ISO and Implementation in NALCO

Transcription

1 ISO and Implementation in NALCO S.K.Jena,AGM(Mech) SMELTER PLANT, NALCO, ANGUL 4/30/2015 1

2 Why Energy Management? 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 4/30/2015 2

3 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

4 ISO 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 4/30/2015 4

5 Aim of ISO 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

6 ISO 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 4/30/2015 6

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8 ISO50001 in NALCO In NALCO, the Captive Power plant was the first Unit to get certified to ISO50001 in January 2013 Alumina Refinery was certified in November Smelter plant, was certified in May Following audits were conducted by M/v DNV, Netherlands: 1.Documentation Audit 2.Stage-I Audit 3. Stage-II Audit ( Cetrification Audit) 4/30/2015 8

9 Before Starting 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. 4/30/2015 9

10 EnMS Scope in Smelter 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 4/30/

11 Plan-Do-Check-Act(PDCA) Cycle

12 Basic requirements 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 4/30/

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14 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 4/30/

15 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. 4/30/

16 Energy Planning 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 4/30/

17 Energy Baseline Quantitative reference providing a basis for comparison of energy performance Regression Analysis Single Variable Multi Variable MONTH ELECTRICAL ENERGY (1000 PRODUCTION NET ANODES KWH) (MT) Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar

18 Energy (1000 KWH) Energy Consumption Vs Production (GAP II) y = x R² = Net Anodes (MT) Estimated Energy Consumption = * (Net Anodes in MT)

19 Some EnPIs in Smelter Sp. AC Electrical Energy consumption in Smelter, KWH/ MT Sp. HFO consumption in Smelter, L /MT Plant level Plant level Sp. DC Electrical Energy consumption in Potline-1 Sp. DC Electrical Energy consumption in Potline-2 Sp. DC Electrical Energy consumption in Potline-3 Sp. DC Electrical Energy consumption in Potline-4 Sp. AC Electrical Energy in Compressor Houses Sp. HFO consumption for Wirerod Mill operation Sp. HFO consumption for Ingot Casting operation Potline Operation Potline Operation Potline Operation Potline Operation Utilities Casthouse-A Operation Casthouse-B Operation + others ( total 20 departmental EnPIs taken at present) 4/30/

20 PL Mech Some Energy Management Programmes in Smelter Depart ment CH-A Operation RP Operation Carbon plant Electrical Utilities Potline Electrical Electrical Substation Electrical Repair Shop RP Electrical EnMP Installation of Air-receiver in PTMs screw compressor Replacement of 1 furnace SMCD with improved door sealing Semi-auto matic firing control system for M&H furnace of Caster # 1 Installation of VFD for general de-dusting system in RS-1 Target 4/30/ % reduction in energ. Consmp. of compressor motor: by 31/03/ % reduction on expected consmpn ; by December lt/t from 206 lt/t by January 2014 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 Installation of 2nos. Energy Efficient Compressors in place of 2% reduction over base-line by August old compressors 2014 Replacement of Energy efficient TL-5 lights in place of 40watt 30% reduction w.r.t baseline by July in FTP 1 to 4 control rooms 2014 Modification of illumination system of 220kv switchyard Reduction of energy cons. ERS&CRS shop lighting by using timer control Reduction of energy cons. ERS&CRS shop lighting by using induction & LED lamps To provide timers & aux. contactors for roof lighting in RP shopfloor bays 10% reduction over base-line by May % reduction w.r.t baseline by June % reduction w.r.t baseline by December % reduction w.r.t baseline by April 2014

21 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) 4/30/

22 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 4/30/

23 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 % In all compressed air systems, leakages are checked on daily basis and sealed.

24 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. 4/30/

25 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 4/30/

26 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 repeatablemeasuring 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 4/30/

27 ISO Internal audits are to be carried out to ensure that system is implemented and effective the 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 periodically and as per agenda conducted Achievements and short-falls/deviations are to be discussed and necessary actions to be agreed 4/30/

28 Some Energy Saving projects undertaken in NALCO, Smelter by Small Groups

29 Quality Circle project : Reduce energy consumption on unwanted glowing of shop-floor lights in day-time in Cast house-a ( Active Quality circle) Solutions Implemented after Analysis Identified shop-floor areas where lighting is not required in daytime Separated power supply to light fittings of areas where sun-light is adequate Installed timers in those areas along with auto/manual selection Project Benefit Operating hours reduced from 24hrs to 14 hrs per day for 46 light fittings resulting in saving of nearly 8 Kwh per day

30 Six Sigma project: Reduction of HFO consumption in Holding and Melting Furnaces of Billet Casting Facility Project Benefit Preliminary measures (Quick Wins) implemented Burner nozzle changed HFO atomisation nozzle cleaned Refractory lining repaired SMCD changed Solutions Implemented after Analysis Auto-control system for maintaining furnace temperature as per set value, which ensures that combustion blowers are used only during raising temperature and excess-air flow is minimized Average Sp. HFO consumption reduced by ~15 ltrs/mt, from earlier 90 lts/mt to avg. 75 ltrs/mt

31 Six Sigma project: Reducing Cycle Time in Billet Homogenising Furnace II Project Benefit Solutions Implemented after Analysis To reduce heat-loss through furnace roof Providing ceramic blanket around heater battery wall Providing ceramic blanket around terminal rods of heating elements, both top and bottom. Door sealing Limit switch re-positioning Door closing Cylinder replacement Interlock preventing cylinder operation if door is not fully down Providing ceramic blanket in the recesses Providing ceramic tubes for terminal rods Billet homogenisation cycle time in Homogenising Furnace-II reduced from 13.2 hrs average to avg hrs i.e by apprx. 2.7 hours Savings by preventing Energy loss of 1600 kwh for every 1 hour reduction in cycle time which translates to 1600 X 2.7 X 300 (cycles per year) i.e 1296 MW

32 Burner optimisation in Rolling PLANT ( PAT PROJECT) To reduce the specific oil consumption of the caster area was taken up departmentally for implementation in Melting and Holding furnace of caster line # 3. The scheme envisaged was to operate the two big burners of Melting furnace semi automatically through On/Off control mode and third small burner with PID control. Both burners of Holding Furnace are to be operated in PID control mode. Savings:- The Cum.specific oil consumption for FY = Lt/Mt The Cum.specific oil consumption for FY t = Lt/Mt Total Oil saved = ( ) X total production for the year = 46.2 L/ Mt X Mt = Lt = KL = Rs Crores ( average furnace oil Rs. 40 per Lt)

33 PAT PROJECT Area Replacement of TFL Tubes with T5 Lamps All Buildings of Smelter Plant Brief Description The existing TFL Tubes are energy intensive. T5 lamps will reduce in energy consumption by 30% with same luminosity. Area Of Focus Estimated Savings Project Period Actual savings achieved Own Power Rs 1.7 Lakhs per Year One Year Considering saving of 30% of energy by installing 1000 No. of tubes of 40W capacity the savings will be Rs.1.75 lakhs (approx.). Present Status COMPLETED IN MAJOR BUILDINGS. CONTINUING IN OTHER BUILDINGS.

34 OTHER ENERGY SAVING PROJECTS IMPLEMENTED AT SMELTER UNDER PAT SCHEME. 1. INSTALLATION OF MAGNETIC SEPARATOR FOR EFFECTIVE ATOMISATION & PROPER COMBUSTION OF FUEL OIL INJECTED TO FURNACE. 2. INSTALLATION OF PID ( PROPORTIONATE INTEGRATED DERIVATIVE) CONTROLLER IN MELTING & HOLDING FURNACES. 3. INSTALLATION OF T5 LAMPS IN PLACE OF TF LAMPS. 4. INSTALLATION OF VVVF DRIVES IN PLACE OF CONVENTIONAL MOTORS. 5. INSTALLATION OF ALPSYS ( ALUMINIUM PECHINEY REGULATING SYSTEM) POT REGULATION SYSTEM IN OLD POTS.

35 OTHER ENERGY SAVING PROJECTS IMPLEMENTED AT CPP UNDER PAT SCHEME. 1. INSTALLATION OF ON LINE CONDENSER TUBE CLEANING SYSTEM FOR VACUUM IMPROVEMENT OF CONDENSER. 2. CONVERSION OF CONVENTIONAL MILLING SYSTEM TO HIGH PERFORMANCE MILLING SYSTEM WITH REDUCTION IN UBMURNT & LESS POWER CONSUMPTION. 3. INSTALLATION OF VAPOUR ABSORPTION MACHINE IN PLACE OF VAOUR COMPRESSION CHILLERS FOR CENTRAL AIR CONDITIONING OF CONTROL ROOMS. 4. INSTALLATION OF VVVF DRIVES IN PLACE OF CONVENTIONAL MOTORS OF COOLING TOWER FANS. 5. ANTICORROSSIVE COATING ON FAN BLADES & OPERATING AT OPTIMUM DIFFERENTIAL PRESSURE ACROSS FEED REGULATING SYSTEM OF PUMPS

36 Use of Slotted anode Slotted anode before dispatch to potline Used anode from potline

37 PROJECT: INCREASE IN STUB HOLE DEPTH OF GREEN ANODE FROM 90 mm TO 110 mm REDUCE PIN TO CARBON CONTACT RESISTANCE AND HENCE REDUCE VOLTAGE DROP REDUCTION OF VOLTAGE DROP OF 15 TO 25 mv/pot ACHIEVED

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