JSWSteelLtdTarapur

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JSW Steel Ltd Tarapur

For a greenertomorrow

JSW Steel is synonymous with high quality Galvanized Steel Products (GP). The Tarapur unit, has an annualsales turnover of more than Rs. 1600 crore and is one of the Quality-conscious units of this conglomerate.With several six-sigma projects currently on and many more in the pipeline, JSW aspires to continuously raise

the benchmark, thereby reducing wastage and conserving the depleting resources. Our products meet world-class benchmarks and more than 80% is exported.

As an organization we understand the importance ofconservation of natural resources. Our EMS(Environment Management System) policy also laysemphasis on this. We declare different yearly mottoslike EARN for the year 2001-02, TURNAROUND forthe year 2002-03, FOCUS for the year 2003-04 andPRAGATI for the year 2004-05 under which weimprovise our own saving targets over and above thebudgeted norms which give motivation andguidelines to achieve exacting standards. EnergyConservation / power saving has been a prime areaof focus. These efforts have resulted in substantialsavings which are to the tune of Rs. 245.10 Lakh inFY 03-04 without much investment but simply byoptimizing the power consumption in differentprocesses. For conservation of energy we areconsistently exploring all the possibilities. Forexample, in blowers we have installed AC Drives, and instead of running individual Boilers at process areasfor steam production, the WHRB installed in DG Set (Captive Power) compound supplies it centrally. Further,installation of lighting transformers, planning our shutdown for maintenance in the peak hours so as to availmaximum benefit as per MSEB tariff, provision of steam heating in coolant tank for rolling mill instead ofelectrical heaters et al, have all helped to reduce the overall energy consumption. To synchronize all theenergy activities we have constituted an Energy Conservation Cell that gives impetus to all the energyconservation related activities.


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Looking at the undiverted focus and immense effort that JSW Steel, Tarapur, puts in conserving energy, webelieve that we are the most eligible for this award.

Brief Summary of Steps Taken to Conserve Energy at JSW

1. Switch over from energy consuming DC to energy efficient ACmotors in Galvanizing Line 1

2. Use of AC drives and energy-efficient motors with common DC busin the new projects also (one Galvanizing line and one ColourCoating Line)

AC motors in newly commissioned ColourCoating Line

3. Variable speed (VVVF) drives installed for all major fans/blowers andcompressors

4. Provided VVVF drive with PID closed loop control for cooling blowerafter galvanizing

Drive retrofitted in panel replacing SoftStarter

5. Replaced Galvanizing line furnace brick-lining with glass-woolblock insulation

Oven insulation changed

6. Replaced electrically heated Vaporizer for LPG with specialheatless vaporizer which runs on normal water

Heatless Vaporizer in LPG Yard


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7. Shut down standby Ammonia cracker in Galvanizing Line 1

8. Replaced existing Ammonia cracker brick lining with specialinsulating blocks in Galvanizing Line 2

Ammonia Cracker in GL-2

9. Lighting energy-saver transformer with panel was installed for all theshed lighting as well as street lights

Lighting Transformer

10. Use of energy saving devices like electronic fan regulators,programmable timers, LCD monitors

LCD monitors have replaced conventional CRTs

11. Translucent sheets for natural illumination inside sheds

Translucent Shed PanelsTransparent panels


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12. Huge glass windows in rooms allow daylight to permeate through, negating the need for any lightingduring day hours.

Main Office

13. Software program developed to switch off energy intensiveloads during breakdown and line-stop, automatically

Easy, GUI based PLC program

14. Replaced 3x30kW motors for hydraulic pumps with1x37kW motor with AC drive

15. Converted lightly loaded motors from delta to star aftera complete analysis

Replaced with smaller motors and changed delta tostar


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16. Converted Accumulators Hydraulic operation to AC drivecontrolled Electrical operation

AC Drive controlled accumulator in Colour CoatingLine

17. Installed 3 WHRB in the DG sets and CCL to recoverwaste heat

2 Waste Heat Recovery Boilers

18. Chimney height increased to reduce load on ID Fan

Increased chimney height


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19. Compressor bank to meet the compressed air demandof Galvanising Line 1 and 2 centrally.

20. Regular audits were carried out for water andcompressed air consumption

21. Maintenance of compressor is carried out regularlybased on volumetric efficiency

Compressor Bank

22. Vermiculture is being carried out in the premises

23. Rain Water Harvesting (figures per year)

Supply of Rain Water in 30 acre campus is 3,00,000 kLWater Demand in plant is 2,50,000 kLSurplus of 50,000 kLHelps meet plant requirement during 4 6 months ayear

Vermiculture Pits

24. All the 2x40W tube light fittings were replaced with 1x36W energy-efficient fluorescent lamps

25. HPMV lamps were replaced with HPSV lamps of less wattage, wherever possible

26. Rearranged power distribution system for optimum utilization of captive power generation

27. Laid one more power cable between Power Plant and Substation to reduce cable losses.

28. Replaced obsolete and inefficient fans and pumps

29. Prime Mover Optimization in all units

30. Optimization of speed of fans and blowers as per system requirement

31. Developing and popularizing other general energy conservation technologies and Six Sigma Projectswhich have demonstrated their maturity and remarkable economic benefits.


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32. Extensive training of all personnel in

Handling equipment

Energy saving methods

I think it should

be switched OFFwhen not in use

*@ Rs. 4 / unit

To focus on Savings is to focus on EffectivenessTo focus on Savings is to focus on Effectiveness

ID Fan

takes

72 units / hour

or

Rs. 288 / hour*

33. Training of employees family membersfor domestic energy conservation

34. Motivating the workers to save energythrough small group and project teamactivities

35. Increasing awareness amongst theworkers by putting placards on themotors

Prototype placard that was put on power-intensive motors

Management Initiatives

36. Maintaining an environment of Cooperation,Coordination and Collaboration within theorganization

Thus, squabbles are minimised reduced time neededto manage them. That is, we try not to waste ourenergy. Instead, we aim to utilise it constructively.

37. Developing an environment of Switched Onpeople who WILL NOT WASTE TIME.

Conclusion

JSW realizes the importance of energy conservation, especially in the wake of increasing energy demandsand dwindling resources. Consequently, it sincerely attempts to reduce its energy consumption and does nothesitate to invest in the latest technology which helps towards this end. It also believes in developing andsustaining an environment of increased learning and awareness so that each and every employeeunderstands the Energy Scenario and does his bit to conserve energy, not only in the plant but also at home.


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Project Impact

Status for reference is as tabulated below ( average of April to Oct. 2004 ) :

Reference power consumption as per project charter

UNIT Bud. Power Actual Power. CR Thi. CR Width Savings Production.

TM4 149.6 U/Mt 135.4 U/Mt 0.275 mm926.7 mm 14.2 U/Mt 9182 Mt/m

TM5 86.57 U/Mt 83.4 U/Mt 0.711 mm1197.0 mm 3.17U/Mt 16640 Mt/m

Actual power consumption and savings for the month of April 05

UNIT Bud.Pow Act. Pow. Savings Net

5.8 U/Mt

3.83 U/Mt

Savings Production.

TM4 186 U/Mt166 U/Mt 20 U/Mt 1.18 Lac 7537 Mt/m

TM5 114 U/Mt107 U/Mt 7 U/Mt 1.56 Lac 15099 Mt/m

Annual benefit : 32 Lac

CR Thi. CR Width

0.22 mm 939 mm

0.57 mm 1057 mm

Proposed

Savings

( Units/Mt )

Annual

Production

( Mt )

Annual Power

Savings

( Units )

Proposed Annual

Savings @ 2.85

Rs/Unit

( lakh Rs. )

TM4 Mill 2 87844 175688 5.01

TM5 Mill 2 196820 393640 11.22

Total 4 284664 569328 16.23


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Project B

Project Name: Conservation of Energy in Colour Coating Line

Background

This line was commissioned very recently (July 2005). In the beginning the wastage (of time, energy, money)was very high. The workers were relatively new. Systems were not in place. The running line had not

stabilized its operation. It was new and as is the case with new lines, it takes time to get into the groove.However, along with this came the opportunity of drastic savings by some very simple measures and steps.The scope of savings was huge and therefore it was decided to take up this project to save energy in CCL.

Steps taken

Changed shed lights in Shed 2 (where white-light is not of importance) from 400W HPMV to 250WHPSV lamps

The ID Fan was pre-fitted with a soft starter (as part of turnkey project). This was replaced with aVVVF drive.

Replaced the spare water-cooled compressor with an air-cooled compressor. This allows us to switch

off the 75kW pump house motor used for water cooling. We have tried to standardize operations by clearly defining all the steps in any process.

We have also tried to improve the Quality of our product, by reducing defects, thereby leading to lesswastage.

Training programs along with awareness drives have slowly but surely demonstrated their benefits byway of reduced power consumption (35kWh/mT reduction).


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Illustrative Analysis for ID Fan Drive

Saving incurred due to installation of 160kW ID Fan Drive

Energy Consumed Actual Prod Approx Prod kWh/ton

Before Drve 2328 214 210 11.09

After Drive 1616 201 210 7.70

712 21360 85440

Saving per ton = 3.39 kWh/ton

= 13.56 Rs/ton

Assuming an average production of 200 tons in a day,

Saving is = 678.10 kWh

= Rs. 2712.38 per day

Saving of Rs. 80,000 per month

Impact of Implementation

S.No Action takenSaving in

Kwh/monthSaving inRs./month

1 Installation of AC Drive for ID Fan Drive 20340 81360

2 Installation of Air-cooled compressor 6120 24480

3Awareness drives etc. reduced power cons. by35kWh/mt

140000 560000

TOTAL 1,66,460 6,65,840


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Project C

Project Name: Installation of VVVF Drives in place of Soft Starters in the plant

BackgroundThere were several motors (small and large) which were running from Soft Starters in our plant. However, as

the universal demand for energy has increased and the need for some serious Energy Conservation

measures was felt, it was decided to undertake a project in which we would replace the Soft Starters of

certain motors with VVVF drives. This would not only help in reducing the power consumption but also

provide for better speed-torque control of the motor. In spite of the investment-intensive character of this

project, it was taken up since it would benefit everybody in the long run.

Observations, Technical and Financial Analysis

Several motors such as the 160 kW ID Fan, 75 kW and 160 kW Air Knife fans, 132 kW and several 37 kW

blowers in Galvanizing Lines 1, 2 and 3 were throttled in suction (damper was kept half closed to reduce load)

and also consuming heavy power during the process. On the other hand, if drives were installed for all these it

was calculated that the total power consumption would reduce significantly even after opening the damper

fully. Assuming a 20% reduction in power consumed, the ROI was calculated to be 6 months.

Motor Rating Quantity Investment forDrive

Savings/month Savings/year

22kW (with panel) 3 4 lakh Rs. 50,000 Rs. 6,00,000160kW (with panel) 1 6 lakh Rs. 1,00,000 Rs. 12,00,000110kW (with panel) 1 4 lakh Rs. 60,000 Rs. 7,20,000160kW 1 4 lakh Rs. 60,000 Rs. 7,20,00055kW 1 2 lakh Rs. 30,000 Rs. 3,60,000110kW 1 3 lakh Rs. 40,000 Rs. 4,80,000

Total 8 23 lakh Rs. 3,40,000 Rs. 40,80,000

Impact of the Implementation

The power consumption of these motors reduced by 32%

It was decided that the new Colour Coating Line would be commissioned with the latest AllenBradleys PowerFlex 700 AC drives, unlike the other sections which have DC drives.

JSWSteelLtdTarapur

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