HIGH EXPLOSIVES FACTORY KHADKI Pune (Maharashtra)

First Prize Ordnance Factory

Unit Profile

High Explosives Factory, Khadki, Pune is located on the river bank Mula. The factory was planned in pre-world war 2 for which foundation stone was laid on 11 th January, 1940 by Mr. G.S. BUTLER, the then Director of ORDNANCE FACTORIES and commenced production from 1942. Since then this Factory has been consistently producing High Explosives such as TNT, DNT, TETRYL, HNS and liquid propellant required for missile. This factory is one of the most important units under A&E Division.

High Explosives Factory has taken active part in Energy Conservation area and has undertaken some of the projects for the same and successfully completed some and some projects are in hand. The details of the projects are as under:-

Reduction in consumption of Furnace Fuel Oil

• HEF has observed that about 25% of budget is expended towards purchase of Furnace fuel oil. On scrutiny of the A category items furnace fuel oil stands at No.1. FF Oil is required for running Boilers to generate steam required for production activities. In view of the above, HEF has taken up this project to study and reduce consumption and following steps were taken as per actual requirement.

• There are 5 Boilers, out of which 1 is standby and 4 are working. After thorough study 2 Boilers were put into operation instead of 4 Boilers as per the load requirement thereby reducing consumption of FF oil maintaining desired production.

• Steam network which was also connected to some of the old manufacturing plants has been reduced to actual requirement of existing working plants, thereby reducing consumption of FF oil maintaining desired production.

• The steam line lagging was found to be worn out / damaged which was rectified and proper lagging was provided which has reduced loss of steam and thereby reducing consumption of FF oil.

Some of the steam traps were found to be defective, thereby, water trap malfunctioned and the steam escaped for longer time causing loss of steam. The steam traps were repaired and reduced steam loss.

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• It was also found that the steam network was extended to Change rooms for heating water for bathing by IEs working in explosive areas for 24 Hrs-365 days. The same was disconnected and alternate arrangement of hot water such as Geysers and Solar water heaters were provided, thereby reducing steam consumption in turn FF oil.

• On successful implementation of above measures, HEF has reduced FF oil consumption from 34, 86,000 litters to 24, 21,500 litters for the year 2012-13 to 2013-14. Thereby net saving of FF oil 16,17,500 litters including enhanced production and in terms of value the total saving is Rs. 8.451Crores.

Reduction in water consumption

About 6 million litters per day is consumed by HEF for production and other services, Out of which only 1.5 million litters is accountable. The water line network is of 1940, laid about 8 Feet below the ground level. Being old water line due to leakages, there is considerable loss of water, which is not traceable since the line is 8 ft. below ground level, therefore, repair/ rectification of damaged line is not feasible. The following measures have taken to reduce water consumption:-

• The water line network to various old plants not in operation has been disconnected.

• The leakages in water line have been repaired.

• Water recirculation facility has been provided for some of the plants.

• In maintenance area close watch is kept in water consumption for cleaning purpose.

• The above preventive measures have resulted into reduction of water consumption from 6 million litters per day to 4.5 million litters per day for the year 2012-13 to 2013-14.

• For further reduction of water consumption, HEF has taken up a new project for replacement of existing water line by laying the network about 2 to 3 feet below the ground instead of 8 feet for easy traceability and access to repair leakages. The water line network dimensions are also reviewed for reduction in diameter to cater for present demand of water. This project will roughly cost about 3 Cr. The cost of the new project will be liquidated in around 3 years. By successful execution of the project, will result into further reduction of consumption of water from 4.5 million litters per day to 2.5 million litters per day.

• In addition to above, as per the MPCB directives to achieve the target of 0 discharge, water from ETP plant will be used for gardening, toilet and in process of cooling hot water, thereby the demand for fresh water will be reduced and this will also aid in reduction of water consumption from 4.5 million liters per day to 2.5 million liters per day.

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Reduction in Electricity consumption Number of projects has been executed for reduction in electricity consumption such as i) Replacement of 11 watt CFL in place of 100 watt lamps. ii) Replacement of 15 watt CFL in place of 100 watt incandescent lamp. iii) Replacement of 20 watt CFL in place of 100 watt lamps. iv) Replacement of 23 watt CFL in place of 100 watt incandescent lamps. v) Replacement of 28 watt T-5 Tube light in place of 40 watt TL. vi) Solar water heater 300 liter in place of 35 liter KW Geyser. vii) Reduction in electricity consumption by optimum utilization of Boiler.

• Due to above measurers, there is considerable reduction in electricity consumption from 4005978 kWh to 3873965 kWh for the year 2012-13 to 2013- 14. There is net saving of 1,32,013 kWh and in terms of value Rs. 53.45 Lakhs and Power factor incentives Rs.25.11 Lakhs and Load factor incentives Rs. 20.54 Lakhs.

The primary objective of H.E. Factory is reducing energy conservation by active participation to achieve sustained energy efficiency in all areas, for which HEF is making endless efforts.

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Second Prize Ordnance Factory

ORDNANCE FACTORY Dehradun (Uttarakhand)

Unit Profile

Established on 10 th February,1934, Gun and Shell Factory is the oldest factory among the forty (40) Ordnance Factories in India under Ministry of Defence. During the year 1941, the Mathematical Instrument Office, 15, Wood Street, Calcutta was taken over the department of supply Munition Branch from the Supply Department and simultaneously the planning of this factory was started under project E.E. 20. Originally, it was proposed that this new Instrument Factory be constructed at Tollygung but owing to the capture of Burma by Japan and bombing of Calcutta, this proposal had to be abandoned and Dehradun was finally chosen as the site of factory. The construction of the factory commenced in December’1942 and was completed in 1943. The factory went into production in October, 1943.

Ordnance Factory, Raipur, Dehradun, Uttrakhand is situated at a picturessive spot, approximately 7 kms. away from Dehradun Railway Station at Raipur at the outskirts of Dehradun City. Factory is connected with Dehradun city by metallic road and city Bus Service also exist city and Raipur. The factory area is 15.90 hectare while the estate area is 137.34 hectare.

Ordnance Factory Dehradun (OFD) has been the leading supplier of a wide variety of Optical, Opto-mechanical and Passive Night vision devices and weapon sights for infantry and artillery wings of Indian Armed Forces, Central Para Military Forces and State Police Organisations.

Energy Consumption

Electrical Energy consumption (in Cr –units)

Year 2012-13 2013-14 Total Electrical Energy consumption 0.3098 0.2983

Specific Electrical Energy Consumption (Cr-unit / VOI in Mn Rs)

Year 2012-13 2013-14 Total Specific electrical Energy consumption 0.0295 0.0248

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Total Specific Electrical Energy Consumption

0.03 0.0295 0.029 0.028 0.027 0.026 0.0248 0.025 0.024 0.023 0.022 2012 -13 2013 -14

ENERGY POLICY

ORDNANCE FACTORY DEHRADUN is committed to demonstrate excellence in Energy Performance in all our activities on a continual basis so as to make our operations environmentally sustainable for future.

We shall achieve this by:

• Monitoring and control of energy consumption through effective energy management system and periodic energy audit. • Continuous up-gradation of process with energy efficient and eco friendly & economically viable technology to optimize energy consumption. • Promote and propagation of energy awareness among all employee through external and in-house training program. • Recognizing efforts of our employees in energy conservation initiatives. Benchmarking our performance with best and starving to beat the best.

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Certificate of Merit Ordnance Factory

GUN & SHELL FACTORY Cossipore, Kolkata (West Bengal)

Unit Profile

Gun and Shell Factory is the oldest ordinance factories in India under Ministry of Defence. Gun and Shell factory was established in 1801 in the name of GUN CARRIAGE AGENCY by the EAST INDIA COMPANY for repair and manufacture of gun carriages. The transformation from bullock-driver contrivances of Gun Carriage Agency to that of a maker of sophisticated weapon systems is an absorbing story of technological advancement in consonance with developments in modern military hardware.

It is a fully fledged engineering factory engaged in manufacturing of ammunition hardware and ordnance stores for army, navy and other civil sectors. Supply to ARMY cover medium caliber guns, mortars elevating mass for L-70 anti-aircraft guns 84 mm, rocket launcher, medium caliber shells ranging from 30 to 125 mm, various types of fuzes and primers.

Energy Consumption

Energy Conservation Measures Taken

1. Field related to improvement of P.F. by implementation of capacitor banks

P.F. without implementing capacitor banks = 0.85 lag (approx).

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P.F. after implementing capacitor banks = 0.99 lag (approx). GSF’s total kVA = 3500 kVA (approx). GSF’s average LF = 0.4 (approx). Average kWh saving per day = 4704 kWh Total annual saving = 1411200 kWh Equivalent amount saving in Rs. = Rs. 101.6 lakhs

2. Field related to implementation of CFLs (65 Watt) in place of mercury vapour lamp (250 Watt) Total Savings in field 1 & 2 = Rs. 110.31 lakhs 3. Future & ongoing plans of GSF (i) Implementation of solar street lights inside factory & estate. (ii) LED lights to be implemented at shop floors very shortly. (iii) APFC panels to be introduced for fine tuning of P.F. at load end. (iv) LF to be improved to at least nearby 0.5 by re-orientation or shifting of bulk loads. (v) Leakages in hydraulic pressure lines to be arrested and new energy efficient compressors to be introduced. (vi) Any procurement of new accessories like AC, FANs, etc. to be compulsory of 5 star rating as per BEE (if available in market).

PHOTOGRAPHS RELATING ENERGY CONSERVATION EXECUTION

• Replacement of mercury vapour lamp (250 watt) by CFL (65 watt) at shop floor

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• Replacement of mercury vapour lamp (400 watt) by CFL (65 watt) at shop

• Installation of APFC panel

• REPLACEMENT OF SON LAMP BY CFL IN STREET LIGHTING • EFFICIENT FUEL INJECTING SYSTEM IN BOILER

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