Optimisation of Production Processes to Reduce Environmental Impacts

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214 IPLOCA Environmental Award sponsored by Shell Optimisation of Production Processes to Reduce Environmental Impacts 3 di es el co ns um pt io n [l/ h] 25 2 26 15 1 5-5% ac tu a ls itu at io 13

1 214 IPLOCA Environmental Award sponsored by Shell Optimisation of Production Processes to Reduce Environmental Impacts 3 di es el co ns um pt io n [l/ h] % ac tu a ls itu at io 13 n op tim ise d sit ua tio n MAX STREICHER GmbH & Co. Kommanditgesellschaft auf Aktien Schwaigerbreite Deggendorf Deutschland / Germany MAX STREICHER GmbH & Co. KG aa May 19, 214 page 1 of 7

2 Table of contents 1. Business profile HSE-Q Background Approach and Findings Achievements Perspective... 7 page 2 of 7

3 1. Business profile The STREICHER Group is characterised by technologies and services in four business sectors: pipelines and plants, mechanical engineering, civil and structural engineering, raw and construction material. The individual corporate divisions are specialised in their business fields. 3,3 employees work with expertise and distinctive customer orientation. The divisions work hand in hand and guarantee a smooth execution of the projects. A tight organisational structure and high reliability in the carrying out of projects result in a cost effective calculation and execution of the projects. The success of the Group is based on a foundation from many years of experience, a consequent quality management and solid capital resources as well as motivated employees. The companies of the STREICHER Group work on a high technological level. The basis for this is regular investments in machinery as well as the qualification of their employees. Innovation and investments result in a continuous extension of the company activities and guarantee the longterm performance of the STREICHER Group. The STREICHER Group possesses extensive expertise and many years of experience. Due to the bundling of specialised business units the Group is able to carry out major projects as a complete package HSE-Q To ensure the safety and health of all our employees, to tackle ecological challenges and to guarantee continuous quality are main aspects of our business objectives. Our management strongly emphasises the implementation of these objectives. In order to reach these goals we do not only rely on technical progress but also on the awareness of our personnel. They obtain comprehensive training and are able to act adequately on safety, health and environmental issues. Our business procedures are constantly being refined to ensure quality and improvement through critical quality control and evaluation. The STREICHER Group maintains an Integrated Management System (IMS) that covers all fields of health and safety as well as environmental and quality control management in order to meet the increasing expectations of the consumer market. Internal and external audits are carried out within the scope of this Integrated Management System so that the implementation of the legal specifications is not only ensured within our company but also by our subcontractors. page 3 of 7

4 2. Background The main production processes in the pipeline industry are often used for a long period. If the framework parameters change and the main process parameters will not be adapted to these changes, the efficiency of the process will decrease. For this reason more resources are consumed, environmental impacts and process costs increase. Pipeline construction is characterised by high energy consumption. In 212 MAX STREICHER GmbH & Co. KG aa had an energy consumption of 76.. kwh. 7 % of the energy consumption was caused by the combustion of diesel and petrol. This value corresponds to a total volume of 5.4 million litres of fuel. The STREICHER Group pursues the aim of reducing the fuel consumption in the long term. This will not only be achieved by buying energy-efficient machines. Also the optimisation of existing machines and processes is necessary. 3. Approach and Findings STREICHER is conscious of its responsibility to the environment. Therefore STREICHER has started a pilot project for the optimisation of the welding process with a welding tractor with particular attention to environmental aspects. For the production process a detailed system analysis was carried out. In teamwork the top management, HSE engineers and executives of the technical department developed and implemented a concept for analysis and improvement of production processes. The participation of the top management underlines the importance of environmental protection in the STREICHER Group. The analysis and improvement of production processes comprises the following steps 1. Definition of the system boundaries 2. Identification of input and output flows 3. Definition of the general framework 4. Analysis of the optimisation potential 5. Comparison of potential improvement with the actual situation This means for the welding process with a welding tractor : 1. Definition of the system boundaries The tractor and the welding equipment are part of the welding process with a welding tractor. The welding equipment is connected with a power unit which is driven by the hydraulic system of the tractor. 2. Identification of input and output flows The following figure shows the main in- and outputs of the process. page 4 of 7

Analysis of the optimisation potential The welding equipment is connected with a power unit which is driven by the hydraulic system of the tractor.

5 3. Definitions of the general framework The foremost goal is to produce a high-quality welding seam and to meet all quality requirements. Furthermore the compliance with all environmental laws and standards is ensured. The aim is to reduce the pollutant emission and the energy consumption of the process without compromising quality. 4. Analysis of the optimisation potential The welding equipment is connected with a power unit which is driven by the hydraulic system of the tractor. Therefore the engine of the tractor must run in a high idling speed the whole working day. If the welding process is interrupted the power output cannot be reduced because it is not possible to adapt the engine to the power requirements of the welding equipment. Under normal conditions the fuel consumption is 26 litres/h. In addition the use of the dozer is characterised by a high consumption of oil and lubricants. A very high optimisation potential lies in the reduction of the fuel consumption. This reduction is accompanied by a reduction of exhaust emissions and soot. The potential for the selection of the welding electrodes is deemed to be low, because of customer requirements and standards no modification options are possible. The optimisation potential is shown in the following figure (3 = high potential, 2 = medium potential, 1 = low potential, = no potential). actual situation diesel [l/h] 3 2 exhaust [m³/h] 1 lubricants [kg/h] welding wire [m/h] electrodes [pieces/h] page 5 of 7

6 5. Comparison of potential improvement with the actual situation To reduce the fuel consumption significantly it is necessary to mount an additional diesel generator set on the existing welding tractor. With a second diesel generator set it is possible to adapt the engine to the power requirements of the welding equipment. Also the engine of the welding tractor runs only when it is necessary to move the tractor. The revised procedure is shown in the following figure. In- and outputs, which could be reduced by the optimisation, are marked with a red minus. comparison actual situation vs. optimised situation diesel [l/h] 3 2 exhaust [m³/h] 1 lubricants [kg/h] welding wire [m/h] electrodes [pieces/h] 4. Achievements The diesel consumption has been reduced by 5 %. Simultaneously exhaust emissions, soot emissions and green house emissions have been reduced. The impact on the employees and the environment is lower. Noise and vibration emissions have been reduced by the use of low-vibration and noise-reduced diesel generator. Also the use of oil and lubricants has been reduced because it is not necessary anymore that the engine of the tractor runs all throughout the working day. The diesel generator set is very low maintenance. In comparison to the engine of the tractor the diesel generator set uses clearly less oil and lubricants. The stability of the welding tractor has been increased by the large weight of the diesel generator set of 25 kg. Therefore the reach of the crane in the front section of the welding tractor has been increased, too % diesel consumption [l/h] actual situation optimised situation page 6 of 7

7 5. Perspective Although the use of system analysis involves considerable expense, these activities are paying off not only for the company. Also hazardous impacts on the environment have been reduced which are caused by the activities of the MAX STREICHER & GmbH & Co. KG aa. In further projects other system analysis will be done. STREICHER has endorsed the objective of a 3 % reduction in energy consumption by 225 compared to 213. page 7 of 7

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