Kirloskar Oil Engines Ltd, Kagal (Kolhapur)
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Kirloskar Oil Engines Ltd, Kagal (Kolhapur) KIRLOSKARKIRLOSKAR OIL ENGINES OIL LTD., ENGINES KAGAL – RKQP LIMITED 29th July’14 1 GreenCo Gold Certification for KOEL Kagal In Mumbai on 25th June 15 KIRLOSKARKIRLOSKAR OIL ENGINES OIL ENGINES LTD., LTD.,KAGAL KAGAL – GreenCo – RKQP Certification 29th July’14 CII Green Co Rating Certification Information More than 100+ Companies Registered with CII from Different Sectors till date 48 companies received GreenCo Certification in last 3 years 17 Companies from Engineering Sector received GreenCo Certifications KOEL Kagal is Pioneer to receive Gold in their Manufacturing Sector KIRLOSKAR OIL ENGINES LIMITED GreenCo Rating System Certification Evaluation Parameter & Weightage Weightage SN Parameters (Points) 1 Energy Efficiency 150 2 Water Conservation 100 3 Renewable Energy 100 4 GHG Reduction 100 GreenCo Rating Level 5 Waste Management 100 Points Awarded Levels 450- 550- 650- 750- Material Conservation, Recycling & 350-449 6 100 549 649 749 1000 Recyclables Certified 7 Green Supply Chain 100 Bronze Silver 8 Product Stewardship 75 Gold X Platinum 9 Life Cycle Assessment 75 Others (Ventilation, Site Selection, 10 100 Green Belt & Innovation) Total 1000 KIRLOSKARKIRLOSKAR OIL ENGINES OIL ENGINES LTD., LTD.,KAGAL KAGAL – GreenCo – RKQP Certification 29th July’14 GreenCo Certification – CFT KIRLOSKARKIRLOSKAR OIL ENGINES OIL ENGINES LTD., LTD.,KAGAL KAGAL – GreenCo – RKQP Certification 29th July’14 About Kirloskar Oil Engines Ltd Manufacturing Plants : Kagal (Kolhapur), Khadki (Pune), Nasik & Rajkot Kagal ( Kolhapur ) Plant Total Employees as on date - 1181 Managers ( TL, GL & UL) - 191 Operators (Team Associates) - 990 Initiatives 5S TPS QMS, EMS & OHSAS ENCON Kaizen & POKA YOKE Autonomous Maintenance Six Sigma, QC Activities Standardized Work KIRLOSKAR OIL ENGINES LIMITED 6 Production Process at Kagal Machining Lines Receive Bought out finished components Crank Case Storage Cylinder Head Engine Assembly Crank Shaft Engine Engine Testing Painting Up fitment Storage Dispatch Cam Shaft Connecting Rod KIRLOSKAR OIL ENGINES LIMITED 7 Green Co Rating System Certification KOEL Signed CII Code –Ecologically Sustainable Growth (MSG) Specific Energy And Water Consumption Specific Generation Of Waste & Waste Going To • Reduce by 3-5% every year over next ten years. Land Fills • Reduce by 3-5% every year over next ten years Use Of Renewables Energy GHG Emissions And Other Process Emissions • Increase by 5% every year over next ten years. • Reduce by 3-5% every year over next ten years Recyclable And Enhance Recyclability Of Resources Share Of Harvested Rainwater In The Overall • Increase use of resources embedded in the Annual Use Of Water product. • Increase by 5% every year over next ten years Life Cycle Assessment Criteria For New Products. Adopt Green Purchase Policy • Incorporate Life Cycle Assessment in alternative • Adopt Green Purchase policy & incorporate clean technologies and products. technologies at design stage Product Stewardship Program Depletion Of Natural Capital • Promoting and managing Product Stewardship • Reduce by 5% every year over next ten Program, By forging partnership with business and years communities. KIRLOSKAR OIL ENGINES LIMITED Power & Fuel Expenditure 2014_15 % of Energy Cost to Sales Turnover KOEL – All Plants % of KOEL – Kagal Energy Cost wrt • 0.84 % Sales Turnover % of Energy Cost wrt Power Sales • 1.24 % Turnover & Fuel KAGAL Cost Plant • Rs. 20.64 Crs. KOEL Power & Fuel Cost Total Sales @ KAGAL Plant Turnover • Rs. 13.17Crs Sales Turnover • Rs. 2,473 Crs. @ • Rs. 1062 Crs. KIRLOSKAR OIL ENGINES LIMITED 9 KOEL- Energy Policy Benchmarking of products with the Executive Chairmanregional and national Shri best.. Atul Kirloskar signed Energy Policy - indicates ProcurementStrong of highCommitment energy efficient products and technologies from Top Management towards Eliminating wastage of energy and ENCON promoting reuse and recycling of resources rd Promoting and increasing use of 3 Revisionrenewable in energy repsect resources, within to Changes in Globaland outside Energy Scenario Adopting New Building Norms Key Highlights of Policy of Policy Highlights Key Involving all stake holders in the energy conservation Sharing and enriching our experiences on energy conservation within & Outside group KIRLOSKAR OIL ENGINES LIMITED 10 Reduction in Specific Energy Consumption 4.00 kWh / BHP – Target Vs. Actual 3.86 Better 3.91 3.70 3.73 3.72 3.63 3.63 3.64 3.54 3.69 3.52 3.50 3.40 Addition of 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 Loads due to 3.86 3200 expansion & 3.73 3.72 3.69 SEC reduced plant 3.64 average 3 to merging 3.50 4 % every year , year 1700 on year 1000 300 450 300 Load in kW in Load KIRLOSKAR OIL ENGINES LIMITED 11 Reduction in Specific Fuel Consumption Fuel Consumption Liters / BHP Target Actual 0.19 0.19 0.191 0.18 0.18 0.17 0.175 0.17 0.16 0.16 0.15 0.15 0.13 Better 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 For New Environmental Norms Few Applications points added in the process, resulted in increase in Fuel Consumption in past years Thru committed ENCON efforts has helped to maintain the Specific Fuel Consumption KIRLOSKAR OIL ENGINES LIMITED 12 Benchmarking Energy Consumption per Engine (ATP) Better kWh / BHP (Internal) 117.00 95.90 MNC Compititor 1 Kagal (20 HP to 150 4.01 3.50 (80 HP to 280 HP) HP) 3.03 For Benchmarking kWh / Engine is available from a KOEL Pune KOEL Kagal KOEL Kagal Close Competitor product Best range. Equivalent Conversion Achieved taken for KOEL engines * Source Data : MEDA KIRLOSKAR OIL ENGINES LIMITED 13 Benchmarking (International) Engine Testing Cycle Time DG Set Testing Time Cycle time in Min. Cycle Time in Min. Better 70 30 61 120 12 Compititor KOEL Kagal KOEL Kagal Compititor 20 30 1 (2013) (2014) 2 Compititor KOEL Compititor 1 2 (MNC) ISO 50001 EnMS Processes Certification Improvement for Bull's eye on & Alternative Standardization Load-Center Technologies Advanced Consumptions EMS for Data & Stringent Certified Lead Involvement Analysis Control of People Auditor - EnMS Installed Mechanism • Santosh Parab Initiated • Initiated Sunil Doshi KIRLOSKAR OIL ENGINES LIMITED 14 Project Summary Energy Saving in Years 13 – 15 (3 Years) Numbers of ENCON Total Cost Saving Projects Rs 309.69 Lakh 100 Annual Annual Fuel Energy Simple Saving Investment ROI Savings Rs. 150.31 Payback (K Liters) 106 % kWh Units Lakh 6 Months 47.49 28.45 Lakh KIRLOSKAR OIL ENGINES LIMITED 15 Project Summary Energy Saving in Years 13 – 15 (3 Years) No. of Units Saving Fuel Saving Cost Saving Investment Category Projects In Lakh in K Liters in Rs. Lakh in Rs. Lakh Zero 57 6.35 47.89 120.24 Nil Investment Low 35 8.5 71.93 15.9 Investment Moderate 5 1.28 15.98 17.07 Investment High 3 12.32 101.54 123.69 Investment Out of total savings, 62 % of Saving thru 92# no investment or small projects KIRLOSKAR OIL ENGINES LIMITED 16 ENCON Savings Year on Year 500 407.93 400 371.48 300 193.68 200 Rs. in Lakhs Rs.in 104.73 100 71.55 Better 0 2010-11 2011-12 2012-13 2013-14 2014-15 Saving in Rs. Lakhs Cumulative Saving in Rs. Lakh KIRLOSKAR OIL ENGINES LIMITED 17 Water Conservation Specific Water Consumption Reduction Units FY 2012-13 FY 2013-14 FY 2014-15 FY 2015-16 Actual Actual Target Achievement Target Total water consumption (cubic 1,20,476 1,37,188* 1,35,816 1,32,696 1,30,705 meters) 17.5 3% % Specific water consumption (L/BHP) 36.59 48 46.56 39.62 38.43 • *(2013-2014)Addition of Genset Expansion & EP-II shed Activities & Allied Processes such as Construction , Industrial, Domestic & Gardening Activities. • *(2014-2015) Shifting ,Erection ,Commissioning of Plant & Machineries from Khadki plant, Deployment of man power , Green belt development for EP-II & Genset Expansion. KIRLOSKAR OIL ENGINES LIMITED Water Conservation Installation of auto sensor to the urinal & wash basins 475 m3 of water saved / year KIRLOSKAR OIL ENGINES LIMITED Water Conservation Use of Hand washing Waste Water for Gardening. 936 m3 of water saved / year KIRLOSKAR OIL ENGINES LIMITED Water Conservation Using of Stored Water for Garden. 829 m3 of water saved / year KIRLOSKAR OIL ENGINES LIMITED Water Conservation Rain Water Harvesting • Water requirement for the Landscape Area reduced due to Increased Humidity • Increase in Water Table in surrounding area KIRLOSKAR OIL ENGINES LIMITED 22 Water Conservation Rain water Harvesting Design (Aerial View ) Earthen Bandhara Earthen Behind fab Rain water Bandhara shop harvesting Near pond N-E Helipad corner Storm water Storage Bandhara Tank East Side of MRS Rain water harvesting pond near MSEB KIRLOSKAR OIL ENGINES LIMITED Renewable Energy Short & Long Term Action plan to Achieve Targets Present Present Renewable Renewable Target for Target for Target for Achievement Units energy energy 2016 2016 2015 In 2015 generated off generated off (if available) - site (2013) - site (2014) kWh 4,851,465 6,069,197 3,000,000 1,785,625 6,350,000 6,800,000 % of total 14.05* * SEM Meter Targets are set to increase Energy 35.78 % 51.01 % SEM installed installation share by 5% consumption in Aug 14 Present Present Renewable Renewable Target for Target for Target for Achievement Units energy energy 2016 2016 2015 In 2015 generated on generated on (if available) (if available) - site (2013) - site (2014) Kgs in terms 3421.5 3000 2786.17 3000 3000 of LPG (Solar+ Biogas Plant) %of total 2.08% 1.85% Energy consumption KIRLOSKAR OIL ENGINES LIMITED Renewable Energy Off-site renewable energy systems installed % of Green Energy wrt Purchased Electricity 30% Share SEM Meter 60% 51% Installationincreased 50% 41% 36% Mandatory 40% Requirement 30% 20% 14% 10% 0% 2011-12 2012-13 2013-14 2014-15 2011-12 2012-13 2013-14 2014-15 1 Electricity Purchased 12,224,920 14,420,880 11,909,160 12,704,223 2 Electricity from Windmill Renewable 4,966,285 4,886,176 6,069,197 1,785,625 % of Green Energy 40.62% 33.88% 50.96% 14.06% Windmill Unit Generation Actual 6,443,831 @51% KIRLOSKAR OIL ENGINES LIMITED Renewable Energy On-site Renewable Energy Systems Renewable Energy Solar Steam Generation System for Canteen Steam Generation : 350 kg / Day @2 bar pressure No of Dish : 8 Area : 315 Sq.