Energy uses in vehicle assembly plant

1. 1
ENERGY USES IN VEHICLE ASSEMBLY
PLANT

2. 2
INTRODUCTION
 Uncertain energy prices in today' marketplace negatively affect
predictable Earning
 Energy efficiency technologies often include benefits which increases the
productivity of the company as well as reduces negative affect on the
environment
 Some of Energy efficiency opportunity we have identified like
- Energy conservation through engine testing
- Environmental issues in energy sector

3. 3
Energy use in vehicle Assembly Plants
11%
35%
15%
9%
7%
6%
9%
8%
HVAC Paint systems
Lighting Compressed air
Material handlings/Tools Metal forming
Welding Miscellaneous
* The data represent typical uses based on a number of plants in the US & EUROPE (Price and Ross, 1989; Dag,
2000; Leven and Weber, 2001). The actual distribution in an individual plant may be different due to variations in
Processes (e.g. engine plant, or body plant), as found in different plants around the US

4. 4
CROSS CUTTING (UTILITIES) ENERGY EFFICENCY
MEASURES FOR THE VEHICLE ASSEMBLY
General utilities
Energy management systems
Combine Heat & power
Compressed air systems
Maintenance
Monitoring
Reduce leak & pipes and equipment
Turn of unnecessary compressed air
Use air at lowest possible pressure
Correctly sizing piping diameter
Properly sizing regulators
Energy efficient chillers
Heat & steam distribution- Boilers
Improve process control
Reduce flue gas
Reduce excess air
Correct sizing in design
 Motors
Sizing of Motors
High efficiency motors
Adjustable /Variable speed drive
Variable voltage control
 Lighting
Controls
Setting lighting standards
Day lighting
Replace incandescent with fluorescents
or CFLs
Replace mercury with metal halide or
high pressure Sodium
 Heat & steam Distribution-
distribution
Improve & maintain insulation
Repair leaks
- Compressor Motors
-Adjustable speed drive
-High efficiency motors

5. 5
COMPRESSED AIR SYSTEM
 Compressed air is probably the most expensive form of energy used in
an industrial plant because of its poor efficiency.
 Maintenance – Inadequate maintenance can lower efficiency and
increase air leakage and excessive pollution
 Blocked pipeline filters increase pressure drop Keep the compressor and
intercooling surface clean & foul free by inspecting and periodically cleaning
filters
 Poor motor cleaning can increase motor temperature and winding
resistance, shortening motor life, in addition to increasing energy
consumption. keep motors and compressors properly lubricated & cleaned
 Inspect fans & water pumps for peak performance
 Specify pressure regulator that close when falling
.

6. 6
COMPRESSED AIR SYSTEM
 Monitoring – Proper monitoring can save lot of energy and money in
compressed air systems
 Pressure gauges on each receiver or main branch line and differential gauges
across dryers, filters
 Temperature gauges across the compressor and its cooling system to detect
fouling and blockage
 Flow meter to measure the quantity of air used
 KWH meter and hours run meter on the compressor drive
 Reduce leaks in pipe and equipment – Leaks can be significant source of
wasted energy. A typical plant has not well maintained could have leak rate
between 20 – 50% of total compressed air production capacity.
 Leak repair and maintenance can reduce this no to less than 10%
 A simply way to detect the large leak is to apply soap water to suspect areas
 The best way to detect leak is to use an ultrasonic acoustic detector