Case Study_Welspun India

Welspun Group | Name of BusinessWelspun Group | Welspun India Limited

Energy & Resource Management – WIL , Anjar5th MAR 2013

Welspun Group | Name of Business

About Welspun ………….

Over the past 25 years ,

Welspun has emerged as one

of the India’s fastest growing

multinationals. From a modest

beginning , Welspun is now a

Welspun Group | Welspun India Limited

Core Businesses…

-Home Textile

-Pipes

-Plate & Coil

-Steel

-Powerbeginning , Welspun is now a

USD 3 billion conglomerate

having a strong international

brand equity , with an

unwavering commitment and

passion towards excellence ,

Driven by our Motto :

“ Dare to Commit “

-Power

-Renewable Energy

-Infrastructure


Welspun India Limited Welspun India Limited


Energy & Resources :

1). Electricity - Machine , compressors , HVAC , water & waste water

2). Thermal energy - Steam , Hot water , Thermic heat 2). Thermal energy - Steam , Hot water , Thermic heat

3). Gas – LPG or Natural gas

& water - the most precious resource now a days


Electricity Electricity -- Present PatternPresent Pattern


Share of Electricity Uses

Spinning Machines

Weaving Prep & Looms

Processing and Made-ups

Compressed Air Compressed Air

Humidification & HVAC

Water & Waste Water Division

Boiler & Heat

Lighting & Others -


Thermal Energy Thermal Energy -- Present PatternPresent Pattern


Sizing

Desizing & Pretreatment

Merserizing

Cont. Dyeing Range

Washer

Finishing -Steam Finishing -Steam

Finishing - Thermic Heat

Caustic Recovery Plant

Distribution Losses &Misc


Welspun India Limited Welspun India Limited –– Way to Energy Conservation Way to Energy Conservation


Our Strength

•Top Management Support

•Measure & Monitoring System

Our Strength

•Top Management Support

•Measure & Monitoring System•Measure & Monitoring System

•Qualified & Competitive Team

•Periodic Review

•Measure & Monitoring System

•Qualified & Competitive Team

•Periodic Review


Electricity Conservation Electricity Conservation –– Major Steps taken in last 2 yearsMajor Steps taken in last 2 years


Target Area Major Steps Target Achieved Tools Adopted

Units/day Units/day

Compressed Air 1). Leakage Minimization 10000 9150 Flow & Energy Metering

2). Pressure Optimization Internal Audit

3). Cleaning Air Control Leakdetection

4). Loading & Unloading Pattern Awareness Program

HVAC 1). VFD at return fans 3000 3587 Flow & Energy Metering

2). Avoid Throttling to Pumps Cordination with prodn Dept

3). Avoid Fan Damper Throttling

4). Modification in Pneumafil Return Trench

Water , Waste Water 1). Trimming Impellers as per Actual Reqn 2500 2788 Internal Audit

and Pumping Systems 2). Avoid Discharge Valve Throlling Flow & Energy Metering

3). Operating on VFD w.r.t. Pressure Reqn Pressure Transmitters

4). Run Blowers with VFD w.r.t. Dissolved Oxygen Dissolved oxygen Controlling

5). VFD on Filter Feed Pumps

6).Elimination of Leakages & Wastages

Boiler & Heat Section 1). Effimax Control System 350 245 Efficiency Controller System

2). VFD at ID Fans of AFBC Boilers & TFH Automation

Production Machines 1).VFD at Exhaust Fans of Finishing Machines 4400 3900 Flow & Energy Metering

2).Lighting Rearrangement & Mirror Reflectors

TOTAL 20250 19670 97%


THERMAL ENERGY Conservation THERMAL ENERGY Conservation –– Major Steps taken in last 2 yearsMajor Steps taken in last 2 years


Target Area Major Steps Target Achieved Tools Adopted

GENERATION SIDE 1). Efficiency Monitoring System 3.0 2.7 Effimax System

2). Automation of ID & FD fan Operation to reduce Coal Counter Meters

Stack losses & control excess air Flow & Heat Metering

DISTRIBUTION SIDE 1). Insulation - Replaced old Insulation with High Density "HITLIN" 6.5 5.6 Internal Audit

2).Periodic Internal Audit Surface Temperature Meter

3). Ensuring Dry Steam

Coal in MT/day

3). Ensuring Dry Steam

CONSUMER SIDE 1). Metering & Monitoring at Each Machine/process 2.5 3.1 Internal Audit

2). Internal Audits for leakages & radiation losses Flow & Heat Metering

3). Steam Trap -Performance Checking

4). Reuse of Steam Condensate in Process M/cs

5). Reuse of Hot Condensate & Hot Circulation Water

of Caustic Recovery Plant

6). Heat Exchangers at Each Machine Drain to recover Heat

7). Control of Exhuast fans of Finishing machines

8). Air Preheating from Stenter Exhaust

TOTAL 12 11.4 95%


Water Water -- The Most Precious Resource ( Not less than a Fuel ) The Most Precious Resource ( Not less than a Fuel )


Target Area Major Steps Tools Adopted

TREATMENT SECTION 1). Recovery from Waste Water 90+% 88.80% Waste Water recovery plant

2). Resue of usable drains like Cooling Water etc 300KLD 320KLD Internal Audit & Cordination

3). Reutilize the Filter drains by re-clarifying 200KLD 150KLD Treatability Studies

AT CONSUMER END 1). Metering & Monitoring at Each Stage , Process & Machine Flow Meters & Controls

( BED SHEET PROCESS ) 2). Optimize the water requirement at each stage Internal Audits

Target Achieved

60L/kg of

Fabric

57.2 L/Kg

of Bed ( BED SHEET PROCESS ) 2). Optimize the water requirement at each stage Internal Audits

3). Periodical Audit for leakage & wastages

4). Resue of Cooling water & usable hot water into the process

AT CONSUMER END 1). Metering & Monitoring at Each Stage , Process & Machine Flow Meters & Controls

( TERRY TOWEL PROCESS )2). Optimize the water requirement at each stage Internal Audits

3). Periodical Audit for leakage & wastages

4). Resue of Cooling water & usable hot water into the process

HARVESTING Rain Water Harvesting Through Trench & Canal Network Harvesting Network1200

Million

L/year

58L/kg of

Fabric

from

49L/kg for

Processin

47 L/Kg of

Terry

Towel

Processed

(19%)

Fabric

from

75L/kg for

Processin

of Bed

Sheet

Processed

(24%)


SUMMARY SUMMARY -- CONSERVATION IN LAST 2 YEARSCONSERVATION IN LAST 2 YEARS


Electrical Saving : 19670 Units /day

or Equivalent to 1512 TOE per annum

Coal ( Fossil Fuel ) Saving : 11.4 MT Coal /DayCoal ( Fossil Fuel ) Saving : 11.4 MT Coal /Day

or Equivalent to 1632 TOE per annum

Water Conservation :- Rain Water Harvesting of average 1200 Million Lt / year- Waste Water recovery – 2000 Million Lt/ year- Conservation & Reuse - 720 Million Lt /Year


RENEWABLE ENERGY RENEWABLE ENERGY


Welspun India Limited

Has Taken Initiative within premises and Installed Nisargruna BioGas Generation plant from Canteen & all other Biodegradable waste . The Plant can handle 5MT of waste per day. Presently feeding 1.5-2.0 MT waste per day and generating methane equivalent to 30Kg of LPG used for cooking in Canteen .generating methane equivalent to 30Kg of LPG used for cooking in Canteen .

Welspun Energy Limited

“WEL” have made plans keeping in mind our long-term goal – to make India energy-independent. Over the next three years, we will develop several renewable energy based power projects. Our capacity buildup plans is helping us create pipelines for developing over 750 MW of solar projects and a wind capacity of 1000 MW.

It has already commissioned 75 MW Solar Projects in India and another 35MW will be added in coming few weeks.

Welspun Group | Name of BusinessWelspun Group | Welspun India Limited

THANKS5th March 2013

Documents

Case Study_Welspun India