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Energy Conservation Procedure

  Januari 10, 2025    


Title: Energy Conservation

Purpose:

  • Identify and establish a response plan for all energy conservation points.

Scope:

  • Applicable to all areas where energy is used in any form.
  • Requires regular monitoring and control of both current and modified systems to ensure continuous improvement in energy conservation.
  • Cross-references ISO 50001, ISO 14001, and local regulations no.[..........]

Responsibilities:

  • Head of Department (HoD) and Site Operation Supervisor: Implement the Energy Conservation Procedure.

Activities and Responsibilities:

Illumination:

  • All Staff: Switch off lights, fans, and electrical devices when not required.
  • HoD/Site In Charge: Use energy-efficient lamps and luminaires.
  • Supervisor: Keep all lighting equipment and reflectors clean; optimize the use of natural lighting.

At the Workplace:

  • Supervisor: Use high-efficiency and appropriately sized equipment; carry out preventive maintenance and remove sedimentation and scaling regularly; stop all leakage and avoid unnecessary long distribution pipelines; optimize refrigeration needs and refrigerant temperature; check regularly all measuring equipment for calibration.
  • Energy officer: Monitor and control all plant parameters strictly; install monitoring instruments like power meters wherever necessary; use gravity wherever possible for liquid flow.

At the Kitchen:

  • All Staff: Avoid frequent reheating of food; store food in insulated containers.

Energy Technical Assessment by Corporate Technical Team:

  • Energy officer: Conduct technical assessments every 3 to 5 years as per organizational needs, with ECM support from all departments.
  • Corporate Technical Team: Carry out Energy Technical Assessments as part of Energy Conservation Measurement for ongoing enhancement. Activities include evaluating Energy Management maturity, identifying and validating technical aspects, and creating business cases for Energy Efficiency Projects.


  

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Power Meter Installation Strategy Procedure

  Januari 09, 2025    


Objective:

  • Install power meters to understand energy usage patterns and identify potential energy savings opportunities.
  • Prioritize metering of main utility feeds and major energy-consuming equipment/systems.

Scope:

  • This applies to all company facilities.

Responsibilities:

  • Energy officer on Site: Oversee the installation of power meters.
  • Qualified Electricians/Contractors: Perform the actual installation of power meters.

Procedure:

  1. Identify Priority Areas:

    • Identify main utility feeds and major energy-consuming equipment/systems for metering.

  2. Select Appropriate Meters:

    • Determine the appropriate type and size of power meter for each location, considering voltage level, current rating, and type of load.

  3. Obtain Necessary Approvals:

    • Secure approval for power meter installation from relevant authorities, if required.

  4. Engage Qualified Personnel:

    • Ensure qualified electricians or contractors install the power meters per applicable codes and standards.

  5. Calibrate and Commission:

    • Calibrate and commission the power meters post-installation to ensure proper and accurate functioning.

  6. Record and Document:

    • Record each power meter's location, type, and specifications in a central database or system. Ensure this information is easily accessible and regularly updated.

  7. Analyze Data:

    • Use data from power meters to understand energy usage patterns, identify potential energy savings opportunities, and make data-driven decisions to improve energy efficiency.

  8. Regular Maintenance:

    • Regular maintenance and power meter checks are conducted to ensure proper and accurate functioning.

  9. Retire or Replace:

    • Retire or replace power meters that are no longer functional or accurate.

  10. Review and Update:

    • Periodically review and update this procedure to ensure it remains relevant and effective.


  

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Thermographic Imaging Inspections Procedure

  Desember 21, 2024    

Thermographic Imaging Inspections Procedure


Objective

To provide a comprehensive guide for conducting thermographic imaging inspections as part of periodic preventive maintenance and inspections of the electrical distribution system. This non-intrusive and non-destructive inspection method helps identify heating issues in faulty plant and equipment, allowing for timely preventive maintenance without interrupting production processes.

Scope

Applicable to site.

Performance Criteria

  • Legal requirements
  • Corporate requirements

Responsible Parties

  • Safety officer Site
  • Qualified User

Related Documents

[List any related documents here]

References

[List any references here]

Procedure

Introduction

Thermographic Imaging Inspections are essential for maintaining the safety and reliability of electrical and mechanical systems. This procedure outlines the responsibilities and steps for conducting these inspections.

Delta-T Classification and Required Actions

The table below indicates temperature change ranges and the corresponding actions:

Delta-T ClassificationAction RequiredCategory
0°C to 10°CPossible fault developing. Continue monitoring for possible deterioration.Monitor
10°C to 20°CSchedule corrective measures.Next Shutdown
20°C to 40°CUrgent corrective measures required.Urgent
40°C and aboveImmediate corrective measures required.Immediate

Note: Immediate action requires an immediate shutdown, replacement of faulty equipment, and a follow-up thermographic inspection to confirm the issue is resolved.

Types of Electrical Equipment to be Surveyed

  • All plant and equipment
  • Cable runs
  • Bus ducts
  • Main switchboards
  • Distribution sub-boards
  • Motor control panels
  • Motors
  • Substation equipment

Qualified Personnel

A qualified person must conduct the survey. This individual should have:

  • Skills and knowledge related to the construction and operation of electrical equipment and installations.
  • Safety training on the hazards involved.

Requirements:

  • Training and certification per legal requirements or equivalent (e.g., NFPA 70E, Electrical Safety Requirements for Employee Workplaces).
  • Knowledge of equipment and system hazards (e.g., medium voltage, low voltage, environment).
  • Use of appropriate personal protective equipment (PPE), including clothing, face shielding, and gloves.

Minimum Information Required in Thermographic Report

  • Identified signs of damage or overheating.
  • Date and location of the survey.
  • Criteria used to identify potential issues.

Frequency of Inspections

Thermographic Imaging Inspections should be conducted at least once per year.

Reporting

The competent person will issue a report detailing any observed damage, deterioration, defects, dangerous conditions, and non-compliances with current safety standards.

Non-Conformity Case

The safety officer should follow up on non-conformity cases until they are resolved and documented in the report.

Report Keeping

The Thermographic Imaging Inspection report should be retained by the safety officer for future reference.

This revised procedure aims to be clearer and more structured, ensuring all necessary steps and responsibilities are well-defined. 

  

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How to reduce energy consumption in manufacturing?

  Desember 20, 2024    

Reducing energy consumption in manufacturing can lead to significant cost savings and environmental benefits. Here are some effective strategies:

1. Optimize Equipment Performance

  • Regular Maintenance: Ensure all machinery is well-maintained to operate efficiently. This includes lubrication, alignment, and timely repairs[1].
  • Upgrade Equipment: Replace old, inefficient equipment with newer, energy-efficient models[2].

2. Implement Energy-Efficient Lighting

  • LED Lighting: Switch to LED lights, which use up to 80% less energy than traditional incandescent bulbs[1].
  • Smart Lighting Controls: Use motion sensors and timers to reduce energy use in unoccupied areas[2].

3. Conduct Energy Audits

  • Identify Inefficiencies: Regular energy audits can help identify areas where energy is being wasted and suggest improvements[3].

4. Improve Insulation

  • Insulate Buildings: Proper insulation of walls, roofs, and windows can reduce heating and cooling costs[2].
  • Seal Leaks: Ensure there are no leaks in the building envelope to maintain optimal indoor temperatures[3].

5. Optimize HVAC Systems

  • Regular Maintenance: Keep HVAC systems well-maintained to ensure they run efficiently[2].
  • Programmable Thermostats: Use programmable thermostats to optimize heating and cooling schedules[1].

6. Reduce Water Consumption

  • Efficient Fixtures: Install water-efficient fixtures and equipment to reduce water heating costs[3].
  • Recycle Water: Implement water recycling systems to reuse water in processes where possible[3].

7. Educate and Train Employees

  • Energy Awareness Programs: Train employees on energy-saving practices and encourage them to contribute ideas for energy efficiency[3].

8. Implement an Energy Management System

  • Monitoring and Metering: Use energy management systems to monitor and control energy use in real-time[3].
  • Set Targets: Establish energy performance targets and track progress regularly[3].

9. Optimize Production Schedules

  • Off-Peak Operation: Schedule energy-intensive operations during off-peak hours to take advantage of lower energy rates[2].
  • Load Management: Balance the load on electrical systems to avoid peak demand charges[2].

By implementing these strategies, manufacturers can significantly reduce their energy consumption, leading to cost savings and a smaller environmental footprint.



References

  

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How to identify Significant Energy Uses?

  Desember 19, 2024    

Identifying Significant Energy Uses (SEUs) is a key part of the energy review process in ISO 50001. Here are the steps to help you identify SEUs:

Steps to Identify SEUs

  1. Data Collection: Gather detailed data on energy consumption across all facilities, equipment, and processes. This includes historical data and real-time monitoring.
  2. Energy Consumption Analysis: Analyze the collected data to determine which areas consume the most energy. Look for patterns and trends in energy use.
  3. Criteria Establishment: Develop criteria for what constitutes a significant energy use. This can include:
    • High Energy Consumption: Systems or processes that consume a large portion of the total energy.
    • Potential for Improvement: Areas where there is significant potential for energy performance improvement[1][2].
  4. Identification of SEUs: Based on the established criteria, identify the specific systems, equipment, or processes that qualify as SEUs.
  5. Performance Evaluation: Assess the energy performance of the identified SEUs, considering factors like efficiency, operational hours, and load variations.
  6. Review and Update: Regularly review and update the list of SEUs to reflect changes in operations, equipment, or energy use patterns[1][2].

Factors to Consider

  • Operational Hours: Equipment or processes that run for long periods.
  • Energy Intensity: Processes that are energy-intensive by nature.
  • Technology Level: Older or less efficient technologies may be significant energy users.
  • Failure Rates: Equipment with high failure rates may consume more energy due to inefficiencies[2].

By following these steps, you can effectively identify and manage SEUs, leading to better energy performance and cost savings.

Do you need more details on any specific step or factor?


References

  

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What is an energy review?

  Desember 18, 2024    

 An energy review is a crucial component of ISO 50001, focusing on analyzing an organization's energy use and consumption. Here's a breakdown of what it involves:

Key Elements of an Energy Review

  1. Data Collection: Gathering data on energy use and consumption from various sources within the organization.
  2. Analysis of Energy Use: Evaluating past and present energy use to identify patterns and trends.
  3. Identification of Significant Energy Uses (SEUs): Determining which facilities, equipment, systems, or processes consume the most energy.
  4. Performance Evaluation: Assessing the current energy performance of identified SEUs.
  5. Opportunities for Improvement: Identifying and prioritizing opportunities to enhance energy performance, such as using renewable energy sources or improving energy efficiency[1][2].

Purpose of an Energy Review

The energy review helps establish:

  • Energy Performance Indicators (EnPIs): Metrics to measure energy performance.
  • Energy Baselines: Reference points for comparing future energy performance.
  • Objectives and Targets: Goals for improving energy efficiency and reducing consumption.

Regular updates to the energy review are essential, especially when there are significant changes in facilities, equipment, or processes[1].

Would you like more details on any specific part of the energy review process?


References

  

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Examples of successful case studies in manufacturing

  Desember 17, 2024    

 Sure! Here are a few examples of successful case studies in manufacturing:

1. Ford Motor Company

Challenge: Ford needed faster prototyping to accelerate product development and reduce waste and costs. Solution: They integrated 3D printing technology into their manufacturing and prototyping processes. Results: This allowed Ford to reduce the turnaround time for prototyping from months to days, minimizing waste and lowering costs[1].

2. Patagonia

Challenge: High environmental impact of traditional textile production and growing demand for sustainable products. Solution: Patagonia adopted organic cotton and recycled materials, and implemented the Worn Wear program to encourage repair and reuse. Results: These initiatives significantly reduced their carbon footprint and water usage, enhancing their brand reputation among environmentally conscious consumers[1].

3. Siemens AG

Challenge: Increasing production efficiency and flexibility while reducing the carbon footprint. Solution: Siemens launched its Digital Factory initiatives, using digital twins, AI automation, and IoT integration. Results: These technologies improved production efficiency, reduced energy consumption, and enhanced overall operational flexibility[1].

4. Cargill Inc.

Challenge: Navigating global uncertainty and supply chain disruptions. Solution: Implemented continuous improvement methodologies like Lean, Six Sigma, and Kaizen. Results: These practices helped Cargill improve operational efficiency, reduce waste, and enhance supply chain resilience[2].

5. Johnson Controls

Challenge: Achieving operational excellence in manufacturing. Solution: Adopted the Johnson Controls Manufacturing System (JCMS) to improve safety, quality, productivity, and delivery. Results: Significant improvements in these areas led to greater customer satisfaction and employee engagement[3].

These case studies highlight how different companies have successfully implemented innovative strategies to improve their manufacturing processes, reduce environmental impact, and enhance efficiency.

Would you like more details on any specific case study or industry?


References

  

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