미래예측정보에대한주의사항 - Hyundai Heavy Industries2 v 미래예측정보에대한주의사항 본자료는미래에대한"예측정보"를포함하고있습니다.
Energy Management System in Forging industries2
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Transcript of Energy Management System in Forging industries2
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Energy Management System inForging Industry
Presented by :Avijit ChoudhuryUL-DQS India
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Forging Industry at a glance One of the major contributors to the manufacturing sector
with YoY growth of more than 10% in last three years. Total annual production is 9.29 lakhs ton. Caters mostly to auto industry (around 70%). Other
sectors served are Aerospace, Oil & Gas, Nuclear etc. Around 400 forging units are present in India- Large,
Medium & Small. Around 10 large players account for 55% of the total
production. Organized sector comprises large & medium size plants
and contributes to around 70% of total production. Rest come from the small and micro sector- mainly
catering to job work and replacement market. 2
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Energy Component of Forging
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Present business environment
Overall growth of auto industry is sluggish. The escalating price of automotive fuel like petrol, diesel &
CNG puts a question mark on the revival of earlier growth story.
So most of the automobile manufacturers are trying to cutting cost to remain competitive in the market.
This is creating back pressure on their suppliers to cut cost without compromising the product quality.
Raw material like carbon steel, stainless steel, high temp alloy etc. have become costlier over 37% in last three years.
Forging Process is labour intensive and further reduction on this front is difficult.
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Energy Scenario of India
Prices of primary energy like HSD/FO/PNG have gone up by more than 50% in last three years.
Price of secondary energy like electricity has increased from 24 to 35% in different states.
More than 70% of petroleum demand of our country is met by import.
The dependency on imported coal is increasing day by day among the thermal power producers.
It is seen that international bidding price of coal has just become double in last three years.
The dollar price which was Rs 51 in last February is hovering around Rs 62-63 at present.
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Sustainability of Energy Price?
Under the present situation the OMCs (oil marketing companies) are incurring huge losses and expected to raise the prices of all products in near future.
The major indigenous supplier of NG in the country –M/s Reliance Industries is asking a much higher price ($14.07/ Mbtu) from the existing approved rate ($ 4.21 / Mbtu).
It is expected that price of PNG/ CNG will increase by 30 to 50% once new price is approved by the oil ministry.
Raw material price is going up but energy price is increasing at a faster rate. But you need to maintain your existing production cost if not reducing it further.
So what is the remedy?So what is the remedy?
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Energy Management System What is energy management?
The judicious & effective use of energy to maximize profit (minimize cost) and enhance competitive position.
What is its objective?
The fundamental goal of energy management is to produce goods or provide services with the least cost and least environmental effect.
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EnMS is more than energy audit
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Basics of EnMS
Know your present energy performance keeping these variables in mind-
Scale of operationVintage of technologyRaw material specification & qualityProduct specification & qualityCapacity utilization factorFixed vs. Variable energy trend
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Plant performance as a whole
a) Energy Performance of the whole plant:
Kg of FO/ ton of production (or Rs/ ton). SCM of NG / ton of production (or Rs/ ton). kWh/ ton of production (or Rs/ ton). Total: TOE/ Ton of production (Rs/ ton).if there is too much variation in specific energy
consumption of different products (due to additional process like surface grinding, phosphating, zinc plating etc.) then SEC of different product lines should be maintained separately.
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Efficiency of major processes
b) Energy performance of the major processes:
Identify major processes like- Preheating, Pressing, heat-treatment/ annealing etc.Define energy performance indicators (EnPI) of all major processes. For example i)Gas fired preheating- scm of NG/ ton of charge materialii)Hammer operated with motor & fly-wheel: kWh/ ton of hammered productiii)Annealing furnace with electrical heating: kWh/ ton of annealed product.
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Efficiency of major equipment
c) Energy efficiency of the major equipment:
Identify energy intensive equipment like- Forging furnace, heat treatment furnace, gas carburizing furnace, hammer, compressor, transformer etc.Define energy efficiency of all the major equipment. For example-i)Furnaces: Thermal efficiency = heat output (m.Cp.∆t)/ heat input (f. GCV)ii)Compressor: Isothermal efficiency = isothermal power / actual power iii)Hammer: % loading & idle running time of motor
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Energy monitoring & targeting
The main principle is:
““You can’t manage what you don’t measure”You can’t manage what you don’t measure”Start installing data measurement and recording devices. For example if you are using NG in your furnace then each furnace should have on-line gas flow meter which will record the consumption of gas on regular basis.Collect past 6 month or one year energy vs. production data. Declare your present energy baseline. Any future comparison of energy performance shall be done against this baseline. Make a reporting system of energy performance on daily, monthly and yearly basis.
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Energy monitoring & targeting Set a target baseline to be achieved within a definite
time frame. Set target for individual process and equipment to
reduce energy consumption. Set operational parameters to control different
processes. Set clear guidelines to take care of deviation or variance. Check the accuracy level of data. Allocate energy cost for each department separately. Define the cost of utilities like compressed air, steam,
chilled water etc. and charge individual department according to their use.
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Energy consumption pattern
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Efficiency of typical forging furnace
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Efficiency of typical forging furnace
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Furnace efficiency by direct method
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Efficiency by heat loss method
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Heat balance of furnace
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Data collected from Hammer
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Saving potential in hammer
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Judging Energy Management System
Once you have implemented EnMS, its efficacy is to be judged in terms of -
Whether it is appropriate for the organization?Whether it involves employees from all layers?Whether it is robust and strong enough to take care of changes in the business environment?Whether it ensures continual improvement in energy performance?Whether it meets legal & other requirement?What is the commitment of top management in supporting and improving the established EnMS?
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ISO-50001:2011
The best way to judge an energy management The best way to judge an energy management system is to check its compliance with the system is to check its compliance with the clause requirement of the international standard clause requirement of the international standard ISO-50001.ISO-50001.
This standard supersedes the earlier European This standard supersedes the earlier European standard EN-16001.standard EN-16001.
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Credentials of UL DQS in EnMS
Getting an ISO-50001 certification is always a joy to any company. But the certificate should bring value to the organization in terms of reduced energy consumption and continual improvement. To ensure this, UL-DQS India has adopted certain measures-
Widest range of accreditation: UL-DQS issues accredited certificates. Certificate carries accreditation mark like DakkS (Germany), ANAB (USA), UKAS (UK) etc.Neutrality & Impartiality: The functioning of UL-DQS India is assessed by and independent “Management Systems Advisory Council”.
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Competence of the auditor: UL DQS ensures that the lead auditor has vast experience in energy field and adequate knowledge of the relevant sector.
Customer satisfaction: All customers are being sent a feedback form to rate the quality of audit and quality of overall service provided by the organization.
Report a violation: UL-DQS website provides a web platform where a customer can directly lodge his complain if he observes any unfair or unethical business practices, breach of guideline or violation of code of conduct.
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Credentials of UL DQS in EnMS
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Areas of Co-operation
We can help you in-
Conducting on site awareness cum implementation training on ISO 50001.
Conducting an Energy Review / Energy Audit.
GAP Assessment.
ISO 50001 Certification
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UL DQS India – a brief
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UL DQS Global : Key Facts
5 Continents
80 Group companies
130+ Countries
2300 auditors
47000 assessment days/yr
150 + Years of cumulative
experience
49000Certified sites
2 Standard Writing Org.
25 + industries
20000customers
5Among top 5 global certification bodies
100 + standards
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How does that help our customers …International – Innovative • Service portfolio includes over
70 types of Management SystemAssessments and Certifications • Proven competence in all business
sectors
Customer and Solution Oriented • Trainings• Process audits• Supplier assessments• Company-specific assessments
• GC Mark
Pan India Customer Reach:India offices: • Bangalore • Baroda• Chennai • Pune• Delhi
• Market Access to Customers.....across the globe ... NA, LA, Europe, Asia
• Multiple Accreditations: ANAB, DakkS, NABCB, IATF, EURA... 30
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Certification Services – a glance
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GeneralGeneral
TelecomTelecom(Mkt Leaders)(Mkt Leaders)
MedicalMedical
SustainabilitySustainability
FoodFood
AerospaceAerospace(Mkt Leaders)(Mkt Leaders)
TransportationTransportation
Information SecurityInformation Security
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Knowledge Solution Services• Training
• Internal Auditor• Implementation Interpretation• Special Process : Welding, Painting, Eletroplating….• Tools and Techniques
• Customized / Gap Assessments• Against National / International Standards• Against customer specific requirements / frameworks• Internal audits
• Supplier / Vendor Assessments
• Safety Excellence• Process Safety Management (PSM)• Behaviour Based Safety (BBS)
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Knowledge Solution Services• Facilitation Services
• Without conflict of Interest
• Brand Image Assessments• Customer Facing / Retail outlets
• Benchmarking (DQS Best)• Industry Benchmarking• Multi-locations / Operations Benchmarking
• Energy Audits
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Public Private Partnership Projects
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Thank You!
Our success is our Customer’s successCo-creating value to our Customers!
That’s how we Partner
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