EXCELLENCE IN ENERGY RBEI COIMBATORE WELCOME TO PRESENTATION BY RBEI

Transcription

1 EXCELLENCE IN ENERGY RBEI COIMBATORE WELCOME TO PRESENTATION BY RBEI Represented by Mr. Ramesh R, Mr.Kandappan D, Mr.Magesh Kumar P , &

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, associates, existence from 1998 Other RBEI locations: Vietnam and Mexico 2

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 E Under deck insulation for the top floor ceiling Day light harvesting on glazed area by providing light sensors RCC roof-top solar panels 3 Floor space design (office area optimized at the center) Internal RBEI/FCM-COB

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 4

5 Specific Energy Consumption Trend Specific Energy Consumption - Trend Power consumption (in MWhr) Area (in Sq.m) SEC (kwhr/sq.m/year) Year Power consumption (in MWhr) Energy Consumption - Trend TNEB (in %) DG (in %) RES (in %) kwhr/sq.m/year Energy Consumption Pattern in 2017 TNEB (in %) DG (in %) RES (in %)

6 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 6

7 Information on National Benchmarking (BEE Standard) Year Specific Energy Consumption (SEC) Power consumption (in MWhr) Area (in Sq.m) SEC (kwhr/sq.m/year) Star Rating kwhr/sq.m/year Year Specific Energy Consumption (SEC) Excluding Lab Area Power consumption (in MWhr) Area (in Sq.m) SEC (kwhr/sq.m/year) Star rating kwhr/sq.m/year

8 Information on National Benchmarking (BEE Standard) Year Power consumption (in MWhr) Specific Energy Consumption (SEC) Area (in Sq.m) Total hours AAhWhr (Whr/Hr/Sq.m Star ) rating AAhEPI (Whr/Hr/Sq.m) % Reduction in SEC from 2014 to

9 Bench Marking with other companies and within RBEI Locations Specific Energy Consumption (SEC) 2017 Power consumption (in MWhr) Area (in Sq.m) SEC (kwhr/sq.m/year) Star Rating IBM Benz RBEI-SEZ kwhr/sq.m/year 2 2 IBM Benz RBEI - SEZ 9 Locations Specific Energy Consumption (SEC) 2017 Power consumption (in MWhr) Area (in Sq.m) SEC (kwhr/sq.m/year) Star Rating RBEI KOR RBEI-SEZ RBEI - KOR kwhr/sq.m/year 2 2 RBEI - SEZ

10 Roadmap to achieve benchmark By Design Solar orientation,low e-glass T-5 Fluorescent lamp Occupancy sensor Low loss dry type transformer Energy saver for lighting Centralised BEMS 10

11 Roadmap to achieve benchmark By Design High COP water chillers Pumps with VFD drives VAV controller for office area Heat Recovery Wheel unit 2-way valves for AHUs Hydro-pneumatic pumps 11

12 Roadmap to achieve benchmark Operation Energy Management System Harmonic Filters Thermography Test Battery impedance test Awareness for Lab Users Lighting standard adherence O&M procedures as per OEM recommendations 12 Installation and deinstallation programs for better efficiency

13 Energy saving projects implemented in Energy Saving Projects Cost 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 PLC DG sets conventional radiator replacement with coil cooler Non quantifiableunits saving Cost saving MINR

14 Energy saving projects implemented in Energy Saving Projects 140kW solar PV system installed at Phase2 building 115nos of street lights(150w) replaced with LED(40W) Cost Benefit in Million INR Lab AC units capacity optimization 0.30 Projector replacement with display units 0.02 Air Compressors capacity optimization 0.01 Units saving Cost saving MINR 14

15 Energy saving projects implemented in Energy Saving Projects UPS optimization at Cob 101 Building (from 900kVA to 600kVA) Cost Benefit in Million INR 0.15 Cooling tower replacement 0.06 Cob SEZ 101 Atrium AC refurbishment kW solar mill (hybrid system of solar and wind) kVA MD reduction 2.52 BMS upgradation and integration at SEZ Non quantifiable Units saving Cost saving MINR 15

16 Innovative project - 1 HVAC 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 16

17 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 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) CO 2 emission reduction of 114 Tonnes / annum 17

18 HVAC system redesign Primary variable flow system Chiller consumption / Day (kwh) Pump panel consumption / Day (kwh) Before After 0 Before After Working Day Non Working Day Working Day Non Working Day Overall HVAC consumption / Day (kwh) Energy Saving / Annum : kwh Cost Saving / Annum : 1.54 MINR Before After Working Day Non Working Day Investment cost Payback Period : 3.0 MINR : 1.94 Year 18

19 HVAC system redesign Primary variable flow system 19

20 Innovative project - 2 AHU 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 20

21 AHU Blower replacement with EC fans Benefits Annual energy saving of 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 21

22 Innovative project - 3 Standalone 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 22

23 Standalone Ac units optimization with VRF and inverter units Benefits Annual energy saving of 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 23

24 Renewable Energy sources Solar PV system Year Total Capacity (in kwh) Total Investment (in Million INR) Generation / Annum (in kwh) Annual cost saving (in Million INR) Return of Investment (in Months) CO2 Emission Reduction (in Tons/year) % of renewable energ on total energy 24

25 Renewable Energy sources Solar PV system 25

26 Renewable Energy sources - Solar Mill (Hybrid system of solar and wind) Installed capacity Investment : 15 kw (solar 12kW + wind 3kW) : 1.4 MINR* Benefits Production per annum Annual cost saving Payback period : units : 0.16 MINR : 105 months * MINR Million INR 26

27 Renewable Energy sources - Solar Thermal Energy Installed capacity Investment Benefits Annual energy saving Annual cost saving Pay back period : units : 0.2 MINR Hot water used for dish washing * MINR Million INR : 2 x 2500 Ltrs : 1.2 MINR* Old system replacement with solar assisted heat pump : 69 months 27

28 Utilization of waste as fuel Bio gas plant 28 Year Quantity of waste as fuel used (MT/Year) Waste as Fuel in % of Total Energy Used Installed capacity Investment Annual cost saving Utilisation of food wastage : 50 Kg : 0.2 MINR* : 0.3 MINR Bio gas plant - 400Kg is completed in 2018 * MINR Million INR New Biogas plant 400 Kg

29 Tons CO2/Mio EUR Excellence in Energy RBEI/Coimbatore Commitment towards Environment GHG Inventorisation Bosch has set itself the following target Relative CO2 emission values to improve our performance in 120 environment protection. 100 o Reduction of relative CO 2 emissions by % by 2012 (based on 2010) o Reduction of relative CO 2 emissions by 35% by 2020 (based on 2010) Target: Tons CO 2 /Mio EUR Published in Bosch worldwide news letters (internal) and forums like CII, IOD, etc., Year 29

30 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 30

31 Team work, Employee Involvement & Monitoring Daily Monitoring system and Review Year 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 * MINR Million INR Encon Budget (in MINR)

32 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 32

33 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 33

34 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 Volunteering hours have been spent on Swachh Bharat mission Implementation of car pooling concept among associates Restoration of lake at Chinnavedampatty, Coimbatore 34

35 Excellence in Energy RBEI/Coimbatore Go Green concept with more green cover 35

36 Way Forward 12% of total consumption from renewable energy source Increase in capacity of solar PV system Solar car parking ISO implementation Reduction in lab consumption 5 Star Rating by 2020 Reduction in losses through BEMS system analysis LED Lightings in office area Purchase of green power 36

37 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

38 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

39 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 39