133

First Prize

General Category

HUBLI ELECTRICITY SUPPLY COMPANY (AG-DSM)

Hubli (Karnataka)

Unit Profile

The Government of Karnataka as part of reforms in power sector has unbundled the

transmission and distribution activities in the state of Karnataka. As a result, the

HESCOM Limited (Hubli Electricity Supply Company Limited) was incorporated on

30.04.2002 under the Companies Act, 1956 (No. 1 of 1956) and the company

started operation w.e.f. 01.06.2002. The company came into existence with

geographical jurisdiction of 7 districts comprising of Dharwad, Belgaum, Gadag,

Haveri, Uttar Kannada, Bagalkot & Bijapur with an objective to carry on the business

of distribution and supply of electricity more efficiently and economically. The

company is operating from Hubli city and covering the areas where the agricultural

consumption is comparatively on higher side. The company is presently operating

through 2 Zones, 7 Circles and 21 O&M Divisions with an area of 54513 sq. kms.

and population of over 1.66 Crs. The company has withstood the initial transitional

problems and achieved its objective of improving efficiency and better consumer

services. The Company today is functioning as a commercial entity in pursuance of

power sector reforms undertaken by Government of Karnataka.

The mission of the HESCOM is to ensure reliable quality power to its consumers at

competitive prices. HESCOM is committed to achieve this mission through:

• Encouraging best practices in distribution

• Ensuring high order maintenance of all its technical facilities

• Emphasizing the best standards in customer services.

Strategies

1. Enhancement of revenue generation.

2. Strengthening and refurbishing distribution network to reduce losses and cost of

operation.

3. Enhancing employee productivity.

4. Providing best services to its consumers.

5. Energy Audit at 33 kV / 11 kV DTC level to bring down avoidable losses.

6. Enhancement of vigilance activities to reduce power theft and pilferage.

Vision

1. 100% rural electrification

2. Reduce T&D losses gradually to below 15%

3. 100% metering at all levels right from feeder end to consumer installations

134

4. Elimination of Low Voltage Pockets by reorganizing the existing feeders

consequent to establishment of new Sub-Stations by HESCOM and KPTCL.

5. Reduction in interruption

6. Power supply on demand

7. Eliminate commercial losses by increased vigilance activities.

8. Application of Information Technology in more and more activities.

9. Increasing business efficiency by reducing AT & C losses.

AgDSM Project at HESCOM Hubli

1. HESCOM awarded the work for survey and Energy audit of approx. 11000

numbers of agriculture pump sets at Nippani and Bydagi Subdivision to M/s

Energy Efficiency Services Limited (EESL). EESL and HESCOM has signed the

agreement on 02.05.2011 for preparation of DPR.

2. EESL in association with Federation of Indian Chambers of Commerce and

Industry (FICCI) prepared a Detailed Project Report for Ag DSM project for

HESCOM for 11000 pumps at Nippani and Byadgi. The study involved

measurement of the present operating efficiency of the agricultural pumps

identified and recommendations of new energy efficient pump replacement.

3. To begin with, a general survey was carried out covering almost 11000 pumps

connected in 44 feeders covering 129 villages. Then detailed energy audit was

carried out in 25% of total pumps, followed by, demonstration of installation of

11 nos. of BEE star rated energy efficient pumps at both the sites. Based on the

energy savings demonstrated, the DPR was finalized and accepted in June 2012.

As per the DPR, expected energy savings was 30%.

4. Based on the DPR recommendations, HESCOM decided to take up the

implementation of Ag DSM project. EESL and HESCOM signed an Energy

Performance Agreement on 22.06.2012 for replacement of 11000 agriculture

pumps on ESCO mode.

5. In ESCO mode, all the investment related to the designing, supply, installation &

dismantling, repair & maintenance of the 590 nos. of agricultural pump sets is

made by EESL. EESL’s investment is recovered through repayment of 95% of the

energy savings achieved for duration of 6 years.

6. HESCOM will benefit by reduction in peak load demand, lesser failure rate of

Agricultural distribution transformers, reduced load of subsidy to agricultural

consumers, 5% monetary benefit of energy savings to be achieved, better image

in front of the farmers etc.

7. In the first phase, 590 nos. of pumps connected in 5 nos. of feeders at Nippani

subdivision and Bydagi subdivision of HESCOM shall be replaced. Replacement of

balance approx. 10500 agricultural pump sets will be taken up after evaluating

the learning from installation of 590 pumps of first phase.

8. HESCOM has provided an ESCROW mechanism to secure investment of EESL.

EESL, HESCOM and its banker has signed a tripartite Escrow agreement on

25.03.2013.

9. Baseline measurement for all 590 pumps was completed by HESCOM and EESL.

135

10. Based on the pump measurements, BEE star rated energy efficient pumps are

selected and the replacement for 590 pump sets was completed in December

2013.

Achievements

1. The old kW consumption (baseline) of all the 590 nos. of agricultural pump sets

was 3693 kW. After replacement of all the pump sets, the new kW consumption

(post-replacement) of all the 590 nos. of agricultural pump sets is 2327 kW.

2. Energy savings of 1366 kW is achieved amounting to 37% energy savings during

the first phase of the AgDSM project.

3. Approx. 34.4 Lakh electrical units are saved per annum by implementation of the

first phase of the AgDSM project.

4. During the project duration of 6 years, EESL has agreed to provide free repair &

maintenance of the installed pump sets to the farmers.

Feeder-wise Energy Savings

Locations Feeders Replaced

pump sets

Old kW

Consumption

New kW

Consumption

Reduction in

kW Consumption

Energy

Saving

NIPPANI 200

Benadi 99 608.36 391.10 217.26 35.71 %

Hanchinal 101 526.41 343.61 182.80 34.75 %

BYDAGI 390

Kummur 149 918.35 566.47 351.89 38.32 %

Inglagondi 95 603.07 369.60 233.47 38.71 %

Nellikoppa 146 1036.62 656.06 380.56 36.71 %

TOTAL 590 3693 kW 2327 kW 1366 KW 37 %

136

Estimated Energy Savings during the project duration

Feeders Reduction in kW Consumption (Units)

kW Savings Per day @ 7

hours

Per Month Per Annum For 6 Years

NIPPANI

Benadi 217 1519 45,570 5,46,840 32.81 Lakhs

Hanchinal 183 1281 38,430 4,61,160 27.67 Lakhs

BYDAGI

Kummur 352 2464 73,920 8,87,040 53.22 Lakhs

Inglagondi 233 1631 48,930 5,87,160 35.23 Lakhs

Nellikoppa 381 2667 80,010 9,60,120 57.61 Lakhs

TOTAL 1,366 9,562 2.87 Lakhs 34.4 Lakhs 206 Lakhs

Energy Conservation Policy

1. To minimize the specific energy consumption.

2. Maintain a sound and effective energy management system to continuously

monitor and optimize energy to use in all the fields.

3. To be world class performer in energy management by adopting energy efficient

technologies.

4. Promote energy conservation through mass awareness.

5. Conduct regular energy audits aimed to minimize the energy losses.

6. HESCOM has taken up energy conservation measures at its corporate office

building by installing a grid connected 30 kW solar roof top PV.

7. HESCOM has conducted energy audit and prepared a DPR for its corporate office

building in collaboration with EESL and will implement the findings of the DPR.

2nd Phase of the AgDSM project at Nippani and Byadgi subdivisions shall be taken

up soon.

137

Second Prize

General Category

KIRLOSKAR OIL ENGINES LIMITED

LARGE ENGINE PLANT

Nashik (Maharashtra)

Unit Profile

In LARGE ENGINE PLANT, Large HP Diesel Engines in the range of 2,400 HP to

11,000 HP are manufactured in collaboration with MAN Diesel SAS (erstwhile SEMT

Pielstick), France for Marine main propulsion & Power Generation application. The

most advanced diesel technology combined with modern design concepts have gone

into the creation of the Pielstick PA6 series of engines. Through this collaboration,

successfully established manufacturing and marketing of Pielstick Engines by

assimilation of technology and development of engineering base (Application/

System/ Control). LARGE ENGINE PLANT is having Indigenous manufacturing and

test facilities with Quality Assurance set-up of very high standards.

LEBG BUSINESSES includes Marine Main Propulsion Engines from 2,400 HP to

11,000 HP mainly for Indian Navy & Coast Guard, Stationary Power plants (SPP) in

range of 2,100 kVA to 6,375 kVA.

138

Energy Consumption

Energy Consumption (Electrical) kWh per BHP produced

Sr. No. DESCRIPTION. FY 12-13 FY 13-14

1. Units Consumed in kWh

(MSEDCL) 581785 583720

2. Units Consumed in kWh (Own

Generation) 25864 49720

3. Total Unit in kWh 607649 633440

4. Total BHP Produced 20800 64800

5. Total No. of Cylinders Produced 52 162

6. Target for the Year kWh/BHP 16.51 12.50

7. Achievement for the Year

(kWh/BHP)

29.21

9.77

139

Energy Policy

140

Certificate of Merit

General Category

MODULAR FABRICATION FACILITY

L&T HYDROCARBON ENGINEERING

Surat (Gujarat)

Unit Profile

LTHE Modular Fabrication Facility (MFF) – Hazira, India; located at Hazira in Gujarat,

295 km north of Mumbai and 21 km from Surat on the banks of river Tapti, is a part

of L&T’s Hazira Manufacturing Complex which is spread over 900+ acres

incorporating several state-of-the-art Units. One of the largest of its kind in South

Asia, MFF - Hazira is capable of manufacturing several large complex modules

simultaneously with an annual fabrication capacity of 50,000 MT. Modules can be

tested, pre-commissioned and full-load tested (string test) on-shore to ensure rapid

and trouble-free hook-up at site.

MFF – Hazira facility has a total area of 4,75,000 square meters including fabrication

yards, well-equipped shops, warehouses/stores and offices. We have an unimpeded

passage to the Arabian Sea - 8 km away via Hazira river channel. Three different

reinforced Jetties within the fabrication facility, namely, the Ro-Ro Jetty, the Main

Jetty and the L-shaped Jetty ensure direct load-out of finished modules using Self-

propelled Modular Transporter (SPMT) or Heavy Crawler Cranes onto barges/marine

vessels for easy transportation to the nearest port of Client’s project site.

Product Portfolio for the Upstream Segment includes Well-Head Platforms, Process

Platforms, Compressor Modules, Living Quarters & Building Modules, FPSO Modules,

Power Generation Modules, Switchgear and Control Room Modules, Offshore

141

Jackets, Bridges, Piles & Conductors etc. Our esteemed Clients in the upstream

sector include ONGC, GSPC, BGEPIL, MOQ, PTTEP, Bunduq etc.

For the Mid & Downstream segment, the unit has extensive expertise and a proven

track record in the construction of Pressure Vessels & Columns, Convection Modules,

Waste Heat Recovery (WHR) Modules, Modular Process Plants, Skid mounted

Equipment, Desalination Plants, Modular Sulphur Recovery Units (SRU), Continuous

Catalyst Regeneration (CCR) Units, Reactors, Fired Heaters, Reformers, Pre-

assembled Pipe Racks (PARs), Pre-assembled Units (PAUs) and Heat Recovery

System Generation Units (HRSG) etc. The Mid & Downstream segment has

esteemed clients which include Air Products, RIL, IOCL, HPCL, NFL, CPCL, MRPL,

Krupp Uhde, Chiyoda, SFCCL, Saudi Aramco etc.

Energy Policy