welcome to presentation by rbei · 2018-09-13 · excellence in energy management @ rbei coimbatore...

EXCELLENCE IN ENERGY MANAGEMENT @ RBEI COIMBATORE

WELCOME TO

PRESENTATION BY RBEI

Represented by

Mr. Ramesh R , Mr.Kandappan D, Mr.Magesh Kumar P 29.08.2018 , 30.08.2018 & 31.08.2018

Excellence in Energy Management @ RBEI/Coimbatore

Internal | RBEI/FCM-COB-SEZ | 09-08-2018

© Robert Bosch Engineering and Business Solutions Private Limited 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.2

Company Overview Bosch since 1886

Headquartered in Germany , operate in over 150 countries, 402,200 associates

Bosch Key business areas : Mobility solutions, Industrial technology, Consumer Goods and

Energy & Building technology

Bosch Business turn over ~ 73.1 billion Euros

Bosch in India : 9 legal entities, 31,330 employees

RBEI is the second largest engineering development centre outside Germany

RBEI turn over : 755 Million Euros, 19000+ associates, existence from 1998

Other RBEI locations: Vietnam and Mexico

E


Internal | RBEI/FCM-COB | 09-08-2018


Design Features Plot area : 27.8 acres

Total Built-up Area : 52,858 sqm

Two office blocks + one canteen block cum office area + Utility block

Solar orientation of the buildings

Glazing: Wall to glazing ratio adopted, double glazing and low e-glass

Under deck insulation for the top floor ceiling

Day light harvesting on glazed area by providing light sensors

RCC roof-top solar panels

Floor space design (office area optimized at the center)




Objectives of Energy Management

Promote energy efficiency and conservation through the use of technology, managing the

natural resources in efficient and sustainable way

Aim at achieving excellence in EnMS system on continual basis considering environmental

impact by reducing carbon footprint

Periodical review of policy and its contents for adequacy

Establish energy objectives and programs

Support in cost effective energy management initiatives

Impart awareness on energy conservation and its impact on environment

Communicate to employees about adopting good energy habits




Specific Energy Consumption – Trend

89

5 6

Energy Consumption Pattern in 2017

TNEB (in %) DG (in %) RES (in %)

Specific Energy Consumption - Trend

Power

consumption

(in MWhr)

Area (in Sq.m)

SEC(kWhr/Sq.m/year)

2015 7915 47192 168

2016 8775 49087 179

2017 8417 49985 168

Energy Consumption - Trend

Year

Power

consumption

(in MWhr)

TNEB (in %) DG (in %) RES (in %)

2015 7915 84 12 4

2016 8775 87 7.4 5.6

2017 8417 89 5 6

168179

168

0

25

50

75

100

125

150

175

200

2015 2016 2017

kWhr/Sq.m/year




Specific Energy Consumption – Trend

Reasons for Variation

New building operation started in 2015 and stabilisation till beginning of 2017

Implementation of Encon projects

Increase in loading pattern due to business growth




Information on National Benchmarking (BEE Standard)

0

25

50

75

100

125

150

175

200

2013 2014 2015 2016 2017

kWhr/Sq.m/year

2

3

4

5

1

Specific Energy Consumption (SEC)

YearPower consumption

(in MWhr)Area

(in Sq.m)SEC

(kWhr/Sq.m/year)Star

Rating

2013 5450 29021 188 1

2014 5571 29021 192 1

2015 7915 47192 168 2

2016 8775 49087 179 1

2017 8417 49985 168 2

Specific Energy Consumption (SEC) – Excluding Lab Area

YearPower consumption

(in MWhr) Area

(in Sq.m)SEC


rating

2013 3028 26823 113 4

2014 3042 26443 115 4

2015 4353 43762 99 5

2016 4738 45140 105 4

2017 4419 46038 96 50

25

50

75

100

125

150

175

200

2013 2014 2015 2016 2017

kWhr/Sq.m/year

2

3

4

5

1




Information on National Benchmarking (BEE Standard)

0

6

12

18

24

30

36

42

48

54

2013 2014 2015 2016 2017

AAhEPI (Whr/Hr/Sq.m)Specific Energy Consumption (SEC)

Year Power consumption (in MWhr)

Area (in Sq.m)

Total hours

AAhWhr (Whr/Hr/Sq.m

)Star

rating

2013 5450 29021 8760 21 5

2014 5571 29021 8760 22 5

2015 7915 47192 8760 19 5

2016 8775 49087 8784 20 5

2017 8417 49985 8760 19 5

13% Reduction in SEC from

2014 to 2017




Bench Marking with other companies and within RBEI

Specific Energy Consumption (SEC) – 2017

LocationsPower consumption

(in MWhr)Area

(in Sq.m)SEC


Rating

RBEI – KOR 7193 42721 168 2

RBEI-SEZ 8417 49985 168 2

Specific Energy Consumption (SEC) – 2017

LocationsPower consumption

(in MWhr) Area

(in Sq.m)SEC


Rating

IBM 7945 42085 189 1

Benz 4053 24714 164 2

RBEI-SEZ 8417 49985 168 20

25

50

75

100

125

150

175

200

IBM Benz RBEI - SEZ

kWhr/Sq.m/year

1

2 2

0

25

50

75

100

125

150

175

200

RBEI - KOR RBEI - SEZ

kWhr/Sq.m/year

2 2




Roadmap to achieve benchmark – By DesignSolar orientation,Low e-glass T-5 Fluorescent lamp

Low loss dry type transformer Energy saver for lighting

Occupancy sensor

Centralised BEMS




Roadmap to achieve benchmark – By DesignHigh COP water chillers Pumps with VFD drives VAV controller for office area

Heat Recovery Wheel unit 2-way valves for AHUs Hydro-pneumatic pumps




Roadmap to achieve benchmark – OperationEnergy Management System Harmonic Filters Thermography Test

Battery impedance test Awareness for Lab Users Lighting standard adherence

O&M procedures as per OEM

recommendations

Installation and de-

installation programs for

better efficiency




Energy saving projects implemented in 2015-16

Energy Saving ProjectsCost Benefit

in Million INR

Projector replacement with display units 0.08

Online Energy monitoring 0.10

LED street lights 0.10

VFD Provision for chiller condenser pumps 0.07

Free Cooling during night hour operation 0.24

APFC panel operation automation through PLCNon

quantifiable

DG sets conventional radiator replacement with

coil cooler0.68

Units saving - 64445

Cost saving - 1.26 MINR






in Million INR

140kW solar PV system installed at Phase2

building1.82

115nos of street lights(150W) replaced with

LED(40W)0.52

Lab AC units capacity optimization 0.30

Projector replacement with display units 0.02

Air Compressors capacity optimization 0.01








in Million INR

UPS optimization at Cob 101 Building (from

900kVA to 600kVA)0.15

Cooling tower replacement 0.06

Cob SEZ 101 Atrium AC refurbishment 0.16

15kW solar mill (hybrid system of solar and wind) 0.16

1000kVA MD reduction 2.52

BMS upgradation and integration at SEZNon

quantifiable






Innovative project - 1HVAC system redesign – Primary variable flow system

Background

Energy loss at PHE due to inefficiency of Brine and TES system

Unbalanced cooling effect

Not able to achieve design performance

Increased Hot spots at work area and lab

Energy saving potential in HVAC system

Source of Idea

Data analysis of HVAC system

Internal energy workshop




HVAC system redesign – Primary variable flow system

Solution

Isolation of PHE and TES

Conversion of brine to chilled water system with variable

primary flow

Benefits

Annual energy saving of 163324 units

Maintenance of design temperature at work area

Design performance improvement in HVAC system

Improvement in chiller COP by 10% (4.8 to 5.2)

CO2 emission reduction of 114 Tonnes / annum




Energy Saving / Annum : 163324 kWh

Cost Saving / Annum : 1.54 MINR

Investment cost : 3.0 MINR

Payback Period : 1.94 Year


0

2000

4000

6000

8000

Before After

6375 6205

2182 2134

Chiller consumption / Day (kWh)

Working Day Non Working Day

0

1000

2000

3000

Before After

28322430

582 508

Pump panel consumption / Day (kWh)


0

5000

10000

15000

Before After

13995 13420

3916 3797

Overall HVAC consumption / Day (kWh)





Innovative project - 2AHU Blower replacement with EC fans

Background


Technology upgradation with precise control

Source of Idea

Acrex Hall of Fame exhibition in 2017

Solution

Replacement of existing AHU blower with EC fans




AHU Blower replacement with EC fans

Benefits


Less spare maintenance / Inventory & less noise

Better operational control with in-built microprocessor

technology

Replication Potential

Rest room Exhaust & ventilation system – implemented in 2018

HRW system – under progress

Fan coil units & Ceiling suspended units

Can be adopted in new and existing firms




Innovative project - 3Standalone Ac units optimization with VRF and inverter units

Background

Decision of phasing out of R22 refrigerant


Source of Idea

Internal energy workshop

Management initiative to phase out of high ODP refrigerants

Solution

Replacement of R22 with less ODP R-410a refrigerant

Enhancement of technology with inverter compressor

Load based optimization of Ac units capacity




Standalone Ac units optimization with VRF and inverter units

Benefits


Increase in system efficiency

Go Green concept - Usage of less ODP refrigerant

Optimization of Ac units from 237.5TR to 205TR

Replication Potential

Can be adopted in new and existing firms




Renewable Energy sources – Solar PV system

Year 2015 2016 2017

Total Capacity (in kWh) 215 355 367

Total Investment (in Million INR)

21 31.5 32.9

Generation / Annum (in kWh) 316855 493552 512646

Annual cost saving (in Million INR)

2.85 4.44 4.61

Return of Investment(in Months)

88 85 86

CO2 Emission Reduction (in Tons/year)

222 346 359

6.09% of renewable energy

on total energy




Renewable Energy sources – Solar PV system




Renewable Energy sources - Solar Mill (Hybrid system of solar and wind)

Installed capacity : 15 kW

(solar 12kW + wind 3kW)

Investment : 1.4 MINR*

Benefits

Production per annum : 17100 units

Annual cost saving : 0.16 MINR

Payback period : 105 months

* MINR – Million INR




Renewable Energy sources - Solar Thermal Energy

Benefits

Annual energy saving : 23400 units


Pay back period : 69 months

Hot water used for dish washing


Installed capacity : 2 x 2500 Ltrs


Old system replacement with solar assisted

heat pump




Utilization of waste as fuel – Bio gas plant

Year 2015 2016 2017

Quantity of waste as fuel used

(MT/Year)

1.8 1.6 1.7

Waste as Fuel in % of Total

Energy Used

26 23.5 25

Installed capacity : 50 Kg



Utilisation of food wastage

Bio gas plant - 400Kg is completed in 2018


New Biogas plant – 400 Kg




Commitment towards Environment – GHG Inventorisation

Bosch has set itself the following target

values to improve our performance in

environment protection.

o Reduction of relative CO2 emissions by

15% by 2012 (based on 2010)

o Reduction of relative CO2 emissions by

35% by 2020 (based on 2010)

Published in Bosch worldwide news letters

(internal) and forums like CII, IOD, etc.,

111

68

43

75

81 7970

0

20

40

60

80

100

120

2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020

To

ns

CO

2/M

io E

UR

Year

Relative CO2 emission

Target: 202072 Tons CO2

/Mio EUR




Best practices implemented on energy front in Green supply chain

Utilization of renewable energy

Bio Gas plant

Turbo ventilator for waste yard

Under deck insulation for the top floor ceiling

Thermal & weather proof coating for roof top




Team work, Employee Involvement & MonitoringDaily Monitoring system and Review

Logs and Trends update, Standard Operating Procedures

Abnormality tracker and History card system

Equipment efficiency mapping

Preventive, corrective and predictive maintenance reports

Daily engineering report and Monthly status report

Review Meeting - chaired by Energy Manager

Top management involvement in Encon

Separate Encon budget allotment for every year

Year 2015 2016 2017

Encon Budget (in MINR)

15.8 17.9 40.8





Team work, Employee Involvement & Monitoring

Energy Efficiency / Awareness Training

Energy workshops with technicians

Associate Engagement through various activities

CIP meetings & Brainstorming session

Knowledge transfer from SME’s

In house & external training

Awareness on energy base line

Rewards & motivational programs

0.07% investment on turnover




Environmental projects

Waste management - segregation at source

Sludge de-watering system and drying bed for STP

Grease trap system for canteen drainage

Introduction of BS IV & ARAI standards for company

transport vehicles

Fuel consumption tracking for all company vehicle

CFC & HCFC free eco friendly refrigerant for Chilling Units

Rainwater harvesting system for Government schools




Environmental projects Afforestation drive (6000+ tree saplings) around the city

Drive for the conservation of Slender Loris at Coimbatore

and Dindigul

Environmental awareness program for school kids

through “Kovai Green League”

2000+ Volunteering hours have been spent on Swachh

Bharat mission

Implementation of car pooling concept among associates

Restoration of lake at Chinnavedampatty, Coimbatore




Go Green concept with more green cover




Way Forward

5 Star Rating by 2020

12% of total consumption from renewable energy source

• Increase in capacity of solar PV system

• Solar car parking

ISO 50001 implementation

Reduction in lab consumption

Reduction in losses through BEMS system analysis

LED Lightings in office area

Purchase of green power




Awards, Acknowledgements & Achievements

CII awarded “4 star” rating for the commitment in

EHS practices in 2014

CII awarded “Excellent Energy Efficient Building”

for the excellence in Energy Management 2015

IOD awarded “Golden Peacock Environment

Management Award 2016”

CII awarded “Excellent Energy Efficient Building”

for the excellence in Energy Management 2016




Awards, Acknowledgements & Achievements

Acknowledgement by Coimbatore City Municipal

Corporation for all the initiatives towards “Cleaner and

Greener Coimbatore” in 2017

Acknowledgement by Coimbatore City Municipal

Corporation for campaigning and segregation of waste

at source – towards “Zero waste ward” in 2018




S e v e n B i l l i o n d r e a m s , O n e P l a n e t

C o n s u m e w i t h c a r e

welcome to presentation by rbei · 2018-09-13 · excellence in energy management @ rbei coimbatore...

Documents