ISO50001

Barriers to Adoption by Industry

August 2016

1
ACTSYS Process Management Consultants Pte Ltd
 Energy Manager = My Wife

Operator = Me
Energy Improvement = Repair Tap
Energy Inefficiency = Not very visible

Energy Audit = The Pail

Energy Inefficiency KPI = # Pails/Day

Energy Planning = Wife’s household review

Putting pail in place
ACTSYS Process Management Consultants Pte Setting
Ltd KPI target
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

 Global Growth of ISO50001

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

ISO50001 EnMS Gap Analysis

Energy Manager

Continuous Improvement Energy Plannning

50%

Energy Training 40% Energy Measurement

30% 60%

10%
Energy Improvement activities
30% 30% Energy Reporting
(Process and maintenance)
10%
10%
50%
Equipment Performance 30% Energy Targets

70%
Energy Audits Energy Performance Indicators

Energy Deviation Monitoring

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

 ISO50001 in Singapore

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

 Energy Consumption Dashboard

ACTSYS Process Management Consultants Pte Ltd

 Energy Consumption Dashboard

ACTSYS Process Management Consultants Pte Ltd

 ISO50001 Dashboard
Refinery A Energy Performance Dashboard 30/7/2016 16:48

Overvi ew Refi nery EII 82 102.4

Crude Di s til l er Uni t 1 CDU1 Del ta +15.2

Crude Di s til l er Uni t 2 CDU2 Del ta -2.5

Na phtha Hydrotrea ter NHT Del ta -4.1

Cont Ca tal ytic Reformer CCR Del ta +3.4

Ga s oi l Hydrodes ul phuri s er GO HDS Del ta +2.1

Hi gh Va cuum Uni t HVU Del ta -1.5

Hydrogen Ma nuf Uni t HMU Del ta -4.5

Hydrocra cker HCU Del ta +3.2

Del a yed Coker Uni t DCU Del ta -2.8

Cogen Uni t COGEN Del ta +4.8

Util i ties UTILS Del ta +7.1

ACTSYS Process Management Consultants Pte Ltd

 Refinery A Energy Performance Dashboard 30/7/2016 16:48
Actua l Ta rget Contri buti on to Refi nery EII
Overvi ew CDU 1 EII 155.1 122 +15.2

Operational Dashboard
Crude Di s ti l l er Uni t 1

Crude Di s ti l l er Uni t 2
CDU Inta ke

F101 Sta ck Temp

m3/h

DegC
347.1

288
351

285
+1.0

+0.0

Na phtha Hydrotrea ter F101 Exces s O2 % 2.4 1.8 +0.29

Cont Ca ta l yti c Reformer C101 Stri ppi ng Stm % 2.8 3 -1.15

Ga s oi l Hydrodes ul phuri s er C101 Pres s ure kg/cm2g 1.45 1.45 +0.0

Hi gh Va cuum Uni t C119 Stri ppi ng Stm % 3.8 3 +2.3

Hydrogen Ma nuf Uni t C103 Reboi l Ra ti o kJ/kg 144 300 -2.1

Hydrocra cker C102 Reboi l Ra ti o kJ/kg 32 45 -0.3

Del a yed Coker Uni t C109 Reboi l Ra ti o kJ/kg 230 200 +4.3

Cogen Uni t C110 Reboi l Ra ti o kJ/kg 137 140 -0.5

Uti l i ti es C110 Pres s ure kg/cm2g 8 8 +0.0

CDU Prehea t Tra i n 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

ACTSYS Process ManagementE136 / E140 kW/C

Consultants Pte Ltd120 300 +2.4
 ISO50001 Dashboard
Pharma Plant Energy Performance Dashboard SEC 30/7/2016 16:42

Overvi ew Overa l l Pl a nt 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

Abs r Chi l l er Abs r Chi l l er +3.3

El ectri c Chi l l er El ectri c Chi l l er +7.4

ChW Pumps ChW Pumps -1.5

Cool i ng Tower Cool i ng Tower -4.5

Ai r Compres s or Ai r Compres s or +1.9

ACTSYS Process Management Consultants Pte Ltd

 ISO50001 Dashboard
Pharma Plant Energy Performance Dashboard 30/7/2016 16:42
Actua l Ta rget Contri bution to Pha rma Pl a nt SEC
Overvi ew Cogen Therm Eff % 76.1 82.3 +8.1

Cogen GT Loa d % 84 100 +0.6

Hot Oi l 1 GT Compr Is en Eff % 81.4 86 +3.3

Hot Oi l 2 GT IAF del ta P mmH2O 67 25 +0.3

Abs r Chi l l er GT Turbi ne Eff % 65 66 +0.0

El ectri c Chi l l er HRSG Act/N&C Stea m 0.93 1 +2.8

ChW Pumps BFW Pump Eff % 65 72 +1.1

Cool i ng Tower

Ai r Compres s or

ACTSYS Process Management Consultants Pte Ltd

 ISO50001 Dashboard
Pharma Plant Energy Performance Dashboard 30/7/2016 16:42
Actua l Ta rget Contri bution to Pha rma Pl a nt SEC
Overvi ew El ect Chi l l er kW/RT 0.74 0.6 +7.4

Cogen ChW Suppl y degC 5.8 7 +2.5

Hot Oi l 1 CW Suppl y degC 28.4 26 +1.3

Hot Oi l 2 CW Fl ow m3/h 734 850 +0.3

Abs r Chi l l er Condens er Subcool degC 3 0 +0.6

El ectri c Chi l l er Eva p Superhea t degC 4 2 +0.3

ChW Pumps Compres s or Eff % 56 66 +2.4

Cool i ng Tower

Ai r Compres s or

ACTSYS Process Management Consultants Pte Ltd

 Case Study - Energy Index Dashboard
MTBE Energy Specific Consumption & Energy Cost (2008-2012)

8,000,000.00 Savings 14.00

RM 2
7,000,000.00 Million/month Energy Cost
12.00

6,000,000.00
10.00
Energy Cost, RM

ESC, mmBTU/MT
5,000,000.00
8.00 MTBE Energy
Specific
4,000,000.00 Consumption
6.00
3,000,000.00

4.00
2,000,000.00

2.00
1,000,000.00

- 0.00
Nov-07 Jun-08 Dec-08 Jul-09 Jan-10 Aug-10 Feb-11 Sep-11 Apr-12 Oct-12 May-13

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
 Learning Points from Others

ACTSYS Process Management Consultants Pte Ltd

 Thank You

AUXILIARY POWER (0.22%)

SHAFT POWER

GT SHAFT POWER (34.23%)

ROTOR COOLING LOSS (2.09%)
WORK (….% of GT

HP TURB POWER (2.18%)

COMPRESSOR

COMBUSTOR LOSS (0.49%)

Shaft Power)

)
8%
.0
(0
INL

SS
ET

LO
A IR IP TURB POWER (6.68%)

PE
(1.

)
4

5%

PI
5% LP TURB POWER (10.87%)

SS
)
.3 CONDENSER LOSS 33.53%
(0

04 LO
SS
SS

RADIATION LOSS (0.06%)

09 LO

(0. ION
LO

%)
RADIATION LOSS
T

(0. ION
%)

AT
C

CHEMICAL
U

(0.34%)

DI
D

AT
ENERGY

RA
DI
(97.32%) HP STEAM (34.39%)

RA
IP STEAM (8.6%)
LP STEAM (4.03%)
STACK LOSS (8.97%)
T
EA
H
% E
00 BL
1. SI
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SE
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FU

www.actsys.com

ACTSYS Process Management Consultants Pte Ltd