page 1 bupyeong facilities management team oct 2006 total utility management system of gmdat...

Bupyeong Facilities Management TeamOct 2006

Total Utility Management System

of GMDAT Bupyeong Plant

June. 2007

Bupyeong Facilities Management Team


CONTENTS

Plant Overview Location / Site Layout

Total Utility Mangement System Installation Work of Flow Meters Utility Management Point

TUMS 활용


Plant Overview


Location■ Plant Introduction

Bupyeong

Gunsan

170km

420km

260km

Boryung

Changwon

Kalos Tosca

• Location : Bupyeong, Incheon, 25Km west of Seoul• Area : 896,400 square meters • Completion of Construction :

Powertrain Plant (1972, Extension 1986, 2001)

Assembly #2 Plant (1972, Extension 1996)

Assembly #1 Plant (1986)

Gentra

Facility ProductCapacity

(000unit/year)

Assembly #1 Kalos / Gentra 264

Assembly #2 Tosca / Winstorm 185

Power-trainEngine : Fam I, XK T/M : D16/D20, D23/D33

541396

Winstorm


Site Layout

BP #1

Model: Kalos, Gentra

Area: 159,657 ㎡

BP #2

Model: Tosca, Winstorm

Area : 153,332 ㎡

Powertrain Plant

Model: Engine, T/A

Area : 86,613 ㎡

Land Area : 896,397 ㎡

G/A #2 shop XK Engine

Pressshop

Tool shop

G/A #1 shop

Body #1 shop

Paint # 1 shop

Paint # 2 shop

KD

Body #4 shop

Engine shopT/A

shop

Diecastingshop

D24 T/A

MainGate

WestGate

A/S Center

Technical Center

U/C#1WWTF

Deliveryyard

Waste Transferstation


1. TUMS 소개


■ 각 부서에서 사용하는 Utility 에 대해 목표 대비 실적 실시간 관리

▶ Flow meter 설치 수량 : 121 set

▶ Utility 계량계 : Compressed Air (25 개 ), Electricity (40 개 ), LNG ( 10 개 ) , Steam ( 23개 ) Water ( 23 개 )

■ 부평 공장의 모든 직원이 사내 Intranet 을 통해 접속 가능

■ 생산량 변동에 따라 각 부서의 Utility 목표량 변경 : 작업중


2. TUMS 운영 Software 개발


Uti l i ty 예산 입력

, 당초 조정 예산 구분하여 표현

Uti l i ty 예산 입력

E-Metri cs 변환

생산량 담당별 생산량 입력

Target실시간 Target생산 계획에 따른 실시간

담당별 부서별 사용량

생산량

Uti l i ty 별 시간대별 사용 현황

과거 데이터 비교

Uti l i ty 부서별 사용량 비교 분석

추세 분석

Uti l i ty / 사용량 금액 저장

E-Metri cs 저장

대당 사용 현황 저장

월간 실적 및 실시간 누계 저장

구 분 세부 항목

Moni toring

Target

Di splay예산

total 부평 공장 사용량

Di splay실적

Analysi s

데이터/저장 출력

비교 분석

시간별 사용 현황

부서별 비교 현황

Target vsActual

월별 사용 현황 데이터 저장


3. Installation Work


11,432,058

2,571,380

5,470,740

16,412,220

5,620,239

41,506,637

6.7

3.9

1.5

1.0

1.0

3.3


4. Installation Status


1차체 1도장 1조립 2차체 2도장 2조립 프레스 FAM1 XK T/A D24

전력 2 1 1 1 1 1 1 8 3 1 1 2 7 1 24 40

압축공기 2 1 1 1 1 1 1 8 1 1 1 1 4 - 13 25

스팀 4 2 2 2 3 2 2 17 2 2 2 6 - - 23

LNG 2 1 2 5 1 1 2 3 10

용수 2 2 2 1 2 2 1 12 2 2 2 2 8 3 23

계 10 8 6 5 8 8 5 50 9 6 7 5 27 1 43 121

Total 구 분 1승용 담당 2승용 담당 엔진 미션계 계 KD 기타 부평 생산 담당 엔진 구동 본부

(*) Utility Flow Meter 는 각 공장 기계실에 각 Utility Main Line 에 설치됨


4. System 구성 (1)


TridiumTridium

AX SupervisorAX Supervisor

일반 웹브라우저를 일반 웹브라우저를

통한 감시 및 제어통한 감시 및 제어

Ethernet TCP/IP

Modbus RTU

RS-485 통신으로 연결

Ethernet TCP/IP

Electricity

Steam

C/A

LNG

Water

Electricity

Steam

C/A

LNG

Water

…


4. System 구성 (2)


1. Server Monitoirng system2. Direct Digital Control (DDC) 13ea3. Electricity Flow meters 40EA4. Steam Flow meters 23EA5. Compressed air flow meter 25EA6. LNG Flow meters 10EA7. Water Flow meters 23EA


5.TUMS 내부 화면 (1)

각 현장 이동

( 좌측메뉴 및 공장조감도 클릭 가능 )



5.TUMS 내부 화면 (2)



6. Daily Target Monitor



7. Daily Actual Monitor



TUMS 활용


■ Energy TFT Activities Contents

TUMS 활용

A. Review the energy actual status compared with budget by TUMS ▶ Check the each shop’s energy actual ( separate production time and non-production time)

▶ Analyze the energy usage status compared with each other ( compare the same utility actual with same period )

B. Share the Energy Saving Activities Method ▶ Introduce the each shop’s improvement case and its saving effect

▶ Recommend other plant energy saving activities case

▶ Utility Shut-down

C. Energy Audit Activities ▶ Member : Facilities Management Team 15 Person (Office 2, Field Worker 13 )

▶ Audit Period : Every weekend

▶ Audit Item - check the idle operating equipment ( Air conditioners, production line using air ) - Utility Leakage ( Compressed air, water, steam ) - Lights status ( Line, Dress Room, Office etc )


■ Analysis Data by TUMS

Attach #1 Review the Energy Actual


1. Shutdown the Utility at non-producing shop :17'th Feb(Sat) ~ 20'th Feb(Tue)

▷ Shutdown the Electric transformers and others power

- Shutdown the primary transformer included Paint Shop & others

( Paint : 5EA, Body : 9EA, Powertrain:4EA, G/A #1 & Press : 2EA , 154KV : 1EA )

▷ Shutdown the all of boilers at Bupyeong Plant ( 35ton:5EA, 20ton:3EA )

- Shutdown steam at Bupyeong Plant

2. Control the Air Compressor operating and fall the supply air pressure : 17'th Feb(Sat) ~ 19'th Feb(Mon)

▷ Fall the supply compressed air pressure

- Decrease the pressure 6.3kg/ ㎠ to 4.5kg/ ㎠

Process Unit ShutdownTerm

Savingamount

Savings/Cost(USD)

Remarks

Electricity Kwh2/17 ~2/20

1,539,150 87,728

Compressed Air ㎥ " 3,448,488included inelectricity

Steam(LNG) ㎥ " 129,293 66,592

Total 154,320

(*) Unit cost: - Electric ity:32.4USD/MWH (2/17~2/19) - Electric ity:65.79USD/MWH (2/20) - LNG : 0.4893USD/m3

● Activities for Energy Saving

● Effect of Energy Saving

Attach #2 Utility Shut-Down


■ Energy Audit Activities

Attach #3 Energy Audit Activities


ENDEND

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