___________________________________________________________________________

2015/SCSC/WKSP2/004
Session: 2

Group Exercise 2: Case Study on Application to

Energy System
Submitted by: Thailand

Multilateral Recognition Arrangement Readiness in

ISO 50001: Workshop for Organization and Internal
Auditors
Bangkok, Thailand
6-9 April 2015
 Workshop Revision 2015.04
Course EnMS Implementation and Internal Audit

Niphon Manufacturing (Thailand) Co., Ltd. is an automotive part producer situated in the
Eastern Seaboard Industrial Estate, Rayong Province, Thailand. The factory manufactures 2 groups
of products: small plastic parts (Product Group A) and plastic parts for interior decoration (Product
Group B). The manufacturing processes for the two products are different, resulting in different levels
of energy consumption. Both processes are housed in air-conditioned buildings. The utilities
department is located outside and is responsible for producing compressed air, steam, and chilled
water for the production processes. The area within the factory, types of energy, and energy uses are
as follow:

Table 1 Details of Areas, Types of Energy, and Energy Uses

Area Type of Energy Energy Uses

Building A Electricity Plug Load, Lighting, Motors in production machines,

Fans/Blowers, Conveyor Belts, Pump, Heaters for plastic
injection machines

Building B Electricity Plug Load, Lighting, Motors in production machines,

Fans/Blowers, Conveyor Belts, Pump, Heaters for plastic
injection machines

Utility Electricity, NG, Plug Load, Lighting, Air Conditioning (split type), Motors in
LPG, Diesel water preparation and water treatment systems,
Fans/Blowers, Pump, Standby Generator, Air Compressor,
Chiller, Cooling Tower, Boiler

Maintenance Shop Electricity, LPG Plug Load, Lighting, Motors in production machines, Forklift

Warehouse Electricity, LPG Plug Load, Lighting, Air Conditioning (split type), Forklift

Office/Canteen Electricity, LPG Plug Load, Lighting, Kitchen Equipment

Others Diesel, Gasohol Company Cars/Trucks

Table 2 Details for Compressed Air Consumption

Area Utility Uses Area Utility Uses

Building A Control system Utility Control system

Building B Control system Maintenance Shop Open Hand-Held Blowguns or Lances

Table 3 Details for Steam Consumption

Area Utility Uses

Building A Hot water generation for part cleaning (Plate Heat Exchanger)

Building B Hot water generation for part cleaning (Plate Heat Exchanger)

Table 4 Details for Chilled Water Consumption

Area Utility Uses

Building A Temperature control for production machines. AHU system

Building B Temperature control for production machines. AHU system

Office/Canteen AHU System

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Table 5 Details for Cooling Water Uses

Area Utility Uses

Utility Water cooled chillers

1. In 2013, the factory imports 5 types of energy, i.e., electricity, natural gas (NG), liquefied
petroleum gas (LPG), diesel oil, and gasohol, with the following monthly consumption data:

Consumption
Month Electricity ก๊าซธรรมชาติ LPG น้ามันดีเซล Gasohol
(kWh) (MMBtu) (kg) (Litre) (Litre)
January 5,462,859 9,942.31 3,332.58 4,998.88 2,499.44
February 5,475,200 10,340.68 3,421.44 5,132.16 2,566.08
March 5,505,662 10,707.51 3,640.77 5,461.15 2,730.57
April 5,449,910 10,537.07 3,239.35 4,859.03 2,429.51
May 5,583,003 10,576.76 4,197.62 6,296.43 3,148.22
June 5,574,774 11,703.69 4,138.37 6,207.56 3,103.78
July 5,539,634 10,080.14 3,885.36 5,828.05 2,914.02
August 5,483,789 9,551.44 3,483.28 5,224.92 2,612.46
September 5,569,938 10,046.34 4,103.55 6,155.33 3,077.67
October 5,479,286 8,971.52 3,450.86 5,176.29 2,588.14
November 5,428,655 9,151.39 3,086.32 4,629.47 2,314.74
December 5,423,029 9,039.27 3,045.81 4,568.71 2,284.36

 Calculate the percentage of consumption for each type of energy, on annual basis.
 Decide which type(s) of energy, if any, you think the consumption level is too low, and
can be considered as “insignificant.”

2. The major equipment list for the factory is shown below with power and operating hours data.

Name Code Area owner kW or MJ/hr Hrs/yr

Electricity
Water pump UT-P101 Utility 55 8,400
Water pump UT-P102 Utility 55 8,400
Water pump UT-P103 Utility 55 8,400
Water pump UT-P104 Utility 55 8,400
Water pump UT-P105 Utility 55 8,400
Air compressor UT-AK-101 Utility 65 8,400
Air compressor UT-AK-102 Utility 65 8,400
Air compressor UT-AK-103 Utility 65 8,400
Air compressor UT-AK-104 Utility 65 8,400
Air compressor UT-AK-105 Utility 65 8,400
Chiller UT-CH-101 Utility 100 8,400
Chiller UT-CH-102 Utility 100 8,400
Chiller UT-CH-103 Utility 100 8,400
Cooling tower UT-CT-101 Utility 30 8,400
Cooling tower UT-CT-101 Utility 30 8,400
Cooling tower UT-CT-101 Utility 30 8,400
Heater A-HT-101 Building A 150 8,400
Heater A-HT-102 Building A 150 8,400

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 Workshop Revision 2015.04
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Heater A-HT-103 Building A 150 8,400

Heater A-HT-104 Building A 150 8,400
Heater A-HT-105 Building A 150 8,400
Heater B-HT-101 Building A 150 8,400
Heater B-HT-101 Building A 150 8,400
Heater B-HT-101 Building A 150 8,400
Heater B-HT-101 Building A 150 8,400
Heater B-HT-101 Building A 150 8,400
Thermal
Boiler UT-B-101 Utility 38,000 4,200
 Identify which equipment(s) should be considered “SEUs.”
3. Production information (in tons/month) for 2014 is as follow:

Month Group A Group B Month Group A Group B

January 131.94 167.39 July 141.39 149.05

February 132.99 145.53 August 135.91 151.48

March 139.68 161.04 September 146.08 157.63

April 137.60 145.36 October 144.86 141.45

May 134.35 164.31 November 141.76 139.14

June 148.73 160.65 December 144.48 142.54

 Generate three (3) baseline equations between total production (tons/month) and total energy
consumption (MJ/month), electricity consumption (kWh/month) and thermal energy
consumption (MJ/month)
 Identify possible drivers for the energy consumption for this factory
 Calculate p-Value for each drivers
 Decide which driver(s) should be part of the baseline equation
 Generate multi-parameter baseline equation between total energy consumption (MJ/month)
and drivers identified above.
4. Base on production and energy consumption information for the first 6 month of 2014,
calculate energy saved/overconsumed.

Group A Group B Electricity NG

Month
(Tons) (Tons) (kWh) (MMBtu)

January 144.83 150.91 5,492,547.00 9,242.08

February 144.88 166.65 5,501,088.00 10,390.51

March 153.41 169.13 5,595,224.00 11,219.81

April 132.48 152.53 5,415,174.00 10,399.55

May 133.55 161.08 5,509,329.00 10,890.81

June 139.69 148.97 5,498,632.00 10,098.72

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