ISO 50001 and

Implementation in NALCO

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S.K.Jena,AGM(Mech) SMELTER PLANT, NALCO, ANGUL

Energy comes in many forms including electricity, fuel oil, steam,

compressed air

Energy is becoming increasingly more expensive as the Earth’s

resources are used up

Industrial energy use represents more than one-third of both

global primary energy and energy related carbon dioxide

emissions. For developing countries, this is often in excess of

50% of the total.

Reducing energy consumption will not only reduce costs, it will

reduce carbon footprint and environmental impact

Reducing energy consumption will also reduce reliance on other,

hence reducing risk to the Organisation

Energy Management is quickly becoming a fundamental concern

in all business sectors worldwide

Why Energy Management ?

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DRIVERS FOR ENERGY MANAGEMENT

1. REDUCING/CONTROLLING COST

2. PROTECTING THE GLOBAL CLIMATE

3. IMPROVING COMPANY REPUTATION AMONG CUSTOMERS

4. COMPLIANCE WITH INDUSTRY BEST PRACTICE OR STANDARD

5. CONSISTENCY WITH LOCAL CORPORATE CULTURE

6. COMPLIANCE WITH LEGISLATIVE REQUIREMENTS

7. CORPORATE SOCIAL RESPONSIBILITY

8. PROCUREMENT ORDERS FROM KEY CUSTOMERS

The new international Energy Management standard,

ISO50001 was issued on 15 June 2011

The International Organisation for Standardisation (ISO) has

a membership of 160 countries national bodies.

ISO only develops standards for which there is a clear

market requirement. The work is carried out by experts in

the subject drawn directly from the industrial, technical and

business sectors

ISO50001, is based on the ISO Management System model

Plan-Do-Check-Act similar to ISO9001 (Quality) , ISO14001

(Environment) etc.

ISO50001 can be implemented separately or integrated with

any other management system standards

ISO 50001

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Aim of ISO 50001

• Increase energy efficiency

• Reduce costs

• Improve environmental performance in energy use

• Continually keep improving year-by-year

• Identify more potential areas

Can influence up to 60 percent of the world’s energy demand

ISO 50001 ISO50001 provides a framework of

requirements enabling organizations to

Develop a policy for more efficient use of

energy

Fix objectives and targets to meet the policy

Use data to better understand and make decisions

concerning energy use and consumption

Measure the results

Review the effectiveness

Continually improve energy management

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ISO 50001

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ISO50001 in NALCO

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In NALCO, the Captive Power plant

was the first Unit to get certified to

ISO50001 in January 2013

Alumina Refinery was certified in

November 2013.

Smelter plant, was certified in

May 2014.

Following audits were conducted by

M/v DNV, Netherlands:

1.Documentation Audit

2.Stage-I Audit

3. Stage-II Audit ( Cetrification

Audit)

Prior to establishing an energy management system, it is

needed to gather background data on energy usage and

consumption so that baselines can be determined.

Background data comes from meter readings records,

fuel issue records etc.

One of the first things to decide is scope and boundaries.

Before Starting…

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EnMS Scope in Smelter

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The Energy Management System in Smelter covers the processes and

facilities within the physical boundary of Smelter plant and includes the

following:

•Production of carbon Anodes in Carbon Area

•Production of aluminium metal in Potlines by smelting

•Production of primary aluminium products in Casthouse-A,

Casthouse-B and Rolling plant

•Compressed air network

•Process water network

•Air-conditioning and ventilation systems

•Illumination

Transportation of products from Smelter plant to stockyards or customers

by railway rakes or trucks on road is excluded from the scope of EnMS at

Smelter as Smelter management does not have operational control over

the same

Plan-Do-Check-Act(PDCA) Cycle

Management Responsibility Top Management needs to be committed

An Management Representative is to be appointed

An Energy Management Team is formed with approval of Top

Management

Energy Policy ISO50001 requires an Organisation to have an energy policy

The Energy policy has to support Commitment to continual improvement

in energy performance

Commitment to provide necessary resources to achieve objectives and

targets

Commitment to comply with Legal requirements related to energy

Purchase of energy efficient products and services

Design for energy performance improvement

The Energy policy needs to be documented and communicated to all levels in the Organisation

Basic requirements

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Energy Planning

Legal and other requirements applicable to energy

use, consumption and efficiency need to be

identified and included in the Legal Register

•National and International Legal Requirements

•State/ provincial legal requirements

•Local Governmental legal requirements

Other Requirements Agreement with public authorities

Agreement with Customers

Requirements of Trade Associations

Agreements with Community groups

Public Commitments

Corporate/company requirements

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Energy Planning

Next, Energy Review is to be conducted – Organisations energy use and consumption to be

analysed based on measurement and other data

Areas of Significant energy Use (facilities, equipment, systems, processes) are

to be identified.

Opportunities for improving energy performance are to be identified, evaluated

and listed. They may include use of non-renewable energy, or other use of energy

produced from waste.

Energy Baselines are to be established, covering suitable time periods- for

monitoring energy performance and checking improvements. Baselines can be changed

in future, if there are major changes in processes, operational patterns or energy

systems

Energy Performance Indicators (EnPIs) eg energy consumption per time,

energy consumption per unit of production which will be used to monitor energy

performance. EnPIs can be based on multi-variable models.

Energy Objectives & targets are to be set and documented including

Programmes i.e projects of modifications etc to reduce energy consumption. They

have to be consistent with the Energy Policy. Action plans are to be established,

implemented and maintained. When establishing and reviewing Objectives & targets, we

have to take into account legal requirements and other requirements, significant energy

uses and opportunities to improve energy performance, as listed earlier.

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Past & Present Energy use

•Performance •Relevant variables

Analyze energy use & consumption

Identify areas of significant Energy Use

Identify Opportunities for improving energy

performance

•Energy Baseline •EnPIs •Objectives •Targets •Action Plans

Energy Planning

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Energy Baseline Quantitative reference providing a basis for comparison of energy performance

MONTH ELECTRICAL ENERGY (1000

KWH) PRODUCTION NET ANODES

(MT) Apr-11 1656.5 12849

May-11 1985.8 17521

Jun-11 1576.3 14192

Jul-11 1756.5 16863

Aug-11 1984.8 17463

Sep-11 1712.1 12826

Oct-11 1634.4 10421

Nov-11 1725.9 14657

Dec-11 1805.9 14368

Jan-12 1539.5 11382

Feb-12 1636.1 13718

Mar-12 1050.8 5728

Apr-12 1958.9 17630

May-12 1790.9 14505

Jun-12 1614.3 13443

Jul-12 1677.2 12683

Aug-12 1573.1 12420

Sep-12 1357.8 9959

Oct-12 1700.8 14558

Nov-12 1624.1 14412

Dec-12 1734.9 16138

Jan-13 1670.1 14664

Feb-13 871.6 7372

Mar-13 1511.2 14263

Regression Analysis

Single Variable Multi Variable

y = 0.0742x + 620.79 R² = 0.7888

0

500

1000

1500

2000

2500

0 5000 10000 15000 20000

Ene

rgy

(10

00

KW

H)

Net Anodes (MT)

Energy Consumption Vs Production (GAP II)

Estimated Energy Consumption = 620.7 + 0.074 * (Net Anodes in MT)

Some EnPIs in Smelter

Sp. DC Electrical Energy consumption in Potline-1 Potline Operation

Sp. DC Electrical Energy consumption in Potline-2 Potline Operation

Sp. DC Electrical Energy consumption in Potline-3 Potline Operation

Sp. DC Electrical Energy consumption in Potline-4 Potline Operation

Sp. AC Electrical Energy in Compressor Houses Utilities

Sp. HFO consumption for Wirerod Mill operation Casthouse-A Operation

Sp. HFO consumption for Ingot Casting operation Casthouse-B Operation

+ others ( total 20 departmental EnPIs taken at present)

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Sp. AC Electrical Energy consumption in Smelter, KWH/ MT Plant level

Sp. HFO consumption in Smelter, L /MT Plant level

Some Energy Management Programmes in Smelter

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Depart ment

EnMP Target

PL Mech Installation of Air-receiver in PTMs screw compressor 20% reduction in energ. Consmp. of compressor motor: by 31/03/2015

CH-A Operation Replacement of 1 furnace SMCD with improved door sealing 5 % reduction on expected consmpn ; by December 13

RP Operation Semi-auto matic firing control system for M&H furnace of Caster # 1

152 lt/T from 206 lt/T by January 2014

Carbon plant

Electrical

Installation of VFD for general de-dusting system in RS-1 Reduce by 1% w.r.t baseline by Sept’ 2015

Provision of VFD in LT& Main Hoist motor of Stacking crane of ABF-1

Reduce by 5% w.r.t baseline by Dec’ 2014

Provision of VFD in Winch motors of ABF-1 Reduce by 5% w.r.t baseline by Sept 2015

Utilities Installation of 2nos. Energy Efficient Compressors in place of old compressors

2% reduction over base-line by August 2014

Potline Electrical Replacement of Energy efficient TL-5 lights in place of 40watt in FTP 1 to 4 control rooms

30% reduction w.r.t baseline by July 2014

Electrical Sub-station

Modification of illumination system of 220kv switchyard 10% reduction over base-line by May 2014

Electrical Repair Shop

Reduction of energy cons. ERS&CRS shop lighting by using timer control

15% reduction w.r.t baseline by June 2014

Reduction of energy cons. ERS&CRS shop lighting by using induction & LED lamps

30 % reduction w.r.t baseline by December 2014

RP Electrical To provide timers & aux. contactors for roof lighting in RP shopfloor bays

25 % reduction w.r.t baseline by April 2014

Implementation and Operation

It is required to ensure that any person working with energy

usage ( including employees and contractor workers) are

competent on the basis of appropriate education, training,

skills or experience. The purpose of this requirement is to ensure that

everyone plays an active part in energy management and is aware of role and

potential benefits of good energy performance.

Operator Competence Training examples: Operating procedures

Testing procedures

Start-up/ shutdown procedures

Controls & Alarm details

Maintenance procedure

Internal communication to be used to make people aware of

energy performance ( posters, bulletin boards, newsletters,

work group meetings). Everyone should have the ability to

make comments or suggest improvements (suggestion

cards or boxes)

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Implementation and Operation

Operations and maintenance activities related to Significant

Energy Uses are to be carried out under specified conditions

Setting of control criteria for operation and maintenance of

areas/equipments of Significant Energy Use

Operating & maintaining as per the criteria/ SOPs

Communication of controls (Dos/DONOTs) to personnel working

Example: Maintenance Controls Compressed air line survey and repair of leaks

Insulation inspection and repair/replacement

Combustion tuning/ damper setting

Tyre pressure checks

Preventive maintenance

Examples of Operational Controls Parameter setting

As per Work Instructions

Alarms or alerts systems

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Operational control Green Anode Plants: • Stopping of Electrical heaters during Long production stoppages

Bake Oven: • Throughout firing temperature of flue gases controlled within a range of ± 50 o C from target temperatures • Incase of oil spillage at the Bake Oven floor due to damage of oil pump seal or leakage of oil hoses, it is mixed with the packing coke and put inside the furnace and which burns subsequently.

Potlines: • Cause of repeated anode effect is investigated. If required feed rate of the pots are be changed. • Resistance addition to the Pots is reviewed in shift by checking computer reports and pot conditions. • Pot showing prolonged instability are attended on priority basis. • Under feeding ratio to be maintained between 25-32 % • In all compressed air systems, leakages are checked on daily basis and

sealed.

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Operational control Casthouse: • The solid metal charging door is kept closed except during scrap charging.

During metal pouring, the lower portion of the solid metal charging door is kept opened to observe the metal level in the furnace. The liquid metal charging door is kept closed except during metal pouring.

• When the firing of burners stop, the dampers of the furnace close automatically to reduce heat loss.

• In all HFO systems, leakages are checked and prevented periodically. Burners of the furnaces are periodically maintained for proper combustion.

Implementation and Operation

Energy performance improvement opportunities

are to be considered when designing new or

modified facilities, equipment, systems and

processes and any output need to be included

When buying energy eg electricity or fuel oil,

purchasing specifications need to be defined and

documented

When buying equipments/products that use energy,

energy consumption over the expected life is to be

assessed and specifications to include energy

consumption related requirements

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Checking Energy Performance need to be monitored,

measured and analyzed ( EnPIs and Targets as

defined earlier). Energy Measurement Plan is to

be defined and implemented.

Energy data should be accurate and repeatable-

measuring equipment need to be calibrated or

otherwise verified

Any significant deviation from expected energy

performance needs to be investigated and responded

to: records are to be maintained for this

Compliance with energy related Legal and Other

requirements are to be evaluated and recorded

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ISO 50001 Internal audits are to be carried out to ensure that the

system is implemented and effective

Records are to be established and maintained in a way that

they remain legible, identifiable and traceable to activities

For non-conformities, corrections are to be

made and than corrective action has to be

taken for the root-cause.

Management Review Meetings are to be conducted

periodically and as per agenda

Achievements and short-falls/deviations are to be

discussed and necessary actions to be agreed

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