TELCO   plant  at  Jamshedpur  ,Jharkhand

Unit Profile

Tata Engineering  (Telco) is leading automobile giant in the country having its manufacturing units
located at Jamshedpur, Luknow and Pune. Tata Engineering which enjoys nearly 62.5% market share in
commercial vehicle sector had a turnover of  Rs. 8918 crores during 2001-02. The unit at Jamshedpur
which is the mother unit  manufactures Medium and Heavy Commercial Vehicles from 8 to 40 ton gross
vehicle weight. Having an installed capacity of 60,000 vehicles, the unit produced 37,551 vehicles during
the year 2001-02 in keeping with the cyclical nature of demand in commercial vehicle industry.

The Automobile unit at Jamshedpur has captive Forge and Foundry divisions which meet its requirement
of all critical steel forgings and alloy iron castings. In order to achieve greater efficiencies and world class
technological edge in its aggregate production, the manufacture of Axles and Gear Boxes have been
de-integrated and formed into separate companies as HV Axles Ltd and HV Transmissions Ltd.

The unit has a township for its employees and supports community services as a part of its social
responsibility towards its employees and local community.

Energy Consumption

Even though total energy cost has increased during the last three years due to increasing rates for
power and fuel oil, with the implementation of energy conservation measures, the specific consumption of
all areas -  Auto, Foundry and Forge divisions has been steadily declining. Last three years specific
energy consumption figures are as shown below:

PRODUCT                               DESCRIPTION        UNIT        1999-00        2000-01        2001-02
Automobile chassis        Electrical energy                                  647               629              596
Thermal energy                                      kCal / Eq. Vehicle       0.454           0.443            0.411
Casting Tonnage       Electrical energy        KWH / MT               2371          2305              2108
Thermal energy                                              MkCal / MT         0.437           0.417            0.393
Forge Tonnage         Electrical energy        KWH / MT              760               681               655
Thermal energy                                              MkCal / MT         4.04              3.63             3.52
Total Energy Cost     Rs. Lakhs.                                               8018            8708              9087

Energy Conservation Commitment, Policy and Set up

Energy Conservation has been a top management priority for the unit for the last three decades. The
priority emerged either from national perspective to fight energy crisis in seventies and energy shortages
in eighties and early nineties, to present day customer-driven need for cost efficiency.

An Engineering Audit group was created in 1983 which co-ordinates the energy conservation activities in
the plant.

Awareness & involvement of people at all levels has been a major plank for implementation of energy
conservation measures. Energy auditing is a function of the Engineering Audit group. Every year targets
are set for the various divisions & energy conservation action plans are worked out. The specific energy
consumption & status of action plans is reviewed with divisional coordinators using a common matrix
which is shared across all divisions and areas to facilitate cross-pollination of ideas.

Specific consumption of each area is monitored by Engineering Audit on daily basis & is shared with each
divisional head / divisional coordinator as well as the top management.


Energy Conservation Achievements

During the period 1999-00 to 2001-02, the Jamshedpur Plant implemented Energy Saving Ideas
generated through regular energy audits, brainstorming & reviews. The major measures implemented
during 2001-02 are given below.

(I,II)        Changeover to lower wattage energy efficient lamps for lighting in the plant & in Township.

(III)        VFDs were installed at 9 locations as a strategy to reduce energy consumption of pump & blower

(IV)        150 nos. of translucent roof sheets were installed in different areas to facilitate use of natural
daylight in place of high bay lights during the daytime.

(V)        Various simple devices like timers, time-switches, interlocking etc. were installed on machines &
equipment thereby reducing idling of drive motors.

(VI)        Use of thermal heating in place of electric heating resulting in saving in energy cost.

(VII)        Efficient heat utilization in energy intensive furnaces & equipment by use of various measures
like improving insulation, right-sizing of chambers, using temperature controllers etc.

(VIII)        Improve loading of transformers resulting in disconnection of 20 nos. of  low loaded
transformers thus reducing losses.

(IX)        Optimising supply voltage for lighting in the Township.

(X)        Process changes like reducing one shift working due to cycle time improvement of pre-treatment
process before ED in painting.

(XI)        Various improved work practices like ensuring  scheduled running of  ATH thermic fluid boilers in
paint shop.

(XII)        Replacement of 3 nos. inefficient pumps in Town Filter Plant.

(XIII)        Saving in compressed air energy by regular audits & correction of leakages from 29% to 15%;
installing of  16nos. flow meters for monitoring in all areas.

Energy Conservation Plans & Targets

Jamshedpur unit of  Tata Engineering is committed to further improve its energy performance  by
exploring new avenues for energy saving on a continuous basis. Some of the major proposals as a part
of future plan for energy conservation are:

(1)        Changeover of electric frame painting baking ovens to thermal baking for achieving cost
advantage in energy.

(2)        Install Cellulose pads in place of  spray type air washer in Air Replacement Plants in paint shop.

(3)        Installing VFDs in New Engine Cooling Tower & other identified areas to save power.

(4)        Phased replacement of metallic blade of small man-cooler in shops by FRP blades.

(5)        Modifying & improving furnaces for more efficient heat utilisation in Forge.

(6)        Conversion of existing electric cooking into LPG based cooking in Central Canteen.

(7)        Installing Solar Water Heaters in Hospital Canteen.

(8)        Covering more shop areas for natural day-lighting by installing translucent roof-sheets.

(9)        Reducing degreasing bath temperature in paint shop.

(10)        Cover all major furnaces for Flue Gas Analysis.


Source : Bureau of Energy Efficiency,India
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