ENERGY SAVING - AUTO MOBILE PLANT CASE STUDY
TELCO plant at Jamshedpur ,Jharkhand
Unit Profile
Tata Engineering (Telco) is leading automobile giant in the country having its manufacturing units located at
Jamshedpur, Luknow and Pune. Tata Engineering which enjoys nearly 62.5% market share in commercial
vehicle sector had a turnover of Rs. 8918 crores during 2001-02. The unit at Jamshedpur which is the mother
unit manufactures Medium and Heavy Commercial Vehicles from 8 to 40 ton gross vehicle weight. Having an
installed capacity of 60,000 vehicles, the unit produced 37,551 vehicles during the year 2001-02 in keeping with
the cyclical nature of demand in commercial vehicle industry.
The Automobile unit at Jamshedpur has captive Forge and Foundry divisions which meet its requirement of all
critical steel forgings and alloy iron castings. In order to achieve greater efficiencies and world class
technological edge in its aggregate production, the manufacture of Axles and Gear Boxes have been
de-integrated and formed into separate companies as HV Axles Ltd and HV Transmissions Ltd.
The unit has a township for its employees and supports community services as a part of its social responsibility
towards its employees and local community.
Energy Consumption
Even though total energy cost has increased during the last three years due to increasing rates for power and
fuel oil, with the implementation of energy conservation measures, the specific consumption of all areas - Auto,
Foundry and Forge divisions has been steadily declining. Last three years specific energy consumption figures
are as shown below:
PRODUCT DESCRIPTION UNIT 1999-00 2000-01 2001-02
Automobile chassis Electrical energy 647 629 596
Thermal energy kCal / Eq. Vehicle 0.454 0.443 0.411
Casting Tonnage Electrical energy KWH / MT 2371 2305 2108
Thermal energy MkCal / MT 0.437 0.417 0.393
Forge Tonnage Electrical energy KWH / MT 760 681 655
Thermal energy MkCal / MT 4.04 3.63 3.52
Total Energy Cost Rs. Lakhs. 8018 8708 9087
Energy Conservation Commitment, Policy and Set up
Energy Conservation has been a top management priority for the unit for the last three decades. The priority
emerged either from national perspective to fight energy crisis in seventies and energy shortages in eighties and
early nineties, to present day customer-driven need for cost efficiency.
An Engineering Audit group was created in 1983 which co-ordinates the energy conservation activities in the
plant.
Awareness & involvement of people at all levels has been a major plank for implementation of energy
conservation measures. Energy auditing is a function of the Engineering Audit group. Every year targets are set
for the various divisions & energy conservation action plans are worked out. The specific energy consumption &
status of action plans is reviewed with divisional coordinators using a common matrix which is shared across all
divisions and areas to facilitate cross-pollination of ideas.
Specific consumption of each area is monitored by Engineering Audit on daily basis & is shared with each
divisional head / divisional coordinator as well as the top management.
ENERGY CONSERVATION TEAM SETUP
Energy Conservation Achievements
During the period 1999-00 to 2001-02, the Jamshedpur Plant implemented Energy Saving Ideas generated
through regular energy audits, brainstorming & reviews. The major measures implemented during 2001-02 are
given below.
(I,II) Changeover to lower wattage energy efficient lamps for lighting in the plant & in Township.
(III) VFDs were installed at 9 locations as a strategy to reduce energy consumption of pump & blower motors.
(IV) 150 nos. of translucent roof sheets were installed in different areas to facilitate use of natural daylight in
place of high bay lights during the daytime.
(V) Various simple devices like timers, time-switches, interlocking etc. were installed on machines &
equipment thereby reducing idling of drive motors.
(VI) Use of thermal heating in place of electric heating resulting in saving in energy cost.
(VII) Efficient heat utilization in energy intensive furnaces & equipment by use of various measures like
improving insulation, right-sizing of chambers, using temperature controllers etc.
(VIII) Improve loading of transformers resulting in disconnection of 20 nos. of low loaded transformers thus
reducing losses.
(IX) Optimising supply voltage for lighting in the Township.
(X) Process changes like reducing one shift working due to cycle time improvement of pre-treatment process
before ED in painting.
(XI) Various improved work practices like ensuring scheduled running of ATH thermic fluid boilers in paint
shop.
(XII) Replacement of 3 nos. inefficient pumps in Town Filter Plant.
(XIII) Saving in compressed air energy by regular audits & correction of leakages from 29% to 15%; installing
of 16nos. flow meters for monitoring in all areas.
Energy Conservation Plans & Targets
Jamshedpur unit of Tata Engineering is committed to further improve its energy performance by exploring new
avenues for energy saving on a continuous basis. Some of the major proposals as a part of future plan for
energy conservation are:
(1) Changeover of electric frame painting baking ovens to thermal baking for achieving cost advantage in
energy.
(2) Install Cellulose pads in place of spray type air washer in Air Replacement Plants in paint shop.
(3) Installing VFDs in New Engine Cooling Tower & other identified areas to save power.
(4) Phased replacement of metallic blade of small man-cooler in shops by FRP blades.
(5) Modifying & improving furnaces for more efficient heat utilisation in Forge.
(6) Conversion of existing electric cooking into LPG based cooking in Central Canteen.
(7) Installing Solar Water Heaters in Hospital Canteen.
(8) Covering more shop areas for natural day-lighting by installing translucent roof-sheets.
(9) Reducing degreasing bath temperature in paint shop.
(10) Cover all major furnaces for Flue Gas Analysis.
Source : Bureau of Energy Efficiency,India
TELCO plant at Jamshedpur ,Jharkhand
Unit Profile
Tata Engineering (Telco) is leading automobile giant in the country having its manufacturing units located at
Jamshedpur, Luknow and Pune. Tata Engineering which enjoys nearly 62.5% market share in commercial
vehicle sector had a turnover of Rs. 8918 crores during 2001-02. The unit at Jamshedpur which is the mother
unit manufactures Medium and Heavy Commercial Vehicles from 8 to 40 ton gross vehicle weight. Having an
installed capacity of 60,000 vehicles, the unit produced 37,551 vehicles during the year 2001-02 in keeping with
the cyclical nature of demand in commercial vehicle industry.
The Automobile unit at Jamshedpur has captive Forge and Foundry divisions which meet its requirement of all
critical steel forgings and alloy iron castings. In order to achieve greater efficiencies and world class
technological edge in its aggregate production, the manufacture of Axles and Gear Boxes have been
de-integrated and formed into separate companies as HV Axles Ltd and HV Transmissions Ltd.
The unit has a township for its employees and supports community services as a part of its social responsibility
towards its employees and local community.
Energy Consumption
Even though total energy cost has increased during the last three years due to increasing rates for power and
fuel oil, with the implementation of energy conservation measures, the specific consumption of all areas - Auto,
Foundry and Forge divisions has been steadily declining. Last three years specific energy consumption figures
are as shown below:
PRODUCT DESCRIPTION UNIT 1999-00 2000-01 2001-02
Automobile chassis Electrical energy 647 629 596
Thermal energy kCal / Eq. Vehicle 0.454 0.443 0.411
Casting Tonnage Electrical energy KWH / MT 2371 2305 2108
Thermal energy MkCal / MT 0.437 0.417 0.393
Forge Tonnage Electrical energy KWH / MT 760 681 655
Thermal energy MkCal / MT 4.04 3.63 3.52
Total Energy Cost Rs. Lakhs. 8018 8708 9087
Energy Conservation Commitment, Policy and Set up
Energy Conservation has been a top management priority for the unit for the last three decades. The priority
emerged either from national perspective to fight energy crisis in seventies and energy shortages in eighties and
early nineties, to present day customer-driven need for cost efficiency.
An Engineering Audit group was created in 1983 which co-ordinates the energy conservation activities in the
plant.
Awareness & involvement of people at all levels has been a major plank for implementation of energy
conservation measures. Energy auditing is a function of the Engineering Audit group. Every year targets are set
for the various divisions & energy conservation action plans are worked out. The specific energy consumption &
status of action plans is reviewed with divisional coordinators using a common matrix which is shared across all
divisions and areas to facilitate cross-pollination of ideas.
Specific consumption of each area is monitored by Engineering Audit on daily basis & is shared with each
divisional head / divisional coordinator as well as the top management.
ENERGY CONSERVATION TEAM SETUP
Energy Conservation Achievements
During the period 1999-00 to 2001-02, the Jamshedpur Plant implemented Energy Saving Ideas generated
through regular energy audits, brainstorming & reviews. The major measures implemented during 2001-02 are
given below.
(I,II) Changeover to lower wattage energy efficient lamps for lighting in the plant & in Township.
(III) VFDs were installed at 9 locations as a strategy to reduce energy consumption of pump & blower motors.
(IV) 150 nos. of translucent roof sheets were installed in different areas to facilitate use of natural daylight in
place of high bay lights during the daytime.
(V) Various simple devices like timers, time-switches, interlocking etc. were installed on machines &
equipment thereby reducing idling of drive motors.
(VI) Use of thermal heating in place of electric heating resulting in saving in energy cost.
(VII) Efficient heat utilization in energy intensive furnaces & equipment by use of various measures like
improving insulation, right-sizing of chambers, using temperature controllers etc.
(VIII) Improve loading of transformers resulting in disconnection of 20 nos. of low loaded transformers thus
reducing losses.
(IX) Optimising supply voltage for lighting in the Township.
(X) Process changes like reducing one shift working due to cycle time improvement of pre-treatment process
before ED in painting.
(XI) Various improved work practices like ensuring scheduled running of ATH thermic fluid boilers in paint
shop.
(XII) Replacement of 3 nos. inefficient pumps in Town Filter Plant.
(XIII) Saving in compressed air energy by regular audits & correction of leakages from 29% to 15%; installing
of 16nos. flow meters for monitoring in all areas.
Energy Conservation Plans & Targets
Jamshedpur unit of Tata Engineering is committed to further improve its energy performance by exploring new
avenues for energy saving on a continuous basis. Some of the major proposals as a part of future plan for
energy conservation are:
(1) Changeover of electric frame painting baking ovens to thermal baking for achieving cost advantage in
energy.
(2) Install Cellulose pads in place of spray type air washer in Air Replacement Plants in paint shop.
(3) Installing VFDs in New Engine Cooling Tower & other identified areas to save power.
(4) Phased replacement of metallic blade of small man-cooler in shops by FRP blades.
(5) Modifying & improving furnaces for more efficient heat utilisation in Forge.
(6) Conversion of existing electric cooking into LPG based cooking in Central Canteen.
(7) Installing Solar Water Heaters in Hospital Canteen.
(8) Covering more shop areas for natural day-lighting by installing translucent roof-sheets.
(9) Reducing degreasing bath temperature in paint shop.
(10) Cover all major furnaces for Flue Gas Analysis.
Source : Bureau of Energy Efficiency,India
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