Post on 29-Dec-2015
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Lala Lakshmipat Singhania( 1910 – 1976 )
A Visionary & Key ofJK Organisation
KTP
Presentation By
D R PAI General Manager Engineering & Project
Kankroli Tyre Plant (KTP) A unit of
JK TYRE & INDUSTRIES LIMITED( TS-16949 , ISO-9001, OHSAS & ISO-14001 Plant )
JK Tyre & Industries Ltd.Kankroli ( Rajasthan )
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Lala Lakshmipat Singhania( 1910 – 1976 )
A Visionary & Key ofJK Organisation
KTP
Presentation By
Team Members D.R. PaiA.K. PamechaM.K. Sharma
Kankroli Tyre Plant (KTP) A unit of
JK TYRE & INDUSTRIES LIMITED( TS-16949 ,OHSAS, ISO-9001 & ISO-14001 Plant )
11th National Award
for Excellence in Energy Management-2010
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Lala Lakshmipat Singhania( 1910 – 1976 )
A Visionary & Key ofJK Organisation
KTP
An Overview of JK Tyre & Industries Ltd.
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Lala Lakshmipat Singhania( 1910 – 1976 )
A Visionary & Key ofJK Organisation
KTP
• Be a Customer Obsessed Company-Customer first 24x7• No.1 Tyre Brand In India• Most profitable Tyre company in India• Motivated and committed team for excellence in
performance• Be a green company• Deliver enhanced value to all stakeholders• Leverage & Enhance global presence through Acquisition /
JV
• To be amongst the most admired companies in India Committed to Excellence.
VISION
MISSION
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Lala Lakshmipat Singhania( 1910 – 1976 )
A Visionary & Key ofJK Organisation
KTP
Manufacturing Process Flow Diagram
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Lala Lakshmipat Singhania( 1910 – 1976 )
A Visionary & Key ofJK Organisation
KTP
Energy Policy
We at J.K.Tyres are Committed to Conserve Natural Resources & Energy by
•Enhancing Equipment Efficiency•Minimizing Waste & idle run•Technology & Innovation•Periodic Reviews and Skill Upgradation•People Involvement
We will continuously Benchmark & Improve Energy Performance in our endeavor to be the World’s Best Bias Tyre Plant By 2010.
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Lala Lakshmipat Singhania( 1910 – 1976 )
A Visionary & Key ofJK Organisation
KTP
Focus areas for
Energy conservationFuel conservation
Resource conservation
Reduction of green house gases
Reduction in consumption of petroleum products
Elimination of ozone depleting substances
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Lala Lakshmipat Singhania( 1910 – 1976 )
A Visionary & Key ofJK Organisation
KTP
Actions:
Optimization of Blowers and pumps
Process Optimization
Energy Efficient Lighting
Use of renewable energy
Efficient compressed air generation
Extensive use of VFDs
Energy Monitoring.
POWER
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Lala Lakshmipat Singhania( 1910 – 1976 )
A Visionary & Key ofJK Organisation
KTP
Plant Specific Power Consumption( Kwh/Kg.)
0.712
0.748
0.776
0.795
0.816
2004-05 2005-06 2006-07 2007-09 2009-10
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Lala Lakshmipat Singhania( 1910 – 1976 )
A Visionary & Key ofJK Organisation
KTP
Actions:Optimization of Usage Pressure
Elimination of redundant lines
Process improvements
Waste heat recovery Switching to alternate economic energy forms
Heat recovery and reuse
STEAM
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Lala Lakshmipat Singhania( 1910 – 1976 )
A Visionary & Key ofJK Organisation
KTP
Plant Specific Steam Consumption( Kg./Kg.)
2.125
2.385
2.516
2.593
2.634
2004-05 2005-06 2006-07 2007-09 2009-10
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Lala Lakshmipat Singhania( 1910 – 1976 )
A Visionary & Key ofJK Organisation
KTP
Saving Realization
Year
KWH * Million
Rs Million
Type of fuel
Tons/KL Rs Million
0.403 1.22 3.82
LDO/LSHS 596** 2.47 0.01 0
21696** 96.44 53711 7402009-10 39.747** 170.91 Coal
0.419 2.22 7.51
LDO/LSHS 734 5.31 0.01 0
28946 120.82 69089 7492008–09 51.725 222.53 Coal
0.453 1.67 6.21
LDO/LSHS 759 7.29 0.01 0
32866 116.3 72203 7662007–08 55.293 243.72 Coal
0.483 3.23 -5.69
LDO/LSHS 731 3.04 0.01 9.1
34670 101.12 71795 7792006–07 55.918 218.65 Coal
(April − March)
Electrical Thermal Electrical KWH / Ton or unit of
prodn
Annual Energy consumption Prodn. in tons or
any other unit of prodn.
Specific Energy Consumption
Redn. in Specific Energy consn. Over previous year **
Thermal tons or kL per ton or
unit of prodn
Electrical Thermal
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Lala Lakshmipat Singhania( 1910 – 1976 )
A Visionary & Key ofJK Organisation
KTP
56.08
39.75
01/01/1900 02/01/1900
31824
21696
2005-06 2009-10
788
596
2005-06 2009-10
Power Consumption ( Million Kwh )Coal Consumption ( MT )
LDO/LSHS ( KL )
Savings
815 Lacs
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Lala Lakshmipat Singhania( 1910 – 1976 )
A Visionary & Key ofJK Organisation
KTP
Plant Power Consuming Loads
Power Consumption
Utilities = 38% , Mixing = 36%.Extruders = 7%, Air Washer = 5%, Calendaring = 4%Tyre Curing = 4%, Tyre Building = 2%, Lighting = 2%.
Plant Energy Data Review
Calendaring, 4
A ir W asher, 5
E x truders , 7
Ty re Curing , 4
Ty re B uild ing , 2
L ight ing, 2
Utilit ies , 38
M ix ing , 36
Utilities & Mixing Consume Maximum Power
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Lala Lakshmipat Singhania( 1910 – 1976 )
A Visionary & Key ofJK Organisation
KTP
Banbury # 4 Single Stage MixingINNOVATION:
Concept of conversion of three stages mixing in to two stages mixing is innovative itself. Which have an added advantage of improvement in productivity, reduction in powerconsumption, low man-hour cost.
The complete concept of conversion of three stages mixing in to two stage mixing was new and developed in-house. The design of required equipment and schemes was done locally including selection of process requirement.
Benefit:-
After implementation of this project we generate extra 150 min/day for mixing which is equivalent to 10500 KG master compound per day or equivalent to 35000 Rs/day.
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Lala Lakshmipat Singhania( 1910 – 1976 )
A Visionary & Key ofJK Organisation
KTP
AIR WASHER Band Building Air Washer Metallic Blades replaced by FRP Blades.Horizontal Deployment to be done on All AHU
AIR FLOW DELIVERED VIS –A-VIS POWER CONSUMED
AIR FLOW (CFM) POWER (KW)
ALUMINIUM ENCON ALUMINIUM ENCON
TOTAL 140000 140000 56 44
Pump Conversion 18KW to 3.7 KW 13.7 KW
SAVING 11 KW
SAVING PER DAY Per AHU 264 KWH
SAVING PER DAY 13 AHU 7800 KWH
SAVING (Rs.)/Year (250 Days) 2.73 LACS/Annum
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Lala Lakshmipat Singhania( 1910 – 1976 )
A Visionary & Key ofJK Organisation
KTP
ENERGY SAVER Batch Off Mill BANBURY # 2
Variable Triggered Voltage (Thyristor Control) with respect to variable load.
Approximately 300 KWH saving per day.
Energy Saver Cost 2.25 Lacs For 200 KW Motor.
Pay Back 8 Months
WORKING PRINCIPLE
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Lala Lakshmipat Singhania( 1910 – 1976 )
A Visionary & Key ofJK Organisation
KTP
Utility Steam (Kg/ Kg ) Power (Kwh/Kg)
JK - KTP 1.98 0.710
Future Plans to Challenge “THE
BEST”
ØReduction of fossil fuelsØ Insulation improvement
on hot steam linesØWaste Heat recovery ØReduction in flash steam
lossesØHot water recovery in
curing pressesØUsing optimum solution
for process heating
q Replacement of in-efficient pumps.
q Strengthen power monitoring system.q On line Energy
managementqVFD installation on
Higher HP MillsqOptimization of Blower
on air washers
Industry Benchmark & Road Map
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Lala Lakshmipat Singhania( 1910 – 1976 )
A Visionary & Key ofJK Organisation
KTP
•Daily capturing of energy parameters, their analysis and investigate for deviations by section and functional heads
•Comparison within similar equipment
•Daily reporting and threadbare discussions in management review meeting
•Review of energy projects by unit head for progress and employee participation
P a r t i c u l a r s U n i tP l a n A c t u a l D i f f P l a n A c t u a l D i f f
K g s 1 7 0 1 7 4 7 7 4 3 2 4 5% 0 .0 1 0 0 . 0 0 0 0 .0 1 0 0 . 0 1 0 0 .0 0 9 0 .0 0 1K g s 1 5 7 0 1 5 6 . 5 4 2 9 1 2 1 0 3 2 1 8 7 . 6% 0 .0 9 0 0 . 0 0 0 0 .0 9 0 0 . 0 9 0 0 .0 4 4 0 .0 4 6K g s 0 5 0 4% 0 . 0 0 0 0 . 0 0 0 0 .0 1 1K g s 1 5 7 0 4 2 9 1 2 6 0 7% 0 .0 9 0 0 . 0 0 0 0 . 0 9 0 0 .0 5 5K g s 4 3 4 6 - 3 1 1 2 7 1 8 2 2 - 6 9 5% 0 .0 6 0 0 . 0 6 4 - 0 . 0 0 4 0 . 0 6 0 0 .0 9 7 - 0 . 0 3 7K g s 2 9 0 3 8 2 - 9 2 7 5 1 2 1 0 0 8 2 - 2 5 7 0% 0 .4 0 0 0 . 5 2 8 - 0 . 1 2 8 0 . 4 0 0 0 .5 3 7 - 0 . 1 3 7K g s 3 3 3 4 2 8 - 9 5 8 6 3 9 1 1 9 0 4 - 3 2 6 5% 0 .4 6 0 0 . 5 9 1 - 0 . 1 3 1 0 . 4 6 0 0 .6 3 4 - 0 . 1 7 4
S q W o v e n F a b r i c K g s 1 6 1 9 - 3 5 0 9 7 2 1 - 2 1 2% 0 .7 2 0 0 . 8 4 3 - 0 . 1 2 3 0 . 7 2 0 1 .0 2 1 - 0 . 3 0 1K g s 2 8 2 1 7 7 5 9 7 7 8 - 1 9% 0 .2 7 0 0 . 2 0 5 0 .0 6 5 0 . 2 7 0 0 .2 7 7 - 0 . 0 0 7K g s 1 9 2 0 - 1 5 4 1 6 2 6 - 8 5% 0 .0 1 0 0 . 0 1 0 0 .0 0 0 0 . 0 1 0 0 .0 1 2 - 0 . 0 0 2K g s 9 8 3 7 6 1 2 6 3 2 3 4 8 0 - 8 4 8% 0 .0 5 0 0 . 0 1 9 0 .0 3 1 0 . 0 5 0 0 .0 6 6 - 0 . 0 1 6K g s 5 2 7 5 2 5 2 1 4 2 1 5 1 8 6 5 5 - 4 4 4 0% 0 .2 7 0 0 . 2 6 9 0 .0 0 1 0 . 2 7 0 0 .3 5 4 - 0 . 0 8 4V a l u e 5 6 7 7 2 5 9 8 3 0 - 3 0 5 9 1 5 3 2 7 3 5 1 9 4 8 8 4 5 - 4 1 6 1 1 0% 0 .3 3 4 0 . 3 4 7 - 0 . 0 1 3 0 . 3 3 4 0 .4 1 8 - 0 . 0 8 4K g s 1 2 4 1 3 0 - 6 3 4 5 6 2 5 7 7 8 7 9% 1 .3 6 3 1 . 4 2 4 - 0 . 0 6 1 1 . 3 6 3 1 .0 1 6 0 .3 4 7K g s 1 8 1 2 6 4 8 4 3 4 7 1 3 7% 1 .2 0 0 0 . 8 0 3 0 .3 9 7 1 . 2 0 0 0 .8 6 1 0 .3 3 9K g s 8 4 1 6 6 7 1 7 4 2 2 7 3 6 2 5 4 0 3 - 2 6 6 8% 0 .4 0 9 0 . 3 2 4 0 .0 8 5 0 . 4 0 9 0 .4 5 7 - 0 . 0 4 8V a l u e 8 5 2 4 1 7 3 8 9 8 1 1 3 4 3 2 3 0 4 2 9 1 2 5 3 8 0 9 5 - 2 3 3 8 0 4% 0 .4 9 4 0 . 4 0 4 0 .0 9 0 0 . 4 9 4 0 .5 1 3 - 0 . 0 1 9
T o d a y M T D
C o m p o u n d S c r a p
F a b r i c S c r a p - B U 1
C o m p o u n d L u m p y -B U 2
C o m p o u n d L u m p y -B U 1
C o m p o u n d L u m p y -T o t a l
F a b r i c S c r a p - B U 2
F a b r i c S c r a p - T o t a l
I n s u l a t e d B e a d
G r e e n T y r e
C u r e d T y r e
T o t a l P r o c e s s S c r a p - T y r eT o t a l P r o c e s s S c r a p - T y r e
T o t a l P r o c e s s S c r a p
T o t a l P r o c e s s S c r a p
C u r e d T u b e
C u r e d F l a p
Eq. Prodn. Power ( Kwh.)
Consumptionper Unit
Power ( Kwh.)
Consumptionper Unit
1 BANBURY # 1 Kgs. 47710 9803 0.205 9337 0.2032 BANBURY#2 Kgs. 45323 12336 0.272 11352 0.2673 BANBURY#3 Kgs. 44967 10101 0.225 11128 0.2674 BANBURY#4 Kgs. 44220 11509 0.260 11344 0.2505 TOTAL BANBURIES Kgs. 182220 43749 0.240 43161 0.2466 DIP UNIT KM 28299 2691 0.095 2911 0.0757 3 ROLL CALENDER Eq.Rolls 1549 3543 2.287 3822 2.9158 4 ROLL CALENDER KM 50292 7798 0.155 7610 0.1629 DUAL EXTRUDER Eq.Trk.Tread 5121 14299 2.792 13011 2.67010 MP EXTRUDER Eq S/W 10504 3671 0.349 3259 0.35911 TUBE EXTRUDER Eq.Trk. Tube 5270 3688 0.700 3769 0.74712 TOTAL BUILDING MT 192.42 3273 17.010 3129 16.20013 TOTAL CURING MT 205.63 11764 57.209 11282 56.82714 PCI AIR M3 64650 8979 0.139 10962 0.17015 PLANT AIR M3 58029 10011 0.173 8924 0.15416 TOTAL AIR M3 122679 18990 0.155 19886 0.16217 COOLING TOWER MT 205633 9106 0.044 9122 0.04618 BOILER MT 205633 3483 0.017 3716 0.01919 OTHER UTILITY 205633 5102 0.025 4779 0.02420 TOTAL UTILITY MT 205633 43510 0.212 45965 0.23221 LIGHTING TOTAL MT 205633 3827 0.019 3553 0.01822 AIR WASHERS TOTAL MT 205633 11827 0.058 11584 0.05823 REST METERED LOAD MT 205633 1467 0.007 2078 0.01024 TOTAL UNMETERED MT 205633 6666 0.032 6280 0.03225 NET PLANT CONSUM MT 205633 161773 0.787 161413 0.81326 RSEB MT 205633 164000 0.798 164554 0.829
Sl.No.
To-Day MTD UnitEquipment
Particulars UnitBuilding Plan Actual Diff Plan Actual DiffTyre MT 192.51 192.42 -0.09 191.56 193.17 1.61CuringTyre MT 192.51 195.01 2.50 191.56 188.03 -3.53Tube MT 8.89 9.13 0.24 8.87 9.06 0.18Flap MT 1.51 1.49 -0.01 1.51 1.44 -0.07Total MT 202.91 205.63 2.73 201.9 198.53 -3.42UtilityPower KWH/Kg 0.750 0.787 -0.04 0.750 0.813 -0.06Coal MT 86.366 77.30 9.07 83.382 92.03 -8.65
Kg/Kg 0.420 0.376 0.04 0.420 0.464 -0.04Kg/MT 153.0 162.05 -9.05 153.0 183.60 -30.60
Steam(G) MT 534.646 477.00 57.65 516.176 501.24 14.94Kg/Kg 2.600 2.32 0.28 2.600 2.52 0.08
Steam(S) Kg/Kg 2.450 2.31 0.14 2.450 2.41 0.04Air M3/Kg 0.675 0.597 0.08 0.675 0.637 0.04Water-Ex Ltr/Kg 5.750 3.676 2.074 5.750 4.162 1.588Water-Inc Ltr/Kg 6.550 4.678 1.872 6.550 5.170 1.380Naphtha Ltr/MT 12.00 14.97 -2.97 12.00 12.73 -0.73
Today MTD
Daily Monitoring Key Parameters
Daily Review of utility Parameters Daily Review of equipment power
Daily Review of Process ScrapeParametersReview Mechanisms
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Lala Lakshmipat Singhania( 1910 – 1976 )
A Visionary & Key ofJK Organisation
KTP
Energy Conservation Structure
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Lala Lakshmipat Singhania( 1910 – 1976 )
A Visionary & Key ofJK Organisation
KTP
Contd ….
Proposed Project for Energy and Fuel Conservation
Location Key Projects Plan Project Cost Saving Remarks
Township Street light to be replaced with LEDlamp. 30 Nos.
Halogen lights of 250W to be replaced with LED lights
20000 per piece
Rs. 7000 PA
Rs. 70000 per annum saving per uint
BU#1 MP F/mill drive - race sent to H.O . Trial Taken 13 lacs 11 Lacs PA Awaited For Race approval
BU#3 G,H line lightining to be linked withpress.
Circuit modification to be done
Rs. 5000 25000 PA approx.25000 per annum saving
BU#3 curing lights to be linked with lightingtransformer.
Transformer available to be taken in line
10000.00 1.25 Lacs PA
Plant AHU pump replacement Relacement of Pump 1.5 Lacs 2.73 Lacs
Plant AHU filter replacememnt Relacement of Filter 1.2 LacsBU#1 MP cooling conveyor D.C motor
replaced with A.C motor .Conversion Of DcMotor with Ac MotorVFD
4 Lacs 3.5 Lacs Technology Upgradation
BU#1 BB#2 Reconditioning in 27 lacsinstead of 1.1 corers. (17lacs/yearto be continued for 6 years)
BB#2 Reconditioning 27 Lacs 17 lacs PA for Six years
17 lacs per year for next six years.
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Lala Lakshmipat Singhania( 1910 – 1976 )
A Visionary & Key ofJK Organisation
KTP
Proposed Project for Energy and Fuel Conservation
Location Key Projects Plan Project Cost Saving Remarks
Utility Bio fuel to be used in boiler. Usage of biomass instead of coal
To Be evaluated.
Utility Boiler blow down control Process Optimization 0 Top Be evaluated
BU#1 Steam reduction by installation of electrical heater (4-roll calander,T.C.U ,hot can,Dil. heating)
Conversion of steam to electric heater
9 Lacs 15 Lacs
SSU#1 Rs. 24 lacs to be saved under W/shop reconditioning
In House spare development with spares.
No Cost 24 Lacs 24 lacs will be saved by development of in house spares.
SSU#1 Ecoventilater to be fixed - 200 Nos. Ecoventillaters to be provided over roof
5000/- per piece
to be evaluated
BU#1 BB V.F.D To Be Evaluated 1 Carore To Be Evaluated
Approx Rs. 60 to 70 Lacs per year saving expected
Utility power saving in ACFC +cooling tower by VFD
Common VFD to be provided or switchng On & OFF of AC motors as per temperature
2.5 Lacs 4 Lacs
BU#3 CBD pump vertical to horizontal.BU#2 slitter D.C motor replaced with A.C
motor + driveTecnology Upgradation
1 Lacs 1.5 Lacs Per Annum
To Be evaluated.
Utility Dome drain + Condensate recovery Process Optimization To Be evaluated.
SSU#1 old age A.C to be replaced by star A.C
Old Low Efficeint AC to be replaced with new efficient AC
22000 per unit
To be evaluated
Utility Air and water Pr. Drop study in drop line
Process Optimization To Be evaluated.
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Lala Lakshmipat Singhania( 1910 – 1976 )
A Visionary & Key ofJK Organisation
KTP
Accolades- Present Glory-2009
National Energy Conservation BEE Award Rajasthan Energy Conservation Award
CII Excellent Energy Efficient Unit CII Excellent Water Efficient Unit
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Lala Lakshmipat Singhania( 1910 – 1976 )
A Visionary & Key ofJK Organisation
KTP
Thank You