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美国某玻璃厂能源成本管理实例 (Glassy Energy Costs)
日期：2025-03-10 19:25
浏览次数：3321
摘要：
| Where, when and how much energy is the company using? Manually registered consumption figures do not usually produce the transparency needed for effective energy management. As Reinhard Bruns* explains taking the Schott glass works as an example, categorised up-to-date data of the kind provided by a modern energy cost controlling system, however, enable clearly defined steps to be determined to optimise consumption. Managers in all branches of commerce and industry can scarcely take a decision these days without calculating and substantiating the associated costs. This process has evolved in recent years from a matter of acquiring information, recording it and cost controlling to a mature management and controlling instrument. The functions today's managers perform are no longer simply operative, but increasingly of a strategic nature. The objective is to optimise company costs in the marketplace. Accurate charging for energy consumption is becoming more important in relation to other operating costs. Most companies, however, still use empirical factors or a percent scale to project their energy costs. How a powerful and all-inclusive system for energy cost controlling can be implemented and how it functions can be seen from the example of the Schott Glaswerke in Mainz. Manual registration cannot really achieve transparency The Schott Glaswerke Group includes 69 companies and is a leading supplier worldwide of special glass. Schott manufactures almost every radiant glass stove top and every TV screen produced in Germany. Their range of products includes about 50,000 articles from special glasses for laboratories to telescope mirrors. The headquarters in Mainz employs around 5,700. The energy requirement of such a large undertaking is of a proportion that makes optimum utilisation of resources absolutely essential. As is the case with many other industrial operations, Schott had installed an enormous number of meters just for this purpose. All of them were read in the course of a month and the data manually recorded and evaluated and in spite of the number of people involved, it was impossible to make a currently valid statement of what the consumption actually was. The results were inaccurate and frequently included errors. It was similarly impossible to determine the costs in relation to output, which in some areas could amount to as much as 50 % of the energy costs, and to allocate them justly to those incurring them. A condition which must be fulfilled before it is possible to do this, is the uninterrupted recording of the fluctuation of power in relation to time for every cost centre using meters fitted with impulse generators, data acquisition equip-ment and appropriate evaluation and processing software. Frequently the cost of replacing the existing meters by meters with an impulse output has stood in the way of a decision in favour of justly apportioning energy costs. |
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Fig. 1: Flow chart of the cost centre accounting software  |
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| A reliable hard and software solution is needed. In the meantime, a dramatic reduction in the price of impulse generator meters has made introducing automatic registration and charging more attractive. The original plan to fit the existing meters with optical detectors was rejected on the grounds of cost and the complete absence of data security. Energy cost controlling requires that electrical and thermal energy and also the consumption of gas, water and steam be accurately recorded, allocated and automatically charged. Apart from reliable hardware, the automatic production of detailed energy reports and balance sheets assumes the availability of reliable, user-friendly and flexible software. After establishing the specification of the future energy cost controlling system and carefully studying the market, Schott decided in the case of the hardware on the summation stations manufactured by GOSSEN-METRAWATT which register, evaluate and save the counter impulses generated by electricity meters, flow meters and thermal unit meters. The multi-master configuration enables them to be linked in any desired arrangement by a wide area two-wire network. All the summation stations connected to the bus can be polled or their parameters set by any of the processor units. Remote manufacturing units are integrated via modems and the public telephone network. The software used is BDE 2000-KOSTAB marketed by Klein & Partner, Wardenburg. It is a processing and evaluation software that fulfils all the Schott requirements and has a modular structure that provides the desired degree of flexibility and user-friendliness. |
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| Variable and simple to operate f KOSTAB runs under the standard MS Windows program EXCEL 5.0. The user shell is thus immediately familiar and a balance sheet for a given cost centre can normally be obtained without any special prior knowledge. It is not only easy to allocate the costs, it is also a simple matter to change the structure to take account of changes in company organisation. Apart from viewing the data on-line from day to day,the Schott system automatically collects - in some cases via modem - the consumption and powers from all the meters connected to the summation stations once a month. Those meters which for technical reasons or reasons of cost are not equipped with an impulse output, are read by a member of the staff and entered manually via a hand terminal. The data from the approximately 1,200 meters for different energy media on the system are stored temporarily in a data base and then checked for plausibility. Typical values can be added manually for missing data, e.g. from defective meters. Following approval by the official responsible, the approximately 300 cost centres can be charged. In addition to directly allocating meters to cost centres, the program also intelligently administers a residual group on the basis of standard percentages entered. Monthly and annual accounts are produced automatically per cost centre and energy medium. A further distinction is made between the accounting and financial years. While producing the accounts, the various graphs, trend analyses and code calculations are brought up to date. The existing SAP interface has proved a valuable asset because it facilitates the exchange of data with the accounting department. The system's open concept lends itself equally to the production of individual analyses. In conjunction with other Windows programs, annual balance sheets and other statistical data can be obtained quickly and simply. According to Lothar Kretschmer, the system manager for Schott's energy cost controlling system, all previous experience and ideas could be implemented without difficulty using the standard BDE 2000 package. |
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| Fig. 2: Current alloction of costs and relative energy consumption chart | ||
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