Energy Management Workshop

Gurukul 15th & 16th June 2015

 Energy Management Workshop
Agenda

SN Time Session By

1 4:00 to 4:15 PM Context Setting DGM (Works)

2 4:15 to 4:45 PM Some Facts / Figures & Discussion CDM-E&E

3 4:45 to 4:55 PM Tea Break

4 4:55 to 5:55PM Brain Storming & Idea generation Participants

5 5:55 to 6:00 PM Summing up CDM Coating Lines

 Energy Management Workshop - Facts and Figures
PBT Vs Power bill

Current situation
PBT (L) Power Bill (L)
9,069

6,782
6,223
5,598
5,367
4,953

FY13 FY14 FY15

 Energy Management Workshop - Facts and Figures
Trend of Tariff Vs kWH consumed
Power Tariff Rate increased by 27.2% with effect from 1st June 2015

6 Rate Rs./kWH 150000000

Plant Power kWH 5.38

5
145000000

4.23
4
3.63 3.71
140000000

135000000

130000000
1

0 125000000
FY13 FY14 FY15 FY16

Impact of it on the current ABP is around 18 Cr

 Energy Management Workshop – Facts and Figures
Process Cost break-up (Works)
Increased Power Tariff will change the Cost base by 5% and its impact is approx. 18 crs on
company’s bottom line. (if other cost remains same…)

Fuel Fuel
17% 16%

Stores (incl. Stores (incl.

packaging) Packaging)
35% 33%

Power
21% Power
Cost 26%
distribution

R&M R&M
27%
25%
FY 14-15 FY 15-16

Power Tariff is changing the Process cost distribution ; Power becoming the 2 nd largest cost
 Energy Management Workshop - Facts and Figures
Drop in Profitability by 18Crs due to increased Tariff rate

PBT (L) Power Bill (L)

9,069

7,914

6,782
6,223
5,598
5,367
4,953 4,982
-1800

FY13 FY14 FY15 Rev. FY15

Power Tariff Rate increased by 27.2% and Profitability impact is 26.5%

 Trend of Specific Power Consumption &
Specific Power Cost

Chart Title
900
872.31863.67 882.25870.03
863.73
837.82 837.66
800 806.31

700 688.57
682
642 645 651 656
623 628 630 626 634 627 620.91
600 610
591 590
547
500

400

300

200 171 162.78146.79155.73149.87162.14160.53 155.7 163.99161.72160.54

154 152 149 149 146 153 157 142 150 143 152 146 142
137
100

KWH/MT Cost/MT
 Energy Management Workshop – Facts and Figures
Plant Power Consumption Distribution for the year FY'15

Period – 14-15
Units- 13,46,76,200 SC Pickling -1
1% 2%
Cost – Rs 56.97 crores
6-Hi -1
ETL-2 16%
20%

ECL-1
2%

BAF -1&2
4%

4-Hi -1
4%

ETL-1
15%
Pump House (CRM -1&2)
5%

LT Compressor
1%
Pickling-2
1%
HT Compressor
3%
4Hi-2 6Hi-2
69% Power bill is from
CPL-1&2 5%
ECL-2 18% ETL-2,6HI-2,6HI-1 AND
1% 3% ETL-1
 Energy Management Workshop – Facts & Figures
CRM Overall Specific Power Consumption FY’15
CRM Sp Power Consumption (KWHr/MT)
274
270
265 266 Sep ’14 Dec ’14 Best
263 achieved

249
249 268 244
30111 PP 25308 PP (Dec’13)
31207 PP

Comp.Air Pick
Period – 14-15 Water 7% 5%
Units- 8,62,16,080 8%
Cost – Rs 36.47 crores CPL
1%
4 Hi
14%
6 Hi
52%
BAF 52% Power bill is from
6%
ECL
6hi-1&2
7%
 Energy Management Workshop – Facts & Figures
CRM-1 & 2 Power Distribution
CRM 1 Power Distribution CRM 2 Power Distribution
Period – 14-15
Units- 4,43,48,340 Period – 14-15
Cost – Rs 18.76 crores Units- 4,18,67,740
Cost – Rs 17.71 crores
Pickling-2
LT Compressor Pickling -1 HT Compressor 4%
3% 6% 11%
Water CPL-1&2
15% 3%

4Hi-2
4-Hi -1 16%
13%
6-Hi -1
46%
6Hi-2
ECL-2 57%
9%
BAF -1&2
12%
ECL-1
5%
46% Power bill is 57% Power bill is
from 6hi-1 from 6hi-2
 Energy Management Workshop – Facts & Figures
6hi Mill No. 1
Sep ’14 Dec ’14 Best
achieved
6 Hi # 1 Specific Power Consumption FY 15
123 KWH 131KWH 123KWH
129 131 130 128 135 129 123 123 134 131 128 129 131 14538 12111 Sep ’14
126 MT MT
113

6 Hi 1 Power Distribution
Period – 14-15 POR
Units- 2,12,59,264 TR 1% Auxiliary
Cost – Rs 9 crores 12% 17%

MSM
70%
83% Power bill is from
Mill & RR Motors
 Energy Management Workshop – Facts & Figures
6hi Mill No. 2
6 Hi # 2 Specific Power Consumption FY 15
137 132 Sep ’14 Dec ’14 Best
125 124 122 125 132 118 124 120 125 128 128 achieved
115
104
122KWH 132KWH 118KWH
17014 MT 14718 MT Aug ’14
17023 MT

6 Hi 2 Power Distribution
Period – 14-15
Units- 2,39,32,668 Auxiliary
Cost – Rs 10.12 crores 19%

LV Drive
7%
MV Drive
74%

74% Power bill is from

MV Drive
 Energy Management Workshop – Facts & Figures
ETL - 1
ETL # 1 Specific Power Consumption F Y 15
185
167 171 161 165 164 174 170 165 164 160 163
157 154 147 143 153 163 146
159 160 160 152
146 152
141

ETL -1 POWER DISTRIBUTION Lighti

Period – 14-15 ng &
AC
Units- 2,00,73,000 MCC 7%
REFLO
7% W
Cost – Rs 8.5 crores AUXILLIA
RY 15%
11%
AC
Drive
2% REC
DC TIFI
DRIVE ER +
6% MCC
Loa
d
53%
 Energy Management Workshop – Facts & Figures
ETL - 2
ETL # 2 Specific Power Consumption FY 15

154 151 143 145 153 159 163 159

147 143 139 139 145 138 146 141 150 140 154 154 149 150
132 130 135 137
et

Se 1 4

No 4

Ja 4

15

Au 5

No 5

Ja 5
16
2 0 -1 4

Ta 5

M 4
Ju 14

Ju 4
Au 4

Oc 4

De 4

Fe 5
M 5

Ap 5
M 15

Ju 5

Se 5
Oc 5

De 5
Ap D

t'1

l'1

t'1
-1

r'1

'1

'1

v'1
c'1

1
1
'1

'1

g'1

v'1
c'1
rg
YT

g'
'

ly'

n'
b'

n'

p'

n'
r'
ne

pt

ar
ay

ay
13
14

Ju
20

ETL -2 POWER DISTRIBUTION

Period – 14-15 Lighting
Units- 2,71,94,820 2% MCC
11%
Cost – Rs 11.5 crores Auxilliary
DRIVES
6%
20%

RECTIFIERS
28%
REFLOW
33%
 Energy Management Workshop – Facts and Figures
Power Distribution
General Services - Power
Power Maximum Demand (MVA) FY 15 Kwhr
Load Sep ’14 Dec ’14
24000 22949 22546 22906 General 340200 344320
21281 Services
Water 74200 76740

Contract MD MD(FY'14) MD(FY'15) Apr.'15 May.'15

Township - Power Kwhr

1.0200 POWER FACTOR FY15
1.0000
Avg Fy.'14-15 in
KWH
0.9800
Apr’15 in KWH
0.9600
May ’15 in KWH
0.9400
TISC
0.9200 O
130320
167760

326090
443700

132240
176400
118940

259893
285600
355680

352540

120400

104040
108960
137280
CRM

51093
58320

69120
66960

44413
50000
0.9000 ETL-I
ETL-II
0.8800 TOW
N
0.8600
4 4 4 14 14 4 4 4 4 5
r il,1 ay
,1
ne,1 ly, st, er,1 er,1 er,1 er,1 r y,1
p Ju Ju u b b b b a
A M ug te
m cto m m nu
A p O ove ece Ja
Se N D
 Energy Management Workshop
Some thoughts………….

• Reducing Power wastage

• Efficiency Factors
• Multiple handling
• Re-work
• Use of Technology/ Automation
 K YO U
THA N
BACK-UP SLIDES
Power Tariff will change the Cost base by 1% and its impact is approx. 20-22 crs, if total unit
consumption will remain constant as in last year 1%
4%
4%
S & W, 7%
Depreciation FC,
General exp 4% 1%
4% Fuel, 3%

S & W, Power, 4%
7%
Fuel
3%
a ny's R & M, 4%
p
Power, 3% Com base
Cost be Stores, 6%
R &M will HR
4%

TIN, 7% FY 15-16
Stores
6% HRC
61%

TIN
7%
FY 14-15

HRC TIN Stores(including packing) R&M (Plant & machinery and building) Power

Fuel salary & wages General expenses & others Depreciation Finance cost
 Power Management Workshop – Facts & Figures
Pickling - 1

Pickling # 1 Specific Power Consumption FY 15

24.7
Focus Areas:
24.3
20.3 20.3
1) Production Planning
19.4 19.1 19.5 19.9
16.6 16.8 17.9 18.7 2) Optimizing Idle time Loads
14.0 3) Natural Lighting/ Lighting
Voltage

4 t r y e ly g t t v c n b r
3-
1 r ge T D Ap Ma Jun Ju Au Sep Oc No De Ja Fe Ma
1 Ta Y
20

Pickling 1 Power Distribution

LDB Sep ’14 Dec ’14 Best
10% achieved
Crane
1% 17.7 20.3 16.8
13382 MT 10321 MT Jun ’14
9212 MT

Overhead Lights & Cranes of both Pickling and ECLs are booked
MCC under Pickling-1
89% WWTP, Solar Pond, Contractor godown including drum making
are booked under Pickling-1
 Power Management Workshop – Facts & Figures
Pickling - 2

Pickling # 2 Specific Power Consumption FY 15

9.4 Focus Areas:
8.4 8.6
7.5 7.9 7.5 7.8 1) Optimizing Idle time Loads
7.0
6.3 6.7 6.8 7.1 6.9 2) Natural Lighting/ Lighting
Voltage

4 et D
Ap
r ay e ly g pt Oc
t v
De
c n b
Fe Ma
r
3-
1
arg YT M Ju
n Ju Au S e No Ja
1 T
20

Sep ’14 Dec ’14 Best

achieved
6.6 7.1 6.3
21332 MT 19215 MT May ’14
23662 MT

ARP-2 is included in Pick-2 Power

Overhead Lights & Cranes are booked under Pickling-1
 Power Management Workshop – Facts & Figures
ECL - 1

ECL # 1 Specific Power Consumption FY 15

Focus Areas:
18.5 17.7 16.9 16.5
1)
16.0 2) Cleaning Current
13.2 14.0
11.8 12.2 11.9 10.6 12.3 3) Optimizing Idle time Loads
10.3
4) Natural Lighting/ Light
control through Occupancy
Sensing/ Lighting Voltage

ECL 1 Power Distribution

Rec
tifi Sep ’14 Dec ’14 Best
er
18 achieved
% M
CC 12.2 12.3 10.3
&
Dr 15409 MT 13190 MT Jan ’15
iv 15292 MT
e
82
% Crane and Lighting are in Pickling-1
Power
 Power Management Workshop – Facts & Figures
ECL - 2

ECL # 2 Specific Power Consumption FY 15

Focus Areas:
22.6 22.4 21.7
18.9 20.4 19.5 19.7 20.1 19.4 20.4 20.7 1)
17.0 18.1
2) Cleaning Current
3) Optimizing Idle time Loads
4) Natural Lighting/ Light
control through Occupancy
Sensing/ Lighting Voltage
5) Technological Intervention

Brush roll Drive Rectifier

VVVF Drive 2%
11% 10%
Sep ’14 Dec ’14 Best
achieved
21.7 20.7 18.1
MCC 16757 MT 13866 MT May ’14
76% 17167 MT

ECL 2 Power Distribution Crane and Lighting are in Pickling-1

Power
 Power Management Workshop – Facts & Figures
4hi Mill No. 1

4 Hi # 1 Specific Power Consumption FY 15 DR Sp. Power = 55 KwHr/Mt

47.0
42.8 44.6 43.4 (Jan ’15)
39.5 39.7 38.7 40.0 37.0 40.4
36.0 34.2 33.8
Focus Areas:
1) Coil Cooling Fans
2) Optimizing Idle time Loads
3) Natural Lighting/ Light
control through Occupancy
Sensing/ Lighting Voltage
4) Technological Intervention
4 Hi 1 Power Distribution
POR
3%
Stand Sep ’14 Dec ’14 Best
2 achieved
15%
Stand Auxili 37 40.4 33.8
1 ary 13948 MT 11992 MT Jan ’15
21% 61% 15586 MT

AUX – Covers Bridle and Screw down DC Motors, Fixed Speed AC

Motors, Lighting loads (6hi1 & 4hi1), 6hi & 4hiMill Bay Cranes
 Power Management Workshop – Facts & Figures
4hi Mill No. 2

4 Hi # 2 Specific Power Consumption FY 15 Without Rerolling, Jan ‘15 Sp.

Power shall be 23.8 Kwhr/Mt
47.0
42.8 Focus Areas:
38.7 40.0
34.9 34.2 34.1 31.7
31.0 33.2 30.5 33.2 33.6 1) Coil cooling fans
2) Optimizing Idle time Loads
3) Natural Lighting/ Light
control through Occupancy
Sensing/ Lighting Voltage
4) Technological Intervention

SD
-1SD SD
To-2 -1 Sep ’14 Dec ’14 Best
SD
p Bo Bo LC
-2
Te
2% t SS
achieved
tPO
&
To
nsi
Exi 1% 58
pon R 30.4 34.1 30.4
t& % 18673 MT 14409 MT Sep ‘14
&ReBri
En Scr
eldle
try
10 ew
18
%Do
Bri % 4 Hi 2 Power Distribution
dlewn
8%3%
 Power Management Workshop – Facts & Figures
CRM Utility
CRM Utility Power Distribution Focus Areas:
1) Compressor/ Pump Efficiency
HT 2) Cooling Tower Operation
Com Wat
er 3) Running only one ICW pump
pres
sor 53%
37% LT
Com
pres
sor
10% Utility KwHr/ Mt (CRM Packed Production
used for calculating this)
Utility Sep ’14 Dec ’14 Best
achieved
Air 17 18.44 13
30111 MT 25308 MT Jun’14
28527 MT
Water 19 19.7 16*
Jan ’15
29851 MT
* - With AC Drive installed in 3 x 200 KW ICW Pumps