National Productivity Council organized the following workshops on Efficient Operation and Maintenance of Boilers in January 2005. Department of Industrial Policy & Promotion, Government of India sponsored the workshops.

Location: Pune, Maharashtra
Date: 7th January 2005
Number of Participants: 52
The workshop was conducted by NPC in association with Directorate of Boilers, Government of Maharashtra at the premises of Forbes Marshall, Pune. The speakers emphasized the importance of refresher training for boiler operators and engineers. The faculty from NPC and the industry delivered lecturers on various boiler operation and efficiency related issues. The workshop was very well appreciated by the participants.

Location: Indore, MP
Date: 18th January 2005
Number of Participants: 54
The workshop was conducted by NPC in association with Directorate of Boilers, Government of Madhya Pradesh at Hotel Sayaji, Indore. The speakers stressed on boiler safety and operational system improvements. The faculty from NPC and industry delivered lectures on various boiler operation and energy efficiency related issues in the technical sessions part of the workshop. The participants gave a very strong feedback about the utility of the workshop and asked to increase the duration of the workshop to two days.

Location: Bareilly, UP
Date: 24th January 2005
Number of Participants: 63
The workshop was conducted by NPC in association with Directorate of Boilers, Government of Uttar Pradesh at Hotel Uberai Anand, Bareilly. The speakers from NPC, Boiler Directorate and Industry stressed on efficient operation and maintenance of boilers and made useful presentations on related topics. The workshop was well taken by the participants.

Location: Malda, WB
Date: 31st January 2005
Number of Participants: 40
The Workshop was conducted by NPC in association with Directorate of Boilers, Government of West Bengal. The speakers explained the importance of safe and efficient operation and maintenance of boilers. The faculty from NPC and industry made useful presentations on various boiler operation and energy efficiency related issues in the workshop. The workshop was a great success in terms of its utility for the participants.

1. ENCON awareness campaign among local residents:

a) Inaugural function of the Mass Awareness Programme on the use of Oil & Gas and distribution of memento to local residents was conducted on 28.01.2005. Shri T.H. Musthfa, local M.L.A inaugurated the function. Mr. M.A. Mohammed Ali Director (R), Kochi Refineries Limited presided over the function. Mr. N. Nandakumar General Manager (HR), Kochi Refineries Ltd delivered the keynote address on energy conservation aspects. Representatives of local panchyat and about 500 local residents participated in the function. About two thousand encon memento were also distributed among the local residents.

b) ENCON awareness campaign was also conducted for contractors and contract employees on 31.01.2005 and ENCON memento was distributed to contract employees.

2. ENCON Essay and Quiz Competition for KRL ENCON club Members:

ENCON Essay Competition with the topic “My Role in Conservation of Energy” was conducted in 15 KRL ENCON clubs associated with Colleges on 19.01.2005. Evaluation of the essays are in progress and prizes for the best 3 entries would be given shortly.

ENCON Quiz Competition was conducted in 10 KRL ENCON clubs associated with Schools on 19.01.2005. Prizes and Certificates were given to the first three winners.

An Inter School Quiz Competition was conducted for KRL ENCON clubs on 30.01.2005. Teams from 10 schools participated in the Quiz Competition. Prizes and certificates were issued to the winners.

3. Distribution of stickers, posters among KRL ENCON clubs:

Stickers, posters and banners were distributed in KRL ENCON clubs on 18.01.2005.

Apart from the above mentioned activities, we have conducted cycle rally, marathon etc; during January, 2005.

All the above activities were carried out as a part of Oil and Gas Conservation Fortnight-2005 (OGCF-2005) activities.

Sub: A brief report on “Small Group Activity Presentation”

Date: 27.01.2005
Venue: Conference Hall
Presentation conducted by Mr. S.C. Tripathy (Vice President)

Mr. S.C. Tripathy, Vice President, categorically highlighted the importance of Small Group Activity. Not only the energy saving aspects arresting waste is also an important role of Small Group. We can easily claim that our plant is virtually running with no wastage. But do we think about the sanctity of parameters in maintaining the pressure, flow, temperature, the operation line etc? Each and every point we have to analyse and justify then only we can achieve energy efficiency more and more. Simple use of up-to-date technology is not the solution. We have to find out what best we can extract from the existing availability.

Small Group Activity is not a duty to perform but it is a motto. It is not a contribution to the company but it is a contribution to the nation. It is a contribution to the culture & also a contribution to the history.

Next, group leaders of all Groups forSGA-1 to 12 narrated their achievement, activity and future programme in details. A synopsis of activity and achievement is also enclosed herewith.

In conclusion, Energy Manager, Mr. B. Sengupta, pointed out that simple activity and achievement of individual group separately has little impact. Each group leader is to share his achievement to other leaders also. Such exchange of views will help them for future programme. We want a healthy competition among the groups. Best group will also be rewarded.

Awareness Programme for Energy Conservation

We have conducted an awareness programme of Energy Conservation by Shri A K Jain, General Manager (Engg.) to all Engineering department staff and workers on 29th December, 2004 – total participants were 26.

Following points were discussed:

1. When we produce the yarn, the operating cost of power is 54%. So the potential of saving is more and whatever quantity we will save is equal to same quantity we have generated.

2. Small savings can give us a big saving through Kaizen.

3. All tube lights, fans & Computers are to be kept “OFF’ before leaving the office as also extra lights in toilets and bathrooms are to be removed.

4. In maintenance room, one common switch is to be provided for fans and lights so that the maintenance staff when come out from the room can switch off the whole lights and fans.

5. In TFO section, if less than 40 spindles are running, the TFO should be stopped so that major power can be saved.

Brief Report on Energy Conservation Activities Undertaken by Gujarat Refinery in the Month of Jan’ 2005

Oil and Gas conservation fortnight-2005 was celebrated by Gujarat Refinery from 15th -31st Jan’ 2005. The fortnight was inaugurated with Oil conservation pledge administered by the Executive Director, Shri K.K. Acharya on 15th January, 2005. A special bulletin on Oil and Gas conservation giving useful information on Energy Conservation tips and related statistics was released and distributed in the inaugural programme.

Steam leak survey by a team constituted by Center for High Tech (CHT) was conducted from 18.01.2005 to 21.01.2005. This increases the awareness amongst the employees and helps in reduction of steam losses.

To increase the awareness amongst the employees of the Refinery, an on-line quiz competition was organised. One day seminar / technical knowledge sharing sessions with eminent external faculty on Encon & Loss Control was also arranged for employees at Refinery training center. Employees from different units of the Refinery were benefited. A special suggestion scheme drive was also launched for employees on Energy conservation.

Oil walk flagged off by Executive Director, Gujarat Refinery was held to convey the message of Energy Conservation with the theme “Save Oil and Gas. These are precious” to residents of township and neighboring village (Bajwa). Around 300 participants including LD, Senior Officials, employees, ladies, children and school students joined the walk.

Awareness to the house wives were carried out through quiz competitions, distribution of PCRA leaflets.

Students were also covered in the Energy conservation awareness programmes through Fancy dress, Painting and Quiz competitions. Students from six different schools of Baroda participated in the programme.

Free PUC checkup camp for three-wheeler was arranged in the city petrol pump on 28.01.2005. Large numbers of auto rickshaw drivers were benefited. Distribution of free lube oil and fuel saving lips leaflets of PCRA were distributed.

Slogan writing competition in Gujarat, Hindi & English for employees and their dependents was also held. Finally, Valedictory Prize distribution function for the winners of different competitions was organised on 31.01.2005 at community hall of Gujarat Refinery Township. Prof. K.C. Upadhyaya, Vice Chancellor, M.S. University, Baroda graced the occasion as the chief guest. He gave away the prizes to various winners.

To include the awareness on energy and oil & gas conservation amongst the employees, their family members and the public, Indian Oil, Panipat Refinery had organized various programmes during Oil & Gas Conservation Fortnight (OGCF 15 – 31st Jan, 2005). The fortnight began with Mr. Rohit Bhardwaj, Executive Director; Panipat Refinery administering the oil & gas conservation pledge to the employees followed by an exhibition and distribution of energy/ fuel savings booklets received from PCRA. On the occasion the Executive Director also released a special issue of in-house newsletter supplement. Various activities such as Steam leak Survey in the Refinery by External Members nominated by CHT, pollution check, on-the-spot painting for children, quiz for housewives, quiz for employees, slogan, poster competitions were organised. To spread the message of Oil & Gas Conservation, banners were displayed throughout the OGCF period at Refinery, Township and near-by villages. Also, message were displayed continuously through cable network. An elocution contest was organized at Dadlana Govt. High School. The programme was well attended by all the school children, the Sarpanch of the village and other villagers. The school children presented their views on the subject. Also, the teachers, Refinery Representative and the Sarpanch of Dadlana village elaborated to the students the importance of energy savings, oil & gas conservation and environment protection. On the concluding day Mr. Rohit Bhardwaj gave prizes away to the various winners. There was good response in all the activities by the employees, their family members and general public of nearby areas.

(i) Awareness Campaign on Energy Conservation among the children of Class V & VI of Kendriya Vidyalaya HPCL, Jagiroad. The programme was conducted on 12-01-2005 by our Sr. Plant Engineer (Utilities) covering definition, type of energy, sources of energy, utilization of energy, conservation, measurement etc. The programme was attended by 47 Students of Class V & VI.
(ii) Half day training programme for workmen (Non-technical) on Energy Conservation & Energy Management was organised on 24-01-2005, which was conducted by our Manager (Electrical) Power House covering details of energy consumption in terms of percentage of manufacturing cost; specific electrical energy consumption etc. The programme was attended by 12 Nos workmen of various sections of Non-technical department. The programme was rates as quite beneficial to work & self development.

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HINDALCO
Workshop On Safety & Savings of Cooking Gas for Housewives

A workshop on the above subject matter was organized by Hindalco jointly with IOC on 28th January, 2005 at Samanvay Vidya Mandir in Hindalco premises Renukoot. The workshop included:

a) lecture on the various methods of cooking gas conservation and the need for it supported by live demonstration.
b) The various safety norms to be followed while using the gas were explained through slides & live demonstration.
c) A small quiz involving the above two points was conducted to make the ladies understand the concepts & apply the same in their daily work practice.

Altogether 150 housewives who attended the workshop gained ample knowledge about conservation of LPG and applying safe cooking practice.

In addition to the above, Hindalco also organised the following planned activities during January, 2005.

1. INTERACTION WITH SCHOOL CHILDREN ON SAVE ENERGY, SAVE ENVIRONMENT.
A lecture was delivered on the above subject matter followed by a small quiz competition involving 160 students of Class VII & VIII of Aditya Birla Public school, Hindalco. The quiz was an educative one and prizes were distributed after the programme.

2. ENERGY CONSERVATION & VEHICLE DRIVING PRACTICES FOR DRIVERS:
Altogether 23 Drivers of different sections of the plant participated in the programme held at Alumina Plant Training Center of Hindalco. They were told about the need of energy conservation and were trained on the same, right driving practices were also illustrated in the programme.

3. TECHNICAL TRAINING PROGRAMME ON FAN ENEGINEERING APPLICATION, PRACTICES:
An inhouse training programme on above subject was organised through an outside faculty from M/S Sumit India for the benefit of our technical team. The programme covered:

a. Basics of Fan Engineering, Fan selection overview, common problem with fans at site.
b. Improvement aspect, procedure.
c. Criteria for replacement.
d. Critical design features-Application based.
e. Duct designing

We have therefore, sent request letters in January, 2005 to the following four colleges/ universities to co-operate for conducting awareness programmes for students of Engineering / Technology in the month of February, 2005.

1. Faculty of Engineering & Technology, MSU Vadodara
2. L.D. College of Engineering, Ahmedabad (Govt. College)
3. Nirma Institute of Technology, Gandhinagar – Ahmedabad
4. Dharamsinh Desai Institute of Technology (DDIT), Nadiad

L.D. college of Engineering, Ahmedabad has confirmed for the programme verbally and the date will be finalised within a week’s time.

We assure you that we are determined to make up for the Programmes which could not be conducted in January, 2005 and send you the status report within three days soon after as and when the programmes are conducted in the month of February, 2005.

A one week programme was conducted from 17th January to 21st January 2005 at Nashik site for the management staff to train them in different waste reduction methodologies and tools. This programme was facilitated by qualified trainers in the field of ENCON and process robustness. Participants agreed to implement waste reduction projects including projects including ENCON of worth Rs. 40.0 Lakhs per annum.

1. Meaning of Waste Heat Recovery was explained.

2. Global Warming – Temperature of the earth is rising day by day due to green house effect. Green house gases are generated from industries during fuel combustion for heating purposes. These gases create an insulating layer above the earth of which prevents dissipation of heat to atmosphere that results in rise in earth’s temperature.

3. By recovering waste heat from industrial exhausts the quantity of fuel to be burned can be reduced which will lead to reduction in the generation of green house gases.

4. Potential waste heat recovery sources are identified as below:

A. Flue Gas from Boiler outlet: Average steam generation – 14 TPH, based on various fuels to be used quantity to be calculated.
Here we can go for Traditional Economizer or CHX – Condensing Type Heat Exchanger. Seminar of personnel from CHX Condensing Type Heat Exchanger (M/S Arudra Engrs Pvt. Ltd.) is planned in 3rd week of February.
B. Flue Gas from Incinerator : Heat quantity to be calculated.
C. Process Heat Recovery from Dicamba Plant : In Dicamba Plant four sources are identified namely Xylene+DCP fractionation, KDCP Prepn, Ester Fractionation. The total heat quantity available is 4,60,000Kcal/Hr.
D. Flue Gas from Diesel Generator : Heat quantity to be calculated.
E. Condensate recovery : Flash steam & hot condensate recycle to boiler.

As part of energy conservation activities planned for this year, following programs were carried out.

1. Energy Conservation Awareness program for our plant engineers and department heads.

The program was organized on 27.12.2004. We also included members from nearby industries to have the interaction.

Mr. R. P. Singhal–General Manager- Engineering of M/s Ghardha Chemicals Ltd. delivered his expertise and experiences about the subject. Issues like wastage of power in pumping due to poor pump efficiencies, substitution of energy sources, process modification to help energy conservation were discussed.

Around 38 people including 22 participants from member industries of Roha Industries Association and 16 plant engineers/ departmental heads from our organization have attended the program.

2. Internal workshop for Equipment Performance Analysis was conducted on 24th January 2005 and 25th January 2005. The program was conducted by our Energy Manager.

Responsibilities of analyzing performance was also assigned in this program and detail plan has been finalized. Accordingly performance analysis of Boilers, Furnaces, Electric motors above 40 HP, Refrigeration system, cooling towers, centrifugal pumps (above 40 HP), Insulation and Lighting will be carried out over a period of one year.

3. Energy Conservation Awareness programme for students of C.D. Deshmukh College of Commerce & Arts, Roha

Excel Industries Ltd., Roha has been invited by the college to create awareness among their students during the NSS Camp of the college at village Vadaghar, Tal Mangaon, District Raigad.

Accordingly, our ENCON Cell members Mr. Sandeep Pore and Mr. Amit Desai delivered the lecture about “Energy Conservation: Need of time” & “Energy Conservation Practices in day to day life”.

We were encouraged by the response & look forward to conduct more such programs in future.

Following programs which were planned in January 2005 but got postponed due to certain reasons:

1. Steam traps: types, selection, working principles, advantages & disadvantages of different types.
Steam distribution: good engineering practices in designing the same.
- By Shri Mohan Tambe – General Manager Forbes Marshall Ltd. Planned on 8th February, 2005.

2. Energy Conservation Practices & Trends
- By Maharashtra Energy Development Agency, Pune Planned on 24th February, 2005.

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Sub.: Launching 1st phase of our “Energy Conservation at Domestic Level” programme.

As a part of our Energy Conservation Activities planned for 2004-05, we have charted out the programme for Energy Conservation at domestic level for our employees by making “Excel Industries Employees Multipurpose Co-Operative Credit Society” (run by our employees only) as a partner.

In the factory, we undertake lot of energy conservation measures like replacement of incandescent bulbs by Compact Fluorescent lamps, replacement of magnetic chokes by electronic chokes etc. These measures are applicable for domestic level also, but are usually not practiced due to high initial costs.

Excel Industries Employees Multipurpose Co-Operative Credit Society made a resolution to provide Rs. 1,000/- as a special loan to all the members against the purchase of these items at a nominal interest rate of 1.5%.

On 3rd January 2005, the memorial day of our founder late Shri C.C. Shroff, an exhibition of these energy saving appliances were held and energy saving potential was practically demonstrated. We had got very good response from our 200 employees for the same & order for 450 CFL lamps, 79 Electronic Chokes and 110 LPG gas saver units was booked. Purchase Department of Excel Industries Limited negotiated for concessional prices for the same.

We are happy to inform you that these efforts were very much appreciated by our Chairman and Managing Director Shri A.C. Shroff. Appliances for the first batch of employees were delivered from his auspicious hands. He also offered all co-operation from Excel Management and good luck for all ENCON efforts on site. He had given us a target to ENCON team to extend this programme to another 100 peoples in next 4 months.

Core Team consisting of workforce and executives from various Departments had a meeting on 31st January, 2005 to design the training programme to increase further awareness amongst employees on Energy Conservation.

The team decided to conduct the training programme on efficient usage of energy by the 3rd week of February, 2005. This programme will be conducted in Hindi and Marathi and will cover efficient usage of electricity, fuel and water with a major focus on reduction of wastages of the same in the activities undertaken in all sections of the Plant and finalise targets for electricity and fuel consumption per unit of production for the year 2005.

Being an industrial sector, we are committed to Energy Conservation Policy and our Management has formed an Energy Cell comprising of Members drawn from both Staff and Officers and we have also appointed an Energy Manager.

The above Energy Cell meets at regular intervals, focusing on the need to conserve energy and the outcome of the meetings are suitably implemented in our system with utmost interest in conserving energy.

Our Company has also formulated a Suggestion Scheme and receives suggestions from our employees. The suggestions which are apt for implementation in our process for better results are being implemented and the employees suggesting result oriented suggestion are motivated through adequate monetary compensation.

Our Company is also sponsoring our employees to various in-house / outstation Training Programmes / Seminars relating to Energy Conservation and the knowledge acquired by them is being updated in our system.

The Energy Conservation Policy designed by our Company is produced below:

WE ARE COMMITTED TO ENERGY CONSERVATION
IN ALL OUR ACTIVITIES BY
TECHNOLOGY UPGRADATION, SYSTEM MODIFICATION
AND PRODUCTIVITY IMPROVEMENT.

In pursuance of National Campaign on Energy Conservation-2005, calendar of events for January, 2005 a seminar was organized at Talwara on 29th & 30th January, 2005 to create awareness amongst the officers and officials of BBMB. Around 225 employees of BBMB attended the seminar. The seminar was successful in motivating the employees to adopt energy conservation practices in their routine life. The seminar was designed to be interactive. Veteran officers of BBMB were also engaged for delivering lectures on the subject. Apart from the motivation lectures, the programme was specially tailored to impart details about energy conservation devices, methods and practices. Caste studies about Bhakra and Pong Power Houses were also demonstrated showing the savings achieved by merely replacing the old electrical light fittings and deploying photo sensitive control switches for street lighting etc.
A quiz was also organized to evaluate energy conservation habits of the participants. Compact fluorescent Lamps (CFLs) of 20 watts were distributed as prizes to 20 employees to crate enthusiasm amongst them and motivating them to adopt the modern energy conservation devices. Discount coupons of a reputed manufacturer of electrical light fittings and accessories were also distributed to decrease the cost of Compact Fluorescent Lamps (CFLs), which would result in motivating the people in adapting such energy conservation devices in their life.

The directives and guidelines to promote and conserve energy have already been issued from time to time. BBMB endeavors to carry forth such issues with full vigour and zeal in the larger interest of the Nation.

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