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Cooperation between the UNIDO IEE Project and Egyptian Petroleum Sector
Project Number: 100349
Project Name: Reducing Greenhouse Gas Emissions through Improved Energy Efficiency in the Industrial
Sector
Submitted to:
Project Manager
United National Industrial Development Organization
May 2018
1
Table of Contents
Page
Nomenclature and Terminology …………………………………………………...............
3
Organizations & Companies ………………………………………………….....................
4
1.
Introduction………………………………………………………………………………….
5
2.
EnMS Training and Technical Support to SIDPEC………………………………………
9
2.1.
Energy Savings within SIDPEC…………………………………………………………….
11
2.2.
UNIDO Support & SIDPEC Recognition……………………..…………………………...
12
3.
Peer to Peer Network and Lessons Learnt……………………..…………………………..
15
3.1.
Training Provision in P2P………………………………………….……………………….
16
3.2.
Peer to Peer Network Establishment……………………………………………………...
17
3.3.
Implementation of EnMS in the Six Involved Companies in P2P……………………….
18
3.4.
Energy Savings and GHG Reduction Outcome of P2P…………………………………..
20
3.5.
Lessons learnt from P2P Project…………………………………………………………..
23
3.6.
Highlights and Summary of Achievements in P2P Network Project……………………
24
4.
EnMS Technical Support to other Petroleum Sector Companies……………………….
28
4.1.
Training and Technical Support to ANRPC……………………………………………...
28
4.2.
Attempt to Support in APC………………………………………………………………..
28
5.
MSO/CASO Support to The Petroleum Companies……………………………………..
30
5.1.
Energy Savings in MSO/CASO in SIDPEC and MOPCO………………………………
32
6.
UNIDO IEE project and Oil & Gas Sector Modernization……………………………...
33
6.1.
Oil and Gas Sector Modernization Project……………………………………………….
33
6.2.
Cooperation between IEE and Modernization Group 4B……………………………….
34
6.3.
MSO Training and Technical Support Provision………………………………………..
34
6.4.
Follow-up Activities of MSO in Petroleum Sector……………………………………….
36
6.5.
Outcomes from the MSO Training in Petroleum Sector………………………………...
38
6.5.1. MSO National Experts Qualified by UNIDO……………………………………..
38
6.5.2. Energy Savings and GHG Reduction Resulting from MSO…………………..…..
38
6.6.
Lessons Learnt from MSO Project in Petroleum Sector………………………………...
40
7.
Common Opportunities to Develop Local Best Practice for the Sector………………...
42
7.1.
MSO Opportunities (Outcome from IEE Support to Petroleum Sector)……………….
42
7.1.1. Cooling Water System (CWS) …………………………………………………….
43
7.1.2. Compressed Air System……………………………………………………………
46
7.1.3. Air Coolers in Different Processes………………………………………………...
48
7.1.4. Sucker Rod Pumps…………………………………………………………………
50
7.2.
General Energy Efficiency Improvement Opportunities………………………………..
51
8.
Total energy savings resulted from IEE support for the sector…………………………
58
9.
Closing Remarks & Recommendations…………………………………………………...
62
9.1.
Recommendations……………………………………………………………………………
63
References……………………………………………………………………………………
64
2
List of Figures
Page
Figure 1.1
Low-Carbon Technologies contributions towards BLUE Map scenario [1] ………
5
Figure 1.2
World CO2 emission & Egypt CO2 emission from 1970 to 2014 – (data source:
EU EDGAR database) …………………………………………………………………
6
Figure 2.1
Timeline from Starting IEE/SIDPEC Cooperation till Starting P2P Network ……
10
Figure 2.2
SIDPEC Savings of Electricity as percentages of Baseline …………………………
12
Figure 2.3
SIDPEC Savings of Fuel Gas as percentages of Baseline …………………………..
12
Figure 3.1
Number of attendees in P2P Training (Excluding Special Sessions within some
Companies) …………………………………………………………………………….
17
Figure 3.2
Electricity Savings within the P2P Involved Companies ……………………………
21
Figure 3.3
Fuel Gas Savings within the P2P Involved Companies ……………………………..
22
Figure 3.4
Estimated GHG Reduction as a result from P2P Project …………………………..
23
Figure 3.5
Distribution of 24 National Experts by Companies before and after P2P…………
25
Figure 5.1
Potential Energy Savings due to CASO/MSO in SIDPEC and MOPCO …………
32
Figure 6.1
Seven Programs of Oil & Gas Sector Modernization ……………………………….
33
Figure 6.2
Number of trainees attended different MSO Training Sessions…………………….
35
Figure 6.3
Distribution of 11 MSO National Experts by Companies …………………………..
38
Figure 6.4
Amount of Electricity Savings Identified from MSO in Oil & Gas Companies……
39
Figure 6.5
Amount of GHG Reduction Identified from MSO in Oil & Gas Companies ……...
40
Figure 8.1
Total Energy Savings Resulted from IEE Support to Petroleum Sector …………..
60
Figure 8.2
Share of Petroleum Sector in Total GHG Reduction by IEE Project ……………...
61
List of Tables
Page
Table 2.1
Energy Savings in SIDPEC as per 2017 Records …………...……………...………..
11
Table 3.1
Training according to UNIDO curriculum including ……………...……………......
16
Table 3.2
Summary for Webinars during P2P project ……………...……………...…………..
18
Table 3.3
Achieved and Potential Savings in Electricity and Fuel Gas ……………..................
20
Table 3.4
Achieved and Potential GHG Reduction in P2P Companies …………….................
22
Table 3.5
Status of EnMS at the end of P2P Network Project ……………...……………...….
24
Table 6.1
Involved Petroleum Companies in MSO ……………...……………...……………...
35
Table 6.2
Electrical Energy Savings and GHG Reduction From MSO Identified
Opportunities in Oil & Gas Sector Companies ……………...……………................
39
Table 8.1
Savings Resulted from Sector Companies Received Support in EnMS…………….
58
Table 8.2
Savings Resulted from Sector Companies in First Groups of MSO & CASO …….
59
Table 8.3
Savings Resulted from MSO dedicated to Petroleum Sector Companies ………….
59
Table 8.4
Total Savings Resulted from IEE Support to Petroleum Sector ……………............
60
3
Nomenclature and Terminology
ASD
Adjustable speed drive
BHAG
Big Hairy Audacious Goals
CASO
Compressed Air system optimization
CCS
Carbon Capture and Storage
CWS
Cooling Water System
EGP
Egyptian Pounds
EnMS
Energy Management System
EnPI
Energy Performance Indicators
GHG
Greenhouse Gases
HID
High-intensity discharge
IE1
Standard Efficiency (IEC Efficiency Classes for Motors)
IE2
High Efficiency (IEC Efficiency Classes for Motors)
IE3
Premium Efficiency (IEC Efficiency Classes for Motors)
IE4
Super Premium Efficiency (IEC Efficiency Classes for Motors)
IEE
Industrial Energy Efficiency
LED
light emitting diode
MSO
Motor system optimization
NG
Natural Gas
P2P
Peer to Peer Network
PMU
Project Management Unit
SEC
specific energy consumption
SEU
Significant Energy Use
SPC
Statistical Process Control
SSO
Steam System Optimization
VSD
Variable Speed Drive
4
Organizations & Companies
AMOC
Alexandria Mineral Oils Company
ANRPC
Alexandria National Refining And Petrochemicals Company
APC
Alexandria Petroleum Company
APRC
Amreya Petroleum Refinery Company
ASORC
Assuit Oil Refinery Company
CEM
Clean Energy Ministerial
CORC
Cairo Oil Refinery Company
ECHEM
The Egyptian Petrochemicals Holding Company
EDGAR
Emissions Database For Global Atmospheric Research
EGPC
Egyptian General Petroleum Corporation
ELAB
Egyptian Linear Alkyl Benzene Company
EPC
Egyptian Petrochemicals Company
EPPC
Egyptian Propylene And Polypropylene Company
EPROM
Egyptian Projects Operation & Maintenance
ESTYRENICS
Egyptian Styrene And Polystyrene Company
GASCOOL
The Egyptian Company For Refrigeration By Natural Gas
GPC
General Petroleum Company
GUPCO
Gulf Of Suez Petroleum Company
IEA
International Energy Agency
MIDOR
Middle East Oil Refinery
MOPCO
Misr Oil Processing& Fertilizers Company
PETROGULF MISR
Petrogulf Misr Company
PPC
Petroleum Pipelines Company
RASHPETCO
Rashid Petroleum Company
SIDPEC
Sidi Kerir Petrochemicals Company
SOPC
Suez Oil Processing Company
UNIDO
United Nations Industrial Development Organization
WASCO
Wastani Petroleum Company
5
1. Introduction
Energy demand is continuously increasing in the 21st century and despite the existing
global efforts to replace the fossil fuel energy sources with renewable energy sources, there are a
lot of barriers that make the fossil fuel continue as the major energy source at least in the next
twenty years. Energy sources based on fossil fuel is the main cause of greenhouse gases emissions
that have the ultimate effect on climate change. International Energy Agency (IEA) presented an
analysis to show how to mitigate the threat of climate change [1]. The analysis is based on having
two scenarios for the trend of energy-related CO2 emissions, the baseline scenario where it is
expected to have about double quantity of CO2 emission (57 Gt annually) in 2050 relative to that
of 2010. The other scenario known as BLUE Map scenario proposes that the CO2 emissions in
2050 shall be (14 Gt) about half of the quantity recorded in 2010. IEA in its publication Energy
Technology Perspective ETP 2010 demonstrated that the low-carbon technologies can effectively
contribute to achieve the BLUE Map scenario and summarize the percentage of each technology
contribution to move from the Baseline scenario as shown in Figure 1.1 where it is noticed that
sophisticated technology which need relatively high investment like Carbon Capture and Storage
(CCS) can contribute with 19% while the low investment approach of end-use fuel and electricity
efficiency can contribute by nearly the double about 38% from which the importance of energy
efficiency is highlighted and energy efficiency improvement show the largest single contribution
among all other technologies.
Figure 1.1 Low-Carbon Technologies contributions towards BLUE Map scenario [1]
6
In this context, energy efficiency became the focus of many organizations and it is
addressed in different end-use sectors including industry, transport, and buildings. Energy
efficiency becomes one of the crucial issues in any manufacturing system especially in heavy
industry where huge amount of energy is consumed which in turn results in huge amount of CO2
emissions. The nowadays concern about reducing CO2 emissions increases because of the global
goal of climate change reduction and limiting the global warming. The world total CO2 emissions
reached 35.67 Gt in 2014, according to the data taken from Emissions Database for Global
Atmospheric Research (EDGAR) [2], recording an increase of about 40% with reference to the
value reached in 2000. Figure 1.2 shows the continuous increase of world CO2 emissions from
1970 to 2014 versus the trend of CO2 emissions in Egypt in the same period. From the curves, it
is clear that despite the relatively low amount of CO2 emissions from Egypt relative to the global
amount, however a higher rate of increase is monitored in Egypt that makes the focus on energy
efficiency improvement a mandatory issue.
Figure 1.2 World CO2 emission & Egypt CO2 emission from 1970 to 2014 –
(data source: EU EDGAR database)
0
10
20
30
40
1970
1972
1974
1976
1978
1980
1982
1984
1986
1988
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
2010
2012
2014
Gt CO2
Year
World CO2 Emmissions
0
0.1
0.2
0.3
1970
1972
1974
1976
1978
1980
1982
1984
1986
1988
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
2010
2012
2014
Gt CO2
Year
CO2 Emmission in Egypt
7
In addition to the efforts towards the improvement of climate change scenarios, it is clearly
noticed that energy sources availability affect the performance of industrial organizations where a
common barrier is still coming from production people who watch the importance of achieving
the production plan regardless the sustainability considerations. Energy management system
(EnMS) standards such as ISO 50001 is one of the solutions provided for the purpose of enhancing
the security of energy supply and reducing CO2 emissions without depending on expensive and
difficult implementation technologies such as carbon capture and storage, renewable energy, or
nuclear energy [1]. However, the implementation of EnMS faces many barriers and needs more
efforts to convince top management in any organization to afford the required commitment without
which it is not easy to be successfully established.
From the above discussion, the efforts exerted by UNIDO demonstrated in Industrial
Energy Efficiency (IEE) project in Egypt are highly appreciated and considered as a good
supportive action to the Egyptian industrial sector to improve energy efficiency and reduce GHG
emissions. The Industrial Energy Efficiency Project (IEE) is a program developed and initiated by
UNIDO to promote energy efficiency in industry as part of its primary objective of “promoting
and accelerating inclusive and sustainable industrial development in developing countries and
economies in transition.”
IEE project in Egypt is implemented by UNIDO in partnership with the Egyptian
Environmental Affairs Agency, Ministry of Industry, Trade and SMEs and the Federation of
Egyptian Industries. For more details, visit http://ieeegypt.org
The IEE ultimate goal is to reduce greenhouse gas emissions by promoting a continuous
improvement of energy efficiency in industries and ultimately transforming the market for
industrial energy efficiency through creating a policy environment that enables and supports
sustainable adoption of energy efficient technologies and management as an integral part of
industries’ business practices; building a cadre of well-trained and equipped experts in system
optimization and energy management assists industries in developing, increasing access to
financing and implementing energy efficiency improvement projects.
IEE aim was to facilitate energy efficiency improvements in the industrial sector through
supporting the development and implementation of a national energy management standard and
energy efficiency services for Egyptian industry as well as the creation of demonstration projects.
8
The cooperation between IEE project and Egyptian oil and gas sector companies is one of
the examples that could be highlighted to effectively demonstrate that IEE successfully achieved
its aims in Egypt in alignment with the ultimate goal.
This report is concerned with summarizing the part of IEE project regarding the
cooperation with the Egyptian Ministry of Petroleum. This cooperation has been demonstrated in
the support received by many companies in Oil and Gas Sector. This report consists of nine
sections as follows;
This section, the first section, presents a brief introduction for the importance of energy
efficiency and GHG reduction and a brief description about UNIDO IEE project in Egypt.
Section 2, introduces the first stage of cooperation which was in Sidi Kerir Petrochemicals
Co. (SIDPEC), the first company the IEE program from oil and gas sector joined.
Section 3, summarizes the peer-to-peer network project which was successfully
accomplished between the petrochemicals company in Egypt to provide training and technical
support regarding energy management system (EnMS).
Section 4, presents the EnMS Technical Support that was provided to Alexandria National
Refining and Petrochemicals Company (ANRPC), and also the attempts with Alexandria
Petroleum Company (APC).
Section 5, provides some examples for the petroleum companies who firstly joined the
system optimization programs.
Section 6, provides a summary about the cooperation between the UNIDO IEE project and
Oil & Gas Sector Modernization Project which is an initiative from the Egyptian ministry of
petroleum to develop the oil and gas sector and make it a role model for the modernized Egypt.
The main component of such cooperation was regarding motor system optimization (MSO)
training and technical support provision.
Section 7, discusses some common and identified energy efficiency improvement
opportunities in order to develop local best practice for the petroleum sector.
Section 8, presents the Total energy savings and GHG reduction resulted from IEE support
for the Egyptian oil and gas sector.
Section 9, the last section introduces a list of recommendations including the potential for
replication of EnMS and MSO programs in all the sector companies.
9
2. EnMS Training and Technical Support to SIDPEC
The journey of cooperation between IEE project in Egypt and Egyptian Petroleum Sector
has been started since SIDPEC joined the two days user training for Energy Management System
(EnMS) on Sep. 18-19, 2013. That training was conducted to industrial companies where two
representatives from SIDPEC have attended the training where the EnMS and the IEE project
framework were introduced so that SIDPEC representatives decided that SIDPEC should be an
effective partner of the IEE project. UNIDO IEE project accepted SIDPEC request to join the first
EnMS expert training as an exception as that training round was specified to consultancy service
providers only and not to production companies. Therefore, the two representatives from SIDPEC
joined that training and demonstrated high commitment to implement EnMS within their company.
Group Photo at the end of EnMS Expert Training Module 3
To transform the intention into action, SIDPEC has signed a non-disclosure agreement with
IEE representative to receive technical support from UNIDO. UNIDO EnMS international experts
and national experts provided all the required technical support till having SIDPEC’s EnMS
successfully implemented and certified according to ISO 50001 requirements in November 2014
as the first petrochemical company to be ISO 50001 certified and the first production company in
Egyptian petroleum sector as well.
The first EnMS expert training program was conducted by two UNIDO International
Experts in three modules. The first module was on Dec. 10-12, 2013, the second module on May
10
11-13, 2014, and the third module Oct. 14-16, 2014 where an EnMS audit was conducted to
SIDPEC on Oct. 15, 2014 by International and national experts as a part of the on-job training
during third module.
At the end of the EnMS expert training program, SIDPEC two representatives have
successfully passed the exam and have been qualified as EnMS national experts. Those two
candidates were the first EnMS national experts qualified by UNIDO in Egyptian petroleum sector.
First Group National EnMS Experts with IEE Steering Committee Members
after Receiving The Certificates of Qualification
Figure 2.1 Timeline from Starting IEE/SIDPEC Cooperation till Starting P2P Network
Sep. 2013
•SIDPEC attended 1st EnMS User Training (2 representatives)
Dec. 2013 to
Oct. 2014
•SIDPEC attended EnMS Expert Training (2 representatives)
•SIDPEC received Technical Support from UNIDO EnMS Experts
Nov. 2014
•Two Engineers from SIDPEC were qualified as National Energy Experts
•SIDPEC ISO 50001 Certification
Nov. 2014
•Energy Efficiency Improvement Workshop in ECHEM (by UNIDO & SIDPEC)
Mar. 2015
•Starting the Peer-to-Peer Network with Petrochemicals Companies (UNIDO -
ECHEM - SIDPEC)
11
The effective participation of SIDPEC representatives and the good implementation of
EnMS within SIDPEC encouraged the IEE project representatives to propose that a peer-to-peer
(P2P) network can be formed from SIDPEC and other petrochemical companies and managed by
SIDPEC in collaboration with ECHEM as appeared in the timeline shown in Figure 2.1. The
proposal has been welcomed by SIDPEC management and the peer-to-peer network project started
in March 2015.
2.1. Energy Savings within SIDPEC
As a result of the EnMS training and the technical support provided by the UNIDO IEE
project through the International energy experts, SIDPEC has an effective EnMS complied with
the requirements of the ISO 50001:2011. During the implementation and operation of SIDPEC
EnMS, SIDPEC has achieved sufficient amount of energy savings in both electricity, and natural
gas (NG) used as fuel gas. In Table 2.1, two types of savings are illustrated as follows:
(i) Achieved savings which have been already achieved by the accomplished energy
efficiency improvement projects fulfilling the previously set targets; and
(ii) Potential savings which are either planned according to the assigned targets, or
already started and in-progress energy efficiency improvement projects.
Table 2.1 Energy Savings in SIDPEC as per 2017 Records
Electricity
Fuel Gas (NG)
Achieved
Savings
Potential
Savings
Baseline
Achieved
Savings
Potential
Savings
Baseline
MWh
MWh
MWh
MWh
MWh
MWh
9127
10373
195,357
23558.89
47000
1943730
Most of the achieved energy savings are coming from no-cost / low-cost opportunities
while most of the potential savings will come from opportunities with investment. The percentage
savings from the company baseline for electricity and fuel gas are shown in Figure 2.2 and Figure
2.3 respectively.
12
Figure 2.2 SIDPEC Savings of Electricity as percentages of Baseline
Figure 2.3 SIDPEC Savings of Fuel Gas as percentages of Baseline
2.2. UNIDO Support & SIDPEC Recognition
The support from UNIDO had an effective role in providing some opportunities for
SIDPEC recognition both locally during Kafaa campaign and its conference & ceremony, and
globally in Vienna Forum and achieving CEM Insight Award.
13
Kafaa Campaign Conference
Kafaa is one of the outputs of Industrial Energy Efficiency project. The campaign aims at
promoting the concepts of improving energy efficiency in the industrial sector and raising the
awareness about the benefits of applying energy management systems in the industrial facilities.
In the conference and ceremony of
Kaffa campaign, SIDPEC was honored
as one of the leading companies in
implementation of the EnMS in Egypt.
Vienna Forum
SIDPEC was honored by UNIDO at the Vienna Energy Forum 2015 that took place in
Austria as one of the best practitioners of EnMS that significantly saved energy.
SIDPEC Energy Management Representative Received the Award
in Vienna Forum 2015
14
CEM Insight Award
SIDPEC was awarded
Energy Insight Award Certificate in
June 2016 from Clean Energy
Ministerial (CEM) as one of the
2016 Energy Management
Leadership Awards. SIDPEC case
study is published in the forum
“CEM” website for the purpose of
disseminating its experience in
EnMS implementation.
ISO 50001:2011 Certification
With the Support of UNIDO IEE
project, SIDPEC staff were engaged in a one
year process to implement an EnMS in
compliance with ISO 50001 starting with
securing management commitment till third
party auditing and certification in November
2014.
SIDPEC has successfully renewed the
ISO 50001 certificate in the end of 2017 and
started the fourth year of EnMS in operation.
15
3. Peer to Peer Network and Lessons Learnt
In first quarter of 2015, the project of peer-to-peer (P2P) network implementation started
according to the contract between UNIDO and SIDPEC. The aim of this project was to provide
services and activities related to delivering training on EnMS, implementation of EnMS to 6
companies in the petrochemical sector and support the knowledge and expertise sharing within
that sector under the Industrial Energy Efficiency (IEE) Project in Egypt.
All the related tasks, efforts and achievements were carried out and gained by the
cooperation between UNIDO, SIDPEC and ECHEM to disseminate the energy knowledge and to
provide the expertise and technical support related to EnMS implementation to the following six
Petrochemicals companies:
i. The Egyptian Petrochemicals Holding Company (ECHEM)
ii. Egyptian Petrochemicals Company (EPC)
iii. Egyptian Linear Alkyl Benzene Company (ELAB)
iv. Egyptian Propylene And Polypropylene Company (EPPC)
v. Egyptian Styrene and Polystyrene Company (ESTYRENICS)
vi. Misr Oil Processing& Fertilizers Company (MOPCO)
Seizing the opportunity, Sidi kerir Petrochemicals Company (SIDPEC) energy
management representative decided to add more participants to the training sessions to maximize
the benefit and train new generation to become national experts in EnMS in addition to the first
two EnMS experts who were the trainers and consultants to this project.
The Opening of the First Training Session in P2P Project
in SIDPEC Office - Smouha, Alexandria
16
IEE project and SIDPEC decided that there are three main components of the P2P project;
First component is training service provision.
Second component is to operationalize a peer to peer network to share expertise and spread
the acquired knowledge.
Third component is the implementation of EnMS through technical expertise and
assistance service provision throughout the three phases of EnMS implementation which
are planning phase, implementation and operation phase, and checking phase.
3.1. Training Provision in P2P
The 6 training programs delivered were classified into two categories, those training
programs according to UNIDO curriculum (4 training programs) and those according to SIDPEC
EnMS experts’ recommendations (2 training programs) as shown in Table 3.1 including the dates
when each training program was held.
Table 3.1 Training according to UNIDO curriculum including
No.
Training Programs
Dates
Notes
1
Two days for user training to introduce EnMS
14-15/03/2015
UNIDO
Curriculum
2
Module 1 of EnMS Expert Training
“Planning phase” (3-days)
26-28/04/2015
UNIDO
Curriculum
3
Lean Six Sigma Yellow Belt (LSSYB) to enhance the
knowledge of Quality Tools (3-days)
19-21/05/2015
SIDPEC
Recommendation
4
Module 2 of EnMS Expert Training
“Implementation phase” (3-days)
4-6/08/2015
UNIDO
Curriculum
5
Statistical Process Control (SPC) to enhance the
knowledge of Statistical Analysis (3-days)
19-21/10/2015
SIDPEC
Recommendation
6
Module 3 of EnMS Expert Training
“Checking Phase” (3-days)
24-31/12/2015
UNIDO
Curriculum
17
The two training programs noted as per SIDPEC recommendations helped the trainees to
apply Lean Six Sigma methodology, associated tools and statistical process control to the EnMS
planning and implementation phase. In addition to those six training programs some other special
training was conducted to some companies as either needed or requested (e.g. Top Management
Half-Day Awareness to ELAB and also to MOPCO). A total of 37 trainees have attended the
provided training courses among which 29 trainees attended the EnMS Expert Training which is
mandatory for certificate of qualification for national experts. Figure 3.1 shows the distribution of
trainees from the six companies and SIDPEC during the P2P project.
Figure 3.1 Number of attendees in P2P Training
(Excluding Special Sessions within some Companies)
3.2. Peer to Peer Network Establishment
The main components used for P2P network establishment were regular meetings within
companies’ premises during EnMS implementation visits by national and also international
experts, the meetings during webinars to communicate and follow-up with the international experts
through Skype conference calls, and the knowledge transfer through the project management portal
called Basecamp which was provided by UNIDO to support the effective communication. Another
very effective component in establishing the P2P network was the possibility provided to
7
5
4
5
4
6 6
NUMBER OF TRAINEES
18
companies’ representatives to visit SIDPEC as a role model for EnMS implementation in the same
industry sector.
Webinars:
Six webinars were held between international / national experts and the representatives
from each company to explain the status throughout the different phases of EnMS implementation
based on a series of well predesigned webinar topics. A summary of those webinars and the
corresponding dates is illustrated in Table 3.2.
Table 3.2 Summary for Webinars during P2P project
Webinar Description
Dates
Webinar 1: Management commitment + policy + scope
12/05/2015
Webinar 2: SEU
15/06/2015
Webinar 3: EnPI
20/08/2015
Webinar 4: Objectives and Target + opportunities
19/09/2015
Webinar 5: Action Plans
19/10/2015
Webinar 6: Operational control
15/12/2015
Basecamp:
The internet portal provided by UNIDO to share knowledge between national /international
experts and participant companies’ representatives under monitoring of IEE PMU in Egypt and
UNIDO Management in Vienna.
The basecamp was very beneficial as many important topics shared and discussed such as
updated legal and other requirements and the experience of the companies in the implementation
of energy management system, etc.
3.3. Implementation of EnMS in the Six Involved Companies in P2P
SIDPEC national experts had regular visits to participant companies and assisted in
implementing the three phases of the EnMS system in-line with ISO 50001 requirements
including: Planning, Implementation and operation, and Checking including management review
and also verification of energy performance indicators.
As indicated before, participant companies had an opportunity to visit SIDPEC to observe
and adapt their EnMS considering SIDPEC best practices as guidelines.
19
Using the effective well designed EnMS spreadsheets provided by UNIDO and commonly
called as “Energy Tools,” the national experts provided comprehensive assistance to the participant
companies in the following:
Ensuring management commitment.
Formulating the energy policy.
Formulating the energy team and defining roles and responsibilities.
Conducting energy review and establishing the energy baseline including
defining significant energy users, data collection and analysis, defining energy
performance indicators and estimating future energy use and consumption.
Identifying, prioritizing and recording opportunities for improving energy
performance.
Setting energy objectives, targets and corresponding action plans.
EnMS awareness sessions based on UNIDO half-day awareness training were conducted
to some of the participant companies to eliminate the barriers that faced by each company and to
increase the top management level of commitment.
International experts visited three companies during the implementation phase including
ELAB, EPC, and MOPCO. Those companies were selected due to some reasons as follows:
ELAB; to help in accelerating the compliance of the company EnMS with the
requirements of ISO 50001:2011 to be ready for certification. Internal audit were
conducted in ELAB on 14-12-2015 by international expert / national expert as
the company was ready and willing to apply for ISO 50001 certification to help
them to fulfill the required records for internal audit as per the international
standard.
EPC; to increase top management commitment in power station to accelerate the
steam turbine repair procedures and in other units as well to follow up the
demonstrated good progress in EnMS implementation.
MOPCO; to deal with the observed decline in the level of top management
commitment due to appointing a management representative from middle
management not top management.
According to EnMS Expert Training Module-3 plan, it was decided to have three site visits
to conduct internal audits (as on-job training) in ECHEM, EPC, and ELAB where the participants
were divided into three groups and acts as either an auditee or auditor or both.
20
As per UNIDO rules, it was clearly communicated that every company should submit a
final report regarding their EnMS system to qualify for the final exams. The final report supported
each company to clarify their final status regarding the EnMS implementation and to identify any
gaps to be reported to top management.
3.4. Energy Savings and GHG Reduction Outcome of P2P
There are many benefits come from applying EnMS including culture improvement and
productivity increase but however the energy savings and greenhouse gases (GHG) reduction
always have the first priority. During the implementation of EnMS in the P2P companies, many
energy efficiency improvement opportunities were identified some of which have been already
implemented the savings are achieved while there are many other opportunities were carefully
studies and are waiting for implementations in the near future to reach the companies set objectives
which are in most situations from the type of BHAG, Big Hairy Audacious Goals, as advised by
one of the UNIDO international experts. The energy savings are stratified by achieved and
potential savings in both electricity and fuel gas within the six companies and SIDPEC as well are
shown in Table 3.3 whereas the corresponding achieved and potential GHG reductions are shown
in Table 3.4 and as usual are presented in estimated values for 10 years as per [3]. To visually
present the data for savings, Figure 3.2 shows the identified amount of electricity savings within
the six involved companies during the P2P project, Figure 3.3 shows the same but for fuel gas
savings. The GHG reduction represented in tCO2 eq. for 10 years are illustrated in Figure 3.4
below.
Table 3.3 Achieved and Potential Savings in Electricity and Fuel Gas
Company
Electricity
Fuel Gas (NG)
Achieved
Savings
Potential
Savings
Achieved
Savings
Potential
Savings
MWh
MWh
MWh
MWh
ECHEM
107
47
0
42
EPC
296
14220
7019
ELAB
959
900
39566
3693
EPPC
8448
11284
Estyrenics
987
430
MOPCO
2520
183
9000
SIDPEC
9127
10373
23559
47000
TOTAL
21457
26710
90428
51165
21
Figure 3.2 Electricity Savings within the P2P Involved Companies
Some notes related to Figure 3.2 are listed below:
• EPC has a highly potential Savings due to the planned project of Change Elctrolysis Cells
in the Chlorine Plant.
• EPC team reported some huge savings in the power generation plant of about 40000 MWh
and they clarified that the steam turbine repair was accelerated as an indirect impact of
EnMS implementation, this amount of savings are avoided in the presented figures and
tables to be more realistic with clear objective evidences.
• EPPC had a limited cooperation in some phases of the project, so that their potential savings
were not disclosed.
• Estyrenics has no achieved savings due to abnormal plant conditions.
0
2000
4000
6000
8000
10000
12000
14000
16000
ECHEM EPC ELAB EPPC Estyrenics MOPCO
Involved Companies in P2P Project
Electricity Savings During the Project
Achieved Savings MWh Potential Savings MWh
MWh
22
Figure 3.3 Fuel Gas Savings within the P2P Involved Companies
When reviewing Figure 3.3, it is clearly observed that:
• There are less opportunities identified for fuel gas savings due to associated difficulties in
implementation.
Table 3.4 Achieved and Potential GHG Reduction in P2P Companies
Company
Achieved GHG
Reduction
Potential GHG
Reduction
tCO2 (10Y)
tCO2 (10Y)
ECHEM
581
338
EPC
15,785
77,314
ELAB
85,122
12,351
EPPC
68,720
0
Estyrenics
0
6,237
MOPCO
31,878
992
SIDPEC
97,203
151,319
Total
299,289
248,552
0
10000
20000
30000
40000
50000
ECHEM EPC ELAB EPPC Estyrenics MOPCO
Involved Companies in P2P Project
Fuel Gas Savings During the Project
Fuel Gas (NG) Achieved Savings MWh Fuel Gas (NG) Potential Savings MWh
MWh
(Fuel)
23
Figure 3.4 Estimated GHG Reduction as a result from P2P Project
3.5. Lessons learnt from P2P Project
• The most important task that each company has taken into consideration when
implementing its EnMS is the evaluation of its current status of energy performance. This
task helped each company in determining main priorities regarding the implementation
processes.
• The implementation of the EnMS in each company has been proven for both easy and cost
effective, giving a strong management commitment and the availability of adequate
technical resources.
• No/Low cost opportunities have been proven to be a strong tool in convincing all company
staff by the potential benefits that could be achieved if a commitment to continuous
improvement becomes an integrated part of the company’s culture and day-to-day
behavior.
• IEE, SIDPEC, and ECHEM are completely satisfied that the highest level of success is
achieved by replicating the success to other companies especially in the same industry like
those Egyptian petrochemical companies.
• EnMS consultation and technical assistance is more effective when it comes from
companies who work in the same industrial sector speaking the same technical language.
0
20,000
40,000
60,000
80,000
100,000
120,000
140,000
160,000
ECHEM EPC ELAB EPPC Estyrenics MOPCO Sidpec
GHG Reduction in tCO2 (10Y)
Achieved GHG Reduction tCO2 (10Y) Potential GHG Reduction tCO2 (10Y)
tCO2
24
• Providing recognition for EnMS achievements to motivate staff and employees in each
company brings positive exposure to the energy management program.
• Regression analysis in developing the baseline is very useful but however it is not
applicable in many cases due to the difficulties associated with the identification of the
drivers of energy consumption in many cases.
• The energy management representative or the person responsible for energy management
implementation and operation should be selected from the top management so that he/she
can easily communicate with different disciplines and support the enhancement of
commitment.
• Working with companies that belong to the same industrial sector provided the opportunity
to compare the performance of some similar common plants or manufacturing systems.
This is the case of comparing the performance of compressed air systems and cooling water
systems in the seven participated companies.
3.6. Highlights and Summary of Achievements in P2P Network Project
At the end of the P2P projects, the status of EnMS implementation after 60 weeks which
was the time of P2P Network project within the six participant companies are presented below in
Table 3.5 as follows:
Table 3.5 Status of EnMS at the end of P2P Network Project
Company
EnMS status at the end of P2P Network Project
ECHEM
Ready for ISO 50001 certification
ELAB
Ready for ISO 50001 certification
MOPCO
Ready for ISO 50001 certification
EPC
Ready for ISO 50001 certification within Power station, Utilities
and Chlorine Plant. Some other boundaries like VCM & PVC
plants still need more commitment to have and effective EnMS.
EPPC
EnMS is implemented but certification decision is postponed.
Estyrenics
EnMS is implemented but to a certain extent due to strategic
circumstances faced by the company.
25
• Expert Training was completely attended by 29 participants from seven companies.
• The final exam were held on 21/02/2016 where 26 participants attended from 29
participants in the training program, 22 participants passed the exam successfully from the
first time.
• The UNIDO–SIDPEC-ECHEM project success has been marked by graduation of 22
qualified national experts that will be very beneficial in their workplaces and to other
companies belong to Egyptian Petroleum Sector. The Experts received their certificates
during Kafaa Campaign Ceremony in April 2016.
i.e. There are now 24 National Energy Experts Qualified by UNIDO as shown in Figure 3.5
below. The first two from SIDPEC who are the pioneers and led the P2P project in addition to
the 22 experts who are the outcome of P2P. This is a sufficient number of experts to lead the
transformation in the whole oil and gas sector if supported by the Egyptian Ministry of
Petroleum and Mineral Resources.
Figure 3.5 Distribution of 24 National Experts by Companies before & after P2P
2
6
4 4
2
3 3
SIDPEC SIDPEC ECHEM ELAB EPC EPPC ESTYRENICS
BEFORE P2P P2P OUTCOME
24 EnMS National Energy Experts Qualified by UNIDO
26
The National EnMS Experts Received Their Qualification Certificates in
Kafa’a Campaign Conference - April 2016
As a result of the effort exerted in P2P
Network Project, Miser Fertilizer Production
Company (MOPCO) has got the international
standards certificate in Energy Management
System ISO 50001 in 2017.
- MOPCO became the first company that got the
certificate between the participating companies
in the UNIDO – SIDPEC – ECHEM project to
be the second petrochemical company has a
certified EnMS in compliance with ISO
50001:2011.
27
• The very good point characterized the UNIDO support is its continual service provided to
the involved companies and individuals. This was demonstrated in many provided
refreshment courses as an example for that, the training course of the energy performance
indicators conducted by one of the international experts in September 2017 where many
representatives from those qualified national energy experts in petrochemical sector have
attended that 2-day training session.
2-days Energy Performance Indicators Training
for partner companies’ representatives – Sep. 2017
28
4. EnMS Technical Support to other Petroleum Sector
Companies
UNIDO IEE project provided EnMS technical support and training for many other
petroleum companies. Some companies have attended some user training while some other
companies were attempted by UNIDO energy experts to provide the required EnMS technical
support. As an example for such case, the exerted effort in Alexandria National Refining and
Petrochemicals Company (ANRPC), and Alexandria Petroleum Company (APC) is described in
this section.
4.1. Training and Technical Support to ANRPC
Alexandria National Refining and Petrochemicals Company (ANRPC) has started the
planning phase of EnMS in October 2015. The IEE UNIDO national experts had their first meeting
with the energy team on October 8, 2015. Since then the experts have regularly visited the
Company to assist in implementing the 3 phases of the EnMS system in line with ISO 50001.
The EnMS User Training was organized in two days session and conducted on Feb. 22-23,
2016. The training was attended by 12 candidates from Alexandria National Refining &
Petrochemicals Co. (ANRPC) and conducted in ANRPC premises in Alexandria.
4.2. Attempt to Support in APC
Alexandria Petroleum Company (APC) were visited many times by UNIDO energy
experts, both national and international experts, where meetings were held at different levels with
CEO and board, top management, and even front floor throughout the year 2016 but however no
tangible result was accomplished due to high level of resistance within the company and some
difficulties related to the long administration procedures with Egyptian General Petroleum
Corporation (EGPC).
UNIDO IEE project continued to support energy efficiency activities within APC when the
company has joined the motor system optimization (MSO) program as will be mentioned in next
sections.
29
The technical support provided to
ANRPC was continued till the end of 2016
which led ANRPC to having an effective
EnMS in place and being ready for ISO 50001
certification.
The company have already acquired its
ISO 50001:2011 compliance certificate from
SGS in the beginning of 2018.
30
5. MSO/CASO Support to The Petroleum Companies
In addition to EnMS as a component of IEE project in Egypt, there is another very effective
component covers system optimization mainly Motor System Optimization (MSO) and
Compressed Air System Optimization (CASO). Both of the MSO Project and the CASO Project
form a part of the IEE Project and have the specific objectives of developing local personnel to
become competent in the application of energy efficiency in industry in order to unlock the
potential for energy savings within their respective local industries.
Three MSO training groups were organized since November 2015 where IEE project was
caring to cooperate with oil and gas sector companies in such scope of energy efficiency
improvement. SIDPEC was represented in the first group by 4 engineers whereas in the second
group SIDPEC was represented by 2 engineers, and MOPCO was represented by 2 engineers. Each
group have attended two training programs, 2-day user training and 3-day expert training including
one day on-job-training in one of the industrial plant.
Part of MSO First Group during on-job-training
inside SIDPEC Plants – Alexandria Nov. 2015
The cooperation was extended to have the part of the on-job-training of the MSO expert
training to be conducted inside SIDPEC premises in Alexandria for 40 trainees, representing 16
organizations, in two groups during the period of Nov. 7-12, 2015.
31
The training was carried out by UNIDO’s international MSO experts. Topics covered
during the training included proven approaches aimed at optimizing motor system performance
and energy efficiency such as having motor systems management plan, motor sizing and high
efficiency motors technologies, applications of adjustable speed drives, and preventive
maintenance schemes.
As a result from the MSO training, there are 4 MSO national experts qualified by UNIDO
who passed the exam and submitted good case studies demonstrating how MSO can be applied
and provide effective benefits in energy efficiency improvement.
UNIDO IEE project has organized the training of CASO in 2017 where 6 representatives
from SIDPEC, one from ECHEM, and 2 from MOPCO have attended the 5-days training
conducted by two CASO international experts. International expert had very successful visits to
both SIDPEC and MOPCO to assist and follow-up the implementation of identified CASO
opportunities in both companies where fruitful discussions and more energy efficiency
opportunities were recognized.
CASO Project Follow-up in SIDPEC – Sep 2017
32
Implementation of CASO Project in MOPCO – Aug. 2017
5.1. Energy Savings in MSO/CASO in SIDPEC and MOPCO
Many opportunities related to both MSO and CASO have been identified in SIDPEC and
MOPCO as the two involved companies from oil and gas sector. The corresponding total potential
saving in Electricity may reach 2670 MWh in SIDPEC and 2935 MWh in MOPCO as shown in
Figure 5.1 (the savings in SIDPEC is included in the potential energy savings shown in Table 2.1
and Figure 2.2 previously; to be noted).
Figure 5.1 Potential Energy Savings due to CASO/MSO in SIDPEC & MOPCO
0
1000
2000
3000
Sidpec MOPCO
Potential Electricity Savings by Applying
CASO/MSO MWh
MW
33
6. UNIDO IEE project and Oil & Gas Sector Modernization
In 2017, when the oil & gas sector modernization project started its implementation phase,
UNIDO IEE project started to have an effective role with group 4B of the modernization project
as a part of the continuous support provided by UNIDO IEE project to oil and gas sector in Egypt.
6.1. Oil and Gas Sector Modernization Project
The objective of Modernization Project is to design and implement an integrated
transformative program for Egypt’s Oil & Gas sector to enhance its contribution as an engine of
economic growth & to reinforce its role as a model for other sectors in Egypt.
The vision of Modernization Project stated that, “By 2021, continuously unlock the sector’s
full value chain potential as a growth and a sustainable development engine for Egypt to achieve
financial sustainability, become a leading regional Oil and Gas hub, and to be role model for the
future of modernized Egypt.
The Oil & Gas Sector Modernization Project has 7 programs as shown in Figure 6.1 where
program 4 related to downstream performance includes a component specialized in energy
efficiency improvement which is identified as Group 4B. The IEE project concentrated its scope
of cooperation with such component “Group 4B”
Figure 6.1 Seven Programs of Oil & Gas Sector Modernization
34
6.2. Cooperation between IEE and Modernization Group 4B
When Group B sought to identify the areas of cooperation that may be initiated from
UNIDO IEE project, several meetings were held till it was agreed that a new round for motor
system optimization (MSO) can be conducted specific for oil and gas sector companies to act as a
part of Group 4B achievements.
Hence, IEE project started the plan for conducting MSO training and technical support to
several oil and gas companies and to concentrate the work to the huge energy consumption
companies identified by Group 4B.
The objective was to qualify some MSO national experts within the oil & gas sector
companies who can act as a nucleus that can be capable of replicate the work within all Petroleum
Companies in Egypt.
MSO Training for Petroleum Companies in Cairo – July 2017
6.3. MSO Training and Technical Support Provision
The specific MSO project to oil and gas sector companies had several stages as follows:
2-Days MSO User Training (two rounds in Cairo and in Alexandria)
3-Days MSO Expert Training (two rounds in Cairo and in Alexandria)
Submission of Case Study Reports by the Trainees
Exam for Qualifying the MSO National Experts
Continuous Technical Support through different communication channels including
visits and meetings by International and National Experts.
35
Figure 6.2 Number of trainees attended different MSO Training Sessions
The provided training was attended by 61 trainees from 20 companies listed in Table 6.1,
11 companies were represented in Cairo training sessions and 9 companies were represented in
Alexandria training sessions. The number of trainees attended each program shown in Figure 6.2
where it is indicated that the user training sessions were conducted in April 2017 and the expert
training sessions were conducted in July 2017.
Table 6.1 Involved Petroleum Companies in MSO
20 Oil & Gas Sector Companies Involved in MSO
Place of Attendance
Cairo
Alexandria
No.
Company
No.
Company
1
ASORC
12
AMOC
2
CORC
13
ANRPC
3
ECHEM
14
APC
4
EGPC
15
APRC
5
Gascool
16
ELAB
6
GPC
17
EPC
7
Gupco
18
EPROM
8
Petrogulf Misr
19
Midor
9
PPC
20
Rashpetco
10
SOPC
11
WASCO
Cairo Alexandria Cairo Alex
Apr-17 Apr-17 Jul-17 Jul-17
MSO User
Training
MSO User
Training
MSO Expert
Training
MSO Expert
Training
37
25 27 25
NUMBER OF TRAINEES
36
In addition to training, the UNIDO International expert visited 14 companies, in Sep. 2017,
from those 20 companies attended the training with representatives from Modernization Group B.
In all the 14 companies that have been visited, at least one project was discussed per site. During
discussions further potential optimization projects were also identified.
Other visits were also conducted by national experts however UNIDO IEE project was
having the willing to conduct more visits and support but some administration difficulties from the
side of Modernization Group 4B were faced by the national experts.
Representatives of UNIDO & Modernization Group 4B
with some Company Staff during AMOC Visit on Sep. 18, 2017
6.4. Follow-up Activities of MSO in Petroleum Sector
The support of IEE project did not stop at that level because IEE team believe that the
follow-up to the beneficiaries is one of their responsibilities. IEE team has invited the petroleum
sector companies’ representatives to attend a refresher course on MSO in May 2018. The MSO
refresher course was conducted by the MSO international expert for two days and repeated in two
sessions one in Alexandria on May 7-8 and the other in Cairo on May 9-10, 2018. This training
program was very useful to increase the engagement of the people to energy efficiency
improvement and to discuss the raised issues during the implementation of the identified
opportunities in their companies.
37
Completion of the UNIDO refresher course on motor system optimization in Egypt 7-10 May 2018
Another good indicator for continuous collaboration, UNIDO representative and regional
director has participated in the first conference on energy efficiency for the petroleum sector on 8
May 2018. The cooperation between the IEE project and the petroleum sector was presented in
addition to the lessons learnt and way forward. The presence of UNIDO regional director and also
the IEE national coordinator was highly appreciated by the Egyptian Ministry of Petroleum as it
enriched the subjects discussed during the first energy efficiency conference.
In the same conference, a detailed presentation was presented by a representative from oil
and gas sector modernization project (Group 4B) about the achievements of MSO project, led by
UNIDO, in sector companies including participated companies, qualified MSO experts, energy
savings, lessons learnt and recommendations.
UNIDO Representative and
Regional Director during her
presentation in the first Conference
on Energy Efficiency For Egyptian
Petroleum Sector
38
6.5. Outcomes from the MSO Training in Petroleum Sector
There are two specific areas where the outcome of the provided MSO training in petroleum
sector can appears. First, qualifying some national MSO experts who can support the replication
of MSO within the whole petroleum sector. Second, the tangible energy savings and the
corresponding GHG reduction.
6.5.1. MSO National Experts Qualified by UNIDO
In addition to the first four qualified MSO national experts from SIDPEC during earlier
rounds of MSO training, there are more 7 MSO national experts qualified from 5 companies as
indicated in the following Figure 6.3. It was observed that the number of qualified experts could
be larger if more commitment was provided from top management in the involved 20 companies.
Figure 6.3 Distribution of 11 MSO National Experts by Companies
6.5.2. Energy Savings and GHG Reduction Resulting from MSO
In this section, the energy savings and corresponding GHG reduction are summarized in
Table 6.2 and are furtherly illustrated in Figure 6.4 and Figure 6.5. Most of the savings are
identified and planned to be acquired in near future after complete the implementation.
4
3
1 1 1 1
SIDPEC ASORC EGPC GPC ANRPC ELAB
EARLIER MSO MSO DEDICATED TO PETROLEUM SECTOR
11 MSO National Experts Qualified by UNIDO
39
Table 6.2 Electrical Energy Savings and GHG Reduction From MSO Identified
Opportunities in Oil & Gas Sector Companies
Company
Identified
Electrical
Savings (MSO)
Corresponding
GHG Reduction
MWh
tCO2 (10Y)
ANRPC
450
2447
AMOC
132
718
ASORC
730
3969
ELAB
172
935
GPC
1240
6742
SIDPEC
1630
8862
SOPC
3480
18920
It should be determined that although there were 20 companies involved in the MSO
training, only 6 companies has completed the cycle which includes training attendance, passing
the written exam, and submit a case study well enough for being approved by the international
experts. Those 6 companies are the base for presented energy savings in this report however the
actual savings may be considerably larger if more management commitment was provided.
Figure 6.4 Amount of Electricity Savings Identified from MSO in Oil & Gas Companies
ANRPC AMOC ASORC ELAB GPC Sidpec SOPC
450
132
730
172
1240
1630
3480
MSO IDENTIFIED ELECTRICAL SAVINGS
(MSO) MWH
40
Figure 6.5 Amount of GHG Reduction Identified from MSO in Oil & Gas Companies
6.6. Lessons Learnt from MSO Project in Petroleum Sector
• Applying a structured approach to motor system optimization can often result in savings
with no or low initial cost.
• The MSO can be easily applied if there is EnMS in place.
• The assessment required for MSO opportunities often include reviewing process
requirements, reviewing historical data, taking system measurements and developing
optimization solutions. This approach requires the engineers to develop a strong
understanding of the system efficiency, operation and control conditions, as well as
maintenance practices impact.
• A clear replacement policy for electric motors is needed to determine whether to rewind or
to replace motors. In the same context, the purchasing policy has to be changed to avoid
replacing the failed equipment with a similar one regardless considering any wrong design
issue like oversizing.
• Focusing on improvement enhances the ideation process. A new idea for replacing the
Aluminum blades of the cooling tower fans with PVC blades was raised in some company,
however it may require more studies and investigation.
ANRPC AMOC ASORC ELAB GPC Sidpec SOPC
2446.65
717.684
3969.01
935.164
6741.88
8862.31
18920.76
CORRESPONDING GHG REDUCTION
TCO2 (10Y)
41
• Energy efficiency improvement has a significant effect on enhancing maintenance
activities.
• Applying MSO can be a good motivation for the companies to widen their energy
efficiency concerns and starting the implementation of energy management system
(EnMS).
• Top management support is mandatory for deployment of an energy efficiency
improvement culture.
• Joining a program like MSO that concerns with improvement can provide a very good
support to deploy a culture of improvement especially in old companies with high
resistance to change.
• The assessment of the motor systems identified the need for many measuring instruments
that could be considered while preparing a measurement plan within the company.
• Energy efficiency initiatives can always encourage many other initiatives that improve the
operations in general.
• Focusing on MSO affects energy efficiency issues in case of planning for any new project
where companies should accept new motors if only of high efficiency type (IE2 or IE3).
• Energy efficiency work has a significant effect on identifying some existing drawbacks in
design.
42
7. Common Opportunities to Develop Local Best Practice for the
Sector
In order to develop a local best practice for the petroleum sector, hereunder in this section, some
subsections will be presented to describe the common opportunities in oil and gas industry. First,
some common opportunities are presented related to motor system optimization captured from the
identified opportunities during the MSO support provision to the sector. Second, some major areas
for energy-efficiency improvement in oil and gas industry in general as determined in [4].
Always keep in mind that successful implementation of energy management system (EnMS), and
system optimization including MSO, CASO, and SSO could not only realize energy savings within
the area of concern but also serve as a stepping stone to realize more energy savings in other areas
of production and furtherly could serve as initiative for culture change towards improvement.
7.1. MSO Opportunities
(Outcome from IEE Support to Petroleum Sector)
It was observed that the majority of motors, in upstream and downstream companies including
refineries and petrochemical plants, are explosion proof as they are located in Hazardous area. For
the purpose of having lower risk to business, it is recommended that safe-area motors like those in
utilities to be studied first to implement the MSO pilot projects. This affords a buy-in to
management commitment as this would secure the provision of resources required to spread the
work of MSO which may need higher investment but with short and effective payback.
Meanwhile the support was provided by IEE project to petroleum sector, some areas for
improvement were identified among which the cooling water system where many companies
found a lot of MSO opportunities. Other areas are compressed air systems, air coolers in processing
units, and crude oil pumping units as well. Hence, the presented cases here are classified into four
subsections based on the raised opportunities in the oil and gas sector companies involved in the
MSO and CASO programs provided by IEE.
43
7.1.1. Cooling Water System (CWS)
It was observed that CWS is identified as a significant energy user (SEU) in almost all oil and
gas sector companies that were involved in IEE project in Egypt. In most cases, the water is either
river water or sea water.
Some types of motor systems are typically found in CWS in the studied companies which are:
Circulating pumps to and from the units to the cooling tower basin
Pumps for lifting the water up to the cooling tower
Air cooler fans located at the top of the tower
Sea water pump stations
According to the conducted studies in oil and gas sector companies, two types of motor systems in
CWS will be presented here as examples with some cases in each; air cooler fans and sea water pump
stations will be presented.
In addition, in some cases, it was observed that maintenance and cleaning of the cooling tower was
identified as an opportunity for certain company where the recorded energy saving was around 73 MWh
per annum. In the same company, the operating philosophy for the five water circulating pumps (two new
pumps and three old pumps with less discharge pressure) was changed to operating the three new smaller
pumps for at least six months of cool weather conditions instead of two small pumps and one large pump
all over the year. The new operation strategy accomplished savings amount of 240 MWh per annum.
Air Cooler Fans in Cooling Towers
In most case, the investigation resulted in focusing on the fans because their corresponding
loads are varying seasonally with different ambient temperature where the other pumps are
working almost at a constant load, what makes the fans good area for energy efficiency
improvement. Some cases will be described below:
Case 1- CWS
The air cooler fans consists of three fans driven by 55kW motors which were oversized
during the design phase. The fan load varies with the ambient temperature, where in summer, the
fans run with full load and in some times the 3 fans are working simultaneously. In winter, 2 fans
run with partial load and in some cases, only 1 fan can do the job.
44
It was investigated that there is an opportunity for energy saving in the fan motor system with
different alternative solutions.
The first solution is to adjust the fans’ blade angles to have higher amounts of air flow per
fan. This will reduce the total operating hours of the fans but there is some difficulties due
to lack of some technical data.
The second solution is to replace the motor by a smaller one (downsize the motor) where
the new motors could be 37 kW instead of 55 kW.
The third is to install VSD(s) which may encounter replacing the existing motors with
newer ones that can work with VSDs.
The company has decided to implement the third solution (installation of three VSDs) which
mandates replacing the three motors with new smaller ones which are suitable to work with
variable speed drives. Total savings are estimated to be 450,000 kWh (or EGP 315,000) per annum
at investment cost of EGP 450,000.
Case 2 - CWS
The fans cooling system consists of eight 110kW fans. However, the process requirements
do not dictate the operation of all eight fans at the same time most of the year. Three possible
opportunities for energy saving in cooling fans system were identified as follows:
Two of them involved operating parallel fans at reduced speeds to get more reduction in
power by either installation of two VSDs in the first studied opportunity, or three VSDs in
the second studied opportunity.
The third opportunity was simply through switching off the equipment based on process
requirements. A more in depth study of the process requirements was found to be necessary
before this option could be implemented.
The first opportunity, Installation of 2 VSD, has been chosen. Where the identified savings amount
to 440,000 kWh (or EGP250,000) per annum at an investment cost of EGP100,000.
45
Case 3 - CWS
In a cooling tower with three cooling fans, it was observed that apply new operating
philosophy, as a demonstration of operational control for cooling fans, such that three fans to be
in operation at lower speed during winter instead of two fans in operation at higher speed along
the year.
In this case, the identified savings amount to 155,000 kWh per annum without any
investment (no cost opportunity).
Sea Water Pump Station (Cooling Water)
Case 4 - CWS
Sea water station provides production units by cooling water. It contains 6 vertical pumps
driven by large motors (6.6 KV, 825 ~ 925 KW) which consumes around 13% of total electricity
consumption in the company under study.
During normal operation, only two pumps are running. The company under study is
considerably an old plant and those pumps were installed in different times; two pumps in 1963,
two pumps in 1982, and the newest two pumps were installed in 2009. Each pump is operating
annually for around two months.
The discharge line diameter for each pump is 28 inch and controlled by manual valves;
three of them are gate valves and the other three are butterfly valves where any valve is operating
at 60% opening. The result of the sea water pumps’ motor system assessment concluded the
identifications of four optimization opportunities.
First, adjusting the discharge valves for sea water pumps to an accurate opening percentage
that can fulfill the required flow rate and pressure while affording energy savings. Second, due to
the old plant status, many unplanned shutdowns happen regularly during the year so that stopping
one of the two running pumps and keeping only one pump operating at max capacity can be a good
opportunity for energy savings. Replacing the existing pumps with smaller pumps driven by higher
efficiency motors is considered as third opportunity. The fourth identified energy saving
46
opportunity is replacing the existing pumps discharge manual valves with new motorized control
valves of butterfly types. Another opportunity was identified to use VSD with the existing pumps,
however the assessment indicated that it is not applicable in the system under study.
The first two opportunities can be implemented at no cost while the latter two opportunities
showed somehow long payback period. The company decided to implement the first two
opportunities and now both are successfully tested and energy savings have already been gained.
Total savings amount to 3,480,000 kWh (or EGP2,430,000) per annum without any investment.
The other two opportunities are approved to be implemented not only from energy efficiency
perspective but also from asset integrity perspective to revamp the very old equipment.
7.1.2. Compressed Air System
Compressed Air Systems in most oil & gas companies are usually identified as one of the
significant energy users. It was observed that the improvement opportunities related to compressed
air systems could be identified during both the specific program of Compressed Air Systems
Optimization (CASO) and during the other program of Motor Systems Optimization (MSO) as
well. Two cases in different petroleum companies will be presented in this subsection.
Case 1
A petroleum company has three air compressors where each is driven by 260 kW motor
and their electrical energy consumption is around 1,440,000 kWh per annum. Due to the expected
potential energy savings opportunities in compressed air system, the company decided to select it
as a pilot project for MSO work and started the systematic assessment.
The dedicated team recognized that the most common optimization strategies for
compressed air systems should include reduction of both leakage and inappropriate usage of
compressed air, in addition to improvement of compressor control.
Check the sources of leak in instrument air network was accomplished and all the required
maintenance was performed. All operators were also advised to eliminate inappropriate usage of
compressed air during daily activities like cleaning or using higher pressure than necessary.
47
An investigation for the optimum load/unload pressure set points was conducted to find
the optimum values for energy savings achievement where it was found that decreasing the cut-in
pressure to be 6.5 bar instead of 6.8 bar and letting the compressor working in the new band 7.8/6.5
bar can result in reasonable energy savings.
Further check for instrument air network leakage is still required and may be done using
ultra sound detector or by third party investigation. Decreasing instrument air network pressure is
still under investigation and may lead to extra savings.
The company has decided to implement the maintenance for the identified leakage points
in instrument air network, increase the awareness of the operators to avoid the inappropriate usage
of compressed air, and adjust the air compressor pressure set points. The achieved total savings
amount of 172,000 kWh (or EGP133,000) per annum without any investment cost.
Case 2
Screw compressor was installed and being in operation since 2008 with a power meter and
compressed air flowmeter in place. According to the assessment, it was observed that the specific
energy consumption (SEC) equals to 0.1349 kWh/m3 and the corresponding cost was 0.0793
EGP/m3 so that the main driver which affects the compressor is the compressed air consumption
through the whole plant.
Identifying the improvement opportunities of the compressed air system in separation unit
is the main issue in the assessment as it leads to considerable reduction in power consumption.
Four possible opportunities for energy savings were identified.
First opportunity is to identify existing leaking points by using the leak detector and fix
them. Second opportunity is to install an automatic drain as it was found out that permanently open
drain valves on the after-cooler take air at 7.5 bar from 25 mm pipe line. These valves always open
at 25 % of their diameters which represent continuous source of air losses. Third opportunity can
be done based on using demineralized water instead of cooling water for the existing Heat
exchanger. The energy heat recovery is calculated based on the given operating conditions and by
using simulation program (Aspen plus V.09). Fourth opportunity was to replace the existing screw
compressors with a centrifugal compressor.
48
Applying these solutions will help the air compressor system to become optimized which
will lead to an increase in savings and keep the current savings within limits. All opportunities
have been recommended to be implemented together.
The annual energy savings amount for the compressor replacement opportunity is
estimated to be 439,200 kWh and the financial Savings to be around 219,600 EGP at total
investment of EGP 369,000.
7.1.3. Air Coolers in Different Processes
It was observed that many energy savings opportunities were identified in air coolers in
different processing units. In this subsection, three cases will be presented concerning a case for
air coolers in gasoil units, another for air cooler of fuel oil, and the third for fractionator condenser
air cooler.
Case 1
In a certain company, the air coolers in gasoil units have a main fan which use air to cool
fluid medium and have a backup fan which is used in case the main fan is not sufficient enough
for cooling the fluid medium to reach its set point. The control method of back up fan is variable
pitch control where the controller adjusts the angle of fan blades (5 level of adjustment) to supply
fluid medium with its demand of air to be cooled. The Levels of adjustment is from 0% to 100%
with step of 25%. At 0% blade angle is adjusted to be zero (Zero flow rate) while at 100% blade
angle is adjusted to be maximum (Maximum flow rate).
This means that the backup fan always works at zero degree (zero flow rates) unless fluid
medium temperature exceeds certain degree, controller starts to adjust blade angle with 25% to
increase supply of air to cool down the fluid medium. If medium has not been cooled yet, controller
start to increase blade angle step by step till reaches 100% and afterwards medium reaches it set
point when controller readjust blade angle to zero degree and fan continues to work without any
flow rate supply just in case of temperature rise again. Since unloading time of the fan is relatively
too long and the energy consumed is almost equal to that at full load, hence there is considerable
waste of energy.
49
After assessment, the dedicated team recognized two applicable optimization strategies.
First, Changing flow rate control of backup fan from variable pitch control method by the existing
pneumatic controller to VSD. In this improvement opportunity, VSD solution would decrease
maintenance cost due to getting rid of variable pitch control. The pneumatic controller annual
maintenance cost of around EGP50,000 will be saved which will be subtracted from the cost of
the new VSD (~EGP90,000). The second improvement opportunity is shutting off the fan when
there is no need for cooling (during night or winter weather) for around 37% of annual operating
time. The company has decided to implement the two applicable improvement strategies and
achieved total savings amount of 132,000 kWh (or EGP100,000) per annum against around
EGP90,000 investment cost.
Case 2
In a petroleum company, fuel oil air cooler fans including two fans driven by 18.5 kW
motors (one fan in operation 24/7). It was investigated that the fuel oil after passing the cooler
entering the storage tank which includes a steam heating coil to keep constant temperature at the
tank. Hence, the idea was to switch off the fan and stop the heating coil by isolating the steam inlet
valve. This action has already been taken without any effect on operation.
It is expected to be effective at least during 8 months of the year according to the weather
in Egypt where a total amount of energy savings will be around 75,000 kWh per annum. For
summer 4 months, a VSD may be installed in future so that a fan can be running according to
weather conditions.
Case 3
In a petroleum company, a fractionator overhead condenser air cooler fans including eight
fans driven by 22 kW motors (six fans in operation 24/7). For the fractionator condenser, two fans
were identified with lower performance as their motors consumes higher current than the motors
for other fans operating in similar conditions. Replacing those two low performance motors with
another existing motors from inventory or performing maintenance to them resulted in decreasing
50
their consumed current to reach the normal value. This no cost temporary action was taken while
replacing the two lower performance motors by new IE2 motors is in progress that can increase
the annual savings. Total savings amount to 732,000 kWh (or EGP510,000) per annum is expected
at an investment cost of EGP150,000.
7.1.4. Sucker Rod Pumps
In an upstream oil company, a very interesting energy saving opportunity was investigated
regarding the application of crude oil pumping units for wells (sucker rod pump or beam pump) in
one of the company’s oil field.
Two motor systems were selected as a pilot project, the first is a group of 15 kW motors
for 10 sucker rod pumps and another group of 37 kW motors for another 10 sucker rod pumps.
From each group, one pump was selected for detailed investigation.
The existing motors of sucker rod pumping units have low efficiency and some are
rewound twice before. The mechanical coupling of almost all motors can be maintained to improve
transmission efficiency. Some operational requirements like control of flow rate is accomplished
by changing the motor speed, in the current situation, this is performed either by using different
size of motor pulley or changing the crank pin position which requires to stop the motor increasing
the downtime. It was noticed that most of motors are oversized.
After detailed investigation, three improvement opportunities were identified. First,
increasing transmission efficiency and decreasing mechanical losses by using proper type and
51
number of belts and performing braking system maintenance. Second, replacing the existing
motors with smaller motor to avoid the oversizing and in some cases using motors with higher
efficiency IE1 or even better. Third, installing new VSDs to increase energy efficiency and control
motor speed without any downtime due to operational requirements.
For both motor systems, the company is going to implement the first and second
opportunities due to their low investment requirements and almost immediate outcome. The third
opportunity of VSD will be focused in the 15 kW motors due to its high amount of potential savings
as a result of increasing productivity and decreasing downtime. After completion of those
opportunities, total savings may amount to 1.7 GWh (4.4 million EGP).
It is very important to mention here that there is another identified energy saving
opportunity using regenerative VSD. Regeneration using electric motors represents a good
opportunity for energy saving in many applications of material handling loads and can be suitable
for sucker rod pump application. It was investigated in the company under study that installing
VSD with regenerative capabilities can save up to 40% of the energy consumption, assuming the
recovered energy is 25%.
7.2. General Energy Efficiency Improvement Opportunities
It is observed that major energy-efficiency improvement opportunities in oil and gas
industry can be identified in the following areas; utilities (30%), fired heaters (20%), process
optimization (15%), heat exchangers (15%), motor systems (10%), and other areas (10%). A
classified list for possible energy efficiency opportunities are stated below as guided by an
ENERGY STAR Guide for Energy and Plant Managers [4].
52
Steam System
Boiler feed water
preparation
Select the suitable boiler feed water treatment program.
Improved process control
Flue gas monitor and control units are used to maintain
optimum oxygen concentration in the combustion zone of the
boiler. The payback of installing flue gas analyzers to determine
proper air/fuel ratios is on average 0.6 years.
Reduce flue gas quantities
Excessive flue gas results from leaks in the boiler and the flue,
reducing the heat transferred to the steam, and increasing
pumping requirements. These leaks are often easily repaired.
Savings amount to 2-5%.
Reduce excess air
The more air is used to burn the fuel, the more heat is wasted in
heating the air. NOx emissions are also impacted by the amount
of excess air in the combustion zone. Poorly maintained boilers
can have up to 140% excess air. Reducing this back down to
15% would save 8% in fuel use. Boiler efficiency can be
increased by 1% for each 15% reduction in excess air, however
actual savings will depend strongly on flue gas temperature.
Improve insulation
New materials insulate better, and have a lower heat capacity.
Savings of 6-26% can be achieved if this improved insulation is
combined with improved heater circuit controls.
Recover heat from flue gas
and boiler blowdown
Heat from flue gasses and boiler blowdown can be used to
preheat boiler feed water in an economizer.
Maintenance
Simple maintenance program savings are estimated at 10%.
Improved maintenance may also reduce the emission of air
pollutants.
Reduce standby losses
In the chemical industry, often one or more boilers are kept on
standby in case of failure of the operating boiler. The steam
production at standby can be reduced to virtually zero by
modifying the burner, combustion air supply and boiler feed
water supply. By installing an automatic control system the
boiler can reach full capacity within 12 minutes. Installing the
control system and modifying the boiler can result in energy
savings up to 85% of the standby boiler.
53
Furnaces/Process Heaters
Heat generation
Improve the efficiency of heat generation by control the air-to
fuel ratio in furnaces. Use flue-gas treatment unit’s new burner
technology allows to reduce emissions.
Heat transfer
Improved heat transfer within a furnace, oven or boiler can
result in both energy savings and productivity gains. There can
be several ways to improve heat transfer such as the use of soot
blowers, burning off carbon and other deposits from radiant
tubes and cleaning the heat exchange surfaces. Typical savings
are 5-10%.
Flue gas heat recovery
Use of waste heat to preheat combustion air is commonly used
in medium to high temperature furnace. Every 2°C drop in the
exit flue gas temperature increases the thermal efficiency of the
furnace by 1%. Typical fuel savings range between 8 and 18%.
Electric Motor
Motor management plan
Creation of a motor survey, Development of guidelines for
proactive repair, Preparation for motor failure by creating a
spares inventory, Development of a purchasing specification,
Development of a repair specification, Development and
implementation of a predictive and preventive maintenance
program.
Strategic Motor Selection
Several factors are important when selecting a motor, including
motor speed, horsepower, enclosure type, temperature rating,
efficiency level, and quality of power supply. When selecting
and purchasing a motor, it is also critical to consider the life-
cycle costs of that motor rather than just its initial purchase and
installation costs. Up to 95% of a motor’s costs can be
attributed to the energy it consumes over its lifetime, while only
around 5% of a motor’s costs are typically attributed to its
purchase, installation, and maintenance.
Properly sized motors
Motors that are sized inappropriately result in unnecessary
energy losses. Replacing oversized motors with properly sized
motors saves on average 1.2% of total motor system electricity
consumption.
54
Adjustable speed
drives(ASDs)
Adjustable speed drives better match speed to load requirements
for motor operations, and therefore ensure that motor energy use
is optimized to a given application. ADSs provide savings
between 7% and 60% with estimated simple payback periods
from 0.8 - 2.8 years.
Power factor correction
A low power factor may result in increased power consumption,
and hence increased electricity costs. The power factor can be
corrected by minimizing idling of electric motors (a motor that
is turned off consumes no energy), replacing motors with
premium efficient motors, and installing capacitors in the AC
circuit to reduce the magnitude of reactive power in the system.
Minimizing voltage
unbalances
A voltage unbalance causes a current unbalance, which will
result in torque pulsations, increased vibration and mechanical
stress, increased losses, and motor overheating. By regularly
monitoring the voltages, voltage unbalances may be identified.
It is also recommended to verify that single-phase loads are
uniformly distributed and to install ground fault indicators as
required. The typical payback period for voltage controller
installation on lightly loaded motors in the United States is 2.6
years.
Pumps
Proper Maintenance
Inadequate maintenance at times lowers pump system
efficiency, causes pumps to wear out more quickly and
increases costs. Better maintenance will reduce these problems
and save energy.
Reduce need
Holding tanks can be used to equalize the flow over the
production cycle, enhancing energy efficiency and potentially
reducing the need to add pump capacity. Bypass loops and other
unnecessary flows should be eliminated. Energy savings may
be as high as 5-10% for each of these. Total head requirements
can also be reduced by lowering process static pressure,
minimizing elevation rise from suction tank to discharge tank,
reducing static elevation change by use of siphons and lowering
spray nozzle velocities.
55
Correct sizing of pump(s)
and pipes
Pumps that are sized inappropriately result in unnecessary
losses. Where peak loads can be reduced, pump size can also be
reduced. Correcting for pump oversizing can save 15 to 25% of
electricity consumption for pumping. Often using multiple
pumps is the most cost-effective and most energy efficient
solution for varying loads. Installing parallel systems for highly
variable loads saves 10 to 50% of the electricity consumption
for pumping.
Trimming impeller
If the pump delivers too much head compared to the demand at
the operating rate of flow (indicating excessive flow), the
impeller (diameter) can be trimmed so that the pump does not
develop as much head.
Controls
The objective of any control strategy is to shut off unneeded
pumps or reduce the load of individual pumps until needed.
Adjustable speed drives
(ASDs)
As described before.
Avoid throttling valves
Variable speed drives or on-off regulated systems always save
energy compared to throttling valves.
Compressors and Compressed Air Systems
Proper Maintenance
Inadequate maintenance can lower compression efficiency,
increase air leakage or pressure variability and lead to increased
operating temperatures, poor moisture control and excessive
contamination. Better maintenance will reduce these problems
and save energy.
Reduce leaks
Leaks cause an increase in compressor energy and maintenance
costs. The most common areas for leaks are couplings, hoses,
tubes, fittings, pressure regulators, open condensate traps and
shut-off valves, pipe joints, disconnects and thread sealants.
Reducing the inlet air
temperature
Reducing the inlet air temperature by taking suction from
outside the building reduces energy used by the compressor.
Importing fresh air has paybacks of up to 5 years, depending on
the location of the compressor air inlet.
56
Maximize allowable
pressure dew point at air
intake
Choose the dryer that has the maximum allowable pressure dew
point, and best efficiency.
Properly sized regulators
By properly sizing regulators, compressed air will be saved that
is otherwise wasted as excess air.
Sizing pipe diameter
correctly
As described before
Adjustable speed drives
(ASDs)
As described before
Buildings: HVAC
Energy efficient system
design
By sizing equipment properly and designing energy efficiency
into a new facility, a facility can minimize the energy
consumption and operational costs of HVAC systems from the
outset.
Non-production hours set-
back temperatures
Setting back building temperatures (i.e., turning building
temperatures down in winter or up in summer) during periods
of non-use, such as weekends or non-production times, can lead
to significant savings in HVAC energy consumption.
Duct leakage repair
Measures for reducing duct leakage include installing duct
insulation and performing regular duct inspection and
maintenance, including ongoing leak detection and repair.
Repairing duct leaks in industrial and commercial spaces could
reduce HVAC energy consumption by up to 30%.
Adjustable speed drives
(ASDs)
As described before.
Fan modification
Changing the size or shape of the sheaves of a fan can help to
optimize fan efficiency and airflow, thereby reducing energy
consumption.
Building reflection
Use of a reflective coating on the roof of buildings in sunny, hot
climates can save on air conditioning costs inside
Building insulation
Adding insulation to a facility will nearly always result in the
reduction of utility bills.
57
Buildings: Lighting
Turning off lights
Encourage personnel to turn off lights in unoccupied building
spaces.
Lighting controls
Lights can be shut off during non-working hours by automatic
controls, such as occupancy sensors that turn off lights when a
space becomes unoccupied. Occupancy sensors can save up to
10% to 20% of facility lighting energy use.
Exit signs
Energy costs can be reduced by switching from incandescent
lamps to light emitting diodes (LEDs) or radium strips in exit
sign lighting. An incandescent exit sign uses about 40 W, while
LED signs may use only about 4W to 8 W, reducing electricity
use by 80% to 90%.
Daylighting
Daylighting involves the efficient use of natural light in order
to minimize the need for artificial lighting in buildings.
Increasing levels of daylight within rooms can reduce electrical
lighting loads by up to 70%.
Lighting Fixtures
Replacement of T-12 tubes with T-8 tubes, Replacement of
mercury lights with metal halide, High-intensity discharge
(HID) voltage reduction, and use High-intensity fluorescent
lights systems.
58
8. Total energy savings resulted from IEE support for the sector
In this section, the total savings in the Egyptian oil and gas sector that were resulted from
the support of UNIDO IEE project are presented. The savings are divided here into three parts as
follows; first part, introduced in Table 8.1, shows the savings in the first company received support
from IEE, which is SIDPEC, in addition to the six companies which were involved in the P2P
project led by UNIDO-SIDPEC-ECHEM. All those seven companies received support, in this first
stage of the project, related to EnMS implementation and operation. The identified savings in this
case is separated to electricity savings and fuel gas (natural gas) savings both represented in
MWh/year where the corresponding GHG reductions for each are represented in tCO2eq/10 years.
Table 8.1 Savings Resulted from Sector Companies Received Support in EnMS
Identified Savings in SIDPEC and P2P
Involved Companies
Company
Identified
Electricity
Savings (P2P)
Corresponding
GHG
Reduction
Company
Identified Fuel
Gas (NG)
Savings (P2P)
Corresponding
GHG
Reduction
MWh
tCO2 (10Y)
MWh
tCO2 (10Y)
ECHEM
154
835
ECHEM
42
85
EPC
14516
78923
EPC
7019
14175
ELAB
1859
10107
ELAB
43259
87366
EPPC
8448
45932
EPPC
11284
22789
Estyrenics
987
5368
Estyrenics
430
868
MOPCO
2703
14694
MOPCO
9000
18176
SIDPEC
19500
106022
SIDPEC
70559
142501
Second part, introduced in Table 8.2, shows the savings in the two companies received
support from IEE regarding MSO and CASO, which are SIDPEC and MOPCO. The identified
savings in this case, only electricity savings, represented in MWh/year where the corresponding
GHG reductions represented in tCO2eq/10 years.
59
Table 8.2 Savings Resulted from Sector Companies in First Groups of MSO & CASO
Identified Savings in
Companies Involved in
First Groups of
(MSO & CASO)
Company
Identified
Electricity
Savings
(CASO/MSO)
Corresponding
GHG
Reduction
MWh
tCO2 (10Y)
SIDPEC
2670
14517
MOPCO
2935
15958
Third part, introduced in Table 8.3, shows the identified savings during the MSO program
dedicated to petroleum companies in cooperation with oil and gas sector modernization project
(Group-4B) where the services and support were provided to 20 companies but however only 6
companies presented higher level of commitment that resulted in successful data collection and
reviewing the identified MSO opportunities. The identified savings in this case, only electricity
savings, represented in MWh/year where the corresponding GHG reductions represented in
tCO2eq/10 years.
Table 8.3 Savings Resulted from MSO dedicated to Petroleum Sector Companies
Identified Savings in Companies
Involved in Special MSO Group for
Oil & Gas Sector Companies
Company
Identified
Electricity
Savings (MSO)
Corresponding
GHG
Reduction
MWh
tCO2 (10Y)
ANRPC
450
2447
AMOC
132
718
ASORC
730
3969
ELAB
172
935
GPC
1240
6742
SOPC
3480
18921
In Table 8.4 and Figure 8.1, the total energy savings identified in petroleum sector as a
result of IEE support are illustrated considering that any opportunities which may be repeated in
both EnMS related support and system optimization related support are calculated only once. The
60
identified savings shows electricity savings and fuel gas savings represented in MWh/year where
the corresponding GHG reductions for both are added and represented in tCO2eq/10 years.
Table 8.4 Total Savings Resulted from IEE Support to Petroleum Sector
Total Identified Electricity
Savings
Total Identified Fuel Gas (NG)
Savings
GHG Reduction Corresponding to
Both Electricity and Fuel Gas Savings
MWh
MWh
tCO2 (10Y)
57305
141593
597530
Figure 8.1 Total Energy Savings Resulted from IEE Support to Petroleum Sector
Knowing that the UNIDO IEE project in Egypt has accomplished in the five years (2012-
2017) an amount of total annual energy savings of 1200 GWh per year which corresponding to
reduction in GHG of 3.44 MtCO2eq. in 10 years, comparing these quantities with the achieved
savings in petroleum sector of around 200 GWh per year and 0.6 MtCO2eq. in 10 years, the
petroleum sector share of total savings is around 15% as shown in Figure 8.2.
57305
141593
597530
0
100000
200000
300000
400000
500000
600000
700000
I D EN T I FI E D
E L E CT R IC I TY S A VI N GS
I D EN T I FI E D FU E L G A S
( N G) SA V I NG S
C O RR E S PO N D I NG G H G
R E D U C T I O N
TOTAL SAVINGS IN PETROLEUM SECTOR
MWh / Year MWh / Year
tCO2 eq / 10 Years
61
Figure 8.2 Share of Petroleum Sector in Total GHG Reduction by IEE Project
62
9. Closing Remarks & Recommendations
There are many achievements have been accomplished by IEE project during the provision
of training and support to Egyptian petroleum sector. IEE project had an effective role in enhancing
the sense of energy savings within the sector and in spreading the culture of energy efficiency
improvement. Around 30 petroleum companies were involved in IEE project different
components.
There are nine companies, from petroleum sector, received technical support related to
EnMS from IEE project among which three companies have been ISO 50001 certified which are
SIDPEC in 2014, MOPCO in 2017, and ANRPC in 2018.
Many case studies were developed by IEE project telling success stories in Egyptian
petroleum sector where the companies working in oil and gas industry, either in Egypt or all over
the World, can get benefits from their contents and some success stories were presented in IEE
newsletters that were issued during the project.
The contribution of petroleum sector in the IEE project targets of energy savings and GHG
reduction was quantified as 15% of all the achieved targets.
With regard to capacity building, UNIDO IEE project provided the petroleum sector by 24
qualified energy management system experts and 11 qualified motor system optimization experts
who can be the corner stone for the replication of EnMS and MSO program within the sector.
The peer to peer network established between petrochemical companies within the
petroleum sector was a role model for this kind of useful approach to be applied in similar IEE
projects in the World.
Many recommendations were documented by many means and well communicated to the
petroleum sector companies and to Ministry of Petroleum as well, among which some
recommendations will be listed here as follows.
63
9.1. Recommendations
The P2P project can be replicated, exploiting the qualified 24 EnMS experts, in all the oil &
gas sector companies.
The MSO project can be replicated, exploiting the qualified 11 MSO experts, in all the oil &
gas sector companies.
Provide some training regarding additional tools like those of Lean and Six Sigma can be useful
in energy review preparation when implementing an energy management system.
Provide some training regarding statistical process control (SPC) can be useful in operational
control stage when implementing an energy management system.
Real case studies to be included in the training material especially from international
companies in different industrial sectors and focusing on those in similar industrial sector of
the participant companies. It may be useful to provide a library of case studies.
The successful model of peer-to-peer network encourage the replication of similar model in
different industrial sectors all over the world. Comparing the similar established peer-to-peer
networks can provide many improvement opportunities for such model according to the gained
experience.
The identified opportunities in petroleum sector can be used as a reference for local best
practice.
The collaboration between IEE project and oil and gas sector modernization project reflects
the commitment of UNIDO to support the governmental improvement initiatives.
64
References
[1] IEA, “Energy Technology Perspectives 2010 Scenarios & Strategies to 2050,” ETP
2010, International Energy Agency, OECD/IEA, Paris, 2010.
[2] Olivier, J., Janssens-Maenhout, G., Muntean, M., Peters, J., “Trends in global CO2
emissions: 2015 Report,” PBL publication number: 1803, PBL Netherlands
Environmental Assessment Agency, The Hague, Netherlands, 2015.
[3] 2006 IPCC Guidelines for National Greenhouse Gas Inventories, chapter 2, Table 2.2
[4] Neelis, M., Worrell, E., Masanet, E., “Energy Efficiency Improvement and Cost Saving
Opportunities for the Petrochemical Industry, An ENERGY STAR® Guide for Energy
and Plant Managers,” Environmental Energy Technologies Division, June 2008
