@ The Ramco Cements Limited, JPM

Transcription

1 Experience of ISO : Implementation & Best Practices for Energy The Ramco Cements Limited, JPM

2 Journey to ISO : Implementation We have started the Energy Conservation activity in the year To begin with, we have divided the whole plant into 11 Teams. These teams comprised of One member (Total 4-5 members) from each department. Review meetings conducted on monthly basis. In the meeting each team presents their Workings on Energy Conservation to the Management. After getting approval, the project gets implemented. In the next month meeting, the project status will be reviewed. The Consolidated Annual Achievement has shown in the next slide.

3 Savings Achieved Year Savings (Lakh KWH)

4 ISO : Implementation / Certification We have implemented the ISO : EnMS in the year with the External Certification Agency British Standards Institute (BSI). It has taken approx 6 months for completion of all the Documentation. The Energy Team Structure continued with addition of 2 more teams on the way of Energy Conservation (to ease out the implementation). In the month of August 2014, Certification Audit was carried out. After successful completion of the Audit, we were certified for EnMS (ISO: ) in the month of October 2014.

5 Energy Conservation Activities The Energy consumption & deviation is being monitored by individual team members on daily basis. Review of the same with Corrective Actions (if any) is being discussed in meeting with concerned HODs. Concerned HOD in turn discuss these with Top Management on daily basis. Monthly once Energy Review Meeting conduced with Energy Team Members to discuss Energy Performance & Energy Management Action Plans with Apex Committee.

6 Energy Conservation Activities Competitions are being conducted twice in a year on Energy Conservation Day & Our Founder s Day. This Competitions include: Energy Conservation Projects Presentation among Energy Teams. For employees, contract workmen, ladies club members, school children: Slogans, Essays, Paintings, Skit programs, etc.

7 Energy Conservation Activities The winners are felicitated with suitable rewards / awards. As a motivation for energy conservation, LED Bulbs are distributed as gifts to: Apex Committee Members Core Committee Members All Energy Team members

8 APEX COMMITEE Sl. No. Name Designation 01 Sri PB Gopalakrishna Sr. President - Mfg. 02 Sri T Sridhar Reddy Asst. Vice President - Works 03 Sri AV Satyanarayana Sr. Mgr.- Mech. CORE COMMITTEE Sl. No. Name Designation 01 Sri S Rajasekharan GM Process & Quality Control 02 Sri D Sitaramaiah Dy. GM - Mech. 03 Sri S Kesavaperumal Dy. GM Inst. 04 Sri V Venkatapathi Asst. GM Elec. 05 Sri VV Trinadha Rao Asst. GM - Elec. 06 Sri SVSN Raju Sr. Manager - Mech. 07 Sri P Sreekanta Reddy Manager Inst. 08 Sri R Venkatapathi Gupta Dy. Manager - Mech. 09 Sri Chandan Kumar Parasar Dy. Manager - Process 10 Sri M Sreedhar Asst. Manager - Elec.

9

10

11

12 Savings Achieved (After Implementation of EnMS) Year Savings (Lakh KWH)

13 Some of The Best Practices carried out for Energy Conservation in the Year

14 Best Practices for Energy Conservation in I. Removal of Line-2 Cooler Fans Inlet Silencers: Description : The Pressure Loss across Line 2 Cooler Fans Inlet Silencers was observed in higher side ( mmwg), which leads to extra load on respective Fan Motor. We have removed Fan Inlet Silencers for 6 Nos. of fans. After removal, the Pressure Loss has dropped to mmwg. After modification, the Sound levels are measured (74-76 db) and these are within the specified limits (85 db). Unit Savings Cost Savings : 1320 KWH/Day : Rs Lakh/annum Project Investment : Internal Resources

15 Before After

16 Best Practices for Energy Conservation in II. Modification of Line II Tertiary Air Duct Damper Design: Description : The OEM has provided Hollow Type Tertiary Air Damper with cooling arrangement. In case of wear or erosion of Damper, cooling air directly entering to the system & thereby reducing the Tertiary Air Temp. To avoid this, we have gone for a solid type Damper with Castable application on surface, which is not supported by any cooling arrangement. By this, the false air entry into the system got avoided fully. Unit Savings Cost Savings :108 kwh/day, 1 TPD of Coal Consumption : Rs. 9,02, per annum

17 LINE2-KILN Bag house KILN FEED TA Duct KILN COOLER

18 Cooling air exit DAMPER OPEN DAMPER CLOSE TA Duct Damper Blower Running for TA duct Damper Cooling TERTIARY AIR DUCT CROSS SECTION OF TA DUCT WITH DAMPER

19 Blower Ideal Running

20 New TA DUCT DAMPER TERTIARY AIR DUCT Page 20

21 Best Practices for Energy Conservation in III. Replacement of SV Lamps with LED Fittings In Silos & Workshop Areas: Description : We have replaced 100 Nos. of SV lamps (150 W each) with LED fittings (40 W each) at Silos & Workshop areas. Savings : KWH (15 kw x 12 hrs x 365 days ) Cost Savings : Rs / year Savings by avoiding bulb replacement : Rs / year Total Cost Savings : Rs =Rs Project Investment : Rs. 4,00,000 Payback : 15 months

22 Best Practices for Energy Conservation in IV. Improvement of Plant Water Supply Pump Performance Description : The length & bends of pipe line has reduced by rerouting and increased the diameter of pipe from 6 to 10 to reduce the friction & Head loss. we achieved the pump out put from 230 to 410 M3/hr. Savings Cost Savings : KW : INR per Anum

23

24 Best Practices for Energy Conservation In

25 Best Practices for Energy Conservation in Replacement of LRS with GRR in Cement Mill Separator Fan Description : The Mill Separator Fan is running in LRS with Damper Opening of 65-70% only to get the required flow. But the Pressure Loss across the Damper was maintaining in the range of mmwg. During the Line-1 Up-gradation we have reused the spare GRR from our Coal Mill Fan to this separator Fan. After GRR installation, we are now running the fan with full damper opening by controlling the speed. With this the Pressure Loss across the damper has reduced to mmwg only & the Power saving has achieved to 55 KW. Savings (KWH) : 660 KWH/Day Cost Savings (INR) : Rs /Anum Project Investment : In House shifting only

26 Best Practices for Energy Conservation in % Petcoke usage as a Fuel in Pyro System Specific Coal Consumption has reduced by 4.5% (From 14% to 9.5%) Coal Mill Specific Power Consumption also reduced by reduction in the Coal requirement (by approx 4-5 hrs)

27 Best Practices for Energy Conservation in (Project under Implementation) Replacement of Flyash Bulk tanker unloading Conventional Screw Compressor with Energy Efficient Low Pressure Lube Compressor Description : Replacement of existing 110 kw Screw Compressor with 55 kw energy efficient Godgrej make Screw Compressor Total Projected savings (KWH) : Cost Savings (INR) : Cost savings in maintenance Rs. : Total annual saving Rs. : Project Investment Rs. : 13,00,000 Payback : 11 months

28 Proposed low pressure Lube Compressor of M/s Godrej make-(55kw)

29 Best Practices for Energy Conservation in (Project under Implementation) Line-1 Up-gradation Capacity enhancement from 3500 TPD to 4600 TPD by New Cross Bar Cooler & New Additional Preheater Installation Thermal energy savings : 30 Kcal/Kg clinker Electrical energy savings : 5.10 KWh/T Clinker Project Under Progress

30