Peak Demand Management at GKN Sintermetals Inc.

Peak Demand Management at GKN Sintermetals Inc.

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APPENDIX

I. The Diagnosis

In this appendix an extensive interpretation of the search for problems at the companies. As pointed out in Chapter 2 the first step of the diagnosis is a walk through the factory floor first, to collect the problems wich are directly visible. After these first quick view, next step, as drawn up by the Dr. R.

Muller, State University of New Jersey: Rutgers, a self-assessment workbook, is to draft the energy balances: At GKN and Usabco an electricity balance and at Falke and Nettex both an electricity balance and a steam balance is needed. The data needed for these balances is:

1 the machines using these energy

2 the amount of this machine running in the factory 3 the usage of the machines

4 the running hours of the machines

5 the total usage for the factory of the last years 6 production rates of the last years

After gathering these data it’s worth analysing the data and making notice of the interesting parts of the balances.

All the problems that arose at the four companies can be summarised in the following table (AI.1)

Factory Electricity HFO

Account Tariff Group Running hours Boiler Condensate Return

GKN Sintermetals x x x

FALKE Eurosocks x x x X

Usabco x x

Nettex x x

Table I.1: Summary of the problems at the four companies

As can be seen are the electricity account problems and the lack of knowledge about the tariff group structure the collective problem fields. Both problems have got something to do with the costs of energy and less about the usage or consumption. After discussing with all the companies, taking into consideration my experiences, background and knowledge picked up during my TBW-study, we decided to focus on both the electricity account and the choice of tariff groups. On first sight both problems seems to get solved very easy but during this thesis you should notice that there is a big opportunity in researching these look-a-like undiscovered niche in the South-African and maybe worldwide discrete industry. For the other problems, most instrumental, some directions are given to get able solving these problems. Because these solutions are not part of the final thesis, they are posted in appendix I

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II. The Difference Between kVA and kW: the Power Factor

The difference between the unity kVA and the unity kW is the power factor. The technical terms of the power factor calculation for a three-phase electricity user: (Tenessee Valley Authority,: Energy Services)

Usage (Wh’s) = 3 * Strength of Current (Amps) * Voltage (V) * power factor (AII.I)

The power factor is for every company different, but known is that the optimal value is one. The existence of the power factor is made clear by using the following figure (AII.1).

Figure AII.1 The power factor

The induction of the machines causes the current to lag, or occur later in time than the applied voltage.

One part of the current is doing the actual work demanded by the machine (kW), while the other is supporting the reactive, inductive load. This is known as the kilovolt Amps Reactive, or kVAR (see figure A1.2)

Figure II.2 The kVAR Figure II.3 The phase angle (θ)

The ratio of the kW to kVA at the power line frequency of 50 Hz (U.S.A.: 60 Hz) is known as Power Factor, or Displacement Power Factor (figure A1.4). The current is displaced in time from the voltage.

This refers specifically to the phase shift, described as the cosine of the phase angle (θ). In this case, apparent power (kVA) can be larger than active power (kW) due to the phase shift of the fundamental current. The current must be larger to produce the same active power. This way, the kVA becomes

Powerfactor

kW kVA

kVAR

Current Voltage θ

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larger because of the larger current. (Power Management in the Studio, www.equitech.com/articles/power.html)

A phase-angle meter is connected to the electricity box at GKN, showing that the phase angle (θ) is between 12º and 23º, with corresponding power factors of respectively 0,92 and 0,98. The 3 in the calculation is because at GKN they’re making use of three-phase current.

III. DATA NEEDED FOR THE SIMULATION MODEL

III.1 The Priority Rules Which Machine to Stop

T500 - if ON and < max I, QD AND - peak-maxpeak > UT400 OR

- peak-maxpeak > UT200 and T400 is OFF, to max I or to max QD OR - peak-maxpeak > UT60, T400 and T60 both or to max I, QD or OFF OR - peak-maxpeak > 0, T400, T60 and t200 all or OFF or to max I, QD

T400 - if ON and < max I, QD AND

- peak-maxpeak > UT60, while < than UT400 or if T500 is or OFF or to max I or QF OR - peak-maxpeak > UT200 and T60 to max I, QD or OFF OR

- peak-maxpeak > 0, T60 and T200 both or OFF or to max I, QD

T60 - if ON and < max I, QD AND

- peak-maxpeak > UT200, but < UT60 or < UT400 and T400 OFF or to max I, QR or > UT400 and T500 and T400 both or OFF or to max I, QD OR

- peak-maxpeak > 0 and T200 OFF or to max I, QD

T200 - if ON and < max I, QD AND

- peak-maxpeak > 0, but < UT200 or < UT60 and T60 OFF or to max I, QD or < UT400 and T400 and T60 both or OFF or to max I, QD or > UT400 and T500, T400 and T60 all or OFF or to max I, QD

No Machine - If T200, T60, T400 and T500 all or OFF or to max I, QD

Table III.1: The priority rules which machine to stop when peak reaches permitted maximum peak demand level

III.2 The Products, the machines, the Setup Time, the Production rates and the Master Plan

Products Machines Set Up Prod. Rates m January February March April May June July August September October November December Hours min/part Pn 433 544 529 559 568 568 584 592 584 584 592 393 F1541 T500 3 24 6100 7600 7600 7600 8000 8000 8000 8400 8400 8000 8400 3800 F1544 T500 3 24 3000 3000 3000 1000 F1718A T500 3 24 1700 2100 2100 2100 2200 2200 2200 2300 2300 2200 2300 1100 F1724A T500 3 24 700 900 900 900 900 900 900 900 900 900 900 400 F3027C T500 5 29 2700 3400 3400 3400 3600 3600 3600 3700 3700 3600 3700 1700 F3071 T500 3 21 500 600 600 600 700 700 700 700 700 700 700 300 F3079 T500 3 21 1000 1000 2000 2000 2000 2000 2000 3000 3000 2000 F3097C T500 5 36 3400 4200 4200 4200 4400 4400 4400 4700 4700 4400 4700 2100 F3200 T500 3 18 10000 10000 10000 10000 10000 10000 10000 10000 10000 10000 F3027R* T500 3 29 2700 3400 3400 3400 3600 3600 3600 3700 3700 3600 3700 1700 F2097R* T500 3 36 3400 4200 4200 4200 4400 4400 4400 4700 4700 4400 4700 2100 Σ 21200 26400 37400 37400 39800 39800 39800 41100 44100 43800 45100 26200 F3084C T400 3 18 4900 6100 6100 6100 6400 6400 6400 6700 6700 6400 6700 3100 F3086 T400 3 21 5100 6400 6400 6400 6700 6700 6700 7000 7000 6700 7000 3200

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F3087 T400 3 24 1000 1300 1300 1300 1300 1300 1300 1400 1400 1300 1400 600 F3106DC T400 3 18 2200 2700 2700 2700 2800 2800 2800 3000 3000 2800 3000 1400 F3113EC T400 3 18 200 300 300 300 300 300 300 300 300 300 300 100 F3145AC T400 3 18 7100 8800 8800 8800 9300 9300 9300 9700 9700 9300 9700 4400 F3179AC T400 3 18 8100 10200 10200 10200 10700 10700 10700 11200 11200 10700 11200 5100 F3084R T400 3 18 4900 6100 6100 6100 6400 6400 6400 6700 6700 6400 6700 3100 F3106DR* T400 3 18 2200 2700 2700 2700 2800 2800 2800 3000 3000 2800 3000 1400 F3113ER* T400 3 18 200 300 300 300 300 300 300 300 300 300 300 100 F3145AR* T400 3 18 7100 8800 8800 8800 9300 9300 9300 9700 9700 9300 9700 4400 F3179AR* T400 3 18 8100 10200 10200 10200 10700 10700 10700 11200 11200 10700 11200 5100 Σ 51100 63900 63900 63900 67000 67000 67000 70200 70200 67000 70200 32000 F1523 T200 3 12 300 300 300 300 300 300 300 400 400 300 400 200 F3089 T200 3 18 200 200 200 200 200 200 200 200 200 200 200 100 F3201 T200 3 18 3400 4200 4200 4200 4400 4400 4400 4700 4700 4400 4700 2100 Fxxx T200 3 18 700 800 800 800 900 900 900 900 900 900 900 400 Σ 4600 5500 5500 5500 5800 5800 5800 6200 6200 5800 6200 2800 F1961 T60 3 9 5800 7200 7200 7200 7600 7600 7600 7900 7900 7600 7900 3600 Σ 5800 7200 7200 7200 7600 7600 7600 7900 7900 7600 7900 3600

* This products needs to get pressed before (compacting) and after (repressing) the sinter process in the furnace. For convenience’s sake they are taken apart as being two different products.

Table III.2: The Products, the Machines, the Setup Times, the Production Rates and the Master Plan

P = 100% Jan Feb mar Apr may Jun Jul Aug sep Oct Nov Dec

500 693 929 590 710 662 662 726 703 571 597 575 515

400 248 365 305 425 382 382 446 396 364 446 396 576

200 1560 1981 1921 2041 2070 2070 2134 2156 2124 2134 2156 1444 60 1645 2071 2011 2131 2162 2162 2226 2254 2222 2226 2254 1512

Table III.3: Available Intervention Time (in periods of fifteen minutes)

III.3 The Machines, TypeNRs, Usage, Operation time and Occupation Rates

Cell Machine TypeNR*** Usage

Operation time

** Frequency Yellow 500t press 3 92 3 -*

Yellow 400t press 3 37,8 3 -*

Yellow 200t press 3 13,3 3 -*

Yellow 60t 3 16,4 3 -*

Furnace Cremer 1 66,5 - ~100%

Furnace FHD 1 45,6 - ~100%

Red R4 3 2 3 60%

Red R4 3 2 3 60%

Red R4 3 2 3 50%

Red 6t 3 2 3 40%

Red Harepress 3 1 3 60%

Red Lathe 3 1 3 40%

Red Barrell 3 0,3 3 30%

Yellow S5 3 2,6 3 60%

Yellow 100t 3 3,3 3 70%

Yellow 280G 3 4,2 3 60%

Blue 280G 3 5,5 3 60%

Blue 280G 3 4,7 3 60%

Blue Oil 3 1,3 4 40%

Blue Barrell 3 1,3 4 40%

Blue 50t 3 3,6 3 60%

Blue C60 3 2,1 3 60%

Green S5 3 5,2 3 70%

Green APEX 3 6,2 3 60%

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Green C60 3 2 3 70%

Green CNC 3 8,8 3 66%

Green CNC 3 8,8 3 70%

Green CNC 3 8,8 3 70%

Green CNC 3 8,8 3 70%

Green CNC 3 8,8 3 70%

Orange Oil 3 1,3 4 30%

Orange Drill 3 1,5 2 33%

Orange Drill 3 1,5 2 33%

Orange Drill 3 1,5 2 33%

Orange Drill 3 1,5 2 33%

Orange C110 3 2,5 2 33%

Orange 60t 3 4 3 50%

Orange drill 3 1,5 2 30%

Orange lathe 3 1 2 30%

Orange X ton 3 8,7 3 50%

Furnace Degussa 2 15,2 504 1%

Furnace Elino 2 5,2 504 1%

Furnace Cracker 1 2 - ~100%

Furnace Compressor 1 44 - ~100%

Res Grasse 3 0,3 2 30%

Res Steam 3 4,7 2 66%

Res Shotblast 3 5,7 2 66%

Res Mall Impr 3 5,4 2 40%

Res Barrell 3 1,4 2 40%

Res Blender 1 3 1,9 2 20%

Res Blender 2 3 1,9 2 20%

Toolroom Cut wire 4 4,5 2 80%

Toolroom N sparker 4 1 2 80%

Toolroom CNC turn 4 1 2 80%

Toolroom TC 20 turn 4 1,5 2 80%

Toolroom O sparker 4 1,5 2 80%

Toolroom Kellenberg 4 1,6 2 75%

Toolroom Graziono 4 3,2 2 80%

Toolroom Profiled r 4 0,2 2 80%

Toolroom Jonnford m 4 3,2 2 40%

Toolroom Blohm 4 5,3 2 60%

Toolroom Brill 4 0,75 2 40%

Toolroom Calchester 4 7,5 2 20%

Toolroom Maho 4 6,3 2 20%

* frequencies depends on the planned parts per month

** operation time is the time between starting and stopping the machine

*** De machines zijn onderverdeeld naar type:

1) Machines running constantly during the whole production time, occupation rate = 100%

2) Machines running constantly during a certain part of the production time, (assumed) occupation rate = 100%

3) Machines running variable during the whole production time, the occupation rate < 100%

4) Machines running variable during a certain part of the production time, occupation rate < 100%

Table AIII.4: The machines, typeNRs, Usage, Production Length and Occupation Rates

III.4 Production Quantities and Available Intervention Time when Production Grows

T500 Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec F1541 6405 7980 7980 7980 8400 8400 8400 8820 8820 8400 8820 3990

F1544 0 0 0 0 0 0 0 0 3150 3150 3150 1050

F1718A 1785 2205 2205 2205 2310 2310 2310 2415 2415 2310 2415 1155

F1724A 735 945 945 945 945 945 945 945 945 945 945 420

F3027C 2835 3570 3570 3570 3780 3780 3780 3885 3885 3780 3885 1785

F3071 525 630 630 630 735 735 735 735 735 735 735 315

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F3079 0 0 1050 1050 2100 2100 2100 2100 2100 3150 3150 2100 F3097C 3570 4410 4410 4410 4620 4620 4620 4935 4935 4620 4935 2205 F3200 0 0 10500 10500 10500 10500 10500 10500 10500 10500 10500 10500 F3027R 2835 3570 3570 3570 3780 3780 3780 3885 3885 3780 3885 1785 F2097R 3570 4410 4410 4410 4620 4620 4620 4935 4935 4620 4935 2205 22260 27720 39270 39270 41790 41790 41790 43155 46305 45990 47355 27510

T400

F3084C 5145 6405 6405 6405 6720 6720 6720 7035 7035 6720 7035 3255 F3086 5355 6720 6720 6720 7035 7035 7035 7350 7350 7035 7350 3360 F3087 1050 1365 1365 1365 1365 1365 1365 1470 1470 1365 1470 630 F3106DC 2310 2835 2835 2835 2940 2940 2940 3150 3150 2940 3150 1470

F3113EC 210 315 315 315 315 315 315 315 315 315 315 105

F3145AC 7455 9240 9240 9240 9765 9765 9765 10185 10185 9765 10185 4620 F3179AC 8505 10710 10710 10710 11235 11235 11235 11760 11760 11235 11760 5355 F3084R 5145 6405 6405 6405 6720 6720 6720 7035 7035 6720 7035 3255 F3106DR 2310 2835 2835 2835 2940 2940 2940 3150 3150 2940 3150 1470

F3113ER 210 315 315 315 315 315 315 315 315 315 315 105

F3145AR 7455 9240 9240 9240 9765 9765 9765 10185 10185 9765 10185 4620 F3179AR 8505 10710 10710 10710 11235 11235 11235 11760 11760 11235 11760 5355 53655 67095 67095 67095 70350 70350 70350 73710 73710 70350 73710 33600

T200

F1523 315 315 315 315 315 315 315 420 420 315 420 210

F3089 210 210 210 210 210 210 210 210 210 210 210 105

F3201 3570 4410 4410 4410 4620 4620 4620 4935 4935 4620 4935 2205

Fxxx 735 840 840 840 945 945 945 945 945 945 945 420

23,625 28,35 28,35 28,35 29,925 29,925 29,925 31,85 31,85 29,925 31,85 14,35

T60

F1961 6090 7560 7560 7560 7980 7980 7980 8295 8295 7980 8295 3780

Table III.5: The production quantities if production (at method-machines) increase with 5%

P =105% Jan Feb mar Apr may Jun Jul Aug sep Oct Nov Dec

500 651 875 523 643 591 591 655 629 492 520 494 472

400 183 283 223 343 297 297 361 307 275 361 307 535

200 1554 1974 1914 2034 2062 2062 2126 2149 2117 2126 2149 1440 60 1641 2067 2007 2127 2157 2157 2221 2249 2217 2221 2249 1510

Table III.6: The Available Intervention Time (in periods of fifteen minutes) during 5% increase production at method-machines

T500 Jan Feb Mar Apr May June Jul Aug Sep Oct Nov Dec F1541 6710 8360 8360 8360 8800 8800 8800 9240 9240 8800 9240 4180

F1544 0 0 0 0 0 0 0 0 3300 3300 3300 1100

F1718A 1870 2310 2310 2310 2420 2420 2420 2530 2530 2420 2530 1210

F1724A 770 990 990 990 990 990 990 990 990 990 990 440

F3027C 2970 3740 3740 3740 3960 3960 3960 4070 4070 3960 4070 1870

F3071 550 660 660 660 770 770 770 770 770 770 770 330

F3079 0 0 1100 1100 2200 2200 2200 2200 2200 3300 3300 2200 F3097C 3740 4620 4620 4620 4840 4840 4840 5170 5170 4840 5170 2310 F3200 0 0 11000 11000 11000 11000 11000 11000 11000 11000 11000 11000

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F3027R 2970 3740 3740 3740 3960 3960 3960 4070 4070 3960 4070 1870 F2097R 3740 4620 4620 4620 4840 4840 4840 5170 5170 4840 5170 2310 23320 29040 41140 41140 43780 43780 43780 45210 48510 48180 49610 28820

T400

F3084C 5390 6710 6710 6710 7040 7040 7040 7370 7370 7040 7370 3410 F3086 5610 7040 7040 7040 7370 7370 7370 7700 7700 7370 7700 3520 F3087 1100 1430 1430 1430 1430 1430 1430 1540 1540 1430 1540 660 F3106DC 2420 2970 2970 2970 3080 3080 3080 3300 3300 3080 3300 1540

F3113EC 220 330 330 330 330 330 330 330 330 330 330 110

F3145AC 7810 9680 9680 9680 10230 10230 10230 10670 10670 10230 10670 4840 F3179AC 8910 11220 11220 11220 11770 11770 11770 12320 12320 11770 12320 5610 F3084R 5390 6710 6710 6710 7040 7040 7040 7370 7370 7040 7370 3410 F3106DR 2420 2970 2970 2970 3080 3080 3080 3300 3300 3080 3300 1540

F3113ER 220 330 330 330 330 330 330 330 330 330 330 110

F3145AR 7810 9680 9680 9680 10230 10230 10230 10670 10670 10230 10670 4840 F3179AR 8910 11220 11220 11220 11770 11770 11770 12320 12320 11770 12320 5610 56210 70290 70290 70290 73700 73700 73700 77220 77220 73700 77220 35200

T200

F1523 330 330 330 330 330 330 330 440 440 330 440 220

F3089 220 220 220 220 220 220 220 220 220 220 220 110

F3201 3740 4620 4620 4620 4840 4840 4840 5170 5170 4840 5170 2310

Fxxx 770 880 880 880 990 990 990 990 990 990 990 440

5060 6050 6050 6050 6380 6380 6380 6820 6820 6380 6820 3080

T60

F1961 6380 7920 7920 7920 8360 8360 8360 8690 8690 8360 8690 3960

Table III.7: The production quantities if production (at method-machines) increase with 10%

P = 110% Jan Feb mar Apr may Jun Jul Aug sep Oct Nov Dec

500 608 822 456 576 519 519 583 555 413 442 414 428

400 118 202 142 262 211 211 275 217 185 275 217 494

200 1548 1968 1908 2028 2055 2055 2119 2141 2109 2119 2141 1437 60 1637 2062 2002 2122 2153 2153 2217 2244 2212 2217 2244 1508

Table III.8: The Available Intervention Time (in periods of fifteen minutes) during 10%

increase production at method-machines

IV. Complete Results of Scenario2

IV.1 The Peak Demands Scenario2 (Table IV.1, page 78)

IV.2 The Number of Interventions Scenario2 (Table IV.2, page 79-81)

V. Complete Results of Scenario3

V.1 The Peak Demands Scenario3 (Table V.1, page 82, 83)

V.2 The Number of Interventions Scenario3 (Table V.2, page 84-89)

ScenarioSCENARIO 2 Max Peak Level 480 460 450 Max Nr Intervention2 4 6 8 6 Month / prod %0%5%10%0%5%10%0%5%10%0%5%10%0%5%10% Jan 471,6471,6471,6471,6471,6471,6460,4459,4459,4460,5459,4459,4449,7449,7451,4 Feb 476,8476,1481476,8477,1481458,4458,5462,5458,4458,5476,9449,9449,4449,3 mart 473,9466,9498,8473,9480479,1458,1459,5457,9458,1461462,4449,7451,5465,9 Apr 473,4477,7477,1473,4475,4478459,8459,4459458,7470462,1449,4449,9453 may 476,5471,5465,5476,5469,1471,3457,5459,3457,7459,8457,5470,8452,8450,1449,7 Jun 476,1478,6481,3476,1479484,6461,6458,8462,4460,4463,2459,4448,9449,4452,7 Jul 475,6478,8470,4475,6473,7478,1457458,8461,2458,7464,2459,9452,1449,8448,8 Aug 477,5478,4479477,5477,5478,4459,2461,1457,5458,5460460,1448,1449,5459,1 sep 470,9472,9477,4475,3480,4475,7458,8459,8459,8458,2460459,4449,3449,6449,5 Oct 468,8473,6471,4465,3473,8464,3459,4458,9458,1457,3459,4458,1454,1449449,6 Nov 473,1474,3477,5477,8479,4479,7460459,2460,4459,2457,9459,4449,1449,6449,3 Dec 475,8476,1469,2473,2479,6477,6459457,7459,7459,5457,7459,8455,3450,7448,9 Mean 474,2474,7476,7474,4476,4476,6459,1459,2459,6458,9460,7462,3450,7449,9452,3 % 1,1%0,4%-0,1%1,1%0,0%-0,1%4,3%3,6%3,5%4,3%3,3%2,9%6,0%5,6%5,0%

IV .1 Resu lt s P eak D em a n d S cenario2

SCENARIO 0 440 6 8 0%5%10%0%5%10% Month 0%5%10% 448,8443449,7448,8443453,9 Jan 471,6471,6471,6 439,3448,3438,8447,9439,3440,1 Feb 476,8471,6474,1 438,6443,3455,7438,9439,4453,9 mart 473,9482,1494,6 449,7452439438,8441,8439,4 Apr 473,4467490,7 438,9445,1446,8439,1440,1452,5 may 479,4463,8465,7 442,8442,4450,4449455,4450,6 Jun 490,4481,7474,7 439,7458,2455,3439439,8451,8 Jul 480,7476,7474,8 441,5439,7439,2442,6439,1439,5 Aug 488493,2470,4 439,2440,6453,1440,5440,8454,8 sep 476,6490,1464,3 439,1439,1446443,7438,9443,2 Oct 470,1470,1479,3 439,9439,4454,4439449,4486 Nov 496,5479,1469,1 439439,8442444,6439,4443,6 Dec 476,8470,5485,9 441,4444,2447,5442,7442,2450,8 Mean 479,5476,5476,3 8,0%6,8%6,0%7,7%7,2%5,4% %0,0%0,0%0,0%