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SKF Client Needs Analysis Energy and Sustainability Industry accounts for as much as one third of all energy consumption. And large increases in energy costs in recent years have made it more crucial than ever to find ways to reduce energy consumption. SKF Client Needs Analysis – Energy and Sustainability In addition, industry is increasingly being challenged to reduce its environmental impact on the world we live in, and show awareness and sensitivity to sustainability issues. This is placing sustainability high on the list of corporate initiatives required to reflect a positive corpo- rate image to shareholders, investors, employees, and the global community. As a result energy and environmental management functions have increasingly become an important aspect of industrial facility operation, helping to main- tain both cost effectiveness and public recognition of environmental stewardship. However, the fundamental need to maintain produc- tion rates and deliver profitability can lead to a lack of the internal resources required to push sustainability issues forward. This is where SKF can help you. Services Mechatronics Seals Lubrication systems Bearings and units Energy and Sustainability solutions from the complete SKF portfolio Seals Energy efficient • seal designs Reduced leakage • Bearings and units Energy efficiency bearings • Lubrication systems Specialized lubricants • Lubrication systems • Minimal quantity lubrica- • tion for machine tools Lubrication management • Services Condition • monitoring Alignment • Remanufacturing • Asset Management • Services Mechatronics Actuators • 2 With 100 years of knowledge in rotating machinery, SKF has become a world leading industrial solution provider with a broad portfolio cov- ering the technologies and services from our five core platforms – bearings, seals, lubrication, mechatronics, and services. Some examples of technologies in the SKF portfolio that can assist your energy and sustainability programmes include: Ultra-low friction, high capacity SKF Explorer bearings that enable • machines to be downsized and more energy-efficient. Specialized bearings such as CARB, a new type of radial roller bear- • ing that accommodates axial movement internally to reduce friction and decrease power consumption. Magnetic bearings that run at high speeds with no surface • contact or lubrication. Asset management services, online and portable condition moni- • toring solutions for reliability and proactive maintenance that ena- ble end users to optimize efficiency and reduce energy use. Mechatronic solutions that eliminate hydraulics. • Engineered units that reduce the number and weight of components. • Sealed-for-life bearing units that require no additional lubrication. • Environmentally friendly lubricants and lubrication systems. • Lubrication distribution systems that optimise and minimize • the use of lubricants and cutting oils. In addition to these technologies, close working partnerships with customers worldwide have provided SKF with an extensive knowledge of applications in virtually every industry. And combining our consultant level expertise with our breadth of products and applications knowledge, means that SKF is ideally placed to help you meet your energy and sustainability targets. Solutions for energy and sustainability What is a Client Needs Analysis? The SKF Client Needs Analysis – Energy and Sustainability is an extensive, web-enabled plant wide assessment tool used to examine areas of operation where energy efficiency improvement opportuni- ties may exist. The assessment also examines chemical treatments, lubrication use and other operating processes that could be improved to reduce environmental impacts within a facility. Today, SKF has many products and services available that can pro- vide energy efficiency and environmental improvements within vari- ous industries, helping to optimise the efficiency and effectiveness of your physical and non-physical assets. Typically, the SKF Client Needs Analysis – Energy and Sustainability is a meeting with the client to review the following four key facets: Energy and environmental management • Energy efficient tools • Energy efficient operations • Environmental controls • The outcome is a detailed report highlighting the areas where improve- ments can be made, and showing how SKF can help you achieve energy savings and make environmental improvements that will help ensure your operations remain sustainable, now and in the future. Can the process deliver value to your operations? Many industries are both significant consumers of energy, and con- sume a significant amount of energy per dollar of product produced. These energy-intensive industries typically understand the impor- tance of energy efficiency and sustainability best practices, and the potential impact on their business. Examples of such energy-intensive industries include: Hydrocarbon processing • Pulp and paper • Chemicals • Metals • Mining • Food and beverage • Marine • If you operate in an energy-intensive industry, then the SKF Client Needs Analysis – Energy and Sustainability can deliver value for you. 3 The SKF Client Needs Analysis – Energy and Sustainability quickly provides a first-level view of your plant situation. And in combination with our Documented Solutions Program (DSP), enables SKF to understand your needs and identify areas where potential solutions may yield a projected return on your investment. Importantly, following your plant review, SKF can then leverage from a market leading portfolio of products and services, combined with 100 years of machine knowledge, to deliver and implement these improvements. A breadth of capability unmatched in industry. An extensive range of benefits A small investment in time and money The SKF Client Needs Analysis – Energy and Sustainability is specifically designed to fit with your current operational priorities, and can help you identify potentially significant opportunities for improvement. The process can be summarized as follows: A cost effective and non-invasive assessment tool that • encourages participation with your key personnel. The SKF CNA – Energy and Sustainability questionnaire • covering four key facets of your operations is completed by plant personnel. An on-site session with your team, guided and facilitated • by a trained SKF professional. You will then receive a report outlining the potential • opportunities for improvement based on expert analysis from SKF personnel that are fully trained in this area. Large potential returns – the benefits Maintain focus on your core business while identifying areas for potential improvements, such as: Opportunities for financial savings through • reducing energy consumption. Opportunities for improved facility • environmental performance. Opportunities for client personnel awareness • and development. Opportunities for continuous improvement regarding • energy and environmental management. 4 Proactive maintenance, reliability and asset efficiency By combining SKF world class knowledge of rotating machinery and reliability with a portfolio of world leading energy efficiency capabilities SKF can help you deliver real improvements in both operations and reduced production costs. And the effective maintenance and optimised performance of your plant assets is an essential element for improving overall efficiency and achieving energy savings and sustainable operations. SKF is a world leading provider of solutions to optimise machine and process reliability and productivity. Our condition monitoring and maintenance technologies and services enable you to apply a proactive maintenance strategy, minimizing asset downtime, avoid- ing costly machine damage, and maximizing the efficient running of your machinery. Leveraging from our knowledge of asset efficiency and reliability, the SKF Client Needs Analysis – Energy and Sustainability provides an effective mechanism to help identify areas for energy savings and reliability improvements that can provide you with a unique competitive differentiator. So, where many “consultants” stop, SKF has the ability to go beyond just making recommendations to help you implement effective solutions and actually realize the potential payback. Energy-saving solutions Thermography analysis • Vibration analysis • AC electric motor monitoring • Belt/shaft alignment • Precision balancing • Performance monitoring: pumps, • turbines, fans and compressors Steam trap monitoring • Heat exchanger efficiency • Low friction and hybrid-magnetic bearings • Variable timing cooling pumps • Pneumatic to electric actuation conversions • Air system leak assessments • Energy analysis of pumping, fans • and compressed air systems Environmentally advanced solutions Minimal Quantity Lubrication • for machine tools SKF Compass Environmental • Health and Safety software Lubrication-free and • self-lubricated bearings. Bearing remanufacturing • Harnessing renewable energy sources with the power of SKF knowledge engineering – SKF solutions for wind energy includes bearings, seals, lubrication systems and condition monitoring. 5 SKF has provided reliability services to clients for many years which provides a strong foundation on which to build energy efficiency and environmental improvements. Several examples illustrate the combination of these capabilities that make SKF unique in this area of service. Real-world results Cement industry Reliability problems resolved by SKF analy- sis and services in a horizontal grinding mill doubled the repair interval and reduced energy consumption up to 2 %. Total savings per grinding mill was almost EUR 20 000 per year based on SKF’s use of thermogra- phy, vibration analysis, and alignment. Pulp and paper industry Repeated bearing failures on a large fan caused reliability problems and production impacts. SKF resolved the mechanical prob- lem with improved bearing and sealing solutions along with precision fitting and shaft alignment. This resulted in a 3 % reduction in energy use per fan with app- roximately EUR 50 000 per year company savings and an increase in the mean time between repairs. SKF factory As part of the CNA-ES performed at one of the SKF factories, a compressed air system survey by SKF service division identified air leaks and their analysis of the air system operation identified potentially inefficient air compressor operation. The combined energy savings by reducing leaks and improving air compressor operation is estimated to be approximately EUR 30 000 per year. Anatomy of hidden energy savings Using a variety of inspection technologies such as thermo graphy and vibration analysis, SKF energy specialists help companies discover energy reduction opportunities in every corner of the plant. The example shown here involves “found energy” within a typical electric motor driven pump system. Electric motor analysis 1. Advanced diagnostics and monitoring can reduce energy use by up to 5 %. Precision alignment 2. Properly aligned machinery is more reliable, and consumes up to 5 % less energy. Lubrication and sealing 3. Optimum lubrication and sealing methods can cut energy use by 1–2 %. Hydraulics 4. Vibration analysis helps identify hydraulic improvements that can cut energy use by 3–5 %. Precision balancing 5. Proper balancing can reduce energy consumption by 1–5 %. 1 2 3 5 4 6 SKF helps refinery reduce energy costs by $5 million per year The energy challenge An oil refinery in the U.S. had installed equipment capable of meeting its daily power requirements of 52 MW. Unfortunately, operational concerns were forcing the plant to limit its power generation to 40 MW per day. To make up the daily difference, the refinery was forced to purchase 12 MW from the local utility, at a cost of USD 100 000 per week. The SKF solution Following an extensive analysis, SKF employed a combination of advanced vibration analysis and machine diagnostics to help the refinery “discover” the megawatts it needed within its existing equipment. In the end, SKF energy and environmental services increased the plant’s daily power output by the 12 MW it required. The savings Helping the refinery meet its daily power requirements meant that it no longer had to purchase the additional 12 MW per day from the local utility. In the end, SKF energy and environmental services helped the refinery save that additional USD 100 000 per week, for a yearly savings of over USD 5 million. 7 ® SKF and CARB are registered trademarks of the SKF Group. ™ SKF Explorer and BeyondZero are trademarks of the SKF Group. © SKF Group 2007 The contents of this publication are the copyright of the publisher and may not be reproduced (even extracts) unless permission is granted. Every care has been taken to ensure the accuracy of the information contained in this publication but no liability can be accepted for any loss or damage whether direct, indirectw or consequential arising out of the use of the information contained herein. Publication 6607 EN · December 2007 Printed in Sweden on environmentally friendly paper. SKF focus on sustainability SKF has had a focus on sustainability since 2005, when we launched our BeyondZero initiative. This initiative looks internally to our own factories and sets goals of reducing environmental impact and energy consumption by 5 % per year. Recently, we also started to look externally, to what products and services we can offer our customers that would bring our net environ- mental impact from negative to positive. SKF has also added Sustainability as a corporate driver and is con- tinuously looking to develop products that support this initiative. The SKF Client Needs Analysis – Energy and Sustainability was born from SKF’s focus on helping customers in their sustainability efforts. www.skf.com