1. Garware Polyester Ltd. Aurangabad

2. Company Profile

3. Unit Profile
Garware Polyester Limited is the pioneer in the field of polyester film. The Company has developed various types of films and is exporting to 57 countries in World. The company has excellent infrastructure and strong commitment to Safety, Quality, Energy Conservation , Environment preservation and R&D.
Winner of Highest Export Award-Plex council (Govt. of India, Ministry of Commerce) since last 20 years.
Winner of “Energy Efficient Unit- 2010” by CII.
Winner of 1st award in 2009 in “Plastic Category” on National Level (NECA)
Winner of 2nd award for excellence in Energy Conservation and Management in 5th Maharashtra State Level Award competition in year 2008 in category “Other Industries“.
The company has set up cross functional Energy Conservation Cell, which focuses on energy management and improvement.
The company recognizes the importance of energy conservation, not only to improve the bottom line but also to help the environment and society at large for sustainable growth.

4. Process Flow Diagram

7. ENCON

8. Energy Management Policy
Garware Polyester Limited plays vital role for producing variety of products
with high level of quality standard and prioritizes energy value for the final
product.
Our mission is :
To produce products with minimum use of energy.
Use of cleaner technologies wherever possible and ensuring efficient and uninterrupted supply of utilities to plants.
This, we plan by following ways.
Efficient energy generation, utilization and distribution.
Continuous evaluation of performance of plant equipments and processes to achieve most efficient, high standard quality products.
Targeting the under-performance equipments and processes for improvement.
Monitoring and targeting the specific energy consumption to achieve best possible as compared to past performance.
Use of internal and external expertise to achieve targeted performance.
Train employees and implement ideas of energy conservation thorough
small ENCON teams.
M S Adsul
Director-Technical

9. ENCON Team Structure DIRECTOR - TECHNICAL ENGINEERING HEAD
DY. GENERAL MANAGER
CENTRAL UTILITY
ENCON TEAM
FILM PLANT
ENCON TEAM
POLYMERISATION PLANT
ENCON TEAM
CENTRAL UTILITY
ENCON TEAM
CHIKALTHANA
PLANT

10. Energy Monitoring 1.Daily
Energy report is generated by Central Utility on daily basis and circulated to all concerned.
2.Monthly
Based on daily energy report, monthly energy report is prepared and circulated to all concerned. Comparison & analysis of energy consumption is done with previous months and deviations are studied for reduction in Energy Bills.
3.Yearly
Yearly reports generated from data collected as above.
Specific energy consumptions are calculated and targets are set for future.
Major ENCON projects are listed in annual report.

11. ENCON Methodology
Identification of high energy consuming equipments/processes through internal & external audits.
Elimination of inefficient equipment & substitution with new & efficient technologies.
Continuous energy performance monitoring through statistical analysis.
Brainstorming in small group activities for innovative ideas.
Reduction in Carbon foot print & implementation of green projects.
Benchmarking with other competitors.
Involvements of employees through suggestion schemes & competitions.

12. Identification of Major losses
1. Failure losses - Breakdown loss Setup / adjustment losses
3. Cutting blade loss Start up loss
5. Minor stoppage / Idling loss Speed loss - operating at low speeds.
7. Defect / rework loss Scheduled downtime loss
9. Management loss Operating motion loss
11. Line organization loss Logistic loss
13. Measurement and adjustment loss Material Yield loss
15. Energy loss Die, jig and tool breakage loss

13. ENCON IMPLEMENTED PROJECTS

14. ENCON PROJECTS

16. ENCON PROJECTS 2010-11 Year of Commissioning of the projects S. No.
Project description
Achievement of energy savings per year basis
Investment incurred on the project (Rs. Lakhs)
Electricity
F.Oil
Others
Total savings in (Rs. Lakhs)
(Lakhs (kWh)
(MT) 1
EIL heater efficiency optimization. Central Utility, Waluj.
0.00
69.3
15.43
11.00 2
Polyplant cutter cooling tower.
7.2
29.38
15.00 3
Direct transfer of condensate from Glycol Recovery to De-aerator.
51.04
11.37 4
Stopping of MDO chilled water system and hook up from Central Utility.
2.38
9.69 5
Commissioning of Biomass fired Boiler.
91.26
332.41 6
p.f. incentive at Waluj.
169.30 7
p.f.incentive at Chikalthana
76.69 8
Use of emulsified F.O. for Thermic fluid heater in CHK plant
0.55
2.26
1.50 9
Provision of VFD to TDO oven blower.in CHK plant
0.24
0.97 10
Secondary hot oil pump impeller trimming in CHK plant.
0.10
0.40
Sub Total
10.47
406.76
361.51

17. ENCON PROJECTS 2011-12 Sub Total 0.58 69.30 1648.00 375.00 42.90
Year of Commissioning of the projects
S. No.
Project description
Achievement of energy savings per year basis
Investment incurred on the project (Rs. Lakhs)
Electricity
F.Oil
Others
Total savings in (Rs. Lakhs)
(Lakhs (kWh)
(KL) 1
Thermal Fluid Heater (EIL) efficiency optimization. Central Utility, (Waluj)
0.00
69.3
18.04
11.00 2
Waste heat recovery from boiler flue gases.(Waluj)
448
21.50
8.00 3
Direct transfer of condensate from Glycol recovery to de-aerator, Waluj.
200
9.60 4
Conversion of Aluminum blade to FRP blade for cooling tower fan (Waluj)
0.25
1.10
1.00 5
Provision of booster compressor for instrument air system (Waluj)
2.52
10.99 6
p.f. Incentive at waluj
190.44 7
p.f. Incentive at Chikalthana
84.95 8
Commissioning of 110 TR chiller & reducing VAHP load (Waluj)
-5.91
1000
22.23
12.00 9
Operation of separate 13TR chiller for Kappa cooler stopped by transferring load to primary chilled water system. (Chikalthana)
1.85
8.06 10
Pneumatic booster installed & stopped operation of portable compressor. (Chikalthana)
0.34
1.46
0.50 11
Return water pump for twin screw vacuum system operation stopped by using gravity flow system. (Chikalthana)
0.17
0.73 12
Energy Efficient lighting used in L#2 TDO & slitter area. Total – 45 Nos (Chikalthana)
0.08 13
Rotary feeder installed at L#1 instead ventury system. (Chikalthana)
1.01
4.39 14
Replacement of 125W HPMV lamps by 23W CFL-60 nos. (Waluj)
0.27
1.17
Sub Total
0.58
69.30
375.00
42.90

18. Achievement of Annual energy savings in 2012-13
ENCON PROJECTS
Year of Commissioning of the projects
S.NO.
Project description
Achievement of Annual energy savings in
Investment incurred on the project Rs. (Lakhs)
Electricity
Fuels*
Total savings in (Rs. Lakhs)
(Lakhs kWh)
Coal (tonnes)
F.Oil
Gas (lakh Nm3)
Total (fuel) in (MTOE)
(kL) 1
Optimisation of Cooling tower pumps (at waluj)
7.35
44.06
0.5 2
Optimisation of chilled water pumps. (At waluj)
5.37
26.99 3
Optimisation of Therminol pumps. (at waluj)
3.1
19.2
0.75 4
Power factor incentive (at waluj)
277.66 5
Replacement of Cooling tower fan blades with FRP blades (at waluj)
0.15
0.76 6
Complete stoppage of FO Boiler (at waluj)
38.4
36.66
12.83 7
Replacement of Condenser water pump by low head. (chikalthana)
1.34
6.75
0.45 8
Provision of Rotary feeder for chips conveying instead of ventury system. (chikalthana)
1.01
5.07
1.2 9
Water Emulsification of furnace oil. (chikalthana)
81.66
77.96
27.3
9.5 10
Twin screw return water pump stopped by using gravity flow system. (chikalthana)
0.25
1.26 11
L#2 AHU No-3 water pump replaced by energy efficient pump. (chikalthana)
0.42
2.11
0.2 12
Power factor incentive (at chikalthana)
98.87
SUB TOTAL
16.68
120.06
114.63
500.5
13.85

19. ENCON SUMMARY - LAST 5 YRS
YEAR
No. of
Measures
implemented
(i)
Investment
made
(Rs.
Lakhs)
(ii
Savings
achieved
(Rs. Lakhs
/ year)
(iii)
Energy
Cost
Lakhs/
year)
(iv) %
of Energy
(iii /iv x
100) 8
65.70
393.7
8.32 10
178.00
417.14
10.17
360.71
406.76
8.28
42.9
375.00
6.69 12
13.85
530.5
8.30

20. Energy Reduction – Chips Plant
10.42%
6.12%
5.61%

21. Energy Reduction – Film Plant
5.46%
7.5%
0.2%
0.87%
1.7%
18.91%

22. INNOVATIVE PROJECTS

23. Loss no: 15 ENCON Project : 1
Title : Poly Plant Cutter Cooling Tower
Loss no: 15
Background of the project : To reduce chilled water load.
Observation made :
Chilled water is used for Poly plant cutter for cooling of chips from 280°C to 40°C.
Cooling water can also be used for cutter cooling.
Technical and Financial Analysis
Investment : Rs. 15 Lacs Implemented : Aug. 2009
1st year cost Saving : Rs Lacs
Impact of implementation : Reduction in chilled water load by 200 TR/Hr.
On annual basis Electricity cons. (Lacs kWh)
Energy consumption before :
Energy consumption after :

24. Before
After

25. Conversion of VAHP Machine Single Effect to Double Effect

26. Process Flow Diagram of Chilled Water System
VAHP MACHINE
Chilled water out
Cooling water out
Film Plant
Chilled water in
Poly Plant
Cooling water in
Batch Plant
Pump
Chilled water return from plants

27. Single effect Machine
Steam consumption single effect machine = 8.1 Kg/TR

28. Double Effect Machine
Condensor
High Temp. Generator
Over flow pipe
Cooling Water
Absorber
Evaporator
Purge Pump
Diluted Solution
Inter Solution
Concentrated LiBr
Refrigerant
Chilled Water
Refrigerant Vapour
Steam/ Flue Gases
Low temp. generator
Steam consumption Double effect machine = 4.1 Kg/TR

29. (fluctuates as per FO Price)
Cost Saving Table
Single Effect Machine
Double Effect Machine
Steam consumption
8.1 Kg/TR
4.1 Kg/TR
Cost of Steam
Rs.
737 Lacs /Annum
373 Lacs /Annum
Cost Saving
(fluctuates as per FO Price)
364 Lacs / Annum

30. Machine Photographs Single Effect Machine - Before
Double Effect Machine - After

31. Background of the project : To reduce Furnace oil consumption for
ENCON Project : 3
Title : Commissioning of Biomass Fired Boiler
Loss No- 15
Background of the project : To reduce Furnace oil consumption for
Boilers.
Observation made :
Cost of steam on briquette is almost half that of F.O.
Unused IAEC make F.O. fired boiler of 18 MT/Hr capacity is available.
Can be used by installing external furnace for biomass firing.
Existing underutilized go down can be used for boiler operation and
briquette storage.
Technical and Financial Analysis :
Investment : Rs. 332 Lacs
Implemented : Jan. 2010
Impact of implementation :Reduction in Furnace Oil consumption.
Thereby reduction in SO2 by Kg/annum and estimated reduction in CER by per annum.

32. Avg. Furnace oil Reduction = 200 MT/M
Savings achieved by converting F.O fired Boiler to Biomass fired Boiler
Avg. Furnace oil Reduction = 200 MT/M
Average Cost of Furnace Oil = Rs./MT
Yearly Cost savings
(Fluctuate as per Price variation in the Fuel) = 183 Lacs/Year

34. Briquette Fired Boiler

35. Boiler Photographs before and after conversion
F.O. Fired Boiler
Biomass Fired Boiler after conversion

36. Before KAIZEN Implementation After KAIZEN Implementation

37. ENCON Project : 4
Title :Optimization of Cooling water system
Loss no- 15
Background of the project :
To reduce power consumption for Cooling water pumping.
Observation made :
1. Cooling water high head and low head requirement areas were identified.
2. It was observed that high head heat exchangers were starving due to low pressure although the flow through pumps was satisfactory.
3. The low head areas were provided with positive isolation wherever possible to reduce the unnecessary power consumption and other heat exchangers were tuned for appropriate diff temp for optimum flow.
Technical and Financial Analysis :
Investment : 0.5 Lacs Implemented : Dec. 2012
1st year cost Saving : Rs Lacs
Impact of implementation : Reduction in power consumption—5.04 LkWh per annum

38. Sample Calculation Equipment Main process cooling tower pump no 1
DG cooling tower pump no 2
DG cooling tower pump no 3
Main process cooling tower pump no 2
Time
17.45
13.20
13.30
11.5 KW
246.2
33.38
41.61
161.6
KVA
275.08
37.76
45.97
191.3
KVAR
17.65
19.12
102.3 PF
0.895
0.883
0.904
0.843
VOLTS
404.2
395.2
395.8
414.8
AMPS
394
55.87
67.91
264
FREQUENCY
50.02
49.77
49.84
49.65
Previous condition : Pumps running : PCT pump no.1 and DGCT pump no. 2 & 3
After optimisation : Pumps running : PCT pump no. 2 only
For saving we have considered the difference in KW of PCT pump no.1 and 2
KW saved = 246 – 161
= 85 KWH
Saving in Rs . = 85 x 24 x 30 x 5.
= Rs lacs / Month
= Rs Lacs / Annum

39. ENCON Project : 5 Title :Optimization of chilled water system
Background of the project : To reduce power consumption for Chilled water pumping.
Observation made :
1. Chilled water high head and low head requirement areas were identified.
2. It was observed that high head heat exchangers were starving due to low pressure although the flow through pumps was satisfactory.
3. The expansion tank of the system was raised by 8 M of height to improve
the suction and discharge head.
4. The low head pumps were put into operation to reduce the power
consumption.
5. All heat exchangers were tuned for required chilled water flow.
Technical and Financial Analysis :
Investment : 0.5 Lacs Implemented : Dec. 2012
1st year cost Saving : Rs Lacs
Impact of implementation : Reduction in power consumption LkWh per annum.

40. Sample Calculation Chilled water system Pump. no.1 pump no.2 TotalKW
70.05
33.7
103.75
39.13
KVA
76.33
,--
29.66
KVAR
29.19
25.15 PF
0.921
0.754 Lag
VOLTS
407.5
410.4
AMPS
107.6
54.72
FREQUENCY
50.09
49.38
Previous condition : Pumps running : pump no.1 and 2
After optimisation : Pump running : pump no. 3 only ( Pump replaced )
KW saved = 103 – 39
= 64 KWH
Saving in Rs . = 64 x 24 x 30 x 5.85
= Rs lacs / Month
= Rs Lacs / Annum (for 300
Days/year)

41. ENCON Project : 6 Title :Optimization of Hot oil system
Background of the project : To reduce power consumption for Hot oil pumping.
Observation made :
1. Hot oil high head and low head requirement areas were identified.
2. It was observed that high head heat exchangers were starving due to low pressure although the flow through pumps was satisfactory.
3. Thermic fluid heater coil flow made fine tuning.
4. Before implementation one high head pump was running with full impeller, after that two pumps impeller trimmed & reduced the head & increased the flow .
Technical and Financial Analysis :
Investment : 0.5 Lacs Implemented : Dec. 2012
1st year cost Saving : Rs Lacs
Impact of implementation : Reduction in power consumption Lac kWh/annum

42. Sample Calculation Equipment Primary santotherm pump no 1
Total
Primary santotherm pump no 2
Time
12.45 12
13.40 Hrs
KVA
105.9
106
254.8 KW
98.29
99.02
197.31
235
KVAR
39.3
39.8
56.44 PF
0.927
0.928
0.922
VOLTS
409.5
410
408
AMPS
149.9
150
353
FREQUENCY
49.85
49.75
49.79
Previously condition : Only pump no. 2 in line
After optimisation : Pump no. 1 & 3 in line.
NET KW SAVED = – 198
= 35 KWH
SAVING IN Rs. = 35 x 24 x 30 x 6
= Rs. 1.6 Lacs / Month
= Rs Lacs / Annum

43. Efforts on Electrical Energy reduction
Utilization of High efficiency motor for blower.
Blower old motor efficiency was lower i.e 88%.
Before implementation blower motor taking Kwh & with high efficiency motor Kwh .
Cost Saving : Rs Lacs
Impact of implementation : Reduction in power consumption---0.3Lac kWh/annum

44. Sample Calculation
BALDOR HIGH EFFICIENCY MOTOR TRIAL AND COMPARISION WITH NORMAL MOTOR
ENERGY READINGS WITH THE HELP OF ENERGY MGR.(DATE-09/05/07,TIME
TRIM SUCTION BLOWER NO - 01
TRIM SUCTION BLOWER NO - 03
Make -
BBL
3Ph I.M.
Baldor
FR -
D160
Type -
1LAJO87-2
160L
Kw -
18.5
V -
415
Hz - 50
Ins cl - B
Amps - 30
RPM -
2915
M/C No - K
ENCL -
TEFC
Hz -
Duty - S1
415 Delta
Ins. Cl - F
SER. F - 1 33
Eff. -
88%
Nima Eff -
93%
IP - 55
2920
Rating -
45 C
AMB -
CONT
P.F. -
0.83
Sr No - Z
Usable at 208 V
Valve position on - 3
MEASURE
AVG R Y V
402.3
RY-400.7
YB-401.8
BR-404.8
400.7
RY-401.8
YB-401.1
RB-399.4,Ln-231.7 A
28.36
28.04
28.77
29.7
22.6
22.34
23.07
21.63, N
50.2
50.18 Wh
18.18
6088
6131
6280
14.92
5002
5028
4904
Vah
20.19
6772
6571
6877
16.03
5426
5416
5252
VARh
7879
2818
2281
2784
5542
1924
1897
1720 PF
0.917
0.904
0.932
0.914
0.936
0.926
0.942

45. Efforts on Electrical Energy reduction
Conversion of motor connections from delta to star.
Methanol recovery cooling tower fan motor connections changed from delta to star reducing power by 0.16 kwh
Calculation: (1.78*24*30*12/100000)*6
Total Cost Saving : Rs Lacs
Impact of implementation : Reduction in power consumption Lac kWh/annum

46. DELTA TO STAR CONVERSION NET ENERGY SAVING PER MONTH
Sample Calculation
DELTA TO STAR CONVERSION
SR NO
NAME OF EQIPMENT
MOTOR RATING
ENERGY PARAMETER
KW SAVING
KVAR SAVING
NET ENERGY SAVING PER MONTH
NET DEMAND SAVING
DELTA
STAR
VAH WH
VARH PF
AMP
FREQ 1
MEOH RECOVERY COOLING TOWER FAN NO 1
11 KW, 1500 RPM
6758
4497
5029
0.667
9.49
49.68
4768
4339
1962
0.91
6.6
50.3
0.16
3.07
113
1.95 2
MEOH RECOVERY COOLING TOWER FAN NO 2
6976
4849
4971
0.72
9.48
50.05
5055
4633
2086
0.90
7.2
49.7
0.22
2.47
155
1.6 3
DMT SCRUBBER PUMP
3.7KW, RPM
1732
929.3
1426
0.537
2.42
49.88
983.8
828
420
0.85
50.0
0.10
0.95
72.72
0.756 4
REBOILER PUMP
7.5 KW, 3000RPM
3984
2812
2715
0.71
5.652
49.51
3011
2782
1131
4.0
0.00
1.59
2.16
0.93

47. DELTA TO STAR CONVERSION NET ENERGY SAVING PER MONTH
Sample Calculation
DELTA TO STAR CONVERSION
SR NO
NAME OF EQIPMENT
MOTOR RATING
ENERGY PARAMETER
KW SAVING
KVAR SAVING
NET ENERGY SAVING PER MONTH
NET DEMAND SAVING
DELTA
STAR
VAH WH
VARH PF
AMP
FREQ 5
SEC EI PUMP
5.5 KW, 3000 RPM
3017
1191
2729
0.39
4.97
49.8
1255
965.3
742
0.77
1.07
50.1
0.23
1.8
162
1.792 6
MEOH FEED PUMP NO 2
3635
2598
2512
0.71
406
49.5
2551
2403
775
0.94
3.58
0.20
1.6
140.4
1.087 7
CASTING COOLING TOWER FAN
9.3KW, 1500RPM
5634
4169
3808
0.73
7.08
49.7
4404
3934
1853
0.90
6.92
49.4
0.24
1.9
169.2
1.313 8
PACKING AHU
11KW, 1500 RPM
8461
6362
5555
0.75
11.51
50.2
6409
5716
2857
0.89
9.75
49.3
0.65
4.4
465.12
2.060

48. List of Awards Sr. No. Awards Title Organized by Year Winner Category1
5th State Level For Excellence in Energy Conservation and Management
MEDA
2008
Second Award in Other Industries. 2
National Energy Conservation Award-2009
BEE
2009
First Award in Plastic Sector. 3
CII – Energy Efficient Unit
CII
2010
Energy Efficient Unit 4
CII – National Award for Excellence in Energy Management
2011
Excellent Energy Efficient Unit 5
6th State Level For Excellence in Energy Conservation and Management
2012
Certificate 6
7th State Level For Excellence in Energy Conservation and Management

49. THANKS