tata engineering

ENERGY MANAGEMENT

Tata Engineering, PuneCase Analysis

4/7/2009

Submitted by:

Avni Jain (109)

Gaurav Virendra (124)

Mithila Singh (217)

Saket Garg (304)

Energy management

Tata Engineering, Pune

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TABLE OF CONTENTS

QUESTION 1................................................................................................................................................................................. 4

INTRODUCTION.......................................................................................................................................................................... 5

COUNTRY WISE SUSTAINABILITY IMPACT...................................................................................................................6

GRAPHICAL REPRESENTATIONS........................................................................................................................................7

QUESTION 2................................................................................................................................................................................. 9

COMPANY OVERVIEW...........................................................................................................................................................10

Company structure.............................................................................................................................................................11

Energy Consumption..............................................................................................................................................................13

Graphic Presentation – Specific Energy Consumption.......................................................................................14

Energy Cost as % of Manufacturing Cost..................................................................................................................15

TRENDS OF OIL CONSUMPTION..................................................................................................................................15

Comparison among different companies......................................................................................................................16

Process Flow Diagram: Automobile Manufacturing.................................................................................................17

Press Shop................................................................................................................................................................................... 18

Weld Shop................................................................................................................................................................................... 18

Paint Shop................................................................................................................................................................................... 19

Assembly Shop.......................................................................................................................................................................... 19

Vendor Components............................................................................................................................................................... 20

Energy management policy.................................................................................................................................................21

The quality policy................................................................................................................................................................22

Energy management initiatives.........................................................................................................................................23

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Environment Friendly Technologies.....................................................................................................................25

Technologies replaced...........................................................................................................................................................26

In house designed Energy Saver for Welding machine controller in Non-arcing perioD...................26

WORKING PRINCIPLE..................................................................................................................................................27

In house designed Energy Saver for High bay 400 W HPSV lamps...............................................................27

SAVINGS............................................................................................................................................................................. 28

Optimization of Pressure & Operation of Compressors.....................................................................................29

Reduce the electrical consumption of AC plant at TTL by installing temperature controller...........29

Introduction of Recuperative Type Gas Heating System for Endogas Generator...................................30

REFERENCES............................................................................................................................................................................. 31

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QUESTION 1

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INTRODUCTION

The sustainability of a technologically intensive activity is reflected by:

(a) How many people use the technology(b) The role of the technology in the economy(c) Some measure of the resource consumption or environmental degradation caused by the technology

The algorithm used here, assumes that population (P) is a good surrogate. Some analysts interpret (GDP/P) and (E/GDP) as aggregate measures of standard of living and energy intensity (i.e., reciprocal energy efficiency). The equation here suggests the seemingly trivial result that SI = E or that total world energy consumption is a measure of sustainability, suggesting that energy use only benefits sustainability. This result alone might satisfy some sustainability "metricators," It can reveal the potency of specific adverse impacts simply by appending its RHS with one further multiplicative factor depicting the intensity of that impact per unit of energy used, e.g., the amount of carbon dioxide CO2 emitted per Btu (CO2/E):

SI = (P) * (GDP / P) * (E / GDP) * (CO2 / E)

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COUNTRY WISE SUSTAINABILITY IMPACT

NationPopulation (P, millions)

GDP (billion $)

Energy Consumption in MKWh (E)

Carbon Emission in tonnes (metric Tonnes)

Sustainability Impact (Si)

United States of America 299.83 11,265.20 4,052,240.00 5,696.77

5,696.77

United Kingdom 60.53 1,684.70 374850 536.48

536.48

South Korea 48.3 671.3 389430 476.1 476.10Japan 127.76 5,087.10 1,050,130.00 1,212.70 1,212.70India 1,109.81 703.33 557970 1,249.74 1,249.74Germany 82.37 2,011.20 590980 823.46 823.46China 1,311.80 2,092.15 2,675,650.00 5,606.54 5,606.54Canada 32.62 844.6 546970 538.82 538.82Australia 20.74 481.4 234560 394.45 394.45

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GRAPHICAL REPRESENTATIONS

Population is found to be directly proportional to SI with an exception of US whose higher SI value despite having low population can be attributed to high GDP and massive industrialization.

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Sustainability Impact for US and China is found to be highest owing to their high GDP

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QUESTION 2

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COMPANY OVERVIEW

Tata Motors is the flagship company of the Tata group with an annual turnover of approximately Rs.20891 Crore for the year 2005-2006. Its product range covers passenger cars, multi-utility vehicles, small, light, medium and heavy commercial vehicles for goods and passenger transport. Medium and heavy commercial vehicles bear the trusted Tata mark. India's most reliable, dynamic and futuristic automobile manufacturer.

With more than 130 models covering a wide range of Commercial Vehicles, Passenger Cars and Multi-Utility Vehicles, Tata Motors provides the wheels for India's growth. Experience the evolution of an auto giant through a virtual drive

More than half a century of impressive presence and Tata Motors continues to provide India with top of the line commercial vehicles. Tata Motors is India's largest and among the world's top ten commercial vehicle manufacturers.

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COMPANY STRUCTURE

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ENERGY CONSUMPTION

Description Unit 2004-05 2005-06 2006-07

Annual Eq. Vehicle production Nos. 218602 244753 281835

Total Electrical Energy Consumption per annum

Lakhs KWH 1208.39 1255.8 1416.78

Specific Electrical Energy Consumption Kwh / Eq.Veh. 552.8 513.09 502.7

Total Fuel Consumption per annum MKcal 56854 60444 81441

Specific Fuel Consumption Mkcal/Eq.Veh. 0.26008 0.24696 0.33275

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GRAPHIC PRESENTATION – SPECIFIC ENERGY CONSUMPTION

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ENERGY COST AS % OF MANUFACTURING COST

Description Unit 2004-05 2005-06 2006-07

Electricity Cost Rs. in Lakhs 3980.88 4571.35 6604.56

Fuel Cost Rs. in Lakhs 1205.35 1457.37 2086.55

Total Energy Cost (Electricity + Fuel) Rs. in Lakhs 5186.23 6028.72 8691.11

Energy Cost as % of manufacturing cost % 0.87% 0.79% 0.88%

TRENDS OF OIL CONSUMPTION

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COMPARISON AMONG DIFFERENT COMPANIES

Tata, Pune

Tata, Jamshedpur

Hyundai Kinetic (per scooter)

Tata, Pune

Tata, Jamshedpur


Tata, Pune

Tata, Jamshedpur


Consumption (in KWh/Eq. Veh)Electricity 752 647 588.38 50.79 678 629 553.39 49.96 655.3 596 521.6 45.7Thermal Energy (Mkcal/Eq.Veh) 0.45 0.454 0.2966 0.04 0.28 0.443 0.2785 0.034 0.26 0.411 0.2812 0.039

1999-2000 2000-2001 2001-2002

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PROCESS FLOW DIAGRAM: AUTOMOBILE MANUFACTURING

The typical process flow diagram for vehicle manufacturing at the site of OEM (Original Equipment Manufacturer) involves the steps as shown in the flowchart. Tata Motor’s Pune Plant also consists of the following facilities:

Bought Out Parts (BOP)

Vendor Components

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PRESS SHOP

The press shop is the first station of manufacturing of any vehicle. It produces the numerous sheet metal panels which constitute the vehicle. A vehicle typically consists of thousands of sheet metal parts of varying shapes and sizes which are integrated. The essential raw material for these sheet metal components are Flat Rolled Steel Coils (Hot Rolled or Cold Rolled) which are procured from TATA Steel.

Generally, only the large sheet metal panels or components such as Floor Panel, Roof Panel and Door Panels are manufactured by the OEM in-house. In terms of numbers, the percentage of components made in-house is not more than 0.5-1% of the total sheet metal components.

The smaller components are outsourced to various vendors specializing in sheet metal components production and they are directly fed to the Weld Shop.

The pressing operation is done by huge mechanical or hydraulic presses which consume a lot of electrical energy.

WELD SHOP

The various sheet metal components made in the earlier facility are welded together to produce the essential or basic structure of the vehicle. The vehicle body is popularly known as the ‘Chassis’ in industrial terms.

The weld shop is increasingly becoming a highly automated workshop which utilizes extremely specialized and customized industrial robots. Mainly, Spot Welding or Spark Welding is done to fuse the different components into one vehicle body.

Weld Shop is the biggest consumer of electrical energy in an automobile plant owing to its use of welding equipment and robots.

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PAINT SHOP

The vehicle chassis including the doors on hinges is transferred to the Paint Shop next for applying the coat of paint on the body in the desired colour.

Inside the paint shop, the chassis undergoes operations on a variety of equipments which include dipping tanks, colour sprayers and baking ovens. For aesthetic purposes, the paint shop operations are conducted in a very controlled environment. Steps are taken to ensure the paint chamber is completely free from dust and other impurities.

The principle followed by TATA Motors for painting operation is Cathodic deposition on metal surfaces. The Chassis being a big metal surface is dipped in a tank of anodic substance after sufficient water cleaning and air blowing operations. As a positive charge is applied on the surface, the paint which constitutes of Cathodic substances is sprayed on the body. The anodic and cathodic particles fuse with each other to deposit a stationery layer of paint on the surface. This electrolytic process ensures a uniform coating on the chassis. The chassis is further baked in an oven which settles the paint.

Thermal energy is used in hot water baths and ovens inside the paint shop.

ASSEMBLY SHOP

The painted chassis or vehicle bodies are then moved to the assembly shop. As the name suggests, this shop is characterised by the assembly of different systems, subsystems and components onto the metal chassis. The functionality of the vehicle originates in this step.

The parts and systems to be assembled excluding Engine Assembly are supplied by the company’s vendors directly to the Assembly Shop. A Single Piece Flow or Line Manufacturing system is implemented which constitutes of a central conveyor line and numerous workstations located on both the sides along the complete length of the vehicles.

The tools used in the Assembly Shop are majorly Battery Operated Hand Held devices such as Screw Drivers etc and some specialized machines. The energy input required in this step

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is entirely Electrical Energy. Continuous improvements are made to make the process less energy intensive and allow make more efficient use of energy.

The completely assembled vehicles are in the end made to go through various testing procedures to check the various subsystems and on approval, taken to the warehouse or storage yard.

VENDOR COMPONENTS

The elaborate set of vendor components are manufactured by many different production processes but some processes which are highly energy intensive are:

- Forging: Components which require a high degree of strength. Engine parts such as Crankshafts, Camshafts ; Chassis components such as Front and Rear Axles ; Transmission and Steering system parts such as Hubs, Wheels, Knuckles

- Casting: Components which are extremely complex and require a high level of detailing. Parts such as Engine Block, Engine Head, Cylinder Block and Transmission Casings

To consolidate, following are the major operations involved in manufacturing of automobile and its components, the energy input required for the processes and their relative energy consumption:

Operation Energy Input ConsumptionPress Electrical ModerateWeld Electrical High

Forging ThermalElectrical

HighModerate

Casting Thermal HighPaint Electrical High

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Thermal ModerateConveyors Electrical LowAssembly Electrical Moderate

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ENERGY MANAGEMENT POLICY

The Tata group has striven to be responsible and sensitive on ecological and environmental matters. It does this by protecting, conserving and restoring natural resources, often beyond what is mandated by government and other institutional policies.

Tata companies are committed to complying in full measure with all regulations relating to the preservation of the environment around its operations. By constantly upgrading the technologies they use and by applying the best of sustainable processes and practices, they endeavour to give environmental issues the priority they deserve.

The companies are dedicated to constantly improving their performance on the prevention of pollution, the proper use of natural resources and the minimisation of any hazardous impact stemming from the production, development, use and disposal of any of their products and services.

Towards this end, the group continuously trains its employees and creates awareness among its business associates, customers, stakeholders and the community at large through a process of participatory dialogue and collaboration.

The Tatas have what is known as a 'group environment network' to guide its companies and organisations on environmental issues. The objectives of this network are three-fold:

To develop a common approach on the environment so that group companies can champion the cause of sustainable growth and enhance the image of the Tata brand.

To integrate environmental parameters in the Tata Business Excellence Model and the Tata Code of Conduct.

To enhance awareness and to train group environmentalists through workshops, and share their experiences through case studies and exchanges.

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The energy policy at Tata Engineering, Pune is

We at Telco are committed to optimum use of Energy and Fuel.

1. By using Energy Efficient Alternatives, methods and Eco-friendly Technology, by adopting diligent & effective maintenance and work Practices to ensure quality & reliable supply.

2. To minimise and eliminate the wastage in every segment of operations.

3. To make an effort to continuously reduce the cost of service by adopting effective “Energy Management System”

At Tata Engineering, carrying out process changes for improving their environmental performance is a continuous process. Top Management commitment to ensure that the operations have the least environmental impact is reflected in the Quality Policy

THE QUALITY POLICY

Tata Engineering is committed to maximizing customer satisfaction and strives to achieve the goal of excellence, by continual improvement, through ongoing design and development, manufacture and sale of reliable, safe, cost-effective, quality products and services of international standards, using environmentally sustainable technologies, for improving levels of efficiency and productivity within its plants and ancillaries.

Tata Engineering also has a commitment towards improving the quality of life of its employees, both within and outside its plants and offices, through improved work practices and social welfare schemes.

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ENERGY MANAGEMENT INITIATIVES

Tata Engineering has taken a lot of initiative for conservation of energy at its plant and they have been quite successful in reducing the energy use at the plant. It is the constant endeavour of the company to increase its efficiency and decrease wastage.

During the period 1999-2002, Tata Engineering, Pimpri has implemented 90 energy saving projects, which are come up through periodic Energy Audit, Brain storming and sharing the ideas within & outside the organisation. It has resulted in percentage reduction of 12.85% in Electricity, 21.99% in Compressed Air & 12.31% in Fuel during last three years as shown below:

Year Electricity Compressed Air Fuel

Specific Consum. kWh/Eq.Veh

% Reduction over 1999-00

Specific Consum.kWh/Eq.Veh

% Reduction over 1999-00

Specific Consum. kWh/Eq.Veh

% Reduction over1999-00

1999-2000 752 88 47.1

2000-2001 678 9.84 75.6 14.09 45.1 4.25

2001-2002 655.3 12.85 68.65 21.99 41.3 12.31

The initiatives that have been taken at the Tata Engineering plant are as follows:

Conversion of 400 W HPMV to 250 W HPSV lamps at C,D,E & J block Without Affecting the Illumination.

Provision of VFDs for pumps for ETP, Compressor house & AC plant

Replacement of conventional chokes by electronic ones for fluorescent Lamps at MSD, PE, CAD & HI Metrology Lab

Lowering & conversion of High bay lamps from 250 W to 150 W at H block. Installation of timers for exhaust fan in toilets at C,D,E & J office blocks

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Improvement in power factor by prudent use of capacitor banks

Replacement of fluorescent fittings by 70 W HPSV fittings at cycle Stands of J & H block

At LPG yard propane is used in place of LPG which has resulted in Elimination of two vaporizers .

At K block compressor house impeller of water circulation pump is modified

At D block compressor house Temperature unit has been installed for auto operations of Hot water pumps.

At Paint kitchen 17 nos. of VFDs are installed to optimise power consumption.

At various shops transparent 700 polycarbonate sheets are installed to allow natural sunlight to illuminate the shop.

At Paint shop chilling plants the operation of cooling tower pump and fan motor have been interlocked with compressor to reduce Idle running

At various Bearing testing and tool regrinding rooms the central AC. Plants have been optimised by controlling the accessories with The compressor motor

Rejuvenation of 2 ASPs done thereby reducing 2 blowers of 55KW

At Cylinder block line 2 washing machines have been designed with direct water jets to increase efficiency eliminating requirement of Hot water heaters .

Reducing the pulley size of the driving motor has optimized blower motors at engine testing area.

Use of electronic 850 chokes in fluorescent lamps with additional advantage of flicker free operation.

Multiple power pack motors on a machine have been combined Into single by modifying the hydraulic circuit.

300 nos. of 40/60 watt bulbs have been replaced by 2 watt LED indicating lamps for EOT crane busbars.

Hydraulic power pack motors have been provided with timers to switch off the machine if it is idle for a known period of time.

In welding machines energy is lost as transformer loss during non Arcing time. A special electronic circuit has been designed in house To control the main power unit.

Special transformer circuit was designed to reduce input voltage to gas filled lamps after known On Time to reduce energy consumption by 20 % for 700 lamps.

A special Energy efficient oven was designed to heat Stub Axle .

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Use of Wind Power at Tata Motors, Pune: M/s Suzlon Energy Ltd. installed & commissioned 114 Nos. x 350 KW wind turbines & 3 Nos. x 1MW wind turbines at Satara and Supa in Maharashtra. Tata Motors, Pune has signed a 35.55 MW Power Purchase Agreement (PPA).

In September 2007, the Certified Emission Reductions were auctioned through the Chicago Carbon Exchange (CCX) and purchased by M/s Eco-Securities Capital Ltd., Ireland

It is to be further noted that Tata Motors is working with the steering committee of National Hydrogen Energy Board, India, to find ways in which India may harness hydrogen potential energy of future.

ENVIRONMENT FRIENDLY TECHNOLOGIES

The Company is working with the ‘Department of Science & Technology’ on the Expert Panel on “Recyclability of automotive Systems & Components”. It is also working with SIAM as a member of task force to study recyclability of vehicles in India.

All manufacturing facilities of the Company are certified to the ISO-14001, International Standard for Environmental Management Systems. The societal & environmental aspects of products and operations & their related impacts have been formally assessed as apart of the installed Environmental Management System

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and Environmental Risk Management Process. Various initiatives like water management system, rain water harvesting, recycling of treated effluent, eco friendly solid waste management, energy conservation, wind energy, recycling of dirty oils & bio-diesel programme are focused on the Company’s goal to preserve the environment.

The Company continues to preserve and develop natural habitat through its tree plantation and wetland development programmes (also detailed in COP 2006-07)

TECHNOLOGIES REPLACED

These technologies have contributed a lot in Tata Engineering’s initiative of energy conservation.

IN HOUSE DESIGNED ENERGY SAVER FOR WELDING MACHINE CONTROLLER IN NON-ARCING PERIOD

Electric Arc Welding machines are used in many production lines. Power to the Welding Transformer remains ON even during idling time (i.e. non-arcing time). During this time roughly 1 kW power is consumed .Energy wastage time may be anywhere between 60 -75% of the total production time. In house Electronic controller has been designed and manufactured to reduce idling wastage of the welding transformers .This controller senses the actual contact of the welding rod to the job and puts ON the input supply to the transformer only after that . Measurements have shown that the ON time of input supply has been reduced by 65%.

Cost of one unit: approx Rs 3000/-

This controller has been installed for 30 machines.

Total saving for 30 machines are Rs.2.16 Lakh.

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WORKING PRINCIPLE

IN HOUSE DESIGNED ENERGY SAVER FOR HIGH BAY 400 W HPSV LAMPS

400Watts HPSV High bay lamps have been used in most of the shops for illumination. These lamps are supplied with full voltage throughout their operating time.

Actually the lamps require full voltage only during initial ignition. After stabilizing the voltage can be dropped down by 8-10% without appreciable loss of illumination but considerable reduction in input energy.

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A special transformer circuit has been designed to perform the desired action. Each unit can handle 20-25 lamps. Cost of each unit ~ Rs 10000/-

50 units have been installed covering around 700 overhead lamps in all shops.

Total saving in Rs. for 700 Lamps Rs. 8, 75,000 & payback is less than 4 Months

SAVINGS

Considering 700 lamps and 8 Hrs per day: Rs 8.75 Lakh Per Annum

Estimated Investment Rs 5.0 Lakh

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NORMAL MODE ENERGY SAVING MODE

(22% Power Reduction)

215 v

230 v

Power : 427 Watt

Current: 1.91 A

Lux : 5000

Power : 333 Watt

Current: 1.72 A

Lux : 4750

Input

230 v

15: 230 Transformer

Input

230 v

15: 230 Transformer

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OPTIMIZATION OF PRESSURE & OPERATION OF COMPRESSORS

Before: Generation Pressure – 6kg/cm2. At upstream of Intermediate control system.

Earlier All Reciprocating Compressor & Centrifugal compressor were operating at 6kg/cm2

After: Optimization of compressor operation is done by Centrifugal Compressor is operated at Base Load. Reciprocating & Screw Compressors are operated as per requirement. Optimization of Pressure of Compressor is done by Introduction of Intermediate control (Results into pressure reduction from 6.5kg/ cm2 to 6kg/cm2)

Centrifugal Compressor (Base Load) is connected after Intermediate controller results in comp. operating pressure reduced from 6 to 5kg/ cm2.

Investment = Rs. 5.0 Lakh

Saving = 5.75 Lakh Kwh / annum; Saving in Rs 23.0Lac per annum

Payback = 2.6 Months

REDUCE THE ELECTRICAL CONSUMPTION OF AC PLANT AT TTL BY INSTALLING TEMPERATURE CONTROLLER

Before: Earlier the temperature was controlled by unloading of compressor. The 2nos X 25 HP motors were running for 24X7.

After: Installed temperature controller for each compressor. The temperature is maintained constant. The total consumption was 900 Kw/day. Reduced to 600Kw/day. i.e. 300Kw/Day

Saved- Rs.1350/ day.

Investment- Rs.0.045 Lakh

Saving- Rs.4.9. Lakh per annum. MBA (Tech) 5th Year

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Payback- within 5 days

INTRODUCTION OF RECUPERATIVE TYPE GAS HEATING SYSTEM FOR ENDOGAS GENERATOR

Before: Earlier, Endogas Generator heating system operated by electrically operated 40Kw heaters resulting in high operating Energy cost.

After: Self-recuperative burner Principle-: Combustion air enters into burner & flows alongside the interior walls of the recuperator to the burner head. In counter direction the hot exhaust gas flows out of the Endo-Gas Generator alongside the exterior walls of the recuperator. A heat exchange is taking place through the recuperator walls between the hot exhaust gas & the cold combustion air.

Investment: Rs.8.5 Lakh

Savings: Rs.3.53 Lakh per annum.

Payback: 2.4 Years

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REFERENCES

www.bee-india.nic.in/index.php?module=intro&id=11

http://www.tatamotors.com/cop/pdf/COP-2007-2008.pdf

www.energymanagertraining.com/eca2007/Award2007_CD/02Automobile/TataMotorsCVBUPune/Profile.pdf

www.ifc.org/ifcext/spiwebsite1.nsf/1ca07340e47a35cd85256efb00700cee/AA9D2712CA888B6885256B7A006336DC

iea.org/Textbase/country/maps/world/pop.htm

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