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Active<br />

<strong>Conservation</strong><br />

Techniques<br />

Government of India<br />

Ministry of <strong>Petroleum</strong> & Natural Gas<br />

<strong>Apr</strong> – Jun 2010<br />

PETROLEUM CONSERVATION RESEARCH ASSOCIATION<br />

inside<br />

■<br />

Seminar on “Indigenous<br />

Development of Roller Head<br />

Jigger for Tableware Industries<br />

of Khurja”<br />

■<br />

■<br />

Revival Story of an ailing State<br />

Transport Unit Through PCRA’s<br />

Driver Training Programme<br />

Improving Reliability of pot<br />

furnaces in Firozabad<br />

SAVE FUEL yaani SAVE MONEY


Quarterly Journal<br />

<strong>Apr</strong> – Jun 2010<br />

CONTENTS<br />

4–5 Editorial<br />

Together We Can Achieve!<br />

6–19 In focus<br />

6–8 First Prize Winner of National Level Essay<br />

Competition OGCF’ 2010<br />

8 Economics of Energy Efficiency<br />

9 Car Free Day Spreads Message to Conserve<br />

Fuel<br />

10 Seminar on “Indigenous Development of<br />

Roller Head Jigger for Tableware Industries<br />

of Khurja”<br />

11–12 Revival Story of an ailing State Transport Unit<br />

Through PCRA’s Driver Training Programme<br />

13 Appreciation letter from North Bengal State<br />

Transport Corporation (NBSTC)<br />

14–16 Investment Grade Energy Audit at Greater<br />

Visakhapatnam Municipal Corporation<br />

16 Energy audit in coal mines of Central<br />

Coalfields Ltd – A Perspective<br />

17–19 Improving Reliability of pot furnaces in<br />

Firozabad<br />

20 Post Graduate Teachers visit <strong>Conservation</strong><br />

Technology Centre at PCRA<br />

21 Websites and Events<br />

22 In the news<br />

First prize winner of National Level Essay Competition<br />

OGCF’ 2010, Shruti Anantharaman, being felicitated<br />

Editorial Team<br />

Editor<br />

: Arun Kumar<br />

Associate Editors : S.P. Goel<br />

A.K. Goel<br />

G.K. Medhi<br />

Content Coordinator : Ashirbad S. Raha, WII<br />

Design and Layout : Jaison Jose, WII<br />

Produced by<br />

Winrock International India (WII)<br />

788, Udyog Vihar, Phase V<br />

Gurgaon – 122001, INDIA<br />

Tel: 0124-4303868 Fax: 0124-4303862<br />

Website: www.winrockindia.org E-mail: wii@winrockindia.org<br />

On behalf of<br />

<strong>Petroleum</strong> <strong>Conservation</strong> <strong>Research</strong> <strong>Association</strong> (PCRA)<br />

Sanrakshan Bhawan, 10 Bhikaji Cama Place<br />

New Delhi – 110066<br />

Tel: 011-26198856<br />

Fax: 011-26109668<br />

Website: www.pcra.org<br />

All communication should be addressed to:<br />

The Associate Editor<br />

Active <strong>Conservation</strong> Techniques Journal<br />

<strong>Petroleum</strong> <strong>Conservation</strong> <strong>Research</strong> <strong>Association</strong><br />

Sanrakshan Bhawan, 10 Bhikaji Cama Place<br />

New Delhi – 110066<br />

Tel: 011-26198856<br />

Fax: 011-26109668<br />

The views expressed in the journal are those of the individual<br />

contributors and not necessarily of PCRA. The main aim of the journal<br />

is to disseminate information of the latest trends, developments, and<br />

R&D efforts initiated, identify opportunities, and explore national and<br />

international advancements in the field of energy conservation and<br />

environment protection.<br />

3<br />

active conservation techniques


Together We Can Achieve!<br />

Efficient energy management involves creating systems and<br />

practices to maintain balance between supply and consumption<br />

on a sustained basis. To sustain the economic growth rate of 8 to<br />

9%, India’s energy needs are projected to grow at a rate of 3.0 –<br />

3.5% per annum over the next few years. This implies many-fold<br />

increase in India’s energy requirement over the next 25 years. In<br />

such a scenario, conservation of energy becomes imperative.<br />

4<br />

Energy is the most vital input for the socioeconomic<br />

development of a nation. India’s energy<br />

consumption is growing at a high rate to meet the<br />

needs of growing population and increasing<br />

economic growth and development. India ranks as<br />

the World’s Seventh largest energy producer and<br />

the fifth largest energy consumer. The hydrocarbon<br />

sector plays a pivotal role in India’s energy sector<br />

with a 45% share in the commercial energy basket.<br />

Predictions are that fossil fuels would<br />

remain the dominant source of energy in the near<br />

future.<br />

As a result of very steep increase in crude oil prices<br />

in the recent past, the impact felt across the world<br />

has been severe. Our domestic crude production<br />

is unable to keep pace with high growth in demand<br />

of oil and gas resulting in heavy dependence (to<br />

active conservation techniques<br />

the extent of 80%) on imports. There is, therefore<br />

imperative need for efficient utilization of existing<br />

energy resources. Hence, a very high priority has<br />

been given by the Government for conservation of<br />

petroleum products so as to reduce ever-increasing<br />

gap between demand and indigenous supply and<br />

also to contain the pollution.<br />

We have been striving for the past few decades to<br />

fulfill our energy requirements. India, with 17% of<br />

the world population and just less than 1% of the<br />

world’s known oil and natural gas reserves is going<br />

to face serious energy challenges in the coming<br />

decades. There is a challenge to meet the energy<br />

requirements of all segments of population in an<br />

efficient, reliable and affordable manner while being<br />

sensitive to the concern for environmental<br />

protection.


Efficient energy management involves creating<br />

systems and practices to maintain balance between<br />

supply and consumption on a sustained basis. To<br />

sustain the economic growth rate of 8 to 9%, India’s<br />

energy needs are projected to grow at a rate of<br />

3.0 – 3.5% per annum over the next few years.<br />

This implies many-fold increase in India’s energy<br />

requirement over the next 25 years. The exercise<br />

becomes challenging when it comes to managing<br />

scarce resources.<br />

But PCRA alone can achieve little. It needs<br />

cooperation from every quarter. We need to<br />

develop habits that promote energy conservation.<br />

Simple things such as switching off excess lighting<br />

load, using fuel effectively in our factories, prudent<br />

use of petrol, paying a little extra initial cost for<br />

energy saving equipment, etc can go a long way in<br />

achieving desired objective.<br />

In such a scenario, conservation of energy becomes<br />

imperative. <strong>Petroleum</strong> <strong>Conservation</strong> <strong>Research</strong><br />

<strong>Association</strong> (PCRA) under MOP&NG, Government<br />

of India has been constantly endeavoring in<br />

promoting efficient use of petroleum products<br />

through various field activities like energy<br />

audits, driver training programmes, technical<br />

workshops, seminars and specially by involving<br />

youth in various activities.<br />

Arun Kumar<br />

Secretary, OIDB & Executive Director, PCRA<br />

There is a need for building the base for conserving<br />

energy by involving the people in general and the<br />

industries in particular for bringing in the desired<br />

behavioral and attitudinal change to make<br />

conservation a habit amongst the masses. PCRA<br />

has undertaken a number of steps by actively<br />

involving itself through energy audits, organizing<br />

seminars, workshops, technical meets and mass<br />

awareness campaign.<br />

active conservation techniques<br />

5


MAKING OIL CONSERVATION A WAY OF LIFE<br />

6<br />

As they say, a drop of oil conserved is a<br />

drop of oil produced. Infact oil is like time,<br />

once gone will never come back. These<br />

facts clearly highlight the importance of<br />

conserving oil. Firstly, oil is so precious that<br />

we cannot tend to waste the natural<br />

resource and moreover with the increasing<br />

number of vehicles plying on the road<br />

everyday, it is sure to become a scarce<br />

commodity very soon.<br />

Secondly, it increases the value of our<br />

import bill. As we depend on the Gulf<br />

region for oil due to the increasing demand,<br />

their prices too rise making us indebted to<br />

them. Thirdly, it also leads to many hazards<br />

like creating air pollution wherein pollutants<br />

like carbon monooxide, carbon dioxide,<br />

sulphur dioxide and nitrogen oxide are in<br />

the atmosphere creating several hazards to<br />

humans.<br />

According to a study conducted by centre<br />

for Ecological Sciences (CES) at Indian<br />

Institute of Science (IISc) Bangalore on<br />

emission from India’s transport sector,<br />

Chennai accounts for 13.5% of the total<br />

CO 2<br />

emissions and leads the four metros<br />

in this respect. Oil and gas conservation<br />

therefore indicates more efficient use with<br />

regard to economic, social or environmental<br />

costs and benefits resulting in attainment<br />

of higher energy use, efficiencies,<br />

minimization of wasteful practices and<br />

wastage and protection of environment.<br />

active conservation techniques<br />

Whenever you save energy, you not only<br />

save money, you also reduce the demand<br />

for such fossil fuels such as coal, oil and<br />

natural gas. Less burning of fossil fuels also<br />

means lower emissions of carbon dioxide<br />

(CO 2<br />

), the primary contributor to global<br />

warming and other pollutants.<br />

Campaigns designed for each target group<br />

are carried out during fortnight. Major<br />

target groups are transport, domestic,<br />

industrial and agriculture. Apart from<br />

special drives for these sectors, mass<br />

awareness programmes are also organized.<br />

Ever increasing dependence on fossil fuels<br />

and resulting environments damages has<br />

reached alarming levels. India imports more<br />

than 71 percent of its crude oil. The oil<br />

import bill for 2008-09 stood at US$ 93.2<br />

billion, an increase of more than 17 percent<br />

over previous year. This unprecedented<br />

increase and the over – dependence on<br />

other countries for the country’s energy<br />

needs make conservation efforts important<br />

for sustaining the economy.<br />

A growing number of scientific researchers<br />

and political leaders have urged prompt<br />

conservation of fossil fuels by investing<br />

immediately in energy-efficient vehicles,<br />

machinery, and structures and by gradually<br />

shifting to alternative sources of energy.<br />

According to them, the basic three reasons<br />

for investing now in fossil fuel conservation<br />

are technological lock-in, institutional<br />

inertia and oil wars. They have stated that<br />

the fossil fuels bonanza will end sooner<br />

rather than later is beyond doubt. The only<br />

reasonable strategy is conservation. The<br />

reason most commonly given in support of<br />

fossil fuel conservation is the need to<br />

prevent future global climate change.<br />

Energy today has become a key factor in<br />

deciding the product cost at micro level as<br />

well as in dictating the inflation and the debt<br />

burden at the macro level. The imperatives<br />

of an energy shortage situation thus call<br />

for energy conservation measure, which<br />

essentially mean using less energy for the<br />

same level of activity.<br />

One such example is Flex-fuel vehicles,<br />

which are cars that run on both gas and<br />

ethanol. It costs very little to turn a regular<br />

car into a flex-fuel vehicle, and there are<br />

about five million of them on the road in<br />

the United States today. Made by all the<br />

major carmakers, flex-fuel vehicles definitely<br />

use less gas, but the best of both worlds is<br />

the hybrid flex-fuel car. Ford, for example,<br />

is making one now.<br />

Another innovator from Pune (India) has<br />

conveyed his idea of coming out with a sky<br />

roller, which is a Low Earth Orbit (LEO)<br />

unmanned craft that converts pollutants like<br />

CO, C0 2<br />

, SO 2<br />

and NO into the fuel that it<br />

uses to power its flight around the earth.<br />

Its function is to monitor and map the


maximum emission areas and identify the<br />

biggest defaulters in terms of air pollution<br />

and suck in that very pollution and convert<br />

it into fuel to sustain its flight. This means<br />

that, until the sky roller patrols the<br />

atmosphere, pollutants will be kept under<br />

hazardous levels and the day it runs out<br />

of fuel, the earth will have been rid of its<br />

pollution. Even, we, human beings<br />

should strive to resolve this issue. Stop<br />

using vehicles for a shout distance. A<br />

stroll on the road in one way, is good for<br />

our health. Like in ancient days we should<br />

not be more dependent on oil driven vehicles.<br />

Afterall, a drop of oil saved today is a saving<br />

for the future generation. Only if we save oil<br />

today, the benefit can reach the generation<br />

of tomorrow. Various steps are being taken<br />

to promote conservation of petroleum<br />

products in several areas.<br />

Effective and result oriented conservation<br />

methods adopted by the upstream<br />

undertakings in the oil sectors include<br />

reduction of gas flowing by re-injection of<br />

gas to underground reservoir, installation<br />

of waste heat recovery system, utilization<br />

of non- conventional energy sources and<br />

close monitoring of all conservation efforts.<br />

Saving or conserving what we don’t need<br />

to use is one of the way. Several ways and<br />

measures can be found out for the alternate<br />

source of energy. For example, Japan has<br />

started selling biofuels made from rice<br />

which is expected to help the country reduce<br />

its dependence on imported gasoline and<br />

make better use of deserted farmland.<br />

Ethanol is also an alcohol-based fuel made<br />

from turning starch crops (like corn, barley<br />

and wheat) into simple sugars. When<br />

combined with regular gasoline, it’s called<br />

E85, which means 85 percent ethanol and<br />

15 percent gasoline. Already widely used<br />

in Sweden and Brazil, ethanol can help<br />

reduce your car’s greenhouse gas<br />

emissions, and nearly all 50 US states have<br />

pump stations that now offer this type of<br />

alternative fuel.<br />

According to experts another potential area<br />

is to tap solar power to harness hydrogen.<br />

State’s immense solar energy potential is<br />

ideal for harnessing hydrogen energy which<br />

is considered by many as the ultimate<br />

solution to energy and environmental<br />

problems.Hydrogen is considered an ideal<br />

energy carrier in the foreseeable future. It<br />

can be produced from water using a variety<br />

of energy sources, such as solar, nuclear<br />

and fossils and it can be converted into<br />

useful energy forms efficiently and without<br />

detrimental environmental effects.<br />

Hydrogen can be used in any application<br />

in which fossil fuels are used. It can be used<br />

as a fuel in furnaces, internal combustion<br />

engines, turbines and jet engines, even<br />

more efficiently than fossil fuels, that is,<br />

coal, petroleum and natural gas. Moreover,<br />

India has the know-how to create hydrogen<br />

energy as many universities, including IITs,<br />

Vanaras Hindu University and RMK<br />

Engineering College are conducting<br />

research on this.<br />

There are other interesting developments<br />

also happening as in use of bubble<br />

technology to boost car’s fuel efficiency.<br />

Engineers at automotive research<br />

consultants Mira in Nuneaton, UK are<br />

developing a system that uses soap bubbles<br />

filled with helium to improve the fuel<br />

efficiency of future cars. The 3 millimeter<br />

bubbles swirl around cars in a wind tunnel,<br />

and the engineers use 12 cameras to track<br />

the bubbles, thus capturing air flows in<br />

unprecedented detail.<br />

The helium in the bubbles gives them<br />

natural buoyancy, left to their own devices<br />

they will neither raise nor fall in the air, so<br />

any up or down movement can be<br />

attributed to airflow around the car. There<br />

aren’t any tools in use today that can give<br />

such insight into what’s going on in the<br />

fluid around a vehicle.<br />

Consumers are beginning to consider fuel<br />

economy and carbon emissions when<br />

choosing a new car, and thus aerodynamics<br />

have become much more important to car<br />

manufacturers.<br />

Cutting a vehicle’s air resistance is a usually<br />

cheaper way of improving those stats than<br />

reworking an engine or drive train. The<br />

bubble technique has long been used to<br />

see how air moves around a structure, but<br />

the new camera system gives extra insight<br />

by capturing the precise movement of<br />

individual bubbles in 3D for later analysis<br />

and exploration. The bubble tracking<br />

approach captures the speed as well as the<br />

direction of air flow, which makes it more<br />

useful than existing tracking techniques such<br />

as injecting smoke trails around the car.<br />

Conclusion<br />

Thus to make oil conservation, a way of<br />

life, the conservation has to start on roads.<br />

The first rule of fuel conservation would<br />

be to travel judiciously and curtail waste<br />

fuel while driving. Apart from that<br />

increased car-pooling habit to work will<br />

not only conserve fuel but will also<br />

improve social relations with your<br />

colleagues. Moreover following traffic<br />

signals will help avoid traffic jams and<br />

reduce lower gear driving and idling and<br />

as a result of all these fuel would be saved.<br />

So basically the message is - Don’t make<br />

your child ask, “What was Oil?” So start<br />

conserving today.<br />

Essay by: Shruti Anantharaman<br />

Student, Class – X<br />

Vivekananda Vidyalaya HR. Sec. School,<br />

Chennai<br />

7<br />

active conservation techniques


I N F O R M A T I O N C A P S U L E<br />

Economics of Energy Efficiency<br />

There are enormous economic benefits<br />

that can be gained by increasing our<br />

nation’s energy efficiency. Therefore,<br />

investing in efficiency measures is the<br />

most immediate and effective way to lower<br />

energy demand, reduce carbon emissions,<br />

and save households and businesses’<br />

money. According to some experts, the<br />

potential for savings throughout all<br />

sectors of the Indian economy is<br />

estimated to be of the order of<br />

90 million tonnes oil equivalent.<br />

Specialists also claim that the current<br />

energy policy does not take full advantage<br />

of savings offered by promoting energy<br />

efficiency in transportation, buildings, and<br />

industrial sectors which can actually make<br />

a significantly large contribution toward<br />

stabilizing energy prices, therfore<br />

strengthening the robustness of the Indian<br />

economy. It’s for all these reasons that<br />

efficiency should be viewed as a hidden<br />

energy reserve as well as an economic<br />

opportunity.<br />

From an economic perspective, energy<br />

efficiency choices fundamentally involve<br />

investment decisions that trade off higher<br />

initial capital costs and uncertain lower<br />

future energy operating costs. In the<br />

simplest case, the initial cost is the<br />

difference between the purchase and<br />

installation cost of a relatively energyefficient<br />

product and the cost of an<br />

otherwise equivalent product that provides<br />

the same services but uses more energy.<br />

As far as doing away with less efficient<br />

equipments is concerned, the cost is much<br />

higher and therefore the decision of<br />

whether to make the energy-efficient<br />

investment requires weighing the initial<br />

capital cost against the expected future<br />

savings. Assessing the future savings<br />

requires forming expectations of future<br />

energy prices, changes in other operating<br />

costs related to the energy use (e.g.,<br />

pollution charges, carbon credits, PF<br />

penalty, contract load reduction rebate<br />

etc), intensity of use of the product, and<br />

equipment lifetime. And finally deduction<br />

of the future cash flows to initial<br />

investment cost reveals the viability of the<br />

investment.<br />

As described above, the relative price will<br />

finally depend on the capital cost of<br />

efficiency improvements, the discount<br />

rate, expected energy prices, equipment<br />

utilization, and decision time horizon.<br />

This framework applies at the household<br />

level as well as at a broad sectoral or multisectoral<br />

level where energy and capital<br />

are used to produce energy.<br />

Courtesy: VK Srivastava, Additional Director,<br />

PCRA<br />

8<br />

active conservation techniques


The residents of Carter Road at<br />

Bandra (West) in Mumbai had a<br />

glimpse of the perfect harmony<br />

of mankind with the nature recently. With<br />

no vehicles on the road, no traffic jams,<br />

No honking, for a day it was like the<br />

resurgence of what was prevalent during<br />

the days of pre-industrial era.<br />

The unique occasion was the daylong<br />

celebration of Car Free Day (CFD) at Carter<br />

road, Bandra (West), Mumbai, organized<br />

by KBS Foundation with support of PCRA<br />

and several other organizations. The<br />

observance of CFD was intended to<br />

generate public awareness on urgency of<br />

conservation of fuel and spur the civic<br />

societies in other parts of the country to<br />

create movement for observing fuel free days.<br />

The entire 2.5 km long stretch of Carter<br />

road with the fascinating ambience of<br />

Arabian Sea coast, had attracted people of<br />

all hues. From tiny tots to artists, from<br />

athletes to musicians, it was a day abuzz<br />

with multitude of fun filled activities viz.,<br />

cycle rally, skating rally, dance<br />

performances, musical concerts, all<br />

pointing towards the common mission of<br />

making the city pollution free through<br />

rationale use of fuel.<br />

Ms Priya Dutt, the young parliamentarian<br />

from Mumbai, emphasized the urgency for<br />

infrastructure to promote public transport.<br />

She stated that the development of Bus<br />

Rapid Transit (BRT) System with dedicated<br />

bus lanes in the road centre and dedicated<br />

cycle lanes in urban areas would not only<br />

avoid traffic jams, but also help the<br />

prevention of air pollution & conservation<br />

of diesel & petrol. The conspicuously<br />

displayed PCRA banners & posters along<br />

the entire Cater road and the amphitheatre<br />

stage had drawn attention of a large number<br />

of people. Ms. Dutt was highly appreciative<br />

of the programs of PCRA to educate the<br />

society on conservation of petroleum fuels.<br />

Shri Baba Siddiqui, MLA from Bandra<br />

constituency visited PCRA stall and evinced<br />

keen interest in PCRA’s activities. He opined<br />

Bollywood actor Salman Khan participating<br />

in the cycle rally<br />

that natural resources including petroleum<br />

fuels need to be efficiently utilized so as to<br />

ensure sustainability of living beings on the<br />

earth. The entire team of PCRA, Western<br />

Region, Mumbai led by CRC, attended the<br />

day long CFD celebrations.<br />

The presence of actor Salman Khan, leading<br />

the cycle rally lent impetus to<br />

the noblest cause of fuel conservation.<br />

The iconic star made clarion call to<br />

conserve fuel for protection of environment<br />

and keeping the planet livable for future<br />

generations.<br />

Courtesy: PCRA, Western Region, Mumbai<br />

active conservation techniques<br />

9


10<br />

Khurja (wasteland in local<br />

language), in Uttar Pradesh<br />

is home to the largest<br />

ceramic cluster in India and is known as<br />

the ceramic city. With the progress of<br />

civilization, the ceramic industries at Khurja<br />

have grown significantly and now they not<br />

just fulfill the domestic requirement but are<br />

also contributing towards resource and job<br />

generation and earnings on export for the<br />

growth of the nation.<br />

At present nearly 200 units are engaged<br />

for manufacturing crockery wares by<br />

conventional process using old technology.<br />

The lack of quality control knowledge<br />

among the manufacturing unit is a major<br />

obstacle which often results into product<br />

rejection. The fuel consumption levels are<br />

also high in these units.<br />

In order to develop a technology upgradation<br />

for the cluster, PCRA sponsored<br />

a project titled “Indigenous Development<br />

of Roller Head Jigger for Tableware<br />

Industries of Khurja” to Central Glass &<br />

Ceramic <strong>Research</strong> Institute (CGCRI),<br />

Khurja. As a part of the activities under the<br />

project, an awareness seminar was<br />

organized at CGCRI, Khurja Centre in<br />

<strong>Apr</strong>il 2010.<br />

In the welcome address, Dr. LK Sharma,<br />

Scientist-in-Charge of CGCRI, Khurja<br />

elaborated the benefits of the research work<br />

carried out by PCRA & CGCRI, to ensure<br />

energy savings in the clusters. Dr. Sharma<br />

also briefed the benefits and savings of<br />

active conservation techniques<br />

energy with the use of indigenous<br />

development of roller head jigger in<br />

comparison to conventional jigger jolly.<br />

Mr. Sudesh Sharma, ex-President of Khurja<br />

Pottery Manufacturers <strong>Association</strong><br />

expressed his views on use of indigenous<br />

development of roller head jigger for table<br />

ware industries in Khurja and further<br />

appreciated the shaping of hollow and flat<br />

wares with saving of energy to be a great<br />

achievement for the Khurja Pottery<br />

Industries. He requested PCRA to help<br />

more entrepreneurs of Khurja by providing<br />

this type of project.<br />

Mr Ajit Kumar, Joint Director (R&D), PCRA,<br />

highlighted about different projects being<br />

carried out for energy saving in pottery<br />

cluster of Khurja. Putting a stress on the<br />

fact that energy conservation is the first<br />

need of changing era, Mr Kumar also<br />

emphasized on different options for energy<br />

saving and requested entrepreneurs of<br />

pottery industries to join CDM for more<br />

benefits.<br />

Welcome address<br />

by Dr. LK Sharma,<br />

Scientist-In-Charge,<br />

CGCRI Khurja<br />

Centre<br />

Demonstration of Roller Head Jigger<br />

Machine at CGCRI, Khurja<br />

Mr Kapil Mathur, Additional Director,<br />

PCRA, New Delhi graced the seminar as<br />

chief guest. In his inaugural speech, he put<br />

focus on the need of energy saving in India<br />

and also explained about CDM projects. A<br />

detailed presentation was also made by Mr.<br />

Onkar Nath & Mr. Kundan Burnawal, GTZ,<br />

who discussed in details about CDM and<br />

its benefit for pottery industries of Khurja.<br />

About 108 entrepreneurs of pottery<br />

industries Khurja, Science & Technology<br />

personnel attended the seminar.


Transportation in India is a large<br />

and varied sector of the<br />

economy. The public<br />

transportation in India is provided by state<br />

road transport corporation within each<br />

state, and union territories of India. Public<br />

state road transport corporation bus<br />

services are also offered in cities where<br />

there are no local municipal road transport<br />

authorities. APSRTC, KSRTC, GSRTC,<br />

JKSRTC, Kerala SRTC, MSRTC, OSRTC,<br />

DTC and other state road transport<br />

corporations offer intercity and inter-state<br />

bus services, at a very affordable rate with<br />

reliable service to passengers.<br />

North Bengal State Transport Corporation<br />

(NBSTC) is one of the oldest state road<br />

transport organizations in India that started<br />

functioning in <strong>Apr</strong>il 1945 with the purpose<br />

of meeting the transport requirements of<br />

the region. The area of operation of the<br />

Corporation, which was initially limited<br />

within the State of Coochbihar and the<br />

neighboring district of Jalpaiguri, was<br />

gradually expanded and now covers all the<br />

districts of the State of West Bengal. In<br />

addition it also operates some inter-state<br />

services with neighboring states of Assam,<br />

Bihar, Jharkhand and Sikkim. The<br />

Corporation completed its golden jubilee<br />

year in 1995. As recognition of its<br />

contribution to the socio-economic<br />

development of the society especially in<br />

rural areas, the corporation was honored<br />

with “National Productivity Award” in<br />

1993-94.<br />

Seen in the pictures are guests attending a programme organised to recognize the efforts<br />

of the achievers at Siliguri<br />

Figure: North Bengal State Transport Corporation comparison of KMPL<br />

before and after driver’s training program of PCRA<br />

11<br />

active conservation techniques


12<br />

Fuel Saved in Litres<br />

Figure: North Bengal State Transport Corporation month wise savings<br />

of fuel in litres with the help of PCRA driver’s training program in NBSTC<br />

active conservation techniques<br />

Media coverage of<br />

the revival story<br />

North Bengal State Transport Corporation<br />

is a public utility service and its sole aim is<br />

to operate efficient transport system to<br />

cater to the needs of the travelers both in<br />

rural and urban areas. Various categories<br />

of Standard, Semi-deluxe, Deluxe, Rocket<br />

and A/C coach buses with attractive<br />

amenities are being operated on those<br />

routes at the cost of the least possible fares<br />

fixed by the Government.<br />

The corporation however had been<br />

incurring an annual loss of close to crore<br />

rupees in recent times and managed to stay<br />

afloat just because of the monthly subsidy<br />

that it was receiving from the government.<br />

Saddled with extra manpower, the payment<br />

of employees’ salaries became irregular.<br />

The superannuation benefits too, could not<br />

be given on time.<br />

However the sinking boat of the<br />

corporation was rescued by PCRA’s<br />

trademark Driver Training Program, which<br />

is one of the most effective and important<br />

tools to improve KMPL. The main objective<br />

of the driver training program is to train<br />

the drivers and mechanics on good driving<br />

habits and maintenance practices in order<br />

to develop a cadre of good drivers and thus<br />

to promote a cadre of good drivers thereby<br />

automatically promoting fuel efficiency in<br />

the transport sector. Through this specially<br />

designed Driver Training Program (DTP)<br />

for the sector, drivers from STUs, Army,<br />

BSF, Oil companies and private transporters<br />

were imparted training to improve their<br />

driving skills which lead to substantial<br />

amount of fuel saving.<br />

PCRA Eastern Region (ER) joined hands<br />

with NBSTC management, to create a saga<br />

of revival, through Drivers Training Program<br />

for all the 21 depots, spread all over West<br />

Bengal. All the crew members employed<br />

in NBSTC were exposed to the PCRA’s<br />

Signature Driver Training Program during


last two years. The “save fuel, raise sale”<br />

campaign through PCRA ER has now<br />

started paying dividends. The employees<br />

have now realized that the corporation is<br />

trying to break out of the loss-making<br />

mould and they appreciate efforts of<br />

management and PCRA ER.<br />

After the training program, the average<br />

KMPL of NBSTC has jumped from 3.85<br />

(Jan 08) to 4.24 (Oct 09). The Alipurduar<br />

depot has improved their MPL from 4.12<br />

(Jan 09) to astounding 4.81 (Mar 10). The<br />

benefits incurred from the program has<br />

helped the loss-making North Bengal State<br />

Transport Corporation (NBSTC) in saving<br />

Rs 9.1 lakh litres of diesel amounting<br />

Rs 3.50 crores of fuel in the past 14 months<br />

(between Feb 09 to Mar 10). The figures<br />

clearly indicate how an ailing state transport<br />

unit got a new life through the PCRA’s<br />

Driver Training Programme.<br />

as a result of all these, PCRA’s drivers<br />

training program has become one of<br />

the main support systems in NBSTC’s<br />

revival path.<br />

To ensure right degree of awareness<br />

generation, the program was supplemented<br />

by regular transport workshops at their<br />

depots. PCRA ER encouraged the achievers<br />

through recognition programs at depot<br />

level and for the same a grand program<br />

was also organised to recognize the efforts<br />

of the achievers at Siliguri. The program<br />

being successful also attracted a lot of<br />

media attention and recognition from<br />

NBSTC.<br />

Appreciation letter from North Bengal<br />

State Transport Corporation (NBSTC)<br />

Not only savings in terms of KMPL, the<br />

Drivers Training Programme has also<br />

improved the spirit of NBSTC employees<br />

and management. The Programme has<br />

managed to improve the morale of the<br />

depressed crew as well staff members<br />

through a competitive atmosphere to<br />

achieve higher KMPL as well earning per<br />

km. As a result of the rewarding<br />

competition, the work culture has got a new<br />

life and a positive atmosphere has been<br />

created in the organization.<br />

Putting its savings campaign through<br />

PCRA’s energy conservation workshops,<br />

NBSTC has also launched a full-fledged<br />

austerity drive, cutting electricity costs by<br />

around Rs 3,000 each month.<br />

Incandescent bulbs have been replaced<br />

by energy saving tube lights in most of<br />

the places. The transport utility, where<br />

the power bills ran up around Rs 9,000<br />

each month, has brought it bills down<br />

to Rs 6,000 in the past few months. And<br />

13<br />

active conservation techniques


14<br />

PCRA recently conducted<br />

Investment Grade Energy<br />

Audit (IGEA) at Greater<br />

Visakhapatnam Municipal Corporation<br />

(GVMC) under Municipal Demand Side<br />

Management (MuDSM) program of Bureau<br />

of Energy Efficiency. The study was<br />

conducted in four segments that included<br />

water supply and treatment, sewage<br />

pumping and treatment, street lighting and<br />

municipal buildings. The study covered<br />

more than 35 pumping stations, six water<br />

treatment plants, two sewage pumping<br />

stations, one sewage treatment plant,<br />

60,000 lights and 20 municipal buildings.<br />

The daunting task of collecting historical<br />

data for all the four segments, compiling<br />

and analyzing the data, integrating it with<br />

the present readings recorded was carried<br />

out efficiently by PCRA.<br />

It was found out that the average annual<br />

total power consumption of the urban local<br />

body (ULB) is around 326 lakh kWh of<br />

which 26% of the total consumption is for<br />

water supply and treatment, 8% for sewage<br />

pumping and treatment, 63% for street<br />

lighting and 3% for municipal buildings.<br />

Below is a sectoral analysis carried out by<br />

the auditors who identified the gaps and<br />

suggested recommendations to increase<br />

the energy efficiency at Greater<br />

Visakhapatnam Municipal Corporation.<br />

Water Supply and<br />

Treatment<br />

There are seven sources (called schemes)<br />

of water supply to Greater Visakhapatnam<br />

Municipal Corporation (GVMC) and the<br />

GVMC main building<br />

total water requirement of GVMC is around<br />

256 MLD with per capita water<br />

consumption of 150.44 liters / day with<br />

specific energy consumption of 20.56 kWh/<br />

KL. The major observations that came up<br />

while studying the water supply and<br />

treatment of the city pointed out that:<br />

● Most of the pipelines observed were<br />

very old and heavy leakages were noticed.<br />

● Large numbers of pumps are more than<br />

15 years old and are operated at lower<br />

efficiencies.<br />

● Reverse pumping to Seethammadhara<br />

area could be avoided by slight<br />

modification in the pipelines of Godavari<br />

and Raiwada schemes.<br />

● Capacitor banks were found to be<br />

connected to the main of the incoming<br />

supply and not at the load end and thus<br />

these banks were never turned off even<br />

when the pumps have been switched off;<br />

there by resulting into wasteful<br />

consumption of energy.<br />

● Most of the motors used are very old<br />

and were rewound several times, there<br />

by reducing their efficiency considerably.<br />

Recommendations<br />

● It was suggested to interlink two<br />

schemes (Godavari and Raiwada) of<br />

pipeline at 4,000 KL and 1,500 KL<br />

reservoirs (used for treated water<br />

storage) which are located adjacent to<br />

each other so that water scarcity in one<br />

scheme can be balanced by the other<br />

at this level and reverse pumping can<br />

be avoided.<br />

● It was recommended to connect the<br />

capacitor banks to the load ends for<br />

better current carrying capacity in cables<br />

and also to reduce wastage of power.<br />

● Replacement of old energy inefficient<br />

pumps with new energy efficient pumps<br />

having closest possible mapping of<br />

pump curve to system curve was<br />

active conservation techniques


advised along with replacement of old<br />

energy inefficient motors with new<br />

energy intensive motors.<br />

Sewage Pumping and<br />

Treatment<br />

Currently, only one sewage treatment plant<br />

(STP) of 25 MLD is in operation for the<br />

ULB and Visakhapatnam being on the east<br />

coast, presently either the treated or<br />

untreated sewage is being let out to sea.<br />

The major observations indentified while<br />

reviewing sewage pumping and<br />

treatment are mentioned in the following<br />

section.<br />

Observations<br />

● Most of the pumps used are very old<br />

with very low level of efficiency and so<br />

there was a requirement of replacement<br />

of old energy inefficient pumps with new<br />

ones. Similarly, energy inefficient motors<br />

need to be replaced with energy<br />

intensive motors.<br />

● Surface agitator type aerators were being<br />

used with large capacity of motors.<br />

● Maintenance cost for rewinding of<br />

motors was very high, as the STP is<br />

located on the beaches of Bay of Bengal<br />

where high moisture levels prevail in<br />

atmosphere.<br />

● The treated sewage was being let out<br />

to sea<br />

Recommendations<br />

● Considering the surface aeration with<br />

compressed air for improving the<br />

Biological Oxygen Demand (BOD) of<br />

the treated sewage was recommended<br />

which would also reduce large size<br />

motors being used for agitating the<br />

sewage water. It would in turn also<br />

reduce the maintenance cost for motors.<br />

● It was also advised to reuse the water<br />

with less than 100 BOD for greenery<br />

instead of letting the same to sea, there<br />

by reducing the usage of sweet water.<br />

The specific energy consumption of<br />

sweet water is more than the energy<br />

consumption for pumping water to tank<br />

trucks.<br />

Street Lighting<br />

There are about 60,000 street lights with<br />

2,628 switching points in 72 wards of ULB.<br />

74% of light fixtures are Fluorescent tube<br />

light (FTL), 14% are 150W High Pressure<br />

Sodium Vapour (HPSV), 7% are 70W SVLs,<br />

3% are 250W High-Pressure Mercury-<br />

Vapor (HPMV) and 2% of them are 250W<br />

& 400 W HPSVs. Street lighting is spread<br />

over 533 sq km of the ULB. The major<br />

observations in this case included:<br />

Observations<br />

● All the cutout controls were without any<br />

protection and were dangerously<br />

installed. In many stretches, even the<br />

spacing between the poles is not<br />

maintained<br />

● Energy meters were not properly<br />

protected / installed.<br />

● Due to multiple fixtures at few junctions<br />

and stretches, zebra effect was observed<br />

and in many areas dark patches were<br />

also observed.<br />

● The overall power factor observed was<br />

very low and it ranged from 0.38 to<br />

0.89.<br />

Recommendations<br />

● It was recommended to replace existing<br />

40W florescent tube with high efficiency<br />

lumen output FTL.<br />

● Providing new control panels with<br />

voltage optimizers, PF compensation<br />

and automatic switching to save energy<br />

was advised.<br />

● It was also suggested to provide<br />

microprocessor controlled automatic<br />

street lighting control including dimming<br />

facility at midnight to early hours and<br />

install automatic timer / photocell unit<br />

for saving energy in lighting system.<br />

● It was also recommended to replace:<br />

i. Existing probe start 250W metal<br />

halide with new 200W energy<br />

efficient pulse start metal halide<br />

including energy efficient control<br />

gear.<br />

ii. Existing probe start 400W MH<br />

lamps with new 320W pulse start<br />

MH lamp including energy efficient<br />

control gear.<br />

iii. Existing electromagnetic control gear<br />

with energy efficient electronic<br />

control gear.<br />

iv. Existing electromagnetic choke with<br />

energy efficient electronic choke for<br />

FTLs.<br />

v. 70W HPSVs with 2x24W T5 FTLs<br />

or LED lighting<br />

Buildings<br />

There are about 516 municipal buildings<br />

including offices, dispensaries, schools,<br />

stadiums, community halls, sulabh<br />

complexes etc. Out of these buildings, 20<br />

buildings were hand picked and audited<br />

through each category of building. The<br />

major observations were:<br />

● Lighting in GVMC Buildings is provided<br />

with incandescent bulbs, FTLs and<br />

CFLs. At the museum, 12V 50W<br />

halogen spot lighting were provided for<br />

the exhibits.<br />

● Standard energy inefficient ceiling fans<br />

and exhaust fans were used in almost<br />

all the buildings.<br />

● Most of the split ACs installed were non<br />

star rated.<br />

Recommendations<br />

● The existing halogen spot light at the<br />

museum was proposed to be replaced<br />

with 12V 35W Infra Red Coated (IRC)<br />

energy efficient spot lights with 500<br />

burning hours, existing incandescent<br />

15<br />

active conservation techniques


ulbs with CFLs and standard 40W FTLs<br />

be replaced with 36W high lumen FTLs.<br />

● The existing ballast was recommended<br />

to be replaced with low loss electronic<br />

ballast with less than 10% THD.<br />

● It was suggested to replace standard<br />

energy intensive ceiling fans with star<br />

rated energy efficient ceiling fans.<br />

Table 1: Average of energy savings measures<br />

Description<br />

Annual Savings<br />

(kWh)<br />

Rs.<br />

(in Lacs)<br />

● Responsive automation system was<br />

proposed for Swarnabharati Indoor<br />

stadium for energy efficient operation<br />

and saving.<br />

● And it was strongly suggested to arrest<br />

the air leakages at the entrances and<br />

exits to the indoor stadium by providing<br />

air curtains.<br />

Investment<br />

(Rs. in Lacs)<br />

Simple Payback<br />

Period Months<br />

Pumping 2,514,337 124 170 16<br />

Sewage 21,900 1.03 - Immediate<br />

Building 460,937 31 64 25<br />

Street lighting 8,791,574 353 1,204 41<br />

It is expected that with the implementation<br />

of recommendations, approximately<br />

10,000 CERs can be generated apart from<br />

the huge energy savings.<br />

Summary of Energy<br />

<strong>Conservation</strong> Measures<br />

The sum up of all the ECMs recommended<br />

for the four segments are summarized and<br />

tabulated (Table 1). The average kWh<br />

savings, investments and payback periods<br />

are also shown in the table.<br />

Courtesy: CRC/RC/SRO/Vizag, PCRA<br />

Energy audit in coal mines of Central<br />

Coalfields Ltd – A Perspective<br />

The overall energy bill of Central Coal<br />

Fields, a subsidiary of Coal India Ltd is to<br />

the tune of Rs 400 crores, of which<br />

approximately 50% of energy is consumed<br />

in each on procurement of power and<br />

petroleum products. The consumption<br />

pattern of energy is very much activity<br />

oriented. Open Cast Project calls for high<br />

consumption of <strong>Petroleum</strong> Oil Lubricant<br />

(POL) vis-à-vis underground projects<br />

which consumes lion share of electricity<br />

in operating pumps and fans.<br />

Broadly energy audit in any coal mines<br />

comprises of auditing of opencast and<br />

underground mines in addition to coal<br />

washeries and townships. HEMM (Heavy<br />

Earth Moving Machinery) is the thrust<br />

area in POL consumption and idling hour<br />

minimization is the key to POL<br />

conservation in mines. Equipment wise<br />

study of specific energy consumption of<br />

all POL and measures to do condition<br />

monitoring does help the organization in<br />

plugging wasteful expenses.<br />

Electrical energy audit therefore helps in<br />

understanding power supply and<br />

distribution, power factor optimization, load<br />

management and performance evaluation of<br />

all electrically operated equipments.<br />

PCRA has inherent strength of making the<br />

energy audit impactful due to one to one<br />

interaction with personnel from grassroot<br />

level to the top management and by<br />

converting intangibles to tangible<br />

components.<br />

It is endeavored to highlight at all level,<br />

that the cost implication of each operation<br />

like dumper operation for an hour means<br />

diesel consumption of 30ltrs(approx.)<br />

depicting erosion of Rs 1200, if taken care<br />

of can change the very attitude of the people<br />

and the the organization’s overall business.<br />

PCRA made breakthrough in energy audit<br />

in central coalfields- kathara areacoalmining<br />

sector<br />

PCRA believes in customization of<br />

activities and modules suiting to<br />

customers requirement be it energy audit<br />

or through subsequent training programs.<br />

Keeping customers abreast with the bench<br />

mark is the key to PCRA energy auditing.<br />

The past experiences reveal that the<br />

energy audit yields 10-15% reduction in<br />

energy consumption and even 1% savings<br />

in coal mines translates into savings of Rs<br />

4 crores.<br />

Courtesy: SK Sinha, SRO, PCRA, Ranchi<br />

Email: sinhask@pcra.org<br />

16<br />

active conservation techniques


Firozabad, the glass capital of<br />

India, is a small town in the state<br />

of Uttar Pradesh that accounts<br />

for roughly 70% of the total glass<br />

production in the small-scale sector. The<br />

molten glass, which is required for<br />

manufacturing bangles and other principal<br />

glass products, is melted in a pot furnace<br />

(a circular dome shaped furnace with 8 –<br />

12 pots lined at the periphery that holds<br />

molten glass which operates at a<br />

temperature of around 1,400 0 C). These<br />

pots used for holding the molten glass are<br />

made of a ceramic mixture and are<br />

manufactured locally by various pot makers.<br />

As regular operation characteristic of pot<br />

furnace operation, the pots break inside the<br />

furnace after several days of use.<br />

The number of days of useful pot life inside<br />

the furnace is dependent on several factors<br />

including the colour of glass being<br />

processed inside the pot. For instance, the<br />

red colour glass due to its inherent chemical<br />

properties has most corrosive effect on the<br />

pot surface and subsequently on the pot<br />

life. Therefore, replacement of damaged<br />

pot results in huge energy and monetary<br />

wastage. It’s not just the energy that is lost<br />

as a part of the furnace operating at a high<br />

temperature but also the damage to the<br />

pot inside the furnace results in huge loss<br />

of production since the glass drained out<br />

of the broken pot is wasted. Another<br />

important aspect of the prevailing situation<br />

is that replacement of pots in the pot<br />

furnace is undertaken in extremely difficult<br />

conditions since the operators have to<br />

replace the pot in running furnace and are<br />

thus exposed to extremely high temperature<br />

conditions during the pot changing process.<br />

On the other side, the pot makers are a<br />

marginalized community completely<br />

dependent on pot making as the sole<br />

occupation. The unreliability of pot’s life<br />

in the pot furnace further adds to the gravity<br />

of the situation as in many cases of short<br />

pot life, the pot maker has to bear the<br />

monetary loss of pot breakage.<br />

There had been a long felt need in the<br />

cluster for an intervention which could<br />

facilitate in enhancing the life and reliability<br />

of the pots being used. To address the long<br />

standing issue of unreliable and short pot<br />

life inside the pot furnace and to address<br />

the ever increasing livelihood challenge in<br />

front of pot making community in<br />

Firozabad, Winrock International India<br />

(WII), New Delhi with support from Small<br />

Grants Program of UNDP/GEF, undertook<br />

the challenging project titled “Technosocial<br />

intervention for improving the<br />

reliability of pots in glass melting furnaces;<br />

Potential of huge energy savings, GHG<br />

reduction and sustainability of livelihoods.”<br />

Since the pot makers are a marginalized<br />

link in the overall glass manufacturing chain<br />

and pot making is the sole livelihood source<br />

for the community, therefore, it was<br />

imperative that any intervention leading to<br />

introduction of any sophisticated and capital<br />

intensive technology would lead to<br />

elimination of an entire community from<br />

the glass processing map of Firozabad.<br />

Hence, WII undertook a techno-social<br />

intervention in the Firozabad glass cluster<br />

with following specific objectives:<br />

● Improving the reliability and life of pots<br />

in glass melting furnace<br />

● Sustaining of livelihood of pot makers<br />

community by developing an indigenous<br />

improved pot making process<br />

● Improvement in production output and<br />

specific energy consumption of the glass<br />

melting units by reduction in breakdown<br />

due to pot failure<br />

● Reduction in GHG emissions due to<br />

reduced specific energy consumption<br />

in pot furnace and increase in specific<br />

output by reduction in waste of<br />

glass melt.<br />

Important project<br />

activities<br />

The major project activities that were<br />

undertaken towards achievement of project<br />

objectives include:<br />

● Enlisting of pot makers ers and<br />

conducting socio economic survey at<br />

community level: A survey exercise was<br />

designed and implemented to reach out to<br />

individual pot makers and discuss the<br />

problems and issues faced by them in<br />

technology as well as commercial and social<br />

aspects of day-to-day activities. The survey<br />

result proved extremely useful in<br />

determining the prevailing situation<br />

regarding the socio economic aspects of<br />

pot making as a livelihood source.<br />

● Development of raw material<br />

processing mixer:<br />

The mixer is a new<br />

addition to the pot making process wherein<br />

a single mixer can serve the requirements<br />

17<br />

active conservation techniques


of several pot making units. The design and<br />

development of mixer has been done by<br />

utilizing only the locally available resources<br />

and the equipment has large replicability<br />

potential in the cluster. With the<br />

introduction of mechanized mixing<br />

equipments, the uniformity of various<br />

physical properties across the volume of the<br />

material has been ensured and the duration<br />

of labour intensive manual mixing operation<br />

substantially reduced. For deeper<br />

penetration of developed technology, it was<br />

essential that the principle of operation and<br />

maintenance should be easily graspable by<br />

the target community and thus the<br />

construction and operation of the mixer was<br />

designed in such a way that the technology<br />

could be easily replicated and installed by<br />

groups of pot makers as well as by individual<br />

pot makers. The mixer works on simple<br />

principle of stirring. Table 1 (below) gives<br />

the components list along with their<br />

specification and other particulars<br />

as mentioned.<br />

Initially unloaded mixer<br />

Loading the mixer tank with clay and grog<br />

mixture<br />

The following pictures show the schematics<br />

of mixer operation.<br />

● Manufacture and Testing of Improved<br />

pots in Pot ot furnace: Three batches of pots<br />

were tested in the pot furnace operation<br />

for establishing the useful life realizable<br />

from the improved pots. Each of the batches<br />

was manufactured from the locally available<br />

Loaded mixer in operation<br />

Table 1: Clay mixing equipment component list<br />

Unloading processed mixture from the<br />

mixer tank<br />

Component<br />

Nos.<br />

Specification<br />

Remarks<br />

Electric Motor 1 AC motor, 2 HP rated power To provide motive power<br />

Reduction Gear box and assembly 2 Dia - 100 mm For adjusting the machine rpm<br />

Gear ratio - 1 : 20<br />

Crown Pinion Gear 1 – For transfer of motion from motor shaft to<br />

mixer shaft<br />

Iron pot with cement lining 1 Holding capacity 650 kg To hold soaked clay and grog while churning<br />

Angular blades pair 1 – To create turbulent movement in soaked mixture<br />

for effective mixing<br />

18<br />

active conservation techniques


esources after removing the material and<br />

process related shortcomings in the existing<br />

pot making process. Three different pot<br />

material compositions were identified for<br />

making of improved as well as control test<br />

pots based on various varieties of clay and<br />

grog. The trial and testing activity of the<br />

pots was carried out at the glass processing<br />

unit (bangle making) of M/s Navjeevan<br />

Glass Industries.<br />

The following pictures show the pot<br />

replacement process in the running pot<br />

furnace at M/s Navjeevan Glass Industries.<br />

Achievement and impact<br />

generated<br />

The most important and easily identifiable<br />

indicator of the successful implementation<br />

of activities is the increase in pot life inside<br />

the pot furnace.The outcome of the testing<br />

activity have been highly rewarding in terms<br />

of increase in pot life by more than twice<br />

of the existing average pot life and more<br />

than thrice of the control case provided for<br />

the experiment. The pot life has increased<br />

from the control case of 10 days to the<br />

best result of 31 days and the average pot<br />

life established for processing the red colour<br />

glass now stands at 15 days. It was reported<br />

by the plant management at M/s Navjeevan<br />

Glass Industries that such successful<br />

intervention and improvement in the pot<br />

life has been possible for the first time in<br />

the history of Firozabad glass processing<br />

units. The achievement becomes more<br />

significant and meaningful when seen in the<br />

light of usage of only locally available<br />

materials, workmanship and resources<br />

which can be accessed, implemented and<br />

adopted by the pot maker community from<br />

within their affordable resources.<br />

The improvement in pot life has not only<br />

reduced the monetary losses associated<br />

with frequent pot replacements rather it has<br />

Taking out damaged pot from running pot furnace and transferring new pot inside the<br />

furnace<br />

also made significant impacts on several<br />

issues such as:<br />

● Reduction in GHG emissions which is<br />

directly linked to the reduction in natural<br />

gas consumption by avoiding frequent<br />

replacement of pots in the pot furnace.<br />

● Huge energy losses are associated with<br />

replacement of pots in a pot furnace as<br />

the entire operation is done while the<br />

pot furnace is running at temperature<br />

of over 1,400 0 C, hence increase in pot<br />

life has a proportionate reduction in<br />

these losses.<br />

● Since the pot replacement operation<br />

exposes workmen to very high<br />

temperatures and difficult working<br />

conditions, thus less frequent instances<br />

of pot breakage would also lead to lesser<br />

times the workmen are exposed to high<br />

temperatures inside the furnace and hence<br />

improvement in workplace environment.<br />

● The margins involved in pot making had<br />

been coming down since last several<br />

years resulting into shutdown of many<br />

units but with the improved pots<br />

decreasing the monetary losses incurred<br />

by the end user (glass melting unit), the<br />

pot makers can now demand a higher<br />

price with a higher profit margin for<br />

the same.<br />

The way ahead<br />

The results achieved from the realtime trial<br />

of pots inside the pot furnace have been<br />

compiled and further development and<br />

testing would be conducted for establishing<br />

the most promising method for pot making.<br />

The improved pot making process shall be<br />

disseminated among the community and<br />

the indigenously developed process will be<br />

envisaged to gain wide acceptance within<br />

the pot makers. The development would<br />

not only address the long standing issue of<br />

unreliable pot failure inside the pot furnace<br />

but would also ensure the sustained<br />

livelihood of the pot makers of Firozabad<br />

as many attempts to harness and implement<br />

cost intensive technology from outside the<br />

cluster would take a back seat owing to<br />

ready availability to local resources.<br />

Courtesy: Manish Soni, Program Officer<br />

Winrock International India<br />

Email: manishs@winrockindia.org<br />

19<br />

active conservation techniques


Agroup of 50 Post Graduate teachers from different<br />

Kendriya Vidyalaya (KV) of India recently visited the<br />

<strong>Conservation</strong> Technology Centre (CTC) at PCRA, New<br />

Delhi. During the visit, the teachers were enlightened about several<br />

topics such as energy scenario in India and across the globe, scope<br />

for energy conservation and potential for savings, easy ways to<br />

save energy, barriers to energy conservation in various sectors<br />

and their solution etc.<br />

The teachers were very much enthusiastic to take part in the touch<br />

screen quiz organized by EDP, Department of PCRA and found<br />

the visit to be highly useful in enhancing their knowledge on<br />

energy conservation. The teachers also greatly appreciated<br />

the state-of-the-art ‘<strong>Conservation</strong> Technology Centre’ as well<br />

as the presentation made by Shri G.K. Medhi, Jt. Director,<br />

PCRA.<br />

Some of the comments shared by the teachers, during their visit<br />

to <strong>Conservation</strong> Technology Centre are:<br />

“I felt glad to visit PCRA. I got wonderful tips to save<br />

energy which can ensure that our future generations<br />

can also use these facilities.<br />

Chetna, PGT, K.V, Rohini<br />

“<br />

“<br />

“<br />

”<br />

”<br />

” ”<br />

Visiting PCRA is a wonderful experience and one learns<br />

a lot of new things that can shared in society.<br />

Arvind Kumar, PGT, K.V, Badarpur<br />

PCRA is working for a very noble cause of conserving<br />

nature & natural resources.<br />

Harminder Kaur, PGT, K.V. Patiala, Punjab<br />

The visit was a fruitful experience. Thanks for reminding<br />

the things that we should actually practice in life to<br />

save fuel.<br />

Renu Bala, PGT, K.V, Shimla, HP<br />

20<br />

Shri Mahendra Chandurkar, Asstt. Manager (EDP) (Right)<br />

conducting touch screen quiz competition for the PGT<br />

active conservation techniques<br />

Post Graduate Teachers from different Kendriya Vidyalaya (KV) of<br />

India visited the <strong>Conservation</strong> Technology Centre


W E B S I T E S<br />

http://www.reegle.info/<br />

Reegle, the search engine for Renewable Energy and Energy<br />

Efficiency is home to clean energy information sources which are<br />

reviewed by experts, connecting actors and stakeholders by providing<br />

organisation details, updates of sustainable energy related topics<br />

on a global map. Current and informative, the reegle blog<br />

provides on site reports from the worlds leading events, as well<br />

as commentary on key clean energy issues and informed debate<br />

on related subject matter.<br />

http://www.house-energy.com/<br />

House- energy is a window that takes you through various small<br />

and big energy saving steps that an individual can take so as to<br />

make energy efficient homes. Specially in the wake of climate change<br />

and increasing energy scarcity, it is becoming a compulsion for every<br />

individual irrespective of location to conserve energy. In this scenario,<br />

House-energy provides simple solutions for a secured future.<br />

EVENTS<br />

3 rd International Scientific “Energy<br />

and Climate Change” Conference<br />

Athens (Greece)<br />

October 7-8, 2010<br />

The conference that will be attended by scientists, researchers,<br />

PhD candidates and policy makers from all over the world, will<br />

have sessions oriented towards energy and environment &<br />

climate change. An International Scientific Committee consisted<br />

of members from Greece, EU, BSEC and Central Asia countries<br />

will ensure the quality of the sessions. All sessions will be hosted<br />

at the “New Amfitheatro” of the Central Building of the National<br />

and Kapodistrian University of Athens.<br />

RENEXPO<br />

Augsbur<br />

ugsburg, g, Germany<br />

October 7 – 10, 2010<br />

International Trade Fair for Renewable Energy and Energy<br />

Efficient Building & Renovation is one of the major trade fairs<br />

for renewable energy and energy efficiency in Europe. Due to<br />

its unique variety of topics, it has become the number one<br />

trade platform. The event traditionally features a guest country,<br />

which this year will be Austria.<br />

Further, the RENEXPO is a member of the EU campaign<br />

“Sustainable Energy Europe”. Another international highlight<br />

is the IBEF International Business Exchange Forum where<br />

companies present themselves at a common international<br />

booth.<br />

DIREC 2010<br />

Greater Noida, National Capital Ter<br />

erritor<br />

ritory y of Delhi<br />

October 27-29, 2010<br />

The Delhi International Renewable Energy Conference (DIREC)<br />

2010 will bring together the world’s leaders in the field of<br />

renewable energy from governments, civil society, and private<br />

sector and provide an interactive forum for them to discuss<br />

and exchange their visions, experience, and solutions for<br />

accelerating the global scale up of renewable energy.<br />

21<br />

active conservation techniques


I N T H E N E W S<br />

Cabinet OKs energy<br />

efficiency plan<br />

The Union Cabinet has approved the<br />

ambitious National Mission for Enhanced<br />

Energy Efficiency, one of the eight missions<br />

under the National Action Plan on Climate<br />

Change. The mission is expected to save<br />

23 million ton oil equivalent of fuel and<br />

avoid the need to build additional capacity<br />

of over 19,000 MW.<br />

Speaking after the Cabinet approval, the<br />

Secretary, Ministry of Power said: “This is<br />

a significant development for India. During<br />

the next four years, the mission will help<br />

achieve greenhouse gas emissions reduction<br />

of 98.55 million tons per year.” The mission<br />

will also kick-start the country’s first marketbased<br />

trading in energy efficiency savings.<br />

Just like the international carbon trade, a<br />

domestic trade in energy saving certificates<br />

would facilitate this process.<br />

Source: http://timesofindia.indiatimes.com/<br />

india/Cabinet-OKs-energy-efficiency-plan/<br />

articleshow/6088416.cms<br />

India tops energyefficient<br />

cement<br />

production<br />

With some of the plants operating at the<br />

lowest energy consumption levels, the<br />

Indian cement industry has become a<br />

forerunner in energy-efficient cement<br />

manufacturing in the world, according to<br />

FE-EVI Green Business Survey 2009-10.<br />

Elaborating about the initiatives taken up<br />

by companies, FE-EVI Green Business<br />

Survey 2009-10 quotes numerous<br />

examples. Companies are also taking other<br />

initiatives to minimize their ecological<br />

footprint. These include substitution of<br />

fossil fuels used in cement kilns by fuels<br />

derived from waste, installation of waste<br />

heat recovery system, modification of the<br />

composition of cement by using cement<br />

constituents which require less energy to<br />

produce than cement clinker.<br />

Source: http://www.financialexpress.com/news/<br />

india-tops-energyefficient-cement-production/<br />

629108/<br />

India’s Ajay Mathur<br />

among energy-efficiency<br />

‘visionaries’<br />

Ajay Mathur, Director General, Bureau of<br />

Energy Efficiency (BEE), is one of the energy<br />

efficiency “visionaries” from Africa, Asia,<br />

Europe and South America to be honoured<br />

by the Alliance to Save Energy.<br />

Mathur received the award in Washington<br />

recently during a conference. Mathur is also<br />

a member of the Prime Minister’s Council<br />

on Climate Change and has been involved<br />

in driving India’s market transformation<br />

towards energy efficiency. His work<br />

includes India’s standards and labelling<br />

programme for equipment and<br />

appliances, its energy conservation<br />

building code and programs for industrial<br />

energy efficiency and demand-side<br />

management in the buildings, lighting,<br />

and municipal sectors.<br />

Source: http://economictimes.indiatimes.com/<br />

articleshow/5920414.cms<br />

Berkeley Lab Report:<br />

Simple Energy Efficiency Measures can Eliminate Electricity Shortage in India<br />

22<br />

Electricity in India can be a dicey<br />

proposition. Half the population lacks<br />

access or is too poor to afford it. The<br />

other half is using so much that demand<br />

far outstrips supply, resulting in daily<br />

power outages. As chaotic as things are,<br />

there is a solution: simple energy<br />

efficiency measures, according to a new<br />

report from Lawrence Berkeley National<br />

Laboratory (Berkeley Lab), can eliminate<br />

the electricity deficit as early as 2013.<br />

What’s more, doing so will add $505<br />

active conservation techniques<br />

billion to India’s gross domestic product<br />

(GDP) between 2009 and 2017<br />

(compared to India’s total GDP of $911<br />

billion in 2007-2008), as businesses that<br />

have had to cut back due to electricity<br />

shortages can restore production.<br />

“None of these measures are retrofits; they<br />

are all new sales of items such as light bulbs<br />

and refrigerators. We tried to keep it as<br />

simple as we possibly could—no buildings,<br />

no transport,” said report co-author Jayant<br />

Sathaye, a Berkeley Lab senior scientist<br />

who leads the International Energy Studies<br />

Group in the Environmental Energy<br />

Technologies Division. “Air conditioners<br />

alone are growing at 25% per year in<br />

India. But because of this rapid growth,<br />

you can capture the new sales, sell only<br />

efficient products and make a difference.”<br />

Source: http://newscenter.lbl.gov/featurestories/2010/05/25/energy-efficiencymeasures-can-eliminate-electricity-shortage-inindia/


Call for Papers – <strong>ACT</strong> Journal<br />

The primary aim of the <strong>ACT</strong> journal is information dissemination<br />

on the latest conservation techniques, R&D Efforts and<br />

developments in the field of energy conservation. PCRA invites<br />

you to contribute orginal articles /papers on topics such as<br />

Energy Efficiency, <strong>Petroleum</strong> <strong>Conservation</strong>, R&D Efforts, Energy<br />

Audits, Environment Protection, Technological Improvement,<br />

Renewable Sources of Energy, Inter-fuel Substitution, Policy<br />

Aspects, Implementation Efforts of New Technologies, and Case<br />

Studies.<br />

The paper/s should be of about 2,000-2,500 words (maximum<br />

of 3-4 pages, which would include relevant graphs, charts,<br />

figures, and tables). Further, we also request you to pass on<br />

this information to authors, writers, agencies, who may be<br />

interested in contributing content to the <strong>ACT</strong> journal. Please<br />

send in your papers/articles/case studies/ success stories [hard<br />

copy + CD] with a photograph, at the following address:<br />

The Associate Editor<br />

Active <strong>Conservation</strong> Techniques Journal, PCRA<br />

Sanrakshan Bhawan, 10, Bhikaji Cama Place, New Delhi – 110066; India<br />

Tel: 011-26198856; Fax: 011-26109668; Email: medhigk@pcra.org<br />

HEADQUARTER<br />

PETROLEUM CONSERVATION RESEARCH ASSOCIATION<br />

Sanrakshan Bhawan, 10, Bhikaji Cama Place, New Delhi - 110066; Tel: 011-26198856; Fax: 011-26109668<br />

Email: pcra@pcra.org; Website: www.pcra.org<br />

REGIONAL OFFICES<br />

NORTHERN REGION<br />

EASTERN REGION<br />

WESTERN REGION<br />

SOUTHERN REGION<br />

Email: motwanipk@pcra.org Email: chattorajp@pcra.org Email: prabhakarants@pcra.org Email: shivkumarv@pcra.org<br />

SUB-REGIONAL OFFICES<br />

Dehradun<br />

Bhubaneshwar<br />

Ahmedabad<br />

Bangalore<br />

Email: kaleras@pcra.org Email: mohiniak@pcra.org Email: bariwalvk@pcra.org Email: prasadbvs@pcra.org<br />

Jaipur<br />

Guwahati<br />

Bhopal<br />

Kochi<br />

Email: kumars@pcra.org Email: bhutiakl@pcra.org Email: dasa@pcra.org Email: kumarg@pcra.org<br />

Lucknow<br />

Ranchi<br />

Nagpur<br />

Vishakhapatnam<br />

Email: dwivediv@pcra.org Email: sinhask@pcra.org Email: srivastavaa@pcra.org Email: pathibl@pcra.org<br />

Raipur<br />

Email: tiwarin@pcra.org<br />

Published by <strong>Petroleum</strong> <strong>Conservation</strong> <strong>Research</strong> <strong>Association</strong>, Sanrakshan Bhawan, 10 Bhikaji Cama Place, New Delhi - 110066; India<br />

Produced by Winrock International India, 788 Udyog Vihar, Phase V, Gurgaon - 122001; India<br />

Printed by Kriti, B-279, Okhla Industrial Area, Phase 1, New Delhi -110020; India

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