CII - Excellence in Water Management - 2008 presented by Ashok Leyland Hosur I
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CII - Excellence in Water Management - 2008 presented by Ashok Leyland Hosur I

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This is a presentation from Ashok Leyland, Hosur I one of the finalists at the 5th CII-GBC National Award for Excellence in Water Management in 2008....

This is a presentation from Ashok Leyland, Hosur I one of the finalists at the 5th CII-GBC National Award for Excellence in Water Management in 2008.

The awards are in 2 categories, Within the Fence for work done on minimizing the organisations water footprint, and Beyond the Fence for work done in the community around the industry.

This presentation was in the "Within the Fence" category.

We thank CII and the respective companies for giving us permission to upload these presentations on the India Water Portal website for dissemination to a wider audience.

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CII - Excellence in Water Management - 2008 presented by Ashok Leyland Hosur I CII - Excellence in Water Management - 2008 presented by Ashok Leyland Hosur I Document Transcript

  • E-Comet (910) TAURUS 2214 - 22 Tons GVW REAR DUMPER (25 Tons) New Gen 2518-H Inter Centur y- Luxur a Stallion 4x4 Mk.III “CII - Excellence in Water Management –2008” Company Profile v Spread of the Plant : 102.4 Acres. v Built up area : 164 592 sq.mtr. v Plant & Machinery : Rs. 645 Cr. v Production Level/Day : 300 Engines & 44 Veh. v Connected Load : 31924 Kva. v Captive Power : 8750 Kva. v Man power : 2740. v Trees : 1850 nos. “Every drop of water counts” 1
  • Manufacturing Process Machining Heat Treatment Engine assy Finished Product Cha ssi s assy Fra me assy Axle a ssy FES dre ssing “Many drops of water will lead to a Ocean” Water Management Structure Unit Head Divisional Heads Utility Manager & Dept Managers Shop Representatives CFTs/SGAs “Save every drop & save the Globe” 2
  • Water Management Planning Review performance of last financial year Set targets for Water conservation Plan to achieve well within targets Try to achieve the stretched targets. Develop projects towards Plan & implement 3R Initiatives WATCON projects. “Every drop of water Recycl ed & Reus ed is water saved for Others/Fu ture” Water Management Policy Mission : To beco me the “Best wate r efficient unit a mong the automo bile industrie s”. To mee t the abo ve objec tive by: § Scientific approach towa rds wa ter manage men t. § Mete ring of wate r con sumption a t micro le ve l. § Identi fy projec ts on 3R –Re duce, Reu se & Recyc le of water. § Encourage sugg estions & initia tive s taken by our e mploye es towards water conservation. “Avoid runoff of water .The wastage is 30%” 3
  • Energy Conservation & Employee Involvement. Ø Monthly One day “Awareness Tr aini ng Prog ra m on Water / Energy Conse rvation”. Ø Water conservation initiatives are shar ed by Utilities team with particip ants. Ø Need for water conservation & mon itoring syste ms are expl ained. Ø SGAs(S mall G roup Activities) & CFTs( Cross Functio nal Tea ms) Ø Suggestions fro m e mp loyees are e ncoura ged. “Availability of Pure Water Scarce” Specific Planned Step for Futurity Preservation of Environment v AL –H 1 is a signatory for MSG – “A im at Growth but Su stain Eco log y”. v MSG – “T o pr omot e R esour ce Con ser vati on without co mpr omising H igh end acceler ated Growth ”. v Ten N atur al C ommandments (F oc us points) are: (1) Specific Ener gy & W ater reducti on (2 –6%). (2) Was te R edcution ( 2 –6%). (3) R enew able energy incr ease (2 –10%) (4) Specific GHG emis sion r educ tion(2- 6%) & CDM. (5) Incr eased r ecy cling of materi als by 2- 10% . (6) Rai n w ater harvesti ng incr ease by 2 –10%. (7) Li fe Cycl e Ass ess ment of new pr oduc ts & new tec hnol ogies . (8) Gr een Purc has e Policy. (9) Pr oduc t s tew ar ds hip pr ogr am & (10) R educti on of other natur al c apait als by 2 – 6%. “Every drop of water counts” 4
  • Specific Water Consumption : 2004 -08 25% redn over 4 years. 10 8 9.72 6 8.73 KL/ECU s 7.28 7.51 4 2 0 2004-05 2005-06 2006-07 2007-08 “Many drops of water will lead to a Ocean” Year Per Day Water Consumption : 2005 -2008 4.6% reduction in abs olute v alue ov er 3 years 678 656 680 647 660 KL/Day 640 620 2005-06 2006-07 2007-08 Year “Save every drop & save the Globe” 5
  • Water Consumption Vs Production Increase WATER CONSUMPTION vs PRODUCTION 68% INCRE AS E INCREASE IN PRODN 35000 12 PRODUCTION IN 30000 27972 31806 32571 10 25000 9.72 ECU 8.73 8 KL/ECU 20000 7.51 7.28 6 15000 19375 10000 4 5000 2 25% REDN IN 0 WA TER 0 CONS U MP TI ON 2004- 2005- 2006- 2007- 05 06 07 08 YEAR “Every drop of water Recy cl ed & Reus ed is water saved for O thers/Fu ture” Water Conservation –Last 4 years : 2004 -08 Water sav ings Water sav ings Year (M3/Annum) (M3/Day) 2007 - 08 45270 124 2006 - 07 18000 49 2005 - 06 15156 41 2004 - 05 26100 71 “Avoid runoff of water .The wastage is 30%” 6
  • WATCON INITIATIVES: 2007-08 “Availability of Pure Water Scarce” Y ea r Sl. Title o W f ater s aving of Annual Water Savings . Invesem ent Payback No imple Made period . Proje t implemented c (Months) m enta ti on M3 R s. Lakhs Rs Lakhs. Ins tallation of " Z ro Disc harge e F acility" at ETP area tow ards 1 reducing raw w ater 2008 15000 292500.00 21500000.00 882 cons um ption by 50 kl/day . Elimination of water s eepage thro' underground w ate r 2 s torage tank s by rec oncreting 2008 3300 64350 300000 55. 9 the tank bottom portion- 2 nos . Water atomis ation in engine 3 w as hing ac tiv ity after testing 2008 1350 26325 20000 9.1 of engines in test cells along w ith us age of c ompress ed air. Replacement of damaged pipelines at underground fire 4 hy drant ines & thereby l 2008 1500 29250 25000 10. 3 eliminate w astage of water in f r e hydrant lines. i Recy cling of c ondensate water from mechanical ev aporator thro' RO Plant & the reby 5 ensure us age of additionally 2008 4500 87750 25000 3.4 treated RO water for cooling tow ers & washing m ac hines . Proc urem ent of w ater pumps w ith m ec hini al seals instead c 6 of gl nd rope to eliminate a 2008 1800 35100 200000 68. 4 w astage of water f orm pum p. Identi ication of old gate f 7 v alv es le ading to wastage of 2008 3000 58500 48000 9.8 water thro' leak s & replac e them w ith butterfly v alv es . WATCON INITIATIVES: 2007-08 “Availability of Pure Water Scarce” Filling o f co oling tow er s umps at Generator house from 8 extra make up water s ump, 2 008 6000 117 000 1 0000 1 .0 therby ensuring no feeding of w ater during 1s t s hift fr m o main overhead tank. Blowdown c ontr l of co oling o towers based on TDS 9 monitoring & thereby red e uc 2 008 30 0 58 50 600 0 12.3 water c ons umption towards top up quantity of water. B ending of raw water with RO l w ater fo r engine tes t bed 10 appli ations at shop5 engine c 2 008 1500 29250 2 0000 8 .2 shop & al o still ensure s required water parameter. Idenitific ation water leaks aro u all shops thro' holiday nd 11 2 008 3600 70200 4 8002 8 .2 patrolling & arres t leakage o f water. Laying o f DM water d istribution s ystem from Gen erator house DM plant to shop4 MDV as sembly for mixing with 12 2 007 1320 25740 2000 00 93.2 radi to r coolant & fiiling o n a C h s i , thereby reducing as s frequ enc y o f filling for the end c usto mer. Intermittent sup ply of water during s ummer to all s hops by 13 2 007 9000 175 500 0 - s topping s upply from OHT during ean hours. l I talation of " Pu type tap ns l sh s" at urinal po in for fl s hing at ts u 14 2 007 114 00 22 2300.00 75 000.00 4 s hop3, s hop9, s hop7 & sho p 1 areas. 7
  • WATCON INITIATIVES: 2006-07 “Availability of Pure Water Scarce” Eliminat ion of wat er wash for concret e floors in shop floor & 15 2007 1200 23400 0 0 resorting to dry floor cleaning using scrubbers. Eliminat ion of raw wat er use for gardening by ext ending t he pipeline of treated water 16 2007 3600 70200 50000 8.5 supply from ETP/STP areas, thereby raw reducing wat er cons umpt ion. Piping modification for us age of "Localised 15 k l capacity c oncrete overhead 17 t ank" at shop5 machine s hop, 2006 4500 87750 15000 2.1 t o rest rict wat er supply to only 2 bays of s hop5 machine shop, in first s hift . Piping installation for using reject water of drinking wat er 18 2006 2400 46800 190000 48.7 Purifiers at urinal points for flushing. Int roduction of fourt h pipeline source from private agency for supply of pot able water, 19 2006 6300 122850 0 0.0 towards reduc tion in water receipt from tanker t o MOQ level of 100 kl. WATCON INITIATIVES: 2005-06 “Availability of Pure Water Scarce” Installation of "Kent" make 6" dia water flow met ers at main 20 & shop5 pump houses, t o 2006 - - 100000 - direc tly quant ify water cons umed at the plant level. Ins tallat ion of "Air cooled Refrigerated t ype compressed air Dryers" - 2nos, to eliminate 21 2006 1800 35100 400000 136.8 use of wat er t hro' cooling tower incase of w ater cooled machines. Extension of "RO water usage" for compressor cooling wat er circ uit , t owards reducing 22 2006 2250 43875 10000 2.7 descaling frequency of intercooler & after cooler tube bundles. Introduct ion of "Foam t ype taps" at all high consumption shops( shop5, shop1 & 2 & 23 2005 11100 216450.00 150000.00 8 employees canteen) of t he plant & t hereby reduce 37 kl/day. 8
  • WATCON INITIATIVES: 2004-05 “Availability of Pure Water Scarce” Im proving cooling effic iency on com pr sor c oolng tower , es i s by replacement of fills, 24 reconditi ning of sprinkler o s 2005 1500 29250 75000 30.8 etc., & thereby reduce evaporation loss . Spillage loss & m ake up water quantity. C ons truction of "Rain water c oll c tion Sum ps " - 10 nos at e plant level, towards c hargi gn 25 2005 6000 117000 1000000 102.6 the ground l vel & thereby e helping to the water supplying agenc y towards better yield. Reduc n g water consumption i at m ai canteen by ins tallation n of 2 nos 5 kl storage tanks on 26 2004 7200 140400 50000 4.3 top of c anteen building, towards reduc ing head from 20 metres to 9 metr e. Introduction of "RO water" for was hing m ac hine & coolant 27 2004 11700 228150.00 700000.00 37 mixing applications in machines hops 1&2 Intr oduction of "new induction hardening machine for shop1 cam shaft line with closed 28 2004 11700 228150.00 600000.00 32 c ir uit RO water utiis ation" as c l against c onventional cooling tower instalation. l Piping line installation to ensure water supply from s hop5 O verhead tank, instead of 29 2004 9900 193050 400000 24.9 main overhead tank, by reduc ing head from 40 m etres to 20 m etres. Bench-marking with other AL Units: 2007-08 25 Lowest among AL 21.6 units KL/ECU 15 13.0 7.28 5 Hosur-1 Hosur-2 AL - AL - Bhandara AL - Units “Every drop of water counts” 9
  • Bench- marking with Competitors : 2006 -07 8.50 8.10 8.00 KL/ECU 7.51 7.50 7.00 Hosur- - CVBU Motors AL - TATA 1 Units “Every drop of water counts” Monitoring & Reporting System M S E A A V S e U R W E A W T A E T R E R. 10
  • Monitoring & Reporting System M S E A A V S e U R W E A W T A E T R E R. Innovative Projects: Scope For water conservation is mainly looked at in 3 areas: (1) Recycling & reuse of waste water. (2) Reduce water consumption by process change. (3) Study water intensive areas & Introduce water efficient products. Water is Scarce ….. Save it. 11
  • Innovative Project No: 1 Water is Scarce ….. Save it. Project : Water conservation by 50 kl/day thro’ recycling of ETP waste water. Methodolo gy : § ETP waste water which was earli er used f or gardenin g,was in excess of STP waste water wh ich was also used f or Garden ing. § RO Plant (Rochem make) & Mecha naical Ev aporator ( Tech nof orce make) were installed to ensure reuse of process waste water. § This treated water was used f or industrial applicati ons like washi ng m/cs, cooling towers, test beds & f or coolant mixing, thereby reducing ra w water consumption. § Zero discharge of process water was alos ensur ed. § 95 % water recov ery was ensured thro’ recy cling. Benef its: § Sav ed raw water pr ocureme nt to the extent of 50 kl/day . § Process water qual ity was enhanced to all shops. § Industrial RO plants av l in shops became standby f acilities. Start Date: 05/07/200 7 Co mpl n. Date: 15/03/20 08 Innovative Project No: 2 Water is Scarce ….. Save it. Project : Water ato mization in en gine washin g activity at testbeds. Methodolo gy : § After testing of engines in test beds, engines need to be washed. § Direct washing with water jet was consuming water by 12 kl/day . § Introduced water wash gu n to minimise water consumptio n by mixing compressed air at low pressur e, to create atomized water wash. § Extended to all testbeds of shops 2 & 5. Benef its: § Sav ed water consumption to the extent of 4.5 kl/day. § Engine washin g quality was not compromised. § Reduced wate r consumption by 2/3 rd. Start Date: 10/05/200 7 Co mpl n. Date: 31/05/20 07 12
  • Innovative Project No: 3 Water is Scarce ….. Save it. Project : Water conservation thro’ introduction of “Air coole d Air Dryers“ in place of “Wate r cooled Air Dryers”. Methodolo gy : § 2 nos Water cooled Compressed air dry ers at shop5 required water circulatio n f or cooling of hot air passing thro’ dry ers. § This deman ded exclusiv e av ailability of a cooling tower f or cold water circulation. § Apart f rom water consumption, water wastage in terms of ev aporation loss, spray loss etc., are inev itable. § while or derin g additio nal air dry ers f or shop2, Air cooled air dry ers which do n ot requir e cooling to wer were or dere d. § Hot air is cooled thro’ a f an arrangement, in air coole d air dry ers. Benef its: § Sav ed water consumption to the extent of 6 kl /day . § Cooling tower oper ation & mainten ance elimin ated. § No compromise was made on dry air quality . Start Date: 01/07/200 7 Co mpl n. Date: 31/12/20 07 13