Garware Polyester Ltd. Aurangabad

Transcription

1 Garware Polyester Ltd. Aurangabad Company Profile 1 2 1

2 Company Profile Garware Polyester Limited is the pioneer in the field of polyester film. The Company has developed different 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 1 st award in 2009 in Plastic Category on National Level (NECA) Winner of 2 nd 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. Process Flow Diagram 3 4 2

3 Film Process Feeding Packing & Despatch Drying Slitting Extrusion Re-cycling ENCON Efforts Chill Roll TDO Aux. Winder MDO 5 6 3

4 Energy Conservation Summary ENCON Projects ( ) Year No. of Measures implemented (i) Investment made (Rs. Lakhs) (ii) Savings achieved (Rs. Lakhs / year) (iii) Energy Cost (Rs. Lakhs / year) (iv) % Savings of Energy Cost (iii/iv x100) Project Description Provision of VFD for VAHP C/T Fan. C U, Waluj. Conversion of VAHP m/c to double effect. C U, Waluj. Commissioning of 40TR & 60TR VCC Chiller, C.U. Waluj.. Conversion of Boiler from F O to Biomass firing. C U, Waluj. Achievement of energy savings per year basis Elect. (LkWh) F O (MT) Total Savings (Rs. Lacs) Investment incurred Cont d 8 4

5 Project Description Provision of cooling water to Poly Plant cutter instead of chilled water Waluj. Optimization of ejector C/T, Poly Plant, Waluj. Palletizing return water pump replaced by high efficiency pump. Film Plant, Chikalthana *Higher cap reci. compressor operation stopped by taking portable compressor in line. Film Plant, Chikalthana. Sub Total Achievement of energy savings per year basis Elect. (LkWh) F O (MT) Total Savings Investment incurred ENCON Projects ( ) Project Description Achievement of energy savings per year basis Provision of HP ejectors to Poly Plant,Waluj. Installation of cost effective Screw Chiller, C U, Waluj. *Optimization of chiller water and stopping one chilled water pump. C U, Waluj. *Optimization of compressed air system and stopping one compressor, C U, Waluj. *Provision of VFD to Boiler No.2, FD Fan, C U, Waluj. Elect. (LkWh) F O (MT) Total Savings Investment incurred. 8 7 Operational tuning 9 Cont d 10 5

6 Project Description Replacement of 150 HP blower motor with 75 HP motor, Film Plant, Waluj. Installation of VFD on Biopeq feed pump. ETP, Waluj. Aeropeq blower motor pulley replaced by smaller dia. pulley ETP (speed red-30%) Waluj. Provision of VFD to Cooling water return sump pump, Poly Plant, Wlj. Achievement of energy savings per year basis Elect. (LkWh) F O (MT) Total Savings Investment incurred Project Description Briquette firing to Boiler Installation of high efficiency screw chiller in Chikalthana plant *Optimization of air compressor operation in Chikalthana Plant Sub Total Achievement of energy savings per year basis Elect. (LkWh) F O (MT) Total Savings (Rs. Lacs) Investment incurred EIL heater efficiency optimization. C U, Waluj Use of available material Cont d

7 ENCON Projects ( ) Project Description EIL heater efficiency optimization. C U, Waluj. Polyplant cutter cooling tower-waluj. Direct transfer of condensate from Glycol Recovery & ecorecir to De-aerator in Waluj. Stopping of MDO chilled water system and hook up from C U, Waluj. Commissioning of Biomass fired Boiler in C.U.Waluj. Achievement of energy savings per year basis Elect. (LkWh) F O (MT) Total Savings Investment incurred. Cont d Project Description *P.F. incentive at Waluj. *P.F. incentive at Chikalthana Use of emulsified F.O. for Thermic fluid heater in Chikalthana plant Provision of VFD to TDO oven blower in Chikalthana plant Secondary hot oil pump impeller trimming in Chikalthana plant. Sub Total Achievement of energy savings per year basis Elect. (LkWh) F O (MT) Total Savings (Rs. Lacs) Investment incurred

8 Specific Energy Consumption For Chips Production Specific Energy Consumption For Film Production

9 Global norms / Benchmark Garware Polyester Limited is producing specialty Polyester Film and hence the specific energy consumption of our product can not be compared with other Film Producers. Innovative Projects

10 Innovative Projects ( ) S. N Project description Polyplant cutter cooling tower-waluj. Direct transfer of condensate from Glycol recovery & economizer recirculation to De-aerator- Waluj. Commissioning of Biomass fired boiler-waluj. Provision of VFD to C.W. return sump pump-waluj. Achievement of energy savings / year basis Elect (L kwh) F. Oil (MT) Total savings Rs. Lacs Investment incurred on the project 19 Innovative projects ENCON Project No. 1 Title : Poly Plant Cutter Cooling Tower Background of the project : To reduce chilled water load. Observation made : o Chilled water is used for Polyplant cutter for cooling of chips from 280 C to 40 C. o Cooling water can also be used for cutter cooling. Technical and Financial Analysis Investment : Rs. 15 Lacs Implemented : Aug st year cost Saving : Rs Lacs Impact of implementation : Reduction in chilled water load by 200 TR/Hr. On annual basis Energy consumption before Energy consumption after Electricity cons. (Lacs kwh)

11 Before Innovative projects ENCON Project No. 2 Title : Direct transfer of condensate from Glycol Recovery and Economiser recirculation to Deaerator Background of the project : To reduce Furnace oil consumption for Boilers Observation made : Glycol recovery steam is collected in tanks and then transferred to De-aerator. We can also use economizer recirculation for De-aerator heating. Technical and Financial Analysis Investment : NIL Implemented : Aug st year cost Saving : Rs Lacs Impact of implementation : Improvement in Deaerator temp. by 20 Deg. C and After reduction in Furnace Oil consumption by MT per annum

12 Before Innovative Projects ENCON Project No. 3 Title : Commissioning of Briquette Fired Boiler Background of the project : To reduce Furnace oil consumption for Boilers. Observation made : Use of standby boiler can be made by installing external furnace for biomass firing Technical and Financial Analysis : Investment : Rs. 332 Lacs Implemented : Jan st year cost Saving : Rs Lacs Impact of implementation :Reduction in Furnace Oil consumption. Thereby reduction in SO2 by Kg/annum and estimated reduction in CER by per annum After 23 On annual basis Furnace Oil cons. (MT/Annum) Energy consumption before MT-F.O CDM Status : Process of PIN, PDD completed. HCA awaited 24 12

13 Innovative Projects Briquette Fired Boiler ENCON Project No. 4 Title :Provision of VFD to C.W.return sump pump. Background of the project :C.W. sump receives C.W. water flow ranging from 70 M3/Hr to 130 M3/Hr. Observation made : If we provide VFD to pump with impulse to pump speed thro LT on sump, we can save pump power and loss of water. Technical and Financial Analysis : Investment : Rs. 1.0 Lacs 1 st year cost Saving : Rs Lacs Implemented :-Mar Impact of implementation :Reduction in power cons and water cons

14 Safety and Environment Management System Environmental Projects Separate EMS teams (Chikhalthana and Waluj) are formed for maintaining and improving environmental norms. Monthly EMS presentations are organized in a meeting chaired by Director of the company. Effluent treatment plants in both the locations viz Chikhalthana and Waluj are managed by highly experienced managers to maintain MPCB norms. Ambient air and stack analysis are carried out and maintained within norms every month. Company has won 16 no's of awards in different categories of safety competition. Internal safety competitions are arranged every year. Energy Conservation Week is organized every year

15 Environmental Projects Year Project Reduction in Water Consumption Commissioning of Biomass Fired Boiler Anaerobic reactor sludge renewed Effect Reduction over Wlj Plant: 23.89% Chk Plant: 16.98% Reduction in emission of SO2 By kg / annum. Estimated reduction in CER by / Annum Improved quality of treated effluent Actions taken Conservation of water through ENCON projects Optimization of DM Plant, Cooling water system Ideas through suggestion. Use of C.W. blow down and treated effluent to Gardens The IAEC make horizontal tubular boiler provided with external furnace for firing briquettes. Sludge purchased from M/s. Sanjivani Sakhar Karkhana, Sangamner, M.S. 29 Clean Development Mechanism (CDM) Project S N 1 Project title Biomass fired boiler Year of implementation Jan. 10 Total CO 2 reduction No. of CERs / VERs Total Annual savings Rs. Million 9.12 Invest. Made Rs. Million Payback (Months) 30 15

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17 Reduction In Ammonia Consumption Reduction In Water Consumption (M3)

18 List of Awards N Awards Title Maharashtra Safety Awards 2008 Maharashtra Safety Awards 2008 Maharashtra Safety Awards 2008 Safety Slogan Competition 2009 Maharashtra Safety Awards th State Level For Excellence in Energy Conservation and Management National Energy Conservation Award-2009 Organi zed by NSC MC NSC MC NSC MC NSC MC NSC MC MEDA BEE Year Winner Category A Plaque and Certificate of Merit Certificate of Merit Certificate of Merit 3 rd Hindi Mr.DK Ghodke A Plaque & Certificate of Merit 2 nd Award in Other Industries First Award in Plastic Sector. Plant Film, Chkl Film, Wlj Batch, Wlj Film, Wlj Film, Chkl GPL GPL 35 Energy Monitoring 36 18

19 Energy Management Policy ENCON Team Structure 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 37 ENCON Team Film Waluj ENCON Team Poly & Batch, Waluj Director -Technical Head Engineering General Manager Central Utility & Energy Manager ENCON Team Central Utility Waluj ENCON Team Chikalthana 38 19

20 Percentage Break up of Time Spent by Senior Executives Sr.No Function Technology Implementation Manufacturing Excellence. Materials Management Marketing coordination activities. Analyzing Competitors Profile. Quality Management. Energy Conservation Measures. Percentage Time Spent Benchmarking of Energy Consumption Norms Film Chips Year (Base year) Electrical % Reduction over Thermal % Reduction over In line with the proposed energy conservation future energy projects are already identified and out of 2 identified projects implementation in progress. Daily ENCON meetings are organized to identify potential areas of Energy Conservation. Weekly meetings are organized for discussion on areas of energy savings. Interaction with external agencies for conservation of energy. KRA to operating staff to conserve energy in their own area of working

21 Energy Monitoring. 1. Daily Energy report is generated by Central Utility on daily basis. Energy Report is checked by Dept Head and corrected if reqd. The report is then circulated to concerned Dept Heads for corrective actions to control energy consumption. 2. Monthly Based on daily energy consumption, monthly energy report is prepared and circulated to all concerned. Comparison of energy consumption is done with previous months and deviations are studied for reduction in Energy Bill. 3. Yearly Yearly reports generated from data collected as above. Specific energy consumptions are calculated and targets are set for future. ENCON projects are identified and budgeted in annual budget. Major ENCON projects are listed in annual report. 41 Daily Monitoring & Reporting Formats E I L - H E A T E R Flow Efficiency Items Supply Temp. Return Temp. Distributed Heat Fired Heat Furnace Oil cons. C C T/Hr MKcal/HR MKcal/HR MT/Day % Unit Power Distribution (kwh) Plant Film Batch Poly Total Cen. Utility Plant Film Total Batch Poly

22 Steam Balance Item Generation thru boiler Consumption by users Batch / Gly. Rec. Poly Plant Jumbo Heater Film Plant Deaerator FO / Tank Farm Losses Furnace oil cons. Briquette Cons. Unit MT/Hr. MT/Hr. MT/Hr. MT/Hr. MT/Hr. MT/Hr. MT/Hr. MT/Hr. MT/Hr. MT/Day MT/Day Water Cons (M3/Day) Plant Cons. Film 250 Batch 179 Poly 167 GIL 23 Total 619 Energy Conservation target setting and monitoring of the same Plant Film Chips Planned target for (a) kwh/ Ton Million Kcal/ Ton Actual achieved in (b) kwh/ Ton Million Kcal/ ton % Reduction (+) or Increase (-) (a-b) / a* 100 Electrical Thermal Money saved during Rs. lacs Boiler efficiency %

23 Sr. No 1 External Energy Audit Observations ( ) 1. EIL New Delhi Observations Arch pressure transmitter changed to higher pressure range transmitter to tune outlet oxygen percentage. 2. CHEMBOND, Mumbai Sr. No 1 Observations Chilled water flow measurement to Pre-Poly condenser done and decided to install Booster Pump Investment Rs. 2.0 Lacs Investment Nil Saving 6.0 MT F.O.- Rs 1.48 Lacs per Month Saving Rs Lacs per Month Present Status Implemented Present Status Under implementation Sr. No External Energy Audit Observations ( ) 1. EIL New Delhi Observations Put burner firing oil pressure control on return header temp. ID/F.D fans speed tuned through drives to maintain oxygen percentage in stack 5-6 percentage Investment Rs 10-lacs _ Saving Improved productivity and product quality 6.0 MT F.O.- Rs 1.48 Lacs per Month Present Status Implemented Implemented

24 2. Kaeser Compressors (India) Pvt Limited, Pune Sr. No Observations Replacement of system blower with energy efficient blower in Film Plant Waluj. Replacement of Nitrogen blower with energy efficient blower in Batch Plant. 3. Atlas Copco, Pune Sr. No 1 External Energy Audit Observations (08-09) Observations Air flow measurement of various systems, and calculation of present specific power consumption. Investment Rs 5.0 Lacs Rs 5.0 Lacs Investment Rs Lacs Saving Rs 0.95 Lacs per Annum Rs 0.95 Lacs per Annum Saving Rs 18 Lacs per Annum Present Status Will be considered for project. Dropped due to process constraints. Present Status Will be considered during project. Sr. No Awareness Creation in Employees Program name & Details Energy Conservation, Renewable Energy & Energy Audit ( ) Energy conservation in utility by Mr. V.S.Saraf. ( ) Energy conservation in electrical by Mr. A.A. Bugdani. ( ) Seminar on rotating equipments ( ) Managing Energy Cost ( ) ENCON MEDA ( ) Seminar on Reducing energy bill for lighting ( ) Organized By MEDA / FICCI In House In House CII Power line, New Delhi MEDA TAACT, Nasik No of Participants Duration 1 Day 3 Hours 3 Hours 2 Days 2 Days 1 Day 1 Day

25 Utility cost for month.. Sr. No Utility 1) Hot oil 2) Steam (F.O.) 3) Steam (Briq.) 4) D.M.Water 5) C.W.Water 6) Compr. Air 7) Instr. Air 8) PSA Nitro 9) Chilled Water 10) Soft Water 11) F.O. 12) Power 13) MIDC-Water Cost Unit Rate Rs/MKcal/Hr. Rs/MT Rs/MT Rs/M3 Rs/M3 Rs/M3 Rs/M3 Rs/M3 Rs/Tr Rs/M3 Rs/MT Rs/Unit Rs/M3 49 Power Factor Incentive Benefit: S N Total Month Apr. May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Grand Total Year (05-06) Year (06-07) PF Incentives Year (07-08) Year (08-09) Year (09-10) Year (10-11)

26 Renewable Energy Utilisation Renewable Energy Sources, Utilization of Waste Biomass fired boiler commissioned in Jan Thereby, replacement of 1800 MT of furnace oil by agriculture waste. Waste wooden material is burned in boiler to reduce furnace oil consumption

27 ENCON Projects Implemented in Garware Industries Limited, Waluj, Aurangabad. Best Practices Implemented On Energy Front Amongst Associates. Sr. No 1. ENCON Project H-line blower speed reduction 15 %. Annual Saving Power Lac-kWh 0.69 Annual Saving Rs-Lacs Investment Rs-lacs 0.10 Simple payback months. 1 Month 2. Primary Therminol circulation pump impeller trimming Month 3 Primary Therminol circulation pump impeller trimming Month 53 4 Total _ 54 27

28 Corrective Preventive Action Company Name/Code Job Description/Code: Product Name : Date(s) : Clause : Department : Contact(s) : Type of findings 24/12/ Analysis of Data Engg-Film - Waluj R.S.Jamdade Minor GARWARE POLYSTER AURANGABAD Re-Certification ISO 9001:2008 Number : Team Leader Team Member (s) : DWA/ Dattatray Waghmare Omprakash Modak

29 Non Conformity Requirement of the clause: As Per standard ISO Clause No Analysis of data The organization shall determine, collect and analyze appropriate data to demonstrate the suitability and effectiveness of the quality management system and to evaluate where continual improvement of the effectiveness of the quality management system can be made. This shall include data generated as a result of monitoring and measurement and from other relevant sources. The analysis of data shall provide information relating to characteristics and trends of processes and products, including opportunities for preventive action Non -conformity- A. Process Engg film plant Waluj- Vibration analysis Dtd 24/Sept 2009 for line 4 specifies various alarms like inspect the bearing, insufficient contact area at motor base etc, data observed to be not analyzed for necessary actions. Corrective Action Report (to be completed by the company) : Proposed Completion Date 30/12/2009 Company Representative : Corrective Action J V Deshmukh A) Variance analysis carried out for the Last three Quarters and wherever required Corrective actions taken in order to achieve the Target. B)Short shutdown was taken on and actions taken on vibration analysis report dated 24/11/09. Motor was removed to inspect the base. Following actions taken. 1)Cleaning of foundation plate. 2)Realignment of the motor. 3)Re-Tightening of blots with torque wrench. Root Cause : (1) The status of recommendation for vibration report was ALERT, which required monitoring the trend, however corrective action could not be taken as shutdown was required. Corrective Action : (1) Tightening of blots on monthly basis for such kind of machines as per status of recommendation. (2) Action plan for observations and action recommended by outsourced NDT activities now implemented in preventive maintenance schedule. (Format F /ENG/023/05)

30 V.S.SARAF G.M. (UTILITY) & ENERGY MANAGER MOBILE NO