3 Unit ProfileGarware 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.
8 Energy Management Policy Garware Polyester Limited plays vital role for producing variety of productswith high level of quality standard and prioritizes energy value for the finalproduct.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 thoroughsmall ENCON teams.M S AdsulDirector-Technical
9 ENCON Team Structure DIRECTOR - TECHNICAL ENGINEERING HEAD DY. GENERAL MANAGERCENTRAL UTILITYENCON TEAMFILM PLANTENCON TEAMPOLYMERISATION PLANTENCON TEAMCENTRAL UTILITYENCON TEAMCHIKALTHANAPLANT
10 Energy Monitoring 1.Daily Energy report is generated by Central Utility on daily basis and circulated to all concerned.2.MonthlyBased 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.YearlyYearly 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 MethodologyIdentification 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 losses3. Cutting blade loss Start up loss5. Minor stoppage / Idling loss Speed loss - operating at low speeds.7. Defect / rework loss Scheduled downtime loss9. Management loss Operating motion loss11. Line organization loss Logistic loss13. Measurement and adjustment loss Material Yield loss15. Energy loss Die, jig and tool breakage loss
16 ENCON PROJECTS 2010-11 Year of Commissioning of the projects S. No. Project descriptionAchievement of energy savings per year basisInvestment incurred on the project (Rs. Lakhs)ElectricityF.OilOthersTotal savings in (Rs. Lakhs)(Lakhs (kWh)(MT)1EIL heater efficiency optimization. Central Utility, Waluj.0.0069.315.4311.002Polyplant cutter cooling tower.7.229.3815.003Direct transfer of condensate from Glycol Recovery to De-aerator.51.0411.374Stopping of MDO chilled water system and hook up from Central Utility.2.389.695Commissioning of Biomass fired Boiler.91.26332.416p.f. incentive at Waluj.169.307p.f.incentive at Chikalthana76.698Use of emulsified F.O. for Thermic fluid heater in CHK plant0.552.261.509Provision of VFD to TDO oven blower.in CHK plant0.240.9710Secondary hot oil pump impeller trimming in CHK plant.0.100.40Sub Total10.47406.76361.51
17 ENCON PROJECTS 2011-12 Sub Total 0.58 69.30 1648.00 375.00 42.90 Year of Commissioning of the projectsS. No.Project descriptionAchievement of energy savings per year basisInvestment incurred on the project (Rs. Lakhs)ElectricityF.OilOthersTotal savings in (Rs. Lakhs)(Lakhs (kWh)(KL)1Thermal Fluid Heater (EIL) efficiency optimization. Central Utility, (Waluj)0.0069.318.0411.002Waste heat recovery from boiler flue gases.(Waluj)44821.508.003Direct transfer of condensate from Glycol recovery to de-aerator, Waluj.2009.604Conversion of Aluminum blade to FRP blade for cooling tower fan (Waluj)0.251.101.005Provision of booster compressor for instrument air system (Waluj)2.5210.996p.f. Incentive at waluj190.447p.f. Incentive at Chikalthana84.958Commissioning of 110 TR chiller & reducing VAHP load (Waluj)-5.91100022.2312.009Operation of separate 13TR chiller for Kappa cooler stopped by transferring load to primary chilled water system. (Chikalthana)1.858.0610Pneumatic booster installed & stopped operation of portable compressor. (Chikalthana)0.341.460.5011Return water pump for twin screw vacuum system operation stopped by using gravity flow system. (Chikalthana)0.170.7312Energy Efficient lighting used in L#2 TDO & slitter area. Total – 45 Nos (Chikalthana)0.0813Rotary feeder installed at L#1 instead ventury system. (Chikalthana)1.014.3914Replacement of 125W HPMV lamps by 23W CFL-60 nos. (Waluj)0.271.17Sub Total0.5869.30375.0042.90
18 Achievement of Annual energy savings in 2012-13 ENCON PROJECTSYear of Commissioning of the projectsS.NO.Project descriptionAchievement of Annual energy savings inInvestment incurred on the project Rs. (Lakhs)ElectricityFuels*Total savings in (Rs. Lakhs)(Lakhs kWh)Coal (tonnes)F.OilGas (lakh Nm3)Total (fuel) in (MTOE)(kL)1Optimisation of Cooling tower pumps (at waluj)7.3544.060.52Optimisation of chilled water pumps. (At waluj)5.3726.993Optimisation of Therminol pumps. (at waluj)184.108.40.2064Power factor incentive (at waluj)277.665Replacement of Cooling tower fan blades with FRP blades (at waluj)0.150.766Complete stoppage of FO Boiler (at waluj)38.436.6612.837Replacement of Condenser water pump by low head. (chikalthana)1.346.750.458Provision of Rotary feeder for chips conveying instead of ventury system. (chikalthana)1.015.071.29Water Emulsification of furnace oil. (chikalthana)81.6677.9627.39.510Twin screw return water pump stopped by using gravity flow system. (chikalthana)0.251.2611L#2 AHU No-3 water pump replaced by energy efficient pump. (chikalthana)0.422.110.212Power factor incentive (at chikalthana)98.87SUB TOTAL16.68120.06114.63500.513.85
23 Loss no: 15 ENCON Project : 1 Title : Poly Plant Cutter Cooling TowerLoss no: 15Background 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 AnalysisInvestment : Rs. 15 Lacs Implemented : Aug. 20091st year cost Saving : Rs LacsImpact of implementation : Reduction in chilled water load by 200 TR/Hr.On annual basis Electricity cons. (Lacs kWh)Energy consumption before :Energy consumption after :
29 (fluctuates as per FO Price) Cost Saving TableSingle Effect MachineDouble Effect MachineSteam consumption8.1 Kg/TR4.1 Kg/TRCost of SteamRs.737 Lacs /Annum373 Lacs /AnnumCost 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 : 3Title : Commissioning of Biomass Fired BoilerLoss No- 15Background of the project : To reduce Furnace oil consumption forBoilers.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 andbriquette storage.Technical and Financial Analysis :Investment : Rs. 332 LacsImplemented : Jan. 2010Impact 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 BoilerAvg. Furnace oil Reduction = 200 MT/MAverage Cost of Furnace Oil = Rs./MTYearly Cost savings(Fluctuate as per Price variation in the Fuel) = 183 Lacs/Year
35 Boiler Photographs before and after conversion F.O. Fired BoilerBiomass Fired Boiler after conversion
36 Before KAIZEN Implementation After KAIZEN Implementation
37 ENCON Project : 4Title :Optimization of Cooling water systemLoss no- 15Background 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. 20121st year cost Saving : Rs LacsImpact 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 2DG cooling tower pump no 3Main process cooling tower pump no 2Time17.4513.2013.3011.5KW246.233.3841.61161.6KVA275.0837.7645.97191.3KVAR17.6519.12102.3PF0.8950.8830.9040.843VOLTS404.2395.2395.8414.8AMPS39455.8767.91264FREQUENCY50.0249.7749.8449.65Previous condition : Pumps running : PCT pump no.1 and DGCT pump no. 2 & 3After optimisation : Pumps running : PCT pump no. 2 onlyFor saving we have considered the difference in KW of PCT pump no.1 and 2KW saved = 246 – 161= 85 KWHSaving 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 improvethe suction and discharge head.4. The low head pumps were put into operation to reduce the powerconsumption.5. All heat exchangers were tuned for required chilled water flow.Technical and Financial Analysis :Investment : 0.5 Lacs Implemented : Dec. 20121st year cost Saving : Rs LacsImpact of implementation : Reduction in power consumption LkWh per annum.
40 Sample Calculation Chilled water system Pump. no.1 pump no.2 Total KW70.0533.7103.7539.13KVA76.33,--29.66KVAR29.1925.15PF0.9210.754 LagVOLTS407.5410.4AMPS107.654.72FREQUENCY50.0949.38Previous condition : Pumps running : pump no.1 and 2After optimisation : Pump running : pump no. 3 only ( Pump replaced )KW saved = 103 – 39= 64 KWHSaving in Rs . = 64 x 24 x 30 x 5.85= Rs lacs / Month= Rs Lacs / Annum (for 300Days/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. 20121st year cost Saving : Rs LacsImpact of implementation : Reduction in power consumption Lac kWh/annum
42 Sample Calculation Equipment Primary santotherm pump no 1 TotalPrimary santotherm pump no 2Time12.451213.40 HrsKVA105.9106254.8KW98.2999.02197.31235KVAR39.339.856.44PF0.9270.9280.922VOLTS409.5410408AMPS149.9150353FREQUENCY49.8549.7549.79Previously condition : Only pump no. 2 in lineAfter optimisation : Pump no. 1 & 3 in line.NET KW SAVED = – 198= 35 KWHSAVING 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 LacsImpact of implementation : Reduction in power consumption---0.3Lac kWh/annum
44 Sample CalculationBALDOR HIGH EFFICIENCY MOTOR TRIAL AND COMPARISION WITH NORMAL MOTORENERGY READINGS WITH THE HELP OF ENERGY MGR.(DATE-09/05/07,TIMETRIM SUCTION BLOWER NO - 01TRIM SUCTION BLOWER NO - 03Make -BBL3Ph I.M.BaldorFR -D160Type -1LAJO87-2160LKw -18.5V -415Hz -50Ins cl -BAmps -30RPM -2915M/C No -KENCL -TEFCHz -Duty -S1415 DeltaIns. Cl -FSER. F -133Eff. -88%Nima Eff -93%IP -552920Rating -45 CAMB -CONTP.F. -0.83Sr No -ZUsable at 208 VValve position on - 3MEASUREAVGRYV402.3RY-400.7YB-401.8BR-404.8400.7RY-401.8YB-401.1RB-399.4,Ln-231.7A28.3628.0428.7729.722.622.3423.0721.63, N50.250.18Wh18.1860886131628014.92500250284904Vah20.1967726571687716.03542654165252VARh78792818228127845542192418971720PF0.9170.9040.9320.9140.9360.9260.942
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 kwhCalculation: (1.78*24*30*12/100000)*6Total Cost Saving : Rs LacsImpact of implementation : Reduction in power consumption Lac kWh/annum
46 DELTA TO STAR CONVERSION NET ENERGY SAVING PER MONTH Sample CalculationDELTA TO STAR CONVERSIONSR NONAME OF EQIPMENTMOTOR RATINGENERGY PARAMETERKW SAVINGKVAR SAVINGNET ENERGY SAVING PER MONTHNET DEMAND SAVINGDELTASTARVAHWHVARHPFAMPFREQ1MEOH RECOVERY COOLING TOWER FAN NO 111 KW, 1500 RPM6758449750290.6679.4949.684768433919620.916.650.30.163.071131.952MEOH RECOVERY COOLING TOWER FAN NO 26976484949710.729.4850.055055463320860.907.249.70.222.471551.63DMT SCRUBBER PUMP3.7KW, RPM1732929.314260.5372.4249.88983.88284200.8550.00.100.9572.720.7564REBOILER PUMP7.5 KW, 3000RPM3984281227150.715.65249.513011278211314.00.001.592.160.93
47 DELTA TO STAR CONVERSION NET ENERGY SAVING PER MONTH Sample CalculationDELTA TO STAR CONVERSIONSR NONAME OF EQIPMENTMOTOR RATINGENERGY PARAMETERKW SAVINGKVAR SAVINGNET ENERGY SAVING PER MONTHNET DEMAND SAVINGDELTASTARVAHWHVARHPFAMPFREQ5SEC EI PUMP5.5 KW, 3000 RPM3017119127290.394.9749.81255965.37420.771.07220.127.116.11621.7926MEOH FEED PUMP NO 23635259825120.7140649.5255124037750.943.580.201.6140.41.0877CASTING COOLING TOWER FAN9.3KW, 1500RPM5634416938080.737.0849.74404393418530.906.9249.40.241.9169.21.3138PACKING AHU11KW, 1500 RPM8461636255550.7511.5150.26409571628570.899.7549.30.654.4465.122.060
48 List of Awards Sr. No. Awards Title Organized by Year Winner Category 15th State Level For Excellence in Energy Conservation and ManagementMEDA2008Second Award in Other Industries.2National Energy Conservation Award-2009BEE2009First Award in Plastic Sector.3CII – Energy Efficient UnitCII2010Energy Efficient Unit4CII – National Award for Excellence in Energy Management2011Excellent Energy Efficient Unit56th State Level For Excellence in Energy Conservation and Management2012Certificate67th State Level For Excellence in Energy Conservation and Management