TATA MOTORS LIMITED - JAMSHEDPUR

CII – NATIONAL AWARD FOR EXCELLENCE IN ENERGY MANAGEMENT 2018

TATA MOTORS LIMITED - JAMSHEDPUR

Copyright, Confidential, Tata Motors Limitedc

FAC

ILIT

IES Manufacturing facility

600 acres

Integrated township of

over 1250 acres

PR

OD

UC

TS

Over 200 models :

Multi axle Trucks

Tippers

Trailers - Tractors

Defense Vehicle

GR

EEN

C O

FIRST COMPANY IN

EASTERN INDIA ”

TO ACHIEVE THE

PRESTIGIOUS

“GREENCO GOLD”

RATING

CLI

MA

TE

CH

AN

GE

SIGNIFICANT REDUCTIONS :

Sp. Carbon Footprint: 31%

Sp. Water Consumption : 37 %

Energy Cost % of Manuf. cost:

58%

INC

EPTI

ON

1954,TML established

its first state of art

manufacturing facility

which can roll out

medium or heavy truck

every 05 minutes

JOURNEY OF TATA MOTORS JAMSHEDPUR


CA

B F

AB

RIC

ATI

ON •FABRICATION

LINES – LP, EDAG, SFC, TILT CAB, PRIMA

•CAB TRIM LINES

•CAB STORAGE

PAIN

T SH

OP •PT CED SETUP

•PAINT KITCHEN, CHILLER PLANT, DM WATER PLANT

•COLOR LINES, ROBOTIC PAINTING & BAKING

FOU

ND

RY •MOULDING LINE

•MELTING LINE

•CORE MAKING AREA V

EHIC

LE A

SSY •PRIMA TRIM

LINE

•VEHICLE FACTORY – I & II

•FORCED DRAFT VENTILATION (FDV’s)

FRA

ME

SHO

P

•5000 TON PRESS

•LM PTCED SETUP

•FRAME ASSY. LINE

•FRAME PAINTING, BAKING, STORAGE

ENG

INE •CYLINDER HEAD

& BLOCK LINE

•CRANK SHAFT / CAM SHAFT MACHINING & HARDENING

•ENGINE ASSEMBLY & TESTING

KEY PROCESS FACILITIES AT TATA MOTORS JAMSHEDPUR


• Governance Policies

• Accountability – ENCON TEAM

• Financial Resources

• Energy Performance

• Carbon Footprint reduction

• Waste minimization

• Process improvements

• Energy Kaizens

• Suggestion campaigns

• Awareness Programmes

• Training & Capability Building

• Green Company Rating System

• ISO 50001

• ISO 14001

• GHG Protocol

OUR APPROACH TO GREEN MANUFACTURING

LEADERSHIPPEOPLE

INVOLVEMENTSYSTEMS &

FRAMEWORKRESULTS

COMMITTMENT PROCESSES ENGAGEMENT OUTCOMES


Increase awareness for Energy

Efficiency & Conservation

Select & Purchase Eco

friendly technologies,

products & services

Minimizing GHG

emission

Use of Renewable

Energy

Minimizing & Eliminating

Waste

Commitment to Energy

performance improvement

ENERGY MANAGEMENT – GOVERNING PRINCIPLES

ELECTRICITY

FUEL OIL

GASES

WATER

ENVIRONMENT


TS 16949

OHSAS 18001SA 8000

ISO 50001

GREEN CO - GOLD

ISO 14001

MANAGEMENT SYSTEMS

CERTIFICATES


ENERGY MANAGEMENT – TEAM SETUP

ENERGY LEADS

(MANUFACTURING)

• FRAME

• ENGINE

• VEHICLE

• CAB & COWL

• FOUNDRY

• PRODN. ENGG.

• UTILITY SERVICES

• CENTRAL MAINT.

SUPPORT SERVICES

• HR & TRAINING

• TRANSPORT

• PLANNING

• CANTEEN SERVICES

• PROCUREMENT

• SUPPLY CHAIN

• LEGAL SERVICES

ENVIRONMENT & ENERGY MANAGEMENT CELL

HEAD – PROD. LINE OPERATIONS(MR – ISO 50001)

Structured Team Approach Monitoring & Measurement Periodic Reviews Learning & Sharing


68

32

ENERGY PROFILE (GJ) :TML JSR2017-18

KWH% Fuel%

JAMSHEDPUR PLANT : ENERGY PROFILE


TML -JSR

ELECTRICAL ENERGY

THERMAL ENERGY

PROPANE / LDO

MOTORS

•Interlock to prevent idle losses

•VFD across blowers/pumps

•Capacity

optimization by

Energy audit

•Energy Efficient Motors

HVAC

•Screw type Chiller

• 5 Star Rated AC

•Micro processor based operation of Chillers

•Scheduling the operation of group of chillers

•Increasing the operating efficiency by Energy audits

COMPRESSED AIR

•Screw Air Compressor

• Portable Air Compressor

•Compressed Air leakage audit

•Air Boosters

•Air cut off valves

LIGHTING

•LED Lights for various applications i.eManufacturing , Offices ,Street Lights

• Energy audits to reduce idle energy consumption

•

OVEN/ FURNACE

•Fuel Saving Device ( Max Fluxiox)

•Flue Gas Analysis

•Heat Loss reduction

•Direct fired Heating System

•Substitution of LDO from Propane

AQUA THERMIC HEATER (ATH)

• Substitution of LDO from Propane

•Flue Gas Analysis

TML ENERGY SAVING INITIATIVES SNAPSHOT


Online Training Module

CLASS ROOM TRAINING

Green School Rating System

Expert Hour Session on Energy Efficiency

Unique Suggestion Scheme

Cross Functional Team on ENCON

IDEA Generation Workshops

More then 4500 no’s of ideas generated over last 03 years

ENCON CULTURE - PEOPLE INVOLVEMENT

Solar Thermal System for LMPTCED Process

KEY

ENCON

IDEAS

• Maximizing the use of Air circulators

• Waste Heat Recovery at CPS

• Maintaining Compressed Air Leakage with in 8%


IT ENABLED - ON LINE ENERGY MANAGEMENT


ENERGY PERFORMANCE REORTS - SAMPLE

Div. Review

EnMs Core Team Review

Energy Audit Team Review

MR Review

VCC Review

Head- JSR Plant


Best Practices in Energy Conservation

Energy

Culture

Energy Policy & ISO 50001 Apex Manual for JSR Plant

Policy

Tips on Energy Saving

Ideas

Energy Saving Action Planning Matrix

Action

Energy Performance Analysis reports

Specific Energy Performance Trends

Analysis

Best Practices in Environ. Conservation

Env.

Culture

Environmental Policy & ISO 14001 Apex Manual for JSR Plant

Policy

Legal Register

Legal

Environmental rules & Regulations

Rules

Industrial Waste Mgmt. Bio-medical Waste Management

Waste Mgmt

All Energy

related

information on

the Energy Web

ONLINE PORTAL : ENERGY AUDIT & ENV. MANAGEMENT


•Sensitizing Mindset for Low Carbon Manufacturing

•Process modification / changes for improved energy efficiency

•Energy Saving in Compressed Air Generation & Utilization

•Increased use of Automation for achieving Energy Saving

•Capacity Utilization / Shift Optimization

•Adoption of Green Lighting Solutions like LEDs

•Energy Optimization in Air-conditioning & Comfort Cooling systems

•Usage of energy efficient / Star rated equipment

•Saving in Fuel Cost – Alternative Fuel / Process Modifications

•Explore feasibilities of Heat Recovery Systems

•Waste Utilization – 3R ( Reduce, Reuse & Recycle)

•Use of non-conventional energy sources like Solar & Wind Power

KEY FOCUS AREAS


2015-16

PROJECTS – 14 Nos.

INVESTMENT - NIL

SAVINGS – Rs. 158.40 LAKHS

2016-17

PROJECTS – 16 Nos.

INVESTMENT - NIL

SAVINGS – Rs. 60.79 LAKHS

2017-18

• PROJECTS – 10 Nos.

• INVESTMENT - NIL

• SAVINGS – Rs. 41.40 LAKHS

2015-16


• INVESTMENT – Rs. 58.2 LAKHS

• SAVINGS – Rs. 79.40 LAKHS

2016-17


• INVESTMENT – Rs. 710 LAKHS

• SAVINGS – Rs. LAKHS 517

2017-18

• PROJECTS –Nos. 25

• INVESTMENT – Rs. 400 LAKHS

• SAVINGS – Rs.151 LAKHS

SUMMARY OF ENCON PROJECTS


ELIMINATION of CHILLER UNITS BY EFFICIENT COOLING SYSTEM



Operating Electrical Load (kW)

Cooling Tower Pump :14.9 kW

Chiller Unit for Straightener -01 : 06

Chiller Unit for Straightener -02 : 09

Chiller for Plate Turnover device : 06

CT Fan: 3.73 kW

Total Load (kW) : 39.63



Operating Electrical Load (kW)

Cooling Tower Pump :14.9 kW

CT Fan: 3.73 kW

Total Load (kW) : 18.63

Energy Savings (kW) = 1.36 Lakhs

Carbon Foot Print Savings (tCO2) = 112


BEFORE

DIRECT FIRED SEALANT OVEN SYSTEM

SEALANT APPLICATION SEALANT CUTTINGSEALANT OVEN


AFTER

DIRECT FIRED SEALANT OVEN SYSTEM

Fuel Saving: 122 MT

Carbon Foot Print Red.

335 tCO2

Better Combustion

Efficiency

Space

optimization


AFTERBEFORE

• Scrap is converted to molten state by the

medium frequency furnace to provide the

molten liquid metal to molding line.

• This medium frequency furnace has following

specifications.

• Power- 4000kw ,Voltage:-1150V (down from

6600v to 1150 by furnace transformer

• Capacity: 5MT/HR

• Operational performance : 567 kWh/ LMT

• Operational performance : 548 kWh/ LMT

• Improvement in operational performance : 19 kWh/LMT

• Annual Energy savings realized (kWh) : 38000

• Reduction in carbon footprint: 312 tCO2e

• Monetary savings realized: Rs. 22 Lakhs

PROVISION OF SWIVELING LID TO INCREASE OPERATION EFFICIENCY


INSTALLATION OF LIGHT PIPES

BEFORE AFTER

LUX LEVEL162

LUX LEVEL324

LUX LEVEL221

LUX LEVEL312Benefits

realized:

Annual Energy Savings (kWh) : 39134

Reduction in tCO2 = 32


OPTIMIZING FDV ENERGY CONSUMPTION

FDV Study

Worn Out Celdek Pads Worn out PartsPresence of vents at utilized areas

Duct Leakages

Uses Uses

Losses Losses


Benefits:Energy Savings: 4.29 Lakh kWh

Reduction in Carbon Footprint : 352

OPTIMIZING FDV ENERGY CONSUMPTION


150 W Vehicle Assembly Area

36W Office Lights

ENERGY EFFICIENT LED LIGHTS

72 W LED Column Lights

150 W O/H LEDPress Shop

18 W LED Tube lightsFrame Assembly Shops

Benefits:Total number of units : 3645

Energy Savings: 4.19 Lakh kWhReduction in Carbon Footprint : 345


Automation done for auto switch ON/OFF

Annual Energy Saving: 70000 kWhAnnual Carbon Foot Print Savings : 57

Annual Monetory Savings Rs. 4.62 Lakhs

TIMER CIRCUIT TO REDUCE THE LIGHTING CONSUMPTION


OPTIMIZING THE LIGHTING LOAD

Annual Energy Saving: 50000 kWhAnnual Carbon Foot Print Savings : 41

Annual Monetary Savings Rs. : 3.32 Lakhs

• Removal of Extra Light fittings from assembly line

• Idea Generated by SDT Team

• Idea verified by Energy audit team

• Zero Investment Project

• Lux level for working area maintained at desired level

KEY POINTS


Purchase of only LED

lights for every new

project

Purchase of only 05 Star rated

equipment

Incorporation of

Energy Efficient Motor during design stage

Increase use of Solar

Energy by Light Pipes

Maximize use of

Variable Frequency

Drive

Low Carbon

Manufacturing by Green Supply Chain

SUSTAINABLE INITIATIVES


Use of VFD ‘s for Pumps & Blowers

on Variable Loads

Maximize use of Energy Efficient LED

lights

Maximize use of natural light by

Solar Light Pipes

Maximize use of portable air

compressors

Maximize use of air circulators in

place of Man Coolers

Conversion of indirect fired oven to

direct fired ovens

Maximize the use of waste heat for pre

heating

Maintaining burner operation on low

mode during non productive hours

Improving burner efficiency by flue gas

analysis

Reducing heat losses by conduction

insulation survey

ENERGY PERFORMANCE TRENDS


Utilization of treated effluent water

Rain Water Harvesting

Root Zone Treatment

Use of GIS mapping for underground water pipe

leakage detection

Use of Water Efficient technologies

Energy Efficient Lighting i.e. LED’s

Indirect to Direct Fired Heating System

Reduction of wastages from energy audits, Kaizen

Use of Water Efficient technologies

Spreading awareness on Environment & Energy

Shift optimization as per production

43% reduction over last 03 years 38% reduction

over last 03 years



BETTER

58% reduction over one decade



EXTERNAL BENCHMARKING


INTERNAL BENCHMARKING


• Migration from Conventional LDO to Propane

• Installation of Organic Waste Converter

• Implementation Paint Sludge Recycling

• Converting Incineration Ash & ETP Sludge in to Non-hazardous Paver Block

• Implementation of Employee Bus Service

CARBON EMISSION REDUCTION PROJECTS

• Ambient Air Quality Monitoring

• Value from Waste Initiative

• Waste Water Treatment Plant Unit – A & B each of (2500 m3/day) , as part of Zero Liquid Discharge Plan

• Awareness Session for Vendors on “Climate Change & Environmental Sustainability”‘

• Celebration of “Tata Sustainability Month” in June’18 – Tree plantation, Seminar on Climate Change, Sit & Draw, Poster making

• Two day Exhibition on Eco-friendly and energy efficient appliances during Energy Conservation Month celebration at TRC on 14th – 15th Jan’18

KEY ENVIRONMENTAL INITIATIVES

ENVRIONMENT CONSERVATION & CARBON EMISSION REDUCTION INITIATIVES


CARBON FOOTPRINT REDUCTION

YARD-1: 2600 tCO2e / Year

PROPANE INSTALLATIONYARD-1 (09-10) : 2 x 100 MT YARD-2 (11-12) : 3 x 150 MT

CARBON FOOTPRINT REDUCTION

YARD-2: 5500 tCO2e

AREAS COVERED

(a) Baking Ovens

(b) Heat Treatment Furnaces

IN PROGRESS

(a) Stress Relieving Furnace

(b) Forging Furnace

(c) Aqua-thermic Boilers

CLEAN FUEL: MIGRATION FROM LDO TO PROPANE


ACTIONS

• INSTALLATION OF TURBO-VENTILATORS ON ROOF TOPS FOR EXHAUSTING THE HOT FUMES / AIR & DECREASING LOAD ON VENTILATION SYSTEMS

INSTALLED • OVER 500 Nos.

PROJECT DETAILS

•ENERGY SAVING – Rs. 3.75 LAKH KWH

•INVESTMENT – Rs. 11.09 LAKHS

•SAVING – Rs. 13.31 LAKHS / ANNUM

CARBON REDN.

• 315 tCO2e

HARNESSING WIND ENERGY


Fig (a): Solar Water Heater in Guest House

Fig (b): Solar Water Heater in Canteen

UTILISATION OF SOLAR ENERGY FOR 100% WATER HEATING IN WORKS CANTEEN, HOSTELS, CLUB, HOSPITAL & GUEST HOUSE

SAVINGS- 200 tCO2e/Annum

• Solar Water Heating System

HARNESSING SOLAR ENERGY


ENVIRONMENT MONITORING SYSTEM

Continuous (Real-time) Ambient Air Quality Monitoring System (CAAQMS) has been installed to measure

the real time status of critical ambient air quality parameters i.e. PM10 , PM2.5, CO, NOx & SO2 and the recorded

parameters will be uploaded online to Jharkhand State Pollution Control Board – Ranchi Office server , CPCB

site and at our Main Gate Display screen (Public domain)

HIND-033

Cylinder Head Spray Painting Station After Painting

WASTE UTILIZATION

PAINT SLUDGE

BEFOREPaint Sludge sent for disposal through Co –

Processing

AFTERPaint Sludge sent for

recycling to make casting sealer grey

Benefits

(a) Savings in Casting Sealer Grey

procurement : 36 KL(b) Better utilization of

waste generated(c) More value realized

from paint sludge

HIND-033WASTE UTILIZATION

BEFORE

Earlier the red/ blue colorplastic Cap comes with everyBS4 silencer and was disposedas waste. 1:1 replacement of

aluminum cover forelectrical socket 220 volt. BENEFITS:

Reduction in procurement ofElectrical Socket (no’s): 3000Monetary Benefits : Rs. 1.56 Lakhs

PROPOSED AFTER


FIG (A): INDUSTRIAL INCINERATOR (LRD-250)

FIG (B): HEAT RECOVERY CHAMBERS

INCINERATION ASH UTILIZED FOR MANUFACTURING PAVER

BLOCKS

Fig (a): Handling Incineration Ash

Fig (c): Paver Blocks for various applications

Fig (b): Manufacturing Paver-blocks using Incineration ash

HEAT RECOVERED FROMINCINERATOR IS USED FORREMOVAL OF PAINT DEPOSITION ONGRILLS (GENERATED FROM CPS ANDOTHER PAINTING AREAS)

More Then “04 Lakhs”Paver Bricks manufactured in

last 05 years

WASTE UTILIZATION


Fig (a): Bio-Gas Plant Fig (b): Bio-digester Unit

BIO-GAS PLANT USING KITCHEN WASTE

CAPACITY – 150 KG

BIO-GAS – 12 CU. MTR./DAY

GHG REDN. - : 43.8T CO2e/Year

WASTE UTILIZATION


Fig (a): Organic Waste Converter

Fig (b): Compost Curing System

Fig (c) Organic Compost

CONVERSION OF CANTEEN

AND GARDEN PRUNING

WASTES INTO ORGANIC

MANURE

WASTE UTILIZATION


HARVEST : 200 MG/Yr. (About 17% of Water Consumption)

OTHER BENEFITS: Saturate the drying aquifers of Plant & surrounding areas

Over “12 lacs m3”of Rain Water Harvested in last

03 years

WATER CONSERVATION


Commissioning of Waste Water TreatmentPlant (WWTP- Unit A & B) near Rain WaterHarvesting:

• Capacity - 2500 m3 / Day X 2

• Convergence of Channel 2, 3, 4 , 5 & 6

WATER CONSERVATION - TOWARDS ZLD


ENCON – FUTURE ROAD MAP

2018-19

2019-20

2020-21

• 2.5 MW Solar Roof Top System

• 500 kWp Solar Thermal System

• Light Pipes :62 No

• Phase :01Replacement motors (20 kW and above) with EEM

• 100 % FDV operation by VFD

• Phase :02 Replacement motors (20 kW and above) with EEM

• Installation of Flux Maxiox to all propane fired ovens

2021-22

• Waste Heat Recovery System to CPS

• Replacement of reciprocating chillers with screw chiller for AC Plants


Energy Conservation Oath

School Energy Quiz

Inter Divisional Energy Quiz Competition – Manf. & Manf. Support Divisions

Energy Idea Workshop

Exhibition on Energy Efficient Products

AWARENSS CAMPAIGN


AWARENESS

• Climate Change & Energy Conservation awareness module shared with 82 vendors, contractors, service providers

• Total participation: 4946 till March ‘18

CARBON FOOT PRINT

MAPPING

• Educating vendors to map their own Carbon Footprint

• Carbon footprint mapping and abatement measures suggested to 126 Nos. vendors till June-18

TRAINING

ENERGY AUDITS

•Conducting regular Energy audit to stop idle wastage during Lunch time & Shift Change Over

•Regular thermal insulation survey & surface heat loss audit

Facilitate Vendors to adopt Energy Management System (ISO-50001)

Facilitate & Hand Holding to suppliers to adopt GREENCO RATING SYSTEM (TML Drivelines) : GOLD RATING ACHEIVED

Suppliers visit to TML- JSR plant for learning & sharing of best practices in Environment & Energy Management

Awareness session on “Sustainable

Supply Chain” , 21th June ’18

Speaker : Mr. Abhay Pathak

( Corporate Lead- SHE &

Sustainability) Tata Motors Limited

BEST PRACTICES ON ENERGY FRONT AMONG VENDORS / SUPPLIERS


Heat Recovery from Chiller System for CO2 Vaporizer ( Annual Savings : 28470 kWh)

Installation of Variable Frequency Drives

(Annual Savings : 4284 kWh)

Energy Efficient LED lights in place of

Metal Halide ( Annual Savings : 52560 kWh)

Modification of Cooling tower filtration system( Annual Savings : 42340 kWh)

BEST PRACTICES ON ENERGY FRONT AMONG VENDORS / SUPPLIERS

Yazaki India Ltd

Tata Auto Comp. Ltd

Caparo Engineering India Ltd

Steel Strips & Wires Ltd

TML Drivelines Ltd


Tata Motors – Jamshedpur Plant won “First Prize – Automobile

Manufacturing ” in National Energy Conservation Award 2017 ,

BEE, Ministry of Power

ACCOLADES


Winner, Environmental Award 2018 by

Jharkhand State Pollution Control Board

Tata Motors – Jamshedpur Plant has

bagged the first prize for Good Green

Governance at the SRISHTI AWARDS’2017

TML – JSR adjudged Excellent Energy Unit in CII -National EnergyAwards for Excellence in Energy Management, 2016

ACCOLADES

TML – JSR won GREENCO “GOLD”AWARD , June 2015‘

TATA MOTORS LIMITED - JAMSHEDPUR

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