Chronographic Implementation of Energy Management System in Small-Scale Plastic Industry ^†

Abstract

The purpose behind this research paper is to recognize the principal achievement factors for the powerful execution, activity, and accreditation of an energy executive’s framework (EnMS) as per ISO 50001, which addresses the quickest-developing norm for board frameworks (International Organization for Standardization, 2018). Associations are spending a lot of cash on their energy utilization. The shortage of energy assets, alongside their value instability, has become a significant worry for all businesses. Thus, the requirement for overseeing and rationing energy has, as of late, acquired bigger consideration. A decent administration consistently seeks reserve-fund openings with the least speculation; thus, when setting up energy, the board’s situation can show the right way to deal with distinguishing openings and support upgrades. In this paper, the most optimized version of the execution plan is discussed that can be embraced by an association named Sparkle Plastic Product to facilitate the execution and decrease the endeavors.

1. Introduction

Energy is one of the main prerequisites for all companies in a country; abhorrent energy costs are basic necessities for a developing country. The utilization of energy should be in a way that it brings a deduction in cost and puts a less antagonistic impact on the natural environment. Energy management is practically equivalent to other intelligent models for board frameworks such as the quality administration framework and the ecological administration framework, and so forth. An energy board framework includes all exercises and work that are planned and started to reduce the expense of energy creation [1,2].

The EnMS is one of the significant devices for information procurement identified with energy utilization and effectiveness following various cycles that, at last, build the productivity of interaction and bring down the expense. The execution of EnMS in an association fortifies its presentation, specialized and legitimate necessity area, strategy making, and culture. Reducing the cost by decreasing unnecessary energy usage or further developing energy productivity benefits the company monetarily as well as benefitting the climate and cutting down the exorbitant fossil-fuel byproducts [3,4].

The entire interaction of the EnMS comprises the specific cycle that is plan, do, check and act (PDCA). An association that needs to carry out the EnMS framework should follow this total procedure totally. A few associations are extremely hesitant regarding the base time frame in which the EnMS framework can be executed by fulfilling the total necessity of the cycle. In our research, we will talk about the total cycle independently and how an association could execute the EnMS in a half year [5,6].

The EnMS has many benefits such as optimizing energy usage in the company, reducing its energy utilization costs, and also decreasing the negative environmental effects on human beings. An EnMS begins with an energy policy which we devised for the Sparkle Plastic Product company (Karachi, Pakistan) In which we defined energy goals and the better ways to achieve these energy-decreasing goals, and we also formed a system for monitoring energy performance in Sparkle Plastic Product and implemented a better and faster methodology for a fluent improvement in energy performance in a faster way [7,8].

EnMS provides a faster path for improving energy performance with higher output efficiency. There have been many projects introduced to reduce energy utilization in any sector, but usually, they were facing a lack of the organization’s vision or strategic goals or objectives and involved only specific departments (e.g., engineering, contracting, and facilities personnel). This is called a technical approach. In EnMS based on ISO 50001, there are two-way approaches, including administrative or management, in which the top management and all the employees of the department including contractors are assigned their tasks to reduce energy [9,10].

Implementing EnMS in any department has vast benefits. Firstly, it helps to reduce energy consumption by unusable and usable loads. Then, we can assign an approach through which we can control that operational consumption energy. It also helps us to understand the current energy usage of loads (usable or unusable), and also the costing of these consumptions so that we can look for different, appropriate, faster ways to reduce energy costs and their consumptions of loads. For this, we need management support, their commitment, and their responsibilities to fulfill our requirements [11]. The development of industries is very useful to decrease the level of poverty, environmental effects and to enhance their quality of life. Therefore, UNIDO recognized that industries ought to enhance aggressiveness while responding effectively to temperature change by reducing the negative environmental effects of industries [12].

Through our research paper, the management of energy approaches is the main and fastest factor for the development in industry and countries. The sustainability of any industry is defined as having a lack of fulfilling customer satisfaction, stakeholders through different business methodological innovations, and also works that have a positive effect on people and the environment all around the country [13].

Our research paper aims to define the ongoing situation regarding the different management of energy practices through appropriate applications in production for the country. The ISO 50001 standard for EnMS considers the achievements in energy management by industries as well as the country. The major impact on the business formations is the good-quality material, the constant flow of energy and also their mutual interactions in a manner that provides useful information to design a methodological structure with as high-quality resource savings as possible and fewer negative environmental effects [14,15].

As the energy utilization increases, the challenge for companies also increases to reduce the negative environmental effects. In industrial systems, the system is responsible for the largest energy consumers in the production systems. Usually, most of the industries have advanced systems for the development of this energy structure, in which the reduction in cost is considered an important part of the management system of energy because energy savings reduce the cost of production and also increase profits. In other words, we can say that energy efficiency is considered as the main element of development in industry and countries.

There are many benefits of EnMS, including decreasing energy usage, decreasing costs, and also reducing the negative environmental effects of human beings. Therefore, different organizations have developed faster ways to manage the energy losses that occur. An energy policy is one of the main initial steps to begin the EnMS which is used to define the energy goals and different appropriate ways to complete these energy goals. It also forms a system for monitoring energy performance in an industry and country and also implements effectively faster ways for a fluent correction of energy performance.

2. Methodology

The EnMS methodology is based on the PDCA model. This research paper explains how the management of energy is planted in Sparkle Plastic Product. Figure 1 shows the methodological structure of the complete system.

Figure 1. Methodological Structure.

2.1. Plan

The planning stage is one of the most significant and basic stages; it comprises seven subparts:

• Analyze the energy resources and their consumption and cost trends by observing their (past and future) electric bills. Then, implement the energy performance indicators (EnPIs).
• Identify the critical operational and maintenance parameters and identify opportunities for their improvement. Then, set objectives, targets and action plans for performance improvement.

2.2. Do

The second stage is the do stage, as planning is carried out in the first stage. Presently, implementation begins as per the rules set down in the first stage. A complete energy audit is required before the beginning of the execution stage. The execution comprises of the accompanying subparts. Training plans are implemented, focused on SEUs and developing necessary documentation based on procedures and records. Furthermore, action plans are implemented and all progress is monitored via EnPIs.

2.3. Check

In the checking stage, the carried-out work is checked through energy reviews. If there should arise an occurrence of any resistance, restorative activities are proposed by the review group. The check stage comprises the accompanying subsegment, checking whether we are doing what we said we would do. Then, we check the standards and the working of all EnPIs. Furthermore, a formal management review is carried out.

2.4. Act

The act stage is likewise named as the executive’s audits for good-quality improvements. The norms of the ISO unmistakably accentuate the demonstration stage, because executing the remedial activity plan according to the inward-review-group act stage assumes a significant part. The improvement in the framework thoroughly relies upon the rules set somewhere around the review group and the execution of the restorative activity plan. The act stage comprises the accompanying subarea.

• Correcting what is wrong and preventing it from happening in the future.
• Developing new action plans for the future and identifying new opportunities.

3. Result

Table 1, Table 2 and Table 3 shows the complete details of energy calculation

Table 1. EnPI in a Department of Sparkle Plastic Product.

ENPI	Quantity
Motor 18 KW	2
Motor 15 KW	1
Ceiling Fan	3
Bracket Fan	4
Exhaust Fan	2
Led	2
Bulb	14
Pump Motor	1

Table 2. Calculation of SEU (Significant Energy User).

SEU NAME	18 KW Motor
Power	18,000
Voltage	380
Current at 0.85 PF	55.72
Current at 0.9 PF	52.63
Time duration	22 h
Energy Consumed in 1 day	396 KWh
Energy Consumed in 1 month	11,880 KWh
Energy Consumed in 1 year	144,540 KWh

Table 3. Calculation after implementing Corrective Actions.

ENPI	Quantity	Power	Load	Time	Energy
Motor 18 KW	2	18,000	36,000	14	504
Motor 15 KW	1	15,000	15,000	14	210
Ceiling Fan	3	70	210	10	2.1
Bracket Fan	4	45	180	8	1.44
Exhaust Fan	2	50	100	6	0.6
Led	2	5	10	5	0.05
Bulb	14	10	140	10	1.4
Pump Motor	1	500	500	3	1.5
Machines	1	500	500	2	1

Energy Calculation of Table 1:

Total energy consumed per day = 938.13 kWh.

Total energy consumed per month = 28,143.9 kWh.

Total energy consumed per year = 337,726.8 kWh.

Average unit cost = 13.

Total cost per day = Rs 12,195.69.

Total cost in a month = Rs 365,870.7.

Total cost in a year = Rs 4,390,448.4.

Corrective action to address nonconformities is taken and the effectiveness of such action reviewed. Then, the evaluation of proactive action is undertaken to eliminate the causes of nonconformity so that it does not reoccur elsewhere. Furthermore, SEU (significant energy user) is identified and also the relevant variables: current energy performance and people that impact on SEU.

Motors being changed to class B with better efficiency and energy performance is also good. Led bulbs are replaced with low-power (more efficient intensity) bulbs. Fans are replaced with an Aero-slim ceiling which uses a BLDC technology motor that typically consumes very little energy; it can reduce power up to 60%.

Furthermore, estimated future energy usage and consumption are calculated and, finally, the effectiveness of the EnMS shall be continually improved. The organization shall demonstrate continual energy performance improvement.

Energy Calculation of Table 3:

Total energy consumed per day = 470.09 kWh.

Total energy consumed per month = 14,102.7 kWh.

Total energy consumed per year = 169,232.4 kWh.

Average unit cost = 13.

Total cost per day = Rs 6111.17.

Total cost in a month = Rs 183,335.1.

Total cost in a year = Rs 2,200,021.2.

4. Conclusions

This research paper gives an easy (and also the fastest) methodological approach to implement EnMS. The factors that cause problems in implementing EnMS are also discussed in which a detailed outline with all four well-defined phases involved in the EnMS is discussed. Each methodological phase is defined in a way that makes it easier to understand for the users of industries and countries. The important key pillars of this EnMS standard including the role of the energy representative—leadership—are also discussed briefly. A detailed analysis of the EnMS standard is also discussed. The chronographic implementation Table 4 is discussed below.

Table 4. Chronographic implementation.

	Checklist	Months												Tasks
		1	2	3	4	5	6	7	8	9	10	11	12
(Phase 1) Management Review
1	Management plan	*												The board plan shows the total responsibility of the top administration for execution.
2	Energy team selection	*												Energy administration will choose an energy supervisory group for all associate divisions.
3	Energy review	*												The energy audit ought to be finished by the energy supervisory crew.
4	Draft energy policy	*												Association’s energy strategy ought to be drafted according to the rules of energy execution guidelines.
5	Set targets and objectives		*											Destination and targets ought to be set to accomplish full execution.
(Phase 2) Plan
6	Record-keeping system		*	*	*	*								The technique should aim to shape an arrangement of record-keeping instruments utilizing programming.
7	Identifying SEU		*	*										After the energy audit, the SEUs ought to be distinguished by the energy supervisory group.
8	Implementing EnPIs			*										Advancement of EnPI following the energy survey.
(Phase 3) Do
9	Documentation			*	*	*	*	*	*					The documentation is sufficiently able to have every one of the records from a solitary stage.
10	Gauge conceivable energy decreases on SEUs (critical energy clients)			*		*	*	*	*	*				Specialized heads ought to foster activity intending to decrease energy misfortunes from recognized SEUs.
11	Gauge expected decrement in energy utilization (complete association)													Energy groups ought to foster a total intent to limit energy utilization.
12	Carry out the plans									*				Energy groups should carry out every one of the plans according to energy strategy rules.
(Phase 4) Check
13	Record-keeping system									*				Documenting entire requirements.
14	EnMS audit										*			Internal audit should include deficiencies and nonconformities list.
15	Declaring corrective action									*				Rectifying nonconformities.
16	Declaring action plan									*				Internal audit also suggests avoiding techniques for the upcoming period.
17	Record controlling									*	*			Energy policy should contain a three-year record.
(Phase 5) Act
18	Top management review										*	*		For corrective actions, a management review of 6 months should be tracked.
19	Management review input											*	*	Internal audit and EnPI must be reviewed, if a revision of suggested objectives/targets is needed.
20	Output of top management											*	*	The targets set by reviewers should be adopted by the energy team to create required fulfillment of the plan.