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Full copy of true-PDF in English version (including equations, symbols, images, flow-chart, tables, and figures etc.), auto-downloaded/delivered in 9 seconds, can be purchased online: https://www.ChineseStandard.net/PDF.aspx/GBT39751-2021(Guidelines for energy consumption detection methods for equipment manufacturing systems) ICS 25.010 J04 National Standards of People's Republic of China Guidelines for energy consumption detection methods of equipment manufacturing systems Released on 2021-03-09 2021-07-01 implementation State Administration of Market Supervision and Administration Issued by the National Standardization Management Committee Table of ContentsForeword Ⅰ Introduction Ⅱ 1 Scope 1 2 Normative references 1 3 Terms and definitions 1 4 Energy testing scope and type 2 5 General requirements 2 6 Detection and calculation method 2 7 Test report 5 Appendix A (informative appendix) Reference coefficients for converting various energy sources into standard coal 6 Appendix B (informative appendix) Energy-consuming working fluid, energy equivalent value and energy measurement unit 8 Appendix C (informative appendix) Energy consumption calculation method for equipment manufacturing process 9 Appendix D (informative appendix) Example of a table involving correlation coefficients in the calculation of energy consumption in the casting process 13 Appendix E (informative appendix) Example of a table involving correlation coefficients in the calculation of energy consumption in the forging process 14 Appendix F (informative appendix) Example of a table involving correlation coefficients in the calculation of energy consumption in the welding process 16 Appendix G (informative appendix) Example of a table involving correlation coefficients in the calculation of energy consumption in the heat treatment process 17 Reference 18 Guidelines for energy consumption detection methods of equipment manufacturing systems 1 Scope This standard specifies the scope and types of energy consumption testing for equipment manufacturing systems, overall requirements, testing and calculation methods, and testing reports. This standard applies to the detection of energy consumption of equipment manufacturing systems. 2 Normative references The following documents are indispensable for the application of this document. For dated reference documents, only the dated version applies to this article Pieces. For undated reference documents, the latest version (including all amendments) is applicable to this document. GB/T 2589-2008 General Rules for Comprehensive Energy Consumption Calculation GB 17167-2006 General rules for the provision and management of energy measuring instruments for energy-consuming units 3 Terms and definitions The following terms and definitions apply to this document. 3.1 Equipmentmanufacturingsystem The input/output system that transforms manufacturing resources into products or semi-finished products is determined by the manufacturing process and the hardware, software, and personnel involved. composition. Note. Including production system and auxiliary production system. 3.2 Productionsystem A complete system consisting of the production process, devices, facilities and equipment determined by the production product. 3.3 Productionassistsystem Processes, facilities and equipment that serve the production system, including power supply, machine repair, water supply, gas supply, heating, cooling, instrumentation, lighting, warehouses And the raw material site, safety, environmental protection and other installations and facilities. 3.4 Energyconsumptionunit A unit of energy consumption with defined boundaries. [GB/T 2589-2008, definition 3.4] 3.5 Energy-consumedmedium What is consumed in the production process is not used as raw materials and does not enter the product. It needs to directly consume energy during production or preparation. substance. [GB/T 2589-2008, definition 3.1] 4 Energy testing scope and types 4.1 The scope of testing includes the energy and auxiliary energy consumed by the main process of the production system (metal cutting, casting, forging, welding and heat treatment). The energy consumed by the production system. 4.2 The energy required to be detected and measured by the equipment manufacturing system includes the types of energy specified in 4.1 of GB/T 2589-2008, including. a) Primary energy, mainly including raw coal, crude oil, natural gas, water power, wind power, solar energy, biomass energy, etc.; b) Secondary energy, mainly including clean coal, other clean coal, briquette, coke, coke oven gas, other gas, gasoline, kerosene, diesel, fuel Oil, liquefied petroleum gas, refinery dry gas, other petroleum products, other coking products, heat, electricity, etc.; c) The energy consumed by the energy-consuming working fluid, which mainly includes fresh water, softened water, compressed air, carbon dioxide, oxygen, argon, nitrogen, Acetylene, calcium carbide, etc. 5 General requirements 5.1 The equipment of energy measuring instruments for energy-consuming units shall meet the requirements of GB 17167-2006. 5.2 When calculating various energy consumption, the statistical boundary should be clearly defined, in accordance with the principles of Chapter 6 of GB/T 2589-2008, and the various energy sources should be converted. For standard coal, the low calorific value of various fuels in the statistical and calculation process should be based on the actual measured value during the company's reporting period, and there is no actual measured condition For the relevant conversion coefficients, see Appendix A and Appendix B B.1, and the energy statistics unit see B.2. 5.3 The statistical period should be based on the process method (metal cutting, casting, forging, welding, heat treatment, etc.), production cycle (shift, batch, month, year, etc.) to make sure. 5.4 When testing energy consumption per unit of energy, a testing plan should be prepared, which mainly includes. a) Detection range; b) Test basis; c) The parameters to be measured and the corresponding detection methods and calculation methods; d) Testing instrumentation; e) Testing conditions, testing duration and various parameter testing procedures; f) Test record form. 5.5 When energy-consuming units conduct energy consumption testing, they should meet the following testing conditions. a) The inspection should be carried out under the conditions of normal production and stable operating conditions of the equipment; b) The accuracy level of the testing instrument should meet the requirements of 4.3.8 in GB 17167-2006; c) The test data of each parameter should be no less than 3 groups and take the arithmetic average; d) Before implementation, testing personnel should undergo relevant training. 6 Testing and calculation methods 6.1 Principles of Testing and Sampling 6.1.1 For different types of process equipment, group sampling is used when testing, and different types of equipment are classified and grouped according to the processing method. Then a simple random sampling is carried out from each group. The ratio of each group is the ratio of the number of equipment in the group to the number of equipment in the group. The different types of equipment converge to get the final sampling result. 6.1.2 For the same type of process equipment, random sampling is used when testing, and a certain amount of equipment is randomly selected from the overall equipment without replacement. The number of samples. 6.2 Energy consumption detection and calculation in the metal cutting process 6.2.1 Energy consumption indicators 6.2.1.1 The energy consumption index of the metal cutting process is the cutting specific energy efficiency, which refers to the total energy and effective energy consumed by the metal cutting process during the statistical period. The ratio of output, the effective output is the number of common workpieces or the quality of material removal. Cutting specific energy efficiency can be divided into workpiece specific energy efficiency and quality Specific energy efficiency. 6.2.1.2 The specific energy efficiency of the workpiece is suitable for comparing the energy efficiency of the cutting process of batch processing of the same kind of workpiece, and the specific energy efficiency of the mass is suitable for comparison Energy efficiency of the cutting process for processing the same material. 6.2.2 Test items and methods The items and methods to be tested during the metal cutting process are as follows. a) The electric energy consumed during the cutting process is detected by the electric energy meter installed on the energy-consuming equipment; b) The quality of material removal is checked with a weighing instrument. 6.2.3 Calculation method For the calculation method of energy consumption and cutting specific energy efficiency of a single metal cutting machine tool during the statistical period, please refer to C.1 of Appendix C. 6.3 Energy consumption detection and calculation in the casting process 6.3.1 Energy consumption indicators 6.3.1.1 The energy consumption index of the casting process is the comparable energy consumption per unit of qualified castings, which refers to the energy consumption during the casting smelting and forming process during the statistical period. The ratio of the total amount to the converted quality of qualified castings. 6.3.1.2 The converted quality of qualified castings is qualified after taking into account the complexity, quality, casting process and furnace type of the casting, etc. For casting quality, the relevant coefficient table example involved in the calculation process can be found in Appendix D (various coefficient values and classifications, etc.) The standard is clear). 6.3.2 Test items and test methods The items and methods to be tested during the casting process are as follows. a) Electric energy is detected by the electric energy meter installed on the energy-consuming equipment; b) The quality of coke, pulverized coal and other fuels should be tested with a weighing instrument; c) The volume of gas fuel and compressed air should be detected with a gas volume flow meter; d) Cooling water consumption, water flow meter (device) testing; e) The quality of qualified castings shall be tested with a weighing instrument. 6.3.3 Calculation method The calculation method of the total energy consumption in the casting process and the comparable energy consumption per unit of qualified castings is shown in C.2. 6.4 Energy consumption detection and calculation in the forging process 6.4.1 Energy consumption indicators 6.4.1.1 The energy consumption index of the forging process is the comparable energy consumption per unit of qualified forgings, which refers to the energy consumption of the forging process and the qualified forgings during the statistical period. The ratio of converted mass. 6.4.1.2 The converted quality of qualified forgings is the quality of qualified forgings converted after taking into account the complexity, material and quality of the forgings. Its calculation For examples of correlation coefficient tables involved in the process, see Appendix E (various coefficient values and classifications, etc., are clarified by the corresponding standards of the forging profession). 6.4.2 Test items and test methods The items and methods to be tested during the forging process are as follows. a) Electric energy is detected by the electric energy meter installed on the energy-consuming equipment; b) The quality of coal, refined oil and other fuels should be tested with a weighing instrument; c) The volume of gas fuel and compressed air should be detected with a gas volume flow meter; d) Cooling water consumption, water flow meter (device) testing; e) The quality of qualified forgings shall be tested with a weighing instrument. 6.4.3 Calculation method Refer to C.3.for calculation methods of total energy consumption during forging process and comparable energy consumption per unit of qualified forgings. 6.5 Energy consumption detection and calculation of welding process 6.5.1 Energy consumption indicators 6.5.1.1 The energy consumption index of the welding process is the comparable energy consumption per unit of qualified weldments, which refers to the energy consumption of the welding process and the qualified weldments during the statistical period. The ratio of converted mass. 6.5.1.2 The reduced quality of qualified weldments is the quality of qualified weldments after considering the complexity, material and quality of the weldments. For examples of the correlation coefficient table involved in the process, see Appendix F (various coefficient values and classifications, etc., are clarified by the corresponding standards of the welding profession). 6.5.2 Test items and test methods The items and methods to be tested during the welding process are as follows. a) Electric energy is detected by the electric energy meter installed on the energy-consuming equipment; b) The volume of shielding gas and compressed air should be detected with a gas volume flow meter; c) Cooling water consumption, water flow meter (device) testing; d) The quality of qualified weldments shall be inspected with a weighing instrument; e) The quality of the consumable welding materials should be tested with a weighing instrument. 6.5.3 Calculation method Refer to C.4 for calculation methods of total energy consumption during welding and comparable energy consumption per unit of qualified weldments. 6.6 Energy consumption detection and calculation in the heat treatment process 6.6.1 Energy consumption indicators 6.6.1.1 The energy consumption index of the heat treatment process is the comparable energy consumption per unit of qualified heat treatment parts, which refers to the energy consumption during the heat treatment process and the total energy consumption during the statistical period. The ratio of the converted mass of the heat-treated parts. 6.6.1.2 The converted quality of qualified heat-treated parts takes into account the heat treatment process, workpiece material, heating method, production method, heat treatment furnace loading, etc. For the quality of qualified heat-treated parts converted after the factors, the correlation coefficients involved in the calculation process are shown in Appendix G (various coefficient values and classifications, etc.) Corresponding standards for processing professions shall be clarified). 6.6.2 Test items and test methods The items and methods to be tested during the heat treatment process are as follows. a) Electric energy is detected by the electric energy meter installed on the energy-consuming equipment; b) The volume of gas fuel is measured with a gas volume flow meter; c) Cooling water consumption, water flow meter (device) testing; d) The quality of qualified heat-treated parts shall be tested with a weighing instrument. 6.6.3 Calculation method Refer to C.5 for the calculation method of the total energy consumption in the heat treatment process and the comparable energy consumption per unit of qualified heat treated parts. 7 Test report 7.1 The basic content of the cover of the statistical report of energy consumption testing of equipment manufacturing system includes. a) The name of the inspection task; b) Testing location; c) Date of testing; d) Testing unit; e) Report writer; f) Report reviewer; g) Report authorized signatory. 7.2 The basic requirements for the text of the energy consumption test statistical report of the equipment manufacturing system include. a) Scope, task and purpose requirements of energy consumption testing of equipment manufacturing system; b) For each part of the equipment manufacturing system, carry out inspection point layout and inspection instrument description; c) For each part of the equipment manufacturing system, a description of the testing conditions is carried out separately; d) Record the energy consumption of each part and the result of energy consumption calculation; e) Analysis of energy consumption test results of equipment manufacturing system; f) Others. 7.3 The original test data and test report shall be archived by the test unit for future reference. ......Source: Above contents are excerpted from the full-copy PDF -- translated/reviewed by: www.ChineseStandard.net / Wayne Zheng et al. 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