Green Power International’s Commitment to Sustainable Power Solutions at PI Industries
PI Industries Limited (PI) is an Agri-sciences company with strong presence in both domestic and export markets founded and incorporated by the name Mewar Oil & General Mills Ltd in 1946. The company has three manufacturing facilities in Gujarat and a research & development center at Udaipur. The manufacturing facilities include 5 multi-purpose plants at Panoli and 3 multi-purpose plants at Jambusar and dedicated high-pressure reaction facilities equipped with futuristic automation. In addition, with two formulation units at Panoli.
PI Industries, Panoli, Gujarat, India
PI Industries’ commitment to technical excellence is evident in its manufacturing Control System (DCS) plant, while Jambusar features three fully automated DCS plants equipped with cutting-edge technology and infrastructure. These facilities, combined with a dedicated granulation and formulation plant, position PI Industries as a leader in the agrochemical manufacturing sector.infrastructure. The Panoli facility boasts four manual and one fully automated DCS plant.
One of PI Industries’ key priorities is environmental sustainability. The company has implemented a comprehensive waste management system at its manufacturing facilities in Panoli and Jambusar. This includes an Incinerator, Effluent Treatment Plant (ETP), and Multiple Effect Evaporator plants, ensuring responsible disposal of waste and minimizing environmental impact.
GPI’s Exceptional Operational & Maintenance service
We, Green Power International Pvt. Ltd have installed 4.288 MWe Natural Gas Genset based Power Plant with complete balance of plant. The MWM Gas engine TBG 620 V16K & TCG2020V16K Gas engine, each output of 1364 kW was installed and commissioned in 2003 & 2004 respectively. Third Gas Genset TCG2020V16 @ 1560 KW was installed & commissioned in 2010 and successfully completed 84288 R/hrs as on date. GG No.2 TCG2020V16K had completed 100,000 Running hours on 04 July 2023.
Green Power International Pvt. Ltd. has been awarded an operational and maintenance contract around the clock from 13th December 2003 to till date.
PI Industries run their critical plant load on three engines with synchronized island mode with an average of 85 % load since the commissioning of the engine till July 2022. Gas engines running hours as on date are: –
- GG No.1 – 97813 hrs
- GG No. 2 – 102058 hrs
- GG No. 3 – 84288 hrs
Reliability and Continuity During Covid-19:
For reliability of the Genset, Green power service team is continuously providing service support 365 days @ 24 X 7, the facilities operated at a utilization level of 100 percent throughout the COVID-19 lockdown period. Thus, PI Industries was able to continuously supply essential Agrochemicals products to the entire nation.
Uninterrupted power supply is crucial, particularly in industrial production, like for agrochemical manufacturers and sensitive chemical formulations. They heavily rely on steady power and suffer greatly from outages. A cogeneration power plant, designed for island-mode operation, guarantees secure and reliable power, using engine exhaust heat for heating.
Over 20 years, Green Power Team has conducted 18 major maintenance tasks for all 3 GGs, including complete overhauls. GG No. 3’s overhaul (E-70 maintenance) took place at Green Power International’s Noida Factory Works. The MWM gas engines, ranging from 1364 to 1560 kW, meet diverse application needs with efficiency, reliability, flexibility, eco-friendliness, low total cost of ownership (TCO), and high profitability.
FELICITATION CEREMONY ON COMPLETION OF GG NO. 2 100,000 RUNNING HRS
To commemorate the achievement of 100,000 running hours for GG No. 2, GPI organized a felicitation ceremony at PI Industries’ Panoli facility on 20 Mar 24. The ceremony recognized the dedicated efforts of the operational and maintenance team in ensuring the reliability and performance of the power plants. We had the privilege of celebrating a remarkable achievement with MWM Territory Manager Mr. Nazmi Tanis, our valued PI customers Mr. Pravesh Kumar Garg & his team and our GPIPL operational and maintenance team for attainment of 100,000 operating hours with our MWM Gas Genset TCG 2020V16 K
The ceremony was organized to recognise and honor the remarkable efforts put forth by our team members on attaining the significant milestone.
At Green Power International, we aim to constantly strive to evolve and expand our outreach to cater to our organizational objectives. We are proud to commemorate this occasion by honoring the team that worked tirelessly and with utmost determination towards the Operation & Maintenance of GG Sets.
GG NO. 3 E- 70 MAINTENANCE
Green Power’s GG No. 3 E-70 underwent major maintenance from Dec 01, 2020, to Feb 02, 2021, by our skilled in-house team. The engine was transported to Noida, Uttar Pradesh, for the maintenance work.
The below activities were carried out as part of the maintenance: –
- Removal of crankshaft, measurement of dimensions and replacement of all main bearings.
- Removal of both banks camshaft , measurement of dimensions and replacement of Valve tappets & camshaft bush.
- Replacement of all 16 Cylinder liners.
- Repairing of connecting rod big end bearing bores and replacement of connecting rod bushes, bolts & bearing assembly.
- All pistons were replaced with new ones.
- All cylinder heads are fitted after replacement of valve seats, valve guides with “O” rings and Valves.
- Replaced the Lube Oil Pump with supporting spares.
- Replaced the flywheel adapter and flange both with a new slip ring & lip seal. Measured the thrust end play found within limit.
- Inspection and replacement of drive gears arrangements.
Engine was assembled at the Noida workshop and thereafter safely transported back to site. The engine was coupled with an alternator. After thorough mechanical and electrical checks, a successful full load trial was conducted on 19 Feb 2021, with all parameters operating within normal limits.”
PI Industries’ partnership with Green Power International exemplifies the synergy between technical expertise, environmental responsibility, and operational excellence. As PI Industries continues to innovate and grow, its commitment to sustainable power solutions remains unwavering, setting a benchmark for the industry’s future.
