GM - Assembly Plant Co-Generation


Shambaugh & Son, L.P.


General Motors Corporation

Services Provided

  • Electrical
  • Mechanical
20-cylinder combustible engines custom designed for GM's methane gas electricity system

Value Delivered

Shambaugh's electrical and mechanical divisions provided a significant amount of value-engineering deductions. Also, by using methane gas to generate electricity, 28 percent of the plant is now alternatively powered. This method saves General Motors Corporation close to $3.5 million per year in energy costs.

Client Objectives

GM required various electrical solutions, fire alarms, and building lighting controls for the the truck and bus assembly plant in Allen County, Indiana. The plant uses methane gas produced by landfills to generate electricity—the first of its kind in North America.

Scope of Services

Electrical Division:

  • Four 1.6 MW Caterpillar generators
  • Paralleling switchgear
  • 6-MVA pad-mount transformer
  • 24-V DC battery system, including all power and control wiring
  • New gas monitoring system
  • Building fire alarm
  • All building lighting and controls

Mechanical Division:

  • Furnished and installed the piping for 4 Caterpillar generators, which have become the prototype installation in other GM facilities.

Client Background

The gas created by decomposing waste is routed through eight miles of pipe to the GM plant. The gas then goes through four 20-cylinder combustible engines that are fitted with generators to produce electricity.