ISO 50001 Energy Management Standard


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ISO 50001 Energy Management Standard

  1. 1. Tennessee 3-Star Industrial Assessment Center ISO 50001: Energy Management Standard Kenneth Currie, PhD, PE, CP EnMS Director Center for Manufacturing Research Chattanooga Regional Manufacturers Association Energy Summit May 8, 2013
  2. 2. Workshop Objectives • An understanding of the ISO 50001 energy management system • What are the benefits of an energy management system • Understanding the PDCA cycle for energy management • Practical applications for developing Energy Performance Indicators
  3. 3. Energy Management Benefits • Why do we want to manage energy? • Low hanging fruit always grow back! • As a risk management strategy • Interdisciplinary energy management team ensures cooperative atmosphere
  4. 4. ISO 50001 – Energy Management Standard • Requires an organization to establish, implement, maintain, and improve an energy management system, enabling systematic achievement of continual improvement in energy performance, energy efficiency, and energy conservation. • Imposes requirements on energy supply and consumption: – Measurement – Documentation and reporting – Design and procurement practices for energy-using equipment and systems – Processes and personnel • Applies to all factors that can be monitored and influenced by the organization to affect energy use. • Does not prescribe specific performance criteria with respect to energy. • Designed to be used independently, yet can be aligned or integrated with other management systems (e.g., ISO 9001 and ISO 14001). Applicable to all organizations that use energy.
  5. 5. PDCA: PLAN
  6. 6. Energy Policy What does the Standard say? • Approved by top management • Appropriate for the organization • Provides framework for setting and reviewing objectives and targets • Supports the purchase of energy efficient products and services • Documented, communicated, and understood • Regularly reviewed and updated
  7. 7. Energy Policy Example: Capsa Corp is committed to: Continually improving energy performance Achieving 25% energy intensity reduction in 10 years Providing available information and resources to meet objectives and targets Supporting the purchase of energy efficient equipment and systems as appropriate for the organization Abiding by legal and other requirements
  8. 8. Scope and Boundary Scope and boundary may be the same. “The EnMS includes all operations of XYZ Manufacturing Company located at 123 Main Street, Nashville, TN.”
  9. 9. Energy Planning Process Planning Inputs Past and present energy uses Relevant variables affecting significant energy use Energy performance Energy Review A. Analyze energy use and consumption B. Identify areas of significant energy use and consumption C. Identify opportunities for improving energy performance Planning Outputs •Energy baseline •EnPI(s) •Objectives •Targets •Action Plans
  10. 10. Energy Sources Total Plant Energy Electricity Natural Gas Propane Off-site Generated Steam Identify all energy sources that cross the fence line! Primary energy sources enter the boundary of a facility from an external or internal supplier.
  11. 11. Energy Uses Total Plant Energy Electricity Natural Gas Propane Off-site Generated Steam Motors A/C Heating Process Heating Forklifts Process Heating
  12. 12. Energy Balance An energy balance takes the total of all energy sources and attributes it to specific equipment and systems. Looks at energy consumption on a smaller scale for each energy use (air compressors, lights, process motors, boilers, dryers, etc.) Can be determined through submeters, load analysis, or DOE software – PEP (Plant Energy Profiler).
  13. 13. Energy Balance Description Size Units Oper hr Load kWh MMBtu % total Electrical Usage VSD screw 125 HP 8760 0.5 439,177 1,498 10.0% Recip backup 50 HP 500 0.7 14,506 49 0.3% Chiller 100 tons 8760 0.5 350,400 1,196 8.0% Air handlers 20 HP 8760 0.75 108,916 372 2.5% Cooling tower 15 HP 8760 0.45 49,012 167 1.1% Refrigeration 3 tons 8760 0.5 10,512 36 0.2% Process pumps 50 HP 6600 0.6 164,120 560 3.7% Votator 20 HP 3300 0.4 21,883 75 0.5% Homogenizer 40HP 3300 0.4 43,765 149 1.0% Plant lights 69 kW 6600 1 455,400 1,554 10.4% Process motors 50 HP 6600 0.4 109,413 373 2.5% Misc electrical use 352,695 1,203 8.0% Natural Gas Usage Boiler 25bHP 6600 0.35 6,909 46.1% Water heater 300000 Btuh 8760 0.2 526 3.5% Misc gas use 335 2.2% Plant total 15,003 100.0% Annual Energy Usage Source Usage Units Natural gas 7,770 MMBtu Electricity 2,119,800 kWh Combined Btu 15,003 MMBtu
  14. 14. 0.0% 5.0% 10.0% 15.0% 20.0% 25.0% 30.0% 35.0% 40.0% 45.0% 50.0% Step 2.3.2-2 Example Energy Balance VSD screw Recip backup Chiller Air handlers Cooling tower Refrigeration Process pumps Votator Homogenizer Plant lights Process motors Misc electrical use Boiler Water heater Misc gas use
  15. 15. SEU Significant Energy Uses give you the most “bang” for your buck. Keep it simple! Choose 1 or 2 to begin with. SEU’s form the basis of much of the EnMS. – Operator competence and training – Procurement – Operational Controls – Monitoring, Measuring, Analysis – Objectives, Targets, Action Plans
  16. 16. SEU Determination Must use and document a method for establishing significant energy consumption. •Energy Balance •Pareto (80 / 20 rule) •Ranking Methods •Benchmarking
  17. 17. Identify Energy Opportunities Develop criteria: • Estimated energy or cost savings • ROI, rate of return • Length of implementation period • Possible safety, health, environmental issues • Maintenance impact • Production impact • Organizational goals
  18. 18. Energy Planning Process Planning Inputs Past and present energy uses Relevant variables affecting significant energy use Energy performance Energy Review A. Analyze energy use and consumption B. Identify areas of significant energy use and consumption C. Identify opportunities for improving energy performance Planning Outputs •Energy baseline •EnPI(s) •Objectives •Targets •Action Plans
  19. 19. Energy Metrics Purpose of energy metrics • We need to know if performance is improving • We need to verify savings of improvements • We need to know how much energy we are using • We need to know if we are meeting our objectives and targets • We need objective support for decision making ISO 50001 Metrics = EnPI and baseline
  20. 20. Relevant Variables Relevant variables are factors that affect energy performance. • Weather – Temperature – Humidity - Cooling degree days – Precipitation - Heating degree days • Production related – Operating hours - Operating temperature – Variation in types of production - Operating pressure – Production rate • Operator training • Maintenance
  21. 21. Simple EnPI EnPI = Annual Energy Use / Annual Production (MMBtu / yr) (e.g. lbs/yr, tons/yr, units/yr) • Easiest to use and calculate • Sufficient if other variables don’t impact energy consumption • KISS rule – keep EnPI as simple as possible
  22. 22. Simple EnPI • Did the plant start using energy less efficiently? • Or, are other variables impacting energy consumption?
  23. 23. Statistical Models – Linear Regression
  24. 24. Energy Baseline • Basis of comparison for evaluating energy performance. • Use information in initial energy review • Facility determines the time period • Apply data from initial time period and model to develop energy baseline • Measure future energy consumption against baseline to determine energy performance improvement
  25. 25. Objectives and Targets Policy Overall direction relative to energy performance Objective Long term, specific, supports policy Objective Long term, specific, supports policy Target Specific, measurable, achievable, timed, supports objective Target Specific, measurable, achievable, timed, supports objective Target Specific, measurable, achievable, timed, supports objective
  26. 26. PDCA - DO
  27. 27. Competence and Training What does the standard require? • Ensure competency of individuals who work with significant energy uses – Education – Skills – Training – Experience • Identify training needs and meet those needs
  28. 28. Awareness The standard requires awareness of individuals working for or on behalf of the organization. – Responsibility in meeting the EnMS requirements – Importance in meeting the EnMS requirements – How their activities impact energy consumption – Energy performance benefits Awareness affects ALL employees, not just those working with SEUs.
  29. 29. Communication The standard requires: Internal communication of energy performance and EnMS Establish process for comments and suggestions External communication decision – Do we communicate externally or not?
  30. 30. Procurement Organizations must make the connection between purchasing and the impact on its energy performance. Will a purchase significantly affect energy performance?
  31. 31. Purchasing Services • Energy service providers who will affect SEUs need to be evaluated – Maintenance service contractors for SEUs – Project engineers/managers/architects – Energy consultants • Informed that procurement is partly based on energy performance • Major component of assessment is competency
  32. 32. Design The standard requires: Consider: • Energy performance in improvements in design; • Operational control in design For: • New or modified facilities, equipment, systems, and processes • That have a significant impact on the organization’s energy performance • Where appropriate, incorporate energy performance into design activities (such as procurement, specifications, and design).
  33. 33. Operational Control What is required by the standard? • Determine and plan operations associated with SEUs • Set criteria for operation and maintenance of SEUs • Communicate to appropriate personnel • Operate and maintain according to criteria Leads to: SIGNIFICANT ENERGY SAVINGS AND BENEFITS WITHOUT CAPITAL EXPENDITURE!
  34. 34. Maintenance The primary purpose of maintenance is to maintain reliability and availability If equipment is properly maintained it is more likely to be energy efficient also Reactive maintenance wastes energy The cost of the energy will often by more than the cost of the maintenance All significant energy users need to be maintained correctly Applies to external service contracts as well as internal maintenance staff
  35. 35. Documentation What is a document? • Electronic or written instruments used to communicate expectations • What you do and how you do it. What is a record? • Document stating results achieved or providing evidence of activities performed • Doing what you said you would do
  36. 36. ISO 50001 Documents Some example documents: • Scope and boundary of EnMS • Energy policy • Energy planning • Methodology and criteria used to develop the energy review • Methodology for determining and updating the EnPIs
  37. 37. ISO 50001 Records Some example records: • Energy baseline • Training records • Decision regarding external communication of EnMS • Results of design activity • Measurement – calibration, energy review, etc • Audit results • Management review records
  38. 38. PDCA - CHECK
  39. 39. Monitoring, Measurement, and Analysis What does the standard require? • At planned intervals key characteristics are: – Monitored – Measured – Analyzed • Results are recorded • Measurement needs are defined, reviewed, and implemented • Measurement equipment provides accurate and repeatable data • Calibration records are kept
  40. 40. What are Key Characteristics? • Significant Energy Uses • SEU relevant variables • EnPIs • Other outputs from energy review: – Energy sources, uses, and consumption – Future energy use – Energy improvement opportunities • Progress toward meeting objectives and targets • Expected vs actual energy consumption evaluation
  41. 41. Analysis • What are the important analysis questions? – Has your energy performance improved? – Has the energy balance changed? – Are SEUs changing? – How effective is the system in meeting objectives and targets? • What type of data analysis will be used? – Absolute analysis – Control limit analysis – Tend analysis – Benchmarking • How often will data analysis be completed? • How will data and analysis results be recorded? • How will significant deviations be handled?
  42. 42. Internal Auditing What does the standard require? • Audits are conducted at planned intervals • Ensures – Conformance with ISO 50001 – Conformance with organization’s EnMS – Maintained and effective – Improves energy performance • Audit plan and schedule – Considers status and importance – Considers results of previous audits • Objective and impartial • Records • Results reported to top management
  43. 43. Continual Improvement Internal audits lead to continual improvement • Identify what the organization is doing well and where they need to improve • Nonconformities lead to actions which ensure continual improvement of energy performance and the EnMS • Internal audit results and the status of corrective/preventive actions are reviewed at management review • The organization determines actions to be taken and ensures the actions are effective • This process effectively starts the Plan-Do-Check-Act continual improvement cycle over
  44. 44. Nonconformances Definition: Non-Fulfillment of a requirement • The organization is not doing what it said it would do • What is being done is not working • Requirement are not being met • The intended energy performance improvement is not being obtained.
  45. 45. Corrective and Preventive Action Addresses actual and potential nonconformances What does the standard require? • Make corrections • Identify the root cause • Determine actions appropriate to the magnitude and consequences • Record • Review for effectiveness
  46. 46. PDCA - ACT
  47. 47. Management Review Involves fact based decision making by top management. What does the standard say? Top management shall review the EnMS At planned intervals to ensure Suitability Adequacy Effectiveness Maintain records
  48. 48. Typical Decisions • What is the status of the EnMS? • What strategic changes are needed? • What changes are needed, expected, or have resulted in terms of energy performance? • Are there any external requirements that will affect the EnMS? • Are there any changes internally that will affect the EnMS? • Is there a need to change current improvement objectives? • What resources are needed? • Is the EnMS suitable and effective and achieving continual improvement in energy performance?
  49. 49. Inputs • Energy policy • Objectives, targets, action plans • EnPIs and past, current, and projected energy performance data • SEUs and their performance and changes • Internal audits • Planned changes in design and procurement • Status of corrective and preventive actions • Recommendations and opportunities for improvement • Action items from previous mgmt review
  50. 50. Outputs Decisions or Actions related to: • Energy Performance • Energy Policy • EnPIs • Objectives and Targets • Resource Allocation • Other EnMS components
  51. 51. More information DOE eGuide for ISO 50001 Acknowledgement: This project is funded under agreement with the State of Tennessee. This material is based upon work supported by the Department of Energy under Award Number DE-EE0000160. CDFA 81.041.