Energy Management Case Studies - Nissan North America Inc.
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Transcript of 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
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Nissan’s Commitments To Improving Energy Performance
Cost ReductionOn Energy Spend
Nissan Green Program 2016
ENERGY STAR® Certification
Of Plants
DOE Better Plants
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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
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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
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Energy Management Systems ISO 50001
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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
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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
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VehiclesOut
StampingStamping
BodyTruck Paint
Car Paint
Trim
Plastics – Fascia Paint
Rolled Steel
FrameAssy
Modern Vehicle Assembly Plants Are ComplexAssemblages Of Individual Plants
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Total Energy
Total Production
Smyrna Manufacturing Plant Monthly Energy Use & Production 2005 To Present
MM
BTU
/Month V
ehic
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onth
Base Line PeriodCY 2008
Baseline Year
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Smyrna Manufacturing Plant Regression Model Study Of Energy Consumption
Prod
uctio
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lum
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tal)
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uct M
ix Ca
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Prod
uct M
ix Tru
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Heat
ing
Degr
ee D
ays
Cool
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ays
Aver
age
Hum
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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
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7.2%
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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
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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%
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5 Things
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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
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Value -Finding Hidden Waste
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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.
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3 Validation Of Savings
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30% Reduction In Energy Intensity 75% Of Conditioned Paint
Booth Air To Be Recycled To Reduce Energy Use
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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.
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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!
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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