honeywell automation india ltd. pune sector... · with approximately 122,000 employees worldwide,...

© Confederation of Indian Industry

Honeywell Automation India Ltd. Pune

Mr. Manoj Kumar SinghHead-Solution Development, Energy Services

Mr. Mohammad InamdarManager-Facility

Mr. Shantanu PathakEnergy Solution Specialist


Brief introduction on Company

Honeywell is a Fortune 100 company that invents and manufactures technologies to address tough challenges linked to global macrotrends such as safety, security, and energy. With approximately 122,000 employees worldwide, including more than 19,000 engineers and scientists, we have an unrelenting focus on quality, delivery, value, and technology in everything we make and do.

Honeywell partners India through our company’s four businesses – Aerospace, Automation & Control Solutions, Transportation Systems & Specialty Materials, with more than 12,000 employees across India.

About Pune Facility

Built-up Area – 27,778 sq. meter, 3 buildings

Contract demand – 2.5 MVA

Number of employees – 3500

Started operation in year 1987, upto year 2015 it was Manufacturing Unit plus office, now it is only Corporate office & labs.


Energy Consumption Trend (kWh/year)

3

5910135

5486933

5361595

5090486

4600000

4800000

5000000

5200000

5400000

5600000

5800000

6000000

2014-15 2015-16 2016-17 2017-18

kwh/year

14% reduction


1. Sp. Energy Consumption in last 3 years

Reason for higher Sp Energy consumption- The facility operates for 16 Hrs. and GBO is 24 hrs. and 100 % area is air conditioned -

213

198 193

183

165

170

175

180

185

190

195

200

205

210

215

2014-15 2015-16 2016-17 2017-18

Sp Electrical Energy Consumption kWh/sq m

14% reduction


2. Information on Competitors, National & Global benchmark

183 203 85 82 -

50

100

150

200

250

HAIL HTSL CTS TCS

Sp Electrical Energy Consumption kWh/sq m

With new initiative of Honeywell Global - 5 years of payback and with available Corporate budget, 100% focus is on CO2 reduction and Energy reduction.


3a. Energy Saving projects implemented in FY 2015-16

No Title of Project DetailsAnnual Electrical

Saving (kWh)

Annual Electrical Cost Saving (Rs

million)

1

HVAC for new area Shifting of Coral Staff which was running on Split AC to one of the unoccupied floor and installing AHU and connecting to existing Chiller

91,000 0.66

2

Thermoconductive Oil for improving performance of HVAC

It is a unique product which when added into a refrigerant circuit more than 3 year old cooling equipment improves cooling efficiency, reduces friction by 1500 times and help reduce compressor run time thereby saving power. It is compatible with all types of Refrigerant and can be used in all types of compressors.

141,223 1.74

3Solar Water Heater for Canteen, Gym

Hot water requirement of Canteen & Gym was fulfilled by rooftop solar water heating system

39,000 0.32

TOTAL271,223 2.72

© Confederation of Indian Industry7

Energy Saving through Solar Water Heating

Honeywell Roof-top Solar Water Heating System of 10 ,000 L/day capacity is installed

for hot water requirement in Gym, Canteen and Kitchen meeting 100 % of the

requirement.


Organic oil additive is injected in the refrigerant tubes will clean up the oil deposited & push it back to

compressor. This will increase lubricity in the system & will enhance the compressor efficiency & life. By

cleaning the tubes, it will improve heat transfer in the evaporator & condensing coils. This will result in

better cooling & efficient working of the compressor & saves power.

This is one time application that lasts the lifetime of the system & requires no modification of the

equipment.

It remains effective even if gas is leaked & recharged. This is zero down time application.

This is applicable for old as well as new systems, which lowers energy bills & reduces maintenance cost.

Energy Saving through Thermoconductive Oil


Thermoconductive Oil

22% Saving


3b. Energy Saving projects implemented in FY 2016-17

No Title of Project Details Annual

Electrical Saving (kWh)

Annual Electrical Cost

Saving (Rsmillion)

1

HVAC for Gym area

Gym operates from 6am to 9am and 6pm to 9pm for which earlier chiller used to operate at very low load with 100 % auxiliary load which was avoided by installing a separate Package AC particularly for this area.

46,800 0.4

2

Separate HVAC for small load of 24X7 operation

Global Business operation started operating 24x7 and which required chilled water, for that area additional hrs. after 6 PM Separate Package AC installed (in Pune condition in night the performance was good , resulted in saving, we avoided running 100 TR chiller for 30 TR GBO AHU)

83,200 0.7

TOTAL 130,000 1.0


Energy Saving through segregation of HVAC load

Package AC installed for Global Business

Operations area which works round the

clock because of which chiller operating

at low load is eliminated results into

energy saving.

Package AC installed for Gym which

works at non office hours because of

which chiller operating at low load is

eliminated results into energy saving.


3c. Energy Saving projects implemented in FY 2017-18

No Title of Project DetailsAnnual Electrical

Saving (kWh)

Annual Electrical Cost Saving (Rs

million)

1

AHU Upgradtion with VFD

All the AHUs are installed with VFDs & integrated with BMS to operate optimally which saves energy

114,799 0.9

2

Chillers & Thermal Storage rectification

Old in-efficient chillers were replaced by new efficient chillers & also the holding capacity of Thermal Storage has increased

411,310 3.3

3

Right Sizing of Condenser Water pumps with VFD

Flow & head of condenser pumps is optimized by replacing it with right sized pumps & VFD is also installed to vary flow

39,096 0.3

4

Lighting Retrofit with advance sensors

Old conventional fittings were replaced by LED fittings along with sensor which senses occupancy, Temp, Co2 and Energy Simultaneously and can be tracked through BMS

394,282 3.2

TOTAL 959,487 7.7


Energy Saving through VFDs for AHU & Pumps

VFDs are installed for AHUs, Chilled & Cooling Water Pumps which

modulates as per the requirement & temperature setting


Energy Saving in Chillers

Existing 4# nos. Chillers each of 75 TR (R 22)

operating at -3 Deg. C

Replaced with higher capacity single chiller of 270

TR capacity and designed to operate at -6 Deg. C

with Thermal Storage system

Before

After


Old overdesigned low

efficiency end suction

Condenser & Chilled

water pumps Replaced

with new high efficiency

right sized vertical inline

pumps with VFD.

Energy Saving in Pumping Systems

Before

After


4. Innovative Projects implemented

Name of the Project

Brief description on why innovative Trigger for implementing the project

Annual Savings(Rs. In lakhs)

Investment (Rs. In lakhs)

LED retrofit with Advance Sensor

Solution--Conventional lighting converted with LED coupled with single sensor having Occupancy ,Temp, CO2 and Energy Measurement which is Modbus compatible and can be seen through BMS,

Higher Energy cost appox 15 % of Total Building load, lower occupancy still higher seats, Higher CO2 level, Hot/Cold pockets complain

32 140.0

Replication potential—all the building lack data in terms of occupants timing of in and out on seat level basis ,CO2 area wise, Temp issues all these problem can be resolved once we have data to analyze and take decision, this is going to be part of Smart Building –Honeywell Initiative


Energy Saving through LED lights & sensors

Old Conventional Lights are

replaced with new energy

efficient LED lights

New LED lights are installed with

combination of advance sensors which

helps in saving more energy by optimum

use of lighting


Energy Saving through LED lights & sensors


Innovative Projects implemented

19

Name of the Project

Brief description on why innovative Trigger for implementing the

project

Annual Savings ( Rs. In lakhs)

Investment ( Rs. In lakhs)

Brine Chiller with Duel set point and with Thermal Storage

Solution-We installed Brine chiller operating at -6 Degree for charging the Thermal Storage and same chiller operate at 10 degree in office time directly to AHU to get advantage of Lower Tariff in night and Ambient advantage of lower WBT and avoiding PHE of 3 degree Approach hence saving of 9 % in chiller while discharging.

Idea was to take TOD advantage and reduction of DG load operation Every Thursday. as Every Thursday there is power shut down in Pune.

33.0 57.0

Replication potential—All the building having power shortage or DG operation can go for this type of system and areas having Time of Day can save energy Cost.


Brine Chiller with Duel set point and with Thermal Storage

• Brine chiller is installed which is operating at -6 Degree for charging the Thermal Storage and same chiller operate at 10 degree in office time to supply directly to AHU.

• To get advantage of Lower Tariff in night and Ambient advantage of lower WBT and avoiding PHE of 3 degree Approach, hence saving of 9 % in chiller while discharging.


Future Energy Saving projects for next years

• AHU Upgradation with EC Blowers

• Installation of Electronically Air Cleaner filters for AHUs

• Installation of Solar Photovoltaic system


Roof-top Solar Water Heating System of 10 ,000

L/day capacity is installed for hot water

requirement in Canteen and Kitchen meeting 100

% of the requirement.

Roof-top Solar PV system is installed for small

lighting load.

5. Utilisation of renewable energy sources


Roof-top Solar Water Heating System of

10 ,000 L/day capacity is installed for hot

water requirement in Canteen and

Kitchen meeting 100 % of the

requirement.

Utilisation of renewable energy sources

Roof-top Solar PV is installed for small

lighting load.


- We Generate mainly these type of waste

- Water ,Paper ,waste oil and E waste.

- Water waste is treated using STP and reused in

Gardening / Land scaping.

- We use identified vendor for paper , waste oil and E

waste for recycling.

6. Utilisation of waste material as fuel


STP for Waste Management

Water waste is treated using STP and

reused in Gardening / Land scaping


- Honeywell is committed to GHG reduction not only by reduction

of its own facilities but also creating Benchmarks for Indian

Buildings as Smart Building and Smart Cities with Govt of India.

- Honeywell Every year allocates Budget for Energy Efficiency

program as a corporate initiative and allocate the Budget based

on Global competition , any project below 5 years of payback

qualifies for it, This year Honeywell Has allocated appox 50

Million USD for this program Globally .

- 2016-17 Project was part of the same corporate budgeting

program.

- Reduction of 574 Tons of CO2 reduction in last 3 years.

7. GHG Inventorisation


8. Green Supply Chain

a. Information on Projects implemented –Our Card

Board and Wooden Packing Boxes are purchased from identified

vendor who manufactures with Recycled material .

b. Information on Evaluation done –Different vendors

were evaluated and manufacturing processes and materials used

were certified by Honeywell as per Honeywell standard before

giving clearance for the Boxes.

c. Information on Benefits achieved- 50 % reduction in

cost and contribution to green initiative by the company.


1.Daily monitoring system-Honeywell facility has full fledged Integrated

Building Management system and Energy Management system which

monitors the Energy consumption through Energy Meters for all the

equipment and compares it with previous day and monthly target value to

improve on continuous basis.

2.Review meeting chaired by –Everyday it is review by Facility Manager and

every month Energy cost is discussed with CFO also as Facility Head directly

reports to the CFO of the Company .Annually the Energy initiative and benefit

is published in Annual report and is part of Board of Directors Meeting.

3 Separate budget for Energy Conservation –As mentioned Honeywell

Allocates corporate Budget for Energy Efficiency and each Facility has to get

approval for the project based on feasibility of project and payback.

9. Team work, Employee Involvement & Monitoring


BMS for Monitoring & Energy Saving


4. Energy efficiency / awareness training program –Honeywell Is BEE

accredited ESCO and myself Accredited Energy Auditor , we give training program on

HVAC/BMS system and Best Operational Practices on quarterly Basis to our operator and

Facility engineers.

5. Projects implemented through Kaizens (Workers and Supervisor

level)

We also have weekly call for all the nine Honeywell facility in india for the Best Practices

and projects on Kaizen .

One of the area which is GBO (Global Business Operation ) which runs 24 hrs had

common chiller and was running through Thermal storage discharge in non working

office hrs with suggestion from Employee we installed Separate package AC for the area

hence avoiding wastage through Chilled water circulation losses and running higher

capacity pump.

Similarly Gym area operate from 6 AM to 9 AM and 6 PM to 9 PM for this also separate

package Ac installed which was suggested by the Employee.

31

9. Team work, Employee Involvement & Monitoring


10. Implementation of ISO 50001/Green Co/IGBC rating

1. Implementation of ISO 50001/ Green Co /IGBC

certification

Honeywell Facility is Silver certified as HOS (Honeywell Operating system,

which has its own global benchmarking in terms of practices followed for

Energy usages, Documentation, best practices ,resource utilization,

Productivity etc,

2. % investment on turnover- As per Honeywell Global CO2

reduction initiative appox 2 % of the profit is spent in Energy Efficiency ,to

bring down the Carbon foot Print to our Global standard.


Any other relevant information

- Any other awards, acknowledgement- Honeywell Plays

important role in defining the Building in terms of Benchmarking as Smart

Building concept worked with Govt and played major role in Smart City

development with a concept that City can be smart only if its Buildings are

smart.

- Major achievements etc.

Has won Smart city award and conducted Honeywell

Smart Building Award 2017 in co-ordination with

CNN TV 18.

33


Honeywell Smart Building Score™

The Honeywell Smart Building Score™ has been developed as a universal framework for quick,

comprehensive, and easy assessment of any building. It focuses on scoring assets that make buildings

across 3 outcomes.

•Green: Environmentally sustainable components of a building

•Safe: Safeguard the building, its occupants, users and owners

•Productive: Enhanced comfort and productivity for users and owners


Thank you

honeywell automation india ltd. pune sector... · with approximately 122,000 employees worldwide,...

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