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Bodycote
Bodycote
Project Challenges
The Bodycote facility was able to measure it’s total gas consumption, but it was unable to measure how much gas was being used at each of its furnaces.
Without a clear understanding of per furnace gas usage, managers were unable to effectively increase plant efficiency, diminishing the plant’s profitability.
Solution
Working with an ISA100 Wireless supplier, Bodycote defined the following parameters for each IQ furnace:
Furnace total gas usage per load
Furnace efficiency
Plant utility costs
Heat treat area gas usage as compared to facility use
ISA100 Wireless transmitters ranged 0-100” H20 were installed on each of the four furnaces main gas lines to sense the actual CfH, as well as summing Cf per second using four virtual pens.
Benefits
Achieved better understanding of associated costs to run specific products in furnaces.
Enabled the development of a baseline for future plant improvement and proactive maintenance.
Improved reliability of gas usage and cost data.
Improved efficiency of four furnaces due to better data analysis.
Increased worker safety through remote furnace monitoring.
Simplified scheduling of furnace preventative maintenance.
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