SKF: the implementation of a monitoring system for the management of energy and the achievement of ISO 50001 and Energy Efficiency Certificates (White certificates)
At the end of 2013 the production plant of Airasca (Italy) has obtained the ISO 50001 certification, which qualifies the site as a high energy efficiency factory. SKF collected all the data required to achieve the Energy Efficiency Certificates using an energy monitoring system and presented the practices of the different projects to GSE (the local Energy Services Authority).
SKF, is a Swedish bearing company founded in 1907, supplying bearings, seals, lubrication systems, mechatronics products, power transmission products and related services globally. The SKF Group is today one of the leading global suppliers of products, solutions and services in its sector, owning about 165 plants worldwide and being present with its own sales companies in 70 countries.
In november 2013 the Airasca plant, headquarters and main production center for SKF in Italy, obtained the ISO 50001 certification which qualifies the site as a high energy efficiency factory. The certification represents an important moment in the history of Italian SKF factories and marks the first step towards the factory of the future focused on energy efficiency.
The certification is the synthesis of a journey that lasted over five years and characterized by the adoption of rules and methodologies to maximize the efficiency of the production plant.
In the Airasca plant, since several years, has been introduced an Electrex monitoring system of power and heating consumption that currently consists of around 300 measuring instruments, with particular attention to the consumption of compressed air. The monitoring system made possible to develop an analytical assessment of the energy performance (Energy Review) based on the data gathered, suitable for identifying improvement opportunities.
|Energy Brain software – Dashboard with graphs||Yocto net gateway panel|
A further qualifying value of ISO 50001 certification is represented by energy objectives and targets established on the basis of data collected through the Energy Review.
In this perspective has been predisposed a program aimed at improving the energy efficiency of the production process, characterized by a precise series of actions.
This aspect highlights the radical change introduced by the ISO 50001 certification, which suggests a systematic approach on energy management when pursuing energy efficiency.
New operational control procedures have been introduced, relating to the efficient management of the facilities.
In addition it has been also arranged the training of personnel starting from the maintenance and technical managers of each department.
Four levels of proficiency, necessary to ensure energy efficiency, were identified and every employee directly involved has been trained based on the task being performed.
The energy consumption and costs in 2013 of SKF Italy
Total consumption of electricity (2013): 152GWh
Total consumption of methane (2013): 6.3Milioni smc
The two most significant energy uses in the level of SKF Italy are represented by:
- Compressed Air (source: electricity)
- Heating (source: natural gas)
ENERGY MANAGEMENT ACTIVITY GOALS
- ISO 50001 certification and raise awareness about energy
- Incentives (Energy Efficiency Certificates – White Certificates)
THE OPERATIONAL PHASE OF ISO 50001 IMPLEMENTATION
The Airasca plant has implemented in recent years an Electrex monitoring system for electricity and thermal consumptions that currently consists of approximately 300 instruments. In particular it is continuously monitored the compressed air consumption.
Preparation of the Energy Review
The assessment of the energy performance based on data and other information has allowed the identification of opportunities for improvement.
The two most significant energy uses that have emerged from the review are represented by the consumption of:
- natural gas for heating (22% of total energy consumed)
- compressed air (16% of total energy consumed).
Objectives and energy targets
On the basis of the findings from the Energy Review has been predisposed a program aimed at improving energy efficiency in the production process.
Integrating the Environment and Safety manual with new procedures dedicated to Energy Management
The EHS (Environment, Health and Safety) manual has been integrated with the new procedures dedicated to the ISO 50001. In particular, have been implemented new operational control procedures relating to the efficient management of the facilities. These procedures have been the subject of training for maintenance technicians and operations managers of each department.
Training and awareness raising
4 levels of competence were identified among the different positions. Every employee has been trained on the basis of the task being performed in the company. In particular, was distributed a brochure to all those employees who do not have managerial / organizational responsibilities on ISO 50001 related tasks. In addition, within the internal magazine the subject has been suitable highlighted and covered.
The benefits of ISO 50001
- Definition of standardized procedures in energy management
- Cost reductionsReduce costs
- Promotion of Energy Best Practices
- Increased competitiveness
- Increased awareness on energy saving
THE MANAGEMENT OF ENERGY EFFICIENCY CERTIFICATES (EEC)
In recent months, SKF has collected all the data measured by the monitoring system required to achieve the Energy Efficiency Certificates and presented the practices of the different projects to GSE (the local Energy Services Authority).
Revenues from the sale of energy efficiency certificates will be used by the company to finance new energy efficiency projects, therefore, creating a virtuous circle.
EXAMPLE OF AN ENERGY EFFICIENCY PROJECT (AIRASCA PLANT)
The Airasca plant planned to optimize the compressor room by replacing two existing compressors of 400 kW with two new ones rated of 600 kW. Lo stabilimento di Airasca ha progettato la modifica della sala compressori sostituendo due compressori da 400 kW con due nuovi compressori da 600 kW. The activity of the system has not been modified either in terms of scope or pressure, but the new compressors – combined with the automatic control of the set of working parameters – allowed to achieve significant energy savings, as described here below.
Real and measurable results, which demonstrates how energy efficiency can be transformed in operational efficiency:
|CURRENT EFFICIENCY||8,6 Nmc/kWh|
|FUTURE EFFICIENCY||9,6 Nmc/kWh|
|ANNUAL PRODUCTION||120.000.000 Nmc/h|
|CURRENT CONSUMPTION||13.953.488 kWh|
|FUTURE CONSUMPTION||12.500.000 kWh|
|kWh PAYBACK||1,6 YEARS|