Classification: Internal Use

ISO 50001 Energy Management System – Case Study

2022 Saudi Arabia

Saudi Arabia

YANSAB
35% energy saving achievement for SABIC strategy and
2MMBTU saving equal 2.2 M $ for SEEC.

Case Study Snapshot

Industry YANSAB
Product/Service Petrochemical plant
Location YANBU
Energy performance improvement percentage (2010-2021) 35% improvement over 2010 years
Total energy cost savings (2010-2021) USD 23,264,482 /year
Cost to implement Energy Management System (EnMS) USD 48,500 /cycle
Total energy savings (2010-2021) 19,653,206 GJ /year

Total CO2-e emission reduction (2010-2021) 1,123,040 Ton/year

Organization Profile / Business Case

Yanbu National Petrochemical Company (YANSAB) is a Saudi Joint Stock Company commenced its Commercial
operations on 1 March 2010. The objectives of YANSAB are to engage in manufacturing of petrochemical products
(Ethylene, Ethylene Glycol, High Density Polyethylene, Low Linear Density Polyethylene, Polypropylene, Butene1,
MTBE and BTX) with 4 million ton production rate in accordance with its Articles of Association, and other applicable
regulations in the Kingdom

YANSAB Established an Energy Management System (EnMS) that complies with the requirements of the
International Standard ISO-50001-2011 and ISO-50001-2018. EnMS shall support the systematic approach to
continual improvement of Energy performance and energy cost index to meet YANSAB long term Energy and
Sustainability Strategy as well as meeting regional regulatory requirement of energy efficiency improvement.

Energy Management improvement is focused on the Energy Intensity (EI) for YANSAB plants and efficiency, energy
consumption and the operational optimization for the manufacturing plants, physical assets, utilities and buildings.

EnMS shall enable YANSAB to achieve SABIC 2025 strategic objective of a 25% Energy Intensity reduction from the
2010 base line, and to achieve their best possible energy quartile performance as per Saudi Energy Efficiency
Program (SEEP) Strategy.

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ISO 50001 Energy Management System – Case Study

2022 Saudi Arabia

“Energy Continual Improvement is one of YANSAB major goals.”

—Hattan Ghandorah, E&S manger

Business Benefits
ISO-50001 enhanced the management workflow to assure energy continual improvement is one of YANSAB policies,
goals, and strategies. Certified EnMS cost of implementation including the estimated staff time = 16500+32000 =
48,500 U$
• In 2019 YANSAB achieved 1st cycle SEEC program by reducing the plant energy consumption and maintained the
plants Energy Intensity (EI) as per global benchmark and get a credit of 2 MMBTU saving that equal to 2.2 M $.
• In 2021, YANSAB energy nonprofit project has been accepted and certified by UN. The project was successful and
resulted in achieving a saving of 126 GWhr and 35,827 CO2 emission.
• Up to date, YANSAB has achieved an Improvement of 35% on its Energy Intensity and a reduction of 23% of GHG
intensity (CO2 emission) from its 2010 base line. Please refer to table 1.

Plan
In 2010, SABIC started the Sustainability program to achieve a reduction of 25% of its Energy Consumption, intensity,
GHG intensity “CO2 emission”, water consumption intensity, and 50% of material effectiveness intensity in 2025.
In 2011, Saudi Energy Efficiency Center program (SEEC) officially requested YANSAB to improve plant energy
performance by maintaining the plant Energy Intensity on 2ndquartile as per global benchmark in 2019 for the 1st
Cycle. 2nd Cycle (2020-2025) with revised the global benchmark target. (Fig 2)
Energy & Sustainability (E&S) management system become one of YANSAB value drivers and strategy to obtain the
financial commitment and resources to achieve YANSAB goals:
• SEEC target (regulation requirement)
• SABIC sustainability target (SABIC business Strategy)
• YANSAB energy continual improvement
YANSAB executive management demonstrated their commitment by initiating new department “Energy &
Sustainability (E&S) department, and involved in development management system focusing on issuance of policy,
business objective, supervision of activities include documentation, training, and the publicity of system to
stakeholders. In addition, approval of the main documents and the policy and participated in management review
meetings. Furthermore, arrangement of required sources such as subject matter experts and financial requirement.
In 2016, YANSAB sustainability team has developed and documented an Energy Management System (EnMS). EnMS
covers and defines YANSAB energy boundary limit, energy natural sources fig-1 (Fuel “sales gas” from Aramco and
power from MARAFEQ), and energy user (Utility, olefin, Ethylene glycol, Butene-1, Benzen, high-density
polyethylene, low-density polyethylene, polypropylene) plants. The EnMS also covers and defines energy significant
equipment like boilers, furnaces, motors, turbines, Extruders and etc. It also covers energy consumption quantity for
each plant, building and equipment. The EnMS defines energy goals and intensity target calculation for the site/
plants, energy indicators for each equipment, energy streams, and key energy variables based on best history and the
design data.
YANSAB EnMS team defined the base line based on following criteria:

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ISO 50001 Energy Management System – Case Study

2022 Saudi Arabia
𝑡𝑜𝑡𝑎𝑙 𝑒𝑛𝑒𝑟𝑔𝑦 𝑐𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛 𝐺𝐽
𝐸𝐼 =
𝑇𝑜𝑡𝑎𝑙 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑟𝑎𝑡𝑒 𝑡𝑜𝑛
1- YANSAB over all Energy intensity ( ) in 2010 to be reduced 25% in 2025 to
achieve SABIC sustainability target. Please refer to table 1
2- YANSAB individual plant EI for (Olefin, Ethylene glycol, Butene-1, Benzen, High Density Poly Ethylene, Low
Density Polyethylene, Polypropylene) with this equation
𝑃𝑙𝑎𝑛𝑡 𝑛𝑒𝑡 𝑒𝑛𝑒𝑟𝑔𝑦 𝑐𝑜𝑛𝑠𝑢𝑚𝑝𝑡𝑖𝑜𝑛 𝑀𝑀𝐵𝑇𝑈
𝑃𝑙𝑎𝑛𝑡 𝐸𝐼 =
𝑃𝑙𝑎𝑛𝑡 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑟𝑎𝑡𝑒 𝑡𝑜𝑛
( ) in 2011 to achieve 2ndQuartile benchmark as per SEEC
target. Please refer to table 2.
YANSAB EnMS team started working in three parallel workflow to achieve the above target.
1- First workflow is to initiate project pipelines workflow that includes specific system and tools like Energy
Assessment tool to generate/ prioritize the ideas/projects and YANSAB Forecast tool to estimate the energy
saving from each idea/project. Table Please refer to Table 5.
2- Second workflow is to develop and build real time E&S monitors that includes all energy resources,
significant equipment, assets, and buildings on all Distributed Control System (DCS), PI vision system, and
YOKOGAWA Exquantum program at YANSAB plants. Full team from process, operation, maintenance,
financial, environment, and business planning departments for each plant are assigned to monitor and
analyze the Energy and Sustainability (E&S) performance in daily, weekly, and monthly basis as per defined
roles and responsibilities in EnMs procedure. If there is any gaps or deviation from the target due to plant
reliability, YANSAB E&S team will justify the incident to create the efficient road map to recover the losses
and maintain the E&S performance. Please refer to table 3 and fig 3.
3- Third work flow ,YANSAB management is reviewing E&S KPIs, project update, and goals in monthly basis to
assure the plant energy performance on high efficient. Please refer to fig 4.
In 2017, with support from Total Quality Management (TQM) department team, YANSAB made contract with BSI
company to Certify the EnMS procedure based on ISO 50001-2011.
In 2018 after reviewing and maintaining all ISO 50001-2011 requirement, YANSAB had been successfully certified.
In 2021, YANSAB has transitioned the EnMS to meet the requirements of ISO 50001-2018 after adding the energy
performance target under business risk management and is successfully certified.
Annual energy audit and annual energy management review are planned with BSI to assure the EnMS procedure is
working well.

Fig-1

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ISO 50001 Energy Management System – Case Study

2022 Saudi Arabia

Base line EI 2010 EI Target 2025

Plant YANSAB performance 2020 Business impact cost
GJ/Ton %
35%
25%
YANSAB 14.83 9.65 GJ/ton 23,264,482 /year
11.13 GJ/ton
19.65 MGJ/year
Table 1
1st Cycle Period (2011-2019) 2ndCycle Period (2020-2025)

Fig 2

Energy
Base line EI EI Target Improvement YANSAB
Consumption Business
Plant 2011 2019 required SAVING
2011 impact cost
MMBTU/Ton MMBTU/Ton (%) MMBTU
(KBDOE)
Olefin 10.36 13.97 19.2 0 0
EOEG 5.8 18.75 17.45 6.93% 2,207,765
PP 2.75 3.06 2.54 509,458
HDPE 0.87 5.3 5.16 2.67% 0
LLDPE 0.57 2.8 3.72 0% 396,746
YANSAB 2,748,907
18.17 2.3% 2.25 M $
Overall 1.298 KBDOE
Table 2

“Continual Energy Management review to meet ISO 50001 requirement is very helpful to have
high efficient energy management procedure”
— Ahmed A-Shaikh, Staff Energy and Sustainability Engineer

Do, Check, and Act

EnMS for continual improvement and achieve YANSAB Energy & Sustainability (E&S) goals & strategy is integrated in
YANSAB policy. It is also communicated to all YANSAB employees with high commitment from YANSAB Executive
management. Process engineering Sr. Manager is assigned to lead (E&S) department that functioned to implement
EnMS. New E&S manger with two full time E&S engineers are appointed in E&S department. New E&S team
implemented EnMS as per role and responsibility that defined on EnMS procedure.
Energy and sustainability campaign was done to announce and introduced the EnMS goals, strategy and commitment
to all YANSAB employee. High engagement from YAMSAB management to inspire YANSAB Employees to improve the
YANSAB energy performance and enhance the energy and sustainability behavior.

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Classification: Internal Use

ISO 50001 Energy Management System – Case Study

2022 Saudi Arabia
Achieving 1st cycle SEEC target was very challenge because of the deficit was very high for EG plant and HDPE plant.
YANSAB management was very attention to have road map including the project required and optimization ideas to
achieve 2019 target. YNSAB has achieved the target successfully with gain 2.75 MM MMBTU = 2.25 U$MM. (Table 2)
YANSAB E&S team is publishing and sharing the E&S targets annually after YANSAB management approval to all
YANSAB employees. The road map that needs to achieve the targets is also to be shared with all YANSAB employees.

Referring to EnMS procedure, energy source (sales gas from ARAMCO, internal Fuel from crackers, and power from
MARAFEQ) consumption for YANSAB site and individual has been identified fig1. The E&S dashboard (fig 3) had been
developed to monitor on real time energy resources, energy significant equipment indicators, energy streams, and
key energy variables based on best historical and the design data. Table 3 lists some Energy Significant Equipment
with energy indicators for each equipment.

Equipment No of Energy consum Tot Energy Energy Key Energy driver

Asset GJ/day GJ/day source
1 Boiler 5 11664 /boiler 58320 Sales gas Steam load, Fuel flow, stack
temp, excess air , boiler
efficiency
2 C.W Pump 6 322.4 / pump 1934.4 Power Pump running status, C.W flow

3 S.W Pump 5 395.9 / pump 1979.5 Power Pump running status, S.W flow

4 BFW Pump 2 344.2 / pump 688.4 Sales gas Pump running status, BFW flow
(Steam)
5 BFW Pump 2 371.5 / pump 743 Power Pump running status, BFW flow

6 Air 2 168.9 / comp 337.8 Sales gas Compressor running status, Air
Compressor (Steam) flow, Air Dew Point
7 Furnace 8 10551/furnace 84408 Off gas TLE outlet temp, stack temp,
cracker excess air
8 K-1301 1 5422.8 5423 Off Gas Compressor control system
(80/54) (steam) mode (CCS)
9 E-2523 1 2385 2385 Sales Gas Steam flow
(Steam))
10 Extruder MX- 2 1150 1633 Sales gas Steam flow
4801 483 Steam
Table 3 (Some YANSAB Energy significant Equipment)
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ISO 50001 Energy Management System – Case Study

2022 Saudi Arabia
Based on plant history data the energy relevant variable effected on energy consumption as per follow:
1- Plant reliability. For example Un-plan Shutdown, plant off spec, plant’s energy significant equipment trip will
effect badly on energy consumption and performance. Like olefin CGC equipment.
2- Plant load “low plant production rate” due to Feed curtailment from supplier, product quality, and marketing
issue.
3- High outside temperature on summer session. High outside temperature lead to increase running of cooling
water and seawater pumps to maintain the coiling water temperature in the plant heat exchangers. Increase
the Fin fans on cooling water towers to reduce the seawater temperature.
YANSAB E&S team is monitoring, analyzing, and prioritizing the actions required to maintain the energy and
sustainability (GHG, energy, water consumption, material waste) intensity performance in daily basis.

Fig 3
In case of any irregularity, gap or deviations from targets identified through the DCS/ PI energy dashboard (Fig 2) due
to plant reliability, operation focal point engineer will report in the process gap report (PGR) including the root cause
(if known), justification, correction with target date, energy value impact. YANSAB E&S team (operation, process,
E&S, and concerned department engineers) will review the incident and agree for efficient road map to bridge the
gap losses and maintain the E&S performance. Table 4

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ISO 50001 Energy Management System – Case Study

2022 Saudi Arabia
An example for the handling of such deviations, a medium pressure steam vent was reported 5-8 t/hr was venting
due to valve passing. Operation Focal Point and Maintenance Engineer took the corrective action in (PGR) to
normalized plant energy performance on target date. Process Engineer calculated the energy losses. E&S team
generated the road map to recover the energy losses by saving some quantity of MPS in the process.
Operation action in (PGR) Energy saving GJ Energy coast saving
(1 MMBTU = 1.25$)
1 Reduce the excess air to 2% in all utility 63,700 GJ/year 75,404 $ /year
boilers 3504 ton CO2 emission
2 Increase steam turbine extraction in steam 129,300 GJ 153,058 $
turbine generator
3 Close HP to MP L/D station valve in olefin 128,000 GJ 151,520 $
header by increase gas compressor turbine
extraction in EG
Table 4
YANSAB E&S team conducts an annual energy assessment for each plant to generate improvement ideas/projects.
The project list is prioritized in the project forecast tools with estimate the energy saving.
YANSAB Project Energy saving GJ Energy coast saving
1 MMBTU = 1.25$)
1 Olefin 80/54 200,000 GJ 236,750 $/year
2 EG DPN 350,000 GJ 414,312 $/year
3 Install new economizer in utility 72833 GJ/year 86,216 $/year
boilers 3800 ton CO2 emission /year
4 Install a New Cycle Water 116,156 GJ 137,500 $/year
Exchanger (PACKINOX)
Table 5
YANSAB EnMS tools
YANSAB EnMS tools Objective type sources
1 E&S Dashboard Monitors all Energy Significant DCS, PI System All data read on real
Equipment, Energy indictors, and KEV time from Tags.
2 Sustainability footprint Data base to record all data of E&S Excel sheet All data recorded
inventory streams, users, consumption, chemical monthly from Tags.
composition to estimate (EI) for
YANSAB site and each plant and
3 KPI forecast tools Database to list all projects/ideas to Excel sheet All data recorded
estimate the benefit energy saving, monthly
energy cost, project tracking, project
priority.
4 Energy & sustainability Database to estimate all YANSAB Excel sheet All data recorded
assessment tools energy project benefit and energy cost monthly
either positive or negative impact.
5 KPI monitors Data base to estimate the site/plant Excel sheet All data recorded
performance tools performance monthly
6 Process gap report It is for recording the deviation in Excel sheet All data recorded
energy for each plant that is obtained daily
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ISO 50001 Energy Management System – Case Study

2022 Saudi Arabia
from the E&S dashboard or plant site
visit
YANSAB executive Management is involving on EnMS implementation, review and continual improvement. They also
conduct a monthly review of the E&S KPIs, project update, and goals to assure the plant energy performance on high
efficient (fig-4)

Fig-4
Competency
A competence Energy team at YANSAB should complete the following:
1- SABIC energy certificate program. YANSAB has up to date 15 Energy Expert Engineers Certified.
2- Certified Energy manger owned by SEEC.
3- Energy and Sustainability awareness

Transparency
YANSAB has announced to public, YANSAB board, Capital Market Authority (CMA), and SABIC to have an EnMS
complied with ISO-5001-2011 in 2017 and - ISO-5001-2018 in 2021.
EnMS Policy has been integrated with YANSAB policy and communicated to all stakeholders. EnMS experience can
also be shared as needed with other SABIC Affiliates, Regulatory Authorities and Partners.

What We Can Do Differently

YANSAB EnMS need to have an installation of energy software for close loop monitoring with high efficient
recommendation.
Best practice to be shared with similar petrochemical plant.
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