pcra –an integrated energy solution provider d vyawahar… · atul d vyawahare b. tech (chemical...

PCRA –An Integrated Energy Solution Provider

1


2


3

Atul D Vyawahare

B. Tech (Chemical Engg)

BEE Certified Energy Auditor

Lead Auditor ISO-50001:2011 EnMS

ISO 9001/ 14001/OHSMS 18001 , Six sigma G.B.

Core Area: EnMS, Energy Audit, Trainer on productivity

improvement

Worked 23 years in BPCL Mumbai Refinery in Ops/ Tech Services

Since May 2012 , on deputation to PCRA under MOP&NG

Currently, Additional Director, PCRA WR Mumbai

Email: [email protected] , cell 09819146864


4


5

� New organisations:

Implementation and development of the management system model.

The implementation of the first PDCA cycle

and establish complete management system model compliant to

ISO 50001.

� Organisations where energy management system has been established and is operating:

Ongoing operation and maintenance,

and ensure it is functioning and delivering energy performance

improvement.

Organisations where energy management system is in place and being

maintained. understand key principles in the improvement or development of the management system model.

Implementation of ISO 50001: various scenarios


6

IMPLEMENTATION MAINTAIN

Operate and maintain

IMPROVE

1st PDCA CYCLE

Conceptual Representation of Implementation and

operation


8

Implementation Process for ISO 50001


9

Implementation Process for ISO 50001 (contd.)


10

1. Preparation of Energy Policy

2. Documentation Related to ISO-50001:2011 EnMS Preparation of Procedure / system Manuals

3. Energy Review document• Identification of Significant Energy Users ( SEU)• Fixing of Base line for the EnPI’s• Fixing of Energy Performance Indicators ( EnPIs)• Objectives, Targets, Action Plan

4. Awareness Training of Employees on ISO- 50001

5. Internal Audit: Training & carrying out audit

6. Management Review Meeting


11

Key elements of EnMS

1. Energy Review

1. Legal and other requirements

2. Awareness and communication on EnMS

3. Projects and design

1. Procurement of energy related equipment


12

1. It is recommended a statistical analysis of the energy

review data to validate the system’s model and the correlation

between variables and energy performances.

2. A statistical model could be used for predicting system

energy performances for analysis.

3. The energy performance opportunities should be compared

with other business key performance indicators like ROI, Low-

cost and Cap-ex/Op-ex and thereafter define the priority in

deploying the action plan.

Energy Review improvement


13

The organization should determine a suitable interval to review thelegal and other requirements which is required due to

�Changes in applicable legal requirements

�Changes in applicable other requirements

�Changes in the operations of the organization which may affect which

requirements may apply to it.

For example an organization may install a new piece of equipment

such as a pressure vessel which causes a pressure vessel law to apply.

Legal and other requirements Review frequency

The process used to identify and evaluate legal compliance should be clear and

simplified.

It should establish who is responsible for monitoring, reviewing and ensuring

compliance.


14

Examples of legal requirements may include:

a)Local, state, provincial, national and international legal requirements;

b)Regulated minimum energy performance equipment standards;

c)Building energy codes and air pollution control laws.

Examples of other requirements , if applicable:

a)Emissions trading requirements,

b)Agreements with customers,

c)Non-regulatory guidelines,

d)Voluntary principles or codes of practice,

e)Voluntary energy agreements

f)Agreements with community groups or non-governmental organizations,

g)Public commitments of the organization or its parent organization,

h)Corporate/company requirements.

Legal requirements and other requirements


15

•EnMS Training Report

•Training calendar

•Template

Awareness Planning


16

Understanding the connection between awareness training and

opportunities for improvement can lead to an improvement in the

awareness campaign involvement.

The effectiveness of awareness campaigns can be continually improved by

a variety of means, (for example use of new technologies, updated

communication techniques, new awareness materials, targeting specific

group on case basis etc., )

Effectiveness of EnMS Training


17

Various communication methods include:

� Organization intranet sites

� Emails and bulletins

� Staff notice boards, staff magazines, energy displays

� Periodic communication meetings, seminars and toolbox talks

� Awareness days and campaigns

These can be used for providing information on:

� The performance of the EnMS, the energy performance of the

organization and the financial benefits achieved

� progress on achieving the objectives, targets and programmes

Employees, contractors, or those working on behalf of the organization should

be encouraged to contribute comments and suggest improvements in energy

performance and the EnMS.

Communication Methods


18


19

�Consider integration of energy management responsibilities with performance evaluation (appraisal) system.

� Consider periodic assessment of additional training needs for the management representative and the energy team.

Improvement Ideas


20

How to improve EnMS further?

a. Frequency of Internal Audit should be planned quarterly for

significant use areas ( for remaining areas it may be once in six month).

b. Please ensure that suggestions are received through suggestionboxes by creating awareness and motivating staff.

e.g. organize a campaign “ Energy week “ to have various programs/competitions/workshops on Energy by involving all employees of all levels.

c. Concerned staff to be motivated to identify more opportunities for saving energy so that improvement in energy performance and set Objectives & Targets could be achieved which is one of the most

important requirements for EnMS.


21

•During earliest stages of design, identify opportunities for improvement of energy performance that are also most cost efficient .

•Opportunities will be identified throughout the entire design process.

•The organization should establish a process for either internal or externally sourced design services that will deliver the most energy efficient design.

•Top management supports this process as consideration of energy performance in long-term planning .

New Project activities: design aspects


22

• For major projects, an energy representative should be part of

the design team, and the team should work in an integrated

manner.

• An energy review should be held as early as possible in the life

cycle of the project, ideally at the concept stage so that the

overall design takes energy performance into account.

• Where appropriate, energy performance targets and

performance measures should be set.

• Whole-system design of the project should be addressed.

• Life-cycle costing should be applied, where appropriate

New Project activities: design aspects


23

When procuring energy related products or equipment, it is important to

consider the energy performance impacts.

The purchases can range from replacement lamps, PCs, printers, etc. to large

scale items such as air compressors, motors, boilers, pumps, large engineering

systems, etc.

•Staff should be aware of the investment criteria used in procurement decisions.

•Specific procurement guidelines may be established for certain items of plant,

equipment or other items.

For example, motor purchasing guidelines specifying that only high efficiency

motors are purchased. If it is possible to purchase energy through competitive

purchasing, there are opportunities for reducing costs in purchasing electricity

and fuels.

Organization may also wish to consider using energy from renewable sources.

Procurement of energy efficient equipment


24


25

Performance comparison

( LPG Terminal )

Energy Performance

Indicator

Annual baseline avg

2012/13

After ISO 50001

Implementation Six

Month avg

KWH/MT of total

throughput

7.28 6.45

Water Consumed in

Litres/MT LPG Handled

66 41.3

Diesel Consumed Ltrs 2600 1478


26

ISO:50001:2011 ImplementationISO:50001:2011 Implementation

the BPCL Mumbai Refinery experiencethe BPCL Mumbai Refinery experience


27

HighlightsHighlights


28

Energy PolicyEnergy Policy


29

Awareness & TrainingAwareness & Training

Specific training was imparted at Unit level for persons Specific training was imparted at Unit level for persons

related to SEUs for operation, monitoring and sustenance related to SEUs for operation, monitoring and sustenance

of EnMS.of EnMS.

5 Nos. officers were trained and certified as Lead 5 Nos. officers were trained and certified as Lead

Auditors for ISO:50001 by M/s Intertek.Auditors for ISO:50001 by M/s Intertek.

18 Nos. officers were trained and certified as Internal 18 Nos. officers were trained and certified as Internal

Auditors for ISO:50001 by M/s PCRA.Auditors for ISO:50001 by M/s PCRA.

Employees were provided awareness training.Employees were provided awareness training.

Contractor employees were covered under awareness training.Contractor employees were covered under awareness training.

Vendors/Contractors were given overview of ISO:50001 during Vendors/Contractors were given overview of ISO:50001 during

Annual Vendor MeetAnnual Vendor Meet

ISO:50001 awareness was incorporated in the orientation ISO:50001 awareness was incorporated in the orientation

module for GETs/ fresh entrants.module for GETs/ fresh entrants.

Banners & Display Boards were put up for general awareness.Banners & Display Boards were put up for general awareness.

Energy Policy was displayed across the RefineryEnergy Policy was displayed across the Refinery


30

Purchase Conditions Purchase Conditions


31

Internal Audit & MRM Internal Audit & MRM


32

External Audit External Audit

Obs. & NCs madeObs. & NCs made

were liquidatedwere liquidated

with evidenceswith evidences

Adequacy checked Adequacy checked

& Gaps analyzed& Gaps analyzed


33

Time lineTime line


34

Time lineTime line


35July 13

Kick off meeting on ISO 50001 Energy Management System

Management Representative and Asst. MR appointed by ED

Developed Energy Monitoring Bar Chart Time Bound Program

Establish Energy baseline and started Training all SEU’s

Started Documentation and Energy Review

July 13

July13

July 13

July 13

Established Refinery energy management policyAug 13

Set energy objectives, targets & action planAug 13

Onward Journey

Aug 13 Established Energy Management System

Oct 13 Internal Audit for Engineers

Jan 15

Jan 14 Certifying EnMS on ISO 50001

BPCL EnMS journey

A journey of a thousand miles begins with

a single step in the right direction


36

CertificationCertification

Handing over of CertificateHanding over of Certificate

by Hon. Minister MOP&G by Hon. Minister MOP&G

Certificate received by GM (Ops)Certificate received by GM (Ops)

& Mumbai Refinery team& Mumbai Refinery team

A number of common areas identified help in the implementation of an EnMS:

a)Making a system too complex

a)Focusing on doing without recording

a)Focusing on the technical aspects and ignoring the system

a)Maintaining two systems – one for use, the other for external auditors to see

e) Not seeing the value in internal audits

f) Restricting communication: e.g. only a core team is involved and really runs the system, while those outside the team are excluded

Areas to avoid while implementingISO 50001


38

A full implementation of the EnMS may require more time

and resources that the company may be able to provide.

Initially we may start with a simple configuration and

thereafter increasing the complexity of the system modelling

for improvement.

FURTHER IMPROVEMENT of ENMS

An effective EnMS provides confidence that you are in control of your

significant energy impacts. It demonstrates an innovative and forward

thinking approach to customers and prospective employees.

pcra –an integrated energy solution provider d vyawahar… · atul d vyawahare b. tech (chemical...

Documents