Electroplaters Plant Performance Optimisation Tool

Transcription

1 IT265 Electroplaters Plant Performance Optimisation Tool Windows version

2 The Environment and Energy Helpline For information on environmental issues and further copies of this tool, please call the Environment and Energy Helpline on Technical Information This electroplaters plant performance optimisation tool requires a computer with a minimum of: a 400 MHz processor; 16 MB RAM; Microsoft Windows 95 operating system; Microsoft Excel 97; a display with a minimum resolution of 800 x 600 and a 256-colour palette. Users need to be familiar with personal computers, with the operating system and have a working knowledge of Microsoft Excel 97 or later versions. Note: Excel 5 and earlier versions will not support the application. 2 Electroplaters Plant Performance Optimisation Tool

3 This tool is designed to help you calculate easily the effect on costs and savings of making changes to your electroplating plant, and can help you to improve your: productivity; efficiency; profitability. The tool will also help you to: prepare for the introduction of the Pollution Prevention and Control (PPC) Regulations 2000; gauge improvement in plant characteristics and estimate the potential cost savings and environmental benefits to be made by adopting various features of the Best Available Technique (BAT) Model Plant in your own installation. The tool has a series of parameters for which one set of figures is given for the BAT Model Plant, and the other for you to insert your own figures. The latter are initially set at a UK benchmark level, but should be personalised to your own plant s particular specifications. By making changes to these figures, eg adding another rinse after pickle, the tool immediately calculates the effect this will have on the operation. The tool is very easy to use and takes all the guesswork and hard work out of optimising electroplating plant. The package The tool comprises two files, one for each of the two processes: zinc plating - rack plant (Rack Plant.xls); zinc plating - barrel plant (Barrel Plant.xls). Each file contains a conventional spreadsheet application containing a number of worksheets. Calculations are contained in worksheet cells and are, therefore, live, giving results directly. These instructions apply to the use of either file. Getting started Copy the files to a suitable directory on the hard disk of your computer. Open Microsoft Excel. Select Open in the File drop-down menu. Change the details in the Look in box to the directory where you saved the files. Double-click your left mouse button on the file you wish to open. If your system asks whether or not to use macros, answer Enable Macros. Macros are essential in the operation of the package. Follow the instructions in red on the Introduction sheet and subsequent sheets. There are only two types of operator command: Buttons: The various sheets in the package are selected by buttons. It is best to avoid using the tabs at the foot of the screen to navigate through the template. Spinners: Values are adjusted by increase/decrease buttons. This method of adjustment is adopted to prevent the entry of out-of-range values that could cause calculation errors. Note that the range of adjustment is deliberately set wide - the limits should not be taken as representing realistic input values! Although files can be renamed, it is recommended that you keep unaltered copies of the original files to preserve the original typical data in case you need them in the future. The copying of individual Worksheets (for example, to your own workbooks) should be avoided as cells will contain links to the original file. Electroplaters Plant Performance Optimisation Tool 3

4 How to use this tool New users should begin by reading the background to the SE2000 project that can be accessed through the WELCOME page. This gives details about the project and advice about deciding the areas that you might want to tackle first. Once you are familiar with the ideas, you can start using the design tool by accessing the STANDARDS screen, or return to the WELCOME page. You will need to set the figures in STANDARDS for your own operation. The tool will calculate the costs and savings from these figures. The SUMMARY of improvements screen acts as a home page and is your at-a-glance information data page. It will give you an overall picture of how any changes you make will affect your bottom line. From here, click on any process you wish to examine more closely and then return to the SUMMARY screen to see how you will benefit. Figs 1 and 2 show the main menu systems for the two files. Until you are familiar with this tool, they can be used to help you navigate through the files. Fig 1 Barrel plant menu system Exit from package Standards DragOut Familiar users route Entry or re-entry to design tool always via Standards sheet. Route to encourage all users to set Cost Standards before involvement in process details Entry to package Disclaimer Not accept Accept New users route Return to use of design tool Summary (acts as a home page) Return to use of design tool Detail sheet invoked by mouse click on corresponding process button in Summary. Return is by clicking on Summary button on detail sheet Plate Intro (navigation sheet) Route for background Rinse4 ProcessDiagramB - Benchmark ProcessDiagram - Model plant New users route Technical backgroun Detail sheet can also be accessed by clicking on the process symbol in the Process Diagram ElectroClean Pla Rinse2 Clean Pickle Detail sheets - for each stage in the process where improvements are applicable 4 Electroplaters Plant Performance Optimisation Tool

5 Fig 2 Rack plant menu system Exit from package Entry to package Guidance Disclaimer Not accept Intro (navigation sheet) Guidance Next section Familiar users route Accept New users route New users route Next section d Return to use of design tool Technical background InfoText Contents Next section Entry or re-entry to design tool always via Standards sheet. Route to encourage all users to set Cost Standards before involvement in process details Summary (acts as a home page) Return to use of design tool Route for background ProcessDiagram - Benchmark ProcessDiagram - Model plant InfoText Contents Next section Standards DragOut Detail sheet invoked by mouse click on corresponding process button in Summary. Return is by clicking on Summary button on detail sheet Detail sheet can also be accessed by clicking on the process symbol in the Process Diagram Rinse3 Rinse4 PlateHeat techem Plate EcoRinse Rinse2 Clean Pickle Detail sheets - for each stage in the process where improvements are applicable Electroplaters Plant Performance Optimisation Tool 5

6 Customising Each package has two plant models: OWN PLANT and MODIFIED PLANT. Initially, the OWN PLANT parameters are set to those of the UK Benchmark Plant and the MODIFIED PLANT settings are set to those of the SE2000 Model Plant. You can adjust the OWN PLANT parameters to represent your existing plant and adjust the MODIFIED PLANT to represent an improved plant, including/excluding features of the new technology. For a detailed discussion of the various best practice techniques available, refer to Surface Engineering 2000 Process Best Practice Group paper, The Integrated Approach to Plating Plant, by David Hemsley, presented at the Zinc and Zinc Alloy Symposium of the Institute of Metal Finishing (IMF). Copies of the paper can be obtained from the IMF, Exeter House, 48 Holloway Head, Birmingham B1 1NQ (Tel: ) or the Surface Engineering Association (Tel: ). Brief descriptions of various techniques described are included in the package. The individual costs of implementing the modifications are added together on the SUMMARY sheet. However, where an existing plant is being modified, the infrastructure costs will be significant and these cannot be predicted by the package - you must, therefore, add a provisional sum on the SUMMARY sheet to cover this item so that you obtain realistic total capital cost and payback figures. Printing Individual Detail sheets or SUMMARY sheets may be printed using the normal File/Print command. The file name appears at the top of each page when printed. This allows you to introduce your company name and details into the title of the printout, simply by saving the file to a suitably descriptive name - for example, Green and Keen Zinc Line No 3. 6 Electroplaters Plant Performance Optimisation Tool

7 Conditions of Use You may use the free Microsoft Excel template supplied on the disk only if you agree to the terms and conditions of use given below. This spreadsheet template is designed to allow users to gauge improvement in electroplating plant characteristics and estimate the potential cost savings to be made by adopting various features of a best available technique model plant in their own installation. Any calculations and guidance are given in good faith, but users should ensure their accuracy, suitability and applicability for their circumstances before acting, for example, through discussions with plant suppliers. Within the UK, this template may be installed simultaneously on up to 20 personal computers within the recipient s business (per original package) but each business must register its use with Envirowise. Further copies of this template are available free of charge through the Environment and Energy Helpline on The template is the property of the Government and the content of the files on the attached disk are Crown copyright. At no time shall any property rights in the template or any part of the template or any modifications or variations thereto be vested in the user.

8 Your disk containing your electroplaters plant performance optimisation tool is in this pocket.

9 Action Plan STEP 1 Read the introductory sections STEP 2 Go to STANDARDS page and insert your own standards STEP 3 Go to SUMMARY page and identify where changes would bring the largest cost savings STEP 4 Go to the Process indicated, explore making changes and return to the SUMMARY page to see the overall effect on your profits This tool was produced by Envirowise. Developed with assistance from McLellan and Partners Ltd and the Surface Engineering Association. For further information please contact the Practical Environmental Advice for Business Harwell International Business Centre 156 Curie Avenue Didcot Oxfordshire OX11 0QJ helpline@envirowise.gov.uk Internet: Envirowise - Practical Environmental Advice for Business - is a Government programme managed by AEA Technology Environment and NPL Management Limited Crown Copyright. First printed November Printed on paper containing a minimum of 75% post-consumer waste. Environment and Energy Helpline