energy management case studies - nissan north america inc
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Energy Management In Manufacturing
Richard Russell, P.E.Sr. Energy EngineerNissan North America
Nissan’s Commitments To Improving Energy Performance
Cost ReductionOn Energy Spend
Nissan Green Program 2016
ENERGY STAR® Certification
Of Plants
DOE Better Plants
Smyrna, TN Decherd, TNCanton, MS
Nissan Americas HeadquartersFranklin, TN
Smyrna, TN
Canton, MS
2012 2011 2010 2009 2008 2007 2006
2012201120102009200820072006
2012201120102009
Top 25% Energy Efficiency Certifications
Use the Energy Program Assessment Matrix to evaluate your current practices.
http://www.energystar.gov/index.cfm?c=guidelines.assess_energy_management
Energy Management SystemsENERGY STAR® Guidelines For Energy Management Matrix
Energy Management Systems ISO 50001
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
Smyrna, TN Decherd, TNCanton, MS
Smyrna Vehicle Manufacturing PlantConditioned Space Area 5.5 MM SqftProduction Capacity 550,000 Vehicles Per YearEnergy Sources Typical Annual UseElectricity 220,000 MWHNatural Gas 650,000 MCFCoal 12,000 Tons
VehiclesOut
StampingStamping
BodyTruck Paint
Car Paint
Trim
Plastics – Fascia Paint
Rolled Steel
FrameAssy
Modern Vehicle Assembly Plants Are ComplexAssemblages Of Individual Plants
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
MM
BTU
/Month V
ehic
les/M
onth
Base Line PeriodCY 2008
Baseline Year
Smyrna Manufacturing Plant Regression Model Study Of Energy Consumption
Prod
uctio
n Vo
lum
e (To
tal)
Prod
uct M
ix Ca
r
Prod
uct M
ix Tru
ck
Heat
ing
Degr
ee D
ays
Cool
ing
Degr
ee D
ays
Aver
age
Hum
idity
Aver
age
Tem
pera
ture
Electricity ● ● X X 0.870 0.000 E = 2.93 x (Prod) +127.08 x (CDD) +93617Electricity ● ● ● 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) -27486Gas ● ● ● X X 0.930 0.00005 G=1.68 x (Car) +3.111 x (Truck)+79.261 x (HDD) -20852Coal ● 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)+19568Coal ● X X 0.910 0.000 C=46.091 x (HDD)+19568
Not Evaluated X
P value <0.2 ● AppliedP value >0.2 ●
ModelsMultiple
Regression F-Test
DataEnergy Source
Parameter Evaluated
Multiple Regression R square
Smyrna Vehicle Plant
CY 2008
Model Testing - Analysis Of Relevant Variables
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
Performance To Commitment To Achive SEP Certification 5% Qualifing ThresholdSmyrna Mfg Plant InScope Electricity Gas & Coal Consumption
Base YearCY 2008 EnPI =0
Silver
Gold
Platinum SEP Silver=>5%
Performance Results
Annual Savings MMBTU – By Source Bottom-Up Analysis
Electric Power 104,867 72,101Natural Gas 52,078 51,139Coal 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 Projects3 Compressed Air Management – Stamping Plant4 Motor Speed Reduction – E-coat Circulation Pumps Paint System 15 Improved Start-up & Shutdown Procedures Paint System 1
Top 5 – 82%
5 Things
New Value – Assigning the Paint System 2 E-Coat Ovenas our first Significant Energy Use, led to a better understandingof its operation and the development of new relationshipswith maintenance, engineering and production.
Value - Process Understanding &
RelationshipsE-Coat Oven SEU (Significant Energy Use)
1
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 HousePredicted Vs. Actual Performance -
Electric Power Use Base Period Calendar Yr 2010MWH/MoEnPI
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
3 Validation Of Savings
30% Reduction In Energy Intensity 75% Of Conditioned Paint
Booth Air To Be Recycled To Reduce Energy Use
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.
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!
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