air conditioner 209 0.02 0.02
19 Helical Pump on bore well no. 06 1282 0.10 0.1
20Heat recovery system for Top coat oven in paint shop- LNG saving
1971 mMBTU 3.00 2.4
21Energy conservation by VFD installation on paint shop pumps & compressor
231429 1.62 0.48
22Energy efficient Air cooler at CMS2 building –78 nos.
485714 3.40 5
23Modification in pneumatic valve actuation system
36285 0.25 0.036
24Heat Pump in Axle line washing machine phase-2
575714 1.69 3.35
25 Plant LED light conversion 467286 3.27 2.934
List – Funded Energy Conservation projects (2015 -18)
SN Title of ProjectAnnual Savings Investment
Kwh MINR MINR
26 Flux maxiox system on Oven LNG pipeline 929 mMBTU 0.72 0.45
27 30 kVA Solar plant at CMS2 44902 0.31 1.5
Total Electrical Energy Savings (MWh) 4518 MWh
Total Thermal Energy Savings (mMBTU) 6861 mMBTU
Total Cost Savings (MINR) 40.0 MINR
EnCon. Project Description
SavingPotential/annum
Investment
kWh MINR MINR
Energy efficientheatingHigh COP Heat Pump onAxle washing machineeliminated electricalheating (225 kWt)
757142 5.3 8.42
Energy efficient helicalpump for bore well11.2 kWh centrifugalpump replaced by Helicalpump 3.7 kWh
14285 0.1 0.1
Compressor operation automation to eliminate unloading hours
23077 1.8 0.35
Funded Energy Conservation Projects (2015-18) - Highlights
Helical rotor
Automation to control
unload power
Specialized supervisory to monitor and
control compressors
operation
(Heat PumpTotal : 4 nos.)
Funded Energy Conservation Projects (2015-18) - Highlights
EnCon. Project Description
SavingPotential/annum
Investment
kWh MINR MINR
Variable Frequency Drives : All the motors above 5.5 KW are now operated through VFD
630372 4.33 1.92
LED lights3876 conventionallights replaced byenergy efficient LEDlights Phase 1 to 4(2015-16 to 2017-18)
1197313 10.1 10.6
Power reduction Per fixture :- 250W to 80W - 36W to 18W etc
250 W
36 W 18 W
80 W
EnCon. Project Description
SavingPotential/annum
Invest-ment
kWh MINR MINR
Modification in pneumaticvalve actuation systemAt CED paint shop,compressor is nowswitched –off during nonworking hours
36285 0.254 0.036
High COP heat pump eliminated electrical heating for dish washer at canteen
20000 0.14 0.3
AC converter operatestwo air conditioners withone out door unit 1857 0.013 0.024
Funded Energy Conservation Projects (2015-18) - Highlights
Bypass line with valve
stop compressor
running during non
working hours
Canteen heat pump system
Before After
EnCon. Project Description
SavingPotential/annum
Investment
kWh MINR MINR
Solar hybrid ACHybrid AC made of Solarcollectors which superheatsthe refrigerant & therebyreduce energy use
9072 0.063 0.165
Air cooler at CMS2 building Evaporative air cooler has high efficiency then Centralized cooling system (ASU)
485714 3.4 5
LED lights installations in2018-19 YTD total 275 nos.In all new projects installed LEDoverhead & process Tube lights
248271 1.74 1.95
Funded Energy Conservation Projects (2015-18) - Highlights
Evaporative Air Cooler 10K CMH @1.1 kWh
LED light installed in plant also improves lux level
EnCon. Project Description
SavingPotential/annum
Investment
kWh MINR MINR
Nano-fluid for compressorUse of POLYTRON MTC – OilAdditive into compressor toimprove compressor efficiency
27648 0.19 0.045
Nano-fluid for chiller – (water)Improvement in heat transferby use of Nano fluid(Hydromx) at Cab weldcooling system
35714 0.25 0.51
Variable Refrigerant flowA/Cinstalled energy efficient VRFAC instead of DX AC unit atnew ME office
37706 0.26 1.5
Funded Energy Conservation Projects (2015-18) - Highlights
VRF A/C Unit
Polytron MTC to Comp. oil
EnCon. Project Description
SavingPotential/annum Investment
kWh MINR MINR
Compressor Heat Recoverysystem Successfully installedheat recovery system oncompressor to generate hotwater from exhaust hot air &reuse at washing m/c
312840 2.19 2.3
Indoor nature switch forhighbay lights Successfullytrail taken of in-door luxsensor for gangway lights(24nos.), Automatic switch on atlow lux level & Automaticswitch off at required lux level
2304 0.016 0.0165
Energy Conservation Projects (2015-18) - Highlights
Light Control by Nature Switch
EnCon. Project DescriptionSavingPotential/annum
Investment
LNG conservation byReuse of waste heat byheat pipe on ED & Topcoat Oven at CED Paintshop
5799
mMBTU
5.04
MINR
4.8
MINR
Burner efficiencyimprovement bystreamlining LNG flow atCED Paint shop
929
mMBTU
0.7
MINR
0.45 MINR
Hot exhaust air for HWGCompressor exhaust use on Hot water generator to preheat the suction air before combustion
639.36
mMBTU
0.53
MINR
0.023MINR
LNG molecules gap increases after passes through flux maxiox device
Funded Energy Conservation Projects (2015-18) - Highlights
Heat Recovery system
Other Process improvement projectsSavingPotential/annam
Investment
LT Room energy meterInstallation Installedefficient & commonenergy meter at main LTroom for effective powermonitoring
It improves right data
collection with same type of
energy meter which is also
compatible to automatically
send data remotely
Day light harvesting210 nos. roof sheets arereplaced by transparentpoly carbonate sheets
171429
kWh
1.2
MINR
1.17
MINR
Compressed air leakagearresting Continuously airleakage arresting done atplant & reported monthlybasis
24576
kWh
0.17
MINR
0.038MINR
Funded Energy Conservation Projects (2015-18) - Highlights
Old to new
Funded Energy Conservation Projects (2015-18)
SNEnCon Projects
(2015-16 to 2017-18)Savings/annum Investment
MWh mMBTU MINR MINR
1 Zero fund investment project 1097 88 10.81 0
2 ROI < 1 year 2654 2900 25.32 10.37
3 ROI > 1 year 1864 3961 14.68 20.30
Total savings 2015-16 to 2017-18
5615 6949 50.81 30.67
CO2 emmission reduction 5329 tons
29
Results
Savings – by heaters elimination Investment Other savings
312 Mwh/annum2.19
MINR/annum2.3 MINR
Reduction in hot air exhaust Compressor cooling improves
Innovation project 1: Hot water generation by Compressor waste heat
Before – Compressor heat exhausted to Ambient
Compressor 72% of energy (hot air)exhausted to atmosphere , for compressedair generation & Compressor cooling
Oil
hea
t re
ject
ed
to A
mb
ien
t
After – Hot water by Compressor exhaust
Exhausted heat recovered by “CompressorHeat Recovery System” & used to washingm/c for washing fluid heating
Schematic “Compressor heat recovery system” Eliminated
washing m/c fluid heaters
Methodology: Brainstorming , VPS 7 step approach
30
Innovation project 1: Hot water generation by Compressor waste heat
• Washing machine using hot water generated from
“compressor heat recovery system” to heat up washing fluid
• Electrical heaters switched off & used as standby
Engine line Washing machine Compressor heat recovery system
Water
Water
Hot
Cold
Compressor
Heat Exchange system
In Future same EnCon activity horizontally deploy on other compressor & use recovered heat at paint shop/Canteen etc.
31
Results
Savings Investment
892 MWh/annum10 MINR/annum 0.128 MINR
6048 mMBTU/annum
Innovation project 2 : Dip Skid Commonization for PT-CED & Ro-Dip process
Before – Different skid for diff. model
Old skid with adaptor plates, need touse adaptors for diff. cab model & takesfitment time
After – Common skid for diff. models
Common skid for 12 different models,eliminate the adaptor plates fitmenttimes, & Saving of 3.5 min in each cycle
32
Existing System/Current Mechanism – CED Paint shopLD Legacy & 2.0 m upgrade Cabin
No Adapter
HD Legacy Cabin
No Adapter
2.1 m Condor – Day
2.1 m Condor – Sleeper
2.3 m Condor – Day
2.3 m Condor – Sleeper
LD Face Cowl
MAV cowl
VE 5100 MAV cowl
Approx. weight of Adaptors 40 Kg
33
Uniqueness & Creativity Content 12 Different models can be accommodated on single skid without any adapter.
Accurate Interfacing in skid exchange from cab weld to Dip skid & dip skid to paint skid .
Smooth interfacing of modified dip skid with Ro dip system in PT/CED process where cabin rotate with skid in high byoncey force and eliminate chance of cabin & adapter falling inside the tanks.
Prove out dip skid performance in all chemicals / Paint / Oven high temperature.
3
3
Old Skid with Adapter Plates New Modified Dip Skid
34
Results
Savings Investment
326 MWh/annum 2.4 MINR/annum ZERO
Innovation project 3 : CED Paint shop – Booth ASU & Exhaust blower optimization
Before – Blowers running continue After– Optimization Blowers running
Booth ASU & Exhaust interlock with cabinpresence sensor during running production.In case of cabin absence supply & exhaust fan willrun @ 25 (Hz) frequency .Horizontal deployment in Axle & Engine booth.
Booth ASU & Exhaust running continue @ 50 Hz.System runs continue irrespective of cabinavailability.Daily cumulative (small slots) approx. 4 hr idlerunning including break hours.
25HZ
25HZ
50HZ
50HZ
35
Results
Savings Investment
148 MWh/annum 1.06 MINR/annum ZERO
Innovation project 4 : Cab weld– Chiller running optimization
Before : Chiller running continues After– Optimization of Chiller running hrs.
60 TR chiller & 90TR cooling tower required for maintain spot welding guns temp i.e. 20 to 25 deg.
Both system were continues run in all 03 shifts round the year.
During winter & Rainy season desired tempcan be achieved only by cooling tower.
Additional demister filter introduced toimprove circulation water quality.
06-08 months chiller power saved
36
Energy management structure
Energy Conservation Cell
Plant head
Energy Manager(Pillar owner)
Co
re T
eam
Pillar coordinator
Plant maintenance
FinancePaint shop
HR Safety Utility
Sup
po
rt
Team
Cabin group( Cab weld - Paint
shop)
TEAM group(Transmission-Engine-
Axle-Machine)
TCF group( Trim- Chassis-
Final)
Energy Monitoring Smart Sense+ meters
Total Energy
Fixed CostVariable Cost
Line wise Area wise
Energy Recording & Monitoring
Electrical Power Head
• Energy Consumption per annum trend
Energy Recording & Monitoring
Electrical Energy consumption –(GWh)
Thermal Energy (LNG) consumption –(mMBTU)
• Power consumption increasing year by year with increase in production volume but specific power consumption in decreasing trend as shown earlier
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
0
10000
20000
30000
40000
50000
60000
70000
80000
Energy Recording & Monitoring
Monthly Power data monitoring
Separate monitoring on Sunday/non-production day power consumptions
40
Energy saving Budget allocation
Comparison with Energy saving budget allocation
Description 2014-15 2015-16 2016-17 2017-18 2018-19
Budget (MINR) 2.6 3 33 10 48
Power bill (MINR) 241 269 214 269 306
Budget (%) 1.08% 1.12% 15.42% 3.72% 15.6%
More then 3% provision for energy conservation projects last & current year of total energy bill.
Projects recommended by energy management cell & approved by FI (finance) pillar are
funded through this budget.
* Present year budget includes special sanction of 38 MINR for 1 MW roof top solar plant
Employee envolvement - People Development Process
PEOPLE DEVELOPMENT
People involvement to ensure continual improvement organization.
• Stringent recruitment process w.r.t. category wise eligibility.
• PACT – Permanent and company trainee
• Permanent• Apprentice (APP)• Technical
operation trainee (TOT)
• Indo – German Tool Room Trainee (IGTR)
1
• Induction training of newly joined operator followed by assessment.
• Classroom training• Hands on training - OJT
• WCQ and VPS training of existing workforce
2
34• Team and individual recognition for morale.
• Best Managed Shop competition to enable competitive spirit among teams
Employee envolvement – Detailed practical training
11 SystemsDetailed Practical Training
10 Standard Documents - Detailed
Practical Training
Awards & ISO Certifications
“GreenCo Bronze Rating”
ISO 50001
LEED Certification
for VECV
Headquarters @ Gurgaon
One of the top 50Platinum
rated green buildings in India
“National Energy management award 2017”
ISO 14001
2013-14
Option Evaluation• Bio Mass• Mini Hydel• Solar
2014-15 & 2015-16• Solar Power Purchase 17 GWh
• Roof top solar 10 kWp
• Solar Pump 5 kWp
• Solar hybrid air conditioners
2016-17 & 2017-18
• Total Solar Power Purchase 27 GWh
• Roof top solar 50 kWp new installation
Renewable Power & percent share
2014-15 2015-16
29.58% 38.48%
2016-17
45 %
2017-18
45 %
Projects implemented to reduce hazardous waste generation
Use of waste as Alternate Fuel/Raw Material
SN
Details of Project Year% of waste disposed as alternate fuel /
raw material
1Exhaust fumes of ED oven reused as fuel & preheat the oven fresh air
2015Total 2485 mMBTU LNG as fuel saved &
total 2.16 MINR cost savings achieved
2Exhaust fumes of Top coat oven reused as fuel & preheat the oven fresh air
2016Total 3314 mMBTU LNG as fuel saved &
total 2.88 MINR cost savings achieved
3 Solvent recycling 2016 100% used solvent recycling
4 Food waste conversion in compost 2016 20% Food waste conversion into manure
5M/C shop washing m/c filter paper Reuse Of Filter Press cloths
2017100% filter clothes are reused for chips segregation.
6Use of compressor waste heat as fuel to generate hot water for axle line
2017
Total 312840 Kwh electricity &
Total 2.19 MINR cost savings per annum
generated
Utilization of Waste as Energy source
48
GHG Emission inventorization
Scope Unit 2014-2015 2015-2016 2016-2017 2017-18
Scope 1tCO2e / Annum 42539 39499 43222 57535
tCO2e / per eq. vehicle 1.03 0.79 0.86 0.88
Scope 2tCO2e / Annum 21341149 23355043 18746926 24710441
tCO2e / per eq. vehicle 517.29 465.85 373.15 376.88
Scope 3tCO2e / Annum 4377 4804 5839 7696
tCO2e / per eq. vehicle 0.11 0.10 0.12 0.12
Total Scope 1, 2 & 3
tCO2e / Annum 21388065 23399345 18795657 24775672
tCO2e / per eq. vehicle 518 467 374 378
FUEL COMBUSTION
GHG emission Sustained this year due to multiple projects and new products trial Overall 3 year GHG emission in reducing trend
49
GHG Emission inventorization
Scope 2016-2018 2018-2020
Scope 1
Installation of heat recovery in paint shop –Completed
Installation of flux maxiox device for LNG reduction
2 to 5 % reduction
Sealer oven elimination by process layout modification.
Scope 2
33 % Solar Power Purchase of total energy consumption - achieved
14 % Hydel Power Purchase of total energy consumption - achieved
Installed 50 KW roof top solar plant in CMS2
Install 1MW roof top solar plant
Day light harvesting (light pipe)
Scope 3
Haz. waste disposal alternate location started.
Inward Logistics - Premium flight reduction 10 %
Trip Reduction by introducing bigger size of vehicle for local delivery
10 to 20 % Reduction GHG
Green supply chain
EEC– Dewas1. LED lights into expansion shed of plant2. Air cooler to replace air conditioner in Gear grinding m/c3. VFD at compressor4. Energy on ventilation system5. Installation of energy efficient VRF air conditioning system
As green supply chain energy conservation initiatives done at supplier end
EEC - Thane 1. Improvement in lighting system by
LED lights conversion
VEPDC - Pithampur1. Plant LED Lights conversion2. Installation of energy efficient VRF
air conditioning system3. Air cooling of training room & rest
area at place of air conditioning.
Vehicle dispatch :1. Centralized Vehicle distribution
center created from Pithampur to save transportation fuel & energy
Other suppliers - Pithampur1. Improvement in lighting system
by LED lights conversion of process & street lights
51
Water conservation
• Water consumption increasing year by year with increase in production volume but specific water consumption in decreasing trend
7.06
8.57 8.28
6.45 6.15
0.001.002.003.004.005.006.007.008.009.00
SWC - Kl/vehicle
Kl/vehicle
288186
353407
417000
365206403134
0
50000
100000
150000
200000
250000
300000
350000
400000
450000
Water Consumption (kL)
WaterConsumption(kL)
52
Water sustainability• For continues water availability in plant COMPREHENSIVE GROUNDWATER
ASSESMENT FOR SUSTAINABILITY STUDIES conducted for ETB plant • In assessment done the Geophysical Investigations, Hydro-geological studies, Study of
Geomorphology, and Land use & recommended to recharge ground water
Water recharging points created for water sustainability Done in Sep’17
Water conservation
Existing Water Extracting Points at plant (Bore wells 09 nos.)
53
Water conservation
Rain water harvesting done to sustain ground water table at 18 locations
2016-17 : Water purchased from outside of 6.8 MINR through tankers.
2017-18- NIL water purchasing
Water Con. projects
Water Con. Project Description
SavingPotential/annum
Investment
Kilo Liter MINR MINR
Utilization of RO waste water by installation of secondary RO on reject water line
7200 0.30 0.6
Eliminate wastages and reuse DM water in process
7839 0.32 0.1
Use of ETP treated water to process 60000 0.6 0.1
Water Con. projects
Water Con. Project Description
SavingPotential/annum
Kilo Liter MINR
Water taps aerator installed to reduce water consumption(It gives 40% water savings)Water consumption reduced from 7 lpm to 4 lpm
1764 0.073
Digital Water level sensor at main pump house water tank to stop water overflow & safe water level monitoring
5.5 0.0002
Use of Eco friendly chemical to conserve water (CORN BASED POLYMER FORMING CHEMICAL)
360 0.015
Manual water level indicator
Digital water level indicator & water consumption totalizer
Water Conservation
Usage of ETP treated water for gardening – step towards zero discharge
Green belt at Plant by
use of ETP water
Design initiatives for energy conservation
• Skylights in shop floor for natural lighting to save energy in day time.
• Energy efficient LED light fittings for all new projects.
• Occupancy Sensors in Meeting rooms & wash rooms.
• Ventilation – Air changes in non AC area through modular coolers
• Use of energy efficient EFF1 Motors in machine.
• Sleep mode for machine screen & auto shut off during idle running of machine.
• Chiller with eco friendly gases R134a.
• VRF AC for new office areas
• Water conservation – RO water is supplied in closed loop system to Engine test beds dyno cooling, and cooling tower is fed through raw water reducing overall water consumption.
Saving Potential per annum : 11428 kWh (0.083 MINR) Investment : 0.5 MINR
Saving Potential per annum : 470576 kWh (3.294 MINR) Investment : 3.29 MINR
Day lighting system trial in progress, Light pipe installed & performance under observation
Saving Potential per annum : 86985 kWh (0.61 MINR) Investment : 0.59 MINR
Way
ah
ead
1 MW roof top solar power plant
Day lighting system for buildings
Phase 5 Plant LED light conversion
Heat pump at Guest house
Airtron AC power saver
Saving Potential per annum :1500 MWh (10 MINR )Investment : 38 MINR
58
Way ahead : Electrical power savings 2935 MWh
Saving Potential per annum : 113288 kWh (0.793 MINR) Investment : 0.645 MINR
Saving Potential per annum :195429 kWh (1.4 MINR) Investment : 2.05 MINR
Saving Potential per annum :316667 kWh (1.9 MINR )Investment : 3.8 MINR
Way
ah
ead
Control air system to control plant compressed air pressure
RTPFC for real time power factor controlling
Plant VFD conversion
Use of POLYTRON MTC – Oil Additive into all compressor to improve compressor efficiency
Saving Potential per annum :240000 kWh (1.68 MINR )Investment : 1.69 MINR
59
Way ahead : Electrical power savings 2935 MWh
Status of Encon projects committed last 3- years
• Projects : 14
• Savings 14.62 MINR
2015-16
• Projects : 11
• Savings:16.67 MINR
2016-17 • Projects : 17
• Savings : 19.52 MINR
2017-18
Last 3 Year
EnCon
Journey
• 42 Encon projects implemented • 5615 MWh savings achieved• 6949 mMBTU savings achieved• 50.81 MINR savings achieved • 5329 ton of Co2 reduction achieved
Cost saving through EnCon projects : 15.45 MINR
Investment : 17.90 MINR
38 MINR - Solar
Business Plan 2018-19
YTD Savings : 4.64 MINR