SADC INDUSTRIAL EE CONFERENCE WINDHOEK, NAMIBIA:

Energy Management Systems

for industry

ISO 50001 EnMS: CRITICAL ELEMENTS , CHALLENGES AND BENEFITS OF BEING

CERTIFIED

A CASE STUDY OF CAFCA LTD-ZIMBABWE

Presenter: Eng. GODFREY MAVERA

CHIEF ENGINEER

CAFCA LTD - ZIMBABWE

16 MAY 2019

OVERVIEW One of six pillars of SIEEP is application of

EE/RE in industry

ISO 50 001 EnMS is one international

framework that ensures best practice in

EE/RE in industry

ISO 50 001 EnMS standard enables an

organization to follow a systematic

approach in achieving continual

improvement of energy performance,

including energy efficiency, energy use and

consumption.

OBJECTIVE

To give an insight into the critical

elements, challenges and benefits of being

certified to ISO 50001 EnMS using

CAFCA Zimbabwe as a case study.

BACKGROUND INFORMATION Central African Cables - CAFCA LIMITED

Cable manufacturer (Al conductors, Low voltage, Medium voltage & telephone cables) situated in Harare

Established in 1947

On Zim & J’burg Stock Exchanges

Annual revenue ~US$20m

~300 employees

Integrated management systems in place comprising of Environmental, Quality, Occupational Health & Safety and Energy.

CAFCA, the only ISO 50 001 certified company in Zim

ROAD TO CERTIFICATION

2011- ISO 50001 :2011 Published

2011 - CAFCA adopted the standard

2012- Implementation of quick wins to reduce energy consumption

2014 – March 1st stage certification audit

2014 – December 2nd stage certification audit

2016 – May awarded SABS certification

2019 – March first re-certification

CAFCA ENERGY MANAGEMENT

SYSTEM –ENERGY SOURCES Covers all CAFCA business processes

Energy sources :

Electricity – 90%

LPG- 4%

CHARCOAL- 1%

Diesel - 4%

Petrol ≈1%

Wood – negligible

MOTIVATION FOR CERTIFICATION

Massive electricity load shedding in 2010

No power reserves in Southern African region

Power factor charge on bill by the Zim’s electricity utility (penalty =9c[0.95/customer pf)-1]xPeak kWh consumption/mth)

Talk of increasing tariffs by the Utility

Push factors forced CAFCA to embark on Demand Side

Management projects to reduce costs

One of CAFCA’s Operating Principles is “We care for

the environment & support the community”

It was in the national interest to save electricity

DECISION TO EMBARK ON ISO

50001 CERTIFICATION PROCESS

Decision made during 2010 Strategic Planning Workshop

Electricity load shedding identified as a Threat to business viability

ISO 50001 certification identified as an Opportunity

Above resulted in decision to integrate ISO 50001 with the existing quality, environmental and OHS management systems

Certification would minimize threat above

CRITICAL ELEMENTS FOR

CERTIFICATIONCritical Success Factors are:

Top Management commitment

Technical assistance/support

Provision of resources – financial, staff time,

EnMS material.

Communication in order to buy-in all

employees and those working on behalf of

CAFCA

Competence, training and awareness for all staff

at Significant Energy Use (SEU) areas.

CHALLENGES RELATED TO THE

CERTIFICATION Interpreting the ISO 50 001 EnMS standard

-ISO 50006 – Energy baselines & Energy Performance

indicators guidelines

- ISO 50015 – M & V of energy performance of organizations

-Engage Consultant

Internal Auditing skills – Receive training from experts

Haphazardly installed electricity meters – Re-

arrange

Technical knowledge (mainly energy measurement &

verification techniques and protocols) – seek technical assistance

Change management issues to get

organizational buy-in -Blitz & form committees

Financial constraints to implement opportunities for

improvement -prioritize & implement in phases

TECHNICAL SUPPORT - A SHOW

STOPPER!! Lack of technical knowledge is the biggest

challenge from our experience

CAFCA was a beneficiary of a sponsored

technical assistance program conducted by

UNIDO/CTCN in partnership with Govt of

Zim, Business Council of Sustainable

Zimbabwe & PricewaterhouseCoopers

(India) in 2018.

YTD energy savings at 8% , thanks to

opportunities identified during the assistance

program

BENEFITS Demonstration of commitment to sustainable

development -1st Sustainability report done in

2015 in accordance to GRI G4 Guidelines (now

GRI Standards).

Effectively manage all our energy sources

Carbon credits ready - if we get a scalable

project

Improvement in GHG intensities FY18 (1. 33

tonsCO2/ton ) FY17 (1.48tonsCO2/ton)

Enhancing our reputation through an improved

corporate image and credibility with all

stakeholders

BENEFITS CONTINUED…… Improved operational efficiencies and

maintenance practices

Greater awareness of energy impacts in view of existing and new equipment or processes

System enabling the organisation to measure the results of energy efficiency improvements (through M&V reports)

Informed decision-making processes - from system design & procurement to use

Improved management of plant power factor FY18 Ave Power factor (0.95)

Whole facility annual energy savings ≈ 2% of total energy consumption in FY18

PROCESS IMPROVEMENTS Smelting & casting furnace process

efficiencies.Reducing major raw material scrap. Plan for long runs and Economic

Order Quantities in plant Switching off switches & all

machines when not in useDecentralization of compressors

to run during low plant loading times.

TECHNOLOGICAL IMPROVEMENTS Upgrading of electronics – installation of

electronic drives on production machines

Demand Side Management projects

Lighting retrofitting – from non-energy saving to LED

Solar energy for company borehole

Solar air conditioner for Sales office

Installation of translucent roof sheets for 2 factory bays

Energy Efficient water pumps for Smelter

Optimization of compressor operating pressures for all 3 compressors

Use of cogged belts instead of vee belts in plant (phasing out vee belts)

OTHER QUICK WINS Monitoring water and air leaks

Use of standing fans instead of air cons

No hot water on standby - use of

electric kettles

Identification of preventive actions to

avoid potential energy losses

Use of natural lighting and blinds during

the day

CONCLUSION

CAFCA’s experiences in EnMS has proved

beyond reasonable doubt that EnMS for

industry stimulate EE best practice

Technical support is key for 2 reasons:

- To interpret the EnMS standard

- To apply energy measurement &

verification techniques and protocols

The benefits of implementing EnMS go beyond

energy savings as it creates competitiveness in

industry.

The End.

Thank you!!