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A Very Warm Welcome to all A Very Warm Welcome to all
Confederation of Indian Industry
A Very Warm Welcome to all A Very Warm Welcome to all
Advanced
Training Program on
E M t
Confederation of Indian Industry
Energy Management
Hosur
27 & 28 February 2014
Agenda
Introduction
Participants
CII team
Training Modules
Confederation of Indian Industry
g
Agenda
Modules on
Energy Audit
Methodology
Fans & Blowers
Pumps
Modules
Air compressors
Electrical
distribution
VSD & Harmonics
Li hti
Confederation of Indian Industry
Motors
Refrigeration & A/C
Boilers & Steam
Systems
Lighting
Miscellaneous
energy saving ideas
Role of energy
manager
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CII - Sohrabji Godrej Green Business Centre,
Hyderabad
A unique Public Private Partnership
( CII, Govt of Andhra Pradesh, USAID and Pirojsha Godrej Foundation )
Confederation of Indian Industry
Centre of Excellence for Energy, Environment, Green Buildings,
Renewable energy, Water & Climate change activities in India
CII-Godrej GBC, Hyderabad
First Green Building in India
First Platinum rated building
outside USA
First Platinum building in the
Confederation of Indian Industry
World under LEED version 2.0
(other 2 buildings are under
LEED version 1.0)
CII Godrej GBC building has achieved 56 points
out of 59 points attempted
CII-Godrej GBC Building - Select features
Zero water discharge
100% waste water recycling
55% reduction in energy
consumption (Over base model)
100% Day lighting
Eco-friendly A/C plant
Non-CFC & High EER
Confederation of Indian Industry
Non CFC & High EER
20% Power - Solar PV
60% recycled materials
Roof garden - 60% area
No toxic paint and sealant
Low VOC carpets
Wind tower
Minimum site disturbance
CII-Godrej GBC - Range of Services
1. World class energy efficiency
2. Environment Audits
ISO 14001, OHSAS 18001
3. Green Audits
4. Water Audits
5. Facilitating Green Buildings
Confederation of Indian Industry
5. Facilitating Green Buildings
6. Green Business Incubation
7. Renewable Energy Services
8. Technology Centre
9. Training programmes
Energy, Water, ISO, OHSAS,
Green Buildings, TCM
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Team of experienced engineers
Energy, Environment, Water
Sectoral strengths
Chemical, Pharma, Paper, Cement, Fertilizer
Facilities with CII-Godrej GBC
Confederation of Indian Industry
Latest instruments almost all major parameters
Energy, Water, Air
Access to international service organizations/experts
USAID, CIDA, WRI
Databank
Publications
Publications for awareness creation
Energy Publications Widely accepted by industry
Manual on Specific Energy Consumption Norms
Manual on Energy Efficiency at Design Stage
Manual on Energy Efficiency in Pumping Systems
Manual & CD on Variable Speed Drives
Confederation of Indian Industry
Training programmes on Energy
Centre-wise and In-house
Environment
Green business directory
Booklet on Industrial Best Practices in progress
Water
Booklet on industrial best practices in progress
Achievements
900 detailed audits conducted
Confederation of Indian Industry
Rs.1900 Million annual recurring savings
achieved
Achievements
Recipient of
Best Energy Auditor Award
Confederation of Indian Industry
Five successive years instituted by
PCRA, Govt. of India
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World Class
Energy Efficiency
Confederation of Indian Industry
Energy Efficiency
World Class Energy Efficiency
Concept developed by CII-Godrej GBC
Based on study of excellent units
India & abroad
Confederation of Indian Industry
Best practice from each organisation
Compilation
Promotion of World Class Energy Efficiency
Vision of Energy Efficiency Council
5 World Class Energy Efficient Units in India
CII Godrej GBC will facilitate
Good response from Industry
Madras Cements, Dalmia, Vasavadatta,
Confederation of Indian Industry
, , ,
Ultratech Cement APCW, Shree
Cement
Tata Power, Lanco Kondapalli
Godrej - Appliances division
Tata Chemicals
ITC Bhadrachalam Ltd, BILT
World Class
Energy efficient company
Confederation of Indian Industry
Energy efficient company
Characteristics
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World Class Energy Efficient Unit
Trend setter in Norms Lowest in world
Leader in implementing Latest Technologies
Energy Wastage Nil
Energy Scorecard
Confederation of Indian Industry
ENCON On-going activity Management system
Good Vs. Best (World class) units
Both appear same
Awareness level high
Significant energy saving
Confederation of Indian Industry
achieved
World class energy efficient units are
unique & different
Bench marking & Trend setting
Good Vs. World class
Confederation of Indian Industry
Follow bench
marks
Set Trends &
Others follow
Information sharing
Good Vs. World class
Confederation of Indian Industry
National & Global level
Coca Cola, Philips
Share within
Operate in
isolation
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Implementation of Latest technologies
Good Vs. World class
Confederation of Indian Industry
Pioneers in
implementation
Capacity to take risk at
organization level
Technology developers
first preference
Want proven
technologies
Need Case studies
before
implementation
Energy wastages
Good Vs. World class
Confederation of Indian Industry
Not apparent
Difficult to identify
Visible
Encon culture
Good Vs. World class
Confederation of Indian Industry
Energy manager
Facilitator
Operation team
approach with
proposals
Engages experts
Energy Manager
Chase people for
Encon proposals
Tries to do all by
himself
Encon activity
Good Vs. World class
Confederation of Indian Industry
Driven by external
factors
Energy cost increase
Mandatory audit
On going activity
Top management
committed to Encon
Resource allocation
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Approach to Encon
Good Vs. World class
Confederation of Indian Industry
Seen in isolation
Holistic
Total cost of
ownership Considered
Monitoring & Energy Scorecard
Good Vs. World class
Confederation of Indian Industry
Monitoring
Excellent data
generation
Energy score card
Some Misnomers about WCEE
1. Only the latest plants can be World
Class
2. Limited to companies which are
already very good
3 B i W ld Cl i i
Confederation of Indian Industry
3. Becoming World Class is expensive
4. World class is only for large
companies
1. Only the latest plants can be World Class
30% of the companies participating in CII National
Award for Excellence in Energy Management more
than
30 years old !!
Some Misnomers about WCEE
Confederation of Indian Industry
Several plants comparable to best in the world
Automobile, Aluminum, Cement, Power Plants ..
Vintage of the plant not a criteria !
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2. Limited to companies which are already very good
A very old cement plant
1993-94 : 110 kWh / ton of cement
2003-04 : 70 kWh / ton of cement
Some Misnomers about WCEE
Confederation of Indian Industry
2003 04 : 70 kWh / ton of cement
Among the top few cement plants in the
country today
Excellent example of old company achieving
World Class standards
Not for already good companies only !
3. Becoming World Class is expensive
CII Godrej GBC Building the
Greenest Building in the World
Only 18% expensive than
Some Misnomers about WCEE
Confederation of Indian Industry
conventional building
Pays back in less than 4 years !
WCEE not necessarily expensive !
4. World Class is for large cos. only
Several Small companies
Excellent trends
Comparable to any large company
Some Misnomers about WCEE
Confederation of Indian Industry
Lessons to be learnt from
WCEE not for large cos. Alone !
A few learnings A few learnings
Confederation of Indian Industry
A few learnings A few learnings
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Two Examples from Sports
Sergei Bubka - Ukranian pole vaulter
I person to cross 6-m mark
Confederation of Indian Industry
p
Continuously improved
Broke his own records > 14 times!
Efficiency Improvement - Continuous
Olympic Gold Medal Winners in High Jump
2.6
2.4
2.2
Fosbury
Flip
Confederation of Indian Industry
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1.8
1.6
1900 1920 1940 1960 1980
Scissors
Western Roll
Straddle
Source: Pascale
Two Examples from Sports
Dick Fosbury
Basically a Gymnast
Confederation of Indian Industry
Adopt the latest technology
Applied principles of gymnastics to high jump
Result A quantum jump!
Inputs from Other Industries - Innovation
Presentation
Confederation of Indian Industry
on
Energy Audit Methodology
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Why Energy Conservation?
National Interest
Depleting natural resources
Saves precious foreign exchange
Business Interest
Reduced manufacturing cost
Improved cost competitiveness
Confederation of Indian Industry
Energy Costs as % of mfg. cost
Cement - 35-45%
Paper - 25-30%
Aluminium - 40-50%
Chemical - 10-30%
Engg. - 3-15%
Energy Conservation at Macro Level
Measure of EnCon
activities
Confederation of Indian Industry
Reduction in specific
energy consumption
Energy conservation at macro level
Three-
Capacity utilisation
Confederation of Indian Industry
Three-
pronged
approach
Fine-tuning
Technology
upgradation
Excellent companies
have tapped all three
opportunities
Energy conservation at macro level
Confederation of Indian Industry
opportunities
3 separate teams with
common objective
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Energy Audit Methodology
Systematic approach
Ask questions like:
What?
Confederation of Indian Industry
When?
Why?
Where?
Macro Level - Methodology
Any process/unit operation
Unavoidable losses
(c)
Confederation of Indian Industry
Energy input
(a)
Theoretical
Requirement (b)
(d)
Avoidable losses
A = b + c + d
Focus should be
To concentrate on avoidable losses
Q if h l
Macro Level - Methodology
Confederation of Indian Industry
Quantify the losses
Identify ways and means for reduction
Implementation
Confederation of Indian Industry