th National Award for Excellence in Energy Management … 11th National Award for Excellence in Energy Management 2010 Kirloskar Oil Engines Ltd., Khadki Contents Introduction SEC

1

11th National Award for Excellence in Energy Management 2010

Kirloskar Oil Engines Ltd., Khadki

Contents

Introduction

SEC Reduction in last three years

SEC – How close to Global best?

Innovation in Project Implemented

ENCON Project (2007-10)

Projects linking to Carbon Emission Reduction & Environment

Employee Involvement & Methodology

Utilization of Renewable Energy Sources

Waste to Energy Projects

Inputs from ISO 14000/9000 & OHSAS

Replication of best practices

CSR initiatives

Award & Accolades

Way ahead

Introduction of KOEL

KOEL - Company Profile

Self Certification by Indian Army -2001

ISO 14001 -> 1998

ISO 9001 -> 1992

Plants at Khadki Kagal, Rajkot, Nagar, Nashik

Incorporated in 1946.

EN 16000 & SA 8000 -> 2012

OHSAS 18000 & FM

Approval 2009

TPM, KAIZEN, CE 2006

Zero water discharge company

TS16949 2004

2

Products

Diesel engines ranging from 3 hp to 11000 hp.

Biggest : 11,000 hp

Smallest : 3 hp

Engine Bearings

The Kirloskar Green Genset

‘KIRLOSKAR GREEN POWER IDEAS’

World’s largest selling Genset Brand

Product Applications

Off Highway Tractors

Defence & Power Generation Agriculture

SEC Reduction in

last three

years

3

Achievement - Specific Energy Consumption

Year KWh/ BHP KWh / Bearing (HSD)Litres /BHP

2007 - 2008 3.66 0.081 0.38

2008 - 2009 3.54 0.074 0.36

2009 - 2010 3.32 0.064 0.33

15% Reduction

in SEC

Benchmark Line

34% Reduction

in SEC

Benchmark Line

29% Reduction in SEC

Benchmark Line

Achievement - Specific Energy Consumption

Absolute Reduction in Energy Resources

Energy / Utility Resource 2007-08 2008-09 2009-10Absolute % Reduction

wrt Previous Year

Electrical Power in MkWh units

22.39 15.46 14.1 8.80

HSD in KL X 102 20.40 13.23 11.02 16.70

Water in KL X 10⁴ 12.89 9.82 7.92 19.31

Compressed Air in MkWh

3.58 2.49 2.36 5.07

Product 2007-08 2008-09 2009-10

Engines (Electrical Energy) 5.9 % 3.27 % 5.0 %

Bearings (Electrical Energy) 17.3 % 9.13 % 13.5 %

Engines (Thermal Energy) 19 % 5.2 % 8.33 %

% Reduction in SEC w.r.t. Previous year’s SEC

Target & Performance - SEC

2

2.4

2.8

3.2

3.6

4

2006-07 2007-08 2008-09 2009-10

3.8

3.66

3.4 3.4

3.89

3.663.54

3.32

KW

h/B

HP

Year

Engine - Specific Energy ConsumptionTarget Vs Performance

Target PerformanceBenchmark = 3.2 kWh/BHP

4

0

0.02

0.04

0.06

0.08

0.1

0.12

2006-07 2007-08 2008-09 2009-10

0.11

0.087

0.075

0.065

0.096

0.081

0.0740.064

KW

h/B

ea

rin

g

Year

Bearing - Specific Energy ConsumptionTarget Vs Performance

Target PerformanceBenchmark = 0.061 kWh/BRG

Target & Performance - SEC

SEC – How close to

Global best?

KOEL, Khadki

MNC Competitor

A

MNC Competitor

B

3.32 KWh/BHP

5 KWh/BHP4.2

KWh/BHP

External Benchmark

Product – Engines

External Benchmark

Product – Bearing

KOEL, Khadki

Competitor A

0.064 KWh/Brg

0.12 KWh/Brg

Internal Benchmark

Product – Engines

KOEL, Khadki

KOEL, Kagal

KOEL, Rajkot

3.32 KWh/BHP

3.85 KWh/BHP

3.2 KWh/BHP

Internal Benchmark

Product – Bearings

KOEL, Khadki

KOEL, Nagar

0.064 KWh/Brg

0.072 KWh/Brg

Data source – www.energymanagertraining.com MEDA Competition CD

SEC –External & Internal Benchmark

Innovation in Project

Implemented

5

Green Technology Cell

The goal of GTC is to develop commercial &sustainable business models based on variousgreen and renewable energy technologies & as wellas energy management solutions to meet theenergy needs of each consumers in an environmentfriendly manner.

Innovative Project No. 1 In-house Research Facility

Pilot Scale Research Facility

Field Scale Biogas plants

Lab Scale Research Facility

Biogas to Power & Fuel

Biogas plants H2S Scrubber

Storage

Biogas Gensets

Compressor

Cylinder Cascade

Vehicle Application

Rural Energy Solutions (Biogas)

Biogas plantsH2S Scrubber Storage Biogas

Genset

Street Lighting / Community Application

House Lighting

Storage

Cooking Gas

6

Innovative Project No. 2

Renewable Energy Supply for Rural Area (RESRA)

GTZ initiated project

Under this project 24 Greengensets are installed at 24 villagesof Korba District of Chhattisgarhstate.

Energy will be produced throughstraight vegetable oil (SVO) andbiogas (Local resources)

Energy for tribal peoples for 6 to 8hours per day.

Similar project is also undertakenby KOEL at Kolwan village of Punedistrict.

After

Regenerative Panel

Total Investment : ` 30 Lakhs

Annual Savings in Rs. : ` 5 Lakhs

Payback period : 6 Years

Description After

• During Genset testing, energy waswasted in resistive load banks.

• We have developed UPS & testingpanel to use generated energy forinternal application.

• Use of double conversion gridinteractive Device consist of IGBTbase front-end rectifier andinverter.

• Regenerative test bed for Genset

• First of it’s kind in industry

• Greater replication potential

Use of Grid Synchronizing UPS & Panel for Genset Testing


After

Furnace after modification



Payback period : 3 months

Description After

• In Heat Treatment plant, there arefour numbers of diesel fired meltingfurnaces. Melting of Al-metal is takeplace at 6600 C.

• Flue gases from these furnaces aregenerally released to theatmosphere through scrubber.

• We have installed small unit onfurnaces through which flue gasesare diverted to the charge.

• We observed that cycle time isreduced by 45 minutes. This hassaved 13.5 lit of diesel per charge.

Waste Heat Recovery from Al-Foundry


Exhaust compressed air stored and reused for low pressure application

Reused exhaust air for cleaning

Total Investment : ` 0.25 Lakhs

Annual Savings in Units:108576 kWh

Annual Saving : ` 5.97 Lakhs

Payback period : 15 days

Before After

Air was wasted through exhaust

Exhaust pressurized air in continuousproduction line is used for low-pressureapplications. Due to this activity overallpressurize air consumption is reduced ofACBG shop.


7

Replaced the Age Old MG Set Induction Motor Generator by Static Converter

Static Convertor Panel


Annual Savings in Rs. : 7.3 Lakhs

Payback period : 34.5 months

Before After

Motor Generator


On Induction Hardening M/c No. 8106,earlier motor generator set is used. Thiswas replaced by Static Converter which isswitched On/Off only when the heatingprocess actually occurs. Also theefficiency of MG Set is only 60% ascompared to static converter.

Reduce idle running of 18hrs

of 26 KW load

First to approach BEE to initiate star ratings for engine driven pumpsets .

Our newly developed VARSHA pumpsets are 25 to 30% more fuel efficient

compared with Chinese pumpsets.

This will help our country to reduce the penetration of inefficient Chinese

pumpsets and improve nation’s energy security.

30,000 Varsha pumpsets sold in 2009-10 and it reduces the CO2 emission by

about 12,000 tons per year.

KOEL’s Digvijay engine of 500 KVA rating is also most energy efficient among its

category. These engines can also be run on 100% biodiesel.

Our 4R810 engines are having highest energy efficient in the world –

Comments given by OEM JCB.

Launched higher fuel efficient gas engines also resulting into 50% reduction in

emissions

Innovation in Products

Response from Customers Response from Customers

KOEL has developed the super silent Genset.

The first super silent Genset is installed at residence of Ministry

of Power, GoI, New Delhi.

This Super Silent Gensets meeting the requirement of less than 65dBA sound pressure level for 15 to 62.5 kVA rating as per measurement guidelines given in ISO 8528-10 .

8

ENCON Project

(2007-10)

Summary of ENCON Projects

Sr.

No.

Year No. of

measures

Implemented

Investment

Made

( ` Lakhs )

Annualized

Saving (`

Lakhs )

Energy

Cost

( ` Lakhs

per Yr)

% saving (saving

achieved /Energy

cost of previous

year)

1 07-08 25 33.55 72.80 1133.04 6.51 %

2 08-09 107 56.77 169.65 843.60 14.97 %

3 09-10 37 73.10 98.35 777.17 11.65 %

Total 169 163.42 340.8

ENCON Projects are always having top priority at Management level.

No budget restriction for the ENCON projects having payback period less than 3 years

ENCON Project CAPEX approval by top Management is within 24 hrs – lowest in any industry.

Particular No. of Projects

Investment in Rs Lakhs

Savings in Rs Lakhs

Avg. Payback Period

Zero Investment Projects 69 0.0 90. 5 Nil

Low Investment Projects (< Rs 5 Lakhs)

59 37.5 110.48 6 Months

Summary of ENCON Projects

Zero Investment Projects

Eliminating the idle running of Hydraulic /Spindle/ Chilling Units by using PLC/ Timers on SPMs and CNCs

Spindle motors run ion Star-Delta-Star as per grinding requirement on Grinding machines

Spindle motors switched off in Logic as per Component variety

Optimization of Compressor operation using EMS System

Casting forged camshaft instead of Steel Camshaft for Ha series eliminated Induction Hardening Operation

Modification in water piping at Admin Bldg sprinkler

Spindle run in Star when not grinding

Total Investment : Nil

Annual Savings : 114504 kWH

Annual Savings in : ` 6.29 Lakhs

Description After

• Start to delta configuration

• Spindle motors of Grindingmachines were run in delta onlyduring grinding operation, in starwhen retracted in cycle

• Horizontally deployed on allGrinding machines in all Mfg.Plants throughout Khadki Location

ENCON Projects


9


Hydraulic switched off when idle

Total Investment : Nil

Annual Savings in Units : 14.60 Lakh kWh

Annual Saving in : ` 80.32 Lakhs

Description After

• Stop the idle running of HydraulicPumps, Spindle motors, Oil andcoolant chilling units and pumpsby modifying PLC Logic, ElectricalLogics or Limit switches.

• Horizontally deployed on allSPMs, GPMs, CNC machines,Conveyors, Press machines in allMfg. Plants throughout KhadkiLocation

ENCON Projects

Motor with Belt drive and VFD


Annual Savings in Rs. : ` 52Lakhs

Avg. Payback period : 5 Months

Before After

Gearbox Assembly

Replaced Gear box assembly by VFD andMotor- Belt drive horizontally deployedon 27 machine in all Mfg. Plantsthroughout Khadki Location

ENCON Projects

Low Investment Projects

Energy Efficient Pump


Annual Savings in Rs. : ` 27.5 Lakhs

Payback period : 4 Months

Before After

Conventional Pumps

Replaced conventional induction Pumpsby Energy Efficient pumps –

As per our KBL water pumping auditreport, we have replaced conventionalinduction pump-motors 23 nos total 85kW by 38 kw in all Mfg. Plantsthroughout Khadki Location

ENCON Projects

Low Investment Projects After

Washing Machine

Total Investment : ` 0.1 Lakh


Payback period : Immediate

Description After

• On Paint booth Washing zoneengine was being washed withheated effluent more than 600 C.

• Now the effluent is replaced bysolution containing Prototex-2,which retains all qualityparameters and requires

• NO HEATING. Hence we havesaved electricity required to heatthe effluent.

Use of Special Type Washing Liquid For Engine Cleaning

ENCON Projects


10




Description After

At our R & D center, hot water wasgenerated by using electrical heaters forcanteen applications. We have installedsolar water heating system for replacingthe electrical geysers. Size of the solarwater heating system is 375 Lits.

Annual Energy Savings = 12840 KWh

Installation of Solar Water Heating System for Canteen

ENCON Projects

Low Investment Projects After



Payback period : 1.5 years

Description After

For improving the internalenvironment & day light level, wehave installed turbo ventilators &transparent sheets at HeatTreatment shop. Turbo ventilatorsare wind driven eco-friendlysystems. To maintain sameenvironmental condition we haveinstalled 36 units instead of 24 fans.

Wind driven turbo ventilators for HT shop

ENCON Projects





Description After

Installation of Godrej Make Control AirSystem to reduce the pressure dropacross the plant and saving theelectrical energy. This system is workedon the basis of demand sidemanagement (DSM) for airconsumption.

Avg. energy consumption before installation = 10200 KWh/Day

Avg. energy consumption after installation = 9626 KWh/Day

Annual Energy Savings = 1,79,088 KWh

Control Air System For Central Compressor HouseDemand Side Management

ENCON Projects




Description After• Installation of VFD for 1000 CFM screw

compressor.

• Benefits of this project are as follows.

• Avoid high starting torque

• Increased the life of motor & compressor

• Reduction in breakdown & maintenance cost

Avg. energy consumption before installation of VFD = 6854 KWh/Day

Avg. energy consumption after installation of VFD = 6162 KWh/Day


VFD For Screw Compressor

ENCON Projects

11

Replacement of old motors by EE Motors

EE Motor




Before After

Old Motor

95% EE,

(NEMA Premium)

Make – Baldor Electricals, USA

Motors of old reciprocatingcompressors were very much old,inefficient & consuming high energy.We have replaced two motors of rating90 KW & 55 KW by NEMA premiumhigh-energy efficiency motors of M/sBaldor Electrical, USA.

ENCON Projects

Waste Heat Recovery from Al-Foundry

Washing Machine



Payback period : 4.3 years

After After

Scrubber

For improving the environmentalconditions of HT shop, we have installedwater scrubber at the exhaust of meltingfurnaces. Hot water available from thisscrubber is used for component washingmachine. Due to this, we can remove theelectrical water heaters of the washingmachine.

ENCON Projects


Annual Savings in Rs. : ` 16Lakhs


Description After

Earlier we were using the heatless dryersfor removing the moisture fromcompressed air. This type of dryers arenot energy efficient & also perform verypoor. Therefore, we have installedrefrigerated air dryer (RAD) of 2000 CFMin place of heatless air dryer (HD).

Annual energy consumption before installation = 336960 KWh

Annual energy consumption after installation = 7270 KWh


Installation of Refrigerated Air Dryer

ENCON Projects

Projects linking to Carbon Emission

Reduction & Environment

12

Projects linking with Carbon Emission Reduction

Sr. No

Title of project implemented

Year of Implementation

Total CO2

Reduction

Total Annual Savings

Invest. Made Payback

monthsNo of CERs /

VERsRs Million Rs Million

1Wind Power Project of 5.6 MW capacity

2007 9100 52.0 280 64

2.Manufacturing of biodiesel at OEM (Program of Activities)

2010 4500 30 100 40

Other Projects linking with Carbon Emission Reduction

• Waste heat recovery project at Al foundry

• Use of canteen waste for biogas generation

• Reduction in engine testing cycle time & use of cold testing

• Use of bio-LDO in place of HSD for melting furnaces

• Use of bio-diesel for in-house power generation

• Engines running on biogas

• Utilization maximum day light

• Elimination of TCE (trichloro ethylene)

• Waste heat recovery from compressors

Employee Involvement

&

Methodology

ENCON – The Kirloskar Way

Our approach is two pronged. One, we will continuously keep minimizing use of energy in ouroperations. Two, we will develop economically viable green products. - Chairman Speech 2007

13

Policies & Strategies

Singed in 2007

• Energy PolicyPublished in

2002

• CII – Code for Ecologically Sustainable Growth

Revised in 2009

• EHS Policy

In Process

• Policy for procuring EE equipments

Energy & EHS Policies

KIRLOSKAR OIL ENGINES LTD.

ENERGY POLICY

Achieving optimum use of energy in our operation and bringing

about improvements in the energy efficiency of our processes and

products will form an important components of the continuous

improvement efforts in our organization.

We shall strive to reduce energy consumption per unit of value

added by :-

• Minimizing wastages using Energy Efficient processes and equipment.

• Conducting periodic Energy Efficiency improvement studies and implementing improvement measures.

• Involvement of employees of all levels in the energy conservation efforts.

• Effective dissemination of information

• Establishing norms and initiating programmes to reach these norms.

• Promotion to renewable Energy resources within & Outside KOEL.

In achieving these, we shall utilize the knowledge and expertise

available from various sources including sister organization,

collaborators and outside experts.

We shall make efforts to bring continuous improvement in the energy

efficiency of our products.

Atul Kirloskar

Reviewed :- 10-May-2005 Chairman & Managing Director

EHS policy Energy Policy

Being Cognizant of the need of sustainable growth as dwindling stock of natural capital, we commitourselves to attainment of the following Ten – Natural Capital Commandments.

1. Reduce specific consumption of energy and water by 3-5% every year over next ten years.

2. Reduce specific generation of waste and reduce the quantum of waste going to land fills by 3-5%every year over next ten years.

3. Increase use of renewables, including renewable energy by 5% every year in place of non-renewableover next ten years.

4. Reduce greenhouse gases emissions and other process emissions by 3-5% every year over next tenyears.

5. Increase use of recyclable and enhance recyclability of resources embedded in the product.

6. Increase the share of harvested rainwater in the overall annual use of water by 5% every year overnext ten years.

7. Incorporate life cycle assessment criteria for evaluating new and alternative technologies andproducts.

8. Strive to adopt green purchase policy and incorporate latest clean technologies at design stage

9. Take lead in promoting and managing product stewardship program, by forging partnership withbusiness and communities.

10. Reduce depletion of natural capital, which is directly attributable to company’s activities by 5% everyyear over next ten years.

We also commit to demonstrate attainment of these commandments in our pursuit to certifications such asISO 9001, ISO 14001, OHSAS 18001, SA8000, Green Buildings, Eco-labels and the like.

Aug 15, 2007 Atul Kirloskar

Chairman & Managing Director

CII- Code for ecologically sustainable growthENCON Culture

(Four Main Pillars)

Data Monitoring

Data Recording

Data Analysis

Data Comparing

Capacity Building

Promotional Programs

Society Awareness

Product improvement

Production process

improvement

Green Technology Cell

Green Energy Product

Use of renewable

Green Promotion

• Energy AOP

• Allocation of Cost

Centers

• Target Setting

• Waste & Losses

Identification

• ENCON Projects

• Data Controlling

• Training &

Awareness

• Energy week

• Information

sharing &

Results &

Achievements

• K-Group Utility

Meeting

• New machines &

Process improvement

• Design, develop and

mfg energy efficient

products

• Implementation of

EURO Stage III

• Procurement of EE

equipments

• Wind power project

• Use of bio-diesel

• Bio-gas based

engine

• Solar water heating

for canteen

• Waste elimination &

recycling

ENCON Cell

• Monthly review by ENCON Cell Head

• Bi -Monthly review by Director (ENCON Mentor for K-Group Companies)

• Annually assessment by K-Group ENCON Competition Assessors

Centralized Energy

Monitoring System

Knowledge

building

Technology up-

gradation

Green Energy &

Green Products

ENCON Achievements

14

ENCON MENTOR

Mr. R.R. Deshpande

Executive Director

ENCON LEADER

Mr. S.B. Gosavi

Sr. G .M. – Utilities

ENCON MANAGER

Mr. Milind Deore

Energy Manager – KOEL

KHADKI PLANT

ENCON TEAM MEMBERS 19

NAGAR PLANT


KAGAL PLANT


RAJKOT PLANT


NASIK PLANT


Utilities Mainteninance Mfg. Engg. Production

Heat Treatment R & E FinancePersonnel &

Safety

KOEL ENCON Cell

• Monitoring & Verification

• Record & Result Review

• OFI – Continuation

• Review & Target

• Revise / update Action Plan

• Set & Compare Benchmark

• Start the Cycle

• Resource Collection

• Project Implementation

• Monitoring Progress

• Capacity Building & Training

• Energy Audit

• Action Plan

• Target Setting

• Short Term & Long Term Action Plan

Plan Do

CheckAct

Methodology - PDCA Cycle

KOEL

ENCON

Management

ENCON team regular meetings

ENCON annual budget & projects

K-Group Utilities Meeting

Monthly review by company Director

Small improvements through employees suggestion scheme

Internal Energy Audit

ENCON annual assessment k-group

interplant competition

Implementation of suggestions from

k-group ENCON assessors

External Energy audit

Routine monitoring of energy

conservation and feedback of same

KOEL

ENCON

Management

Productivity improvement programs like TQM, Kaizen 5S, TPM etc.

ENCON Management Process

Inputs from ISO, TS & OHSAS internal &

external Audit

Centralized Energy Monitoring System

KOEL has undertaken the project for Centralized Energy Monitoring System in 2008-09.Under this system we have installed more than 125 digital energy meters. We aremonitoring following resource consumption using this system .• Electrical Energy• HSD & Biodiesel• Air Consumption• Water Consumption

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Competition --> Slogans Poem Poster Suggestion KAIZEN ENCON Projects

Location

Khadki 248 22 52 70 27 5

Kagal 465 65 122 105 16 0

Nashik 48 13 14 30 3 3

A'Nagar 22 3 10 5 16 0

Rajkot 224 9 33 65 4 23

Total 892 112 225 247 70 31

Response to ENCON Week

Celebration of EC Week Celebration of EC Week

16

ENCON ACTION PLAN 2009-10 Training Programs

Half-day training program onEnergy Efficient Motors –

With the help of InternationalCopper Promotional Council ofIndia (ICPCI), KOEL Khadki hasorganized half training programon Energy Efficient Motors.

Training Program for Energy AuditProcess

Workshop on Green Building Technologies

UTILITY HIGHLIGHTS

17

ENCON at Employee’s Home

During last financial year KOEL has won the K-Group level ENCON awards. The prize moneyis used for purchasing energy efficient CFL lamps and these lamps were distributed to eachemployee of KOEL. More than 2500 CFLs are distributed to KOEL employees.

• No. of CFL distributed = 2500 Nos. of 15 W

• Energy Savings through these CFLs = 246000 KWh of worth Rs 14.78 Lakhs.

• Reduction in emissions = 210 Ton of CO2

We have also organized exhibition cumdiscounted sale of EE lamps & RE devices forKOEL employees.

Prize distribution function

Year 2008-09

6 Kaizens/person

8 Kaizens/person

Year 2009-10

22 Kaizens/person

BenchmarkTOYOTA

Employee Involvement… Strategy……

18

KAIZEN (Year 2009-2010)

BG (Engines)-----Location

Monthly

target

APR MAY JUN

E

JULY AUG SEPT OCT NOV DEC JAN FEB MAR CUMM

Khadki 600 603 614 616 624 607 613 604 731 630 608 583 628 7461

Kagal 335 322 364 454 304 260 243 192 174 193 269 143 342 3260

Nasik 165 164 165 167 163 165 165 191 87 137 86 88 48 1626

Rajkot 65 60 63 67 65 60 61 00 27 25 52 50 38 568

Bearings -----Location

Khadki 45 09 11 11 15 36 54 24 50 100 69 70 51 500

Nagar 45 39 38 40 48 49 83 20 47 33 15 03 08 423

Sourcing

125 127 129 130 126 128 131 132 128 152 127 130 130 1571

Utilization of Renewable

Energy

Sources

Green Energy Profile

Contribution of Green Energy 31.5%

Total Connected Load 15246 KW

Total no. of Transformers 16 Nos.

Constant Power factor recorded 1.0

Total Energy Consumption (MSEDCL) 141.03 Lakh kWh

Total standby Generation capacity 9320 KVA

Power generation on DG set 1.19 Lakh kWh

Wind Energy Generation 99.14 Lakh kWh

Fuel Consumption (HSD) 1090 KL

Green Fuel Consumption (Bio-diesel) 30 KL

Gas Consumption (LPG) 60000 Kgs

Green Gas Consumption (Bio-gas) 6840 Kgs

Wind Power Project

• Installed Capacity = 5.6 MW

• Energy Generation in 2009-10 = 99.20 Lakhs kWh

• Emission reduction = 9100 Ton CO2

Canteen Waste based Bio-Gas Generation

• Waste to Energy Project

• Bio-gas Generation : 360 cylinder/year

• Cost Saving = Rs. 2.88 in Lakhs

Bio-diesel based Power Generation

• Bio-diesel is being used for In-house Power Generation

• Bio-diesel based Power Generation in 2009-10 = 1.19 Lakhs kWh

• Cost Saving = Rs. 3.2 in Lakhs

• 60% Reduction in emission

Solar Water Heating System

• Two Solar Water Heating System installed for Canteen application

• Energy Saved = 18,000 units/year

Renewable Energy Initiatives

19

Use of Day light

• Incorporated transparent sheets to improve day light

• Day light level is more than 1000 lux

• Energy Savings = ` 11. 30 Lakhs

Use of Turbo vent to improve the air circulations

• Use of Natural Air

• Improvement in Environmental Conditions

• Energy Savings of worth = ` 5. 23 Lakhs

Solar Street lights

• Use of solar energy for street illumination

• Green Energy Promotion

• Energy Savings = ` 0.3 Lakhs

Biogas based power generation

• Gensets are run on Bio-gas at GTC

• Testing Energy is used for canteen application

• Energy Savings in 2009-10 is = = ` 1. 1 Lakhs

Renewable Energy Initiatives

Waste to Worth

Projects

Waste to Worth Projects

Canteen Waste based Bio-Gas GenerationWaste to Energy Project Reduce 15 % LPG consumption of

Canteen Bio-gas Generation : 360 cylinder/year Cost Saving = ` 2.88 Lakhs

Reduction in Carbon Emission -

Recovery of AL from waste Dross Project Investment - ` 0.5 LakhsMetal Saving of Worth - ` 9.54 Lakhs

Payback is only 1 Month. Reduction in hazardous waste

Dross Before recovery

Dross After Recovery

Waste to Worth Projects

Utilization of waste heat for washingWaste heat recovery project Project Investment - ` 10 Lakhs Annual Cost Saving = ` 2.30 Lakhs

Improvement in Environmental conditions

Recovery of waste heat from Flue Gases Waste heat recover project Project Investment - ` 2.0 Lakhs HSD Saving of Worth - ` 8.0 Lakhs

Payback is only 3 Months Improvement in Environmental

conditions

After Recovery

Before recovery

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20

Inputs from ISO

14000/9000

& OHSAS

Elimination of TCE from BRG plantReduction in testing cycle & cold testing Elimination of water heating Use of green energy i.e solar, wind Energy efficient procurement program Green sourcing program

ProcessReplacment of asbestos sheetUpgardation of ETP plants Use of maximum day lights Use of turbo vents Adoption of Green building concepts

Infrastructure

Green technology centere Intergation of product with green energy sources like bio-diesel, biogas, SVOAdoption of upgarded emission normsFule efficient engines & pumpsetsBEE labelling program

Awareness campaign for schools, Residential colonies etc.Corporate sustainability reporting

Society

Inputs from ISO 14001/9000 and OHSAS 18000

During the internal & external audit of ISO 14001/ 9000 and OHSAS 18000, we havereceived OFI. With respect to these OFIs, we undertake objectives, targets & programs.Some of the environmental initiatives are as follows.

Products

Replication of best

practices

21

FRP Fan Blade

• Reduction in Energy Consumption by 25%

• Better Air Flow due to Aerofoil Shape

Fan less Cooling Tower

• Use of Natural Draft

• Removal of Electric Fan

• Reduction in maintenance cost

Unity Power Factor

• Power Factor Benefits by MSEDCL

• Reduction in Line Losses

• Increase in Efficiency of Electrical System

Replication of Best Practices

Use of T5 Lighting in Office Areas

• Reduction in Energy Consumption up to 30%

• Improvement in Lux Level

Occupancy Sensors

• Avoid idle running & wastage of Energy

• Switch ON lights & Fans only when required

Solar Water Heating System

• Use of Natural Resources

• Use in Canteens & process applications

• No need of Electrical Energy


VFD Application for ENCON Projects

• Significant Reduction in Energy Consumption

• Highly Efficient

• Used in Compressor, Electric Motors, Pumps etc.

Use of Energy Efficient Motors

• Energy Reduction from 15% to 20%

• Long Life

• Less Pay Back Period

Use of Turbo-Ventilators

• No Need of Electrical Energy

• Zero Maintenance

• Cost Effective


Improvement in Insulation

• Reduction in thermal energy losses

• Reduction in Fuel Consumption

• Improve working conditions

Replacement of Old & Inefficient A/C’s by BEE Star Labeled A/C’s

• Promote Use Efficient BEE Star Labeled Products

• Saving in Electrical Energy

• Reduce the maintenance cost

Replacement of Oversize Pump & Motors

• Conduct Audit by K.B.L.

• Replaced Inefficient Pumps by EE Pumps

• Process Improvement

• Significant Saving in Electrical Energy


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Electronic Ballast

• Energy Saving of 60-70 %

• Improvement in PF

• Increase the life of lamp

Use of Natural light

• Avoid the use of artificial lighting

• Energy saving

• Improve the working conditions

Energy Saving Devices for Street lighting

• Maximum use of day light

• Reduce the energy wastage

• Lower maintenance cost


CSR initiatives

Awareness Program for Women

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Award

& Accolades

KOEL receiving the ‘National ENCON Award’ from Hon. Minister of Power Mr. Sushilkumar Shinde.

KOEL bagged First Award in the competition of “State Level Award for Excellence inEnergy Conservation and Management-2007” organized by Govt. of Maharashtraand MEDA.

K-Group ENCON Awards

KOEL, Khadki has bagged First Award in the“K-Group Interplant ENCON Competition2007-08” into large unit category.

KOEL, Khadki has bagged Second Award in the“K-Group Interplant ENCON Competition2008-09” into large unit category.

KOEL, Khadki has bagged Second Award in the“K-Group Interplant ENCON Competition2006-07” into large unit category.

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Other Awards & Accolades

CII EXIM Bank Award for BusinessExcellence 2009 – KOEL receivedCommendation Certificate for StrongCommitment to Excel.

KOEL received DSK Energy Award -2007

Way

Ahead

BEE Star labeling for pumpsets & engines 2

1 IGBC Green Factory Rating system

3 Green Sourcing program for suppliers

Long Range Plan for ENCON (up to 2015) 4

Energy purchasing from Power Exchanges 6

5 Publishing first Corporate Sustainability Report & carbon foot print

7 Increase the % contribution of green energy through renewable

EE Procurement Policies / Standard Guideline Manuals 8

9 Celebration of ENCON for full Month instead of week

EE & Environment Check for new Equipment or CAPEX projects. 10

Way Ahead : 2010-11

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On Our Way to Sustainable Development …

Thank you

Questions

Documents

th National Award for Excellence in Energy Management … 11th National Award for Excellence in Energy Management 2010 Kirloskar Oil Engines Ltd., Khadki Contents Introduction SEC