Best Practices adopted by Grasim Bhiwani Textile Limited, Haryana

Grasim Bhiwani Textiles Limited (A Subsidiary of Grasim Industries Ltd.)

Bhiwani - 127 021, Haryana, India

Index

Introduction Production Process & Flow chart Production Capacity Result Indicators Energy Saving Projects (Electrical, Steam & Water) Best Practices towards Energy Conservation

Aditya Birla Group is a leading multinational from India

Revenues of $ 41 billion

Over 50% revenues from overseas operations spanning 36 countries

Anchored by an extraordinary force of over 120,000 employees belonging to over 42 nationalities

Globally No. 1 in viscose staple fiber and No. 1 in Carbon Black.

In India – Second largest player in Viscose filament yarn

The fifth largest producer of Acrylic fibre.

Introduction

Our Values Integrity | Commitment | Passion | Seamlessness | Speed

Established in 1938 as Punjab Cotton Mills

Taken over by Grasim Industries Ltd in 1964 and renamed as Bhiwani Textiles Mills (BTM)

Became a subsidiary of Grasim Industries Ltd, a separate company from October 2007 with a name of Grasim Bhiwani Textiles Limited (GBTL) having its registered office in Mumbai, India.

GBTL had gone for the capital expenditure to the tune of Rs. 6 crores during FY13 to FY15, which was used for energy conservation measures

Introduction

Grasim Bhiwani Textiles is a Subsidiary Unit of Grasim Industries Limited.

Situated 120 Kms distance away towards

North-West of National Capital DELHI at Bhiwani in Haryana.

Designing, Developing & Producing variants of Suiting, Shirting & Clothing to delight the customers

Introduction

• 2000-01: Launch of Grasim suiting premium suiting brand for domestic over the counter retail in addition to existing brand Graviera value for money brand • 2002-03: Launch of successful products Ice touch & Uncrushables providing tangible benefit to consumer • 2005-06: Global brands Haggar & Levis ordering huge volumes for garment conversion contributing 40% to total exports • 2006-07: Investment in 8 MW Thermal power plant & Expansion of looms capacity • 2007-08: Implementation of SAP ERP • 2007-08: Corporatized the division into new 100% subsidiary of Grasim Industries Ltd • 2007-08: Launch of Akshay Kumar as Grasim Suiting brand ambassador • 2009-10: ISO Certification on Quality and complies with the latest standards for Quality Management System (ISO-9001:2008) • 2009-10 : OH&Safety Management System (OHSAS-18001:2007) and SA 8000 Certification • 2010-11 : Oeko-Tex Standard 100 Certification • 2012-13: Launch of John Abraham as Grasim Suiting brand ambassador • 2013-14: Introduced Sonu Sood and Pooja Chopra as Graviera Suiting brand ambassadors • 2014-15: Domestic Textiles (JST,GBTL,VW) - Business Excellence in the country awarded by Confederation of Indian Industries • 2015-16: Environment Management System -ISO 14001:2004 • 2015-16: Energy Management System –ISO EnMS 50001

GBTL At a Glance - Major Milestones, Awards & Accolades

Process flow chart

Spinning : 6171 MT Weaving : PV Fabric – 134 Looms Processing : 18 Million Meters Captive Power Plant : 8.40 MW

Production Capacity

2.341

3.23

1.88 1.68

0

0.5

1

1.5

2

2.5

3

3.5

Baseline(2007-08;2008-09;2009-10)

2012-13 2013-14 2014-15

Specific Energy Consumption (MTOE/MT of Production)

Result Indicators

206.25

205.00

204.00

202.50

203.00

203.50

204.00

204.50

205.00

205.50

206.00

206.50

2012-13 2013-14 2014-15

Water Intensity (KL/MT of Production)

Energy Saving Projects (Electrical, Steam & Water)

Energy Rate: $ 0.09 / Kwh Steam Rate : $ 14.32 / MT

Project (Electrical Energy) Measurement Saving / annum

Savings Amount (USD)

Re-Engineering of Humidification Plants Kwh 1781976 161192 Replacement of old inefficient motors (77 Nos.) of various ratings with energy efficient motors

Kwh 284130 25701

VFD installation on Stenter machine Kwh 146554 13257 VFD Installation on ID Fan, FD Fan & Screw feeders of 30 Lac Kcal Capacity thermopac at SPH

Kwh 79680 7208

VFD Installation HTHP (High Temperature High Pressure) Machine Kwh 36000 3256 Replacement of Straight type Overhead blowers with Bend type blowers Kwh 112515 10178 Replacement of Old Chese Winding Machine with Energy Efficient Machine Kwh 63815 5773 Air Compressor pressure optimisation at Spinning Kwh 99000 8955 VFD Installation - BFWP 1 & 2 (Boiler Feed water Pump) Kwh 135449 12252 VFD Installation - PA Fan (Primary air fan) Kwh 43998 3980 VFD Installation - CT Fan (Cooling tower fan) Kwh 81997 7417 VFD Installation – Compressor Kwh 30762 2783 VFD Installation - ACWP (Auxiliary cooling water pump) Kwh 20307 1837 VFD Installation - CWP (Cooling water pump) Kwh 26256 2375 2942439 266164 Project (Steam Saving) TPP Boiler Modification to reduce dump steam & to meet variable PLF requirement Metric Ton 7335 105056 TPP Boiler Automatic blowdown & blowdown flash steam recovery system Metric Ton 260 3721 TPP Turbine Modification to reduce specific steam consumption Metric Ton 60798 870769 68393 979545 Project (Water Saving) Water Recovery from Relax Scouring Machine Kilo Litre 60687 4117 Backwash water from Softening Plant Kilo Litre 60111 4078 ETP Water Recycle by RO Plant Kilo Litre 106780 7244 Cooling water Recycle in Process House Kilo Litre 15901 2397

243479 17837

Total Amount 1.264 $ Million

The necessity of Humidification in textile processing is to : 1) Improve the moisture regain 2) Maintain the yarn strength, reduce the yarn broken

problem. 3) Reduce static build-up 4) Maintain product weight 5) Reduce fly and micro-dust 6) Provide free cooling 7) Provide a healthier and more comfortable working

environment.

Electrical Energy-1 Re-Engineering of Humidification Plants

At our mill, humidification plants are of Conventional type (Water spray type). The effectiveness of this system is very low & consumes high electrical energy input. We have re-engineered the humidification system by using water mist spray. This is very effective and consumes significantly lesser energy compared to conventional system.

Contd…

Electrical Energy-1 Re-Engineering of Humidification Plants – Elegant Spinning

Before Modification

S No. H Plant Section

CFM SA Fan Water Pump Total

Actual Load

Installed Load

Actual Load

Installed Load

Actual Load

1 Carding 92000 2 X 11 16.5 2 X 9.3 13.95 30.45 2 Ring Frame 1 100000 2 X 22 35.2 2 X 9.3 13.95 49.15 3 Ring Frame 2 100000 2 X 22 35.2 2 X 9.3 13.95 49.15 4 Autoconer 143000 3 X 15 33.75 2 X 11 16.5 50.25 5 TFO 190000 4 X 15 45 3 X 11 24.75 69.75

165.65 83.1 248.75 After Modification

S No. H Plant Section

CFM SA Fan Water Pump Total

Actual Load

Installed Load

Actual Load

Installed Load

Actual Load

1 Carding 92000 2 X 11 12.27 2 X 2.2 3.08 15.35 2 Ring Frame 1 100000 2 X 22 13.33 2 X 2.2 3.52 16.85 3 Ring Frame 2 100000 2 X 22 13.33 2 X 2.2 3.52 16.85 4 Autoconer 143000 3 X 15 19.07 2 X 3.7 5.18 24.25 5 TFO 190000 4 X 15 25.33 3 X 3.7 7.77 33.1

83.33 23.07 106.4

Power Saving (KW) 142.35 Power Saving (KW / annum) 1195740

Contd…

Before Modification

S No. H Plant Section CFM SA Fan Water Pump Total

Actual Load

Installed Load Actual Load

Installed Load

Actual Load

1 Warping 45000 2 X 5.5 10.07 2 X 5.5 8.95 19.02 2 Dornier + Air Jet 1 45000 2 X 5.5 10.07 1 X 5.5 4.48 14.55 3 Dornier + Air Jet 1 72000 3 X 5.5 + 1 X 9.3 23.5 2 X 7.5 11.94 35.44 4 Sulzer + Air Jet 2 94000 4 X 5.5 20.14 2 X 7.5 11.94 32.08 5 Sulzer + Air Jet 2 72000 3 X 5.5 15.11 2 X 5.5 8.95 24.06

78.89 46.26 125.15 After Modification

S No. H Plant Section CFM SA Fan Water Pump Total

Actual Load

Installed Load Actual Load

Installed Load

Actual Load

1 Carding 92000 2 X 5.5 6.0 1 X 2.2 1.45 7.45 2 Ring Frame 1 100000 2 X 5.5 6.0 1 X 2.2 1.45 7.45 3 Ring Frame 2 100000 3 X 5.5 + 1 X 9.3 9.6 1 X 3.7 2.80 12.4 4 Autoconer 143000 4 X 5.5 12.5 1 X 3.7 3.13 15.66 5 TFO 190000 3 X 5.5 9.6 1 X 3.7 2.80 12.4

43.73 11.63 55.36

Power Saving (KW) 69.79 Power Saving (KW / annum) 586236

Electrical Energy-1 Re-Engineering of Humidification Plant – Weaving

Electrical Energy-2 Replacement of old inefficient motors (77 Nos.) of various ratings with energy efficient motors

At Spinning department, old low efficient motors replaced with IE3 Premium energy efficient motors. Old motors are in operation since last 20 years. Most of the motors are re-winded & consuming considerably high power.

S No. Particulars No. of motors

replaced

Average Operating power consumed per motor

/day (KWh) Working days /

annum

Total Power Consumption of all replaced motors (KWH/

annum) Before After Before After

1 22KW motors 52 380 368 330 6520800 6314880 3 18.5 KW, 1460 RPM 7 324 312 330 748440 720720

4 5.5 KW, 1460 RPM 8 93 89 330 245520 234960 5 15 KW, 2900 RPM 3 243 233 330 240570 230670 6 30 KW, 1460 RPM 7 467 454 330 1078770 1048740

8834100 8549970

Energy Saving: 284130 Kwh / annum

Electrical Energy-3 VFD installation on Stenter machine

Particulars Machine load (KW)

Before installation

After Installation

Avg. load on each stenter machines (KW)

71.82 64.74

No. of stenter machines on which VFD's installed

3 3

Cumulative Working hours per annum for 3 machines

20688 20688

Energy Consumption (Kwh / annum)

1485812 1339258


In process house, stenter machine motor was operating in single speed and double speed mode. It has been replaced with suitable rating VFD’s. This system enables to regulate the speed of Blower fan from its rated to process demand. The gap in power consumption by motor at rated and process demand speed is electrical energy conservation.

Electrical Energy-4 VFD Installation on ID Fan, FD Fan, PA Fan & Screw feeders of 30 Lac Kcal Capacity thermopac at SPH

The unit has 30 Lac Kilocalories capacity Thermopac at process house which is being used for drying and heat setting of Fabric. Thermopac is of AFC type

Energy Saving Particulars Machine load

Before installation

After Installation

Avg. monthly power consumption of the thermopac auxiliary (KWH)

47052 40412

No. of months operation 12 12

Energy Consumption (Kwh / annum) 564624 484944


Auxiliary Before After ID Fan 30KW

Motor Starter DOL - rated speed Variable frequency drive

Furnace draft control Damper opening 30 - 50%

Speed regulation (damper 100% open)

FD Fan 18.5KW


Combustion air control Damper opening 30 - 50%


PA Fan 2.2KW


Combustion air control Damper opening 30 - 50%


Fuel Feeders 1.5KW

Motor Starter Variable frequency drive Variable frequency drive

Fuel feeding control Manual operation Speed regulation, and Auto cut-off by thermic fluid temp sensing

Highlights of Project: Closed loop control for furnace pressure Closed loop control for Outlet thermic fluid temperature

Electrical Energy-5 VFD Installation HTHP (High Temperature High Pressure) Machine

In Fiber Dyeing, HTHP (High Temperature High Pressure) machine, 30 KW turbo pump motor operate by Star-Delta starter at rated frequency. Installed a 30 KW VFD drive & optimized its operation at frequency 48 Hz.

Turbo pump motor power consumption with Star-Delta starter

KW 29.0

Turbo pump motor power consumption with VFD installation

KW 24.0

Units Saving KW 5.00


Electrical Energy-6 Replacement of Straight type Overhead blowers with Bend type blowers

Earlier, 13 over head blower was installed for 32 Nos. TFO machines. Modification carried out, and utilization of 7 Nos. over head blower for 32 Nos. TFO machines.

Particular Units Before

Modification After

Modification Total installed load of 1 No. OHB (Over head blower) KW

2.46 2.46

Total No. of OHB's in operation Nos. 13 7

Avg. operating hours Hrs 21 21 Total Power Consumption KW 672 362

Power Saving per day KW 310

Power Saving per annum KW 112515

Before

After

Particular Units Before

Modification After

Modification

Chese Winding machine installed load KW

9.5 7.2

No. of chese winding machines Nos. 3 3

Avg. operating hours Hrs 19 15 Load factor 0.8 0.8

Total Power Consumption Kwh/day 433 257 Avg. production Kg/day 400 531

Specific Energy Consumption KW/KG 1.08 0.48

Power Saving per day KW 176

Power Saving per annum KW 63815

Electrical Energy-7 Replacement of Old Chese Winding Machine with Energy Efficient Machine

RKJ make 3 Nos. Chese Winding machine were installed 20 years back. Those machine became old and performing inefficiently. Replaced SSM make 3 Nos. cheese winding machine, whose performance is higher than earlier machine.

Electrical Energy-8 VFD Installation - BFWP 1 & 2 (Boiler Feed water Pump)

Boiler Feed Water Pump is operated through Soft-Starter which consumes 208 KW/hour by delivering a pressure of 105 Kg/cm2. Practically 90 Kg/cm2 is sufficient to feed the water into Boiler steam drum. Installed VFD in place of Soft-Starter to regulate the discharge pressure by varying motor speed. Now, motor is consuming 178 KW/hour with pump delivery pressure 95 Kg/cm2.

Month

TPP Running hours

% Running hours after deducting standby equipment running hours

Running hours for Calculation

VFD Installation - BFWP (Boiler Feed water Pump)

Hrs % Hrs kwh

Apr-12 561 93.5 525 9769

May-12 478 93.5 447 8324

Jun-12 712 93.5 666 12399

Jul-12 743 93.5 694 12930

Aug-12 744 93.5 696 12956

Sep-12 720 93.5 673 12538

Oct-12 670 93.5 626 11659

Nov-12 673 93.5 629 11720

Dec-12 729 93.5 682 12695

Jan-13 742 93.5 693 12913

Feb-13 649 93.5 607 11302

Mar-13 359 93.5 335 6243


Electrical Energy-9 VFD Installation - PA Fan (Primary air fan)

PA Fan is operated through DOL starter which consumes 48.8 KW/hour. Damper opening is 30% and PA header pressure is 1050 mmwc. Installed VFD in place of DOL starter & VFD is running at 92% with damper opening of 100%. Now, motor is consuming 42.75 KW/hour with desired PA header pressure of 1050 mmwc.

Month

TPP Running hours

% Running hours after duducting standby equipment running

hours


VFD Installation - PA Fan (Primary air

fan)

Hrs % Hrs kwh

Apr-12 561 93.5 525 3173

May-12 478 93.5 447 2704

Jun-12 712 93.5 666 4028

Jul-12 743 93.5 694 4200

Aug-12 744 93.5 696 4209

Sep-12 720 93.5 673 4073

Oct-12 670 93.5 626 3787

Nov-12 673 93.5 629 3807

Dec-12 729 93.5 682 4124

Jan-13 742 93.5 693 4194

Feb-13 649 93.5 607 3671

Mar-13 359 93.5 335 2028


Electrical Energy-10 VFD Installation - CT Fan (Cooling tower fan)

Month

TPP Running hours



VFD Installation - CT Fan (Cooling tower fan)

Hrs % Hrs kwh

Apr-12 561 93.5 525 5914

May-12 478 93.5 447 5039

Jun-12 712 93.5 666 7506

Jul-12 743 93.5 694 7828

Aug-12 744 93.5 696 7843

Sep-12 720 93.5 673 7590

Oct-12 670 93.5 626 7058

Nov-12 673 93.5 629 7095

Dec-12 729 93.5 682 7685

Jan-13 742 93.5 693 7817

Feb-13 649 93.5 607 6842

Mar-13 359 93.5 335 3779


To maintain the cooling water temperature, 2nd CT Fan is operated through DOL starter which consumes 35 KW/hour. The raised temperature can control by varying speed of 2nd CT fan. As the motor starter is DOL, it is not possible to regulate the speed of motor. Installed VFD in place of DOL starter to regulate the motor speed. Now, motor is consuming 23KW/hour.

Electrical Energy-11 VFD Installation - Compressor

Air compressor (Atlas Copco – GA 37+) is operated through Star-Delta starter which consumes 39 KW/hour. Loading and Un-loading hours are 16 and 8 hours respectively. Installed VFD in place of Star-Delta starter to regulate the motor speed. Now, motor is consuming 31.57 KW/hour, with loading and Un-loading hours of 19 and 5 hours respectively.

Month

TPP Running hours



VFD Installation - Compressor

Hrs % Hrs kwh

Apr-12 561 93.5 525 2219

May-12 478 93.5 447 1891

Jun-12 712 93.5 666 2816

Jul-12 743 93.5 694 2937

Aug-12 744 93.5 696 2943

Sep-12 720 93.5 673 2848

Oct-12 670 93.5 626 2648

Nov-12 673 93.5 629 2662

Dec-12 729 93.5 682 2883

Jan-13 742 93.5 693 2933

Feb-13 649 93.5 607 2567

Mar-13 359 93.5 335 1418


Electrical Energy-12 VFD Installation - ACWP (Auxiliary cooling water pump)

ACW Pump is operated through DOL starter which consumes 43.42 KW/hour. Pump discharge pressure is 3.39 Kg/cm2. Installed VFD in place of DOL starter & VFD is running at 90%. Now, motor is consuming 37.81 KW/hour with discharge pressure 3.30 Kg/cm2.

Month

ACW Pump with VFD Running hours

Units Saving in ACW

hrs kwh

Apr-12 337 1888

May-12 332 1862

Jun-12 334 1875

Jul-12 298 1675

Aug-12 346 1942

Sep-12 337 1888

Oct-12 348 1951

Nov-12 307 1720

Dec-12 348 1951

Jan-13 319 1791

Feb-13 314 1762

Mar-13 295 1652


Electrical Energy-13 VFD Installation - CWP (Cooling water pump)

CWP Pump is operated through DOL starter which consumes 86.78 KW/hour. Pump discharge pressure is 1.0 Kg/cm2. Installed VFD in place of DOL starter & VFD is running at 95%. Now, motor is consuming 75.9 KW/hour with discharge pressure 0.96 Kg/cm2.

Month CWP Pump with VFD

Running hours Units Saving in CWP

hrs kwh Apr-12 224 2441

May-12 221 2408

Jun-12 223 2425

Jul-12 199 2165 Aug-12 231 2511

Sep-12 224 2441 Oct-12 232 2523 Nov-12 204 2224

Dec-12 232 2523 Jan-13 213 2316

Feb-13 209 2279 Mar-13 196 2136


Steam Saving-1 TPP Boiler Modification to reduce dump steam & to meet variable PLF requirement

Month Dump steam before boiler

modification (MT)

Dump steam after boiler modification

(MT)

Actual steam rate (Rs./ MT)

Saving in Steam (MT)

Apr-14 773.661 30.43 818.0 743.2

May-14 773.661 42.98 962.3 730.7

Jun-14 773.661 107.51 858.6 666.2

Jul-14 773.661 137.77 914.4 635.9

Aug-14 773.661 82.27 985.4 691.4

Sep-14 773.661 100.60 1020.5 673.1

Oct-14 773.661 95.80 1106.1 677.9

Nov-14 773.661 58.21 1027.6 715.4

Dec-14 0 0.00 0.0 0.0

Jan-15 773.661 296.80 1221.2 476.9

Feb-15 773.661 147.33 1027.6 626.3

Mar-15 773.661 75.44 1027.6 698.2

Total 8510.27 1175.14 914.1 7335.1

TPP is 8 MW Capacity, during FY 11 & 12:

•Average PLF (Plant load factor) on Power plant is 83%, i.e., 6.68 MW against installed 8.0 MW.

•Steam extraction from turbine to process is 50 – 60% against designed capacity of 10 MT/hour.

Losses Identified due to low Plant Load Factor:

• Less extraction of steam & excess steam available at Boiler was causing dumping into condenser.

• Average dumping of steam in tune of 31 – 35 Tons/day due to which consumption of fuel on higher side and causing losses.

Detailed modification work: • Modification in existing FD Fans &

Incorporation of New FD Fan to increase Pressure head for effective fluidization of bed.

• Blocking of Air Nozzles to increase velocity from 800 mmWC to 1300 mmWC.

• Increase of Super heater surface Area to increase temperature of super heated steam.

• Fuel feeding auto-operation to decrease operator intervention, thereby maintaining furnace stable condition & achieve zero dumping of steam.

Steam Saving: 7335.1 MT / annum

Steam Saving-2 TPP Boiler Automatic blow down & blow down flash steam recovery system

GBTL has installed an Automatic boiler blow down; and blow down waste heat recovery system for its 45TPH boiler at power plant. Automatic blow down: Boiler steam drum water TDS is measured online through TDS sensor; and TDS controller commands to blow down valve when TDS raises beyond 50 ppm. Thus quantity of blow down decreased. Waste heat recovery: Blow down water gets collected in a flash vessel and steam pressure builds up to 10 Kg/cm2; and purge the steam into process steam line.

Month Flash steam recovery (MT)

Apr-13 98

May-13 120

Jun-13 113

Jul-13 56.0

Aug-13 35.0

Sep-13 70.8

Oct-13 66.0

Nov-13 32.0

Dec-13 0.0

Jan-14 0.0

Feb-14 0.0

Mar-14 0.0

Total 259.79

Steam Saving: 259.79 MT / annum

Steam Saving-3 TPP Turbine Modification to reduce specific steam consumption

Month Generation Units SSC (Kg/kwh) Steam Consumption (MT)

Before modification After Modification Before modification After Modification Apr-14 5060320 4.56 - 23060 -

May-14 5547200 4.57 - 25362 - Jun-14 5477300 4.55 - 24916 - Jul-14 5419381 4.56 - 24707 -

Aug-14 5537000 4.58 - 25337 - Sep-14 4747426 4.54 - 21572 - Oct-14 4817174 4.52 - 21793 - Nov-14 2455185 4.52 - 11097 - Jan-15 3955025 - 4.02 - 15899 Feb-15 4353400 - 4.00 - 17427 Mar-15 4627190 - 3.93 - 18166

Average/month 22231 17164 Average/annum 266767 205969

Steam Saving: 60798 MT / annum

8 MW rating extraction cum condensing steam turbine, which mechanically coupled with Generator for producing electric power. The turbine designed to deliver 8 MW electrical power with process extraction of 10 TPH. Due to low steam demand at processing section, the extraction steam for process is 5.5 TPH with 7 to 8 MW load. Specific stream consumption was 4.57 Kg/unit against the design of 3.84 kg/unit after extraction. The turbine rotor blades profile changed & extraction tapping changed to later stage.

Water Saving-1 Water Recovery from Relax Scouring Machine

Water Recycled: 60687 KL/annum Soft Water Rate: 4.50/ KLD

1) Apply of Thermal insulation paint (Stanvac make) on Side Surface of Steam drum (Vertical Drying range)

2) Apply of Universal coat (Technofit make) on Pump impeller to control rate of degradation

3) Use of Sun Pipes at Godowns to make all godowns wire free. 4) Optimization of compressor air pressure setting in Weaving, Processing and Spinning

sections. 5) Use of machine cleaning air through installation of Pressure regulators @ 3 Kg/cm2 6) Introduction of Energy Saving device (Star Delta converter) for capacity optimization in

TFO machine 7) Old Auto winding machine (Connected load: 15KW) replaced with energy efficient

machine (Connected load 11KW) controlled by VFD drive and also reduction in air consumption from 35 - 40 cfm to 15 -18 cfm.

8) Online monitoring of Equipment bearing temperature > 40KW motor capacity 9) Improve yarn recovery from 96.8% to 96.95% at Spinning. 10) Use of Biomass fuel along with Coal (20% of total coal consumption) and reduced

Carbon emission by 20 %.

Best Practices – Energy Saving

THANK YOU

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Best Practices adopted by Grasim Bhiwani Textile Limited, Haryana