[信息与通信]某半导体分立器件封装测试厂厂务能源管理系统介绍课件.ppt

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1、Energy Statistics&ManagementSystemVishay Micro-electronics(Xian)Co.,Ltd.January 16,2008IEHS/FSD Cost Reduction Plan General Description of Energy Administration SystemEnergy supply specificationlOutsourcing specificationlSupply specification User energy management systemlEstablish tree chart of ener

2、gy supply systemlApplication system for user demand modification or addition.lEnergy management for temporary user.Oct 12,20072IEHS/FSD Cost Reduction Plan General Description of Energy Administration SystemEnergy statistics&analysis system.lRoutine record of energy consumptionlWeekly statistics of

3、energy consumptionlAnalysis on weekly statistics dataQuantity of energy consumptionCost of energy consumptionCost per k products for each outsourcing energies.Energy cost per k productslFeed back abnormal data to relevant personnel of production,maintenance and IEHS to find the reason.ReportinglProv

4、ide energy statistics data to finance.lReport energy statistics data to Asia IEHS director.Oct 12,20073IEHS/FSD Cost Reduction Plan Energy outsourcing specificationNo.ItemSpecificationSupplierRemarks1Power50Hz,3 phase,10KV10Municipal Bureau of Power SupplyState Grid Northwest Company2N2 Bulk nitroge

5、n tank,purity not less than 99.999,Dew point-60,Oxygen less than 10PPMTaida Low Temperature Equipment Co.,Ltd.3H2Cylinder,purity not less than 99.999,Dew point-60,Oxygen less than 10PPMTaida Low Temperature Equipment Co.,Ltd.4Tap waterP0.3MPa，quality to meet relevant standard of drinking water quali

6、tyMunicipal Utility ServiceMunicipal Utility pipeline5Natural gasP8KPa,methane not less than 94%(V/V)，Low Heat Value not less than 33MJ/Nm3Qinhua Natural Gas Co.,Ltd.Municipal Utility pipelineOct 12,20074IEHS/FSD Cost Reduction Plan Energy supply specificationNo.ItemTypeSpecificationRange of SupplyR

7、emarks1Power3 phase 380VAC50Hz,3 phase 380V，10All building(Except for office)1.Plug-in Bus supply in Production area21phase 220VAC50Hz,1phase 220V,10All building 2.TN-S power supply system33 phase 380V EPS50Hz，3 phase 380V，10Fire fighting,EPS,exhaust scrubber system3.Beaker+terminal connection shall

8、 be used if power load more than 5 Kw.Power socket could be used when load less than 5Kw4Normal lighting400LUXOffice,control room,warehouse1.The luminance of fluorescent lamp reduces slowly.IEHS makes plan to replace regularly.5600LUXProduction area,lab,IQC2.Lux of Emergency lighting will be lower t

9、han normal.6200LUXHall way3.The luminance of outdoor and exterior walls lighting complies with relevant specification.7Emergency lighting50LUXOther individual building,emergency lighting of each room4.Emergency exit indication lamps installed 8GasNitrogenPurity not less than 99.999，Pressure 0.70.85M

10、Pa(system pressure)Dew point lower than-60,Oxygen content less than 10PPMDI water station,FG warehouse,Reliability Lab,FE Lab,Die Bank,IQC,FOL/Mold/Solder Dip area.9Forming gasN2:89%87%，H2:11%13%,pressure 0.340.41MPa(system pressure),Dew point less than-60,Oxygen content less than 10PPMDie bond10Com

11、pressed air0.60.7MPa，压力露点不大于+5，经精密过滤Reliability Lab,FOL/Mold/Solder Dip/testing/plating area11VacuumVacuum0.8BarFOL12SteamPressure 0.30.4barHeating of Facility station,Facility office and control room,heating and humidification of AHU,heat supply of FCU heat exchanger.Oct 12,20075IEHS/FSD Cost Reduc

12、tion Plan Energy supply specificationNo.ItemTypeSpecificationRange of SupplyRemarks13Feed&DischargeProcess cooling water0.2MPa0.3MPa，28Mold/Solder Dip,Test area,Rel.LabTotal hardness less than 5PPM14DI waterResistance15M，0.MPaMold/Solder Dip,Test area,calibration Lab,Rel.Lab,FE Lab,Plating15Hot wate

13、r0.15MPa，4060Toilets(main building)and kitchen16Tap water0.2MPaSolder Dip,Plating,Toilets,Kitchen,FE Lab,Rel.Lab,Calibration LabFor eyewash and water replenishment&washing of some equipment17Industrial wastewater dischargeDischarged directly,max.flow 7.5M3/HDI water Station,FOL,Solder Dip,FE Lab,Rel

14、iability Lab,Kitchen.18Domestic Wastewater dischargeDischarged through oil separation/septic tankToilets and kitchen19Industrial wastewater dischargeDischarged after waste water treatmentPlating20HVACAmenity air conditionerT=1825Offices,Meeting room,cafeteria,training room.21Industrial air condition

15、er1.T&H:TestingT=25，2,RH=4060,Plating T=23,2，RH=3070%,others T=25,5,RH=4060%;2.Pressure difference:Mold,Solder Dip,Plating:negative pressure(-105Pa),FOL,Testing,Die Bank:positive pressure(+105Pa);Lab(05Pa)3.Cleanliness:ISO 8 level in K1 area and ISO 9 level in other area.FOL,Mold,Solder Dip,Test,Pla

16、ting,Dise Bank,IQC,Rel.Lab,FE Lab,Calibration LabOct 12,20076IEHS/FSD Cost Reduction Plan User Energy Management 1Establish tree chart of each kind of energy suppliesFacility supply pipelines system diagramUser of each main lines and branchesCapacity of each main lines and branchesOccupied capacity

17、of each main lines and branches can be calculated automatically based on equipment installation information.If occupied capacity of one supply line reaches 80%of design capacity,alarm will be given in the system that no end equipment shall be added in this line.Oct 12,20077IEHS/FSD Cost Reduction Pl

18、an Supply pipe&line system diagram Oct 12,20078IEHS/FSD Cost Reduction Plan Facility supply system diagramOct 12,20079IEHS/FSD Cost Reduction Plan Facility supply system diagramOct 12,200710IEHS/FSD Cost Reduction Plan Facility supply system diagramPower system is analyzed by logistic sheetOct 12,20

19、0711IEHS/FSD Cost Reduction Plan User energy management 2Establish Application Form for supply demand changeApplication for supply increase or change.Ensure supply change will not affect facility system negatively.Insufficient capacity of supply linesDue to user equipment addition,some equipment aff

20、ects other equipment negatively.Review facility supply system while user equipment capacity increase.Oct 12,200712IEHS/FSD Cost Reduction Plan StartUser submit technical specification to confirm technical requirement and supply demandUser submit Applicarion form for Facility Supply IncreaseIEHS revi

21、ew the system capacity and make assessmentFeasibleIEHS manager approve and sign on technical specificationYESNOPR and PurchasePlan to be modifiedYESSupply upgradingEndNOIs supply to be increasedInstallationYESNOPlant GM approveProcess of Supply Increase ApplicationOct 12,200713IEHS/FSD Cost Reductio

22、n Plan Application for facility supply changeOct 12,200714IEHS/FSD Cost Reduction Plan Application for facility supply changeOct 12,200715IEHS/FSD Cost Reduction Plan Energy management for temporary userOct 12,200716IEHS/FSD Cost Reduction Plan Energy statistics&analysis systemThe responsibility and

23、 requirement of energy consumption record,statistics and analysis are specified in Energy Management Regulation.Routine parameters and consumption record(by operation engineer).Weekly statistics and analysis(by PM engineer)Abnormal data will be fed back to relevant personnel to find the reason.Stati

24、stics information is provided to related departments regularly.Monitoring if energy charges are consistent with actual consumption.Oct 12,200717IEHS/FSD Cost Reduction Plan Statistics&analysis of energy consumptionOriginal data recordRecord readings of power supply,water supply,natural gas supply,ni

25、trogen flow,hydrogen flow at 8 oclock on every Sunday.These records are to be used as original data of energy statistics&analysis.Calculate weekly consumption quantities and costs.Calculate energy costs per k productsConfirm if the data is abnormal according to the comparison with historical data.Us

26、e the tools such as line chart,column chart,pie chart to compare&analyze energy costs.Find the reason of abnormal data and eliminate the problems.Oct 12,200718IEHS/FSD Cost Reduction Plan Energy statistics processStartOperation engineer submits original data to PM engineerPM engineer handles&analyze

27、s dataPM engineer provides analysis results to financeEndIs data normal?Inform operation and maintenance supervisor to find reason and resolve in timeYseNoOct 12,200719IEHS/FSD Cost Reduction Plan Energy statisticsOriginal recordOct 12,200720IEHS/FSD Cost Reduction Plan Energy statisticsEnergy consu

28、mptionOct 12,200721IEHS/FSD Cost Reduction Plan Weekly energy costOct 12,200722IEHS/FSD Cost Reduction Plan Weekly energy consumption trend(except N2 and H2)Oct 12,200723IEHS/FSD Cost Reduction Plan Advantage and limitation of trend diagramsAdvantageReflect the trend of energy consumptionsDetect abn

29、ormal data according to comparison between total consumption and consumption per k products.Judge whether the reason is from supply lines and user equipment according to variation trends of consumption.LimitationNatural gas consumption only correlates with outdoor temperature instead of product outp

30、ut.So when the efficiency drops,abnormal data cannot be found on the trend diagram.Abnormal data will be detected when water consumption rises in summer.But it is hard to judge if the data is reasonable.Oct 12,200724IEHS/FSD Cost Reduction Plan Monthly cost analysisPurpose of cost comparison column

31、chartl Reflect the relative scale of each cost accounts in total cost.lShow the variation trend of each cost.Oct 12,200725IEHS/FSD Cost Reduction Plan The purpose of pie chart：Directly shows relative ratio of each costs.Oct 12,200726IEHS/FSD Cost Reduction Plan Pie chart of annual average cost per k

32、 products provides finance detailed information of cost analysis.Oct 12,200727IEHS/FSD Cost Reduction Plan Line chart-Energy cost per k products vs outputlThe unit of output is 100K.lThrough the comparison between output and energy cost correlation between them is reflected directly.Oct 12,200728IEH

33、S/FSD Cost Reduction Plan Application practice of energy statistics&analysis in actual cost control 1Energy budget can be made based on the result of energy statistics&analysis.Energy budget is calculated according to energy cost per k products and planned output.Due to equipment move,the output var

34、ies every month which leads to the variation of cost per k products.The cost per k products can be calculated according to the result of analysis.The difference between budget energy cost and actual cost is controlled within 5%.Oct 12,200729IEHS/FSD Cost Reduction Plan Application practice of energy

35、 statistics&analysis in actual cost control 2uDuring the week from July 2 to July 9,total consumption increased slightly while the consumption per products increased greatly.It was abnormal data and gas leakage was detected.After the leakage problem was eliminated the consumption per k products tren

36、ded stable.uDuring the week from November 21 to November 27,both total consumption and consumption per k products increased a lot which was also an abnormal data.After inspection it is found that production operator adjusted plow rate of equipment.Then after coordination with MD and Engineering,the

37、gas flow was adjusted properly and the gas consumption came back to normal value.Oct 12,200730IEHS/FSD Cost Reduction Plan Y07 Energy Purchase Cost statisticsMonthOutputTap water PowerTransformer Basic chargeNGH2N2SubtotalKUSDUSDUSDUSDUSDUSDUSDJan-076721 23762578365101431830661558061123Feb-076571 22

38、892611065101011328951520956615Mar-077231 2170262633255787127961559454695Apr-076353 2335269733255527425211439751500May-076866 2536281943255424928181624354040Jun-077832 2696342133255372132602250966399Jul-076713 3002289493255365129872130459893Aug-079777 2396312733255366738852759668817Sep-0711439 275833

39、5843255528246412668672950Total 69503 22558261342358075814528869175120546034Annual average cost/k(USD/k)0.323.760.510.220.492.517.86Application practice of energy statistics&analysis in actual cost control 3Oct 12,200731IEHS/FSD Cost Reduction Plan Experience of energy management 1Energy management s

40、ystem shall be established to be applicable to all departments especially process engineering and equipment maintenance department.Potential consumption increase can be found and resolve ASAP.Energy Consumption can be controlled within a reasonable range.Coordination and cooperation between each dep

41、artments is needed to effectively control the consumption.The output affects consumption per k products greatly.For fixed facility system the most efficient way to reduce energy consumption per k products is to increase production output.Oct 12,200732IEHS/FSD Cost Reduction Plan Experience of energy

42、 management 2The largest energy reduction shall be process energy reduction.It is important to concern system energy saving during planning and design.Compressed air consumption will be reduced if supply is classified by pressure.But the investment will be increased.It affects the power consumption

43、of AHU system greatly that whether building enclosure structure and temperature and humidity parameter are reasonable.It affects tap water consumption greatly that whether industrial waste water could be recycled.Process energy reduction and system energy reduction is considered as key subject in Phase II project.So the energy conservation of future completed project is guaranteed in planning and design stage.Oct 12,200733IEHS/FSD Cost Reduction Plan Thanks You!Vishay Micro-electronics(Xian)Co.,Ltd.October 12,2007Oct 12,200734