PCRA –An Integrated Energy Solution Provider D Vyawahar… · Atul D Vyawahare B. Tech (Chemical...
Transcript of PCRA –An Integrated Energy Solution Provider D Vyawahar… · Atul D Vyawahare B. Tech (Chemical...
PCRA –An Integrated Energy Solution Provider
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PCRA –An Integrated Energy Solution Provider
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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
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� 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
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IMPLEMENTATION MAINTAIN
Operate and maintain
IMPROVE
1st PDCA CYCLE
Conceptual Representation of Implementation and
operation
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Implementation Process for ISO 50001
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Implementation Process for ISO 50001 (contd.)
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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
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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
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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
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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.
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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
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•EnMS Training Report
•Training calendar
•Template
Awareness Planning
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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
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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
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�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
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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.
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•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
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• 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
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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
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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
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ISO:50001:2011 ImplementationISO:50001:2011 Implementation
the BPCL Mumbai Refinery experiencethe BPCL Mumbai Refinery experience
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HighlightsHighlights
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Energy PolicyEnergy Policy
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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
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Purchase Conditions Purchase Conditions
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Internal Audit & MRM Internal Audit & MRM
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External Audit External Audit
Obs. & NCs madeObs. & NCs made
were liquidatedwere liquidated
with evidenceswith evidences
Adequacy checked Adequacy checked
& Gaps analyzed& Gaps analyzed
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Time lineTime line
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Time lineTime line
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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
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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
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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.