ACTSYS Process Management Consultants Pte Ltd ACTSYS Process Management Consultants Pte Ltd
ISO50001 Barriers to Adoption by Industry
August 2016
1
ACTSYS Process Management Consultants Pte Ltd
Operator = Me
Energy Manager = My Wife
Energy Inefficiency = Not very visible
Energy Inefficiency KPI = # Pails/Day
Energy Audit = The Pail
Energy Planning = Wife’s household review
Putting pail in place
Setting KPI target
Energy Improvement = Repair Tap
ACTSYS Process Management Consultants Pte Ltd
ISO 50001 Energy Mgmt System
• Overview of Requirements – Based on the Plan-Do-Check-
Act continual improvement framework Plan: establish the objectives and
processes necessary to deliver results in accordance with opportunities to improve energy performance and the organization's policies
Do: implement the processes
Check: monitor and measure processes and product against policies, objectives and the key characteristics of its operations and report the results.
Act: take actions to continually improve energy performance.
ACTSYS Process Management Consultants Pte Ltd
High Growth Countries
• Germany – Energy intensive industries (>5 GWh/Y) minimum
requirement ISO50001 certification for energy tax incentives and partial exemption from renewable levies
– Mandatory Energy Audits
– 3500 ISO50001 certifications (2014)
• Sweden – Large Industries mandatory Energy Audits by certified
energy auditor
– Obligatory Implementation of certified Energy Management System
ACTSYS Process Management Consultants Pte Ltd
ISO50001 in Singapore
• Limited number of companies have gone for certification (<20)
• Common reasons
– Perception of limited benefits
– In-house Energy Management good enough
– Certification and verification generate high work load
– Audit fatigue from ISO9001, ISO14001
ACTSYS Process Management Consultants Pte Ltd
Sustaining Energy Performance
50%
40%
60%
30%
10%
10%
30%
70%
50%
30%
10%
30%
Energy Manager
Energy Plannning
Energy Measurement
Energy Reporting
Energy Targets
Energy Performance Indicators
Energy Deviation Monitoring
Energy Audits
Equipment Performance
Energy Improvement activities(Process and maintenance)
Energy Training
Continuous Improvement
ISO50001 EnMS Gap Analysis
ACTSYS Process Management Consultants Pte Ltd
Singapore ECA Findings
• Energy Conservation Act covered 213 energy intensive facilities
• Findings over 2 years of Reporting – Varying levels of rigour in Energy Management
– Low level of ambition in Energy Efficiency Improvement
– Room for improvement in Energy Efficiency
– 62% of Energy Performance of major systems not tracked
– Over 50% measured less than 1/3 of important parameters
Source : NEA
ACTSYS Process Management Consultants Pte Ltd
Actsys Observations
• Customer Segments
– Refineries
– Petrochemical Plants
– Pharmaceuticals
– Semiconductor
– Food Industry
• Energy Audits
• Measurement and Verifications
• Regular Performance Monitoring
ACTSYS Process Management Consultants Pte Ltd
Observation of Common Gaps
• Energy Planning (4.4)
– No Energy Reviews / Audits (4.4.3)
• Lack of internal capacity
• Not considered use of external Energy Auditors
• No structured plan for improvement
– No Energy Baseline (4.4.4)
• Not established without Energy Review
– Inadequate Energy Performance Indicators (4.4.5)
• Usually no Plant Wide EnPI (and no KPI targets)
• Not normalized for production levels or ambient conditions
ACTSYS Process Management Consultants Pte Ltd
Observation of Common Gaps
• Implementation and Operation (4.5)
– Operational Control (4.5.4)
• No targets given to adjust for energy efficiency
• No criteria available to trigger maintenance for energy efficiency
– Design (4.5.6)
• Often farmed out to EPC contractors or Equipment Suppliers who do not place high priority on energy efficiency features
ACTSYS Process Management Consultants Pte Ltd
Observation of Common Gaps
• Checking Performance (4.6)
– Measurement, Monitoring and Analysis (4.6.1)
• Insufficient instrumentation
• None or disparate data logging systems eg flows, temps on Scada and motor power on Motor Control Centre Panel
• Incomplete comprehension which operating parameters contribute to energy performance eg Chiller Condenser sub-cooling
ACTSYS Process Management Consultants Pte Ltd
Energy Management Dashboards
• Enabler for ISO50001 integration into organization
• Many varieties commercially available
• Important features
– Plant Wide Energy KPI vs Target
– Drill down into plant subsections
– Drill down into equipment level operating parameters
ACTSYS Process Management Consultants Pte Ltd
ISO50001 Dashboard Refinery A
Overview Refinery EII 82 102.4
Crude Dis ti l ler Unit 1 CDU1 Delta +15.2
Crude Dis ti l ler Unit 2 CDU2 Delta -2.5
Naphtha Hydrotreater NHT Delta -4.1
Cont Catalytic Reformer CCR Delta +3.4
Gasoi l Hydrodesulphuriser GO HDS Delta +2.1
High Vacuum Unit HVU Delta -1.5
Hydrogen Manuf Unit HMU Delta -4.5
Hydrocracker HCU Delta +3.2
Delayed Coker Unit DCU Delta -2.8
Cogen Unit COGEN Delta +4.8
Uti l i ties UTILS Delta +7.1
30/7/2016 16:48Energy Performance Dashboard
ACTSYS Process Management Consultants Pte Ltd
Operational Dashboard
Refinery A
Actual Target Contribution to Refinery EII
Overview CDU 1 EII 155.1 122 +15.2
Crude Dis ti l ler Unit 1 CDU Intake m3/h 347.1 351 +1.0
Crude Dis ti l ler Unit 2 F101 Stack Temp DegC 288 285 +0.0
Naphtha Hydrotreater F101 Excess O2 % 2.4 1.8 +0.29
Cont Cata lytic Reformer C101 Stripping Stm % 2.8 3 -1.15
Gasoi l Hydrodesulphuriser C101 Pressure kg/cm2g 1.45 1.45 +0.0
High Vacuum Unit C119 Stripping Stm % 3.8 3 +2.3
Hydrogen Manuf Unit C103 Reboi l Ratio kJ/kg 144 300 -2.1
Hydrocracker C102 Reboi l Ratio kJ/kg 32 45 -0.3
Delayed Coker Unit C109 Reboi l Ratio kJ/kg 230 200 +4.3
Cogen Unit C110 Reboi l Ratio kJ/kg 137 140 -0.5
Uti l i ties C110 Pressure kg/cm2g 8 8 +0.0
CDU Preheat Tra in HX UA
E137 kW/C 257 260 +0.0
E105A/B kW/C 52 116 +1.2
E139 kW/C 31 20 -0.1
E142A/B kW/C 106 212 +2.4
E108A/B kW/C 65 123 +3.5
E112A/B kW/C 180 220 +2.2
E141 kW/C 492 318 -0.24
E136 / E140 kW/C 120 300 +2.4
Energy Performance Dashboard 30/7/2016 16:48
ACTSYS Process Management Consultants Pte Ltd
Pharma Plant
Overview Overal l Plant 100 116.4
Cogen Cogen +8.2
Hot Oi l 1 Hot Oi l 1 -1.5
Hot Oi l 2 Hot Oi l 2 +3.1
Absr Chi l ler Absr Chi l ler +3.3
Electric Chi l ler Electric Chi l ler +7.4
ChW Pumps ChW Pumps -1.5
Cool ing Tower Cool ing Tower -4.5
Air Compressor Air Compressor +1.9
Energy Performance Dashboard SEC 30/7/2016 16:42
ISO50001 Dashboard
ACTSYS Process Management Consultants Pte Ltd
Pharma Plant
Actual Target Contribution to Pharma Plant SEC
Overview Cogen Therm Eff % 76.1 82.3 +8.1
Cogen GT Load % 84 100 +0.6
Hot Oi l 1 GT Compr Isen Eff % 81.4 86 +3.3
Hot Oi l 2 GT IAF delta P mmH2O 67 25 +0.3
Absr Chi l ler GT Turbine Eff % 65 66 +0.0
Electric Chi l ler HRSG Act/N&C Steam 0.93 1 +2.8
ChW Pumps BFW Pump Eff % 65 72 +1.1
Cool ing Tower
Air Compressor
Energy Performance Dashboard 30/7/2016 16:42
ISO50001 Dashboard
ACTSYS Process Management Consultants Pte Ltd
Pharma Plant
Actual Target Contribution to Pharma Plant SEC
Overview Elect Chi l ler kW/RT 0.74 0.6 +7.4
Cogen ChW Supply degC 5.8 7 +2.5
Hot Oi l 1 CW Supply degC 28.4 26 +1.3
Hot Oi l 2 CW Flow m3/h 734 850 +0.3
Absr Chi l ler Condenser Subcool degC 3 0 +0.6
Electric Chi l ler Evap Superheat degC 4 2 +0.3
ChW Pumps Compressor Eff % 56 66 +2.4
Cool ing Tower
Air Compressor
Energy Performance Dashboard 30/7/2016 16:42
ISO50001 Dashboard
ACTSYS Process Management Consultants Pte Ltd
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
-
1,000,000.00
2,000,000.00
3,000,000.00
4,000,000.00
5,000,000.00
6,000,000.00
7,000,000.00
8,000,000.00
Nov-07 Jun-08 Dec-08 Jul-09 Jan-10 Aug-10 Feb-11 Sep-11 Apr-12 Oct-12 May-13
Ene
rgy
Co
st, R
M
ESC
, mm
BTU
/MT
MTBE Energy Specific Consumption & Energy Cost (2008-2012)
Energy Cost
MTBE EnergySpecificConsumption
Savings
RM 2
Million/month
Case Study - Energy Index Dashboard
ACTSYS Process Management Consultants Pte Ltd
Learning Points from Others
• 3M 3M_Global.pdf
– EE program already in place 40 years
– ISO50001 gave tools for continuous improvement
– Implemented ISO50001 since 2011 in 18 facilities in 7 countries, they show EE improvement 60% more than group average
• Abbott Abbott.pdf
– Deciding Energy Performance Indicators and putting in place metering plan
– “We should have done it earlier”
ACTSYS Process Management Consultants Pte Ltd
Learning Points from Others
• JK Lakshmi Cement Ltd JK Lakshmi.pdf
– Many years of Energy Management activities but ISO50001 provided structure
– Smooth implementation of ISO50001 as staff already well versed with ISO9001 and ISO14001
– Challenge was to involve bottom line workmen
ACTSYS Process Management Consultants Pte Ltd
Learning Points from Others
• Nissan USA Nissan_USA.pdf
– “ISO50001 adds rigor, analysis, and gives good guidance. It’s one thing to have a target and objective, but ISO 50001 gives tools that empower you to be more disciplined and prove the impact certain activities have.” —Nissan North America Energy Team
– Some believed the company had already seized all opportunities to reduce energy usage; however, the EnMS and the EnPI tool enabled discovery of correctable, previously undetected energy losses.
ACTSYS Process Management Consultants Pte Ltd
Thank You
GT
SH
AF
T P
OW
ER
(3
4.2
3%
)INLET AIR (1.45%)
HP STEAM (34.39%)
HP
TU
RB
PO
WE
R (
2.1
8%
)
LP TURB POWER (10.87%)
CONDENSER LOSS 33.53%
SHAFT POWER
IP TURB POWER (6.68%)
AU
XIL
IAR
Y P
OW
ER
(0
.22
%)
ROTOR COOLING LOSS (2.09%)
COMBUSTOR LOSS (0.49%)
CO
MP
RE
SS
OR
WO
RK
(…
.% o
f G
T
Sh
aft
Po
we
r)
FUEL
SENSIB
LE H
EAT
1.00
%
DUCT L
OSS (0
.35%
)
RADIATION LOSS
(0.34%)
PIP
E L
OSS (0
.08%
)
LP STEAM (4.03%)STACK LOSS (8.97%)
IP STEAM (8.6%)
CHEMICAL
ENERGY
(97.32%)
RADIATION LOSS (0.06%)
RA
DIA
TIO
N L
OS
S
(0.0
9%
)
RA
DIA
TIO
N L
OS
S
(0.0
4%
)
www.actsys.com