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Energy Management Case Studies - Nissan North America Inc.

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  • 1. Energy Management In Manufacturing Richard Russell, P.E. Sr. Energy Engineer Nissan North America
  • 2. Nissan’s Commitments To Improving Energy Performance Cost Reduction On Energy Spend Nissan Green Program 2016 ENERGY STAR® Certification Of Plants DOE Better Plants
  • 3. Smyrna, TN Decherd, TN Nissan Americas Headquarters Franklin, TN Smyrna, TN Canton, MS 2012 2011 2010 2009 2008 2007 2006 2012 2011 2010 2009 2008 2007 2006 2012 2011 2010 2009 Top 25% Energy Efficiency Certifications
  • 4. Use the Energy Program Assessment Matrix to evaluate your current practices. http://www.energystar.gov/index.cfm?c=guidelines.assess_energy_management Energy Management Systems ENERGY STAR® Guidelines For Energy Management Matrix
  • 5. Energy Management Systems ISO 50001
  • 6. ISO 50001 Energy Management System Model Energy Policy Energy Planning Implementation & Operation Checking Monitoring Measurement & Analysis Nonconformities, Corrective & Preventive Action Internal Audit Of The EnMS Management Review
  • 7. Smyrna Vehicle Manufacturing Plant Conditioned Space Area 5.5 MM Sqft Production Capacity 550,000 Vehicles Per Year Energy Sources Typical Annual Use Electricity 220,000 MWH Natural Gas 650,000 MCF Coal 12,000 Tons
  • 8. Stamping Modern Vehicle Assembly Plants Are Complex Assemblages Of Individual Plants
  • 9. 0 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000 100,000 - 100,000 200,000 300,000 400,000 500,000 600,000 Jan-05 Jan-06 Jan-07 Jan-08 Jan-09 Jan-10 Jan-11 Jan-12 Total Energy Total Production Smyrna Manufacturing Plant Monthly Energy Use & Production 2005 To Present MMBTU/Month Vehicles/Month Base Line Period CY 2008 Baseline Year
  • 10. Smyrna Manufacturing Plant Regression Model Study Of Energy Consumption ProductionVolume(Total) ProductMixCar ProductMixTruck HeatingDegreeDays CoolingDegreeDays AverageHumidity AverageTemperature Electricity ● ● X X 0.870 0.000 E = 2.93 x (Prod) +127.08 x (CDD) +93617 Electricity ● ● ● X X 0.880 0.00056 E = 2.134 (Car) + 3.786 (Truck) + 138.3 (CDD) + 98947 Gas ● ● X X 0.920 0.000 G=2.326 x (Prod) +84.732 x (HDD) - 27486 Gas ● ● ● X X 0.930 0.00005 G=1.68 x (Car) +3.111 x (Truck)+79.261 x (HDD) - 20852 Coal ● 0.323 ● 0.689 ● 0.642 ● X X 0.920 0.000 C=- 0.188 x (Car) - 0.254 x (Truck) +46.091 x (HDD)+19568 Coal ● X X 0.910 0.000 C=46.091 x (HDD)+19568 Not Evaluated X P value <0.2 ● Applied P value >0.2 ● Models Multiple Regression F-Test Data Energy Source Parameter Evaluated Multiple Regression R square Smyrna Vehicle Plant CY 2008 Model Testing - Analysis Of Relevant Variables
  • 11. 7.2% -5.0% 0.0% 5.0% 10.0% 15.0% Sep-07 Mar-08 Sep-08 Mar-09 Sep-09 Mar-10 Sep-10 Mar-11 Sep-11 Mar-12 PerformanceTo CommitmentToAchiveSEP Certification 5%QualifingThreshold SmyrnaMfg Plant In Scope ElectricityGas& Coal Consumption Base Year CY2008 EnPI =0 Silver Gold Platinum SEP Silver =>5% Performance Results
  • 12. Annual Savings MMBTU – By Source Bottom-Up Analysis Electric Power 104,867 72,101 Natural Gas 52,078 51,139 Coal 93,174 5% Threshold 91,052 Total 250,119 173,091 < 214,292 Bottom-Up Sanity Check Top 5 Projects Bottom-Up Analysis 1 Cascade Air & Dry Line Booth Controls Paint System 2 2 Boiler Flue Gas O2 Management & Insulation Projects 3 Compressed Air Management – Stamping Plant 4 Motor Speed Reduction – E-coat Circulation Pumps Paint System 1 5 Improved Start-up & Shutdown Procedures Paint System 1 Top 5 – 82%
  • 13. 5 Things
  • 14. New Value – Assigning the Paint System 2 E-Coat Oven as our first Significant Energy Use, led to a better understanding of its operation and the development of new relationships with maintenance, engineering and production. Value - Process Understanding & Relationships E-Coat Oven SEU (Significant Energy Use) 1
  • 15. Value -Finding Hidden Waste 0.9 0.95 1 1.05 1.1 - 2,000 4,000 6,000 8,000 10,000 Nov-09 May-10 Nov-10 May-11 Nov-11 May-12 Forecast Electricity (MWH) Actual Electricity (MWH) EnPI 12 Mo Moving Avg Smyrna Boiler House Predicted Vs. Actual Performance - Electric Power Use Base Period Calendar Yr 2010MWH/Mo EnPI Based on control charts created using the EnPI tool, a re- examination of management practice at our central chiller plant identified cost savings that could be achieved without investment! This program implemented 11 months ago has delivered a total of $67,000 savings. 2
  • 16. 3 Validation Of Savings
  • 17. 30% Reduction In Energy Intensity 75% Of Conditioned Paint Booth Air To Be Recycled To Reduce Energy Use
  • 18. 4 Support For Management Commitments Are We Going To Meet Our Targets? SEP processes and tools aid in forecasting, documenting and verifying results. Third party verification builds confidence in measured improvements – on the shop floor, the executive suite and the equities market.
  • 19. 5 Design & Procurement Did We Consider How This Equipment Or New Process Will Impact Our Energy Use, Consumption And Efficiency? Energy Engineers Are Now Approvers On Shopping Baskets Over $50,000!
  • 20. Value of Management Systems • Method For Documenting & Tracking Cost Savings • Provides Third Party Verification & Rigorous Measurement &Verification • Public Recognition Of Savings • Future Monetization Of Operational Improvements