TATA MOTORS LIMITED - JAMSHEDPUR

CII – NATIONAL AWARD FOR EXCELLENCE IN

ENERGY MANAGEMENT 2018
 JOURNEY OF TATA MOTORS JAMSHEDPUR

1954,TML established

INCEPTION
its first state of art
manufacturing facility
which can roll out
medium or heavy truck

FACILITIES
Manufacturing facility
600 acres every 05 minutes

Integrated township of
over 1250 acres

Over 200 models :

PRODUCTS
Multi axle Trucks
Tippers
Trailers - Tractors
Defense Vehicle

FIRST COMPANY IN
EASTERN INDIA ”
SIGNIFICANT REDUCTIONS :
GREEN C O TO ACHIEVE THE
CLIMATE
CHANGE

Sp. Carbon Footprint: 31% PRESTIGIOUS

Sp. Water Consumption : 37 % “GREENCO GOLD”
RATING
Energy Cost % of Manuf. cost:
58%

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 KEY PROCESS FACILITIES AT TATA MOTORS JAMSHEDPUR

FRAME SHOP

ENGINE
•5000 TON PRESS •CYLINDER HEAD

FOUNDRY

VEHICLE ASSY
PAINT SHOP
CAB FABRICATION

•FABRICATION •PT CED SETUP & BLOCK LINE •MOULDING LINE •PRIMA TRIM
LINES – LP, EDAG, LINE
SFC, TILT CAB, •LM PTCED SETUP •MELTING LINE
•PAINT KITCHEN, •CRANK SHAFT /
PRIMA CHILLER PLANT, •VEHICLE
CAM SHAFT
DM WATER PLANT •FRAME ASSY. LINE •CORE MAKING FACTORY – I & II
MACHINING &
•CAB TRIM LINES HARDENING AREA
•COLOR LINES, •FRAME PAINTING, •FORCED DRAFT
•CAB STORAGE ROBOTIC BAKING, STORAGE VENTILATION
•ENGINE
PAINTING & ASSEMBLY & (FDV’s)
BAKING TESTING
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 OUR APPROACH TO GREEN MANUFACTURING

SYSTEMS & PEOPLE

LEADERSHIP INVOLVEMENT
RESULTS
FRAMEWORK

• Governance • Green • Energy Kaizens • Energy

Policies Company • Suggestion Performance
Rating System campaigns • Carbon
• Accountability Footprint
– ENCON TEAM • ISO 50001 • Awareness
reduction
Programmes
• Waste
• Financial • ISO 14001 • Training & minimization
Resources Capability • Process
• GHG Protocol Building improvements

COMMITTMENT PROCESSES ENGAGEMENT OUTCOMES

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 ENERGY MANAGEMENT – GOVERNING PRINCIPLES

Increase
Commitment
awareness
to Energy
for Energy
performance
Efficiency &
improvement
Conservation

Select &
Purchase Eco
Minimizing &
friendly
Eliminating
technologies,
Waste
products &
services

Use of Minimizing
Renewable GHG
Energy emission

ELECTRICITY
FUEL OIL
GASES
WATER
ENVIRONMENT

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 MANAGEMENT SYSTEMS

TS 16949 GREEN CO - GOLD

SA 8000
OHSAS 18001 CERTIFICATES

ISO 14001
ISO 50001

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 ENERGY MANAGEMENT – TEAM SETUP

HEAD – PROD. LINE OPERATIONS

(MR – ISO 50001)

ENVIRONMENT & ENERGY MANAGEMENT CELL

ENERGY LEADS
SUPPORT SERVICES
(MANUFACTURING)

• FRAME • HR & TRAINING

• ENGINE • TRANSPORT
• VEHICLE • PLANNING  Structured Team Approach
• CAB & COWL • CANTEEN SERVICES  Monitoring & Measurement
 Periodic Reviews
• FOUNDRY • PROCUREMENT
 Learning & Sharing
• PRODN. ENGG. • SUPPLY CHAIN
• UTILITY SERVICES • LEGAL SERVICES
• CENTRAL MAINT.

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 JAMSHEDPUR PLANT : ENERGY PROFILE

ENERGY PROFILE (GJ) :TML JSR

2017-18

32

68

KWH% Fuel%

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 TML ENERGY SAVING INITIATIVES SNAPSHOT

TML -JSR

ELECTRICAL THERMAL ENERGY

ENERGY PROPANE / LDO

MOTORS HVAC COMPRESSED AIR LIGHTING OVEN/ FURNACE AQUA THERMIC HEATER (ATH)

•Fuel Saving Device ( Max • Substitution of LDO from

•Interlock to •Screw type Chiller •Screw Air •LED Lights for
Fluxiox) Propane
prevent idle losses • 5 Star Rated AC Compressor various
•Flue Gas Analysis •Flue Gas Analysis
•VFD across •Micro processor • Portable Air applications i.e
Manufacturing , •Heat Loss reduction
blowers/pumps based operation of Compressor
Offices ,Street •Direct fired Heating System
Chillers •Compressed Air
•Capacity Lights •Substitution of LDO from
•Scheduling the leakage audit Propane
optimization by operation of group •Air Boosters • Energy audits to
of chillers reduce idle energy
•Air cut off valves
Energy audit consumption
•Increasing the
•Energy Efficient operating •
Motors efficiency by
Energy audits

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 ENCON CULTURE - PEOPLE INVOLVEMENT

More then 4500 no’s of ideas

generated over last 03 years

IDEA Generation
Workshops
Cross Functional
Team on ENCON
Unique
Suggestion
Scheme

KEY
Expert Hour Solar Thermal System for
Session on ENCON LMPTCED Process
Green School Energy
Rating System Efficiency IDEAS
CLASS
ROOM • Maximizing the use of Air circulators
Online TRAINING • Waste Heat Recovery at CPS
Training
Module
• Maintaining Compressed Air Leakage
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with in 8%
 IT ENABLED - ON LINE ENERGY MANAGEMENT

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 ENERGY PERFORMANCE REORTS - SAMPLE

Head- JSR
Plant
MR Review
Div. Review VCC Review
EnMs Core
Team
Review
Energy
Audit Team
Review

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 ONLINE PORTAL : ENERGY AUDIT & ENV. MANAGEMENT

Energy
Ideas Policy
Analysis Action Culture
Energy Energy Tips on Energy Policy Best
Performance Saving Energy & ISO 50001 Practices in
Analysis Action Saving Apex Manual Energy
reports Planning for JSR Plant Conservation
Specific Matrix
Energy
Performance
Trends

All Energy
related
information on
the Energy Web

Env.
Rules Legal Policy
Waste Mgmt Culture
Industrial Environme Legal Environme Best
Waste ntal rules & Register ntal Policy Practices in
Mgmt. Regulations & ISO Environ.
Bio- 14001 Apex Conservati
medical Manual for on
Waste JSR Plant
Manageme
nt

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 KEY FOCUS AREAS

•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

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 SUMMARY OF ENCON PROJECTS

2015-16 2016-17 2017-18

• PROJECTS – 23 Nos. • PROJECTS – 15 Nos. • PROJECTS –Nos. 25
• INVESTMENT – Rs. • INVESTMENT – Rs. • INVESTMENT – Rs.
58.2 LAKHS 710 LAKHS 400 LAKHS
• SAVINGS – Rs. 79.40 • SAVINGS – Rs. • SAVINGS – Rs.151
LAKHS LAKHS 517 LAKHS

2015-16
PROJECTS – 14 Nos.
INVESTMENT - NIL
SAVINGS – Rs. 158.40
LAKHS
2017-18
2016-17
• PROJECTS – 10 Nos.
PROJECTS – 16 Nos. • INVESTMENT - NIL
INVESTMENT - NIL • SAVINGS – Rs. 41.40
SAVINGS – Rs. 60.79 LAKHS
LAKHS

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 ELIMINATION of CHILLER UNITS BY EFFICIENT COOLING
SYSTEM

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 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

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 ELIMINATION of CHILLER UNITS BY EFFICIENT COOLING
SYSTEM

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

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 DIRECT FIRED SEALANT OVEN SYSTEM

BEFORE

SEALANT APPLICATION SEALANT CUTTING

SEALANT OVEN

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 DIRECT FIRED SEALANT OVEN SYSTEM

AFTER

Carbon Foot Better

Fuel Saving: Print Red. Space
Combustion
122 MT
335 tCO2 Efficiency optimization

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 PROVISION OF SWIVELING LID TO INCREASE OPERATION
EFFICIENCY
BEFORE AFTER

• Scrap is converted to molten state by the • Operational performance : 548 kWh/ LMT
medium frequency furnace to provide the
• Improvement in operational performance : 19 kWh/LMT
molten liquid metal to molding line.
• Annual Energy savings realized (kWh) : 38000
• This medium frequency furnace has following
specifications. • Reduction in carbon footprint: 312 tCO2e
• Power- 4000kw ,Voltage:-1150V (down from • Monetary savings realized: Rs. 22 Lakhs
6600v to 1150 by furnace transformer
• Capacity: 5MT/HR
• Operational performance : 567 kWh/ LMT
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 INSTALLATION OF LIGHT PIPES

LUX
LUX LEVEL
LEVEL Benefits 312
162
realized:
BEFORE AFTER
Annual
Energy
Savings
(kWh) :
39134

Reduction in
LUX LUX
LEVEL tCO2 = 32
LEVEL
221 324

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 OPTIMIZING FDV ENERGY CONSUMPTION

FDV Study

Uses Uses

Losses Losses

Duct Leakages Presence of vents at Worn out Parts Worn Out Celdek Pads
utilized areas
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 OPTIMIZING FDV ENERGY CONSUMPTION

Benefits:
Energy Savings: 4.29 Lakh kWh
Reduction in Carbon Footprint : 352

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 ENERGY EFFICIENT LED LIGHTS

150 W Vehicle 18 W LED Tube lights

Frame Assembly Shops 150 W O/H LED
Assembly Area
Press Shop

Benefits:
Total number of units : 3645
Energy Savings: 4.19 Lakh kWh
Reduction in Carbon Footprint : 345

36W Office Lights

72 W LED Column Lights
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 TIMER CIRCUIT TO REDUCE THE LIGHTING CONSUMPTION

Automation done for auto

switch ON/OFF

Annual Energy Saving: 70000 kWh

Annual Carbon Foot Print Savings : 57
Annual Monetory Savings Rs. 4.62 Lakhs

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 OPTIMIZING THE LIGHTING LOAD

KEY POINTS
• Removal of Extra Light fittings from
assembly line
• Idea Generated by SDT Team Annual Energy Saving: 50000 kWh
• Idea verified by Energy audit team Annual Carbon Foot Print Savings : 41
• Zero Investment Project Annual Monetary Savings Rs. : 3.32 Lakhs
• Lux level for working area
maintained at desired level
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 SUSTAINABLE INITIATIVES

Purchase Purchase Incorporati Increase Maximize Low

of only LED of only 05 on of use of use of Carbon
lights for Star rated Energy Solar Variable Manufact
every new equipment Efficient Energy by Frequency uring by
project Motor Light Pipes Drive Green
during Supply
design Chain
stage

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 ENERGY PERFORMANCE TRENDS

Use of VFD ‘s for Pumps & Blowers Conversion of indirect fired oven to
on Variable Loads direct fired ovens
Maximize use of Energy Efficient LED  Maximize the use of waste heat for pre
lights heating
Maximize use of natural light by  Maintaining burner operation on low
Solar Light Pipes mode during non productive hours
 Maximize use of portable air  Improving burner efficiency by flue gas
compressors analysis
 Maximize use of air circulators in Reducing heat losses by conduction
place of Man Coolers insulation survey

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 ENERGY PERFORMANCE TRENDS

43% reduction
over last 03 years 38% reduction
over last 03 years

 Utilization of treated effluent water  Energy Efficient Lighting i.e. LED’s

 Rain Water Harvesting  Indirect to Direct Fired Heating System
 Root Zone Treatment  Reduction of wastages from energy audits, Kaizen
 Use of GIS mapping for underground water pipe  Use of Water Efficient technologies
leakage detection
Spreading awareness on Environment & Energy
 Use of Water Efficient technologies
 Shift optimization as per production

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 ENERGY PERFORMANCE TRENDS

BETTER

58%
reduction
over one
decade

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 EXTERNAL BENCHMARKING

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 INTERNAL BENCHMARKING

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 ENVRIONMENT CONSERVATION & CARBON
EMISSION REDUCTION INITIATIVES

• Migration from KEY ENVIRONMENTAL

Conventional LDO to INITIATIVES
Propane
• Installation of Organic • Ambient Air Quality Monitoring
Waste Converter • Value from Waste Initiative
• Implementation Paint • Waste Water Treatment Plant Unit – A & B
Sludge Recycling each of (2500 m3/day) , as part of Zero Liquid
Discharge Plan
• Converting Incineration Ash
• Awareness Session for Vendors on “Climate
& ETP Sludge in to Non- Change & Environmental Sustainability”‘
hazardous Paver Block
• Celebration of “Tata Sustainability Month” in
• Implementation of June’18 – Tree plantation, Seminar on Climate
Employee Bus Service Change, Sit & Draw, Poster making
• Two day Exhibition on Eco-friendly and energy
CARBON EMISSION efficient appliances during Energy Conservation
REDUCTION PROJECTS Month celebration at TRC on 14th – 15th Jan’18

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 CLEAN FUEL: MIGRATION FROM LDO TO PROPANE

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

CARBON FOOTPRINT REDUCTION

YARD-1: 2600 tCO2e / Year

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
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 HARNESSING WIND ENERGY

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

INSTALLED • OVER 500 Nos.

•ENERGY SAVING – Rs. 3.75 LAKH KWH

PROJECT
•INVESTMENT – Rs. 11.09 LAKHS
DETAILS
•SAVING – Rs. 13.31 LAKHS / ANNUM

CARBON
• 315 tCO2e
REDN.

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 HARNESSING SOLAR ENERGY

Fig (a): Solar Water Heater in Guest House

UTILISATION OF SOLAR ENERGY FOR 100% WATER

HEATING IN WORKS CANTEEN, HOSTELS, CLUB,
HOSPITAL & GUEST HOUSE
SAVINGS- 200 tCO2e/Annum Fig (b): Solar Water Heater in Canteen

• Solar Water Heating System

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 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)
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 WASTE UTILIZATION
HIND-033

Benefits
(a) Savings in Casting
Sealer Grey
procurement : 36 KL
Cylinder Head Spray Painting Station After Painting (b) Better utilization of
waste generated
(c) More value realized
BEFORE
from paint sludge
Paint Sludge sent for
disposal through Co –
Processing

AFTER
Paint Sludge sent for
recycling to make casting
sealer grey
PAINT SLUDGE
 WASTE UTILIZATION
HIND-033

BEFORE PROPOSED AFTER

Earlier the red/ blue color

plastic Cap comes with every
BS4 silencer and was disposed
as waste. 1:1 replacement of
aluminum cover for
electrical socket 220 volt. BENEFITS:
Reduction in procurement of
Electrical Socket (no’s): 3000
Monetary Benefits : Rs. 1.56 Lakhs
 WASTE UTILIZATION

INCINERATION ASH UTILIZED

FOR MANUFACTURING PAVER
BLOCKS

HEAT RECOVERED FROM

INCINERATOR IS USED FOR
REMOVAL OF PAINT DEPOSITION ON
FIG (A): INDUSTRIAL INCINERATOR GRILLS (GENERATED FROM CPS AND
OTHER PAINTING AREAS)
FIG (B): HEAT RECOVERY CHAMBERS
(LRD-250)

More Then “04 Lakhs”

Paver Bricks manufactured in
last 05 years

Fig (b): Manufacturing Paver- Fig (c): Paver Blocks for

Fig (a): Handling
blocks using Incineration ash various applications
Incineration Ash

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 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
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 WASTE UTILIZATION

CONVERSION OF CANTEEN
AND GARDEN PRUNING
WASTES INTO ORGANIC
MANURE

Fig (a): Organic Waste Fig (b): Compost Curing System

Converter

Fig (c) Organic Compost

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 WATER CONSERVATION

Over “12 lacs m3”of Rain

Water Harvested in last
HARVEST : 200 MG/Yr. (About 17% of Water Consumption)
03 years
OTHER BENEFITS: Saturate the drying aquifers of Plant &
surrounding areas

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 WATER CONSERVATION - TOWARDS ZLD

Commissioning of Waste Water Treatment

Plant (WWTP- Unit A & B) near Rain Water
Harvesting:
• Capacity - 2500 m3 / Day X 2
• Convergence of Channel 2, 3, 4 , 5 & 6
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 ENCON – FUTURE ROAD MAP

• Waste Heat Recovery System to

CPS
• Replacement of reciprocating
2021-22
chillers with screw chiller for AC
Plants

• Phase :02 Replacement motors

(20 kW and above) with EEM
2020-21
• Installation of Flux Maxiox to all
propane fired ovens 2019-20

• Phase :01Replacement motors

(20 kW and above) with EEM

• 100 % FDV operation by VFD

• 2.5 MW Solar Roof Top System

• 500 kWp Solar Thermal System
2018-19
• Light Pipes :62 No

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 AWARENSS CAMPAIGN

Energy Conservation Oath

School Energy Quiz

Inter Divisional Energy Quiz Exhibition on Energy Efficient

Competition – Manf. & Manf. Products
Support Divisions
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Energy Idea Workshop
 BEST PRACTICES ON ENERGY FRONT AMONG VENDORS /
SUPPLIERS

• Climate Change & Energy Conservation

awareness module shared with 82 vendors,
AWARENESS contractors, service providers

• Total participation: 4946 till March ‘18

• Educating vendors to map their own Carbon

Footprint
CARBON
FOOT PRINT
• Carbon footprint mapping and abatement
MAPPING measures suggested to 126 Nos. vendors till June-
18

Facilitate Vendors to adopt Energy Management System

(ISO-50001)
TRAINING 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 •Conducting regular Energy audit to stop idle wastage
during Lunch time & Shift Change Over
ENERGY
Speaker : Mr. Abhay Pathak AUDITS •Regular thermal insulation survey & surface heat loss
( Corporate Lead- SHE & audit
Sustainability) Tata Motors Limited
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 BEST PRACTICES ON ENERGY FRONT AMONG VENDORS /
SUPPLIERS

Yazaki India Ltd

Tata Auto Comp. Ltd

Heat Recovery from Chiller System for CO2 Installation of Variable Frequency Drives
Caparo
Vaporizer ( Annual Savings : 28470 kWh)
Engineering (Annual Savings : 4284 kWh)
India Ltd
Steel Strips & Wires
Ltd
TML Drivelines Ltd

Energy Efficient LED lights in place of Modification of Cooling tower filtration system
Metal Halide ( Annual Savings : 52560 kWh) ( Annual Savings : 42340 kWh)

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 ACCOLADES

Tata Motors – Jamshedpur Plant won “First Prize – Automobile

Manufacturing ” in National Energy Conservation Award 2017 ,
BEE, Ministry of Power

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 ACCOLADES

Tata Motors – Jamshedpur Plant has

Winner, Environmental Award 2018 by bagged the first prize for Good Green
Jharkhand State Pollution Control Board Governance at the SRISHTI AWARDS’2017

TML – JSR won GREENCO “GOLD”

TML – JSR adjudged Excellent Energy Unit in CII -National Energy AWARD , June 2015‘
Awards for Excellence in Energy Management, 2016
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