INDUSTRIAL SUSTAINABILITY GUIDELINE

INDUSTRIAL SUSTAINABILITY GUIDELINE

Version 1.0

September 2020

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Industrial Sustainability Guideline for Emirate of Abu Dhabi

Tel +971 28158888

Fax +971 28158000

P.O. Box 12, Abu Dhabi

www.ded.abudhabi.ae

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This guideline is part of IDB’s comprehensive program for Industrial sustainability performance in Abu Dhabi Emirate. A multidisciplinary team was involved in developing Industrial sustainability guideline, which could have not been produced without commitment, data and review from experts of many different sectors.

IDB would like to thank all the individuals and organisations for their contribution in developing Industrial sustainability guideline.

Abu Dhabi Department of Economic Development (ADDED)ChairmanH.E. Mohammed Ali Al Shorafa Al Hammadi

Undersecretary H.E. Rashed Abdulkarim Al Blooshi

Director General H.E. Mohamed Munif M. AL Mansoori

Industrial Development Bureau (IDB) Project Management TeamDivision Director Project Director- Nabeel S. Al Awlaqi

Section HeadProject Leadear- Onoud Saleh A. Al Marzooqi

Chief Engineer

Project Manager- Khawaja M. Hassan

IDB Admin and Technical Support TeamAswan A. Saif

Shamsa Khamis M. Al Mansoori

Shabu K. Backer

Venkataramana Ayyagari

Jean Daoud

Abdulla Al Harthi

ACKNOWLEDGEMENTS

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Ibrahim Al Hammadi

Hazaa Al Raeesi

Peter J. Hurley

Mutasim Kabashi

Government, Semi-government and Private EntitiesIndustrial Entities operating in Abu Dhabi

Department of Municipalities and Transport (DMT)

Environment Agency – Abu Dhabi (EAD)

Department of Energy (DoE)

Abu Dhabi Distribution Company (ADDC)

Abu Dhabi Waste Management Center – Tadweer

Abu Dhabi Public Health Center (ADPHC)

Consultant Team – GE3SExecutive Director

Satyapal Singh

Technical Manager

Chilamburaj Anbarasu

Technical Support TeamMartin R Feustel

David Buckwell

Vishal Kumar

Mayank Kumar

Abhijeet Chaudhary

Core Technical TeamIDB would like to appreciate and thank the contributions of many individuals who undertook reviews of the various drafts of the Industrial Sustainability documents.

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Abu Dhabi’s economy has made great strides in the past years. The industrial manufacturing sector posted continual growth and will become the key driving force to diversify Abu Dhabi’s economy in the coming years.

Abu Dhabi’s manufacturing industries are producing a wide range of products to cater to the local, regional, and international consumers. While manufacturing different products, industry incurs a significant cost on the usage of energy, water and waste management and therefore; presents an opportunity for cost optimization.

Last decade has seen a gradual shift towards energy and water efficient technology along with reduced waste generation from the manufacturing process; however, studies have indicated that there is a still significant scope for improvement in energy and water efficiency. 4R (Reduce, Reuse, Recycle, Recovery) approach of waste management has been effective in reducing the waste disposal to landfill; however, we are still far from achieve zero waste disposal to landfill.

During the manufacturing process, there are also concerns related to air quality and noise levels. There has been significant development

in technologies to attenuate the noise levels and reduce the air pollution, which must be systematically integrated into the manufacturing sector.

ADDED-IDB is committed to “Making Abu Dhabi region a Hub of World Class Sustainable Manufacturing Industries”. As a part of this initiative, a comprehensive study was undertaken by ADDED-IDB at the local, regional and international level to identify the best practices related to efficient use of resources and waste minimization. These have been shaped into a guideline for widespread dissemination among the stakeholders.

I take this opportunity to thank the industrial fraternity for their contribution in developing these Industrial Sustainability Guidelines. I am hopeful that these Guidelines will act as a catalyst in greening and decarbonising the Emirate’s economy.

H.E. Mohammed Ali Al Shorafa Al HammadiChairman, Abu Dhabi Department of Economic Development

FOREWORD

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Climate-related risks dominated the top-five long-term risks in the World Economic Forum’s latest Global Risk Report. We must act to reduce GHG emissions and mitigate climate change. The low carbon transformation of Abu Dhabi’s industrial sector can be achieved by embracing energy & water efficiency along with reduction in waste as these are the primary sources of industrial GHG emission in the UAE.

There is a need for commitment and strong support from Abu Dhabi’s industries to integrate low carbon technologies that reduce not only GHG emissions but also operational costs. This will support the efforts to augment further the vibrant and innovative industrial sector that Abu Dhabi Economic Vision 2030 envisaged.

The Industrial Development Bureau (IDB) of Abu Dhabi Department of Economic Development (ADDED) is committed to promote inclusive and sustainable industrial development in Abu Dhabi.

As part of our holistic approach, IDB consolidates best practices and develops the necessary guidance and tools to support manufacturing industries on issues related to industrial sustainability. We developed the “Benchmarking and Sustainability Guidelines for Industrial

Sector,” a comprehensive reference framework to leaven the development of competitive, inclusive, and sustainable industries.

Adoption and implementation of industrial sustainability guidelines shall have multi-fold benefits for the industries through utility cost savings, electricity tariff incentive program and other government initiatives to help Abu Dhabi industries to become efficient, and competitive at a global scale.

Through the sustainability initiatives, we are confident of giving stimulus to a virtuous industrial improvement that will lead to higher productivity, low operational cost, competitive product manufacturing, and attract investment in Abu Dhabi’s manufacturing sector.

H.E. Rashed Abdulkarim Al BlooshiUndersecretary, Abu Dhabi Department of Economic Development

FOREWORD

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It is indeed unique in UAE and Arab region, for a Government to commission a strategic look at the future of sustainable manufacturing as far ahead as 2050.

Abu Dhabi is leading sustainable practices in the region, which are evident through promotion of low carbon technologies, implementing mandatory sustainability program for built environment and developing new competitive business landscape . With the advancement of sustainability practices, Abu Dhabi is well placed to gain the benefit of the growing global market for sustainable products and innovations. Manufacturing industry shall focus on productivity gains through efficient resource utilization while protecting the environment.

I present this report to industry stakeholders to get benefits of untapped potential in resource efficiency. Over the last decade, built infrastructure sustainability was key agenda of the world sustainability forums and Industrial sustainability has not received the ample attention that it deserves, which can enhance profitability through improvement in resource efficiency. While adopting the best practices, the consequent reductions in operational expenditure, savings from energy, water, waste

and GHG emissions reduction are massive.

In its first phase, the project focus on highly productive factories that consume large amounts of energy and water; and environmental impact they make in terms of carbon and other gaseous emissions. This will help in IDB’s implementation of the strategy it has developed to support factories in the emirate in their move to achieve sustainability.

The UAE Vision 2021 and Abu Dhabi Economic Vision 2030 both stipulate that GHGs emission should be reduced from its current levels to reach 50%, and our collective contributions will go a long way in realizing this improvement. Benchmarking and development of Industrial Sustainability Guideline bolsters our commitment to preserving our environment and create a competitive economy for generations to come.

I encourage the industrial manufacturing fraternity to adopt this ISG and other sustainability practices, which would create a cleaner environment as well as increase the profit and directly impact the bottom line of businesses.

H.E. Mohamed Munif M. AL MansooriDirector General, Abu Dhabi Department of Economic Development

FOREWORD

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ACRONYMS ........................................................................................................ 17

UNITS ...............................................................................................................21

GLOSSARY .......................................................................................................... 22

1. INTRODUCTION ............................................................................................. 27

1.1 PURPOSE .................................................................................................................................... 27

1.2 BACKGROUND ............................................................................................................................. 27

1.3 ISG GUIDELINES AND THEIR APPLICABILITY ............................................................................. 29

1.4 BENEFITS OF ISG......................................................................................................................... 30

2. POLICY FRAMEWORK & CURRENT PRACTICES ............................................. 35

2.1 FEDERAL & LOCAL ENVIRONMENTAL STANDARDS ................................................................... 35

2.2 FEDERAL & LOCAL ENVIRONMENTAL STANDARDS .................................................................... 37

2.3EXISTING SUSTAINABILITY FRAMEWORKS/ PROGRAMS AND RELATIONSHIP TO THE ISG ...... 38

3. INDUSTRIAL SUSTAINABILITY GUIDELINES .................................................. 47

3.1 SUSTAINABILITY KPIs FOR THE INDUSTRIAL SECTOR ..................................................47

3.2 KEY TEAM MEMBERS ......................................................................................................48

3.3 ISG IMPLEMENTATION PROCESS ...................................................................................49

3.3.1 STEP 1: ESTABLISHING THE ISG TEAM ...............................................................................................51

3.3.2 STEP 2: BASELINE DATA COLLECTION ...............................................................................................51

3.3.3 STEP 3: GAP ANALYSIS ........................................................................................................................51

3.3.4 STEP 4: ESTABLISHING BASELINE KPI’S ............................................................................................52

3.3.5 STEP 5: IDENTIFY SUSTAINABILITY OPPORTUNITIES .......................................................................55

3.3.6 STEP 6: INDUSTRIAL SUSTAINABILITY EXPERT ..................................................................................57

3.3.7 STEP 7: ENGAGE WITH IDB SUSTAINABILITY PROGRAM MANAGER ..................................................57

CONTENTS

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3.3.8 STEP 8: IMPLEMENT SUSTAINABILITY MEASURES ...........................................................................58

3.3.9 STEP 9: PERFORMANCE MONITORING AND REPORTING ..................................................................58

3.3.10 STEP 10: ANALYSE, REVIEW RESULTS & CONTINUAL IMPROVEMENT .............................................58

3.4 THE ISG MEASURES ........................................................................................................59

3.4.1 UNDERSTANDING THE ISG MEASURES ..............................................................................................60

3.4.2 GENERAL REQUIREMENTS .................................................................................................................61

3.4.3 ENERGY ...............................................................................................................................................67

3.3.4 WATER ...............................................................................................................................................105

3.3.5 BY-PRODUCT AND WASTE MANAGEMENT .......................................................................................113

3.4.6 INDOOR ENVIRONMENT QUALITY ....................................................................................................118

4. CASE STUDY ILLUSTRATION ........................................................................ 129

Appendix-A: Regulatory Air Quality and Noise Level standards ......................................137

Appendix-B: Gap Analysis Checklists ................................................................................142

Appendix-C: IT Dashboard .................................................................................................147

Appendix-D: Due Diligence Tool .......................................................................................149

Appendix-E: ISG Standards & Guideline Values ................................................................150

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ACRONYMSAADC Ai Ain Distribution CompanyAAQ Ambient Air QualityADDC Abu Dhabi Distribution CompanyADDED Abu Dhabi Department of Economic DevelopmentADM Abu Dhabi City MunicipalityADNOC Abu Dhabi National Oil CompanyADSSC Abu Dhabi Sewerage Service CompanyADWEA Abu Dhabi Water & Electricity AuthorityAED Arab Emirate DirhamAEE Association of Energy EngineersASME American Society of Mechanical EngineersCEA/EEP Certified Energy Auditor/ Energy Efficiency ProfessionalCO Carbon MonoxideCO2 Carbon DioxideCOP Coefficient of PerformanceCOPC Contaminant of Potential ConcernCFL Compact Fluorescent LampDMT Department of Municipalities and TransportDPFC Distribute Power Flow ControlledEAD Environmental Agency-Abu DhabiEER Energy Efficiency RatioEMP Environmental Management PlanEMS Environmental Management SystemEnMS Energy Management SystemERV Energy Recovery VentilationES Energy SpecialistESP Environmental Service ProviderEVO Efficiency Valuation OrganizationGCFA Gross Conditioned Floor AreaGDP Gross Domestic ProductGE3S Global Energy and Environmental Engineering Services LimitedGHG Green House GasesGIS Geographic Information Systems

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GSEC General Secretariat of Executive CouncilHSE Health, Safety & EnvironmentHVAC Heating Ventilation and Air ConditioningIAQ Indoor Air QualityICAD Industrial City of Abu DhabiIDA Integrated Development ApproachIDB Industrial Development BureauIEC International Electromechanical CommissionIEEE Institute of Electrical and Electronics EngineersIPLV Integrated Part Load ValueIPMVP The International Performance Measurement and Verification ProtocolISG Industrial Sustainability GuidelineISO International Standards OrganizationKIZAD Khalifa Industrial Zone of Abu DhabiKPI Key Performance IndicatorLCC Life Cycle CostingLED Light Emitting DiodeLEED Leadership in Energy and Environmental DesignLLC Limited Liability CorporationLPD Light Power DensityMBR Membrane BioreactorM&V Measurement and VerificationMSDS Material Safety Data SheetMWh Megawatt Hour ND Not DetectedNO2 Nitrogen dioxideNOC No Objection CertificateO3 OzoneODC Ozone Depleting ChemicalsODP Ozone Depleting PotentialOSHAD Abu Dhabi Occupational Safety and Health Center Pb LeadPBRS Pearl Building Rating System

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PM Particulate MatterPPE Personnel Protective EquipmentPRS Pearl Rating SystemPV Photo VoltaicPVC Poly Vinyl ChlorideRO Reverse OsmosisSCAD Statistic Centre of Abu DhabiSCADA Supervisory Control and Data AcquisitionSCFM Standard cubic feet per minuteSHGC Solar Heat Gain CoefficientSLD Single Line DiagramSO2 Sulphur dioxideSOP Standard Operating ProcedureSTEL Short Term Exposure LevelTADWEER Abu Dhabi Waste Management CenterTBT Toolbox TalkTLV Threshold Limit ValueTSP Total Suspended ParticlesTVOC Total Volatile Organic CompoundTWA Time Weight AverageUAE United Arab EmiratesUSA United States of AmericaUS EPA United States Environmental Protection AgencyVFD Variable Frequency DriveVOC Volatile Organic CompoundsWHO World Health OrganizationWWTP Wastewater Treatment PlantZLD Zero Liquid Discharge

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Ach Air changes per hourBTU British thermal unitºC ºCelsiusdB DecibelHz HertzGJ Giga JouleJ JouleK Kelvinkg Kilogramkm KilometerkW KilowattkWh Kilowatt hourkWh/ton Kilowatt hours per tonlt Litrelit/ton Litre per tonm MeterM2 Square meterM3 Cubic meterMBTU MBtuMMSFC Million Standard Cubic FeetPa Pascalppm Parts per millionsec SecondTon TonnesTR Total Returnμg Microgramμg/m3 Microgram per cubic meterμm MicrometerW WattW/m2K Watts per square metreYr Year

UNITS

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GLOSSARYAirtightness The resistance of the building envelope to inward or outward air leakage.American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE)

The international organization that establishes standards for the uniform testing and rating of heating, ventilation, air conditioning and refrigeration equipment. It also conducts related research, disseminates publications and provides continuing education to its members.

Ballast An electrical device for starting and regulating fluorescent and discharge lamps.

Benchmark A standard against which something can be measured or judged.Central monitoring system

A central point for the storage and monitoring of information.

Coefficient of performance (COP) - cooling

The ratio of the net cooling energy exported from the system to the total electric power used by the system.

Commissioning The process of ensuring that newly constructed/installed systems (Process equipment like motors, pumps, fans, etc., HVAC, plumbing, electrical, fire/life safety etc) operate as designed.

Fan Coil Unit (FCU) A unit that provides cooling and/or heating air as part of a comfort air conditioning system. An FCU uses heated or chilled water and supplies air via one or more electrically driven fans.

Formaldehyde A simple, highly reactive hydrocarbon that is used as a fixative in the pathology laboratory, a fumigant, and in the manufacture of foam insulation, cosmetics, drugs, clothing and furniture. It is also a major toxic component of photochemical smog. Formaldehyde is a strong allergen.

Greenhouse gas (GHG) A gas which absorbs infrared radiation (heat) and contributes to the greenhouse effect (examples include water vapour, carbon dioxide, methane etc).

Global Warming Potential (GWP)

An indicator that reflects the relative effect of greenhouse gas in terms of climate change considering a fixed time period, such as 100 years (GWP100). The GWPs for different emissions can then be added together to give one single indicator that expresses the overall contribution to climate change of these emissions.

Heating, Ventilation and Air Conditioning (HVAC) system

The equipment, distribution systems and terminals that provide heating, ventilating or air conditioning to a building or portion of a building.

High-frequency electronic ballast

A ballast that operates at a frequency greater than 20 kHz and typically around 30kHz.

Life Cycle Cost LCC) analysis

An analysis of building impacts covering the consecutive and interlinked stages of a constructed building, from raw material acquisition to the final disposal.

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Ozone Depletion Potential (ODP)

The relative amount of degradation to the ozone layer a chemical compound can cause. The ODP of CFC-11 is 1 and the ODPs of other compounds are calculated relative to this.

Solar Heat Gain Coefficient (SHGC)

The ratio of the solar heat gain entering a space through a transparent/ translucent element to the incident solar radiation on the element. Solar heat gain includes directly transmitted solar heat and absorbed solar radiation, which is then reradiated, conducted or convicted into space.

Solar Reflectance Index (SRI)

The measure of a material’s ability to reflect solar heat on a scale of 0 to 100. A standard black material has an SRI of 0 and a standard white material has an SRI of 100.

Sub-meter A utility meter that allows for the monitoring of usage on a portion of a distribution system passed a main meter.

Total Volatile Organic Compound (TVOC)

The total concentration of volatile organic compounds (see definition) in a given sample.

U-value (thermal transmittance):

The heat transmission in unit time through a unit area of a material or Construction and the boundary air films, induced by the unit temperature difference between the environments on each side. The units of U are W/m2K.

Variable Air Volume (VAV) System

An HVAC system that controls the temperature within a space by varying the volumetric flow of heated or cooled supply air.

Visible light transmittance (VLT)

The percentage of visible light passing through a material relative to the total amount of light incident upon it.

Volatile Organic Compound (VOC)

An organic chemical which has a boiling point range below 250°C. Under normal conditions, a VOC will significantly vaporize and enter the atmosphere. Many VOCs have significant health implications.

Wastewater Water that has been adversely affected in quality by human activity. Wastewater is a source of potentially valuable resources including bio solids, nutrients and water.

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INTRODUCTION

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The Abu Dhabi Economic Vision 2030 identifies sustainability at the core of Government Policy Agenda and Development Plan. The Industrial Development Bureau (IDB) under the Abu Dhabi Department of Economic Development (ADDED) is mandated through Law No. 08 of 2013 by General Secretariat of the Executive Council (GSEC) to oversee Abu Dhabi’s industrial development & growth and enhance industrial competitiveness and achieve sustainable development of the industrial sector within the Emirate of Abu Dhabi.

With the primary objective of furthering its efforts towards industrial sustainability, IDB has developed “Industrial Sustainability Guideline (ISG)” for the industrial entities to implement within their facilities.

The purpose of the ISG is to provide a set of implementable action items for sustainable management of the following attributes:

• Energy

• Water

• Waste & By-Product

• Greenhouse Gas Emissions (CO2)

• Indoor Air Quality

• Indoor Noise Level

Implementing these attributes would help the industries achieve financial benefits and contribute towards the Abu Dhabi Emirate’s sustainability goals.

1. INTRODUCTION

1.1 PURPOSE

1.2 BACKGROUNDSustainable development is the development that satisfies the present needs without compromising the ability of future generations, ensuring the balance between economic growth, care for the environment and social well-being (Brundtland Report, 1987).

Challenges such as climate change, water scarcity, inequality, and health issues can only be resolved at a global level by promoting sustainable development: a commitment to balance between three pillars, environment, economic, and social progress.

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Understanding the need of sustainability and to preserve the local heritage, Emirate of Abu Dhabi introduced “culture” as the fourth pillar of sustainability.

Sustainable development has been key consideration while developing the policies in recent years. Renewable energy development, energy efficiency programs, waste management, low carbon development, and environmental conservation related initiative haves been undertaken at both Federal and Emirate level in the recent years. Several sustainability/green building codes are in practice and are being implemented by new and existing built infrastructures.

The mechanism for the facilitation of the green building regulations/guidelines for new construction has developed to a satisfactory level and the awareness among stakeholders & developers has spread to a stage where there is a keenness to embrace the sustainability in New Construction.

Within the Abu Dhabi Emirate, sustainability in the built environment is implemented through various program such as Estidama Pearl Rating System (PRS) under Department of Municipalities and Transport (DMT). Leadership in Energy and Environmental Design (LEED) developed by U.S. Green Building Council (USGBC) is also being adopted by a limited number of development projects on a voluntary basis. Further, Abu Dhabi Distribution Company (ADDC) and Al Ain Distribution Company (AADC) have launched the Tarsheed program that focuses on electricity & water conservation in existing buildings and industries.

It is recognized that several industrial segments hold the key to sustainability and play a vital role in reducing carbon footprint through cleaner production, improving operational efficiency and efficient use of available resources.

Currently, availability of sustainability programs specific to industrial entities is limited and very few industries have voluntarily adopted to such sustainability measures. This has presented IDB with the opportunity to develop specific programs, action and best practices for the industrial entities so that they can adopt, benefit and contribute to the sustainable growth of the industrial sector.

Against this backdrop, IDB has developed these guidelines and priorities for the Emirate’s industrial manufacturing sector. When implemented, ISG is expected to transform Abu Dhabi into a model of low carbon industrialization. Its aim is to promote sustainable manufacturing process, resource optimization, improving competitiveness, and positively impact the pillars of sustainability: economic, environment, society, and culture.

Currently, this ISG document is voluntary and generic and encourages all industrial entities within

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the Emirate of Abu Dhabi to adopt and implement sustainability measures as per the programs and action items identified in section 3.4 of this document. The ISG is applicable to existing and new industries.

This industrial sustainability program for manufacturing industries is a structured process. The process comprises the following activities/stages :

a. Formulate the Industrial Sustainability Team

b. Conduct Baseline Performance Assessment

c. Set Goals in the form of Objectives & Targets

d. Create Action Plan

e. Implement Action Plan

f. Evaluate Progress

g. Recognize Achievements

h. Continual Improvement

These Guidelines for Sustainability Management follow ten main steps that are outlined in section 3.3.

The ISG focuses on the following main areas:

• Industrial Manufacturing Process: Operations through which the raw materials are converted / transformed into a final product using various machineries and equipment.

• Industrial Manufacturing Process Buildings: The buildings that houses the industrial manufacturing process.

• Industrial Warehouse/Storage: The permanent building to store industrial raw materials and finished products of the industry. The building space may either be conditioned or non-conditioned.

• Administration/office building (Gross Conditional Floor Area < 2000m2) : The permanent building with conditioned space that houses administration and/or engineering workforce of the industry.

This ISG must be read in conjunction with the applicable Abu Dhabi regulations, listed in section 2.1. The manufacturing facility can evaluate the applicability of their sustainability program based on Figure 1.1.

The Industrial Sustainability Guidelines have been designed to improve the sustainability performance of manufacturing facilities. The ISG, when implemented by the industrial entities, would help them optimize operational costs & achieve higher productivity through:

1.3 ISG GUIDELINES AND THEIR APPLICABILITY

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a) Reducing demand-side energy consumption

b) Efficient water utilization

c) Process waste reduction, better utilization of raw materials & by-products

d) Reducing carbon footprint

e) Ensuring a healthy working environment for facility workforce

f) Improving competitiveness locally and regionally

Additionally, this would ensure that the manufacturing entities contribute towards the Abu Dhabi’s sustainability goals and vision through the following:

• Conserving the existing available resources within the Emirate of Abu Dhabi

• Reducing industrial sector’s contribution to Greenhouse Gases emission and contribute towards carbon emission reduction targets.

1.4 BENEFITS OF ISG

Figure 1.1: Industrial Sustainability Guideline Applicability

Industry Entity

- Manufacturing Process Building- Manufacturing Operations- Conditioned Warehouse- Admin / Office Building with GCFA <2000 m2

- Admin / Office Buildings with GCFA >2000 m2

Industrial Sustainability Guideline (ISG)

Estidama Pearl Building Rating System (PBRS) Guideline

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• Contribute towards circular economy through waste & by-product management

• Reducing strain on the existing landfills through reduced waste loads

• Enhance sectoral contribution to the GDP

• Promote innovation and research & development in the industrial sector

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POLICY FRAMEWORK & CURRENT PRACTICES

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Sustainable development has been at the core of the UAE’s policymaking, pioneered by the nation’s founding father the late Sheikh Zayed bin Sultan Al Nahyan. Given this legacy, the UAE is committed to the United Nation’s 2030 Agenda for Sustainable Development whilst pursuing economic development. The United Nations Sustainable Development Goals (SDG) are the blueprint for achieving a better and sustainable future.

In line with this, Abu Dhabi government is committed towards implementing sustainable practices in the industrial sector, which is also reflected in the Abu Dhabi Economic Vision 2030 that has a roadmap of the economic progress of the Emirate of Abu Dhabi.

Over the years, IDB has been working towards the establishment, development, and regulation of the industrial manufacturing sector of Abu Dhabi. As per Abu Dhabi’s Law No. 8 of 2013, IDB has mandated for following but not limited to:

• Develop overall Emirate of Abu Dhabi manufacturing strategy and follow up on its implementation

• Develop policies and program for the manufacturing sector based on best practices

• Ensure a competitive manufacturing environment within Abu Dhabi

• Issuance and renewal of licenses allowing industrial facilities to operate in Abu Dhabi.

IDB is also the Industrial Sector Regulatory Authority (SRA) for occupational, safety, and health; and mandated with the implementation and enforcement of Decree No. 42 of 2009 within the industrial sector in the emirate of Abu Dhabi.

2. POLICY FRAMEWORK & CURRENT PRACTICES

2.1 FEDERAL & LOCAL ENVIRONMENTAL STANDARDS The federal and local regulations prescribe compliance standards & limits as mandatory requirements to ensure legal compliance by the manufacturing industries. However, Industrial sustainability guidelines extend beyond these legal requirements and offer continual improvement and help industries achieve excellence.

Environmental protection in the UAE is enforced through Federal & Local Laws and Executive Regulations. The principal Federal Law covering environmental protection is Federal Law No. (24) of 1999 for the Protection and Development of the Environment.

The Ministry of Climate Change and Environment (MoCCE) is the Competent Authority responsible for implementing federal law in the UAE. The designated Competent Authority for administration of Federal Law No.24 and its Regulations in Abu Dhabi is the Environment Agency-Abu Dhabi (EAD).UAE and Abu Dhabi regulations and other environmental policies applicable to the project include the following:

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● Federal Laws ● Federal Law No.24 of 1999 on the Protection and Development of the Environment and

related Regulations

● Executive Orders to Law No. 24 (2001) on Regulations Concerning Environmental Impact Assessments of Projects

● Executive Orders to Law No.24 (2001) Regulation concerning Handling of Hazardous

Substances, Hazardous Waste and Medical Wastes

● Ministerial Orders

● Ministerial Order No. 12 of 2006 on Framework for protection of Air from pollution

● Ministerial Order No. 32 of 1982 on the determination of retentive methods and measures for the protection of workers from risk at work

● Abu Dhabi Local Laws & Regulations

● Waste Management Law No. (21) of 2005 concerning Managing Solid Wastes in Abu Dhabi Emirate

● Decree of the Crown Prince, Chairman of the Executive Council No. (42) of 2009, Concerning the Environment, Health and Safety Management System in Abu Dhabi Emirate

● EAD Guidelines and Standards

● Relevant standards and guidelines apply for air quality, noise quality, water & wastewater discharge quality and soil & groundwater quality

● Abu Dhabi Environment Policy Agenda

● EAD/CWM’s Waste Management Policies

● Waste Classification Policy (EAD-EQ-PR-P-01)

● Waste Planning Policy (EAD-EQ-PR-P-02)

● Waste Classification Guidelines (EAD-EQ-PR-TGD-01)

● Waste Reuse, Recycling, Resource Recovery, Treatment and Disposal Policy (EAD-EQ-PR-P-05)

● Licensing and Enforcement Policy for Waste Sector

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● Waste Collection, Segregation, Transfer and Tracking Policy (EAD-EQ-PR-P-04)Environmental regulations and standards for environmental control have been developed in Abu Dhabi by EAD in response to UAE Federal Law No. 24 of 1999.

Below applicable regulatory Air Quality and Noise Level Standards are included in Appendix-A of this guideline. Table 1: Recommended Ambient Air Quality Standards for the Emirate of Abu DhabiTable 2: Air Pollutants Emission Limits for Stationary Combustion Sources Table 3: Maximum Allowable Limits for Air Pollutants inside Working Areas (Dust)Table 4: Allowable Limits for Ambient Noise Level in Different AreasTable 5: Occupational Air Pollutants Limits

Table 6: Occupational Noise Level Limits

Above regulatory requirements are mandatory and may not necessarily qualify industries for sustainability. Therefore, industries should strive to implement resource efficiency and indoor environmental improvement measures to improve their sustainability performance.

2.2 FEDERAL & LOCAL ENVIRONMENTAL STANDARDSThe different Emirates of the UAE have adopted various programs to foster environmental sustainability such as but not limited to:

a. Estidama Program of Department of Municipalities and Transport, Abu Dhabi

b. Abu Dhabi Sustainability Group (ADSG)

c. Tarsheed Program of the Abu Dhabi Distribution Company and Al Ain Distribution Company (ADDC & AADC)

d. Emirates Green Building Council (EGBC)

e. EHS Trakhees’s Green Building Rating Program

f. Dubai Municipality’s Green Building Guidelines/ Al Safat

g. Barjeel, Ras Al Khaimah’s Green Building Regulations

h. Leadership in Energy and Environmental Design (LEED) Program of the US Green Building Council

i. Livable Buildings

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2.3 EXISTING SUSTAINABILITY FRAMEWORKS/ PROGRAMS AND RELATIONSHIP TO THE ISG

Estidama Program

In 2010, Abu Dhabi Urban Planning Council (now part of Department of Municipality and Transport) has established the Estidama. Estidama Pearl Rating System (PRS) requirements are under implementation for the design & construction phases of new construction Estidama Pearl Rating System focuses on the following elements of the built environment

1. Integrated Development Process

2. Natural System

3. Livable Buildings

4. Precious Water

5. Resourceful Energy

6. Stewarding Materials

7. Innovative Practices

Each element has mandatory and optional credits that to be complied to achieve the desired pearl rating. Permanent stand-alone building with more than 2000m2 Gross Conditioned Floor Area (GCFA) must comply with Estidama PRS in accordance with Information Bulletin #3 version 2.0.

PRS addresses the sustainability measure of a new community and buildings under the preview of Abu Dhabi Plan 2030 and mandatory for all new development since 2010. The PRS consists of the following

• Pearl Community Rating System: Design & Construction

• Public Realm Rating System: Design & Construction

• Pearl Building Rating System: Design & Construction

• Pearl Villa Rating System: Design & Construction

• Pearl Operational Rating – The operational rating assesses the built-in features and operational performance of an existing building and ensures the building is operating sustainably. The operational rating can only be achieved a minimum of two years after construction completion and when the building has reached a minimum occupancy of 80%.

In contrast to Estidama, Industrial Sustainability Guideline (ISG) caters to the sustainability objective of Abu Dhabi industrial landscape. Primarily, the shop floor and manufacturing process & process

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building will fall under the purview of this ISG. Administration/office building (permanent, stand-alone) with area < 2000 m2 GCFA will also follow this ISG.

1. Integrated Development Process

a. The integrated design approach for a new manufacturing unit

b. The integrated design approach for industrial retrofit measures

2. Resourceful Energy

a. Energy consumption in production

b. Fuel consumption in production

3. Water Resource

a. Water consumption in production

4. Environment

a. Greenhouse Gas emission (GHG), primarily CO2

5. Stewarding Materials

a. Waste Management

b. By-products management

6. Healthy Workplace (Buildings/Shop Floor/Operational Areas)

a. Workplace Air Quality (VOCs) emission in processes

b. Occupational Noise Level

Industrial Sustainability Guideline acknowledges the different phases of manufacturing facility development. The sustainability measures adopted during the design must be embraced during construction. The manufacturing facility operations team is responsible to operate and enhance the facility’s sustainability continuously over the operational life. This Sustainability Guideline is applicable for both New and Existing Industries. Accordingly, this ISG will be apply to the following stages

• Design

• Operational and Retrofitting – During the entire operational life of the industrial facility

The Design stage recognizes the industrial sustainability measures to be implemented during the design phases of the industry that meets the criteria of each requirements of this Industrial Sustainability Guideline (ISG). The Design measures recognize the need for Life Cycle Costing

40

8

Figure 2-1: A link between Industrial Sustainability Guideline and Estidama

A Mandatory Estidama Program applicable to infrastructure and building development projects.

Guideline for Industrial sectors. Primarily focus to improve the sustainability performance of an existing industry.

Estidama Program

Design Rating

Construction Rating

Industrial Sustainability Guideline

Design Stage

Retro tting and Operation Stage

Figure 2.1: A link between Industrial Sustainability Guideline and Estidama

analysis while selecting any equipment/items in the manufacturing process. Similarly, operational & retrofitting stage recognize the operational performance related to sustainability attributes.

ISG are aligned with Estidama Pearl Rating System and ensure that they are complementary and act cohesively. This ISG must be read in conjunction with Estidama guidelines introduced by Department of Municipalities and Transport, Abu Dhabi. Mapping of Estidama and ISG is depicted in the Figure 2.1

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ISG ISG CATEGORIES:

ESTIDAMA CATEGORIES :1. To Promote Building Sustainability

2. Applicable to buildings that meet requirements

1. Integrated Development Process2. Natural Systems3. Livable Building4. Precious Water5. Resourceful Energy6. Stewarding Materials7. Innovating Practice

1. To Promote Industrial Sustainability

2. Applicable to Administration Office Buildings

1. Integrated Development Process2. Healthy Workplace

3. Water Resource4. Resourceful Energy5.Environment 6. Stewarding Materials

Similarities and differences between Estidama (PBRS) and Industrial Sustainabilty Guideline (ISG)

1

2

Applicable to: -Buildings (General/Office/Retails)-Multi Residential-School-Mixed Use

SUSTAINABILITY CREDITS: 177 MAXIMUM*

Applicable to:-Industial Manufacturing Process-Inudstiral Manufacturing Process Buildings-Industrial Warehouse Storage

(Gross Conditional Floor Area <2000 m2)

SUSTAINABILITY MEASURES: 48

(Building/Shopfloor/Operational Areas)

ESTIDAMA

defined in Estidama Pearl Rating System – Information Bulletin #3 version 2.0

*Total : Excludes Sustainability practice credits which are offered as bonas credits

42

Abu Dhabi Sustainability Group

Set up by EAD in 2008, “The Abu Dhabi Sustainability Group (ADSG) promotes sustainability management in the emirate of Abu Dhabi by providing learning and knowledge sharing opportunities for government, private companies and not for profit organizations in a spirit of cooperation and open dialogue” .

ADSG bring its members together with global thought leaders to discuss global and local sustainability trends that facilitate the member organization to develop the capabilities, improve knowledge, share experience and build the network.

The ADSG is open to new members willing to practice and champion sustainability in Abu Dhabi. Organizations willing to join ADSG can get benefit from various sustainability assessment tools, flagship programs, sustainability awareness etc.

Tarsheed, Abu Dhabi

In 2017, Abu Dhabi Water and Electricity Authority (ADWEA) and the distribution companies, ADDC & AADC, launched the Tarsheed program (Conservation, in Arabic) . The program aims to raise awareness at both domestic and industrial level to bring out resource conservation and achieve a 20% reduction in the emirate’s water and electricity usage, by 2030 .

Tarsheed aims to achieve its objectives in three ways:

1. Education: To promote awareness and change behavior

2. Technology: To reduce energy and water consumption

3. Efficiency: Measures to reduce demand

The Tarsheed Program is being implemented through a number of initiatives, evaluated based on their costs, benefits, sustainability, availability, and suitability within the emirate's culture, climate and economy.

Tarsheed’s Industrial Electric and Water Consultation initiative aims to gain a greater understanding of industrial water and electricity usage patterns within the emirate, to seek ways of improving overall efficiency. It is envisaged, IDB’s ISG will complement Tarsheed’s Industrial Electric and Water Consultation initiative.

43

44

45

INDUSTRIAL SUSTAINABILITY GUIDELINES

46

47

3. INDUSTRIAL SUSTAINABILITY GUIDELINES3.1 SUSTAINABILITY KPIs FOR THE INDUSTRIAL SECTOR

ENERGY USE INTENSITY

WATER USE INTENSITY

WASTE DISPOSAL AND BY-PRODUCT

GHG EMISSIONS (CO2) PER TONNES OF PRODUCTION

OCCUPATIONAL INDOOR AIR QUALITY

INDOOR NOISE LEVEL

Industrial Sustainability guideline has been tailored to focus on the six KPIs that are fundamental to the sustainable development of the industries and form the core of the ISG:

1. Energy Use Intensity: Targeting energy conservation through integrated and passive design measures, reduced demand, energy efficiency and renewable sources. It’s calculated by dividing the total energy consumed by the industry in one year (measured in GJ) by the total gross production of various products (measured in ton).

2. Water Use Intensity: It targets recycling and reusing process wastewater thereby reducing water demand and encouraging efficient water use in the manufacturing industry. It is calculated by dividing the total freshwater consumed by the industry in one year (measured in cubic meter) by the total gross production of various products (measured in Ton).

3. GHG Emissions: It targets to lower the GHG emissions of the industrial process and encouraging resource efficiency. It considers the Scope 1 and Scope 2 GHG emissions (As defined in GHG Protocol ).

4. Indoor Air Quality: It considers improving all the workplace air quality and connectivity of outdoor and indoor spaces.

5. Indoor Noise Level: It considers improving all the workplace noise level to ensure the wellbeing of industries personnel and reduce the long-term negative impacts on workers.

6. Waste Disposal and Byproduct: It targets to reduce the waste generated from the process and use the byproduct to create a circular economy model. It is calculated by dividing the total waste generated by the total raw material consumed in the process.

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3.2 KEY TEAM MEMBERSThe success of the ISG implementation depends on the contribution of all stakeholders from the industrial entity, third party specialist, and government authorities.

The ISG implementation and assessment process requires establishing a team having the following members:

Industrial Sustainability Program Manager: Industrial Sustainability Program Manager is the IDB representative who assesses the Sustainability Performance of industries.

Energy Specialist: Energy Specialist is a member of the design and operation team who facilitates the industry to implement sustainability guideline for both design and operation stages. An Energy Specialist is an individual:

• Holding an engineering degree in Mechanical/Electrical/Chemical/Energy/Environment or equivalent with a minimum of 3 years of industrial experience.

• Desirable qualifications

IDB

Industrial Entity

Third- Party

Throughout the Program

Operation Phase

Retrofit / Technical Modifications

Throughout the Program

Energy Specialist

Enviromental Specialist

Process Expert

Industrial SustainabilityProgram Manager

Pool of Qualified Professionals from

Third-Party

Stakeholder Program Phase Key Members

Design and Construction Phase

Figure 3.1: Key Team Members

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• Holding international certification in energy management/efficiency (CEA/EEP from AEE, USA) or equivalent

• Proficient in ISO 50001 – Energy Management Systems (EnMS)

Environmental/HSE Professional: Environmental/HSE Professional is a member of the sustainability team who facilitates the industry to meet the Sustainability requirements. The professional should have demonstrated experience of 5 years in Environmental Compliance.

Process Manager/Engineer: Process Manager/Engineer is a member of the sustainability team who works along with Energy and Environmental professionals to ensure the sustainability targets established for the project, are aligned with process safety and product quality.

Industrial Sustainability Expert: Industrial Sustainability Expert is a third -party engineering sustainability firm with minimum three experts having at least 3 years experience in Energy, Water, Waste and sustainability field.

3.3 ISG IMPLEMENTATION PROCESSThe implementation process has been developed to provide guidance on how to use and implement the ISG in order to maximize the benefits. Implementation process helps the industries, regardless of capacity or product if they are willing to make the commitment and benefiting from this.

The implementation process builds on the commitment that an industrial entity makes when they subscribe to the ISG, and becomes IDB’s sustainability partner.

The subscribing industrial entities are required to follow the below steps to implement the ISG.

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Appendix - B

51

Industrial entity shall identify key ISG team members whose desired qualifications & requirements have been defined in Section 3.2. The industrial entity’s Sustainability Manager or appointed third party sustainability expert’s key duties include:

• Focal point for the implementation of the ISG program

• Drafting the sustainability Policy, if desired

• Creating and leading the Sustainability Team

• Identifying necessary resources to implement ISG

• Ensuring accountability and commitment from top management

• Identifying sustainability opportunities and ensuring ISG implementation

• Monitoring, verifying, evaluating and communicating results

3.3.1 STEP 1: ESTABLISHING THE ISG TEAM

3.3.2 STEP 2: BASELINE DATA COLLECTIONThe industrial entities shall gather the necessary process data, energy & waste consumption data and process waste & wastewater data for establishing the baseline KPIs. The data collection checklist detailing all possible requirements is provided in Appendix -B. This step is for the currently operating industries.

3.3.3 STEP 3: GAP ANALYSISThis step is only applicable to the existing operating industries. In order to establish the baseline KPIs, the operating industrial entity must use the Gap Analysis checklist, provided in Appendix-B, to gather preliminary data and identify the data gaps.

Subsequently, the identified data gaps shall be closed, and all information shall be generated/collected as per gap analysis checklist before proceeding to the next stage of ISG implementation.

52

Baseline for operational industrial entity is the base year, before implementing sustainability measures, from where entity start monitoring its sustainability performance. Whereas for newly established industry or industry in design phase, the first year of operation is the baseline year for monitoring the sustainability KPIs.

Industrial entity shall establish the baseline for sustainability KPI and shall input in the IDB’s IT Dashboard to record the baseline value.

Industrial entities subscribing to this ISG shall contact IDB to get access of IT Dashboard.

IT Dashboard is a web-based sustainability performance tracking and benchmarking tool primarily designed for existing industrial manufacturing entities. IT Dashboard helps you track and assess Sustainability KPIs performance within industrial manufacturing entities. After creating an account, users enter sustainability performance data into the IT Dashboard account to monitor their sustainability performance, assess ISG KPIs over time, and identify potential opportunities for savings. Please refer the Appendix -C for further details.

The IT Dashboard has built in formula, which are detailed below, to calculate the KPIs for Energy, Water, GHG and Waste & By-product management. The first reporting values obtained shall be considered as the facility’s baseline.

Energy Intensity

Where,

EIy = Energy Intensity in year y (TJ/Ton)

ECy = Electricity Consumption in year y (GWh/Annum)

3.6 = Conversion Factor (TJ/GWh)

HFi,y = Quantity Hydrocarbon Fuel type i consumed in year y (Mass or volume unit/annum)

NCVi = Net calorific Value of hydrocarbon fuel type i (TJ/mass or volume unit)

Pi,y = Quantity of Product i manufactured in year y (Ton/annum)

3.3.4 STEP 4: ESTABLISHING BASELINE KPI’S

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Water Intensity

Where,

WIy = Water intensity in year y (m3/ton)

PWIy = Total Process Water Input in year y (m3/annum)

RWCy = Recycled Water Consumption in year y (m3/annum)


GHG Emission

Where,

GHG Emission y = GHG Emission in year y (tCO2-eq)

ECy = Electricity Consumption in Year y (MWh/annum)

GEF = Grid Emission Factor of Abu Dhabi (tCO2-eq/MWh)

HFi,y = Quantity of Hydrocarbon Fuel i consumed in year y (Mass or Volume Unit/Annum)

NCVi = Net calorific Value of hydrocarbon fuel type i (TJ/mass or volume unit)

EFi = is the CO2 emission coefficient of fuel type i in year y (tCO2-eq/mass or volume unit)

Industrial Waste Intensity

Where,

IWIy = Industrial Waste Intensity in year y (Ton of waste/Ton of Product)

PWi,y = Process waste i generated in a year y (Ton/annum)


Operating industrial entity shall establish the baseline for occupational indoor air quality and indoor noise level from the latest third-party laboratory monitoring reports.

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20

KPI Calculation – Illustrative Example An industry manufacturers product A (100 tonnes/ annum) and product B (200 tonnes/ annum) from raw material C (150 tonnes/annum), D (200 tonnes/ annum) and E (10,000 tonnes/ annum). The manufacturing process consumes X (50 GWh/ annum) amount of electricity, Y (1000 m3/ annum @ density 0.7 kg/m3) amount of natural gas and Z (20 m3/annum) amount of diesel in a year.

Along with raw materials Q (200 m3/ annum) amount of water is fed to the process. The process generates R (75 m3/ annum) quantity of wastewater out of which S (25 m3/annum) amount is treated as reused in the process.

Other data, Abu Dhabi Grid Emission Factor= 0.420 tCO2/MWh; NCV of diesel = 0.043 TJ/ tonnes; NCV of Natural Gas = 0.048 TJ/tonnes; Diesel Emission Factor= 74.1 tCO2/TJ and Natural Gas Emission Factor = 56.1 tCO2/TJ.

𝑬𝑬𝑬𝑬𝒊𝒊,𝒚𝒚 �𝑻𝑻𝑻𝑻

𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕�

=�50 𝐺𝐺𝐺𝐺ℎ

𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 𝑥𝑥 3.6 𝑇𝑇𝑇𝑇𝐺𝐺𝐺𝐺ℎ� + �200 𝑡𝑡𝑡𝑡𝑎𝑎𝑎𝑎𝑡𝑡𝑡𝑡

𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 𝑥𝑥 0.043 𝑇𝑇𝑇𝑇𝑡𝑡𝑡𝑡𝑎𝑎𝑎𝑎𝑡𝑡𝑡𝑡 + 10000 𝑎𝑎�

𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 𝑥𝑥 0.71000

𝑡𝑡𝑡𝑡𝑎𝑎𝑎𝑎𝑡𝑡𝑡𝑡𝑎𝑎� 𝑥𝑥0.048 𝑇𝑇𝑇𝑇

𝑡𝑡𝑡𝑡𝑎𝑎𝑎𝑎𝑡𝑡𝑡𝑡�

(100 + 200) 𝑡𝑡𝑡𝑡𝑎𝑎𝑎𝑎𝑡𝑡𝑡𝑡𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎

== 00..662299 TTJJ// ttoonnnneess

𝑾𝑾𝑬𝑬𝒚𝒚 �𝒎𝒎𝟑𝟑

𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕� =

200 𝑎𝑎�

𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 − 25 𝑎𝑎�

𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎[100 + 200] 𝑡𝑡𝑡𝑡𝑎𝑎𝑎𝑎𝑡𝑡𝑡𝑡

𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎

== 00..558833 mm33// ttoonnnneess

𝑮𝑮𝑮𝑮𝑮𝑮 𝑬𝑬𝒎𝒎𝒊𝒊𝒕𝒕𝒕𝒕𝒊𝒊𝒕𝒕𝒕𝒕𝒚𝒚 �𝒕𝒕𝒕𝒕𝒕𝒕𝟐𝟐�𝒕𝒕𝒆𝒆

𝒂𝒂𝒕𝒕𝒕𝒕𝒂𝒂𝒎𝒎�

= 50 𝐺𝐺𝐺𝐺ℎ

𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 𝑥𝑥 0.420

𝑡𝑡𝑡𝑡𝑡𝑡�

𝑀𝑀𝐺𝐺ℎ+ 200

𝑡𝑡𝑡𝑡𝑎𝑎𝑎𝑎𝑡𝑡𝑡𝑡𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎

𝑥𝑥 0.043 𝑇𝑇𝑇𝑇

𝑡𝑡𝑡𝑡𝑎𝑎𝑎𝑎𝑡𝑡𝑡𝑡 𝑥𝑥 74.1


𝑇𝑇𝑇𝑇

+ 10000 𝑎𝑎�

𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 𝑥𝑥

0.71000

𝑡𝑡𝑡𝑡𝑎𝑎𝑎𝑎𝑡𝑡𝑡𝑡

𝑎𝑎� 𝑥𝑥 0.048 𝑇𝑇𝑇𝑇

𝑡𝑡𝑡𝑡𝑎𝑎𝑎𝑎𝑡𝑡𝑡𝑡 𝑥𝑥 56.1


𝑇𝑇𝑇𝑇

== 2211665566..1111 ttCCOO22--eeqq //aannnnuumm

𝑬𝑬𝑾𝑾𝑬𝑬𝒚𝒚 𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕 𝒕𝒕𝒐𝒐 𝒘𝒘𝒂𝒂𝒕𝒕𝒕𝒕𝒕𝒕

𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕 𝒕𝒕𝒐𝒐 𝒑𝒑𝒑𝒑𝒕𝒕𝒑𝒑𝒂𝒂𝒑𝒑𝒕𝒕=

( 𝑡𝑡 + 𝐷𝐷 + 𝐸𝐸) − (𝐴𝐴 + 𝐵𝐵)𝐴𝐴 + 𝐵𝐵

= (��)�(�� )��

== 0.5 tonnes of waste per tonnes of product

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Assessing your KPI performance helps you to:

• Understand current energy use by fuel type, process/product line, etc.

• Identify best performing practices/process for recognition and replicable practices.

• Identify less efficient practice/process for immediate improvement.

• Understand the contribution of energy, water and waste management expenditures to operating costs.

• Develop a historical trend analysis and basis for further improvements.

• Establish baseline.

Once the baseline for sustainability KPIs is developed, the industrial entity shall establish internal targets for year-on-year improvement of sustainability KPIs in their management system.

3.3.5 STEP 5: IDENTIFY SUSTAINABILITY OPPORTUNITIES Continuous assessment of equipment, process and production lines will help identify inefficiencies for further improvement. This shall be through sustainability assessments.

Sustainability assessment is a comprehensive review to be conducted by Sustainability/energy professionals and/or engineers that evaluate the actual performance of the industrial facility's systems and equipment against their designed performance level or against Best Available Technology (BAT). The difference between these is the potential for resources (Energy, Water and Raw Material) saving and will also lead to reduction in GHG emissions, improve indoor air & noise quality.

Due Diligence Tool can be used to carry out estimation of saving potential and probable sustainability measures.

Due diligence tool is an independent Microsoft Excel-based decision-making tool for the industries to carry out due diligence of any proposed sustainability measure. Please refer Appendix -D for further details.

Performance goals drive sustainability management activities and promote continuous improvement. The industries, after establishing the KPIs, should list possible sustainability measures and set their targets to improve their KPIs performance. To set sustainability targets, it is essential to have the information of current technology used in the industry and comparative analysis with respect to best available technology. Selection of sustainability measure for implementation depends on a number of factors, such as competent resources, time, cost and management commitment.

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Industrial facility shall use a detailed action plan to ensure a systematic process to implement sustainability performance measures. Each identified opportunity shall be assessed according to feasibility, cost and benefit in order to prioritize implementation. An illustrative decision-making tool is presented below. This is an example only and is presented for the purpose of understanding.

Securing the support and cooperation of top management along with the industrial process team is an important factor for successful action plan implementation. Additionally, industrial sustainability training, awareness and commitment, will play a key role in identifying and implementing sustainability initiatives & projects.

Phase 1- Process and Organization Improvement1. Strengthen involvement with industry

association2. Integrate sustainability considerations

in all business3. Delegate responsibility for sustainability

management 4. Implement ISO 500015. Target development of performance

criteria6. Performance incentives options to be

provided7. Install submeters8. Internal stakeholder training and

awareness

Phase 2- Market the co2 Strategy1. Low Carbon procurement 2. Enhance carbon procurement3. Engage with customer

4. Define low carbon technology roadmap

Phase 3- GO ZLD/Low Carbon/Waste Diversion1. Place Advance Water Treatment System2. Install the High Efficiency Motors3. Replace the Heat Pump4. Replace the Manufacturing assembly

with efficient equipment

5. Install the Waste recovery system

Low High

High

Low

Bene

�t

CostCost

02 03

14

04 0915

01 0510

07

12

13

06

08 11

16

17

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If the industrial entity’s in-house team does not have the capacity to identify the possible sustainability design measures, it is encouraged to appoint a third-party sustainability expert. Industrial entity shall contact IDB for a list of the enlisted sustainability experts.

The sustainability expert would help the industry in carrying out the gap analysis, closing the gaps, identifying the sustainability opportunities, and carrying the due diligence of identified sustainability opportunities.

3.3.6 STEP 6: INDUSTRIAL SUSTAINABILITY EXPERT

3.3.7 STEP 7: ENGAGE WITH IDB SUSTAINABILITY PROGRAM MANAGERIndustrial entity shall regularly engage in consultation with the IDB program manager. Such consultations include understanding of the program, implementation process, performance monitoring & reporting and on-going incentives (if any) in relation to sustainability measures.

Once the sustainability opportunities are identified, the industry shall prepare and submit a “Sustainability Measures Implementation Plan” through the IT Dashboard established by IDB.

Sustainability Measures Implementation Plan is an action plan based on the opportunities identified against the chosen KPIs, their management plan, the resources, timeline etc. The subscribing entity can develop this implementation plan as per their own format. It is recommended to have following information as part of the Sustainability Measures Implementation Plan:

A. Introductiona. Goals, Objectives and Targets

B. Process Descriptiona. Manufacturing Technologyb. Mass Balance Diagramc. Water Balance Diagramd. Energy load schedule

C. ISG Team MembersD. Baseline Sustainability KPIs ResultsE. Identified OpportunitiesF. Measures Selected for ImplementationG. Implementation Schedule H. Management Plan

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Industrial entity shall implement the sustainability measures through in-house team or by appointing relevant specialist contractor(s) with proven experience in implementing similar scope of work.

3.3.8 STEP 8: IMPLEMENT SUSTAINABILITY MEASURES

3.3.9 STEP 9: PERFORMANCE MONITORING AND REPORTINGPerformance monitoring and reporting include periodic data compilation (refer section 3.3.5) and compared to the established performance goals. Subscribing entity shall report the sustainability performance data in the IT dashboard on a quarterly basis or as required by the IDB.

This step includes formal review of both sustainability data and the activities carried out as part of the action plan. Industrial entity shall compare the performance of each sustainability measure and actual performance. It must understand the measures that performed well and that didn’t perform.

Industrial entity shall apply the following steps while assessing the performance

• Feedback – Gather feedback from ISG team, implementation staff, process operations department and other stakeholders on each sustainability measures implement in the industry.

• Identify Key Factors – Identify the factors that contributed to achieving or missing set sustainability goals

Results obtained from analyse & review gathered during the formal review process shall be used by the industrial entity to create new action plans, identify best practices, and set new performance goals.

3.3.10 STEP 10: ANALYSE, REVIEW RESULTS & CONTINUAL IMPROVEMENT

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3.4 THE ISG MEASURESThis section of the ISG defines the measures that are to be followed throughout the Industrial Manufacturing project phases to achieve the sustainability goals. Six (6) KPIs identified for manufacturing industries in Abu Dhabi is detailed in Section 3.1. The ISG has identified possible sustainability opportunities that a manufacturing industry shall implement to improve their performance. All the sustainability opportunities are grouped in the following categories:

i. General requirements

ii. Energy

iii. Water

iv. By-product and Waste Management

v. Indoor Environment Quality

a. Indoor Air Quality

b. Indoor noise Level

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3.4.1 UNDERSTANDING THE ISG MEASURESIntergrated design approach for achieveing ISG KPI’SSustainability Opportunity Title

Intent To encourage a collaborative and integrative process for designing, constructing and operating the Industrial Manufacturing process & process buildings, warehouse/ storage area etc., and process improvement measures.

Requirements: Demonstrate that the design and development team, and development process are organized and programmed to gain maximum benefit from integrated approach.Demonstrate that all key stakeholders are involved in the following • Establishing the Specific Energy Consumption target lower than similar industries in the region and • Water use intensity target shall be lower than regional and international benchmarking for similar industries.• Design approach to achieve Zero Liquid Discharge.

Implementation Requirements: Design and Development team comprising all of stakeholders but not limited to designers, process specialist, technology providers and builders should be part of integrated design development process wherein ISG KPI’s are explained.The IDA should include discussions on technology/ process selection and way towards achieving KPI’s of ISG, for all manufacturing process related design. In addition to the manufacturing technology/ process, IDA should include discussion on Manufacturing/Warehouse/Storage building’s envelope, HVAC options, lighting schemes, innovative day lighting technologies, renewable technologies, commissioning, ease of operations & maintenance etc. as applicable for all associated buildings and structures.

Evidence required during design and Retrofitting stage: 1. Goals and Target matrix against the six KPIs2. Sustainability assessment and benchmark target (in comparison with similar local and international industries) set for Energy, water and GHG emission intensity. 3. Design Specification & Calculation sheet.

Evidence required during Operation StagePerformance assessment to Sustainability KPIs against set design targets and the peer industries after 2 Years of Operations.

Calculations and MethodologyIntegrated design approach is a mandatory for New Manufacturing Units and existing Manufacturing units in IDB’s Industrial Sustainabilitu review process.

Primary purpose of identified Sustainability Opportunity

Description of implementation requirements

Description of assosiated documentation to jusify the achievement of Sustainability Opportunity during Design, Cnstruction and Operation Stage

Clarification of any calculation or methodology

Description of what should be done under identified Sustainability Opportunity

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This section details the requirements that are common to all type of industries. These requirements form an effective base to achieve the ISG goals. It would help the ISG project team to improve the design and development process. It calls for a multi-disciplinary approach while designing the manufacturing process. The emphasis on the sustainability expert and process engineer will steer the design towards sustainability goals whether it is a new industrial project or retrofitting/ technical modifications of an operating facility.

3.4.2 GENERAL REQUIREMENTS

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To establish interdisciplinary team for designing, constructing, and operating the Industrial Manufacturing process & process buildings, warehouse/storage area etc., and sustainability management.

Demonstrate that the design and development team and development process are organized and programmed to gain maximum benefit from an integrated approach. Demonstrate that all key stakeholders are involved in the following

• Establishing the Specific Energy Consumption target lower than similar industries in the region and

• Water use intensity target shall be lower than regional and international benchmarking for similar industries.

• The design approach to achieve Zero Liquid Discharge.

Design and Development team comprising all of the stakeholders but not limited to designers, process specialist, technology providers and builders should be part of integrated design development process wherein ISG KPIs are explained.

The IDA should include discussions on technology/process selection and way towards achieving KPIs of ISG, for all manufacturing process related design.

In addition to the manufacturing technology/process, IDA should include discussion on Manufacturing/Warehouse/Storage building’s envelope, HVAC options, lighting schemes, innovative daylighting technologies, renewable technologies, commissioning, ease of operations & maintenance etc. as applicable for all associated buildings and structures.

1. Goals and Target matrix against the six KPIs

2. Sustainability assessment and benchmark target (in comparison with similar local and international industries) set for Energy, water and GHG emission intensity.

3. Design Specification & Calculation sheet.

Integrated Design Approach for Achieving ISG KPI’s.

Intent

Requirements

Implementation Requirements

Evidence required during the Design and Retrofitting stage

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Performance assessment to Sustainability KPIs against set design targets and the peer industries after 2 Years of Operations.

The integrated design approach is mandatory for New Manufacturing Units and Existing Manufacturing units who are subscribing to this ISG.

Evidence required during Operation Stage

Calculations and Methodology

64

To encourage the selection of highly energy-efficient technology/ equipment and benefit from low operational cost, and thereby reducing the CO2 emissions to the environment.

The LCC qualified professional must be a Chartered Engineer with previous knowledge/experience in LCC modeling. The qualified professional must also be familiar with internationally recognized LCC standards.

Demonstrate that Life Cycle Costing was undertaken as part of the IDA as follows:

• Demonstrate that an LCC analysis was started during design by a qualified professional to evaluate and compare various design options. The LCC model developed must be maintained and upgraded throughout the design stages in option appraisals.

• At the end of construction, update the LCC report with final construction costs.

LCC report produced at the end of design with a summary history of the decisions that benefited from LCC.

Life Cycle Costing Analysis report while replacing any process equipment (e.g. Motor, Fan, Pump, Compressor etc).

The qualified LCC professional charted professional engineer the previous experience is LCC modeling.

Intent

Requirements





Life Cycle Costing – Technology and Process Equipment

65

To assess the benefits of the energy conservation measures that the industry has addressed in its design.

To review and verify the performance of the ECM’s.

M&V Plan and M&V Reports in accordance with International Performance Measurement and Verification Protocol (IPMVP) by

• Professional certified by Association of Energy Engineers (AEE, USA)

• Professional with equivalent experience and proficient in ISO 50001 Energy Management Systems (EnMS)

Demonstrate a comprehensive M&V plan has been developed during the design phase of the new project or retrofit.

During operation, the M&V report must be developed by the specialist.

M&V plan developed by the specialist.

M&V report as per IPMVP on a yearly basis.

M&V plan must establish the baseline performance and targeted improvements. The plan must detail the followingi. Baseline performanceii. Parameters required to estimate the achieved savingsiii. Monitoring meters/equipment accuracy and calibration requirement.

iv. Formula to normalize any unforeseen errors (Adjustments)

Intent

Requirements





Energy Conservation Measures Measurement and Verification (M&V)

66

Strategic approach for best results strong energy/sustainability specialist play a vital link to energy savings. Having managerial skills more than technical abilities play a significant role in improving sustainability performance.

Qualified engineer with demonstrated sustainability skills.

Characteristics of best sustainability/energy manager comprise- motivator, facilitator and ability to involve

At a macro level responsible for

• Achievement of results

• Monitoring & sustaining efficiency improvements

• Organizer for training programs

• The initiator of new ideas

• Make sustainability KPI improvement as a permanent activity.

• He must create a database of Sustainability KPIs

Sustainability Awareness session to design and retrofitting team.

Life cycle costing analysis report of major energy and water consuming equipment.

Waste minimization strategies.

Year on Year basis sustainability performance of the selected KPI’s.

Sustainability Policy in line with the National Mission towards sustainable development.

Energy, water and waste minimization strategies in place.

None

Intent

Requirements





Role of Energy and Sustainability Specialist

67

Manufacturing industries have multiple types of energy-consuming equipment/process based on the product manufactured. The ISG is designed to identify the scope to reduce the overall energy intensity. Possible energy-saving opportunities, that shall contribute to improve overall energy intensity, is detailed under in section 3.4.3.

Cost of energy in the UAE is highly subsidized. The low energy cost is one of the major contributing reason for the inefficiency being unnoticed in the manufacturing sector. If the industry could make its efforts and investment towards energy efficiency, Abu Dhabi could achieve the benefits presented in the below graph.

In 2020, IDB has carried out the benchmarking and cost benefit analysis for the energy saving opportunities in the emirate of Abu Dhabi for Industrial Manufacturing sector in Year 2020. Above graph represents the findings of potential energy cost saving opportunity during next 20 years if industrial entities implement reasonable Energy Conservation Measures (ECMs).

NOTE: Cost of electricity projection for the industrial sector has been derived from the historical data from 2010-2017 ( Ref. SCAD 2017 ) . Historical data demonstrate, there is an incremental electricity demand of more than 7%/annum, however for our analysis a conservative 5% incremental demand has been considered for ENERGY COST prediction during 2018-2040.

Pre-Vision

Phase 1(2020-2030)

Phase 2(2030-2040)

Cost saving with 5% energy use reduc�onCost saving with 10% energy use reduc�onCost saving with 15% energy use reduc�on

Mill

ion

AED

2018 2020 2025 2030 2035 2040

Cost of Industrial Electricity(AED)

Cost saving with 5% energy use reduc�on



1519.411939.19

2474.953158.73

4031.44

473.81604.72

68.91151.94 193.92 247.50

3.4.3 ENERGY

A total AED 604 Million/annum can be potentially saved

in 2040 with just 15% of energy efficiency

measures.

68

To encourage the selection of energy-efficient motors in new plant and existing plant.

Motors with efficiency classification IE3 & IE4 as per IEC standard must be selected for all new industries and retrofitting of the existing plant.

Select and install IE3 & IE4 as per IEC standard for all new industries and retrofitting of existing industries

Motor with right VFD must be selected for the process with variable speed requirement.

1. Motor load curve

2. Motor load pattern (Predicted)

3. VFD details

Performance testing of motors against the design, every 3 years from the date of commissioning of the industry.

Motor performance testing for retrofitted fans during commissioning and every 3 years from the date of commissioning.

Motors contribute to major energy consumer in an industry. Potential for energy savings is high. Selection of energy-efficient motors will contribute to energy savings in a constant load process. In the variable load process, VFD/ voltage optimization could help to reduce losses.

Intent:

Requirements:

Implementation Requirements:

Evidence required during the Design and Retrofitting stage:



Industrial AC Motors

69

To encourage right pump sizing and selection of energy-efficient pump during new plant design and retrofitting of the existing plant.

1. Demonstrate that the specialist is involved in the pump sizing, selection.

2. Eliminate bypass valves and valve throttling in all retrofitting projects.

Pump sizing and selection must consider all possible scenarios of the operation.

Right pump technology must be selected based on process requirement.

Pump with right VFD must be selected for the process with variable flow requirement.

1. Pump sizing calculations.2. Pump curves.3. Pump commissioning & performance test results

Performance testing of pumps against the design, every 3 years from the date of commissioning of the industry.

Pump performance testing for retrofitted pumps during commissioning and every 3 years from the date of commissioning.

Pump sizing depends on the mass flow rate and the hydraulic head of the process. The efficiency of the fan shall be calculated with the below equation

Intent:

Requirements:





Industrial Process Pumps

70

Whereηp = Pump Efficiencyq = Flow rate (m3/hr)h = Head or pressure (m) ρ = Density of Fluid (kg/m3) g = Gravitational constant (m2/s)

Ps = Shaft Power (kW) motor

71

To encourage right fan sizing and selection of efficient fans during new plant design and retrofitting of existing industries.

1. Demonstrate that the specialist is involved in fan sizing, selection.

2. Fan to comply with Fan Efficiency Grade (FEG) of 85% as per Air Movement and Control Association (ACMA) or equivalent standards.

Fan sizing and selection must consider all possible scenarios of the operation.

Right fan technology must be selected based on process requirement.

Fan with right VFD must be selected for the process with variable flow requirement.

1. Fan sizing calculations.

2. Fan curves.

3. Fan commissioning & performance test results

Performance testing of Fan against the design, every 3 years from the date of commissioning of the industry.

Fan performance testing for retrofitted fans during commissioning and every 3 years from the date of commissioning.

Fan sizing depends on the mass flow rate and the hydraulic head of the process. The efficiency of the fan shall be calculated with the below equation

Requirements:





Intent:

Industrial Process Fans

72

Whereηf = Fan Efficiencyq = Flow rate (m3/hr)ΔP = Static Head (m) ηmotor = Motor efficiency Mp = Motor Power (KW)

73

To encourage the selection of low energy consuming compressed air system in new plant design and existing plant.

Most suitable compressor technology must be selected by appointing a specialist.

Leakage in the compressed air system must be minimized in the existing plant.

Compressed air system must select an efficient system suitable to plant requirement.

Aluminum pipes shall be selected for the piping to improve pressure loss and workability.

Compressed air system leakage must be assessed, and an area of improvement must be identified.

1. Technical details of the selected compressor for the new and existing plant.

2. Air leakage assessment report for the existing plant.

Air leakage assessment report every three years from the date of commissioning of the new or retrofitted system.

Air leakage can be calculated using the below formula

Air Leakage L = T x Q / (T+t)

% Air Leakage = Air Leakage x 100/ Q

Where T = On load time of compressor (s)

t =Off load time of compressor (s)

Q = Compressor Capacity (l/s)

Intent

Requirements





Compressed Air System

74

To encourage the selection of efficient industrial boilers in plant design and retrofit of the existing plant.

To encourage efficient operation of the boiler, thereby reducing the energy intensity of the product and GHG emission into the atmosphere.

Demonstrate high energy efficiency boiler is selected to the plant process.

Demonstrate the boiler has a smart control system to improve operational efficiency.

Boiler sizing and design operating parameters must consider all possible scenarios of the operation.

The selected boiler must have smart controls to regulate the fuel and excess air supply to the boiler based on process load variation, thereby by achieving higher combustion efficiency.

1. Boiler sizing and operation parameter data.

2. Boiler load Vs thermal efficiency curve.

3. Boiler commissioning & performance test results

1. Performance testing of boiler against the design, every 3 years from the date of commissioning of the industry.

2. Performance testing for retrofitted boiler during commissioning and every 3 years from the date of commissioning.

ASME.PTC4.1. Power Test Code for Steam Generating Units (Part Two) Indirect method can be used to assess the efficiency of the boiler. This standard allows the industry to assess various loss in the steam generation unit and help the process engineer to narrow down to the energy-saving opportunities.

Intent

Requirements





Industrial Boilers

75

To encourage heat loss reduction in steam distribution lines.

Demonstrate that the steam distribution systems are insulated to a sufficient level to avoid heat loss to the environment.

Steam distribution system insulation requirement must be carried out by a specialist.

Effectiveness of the insulation must be tested on an annual basis.

Economic insulation thickness calculation for the steam distribution system.

1. Report of the thermography test undertaken clearly tabulating the identified inconsistencies/heat loss areas in the steam distribution system.

2. Report of corrective actions undertaken to rectify the defects. The thermal image should be provided to demonstrate compliance (before and after rectification).

3. Date stamped photographs

4. Pipe insulation effectiveness testing must be performed once in a year.

Economic insulation thickness for steam pipes can be calculated with formula

Intent

Requirements





Steam Distribution System

76

Where:

Ts = Steam Temperature (°C)

Ce = Energy Unit Cost ($/MJ)

Ci 2 = Insulation and Labor Costs (x1000$/m³)

h = Annual Operating Hours (h)

i = Annual Interest Rate (%)

m = Payback Period (year)

l = Pipe Length (m)

Tam = Ambient Temperature (°C)

λ = Thermal Conductivity Coefficient (W/m-K)

α = Heat-Transfer Coefficient (W/m²-K)

Qr = Radiant Heat (W/m)

L = Insulation Thickness (m)

d1 = Outer diameter of pipe (m)

N = Rate of payback

Ci1 = Annual average insulating costs (AED/m)

77

To optimize the energy consumption of industrial chillers in new project design.

Demonstrate that energy-efficient chiller has been selected for the project.

All chiller units should meet the Minimum Energy Efficiency Ratio (EER) as mentioned in Table-3 of Appendix-E.

All chiller units should meet the minimum EER as mentioned in Table-3 of Appendix-E.

1. Extract from Specification highlighting the requirements on EER.

2. Schedule of AC equipment alongside committed EERs.

1. Approved material data sheets/technical submittal for the installed equipment.

2. Date stamped photograph of the installed units. This should include the nameplate of units which covers type refrigerant used, total kW & refrigerant charge.

None

Intent:

Requirements:





Industrial Chiller System

78

Chilled Water Distribution System

To encourage energy loss reduction in chilled water distribution lines.

Demonstrate that the chilled water distribution systems are insulated to a sufficient level to avoid energy loss to the environment. Design the system to reduce parasitic pumping losses through bypass/re-circulation.

Chilled water distribution system economic insulation requirement must be carried out by a specialist.

Effectiveness of the insulation must be tested on an annual basis.

Economic insulation thickness calculation for the chilled water distribution system.

1. Report of the thermography test undertaken clearly tabulating the identified inconsistencies/energy loss areas in the chilled water distribution system.

2. Report of corrective actions undertaken to rectify the defects. The thermal image should be provided to demonstrate compliance (before and after rectification).


4. Pipe insulation effectiveness testing must be performed once in a year.

Economic insulation thickness can be calculated with below formula

Intent:

Requirements:





79

Where,

Ti = Internal Temperature (°C)

Tam = Ambient Temperature (°C)

λ = Thermal Conductivity Coefficient (W/m-K)

α = Heat-Transfer Coefficient (W/m²-K)

Tdp = Dew Point (°C)

L = Insulation Thickness (m)

D1 = Outer diameter of pipe (m)

80

To encourage usage of high-efficiency condenser with a smart control system and benefit from low operational cost, and thereby reducing the CO2 emissions to the environment.

Demonstrate that high-efficiency condenser suitable for the plant is selected.


2. Schedule of condenser alongside committed EERs.


2. Date stamped photograph of the installed units. This should include the nameplate of units which covers type refrigerant used, total KW & refrigerant charge.

None

None

Intent

Requirements





Refrigerated Storage Area

81

To promote good power quality within the industrial unit and benefit from low operational cost, and thereby reducing the CO2 emissions to the environment.

Demonstrate the electrical system incorporates control measures like

1. Distributed Power Flow Controller (DPFC)

2. Voltage Optimizer

3. Harmonic Filters

4. Capacitor Banks

To maintain high power factor and low hormonic levels, hence power quality.

Energy Efficiency specialist must be appointed to analyses the plant electrical load and impact on power quality.

Based on the assessment suitable control/improvement measures must be incorporated in the design.

Power quality assessment report with details of control measures.

Power quality analysis report on an annual basis.

Industry should adhere to the below mentioned level in the power factor and harmonics

Intent

Requirements





Power Quality

Parameter ValuePower Factor ≥ 0.95

Total Harmonic Distortion (THD)

≤ 8%

82

To encourage the recovery of waste heat from the process and utilize for low-pressure steam generation or preheating requirement.

Demonstrate the design identifies the waste heat generated from the process and suitable recovery system is considered.

Develop Waste heat recovery and utilization strategy

1. Waste heat recovery feasibility report demonstrating source of waste heat and proposed recovery technology (e.g. re generator, recuperator, economizer, waste heat boiler, thermoelectric generator)

2. Provide the calculation and use of heat recovery

Continuous recovery of waste heat and how it is used in the process

Calculate the heat recovery from heat treatment process

Q = V × ρ × Cp × ΔT

Q is the heat content in kCal V is the flow-rate of the substance in m3/hr

ρ is density of the flue gas in kg/m3

Cp is the specific heat of the substance in kCal/kg °C

ΔT is the temperature difference in °C

Intent

Requirements





Process Waste Heat Recovery

83

To encourage process sub-metering facilities. To record and monitor the energy performance of industry/industrial process for identifying future improvement and better mapping of energy usage within industry.

To encourage industry and/or process energy intensity benchmarking and to identify the scope of improvement

Demonstrate that easily accessible and clearly labeled energy sub-meters are provided and capable of monitoring the energy consumption of all and/or high energy-consuming sub-process of the industry.

Sub-meters should be duly labeled for easy identification and tracking.

Develop a sub-metering and monitoring strategy to account for a minimum of the following

1. Heating and cooling system

2. Internal & External Lighting

3. Compressed air system

4. Loads above 50kW

5. Production line-wise sub-metering

6. Sub-process energy metering

In case the facility is contemplating a SCADA/Automatic controls, these meters should be capable of providing the required outputs and integration.

1. Electrical Single Line Diagrams (SLD) showing the type, location and the designation of the meters.

2. Technical specifications of the meters

3. Schedule of Sub-meters in a tabular format providing details of sub-meters, location and loads/areas being served by the sub-meters.

Intent

Requirements



Process Energy Sub-Metering

84

1. As-built Electrical Single Line Diagrams (SLD) showing the type, location and the designation of the meters.

2. As installed Schedule of Sub-meters in a tabular format providing details of sub-meters, location and loads/areas being served by the sub-meters.

3. As-Built drawings showing the locations of the meters.

4. Date stamped photographs of the sub-meters.

5. Annual Energy performance reports and Energy intensity calculation prepared by Certified Energy Manager.

None



85

To lower solar heat conduction to work environment through opaque envelope/glazing elements. To promote use of insulation material in the building envelope to reduce the building operational energy consumption.

Demonstrate that the development team considers the improvement in the energy efficiency of the building’s envelope. The envelope addresses the following1. Horizontal Opaque elements – Roof, Slabs 2. Vertical Opaque element – Wall, door.3. Horizontal Glazing – Sky light.4. Vertical Glazing – Glass Door, windows.

All the plant design and retrofit design for the existing plant should be designed to achieve the environmental parameters (U-values, Solar heat gain coefficients, etc.) for various components of the building Fabric/ Envelope as mentioned in Table-1 of Appendix-E.Rest other buildings in the industries, e.g. Admin and office building shall adhere to mandatory Estidama guideline prescribed in PBRS Version 1 or updated guideline.

1. U- value calculation report for roof, walls and glazing areas2. Sectional drawings of envelope 3. Synergy between heat load calculation and selected U-value for the

envelope4. Specification documents for envelope insulation materials

1. As-Built envelope details i.e.. glazing, roof and wall to confirm compliance to design values.

2. Contractor’s material data sheets for the envelope elements.3. Date stamped photographic evidence as applicable.

Weighted average approach to be used for calculating the overall U- Value of Wall, Roof and Glazing area

Intent

Requirements




Energy Conservation Techniques and Thermal Insulation(Applicable for both Air-conditioned and Non-Air-Conditioned buildings)


86

To identify defects in the plant building envelope and rectify them on time before operations to avoid loss of precious energy through leakages in the envelope (flow of air through gaps and cracks in the fabric of a plant building). To eliminate the air leakage paths through the fabric except through intentional openings.

To ascertain if there are any inadequacies hidden in and around walls, ceilings, windows, doors and air ducts of the plant building as these are potential areas for wastage of energy thus raising the energy costs of the proposed facility.

Thermal Imaging

This principle is used to ascertain the continuity of the insulation following the construction drawing and to identify patterns of heat loss from the facility that are invisible to the naked eye.

Demonstrate that the project has

1. Carry out interior thermal imaging for the Air-Conditioned/climate-controlled spaces to identify the building defects caused by cracks, poor insulation or shoddy construction.

2. Apply appropriate corrective actions to locate and fix the leaks and gaps identified.

3. The tests and the reports should comply with specific conditions. Details as per Table-2 of Appendix-E

1. Thermal imaging carried out by a qualified thermographer.

2. The thermography report highlighting

a. The defects in the building envelope

b. The leakage spots noticed in the space and,

c. Recommendations for rectifications

Intent

Requirements


Envelope Tightness for Air- Conditioned Spaces - Thermal Imaging Technique

87

1. Strategy developed for checking the tightness of the envelope and the description of the system.

2. Detailed Method statement for the proposed works before and after the test.

1. Thermography Report clearly tabulating the following:

a. Inconsistencies/leakage areas in the envelope

b. Corrective actions undertaken to rectify the defects/ leakage. The thermal image before and after rectification.

2. Copy of the contract with the specialist


As described in Table 2, Appendix-E




88

To identify construction defects in the plant envelope and fix them before plant operations to avoid energy loss through leakages in the envelope (leakage of condition air via gaps and cracks in plant building envelope).

To ensure that all the hidden gaps in and around walls, ceilings, windows, doors and air ducts of the plant building are identified as these are the potential areas for energy wastage.

Where evidence provided demonstrates that the industrial facility/warehouse

1. Has installed an airtight envelope

2. Has taken the measures to identify the defects/leakages in the envelope by subjecting it to door blower test

3. The air leakage is contained within a maximum of 10 m3/hr/m2 @ 50 Pascal.

4. Details as per Table-2, Appendix -E

Implementation team/contractor is accountable for the following tasks:

Set up the blower door.

1. Make ready the building for the Pre blower door test.

2. Perform the blower door test.

3. Record the results on performance testing form

4. Report the results and fill the leaks to ensure that the air leakage does not exceed the prescribed limit.

5. These tests need to be conducted with the use of a blower door to measure the amount of leakage of an object. If required these tests can be extended to use the techniques such as thermography and smoke simulations to locate any excessive leakages.

1. Specification documents stating the strategy proposed to be

Intent

Requirements


Envelope Tightness (Performance-based)Blower Door Test Technique

89

deployed for checking the tightness of the envelope, the description of the system and the numerical values proposed to be met.

2. Detailed method statement by the appointed specialist.

1. Test Report demonstrating compliance/corrective actions undertaken to seal the envelope. The report should include all of but not limited to the following

a. Executive summary of the airtightness test

b. Test objective

c. Test Methodology

d. Test details

e. Formal test Report – Positive pressurization test

f. Test Envelope description and Fan diagram

g. Date stamped Photographs as evidence.

2. Copy of the contract with the specialist, providing a definitive time frame for completing all the sub-elements. It also becomes legally binding on their part to submit the report on or before the committed date.

As described in Table 2, Appendix- E.




90

Optimum Engineering design approach to sizing and selection of HVAC systems.

To meet the accurate predicted Cooling loads and Energy use of the facility.

Demonstrate that HVAC systems have been selected after studying substantial impact on the efficiency and operating cost.

1. Zoning the condition area

2. Perform the Heat load calculations

3. Select the Air- Conditioning equipment

4. Design consideration of heat recovery units

Ventilation calculation should be carried out and the results of such calculations should be used for sizing the fresh air systems, exhaust systems and Energy Recovery Units etc.

1. Heat load calculations for conditioned area incorporating the right envelope thermal characteristics

2. Fresh air/ventilation calculation.

3. Schedule of equipment with the capacities

4. Confirmation of air balance for energy recovery system

1. Technical submittal/material data sheets for the installed equipment.

2. Date stamped photograph.

HAP or equivalent software

Intent

Requirements


Evidence required during design and Retrofitting stage



Optimal System Sizing - HVAC

91

To recover the energy content of the exhaust conditions air and reuse for productive purpose.

Demonstrate that project has incorporated strategies to avoid energy loss brought about by exhausting conditioned air to the atmosphere.

Energy Recovery Systems (ERV) should be used in all combined supply & extract air handling units where applicable and found practical in terms of1. Quantity of air extracted.2. Availability of ERV systems for that capacity.

3. Assessment of the benefits.

1. Extract from specifications on the of heat recovery units.2. Schedule of equipment

3. Design drawing highlighting the layout of heat recovery units.


2. Date stamped photograph of the installed units.

None

Intent

Requirements





Installation Of Energy Recovery Units And Regulated Air Intake System

92

Energy optimization for Air Conditioning units

Demonstrate that energy-efficient cooling equipment has been procured and installed Note.

The selected unit should be consistent with the capacities indicated under "Optimal System Sizing - HVAC"

All Air Conditioning units should meet the Minimum Energy Efficiency Ratio (EER) as mentioned in Table-3 of Appendix- E.

For those units that do not find mention in the Table-3, the Energy Efficiency Ratio (EER) should follow the requirements set out in ASHRAE 90.1-2019.


2. Schedule of AC equipment alongside committed EERs.

1. Material data sheets/technical submittals for the installed equipment.

2. Date stamped photograph of the installed units. This should include the nameplate of units which covers type refrigerant used, total kW & refrigerant charge.

None

Intent

Requirements





Selection of Cooling Equipment with High Energy Efficiency Ratio (EER)

93

To avoid the HVAC units from operating during non-essential hours and unoccupied area, thereby saving wastage of energy and reducing the environmental impact from unnecessary operation of the units.

Demonstrates that the HVAC system design has incorporated the required strategies for efficient control and operation of the units.

Zoning strategies is applied for the entire HVAC controlled area. Zones in the industrial facility or warehouse should be created keeping in mind various factors such as individual temperature preferences, window size and direction of sunlight, flooring, and purpose of the area (workshop/kitchen /gym/office/process area).

Provide the CO2 in the breathing zone of occupied space. Sensors should be placed 4-6 Feet above the floor.

All thermostats linked to air conditioning or comfort cooling systems should be fitted with a programmable thermostat which at the basic level provides on/off controls (timer controls) at a minimum level. Temperature control functionality is encouraged as it provides additional savings.

The control should be simple and capable of operating independently without the need for BMS or any advanced integrations.

The programmable thermostats shall be fixed on an interior wall, that shall not be affected by heating/cooling diffusers or other openings like doors, windows, skylight, direct sunlight or bright lamp which may potentially influence their functioning

1. Specification of thermostat incorporating the programming functionality.

2. Electrical Layout showing locations of controls for the thermostats.

3. Provide the CO2 control Sequence of Operation.

1. Approved material data sheets

2. As-built layout clearly indicating the thermostat location and CO2 Sensor.

3. Date stamped photograph of installed timer unit (s).

None

Intent

Requirements


Evidence required during the Design, and Retrofitting stage

Programmable Thermostats and CO2 Sensors for HVAC System



94

To reduce the power density of interior lighting space

Demonstrates that the interior lighting levels are improved and not exceed those limits prescribed by Table-4, Appendix- E.

The Interior lighting levels (both plant building and office areas) should comply with the limits specified in Table -4 of Appendix-E.

For those units that do not find mention in the Table -4 of Appendix-E, the lighting levels specified should be at least 20% lesser than those levels prescribed in ASHRAE 90.1-2019.

1. LPD calculation

2. Specifications of the selected interior lighting

1. As-built calculations to confirm the design values/lighting values required in the guideline.

2. As-built drawings.

3. Date stamped photos of the installation

Apply either space by space method or whole building method

The manufacturing facility shall follow the calculation methodology specified in ASHRAE 90.1: 2019.

Light Power Density - Interior



Intent:

Requirements:


Evidence required during the Design, and Retrofitting stage:

95

To turn off internal lighting system during non -essential hours and thereby saving energy.

Demonstrates that select internal lighting systems have incorporated strategies to switch on/automated control based on the needs/specific timings etc.

Installation of occupancy sensors/motion sensors for automated control of internal lighting.The Occupancy sensors after due consideration shall be provided for the following areas within the facility1. Areas within the industry if relevant and appropriate2. Workshop area3. Pedestrian pathway4. Pantry5. Prayer room.6. Corridor/passage.7. Ablution8. Other areas if found suitableExceptions: Process area/Machine areas

1. Automated lighting control strategy along with the details of the control scheme.

2. Electrical drawings indicating the above strategy

1. Approved material data sheets of the electrical interlock used in the project.

2. Date stamped photographic evidence.3. Relevant documents such as as-built drawings, material submittals

etc

Task lighting if applicable can potentially be engaged as one of the strategies to fulfill the requirements of this ISG measure.Requirements are defined in IECC Section C405.2.2 and ASHRAE 90.1 Section 9.4.1

Intent

Requirements



Automated Lighting Control/Motion Sensor For Internal Lighting



96

To optimize the energy use of exterior lighting in order to reduce the total lighting-related energy use of the facility.

Where evidence demonstrates that the exterior lighting levels are improved and Not exceed those limits prescribed by Table-4, Appendix-E.

The Exterior lighting levels in the industry development should comply with the limits specified in Table -4 of Appendix-E.

For those units that do not find mention in the table – 4 of Appendix-E, the lighting levels specified should be at least 20% less than those levels prescribed in ASHRAE 90.1-2019.

1. Proposed specifications on the lighting levels.

2. A comparative table with the LPD values for IDB case and the proposed case scenario for various areas of the project including the overall savings achieved.

1. As-built calculations to confirm the design values/lighting values required in the Guideline.

2. As-built drawings.

3. Date stamped photos of the installation

None

Intent

Requirements





Exterior Light Power Density

97

Automated operation of the external lighting systems during non- essential hours to avoid unnecessary use of energy during such operations.

Demonstrates that the external lighting systems have incorporated strategies to switch on based on the needs/specific timings.

Switching external lighting (or specific circuits of the lighting system as per the project needs) by any of the following ways:

1. Daylight sensors (for precise switching and control of lights based on daylight availability).

2. Control motion control devices, occupancy sensors (if relevant to the project).

3. Timer control for operation at preset times.

1. Extract of the design specification confirming the controls required for external lighting.

2. Electrical layout/drawings highlighting the control strategy.

1. Approved material data sheets of the external lighting controls used in the project

2. As-built layout clearly indicating the thermostat location.

3. Date stamped photograph of installed timer unit (s).

None

Intent

Requirements




Control of External Lights


98

To encourage the use of renewable energy and reduce dependence on grid power for domestic hot water, thereby avoiding the GHG emissions associated with fossil fuel.

Demonstrates that feasibility is assessed for the solar thermal hot water system and reduction in CO2 emission is estimated.

Solar water heating (solar thermal) technology shall be employed for domestic hot water requirements.

The solar hot water heating system must incorporate measures for the efficient distribution system, pipe insulation and use of energy-efficient electric hot water system (which is normally used as backup).

1. Solar Water system Sizing and annual cost saving

2. Details of the solar system proposed i.e. power generated, heating capacity etc.

3. Extract of specification about the system

4. Plumbing drawings and schematics incorporating the above.

1. Material data sheets/technical submittals

2. Date stamped Photographic evidence

3. Commissioning report

4. As-built plumbing/water supply layout showing the installed solar water heating system.

None

Intent:

Requirements:



Renewable Power Source - Industrial Hot Water



99

To promote the use of renewable power and reduce dependence on grid power for a proportion of the energy (lighting, ventilation) demand, thereby reducing GHG emissions associated with fossil fuel.

Demonstrate that a feasibility study considering renewable power generated at the site has been carried out.

Renewable energy system shall be utilized to generate power and cater to select loads of the development such as ventilation load, external security lighting loads, security lamps and any other lighting requirements specific to the project.

1. A renewable report comprising energy calculations and minimum kW of renewable energy proposed to be generated in the project

2. Details of the Solar renewable energy system proposed.3. Extract of specification containing the renewable energy system.

4. Electrical drawings/layout incorporating the scheme.

1. Approved material data sheets/technical submittals2. Date stamped Photographic evidence3. Commissioning report

4. As-built drawing of the renewable power source

Applicable on-site renewable technologies in Abu Dhabi include, but are not limited to:

• Solar energy, including solar electricity and solar thermal systems

• Landfill gas systems and• Organic/agricultural and animal waste to energy systems.

Any other form of renewable technology may be proposed and will be subject to approval from IDB.

Intent

Requirements





On-site Renewable Energy Generation

100

On-site Systems: On-site systems are defined as renewable energy generated within the project site boundary.

The on-site renewable energy feasibility study must cover a minimum of three renewable technologies and cover the following:• Annual energy generated from each renewable technology; • Percentage of total annual energy consumption supplied through on-

site renewable technologies; • Payback; • Water use; • Land use; • Visual issues; • Maintenance; and • Where the renewable technology will be used (e.g. car park lighting

systems).

The study must include a summary matrix detailing the relative merits of each renewable technology in reference to the above issues with the selected technology highlighted.

Small Scale Solar PV Systems (Grid Connected)

Industry should follow Regulation and Supervision Bureau’s “Small-Scale Solar Photo-voltaic Energy Netting Regulations”.

101

To encourage the use of daylighting technologies thereby enhancing the quality of the work environment while at the same time-saving energy and avoiding associated GHG emissions.

Demonstrates that the industrial design has explored the possibility and accordingly incorporated daylighting technologies.

The design should seek to embrace a judicial mix of solar daylighting systems i.e. systems/technologies and Architecture manifested in one of the following ways:1. Daylight optimized building footprint2. Skylights (Passive or Active)3. Tubular daylighting devices4. Daylight redirection devices5. Solar Exterior shading and control devices.6. The reflectance of room surfaces7. Others

1. Copy of the relevant clause of the specification detailing the daylighting.

2. Architectural drawings highlighting the skylight.3. Lighting levels - calculations in support of the decisions.

1. As-Built drawing.2. Date stamped site photograph of the daylight installation3. As-Built lighting calculations.

None

Intent

Requirements





General Plant Lighting - Use of Solar Daylighting Technologies

102

103

Compared to other parts of the world, middle east countries does not have ample surface or underground freshwater to fulfill its domestic and industrial need. Hence the middle east region desalinates the seawater to achieve portable water quality. The portable water supplied for domestic and industrial usage has high embedded energy and GHG emission. Conservation of water contributes

• To conserving the marine pollution (temperature and salinity)

• To reduce GHG emission to the atmosphere

• To reduce the capital investments to increase the capacity

• To reduce the distribution infrastructure for increased demand

3.3.4 WATER

AED 79 Million/annum saving in 2040 with 15%

water efficiency measures, higher percentage of

water can be saved with better water management

techniques.

In 2020, IDB has carried out the benchmarking and cost benefit analysis for water saving opportunities in the emirate of Abu Dhabi for Industrial Manufacturing sector. Above graph represents the finding of potential water cost saving opportunity during next 20 years if industrial entities implement reasonable Water Conservation Measures (WCMs).

NOTE: Cost of water projection for the industrial sector has been derived based on the historical data from 2010-2017 (Abu Dhabi Statistics Center “Water Statistics 2018"), there is an incremental water demand of more than 2% per annum. However, for our analysis a conservative 1% incremental demand has been considered for forecasted WATER COST during 2018-2040.

Cost of water tariff has been kept CONSTANT throughout the projected period.

104

To encourage process wastewater treatment to tertiary level and re-use in the plant process.

To encourage a reduction in wastewater discharged to ADSSC network.

Where evidence provided demonstrates that the processes wastewater discharged to ADSSC network is reduced or zero; through treatment and/or reuse.

Treating the process wastewater to tertiary level with Membrane Bioreactor (MBR), Reverse Osmosis (RO) and any other technology; to use in the plant process.

Achieve zero liquid discharge to ADSSC network by implementing natural evaporation or thermal process

1. Feasibility study exploring the possibility of achieving ZLD.

2. Description and specifications of selected technology and equipment.

3. Design drawings/layout showing the collection/ treatment system.

1. Approved material datasheet of the greywater recycling system.

2. Date stamped photographic evidence of the installation.

3. As-built drawings of the recycling system.

None

Intent

Requirements





Integration of Zero Liquid Discharge (ZLD) Technologies

105

To reduce water footprint in sanitary applications by selecting water efficient sanitary fittings.

Extract of the specification detailing water efficiency/flow limits for sanitary fittings.

The flow and flush fixtures used in the project should conform to the flow rates specified in the Table-5 of Appendix-E.

1. The relevant extract of the specification detailing the sanitary fittings.

2. Plumbing drawings highlighting the flow/flush rates of the fixtures.

1. Approved material datasheet of flow/flush fixtures installed.

2. Date stamped photographic evidence of the fixtures.

None

Intent

Requirements





Efficient Water Fixtures

106

To reduce potable water consumption in soft landscape irrigation.

Provide specification that details requirement for a low-water irrigation strategy/system

All irrigation should implement either drip irrigation or sprinkler systems for soft landscape areas.

1. Drip irrigation systems: it should employ strategies such as moisture sensors, landscape zoning, timers, controllers and self-closing nozzles.

2. Sprinklers System: It should employ a combination of high-efficiency sprinkler with timer switch controls should be utilized.

1. Marked-up site plan showing all landscaped areas to be irrigated.

2. Specifications of irrigation systems to be installed.

3. Details of the Native plants proposed to be used.

4. Water demand calculation for the soft landscape area

1. Approved material datasheet of the irrigation equipment.

2. As-built landscaping drawing.

None

Intent

Requirements





Landscaping – Efficient Irrigation System

107

To encourage the use of recycled wastewater for irrigation and eliminate the consumption of potable water for irrigating soft landscape.

Demonstrate that entire irrigation system uses the recycled wastewater for irrigation, or the irrigation has been totally eliminated.

The irrigation system specified for internal or external planting and/or landscaping uses only the following

a. On-site recycled wastewater

b. Non-potable water treated by ADSSC

c. Planting species that thrive in UAE climatic conditions

d. The system uses reclaimed condensate water from air conditioning systems

1. Wastewater treatment system design drawings

2. Outlet recycled wastewater characteristics

3. Irrigation system network drawings and water demand calculation

1. Test report of outlet recycled wastewater treatment plant confirming the suitability to use for irrigation and internal requirements.

2. Date stamped photographic evidence of the installation

3. As-built drawings of the landscaping and irrigation system.

None

Requirements




Recycled Wastewater For Irrigation

Intent


108

To encourage the collection, treatment and re-use of greywater for toilet flushing needs and reduce freshwater demand.

Greywater collection, treatment, and storage system specification.

The use of greywater for toilet flushing should be explored and if feasible considered.

1. Feasibility study exploring the possibility and ruling out the use of greywater recycling; OR

2. Description and specifications of the greywater recycling system.

3. Design drawings/layout showing the treatment system.

1. Approved material datasheet of the greywater recycling system.



Industry must obtain necessary license/permit from DOE/ADSSC for the interior recycling of water.

Intent

Requirements





Treated Greywater Usage

109

To encourage the collection and re-use of HVAC condensate water to meet toilet flushing needs/cleaning/landscaping & irrigation and reduce freshwater demand.

HVAC condensate water collection, treatment, and storage system specification.

The use of condensate water for toilet flushing/cleaning/landscaping & irrigation systems should be explored and if feasible considered.

1. Feasibility study exploring the possibility and ruling out the use of condensate water recycling; OR

2. Description and specifications of condensate water recycling system.

3. Design drawings/layout showing the collection/treatment system.

1. Approved material datasheet of the condensate water recycling system.



Industry must obtain necessary license/permit from DOE for the interior recycling of water.

Condensate Water Recycling

Intent

Requirements





110

111

This section discusses Non-hazardous waste & Hazardous waste, and by-products generated in the industry. Waste is generated during the process of conversion of raw material to a final product. This KPI doesn’t talk about the reuse or recycle of the waste but is only the indicator of the waste generated from two categories Non-hazardous and hazardous. Manufacturing industries primary target shall be to reduce the process waste generation to maximize the first time yield and mass balance yield, minimizing internal rework and recycling. On the other hand, the industry shall look possible opportunity to recycle the generated waste. This would reduce the load on the landfills in Abu Dhabi. In addition, industries & IDB shall find opportunities to utilize the by-product generated within Abu Dhabi to be utilized in other manufacturing processes. These measures will result in a great economic benefit to the industrial section

In 2020, IDB has carried out the benchmarking and cost benefit analysis for reducing the waste in Abu Dhabi for Industrial Manufacturing sector. Above graph represents the findings of potential waste reduction cost saving opportunity during next 20 years if industrial entities implement reasonable waste reduction & management techniques.

NOTE: Cost of waste transportation and disposal projection for the industrial sector has been derived based on the historical data from 2010-2017 (Ref. SCAD Waste Statistics 2018). Historical data demonstrate that there is an incremental waste generation of more than 10% per annum. However, for our analysis a conservative 5% incremental waste generation has been considered for WASTE GENERATION prediction during 2018-2040.

3.3.5 BY-PRODUCT AND WASTE MANAGEMENT

Pre-Vision

Phase 1(2020-2030)

Phase 2(2030-2040)

2018 2020 2025 2030 2035 2040

Cost Post 7.5 %Cost of Disposal Business As Usual scenario(BAU) (AED)

Mill

ion

AED

201.0

256.6

327.4

417.9

157.5138.8

157.5

125.664.1 81.8 104.4

Estimated cost of industrial waste disposal

& transportation was AED 150 Million/Annum

(Derived from SCAD 2018 Report).

112

Possible list of Non-hazardous process waste1. Hot rolled coil trimming, slit coils and end scrap2. Defective GRP Products3. Plastic injection scrap4. Dry concrete5. Aluminum scrap6. Metal scrap7. Wooden/packaging materials

8. Organic waste

To encourage resource conservation.

Provide evidence that process non-hazardous waste is 1. Recycled on-site or 2. Sold to other industry 3. Sent to TADWEER approved recycling facility

Process Engineer/Industrial Sustainability Manager must identify the possible diversion option for all process non-hazardous waste

Feasibility study exploring the possibility process waste diversion

1. Approved list of industries that use the process waste2. Tracking log for the diverted process waste along with manifest from Bolisaty

The manufacturing facility must send the non-hazardous process waste to TADWEER approved recycling facility, which should be duly manifested on the Bolisaty system.

Diversion of Non-hazardous Waste To Recycling Facility/Industries

Intent

Requirements





113

Possible hazardous waste 1. Hot rolled coil trimming, slit coils and end scrap 2. Iron oxide from acid regeneration 3. Spent liquor from acid regeneration 4. Aluminum scrap (sharps and burr) 5. Residual silica 6. Per sludge 7. Used lubricant oil

8. E-waste

To encourage treatment and reuse of hazardous waste.

Provide evidence that demonstrates the hazardous wastes of the plant can be diverted from landfill.

Demonstrate that hazardous waste generated from industry is being treated on-site or sent to TADWEER approved hazardous waste treatment facility.

Process Engineer/Industrial Sustainability Manager must identify the possible diversion option for all hazardous waste to be diverted from landfill.

Prioritized treatment options:

1. On-site hazardous waste treatment system

2. TADWEER approved off-site hazardous waste treatment facility

Feasibility study exploring the possibility process waste diversion

Diversion of Hazardous waste

Intent:

Requirements:



114

1. List of hazardous waste generated from manufacturing process 2. Evidence for on-site hazardous waste treatment system(s)

3. Log for the diverted hazardous waste along with manifest from Bolisaty

The manufacturing facility must send the non-hazardous process waste to TADWEER approved recycling facility, which should be duly manifested on the Bolisaty system.



115

To encourage space allocation for storage of operational-related recyclable waste streams.

To avoid the commingle of recyclable and non-recyclable waste

Provide an accessible waste storage room / space for recyclables generated from the manufacturing facility.

Dedicated space for recycling the waste generated from the process. Recyclable space shall contain separate skips / bins to segregate followings but not limited to:

1. Paper and Cardboard

2. Metal scrap

3. Wood

4. Glass

5. Dry sludge containing the valuable items

1. Specification requiring the installation of bins.2. Marked up a plan showing proposed location within the unit.

1. Date stamped photo of installed recycling facilities.2. Letter of commitment from the Recycling agencies about their

involvement in the operations.

NoneCalculations and Methodology

On-site Recycling Facility Storage and Collection of Recyclables

Intent:

Requirements:




116

Industrial workers are spending one-third of their day in the workplace. The work environment has a considerable impact on their health. This section identifies the possible scope for improvement in the indoor air quality and noise level in the work area.

3.4.6 INDOOR ENVIRONMENT QUALITY

117

To ensure sufficient fresh air rates by establishing minimum Indoor Air Quality (IAQ) performance in order to maintain a healthy indoor environment, thus contributing to the comfort and well-being of the workers.

To provide the provision for air pollution control equipment’s (such as local exhaust ventilation (LEV),VOC hoods,air scrubbers,cyclone collectors,bag filters, etc.) in the process.

Provide calculation and specification that demonstrates each space within the manufacturing facility meets recommended minimum fresh air rates set by ASHRAE.

Provide specification/drawings the demonstrate necessary pollution control equipment are installed in the process to contain or control indoor air pollution.

Meet the minimum requirement of ASHRAE 62.1-2016, Ventilation for acceptable indoor air quality (IAQ) and design ventilation systems to meet/exceed the rates.

Ventilation Rate Procedure or the applicable Abu Dhabi local code whichever is stringent, shall be considered while designing mechanical ventilation system.

Indoor pollutant source from the process is assessed and control equipment is selected to control pollution and comply with OSHAD-SF TG Occupational Air Quality Management Version 3.1 & Occupational Standards and Guideline Values, Version 3.0.

Calibrated monitoring equipment with an accuracy class meeting US EPA Indoor Air Quality Assessment Program must be used to monitor indoor air quality.

1. Extract of specification on the ventilation/indoor air pollution control system.

2. Fresh air calculations for all areas3. Schedule of the ventilation air quantity along with the flow rate of

ventilation being provided.

Ventilation and Minimum Indoor Air Quality (IAQ)

Intent

Requirements



118



4. Feasibility study for the indoor air pollution control strategy and equipment for the plant.

1. Material datasheet of the fresh air fans/indoor air pollution control systems.

2. Date stamped photographic evidence of the installation3. As-built drawings of the fresh air/ indoor air pollution control system.4. Indoor air quality survey after commissioning and within one year of

plant operation through a third-party environmental consultant.5. Annual indoor air quality performance report through a third-party

environmental consultant registered under Environmental Agency-Abu Dhabi (EAD).

None

119

To recognize the provision of process noise control strategy in order to maintain a healthy indoor environment, thus contributing to the comfort and well-being of the workers.

Demonstrates that noise survey is carried out and noise generated in the plant process is evaluated and control measures are identified.

Evaluate the noise generated from the process plant and identify the control strategy.

Meet minimum requirements set in OSHAD SF for noise level at the workplace. For plants with high noise level provide noise protection Personal Protective Equipment (single & double protection) and limit the worker's exposer time as per OSHAD.

1. List of Noise generation sources in tabular form for all areas.

2. Noise Modeling study and recommendation to incorporate the noise reduction techniques and strategy

1. As-built drawings of the noise control system

2. Noise survey for the entire plant after commissioning and within one year of plant operation through a third-party environmental consultant. After commissioning, a noise survey shall be carried out once in 5 years.

3. Noise Modeling study report with contour map.

None

Intent

Requirements





Plant Indoor Noise

120

To provide healthy indoor air quality with suitable ventilation systems and controls and thus reduce the risk to health from passive smoking.

Demonstrates there will be a smoking ban in common areas and there is a dedicated smoking room/space away from all entrances, ventilation air intakes and openable windows.

The following demonstrates compliance:

1. Smoking ban in place covering all public and staff-only areas of the plant buildings “No Smoking” signs boards should be posted at suitable points, i.e. common lobby, offices and building entrances so that they are clearly visible to all occupants.

2. If smoking is permitted in indoor environment, then there shall be a dedicated smoking rooms with a proper ventilation rate. Smoking rooms must be directly exhausted to the outdoors and must effectively contain, capture and remove tobacco smoke.

3. If Smoking is permitted in Ambient environment then external smoking area shall be 25 m away from all entrances, ventilation air intakes and openable windows.

Extract of specification confirming " The smoking ban"

Extract of specification and marked-up drawings confirming " The presence of appropriate signage indicating that there is a smoking ban"

Extract of specification and marked-up MEP drawings confirming:

1. Smoking room ventilation system

2. The flow rate of ventilation being provided

3. Separation of the smoking room

4. Layout highlighting external smoking areas and distance from air intakes, main entrance, other doors & openable windows

Tobacco Smoke Zoning

Intent

Requirements



121


Building/site inspection confirming that the SMOKING BAN NOTICE is in effect.

Smoking room ventilation system commissioning data and photographic evidence for no smoking signage within plant building/premises.

Building Smoking Survey Report demonstrating that occupants are not having any complaints related to smoking

NoneCalculations and Methodology

122

To encourage a healthy indoor environment through low emissions of volatile organic compounds (VOCs) containing finish materials.

Demonstrates that organization has implemented a sustainability policy to procure low emitting finishes and fittings applied/installed in the plant building.

All finishing materials such as adhesives, sealants, paints & coating used on the interior of the building/warehouse/workshop area must comply with the requirements as mentioned in the Table-6 of the Appendix-E.

Sustainable procurement policy demonstrating the management commitment to use the low VOC materials

Extract of specification confirming the finish material VOC limits as mentioned in Table-6 of the Appendix-E.

1. Tracking sheet of each indoor adhesive sealant, primer product, aerosol adhesive and indoor paint and coating

2. Manufacture technical data sheet, VOC test reports for all materials listed in the tracking sheet

3. Date stamped photographic evidence.

4. VOCs (BTEX & Formaldehyde) measurements for the indoor environment

None

Intent

Requirements





Low Volatile Organic Compounds (VOCs) use in the Industrial facility

123

To reduce the long-term negative impact to the Earth’s stratospheric ozone layer by release of ozone-depleting substances to the atmosphere.

Demonstrates that all refrigerant types& fire suppressants used in plant building have an Ozone Depletion Potential (ODP) of zero unless otherwise stated for specific purpose.

CFCs use is prohibited in the industrial facility.

HVAC, Refrigeration systems, fire suppression system must use Zero Ozone Depleting Potential (ODP) substances.

Specifications showing the substances used for each of these items and supporting technical documentation confirming zero ODP.

1. Approved material data sheet

1. Date stamped photographic evidence of the units where applicable along with the nameplates of installed units

None

Intent

Requirements





Usage of Low Ozone Depleting Potential Materials

124

125

CASE STUDY ILLUSTRATION

126

127

This section of the report presents some of the illustrations of energy saving opportunity. Motors and pumps are very common in industry. Hence similar case study is presented below.

Illustration 1 – Effect of throttling valve

There is a pump, pumping process fluid to the process. The line pressure before the valve is 4.8 kgf/cm2 and the process require flow of 55 lps at 3 kgf/cm2 pressure. Hence the industry has value that is open by 60% to reduce the pressure to 3 kgf/cm2.

Design:Pump Capacity = 85 lpsPump Head = 4 kgf/cm2

Existing head = 4.8 kgf/cm2

kWExisitng = 55 x 48 / (102 x 0.7) = 37 kW

Modified:Pump Head = 3 kgf/cm2

kw-proposed = 55 x 30/ (102 x 0.7)= 23 kWCapacity Saving = kW-existing - kW-proposed = 37-24 =14 kW

4. CASE STUDY ILLUSTRATION

128

This illustration has energy saving by proper pump sizing to avoid loss due the partial closure of the valve.

Illustration 2 – Energy saving AC Motor with varying load (Automatic Star-Delta-Star)

• Automatic star-delta-star converter has load sensor & Timer

• Capacity α V2

• Principle of Voltage optimization

A motor of capacity 18.5 kW can save energy when they switch the starter mode (Star Mode and Delta Mode). Below table presents the motor starting parameter on delta and star starting mode and achievable energy savings.

Parameter Delta Mode Star ModeVoltage (V) 415 415Current (A) 18.5 9.5Power Factor 0.505 0.873Power Input (kW) 6.72 5.96Speed (rpm) 1469 1454

Energy Savings 0.76 kW11.3%

129

Illustration 3 –Energy Savings due to flash steam recovery

Flash steam is produced when high pressure steam is released to a low-pressure environment. Below figure presents the flash steam recovery from boiler blow down (steam generation side) and steam consuming equipment (steam utilization side).

Below case represents the steam process and flash steam and its recovery. Utilization of steam from section 101,102,103,104, 105 & 128. Initially the flash steam is released to atmosphere

117

Energy Savings 0.76 kW 11.3%

Illustration 2 –Energy Savings due to flash steam recovery

Flash steam is produced when high pressure steam is released to a low-pressure environment. Below figure presents the flash steam recovery from boiler blow down (steam generation side) and steam consuming equipment (steam utilization side).

Boilers blow down (steam generation side) Steam consuming equipment (steam utilization side)

Below case represents the steam process and flash steam and its recovery. Utilization of steam from section 101,102,103,104, 105 & 128. Initially the flash steam is released to atmosphere

130

Flash steam generated from each process is connected to a hot water generator, which generate hot water which can be used in steam generation Doing so will save thermal energy as well as fuel fed to the boiler

FlashVessel

Consumed in Section 104

CondensateTank

CondensateTank

CondensateTank

Flash Steam To A

tmosphereCondensate

to NG Fired Deaerator Tank

Condensate & Steam @ 3Kg from Sec�on 105

*1 Condensate to NG Fired Deaerator

*1

Condensate & Steam @ 3Kg from

Sec�on 101, 102,103

Condensate & Steam @ 3Kg from Sec�on 128

Flash Steam @ 3.5Kg

Condensate & Steam

@ 11Kg from Sec�on 104

*1

*1

CondensateTank

131

132

133

APPENDIX

134

135

Substance Symbol Max. Allowable Limits (ug/m3)

Average Time

Sulphur Dioxide SO2 35015060

1 hour24 hours1 year

Carbon Monoxide CO 30 (mg/m3 )10 (mg/m3 )

1 hour8 hours

Nitrogen Dioxide NO2 400150

1 hour24 hours

Ozone O3 200120

1 hour8 hours

Total Suspended Particles TSP 23090

24 hours1 year

Particulate Matter (with 10 microns or less in diameter)

PM10 150 24 hours

Lead Pb 1 1 yearSource: Cabinet Decree (12) of 2006 regarding Regulation Concerning Protection of Air from Pollution

Table 1: Recommended Ambient Air Quality Standards for the Emirate of Abu Dhabi

Appendix -A: Regulatory Air Quality and Noise Level standards

Table 2: Air Pollutants Emission Limits for Stationary Combustion Sources

Substance Symbol Sources Emission Lim-its (mg/Nm3)

Visible Emissions - All Sources 250

Nitrogen Oxides (expressed in Nitrogen di-oxides (NO2))

NOx Fuel Combustion units:Gas FuelLiquid Fuel

350500

Turbine Units:Gas Fuel Liquid Fuel

70150

Sulphur Dioxide SO2 All Sources 500Total Suspended Particles TSP All Sources 250Carbon Monoxide CO All Sources 500

Source: Cabinet Decree (12) of 2006 regarding Regulation Concerning Protection of Air from Pollution

136

Substance Maximum Allowable Limits (mg/m3)

Respirable DustCrystallized Silica (Quartz) 0.1Un-Crystallized Silica (Graphite) 2.5Asbestos (Chrysotile) 2 (fiber/cm3)Total DustUn-Crystallized Silica (Graphite) 10Stone Wool 10Silica Gel 10Portland Cement 10Dust from Biological SourcesHard Wood Vapour 1Soft Wood Vapour 5Other SourcesInorganic Lead 1


Area Allowable Limits for Noise Level (dBA)Day (7 am – 8 pm) Night (8 pm –7 am)

Residential areas with light traffic 40-50 30-40Residential areas in the downtown 45-55 35-45Residential areas which include some workshops and commercial business or residential areas near highways

50-60 40-50

Commercial areas and downtown 55-65 45-55Industrial areas 60-70 50-60


Table 4: Allowable Limits for Ambient Noise Level in Different Areas

Table 3: Maximum Allowable Limits for Air Pollutants inside Working Areas (Dust)

137

S.NO Substance CAS NO:

Threshold Limit Val-ue (TLV)

Unit Notation

TWA STEL1 CO2

124-38-95000 9000

3000054000

ppm mg/m3

A4

2 CO 630-08-0

25 29

--

ppmmg/m3

BEI

3 Coal Dust (Anthracite) -0.4®

ppmmg/m3

4 Coal Dust (Bituminous) -0.9®

ppmmg/m3

A4

5 Flour Dust -0.5 (IFV)

--

ppmmg/m3

SEN

6 Formaldehyde --

C 0.3C 0.37

ppmmg/m3

SEN; A2

7 Grain Dust (Oat, Wheat, bar-ley)

-4

--

ppmmg/m3

-

8 H2S 11.4 57 ppmmg/m3

-

9 NO2 35.6 59.4 ppmmg/m3

A4

10 Silica (Inhalable Particle) -10 --

ppmmg/m3

-

11 Silica (Respirable Particle) -3

--

ppmmg/m3

-

12 SO2 --

0.250.65

ppmmg/m3

-

13 SO2 5213.75

13034.4413

µg/m3mg/m3

NIOSH

Table 5: Occupational Air Pollutants Limits

138

S.NO Substance CAS NO:

Threshold Limit Val-ue (TLV)

Unit Notation

TWA STEL

14

OzoneHeavy Work

Moderate Work

Light Work

Heavy, Moderate, or Light workloads (≤ 2 hrs)

93.250.1149.20.16186.50.23730.4

-

-

-

-

µgm3mg/m3µg/m3mg/m3µg/m3mg/m3µg/m3mg/m3

A4

A4

A4

A4

15Particulates Not Otherwise Regulated (PNOR)TotalRespirable

150005000

--

µg/m3µg/m3

NIOSH

16 PM10 150/24 hrs - µg/m3 EAD17 BETX

Benzene0.5 2.5 ppm Skin; A1;

BEI

1.6 8 mg/m3 A4;BEI

20 - ppm

18 Toluene 2073

--

ppmmg/m3

A4; BEI

19 Ethylbenzene 100434

125543

ppmmg/m3

A3; BEI

20 Xylenes 100434

150651

ppmmg/m3

A4; BEI

Reference: OSHAD SF-Standards and Guideline Values Version 3.0 – 1st July 2016Note: TWA: 8 Hour, time-weighted average exposure concentration. STEL: Short-term Exposure Limit. Usually, a 15-minute time-weighted average (TWA) exposure that shall not be exceeded at any time during a workday, even if the 8-hour TWA is within the TLV-TWA.NIOSH: http://www.cdc.gov/niosh/docs/2005-149/pdfs/2005-149.pdf

139

Exposure Level, L

Duration, T Exposure Level, L

Duration, T

dBA Hour Minutes Second dBA Hour Minutes Second80 25 24 - 106 - 3 4581 20 10 - 107 - 2 5982 16 - - 108 - 2 2283 12 42 - 109 - 1 5384 10 5 110 - 1 2985 8 - 111 - 1 1186 6 21 112 - - 5687 5 2 113 - - 4588 4 - 114 - - 3589 3 10 115 - - 2890 2 31 116 - - 2291 2 - 117 - - 1892 1 35 118 - - 1493 1 16 119 - - 1194 1 - 120 - - 995 - 47 37 121 - - 796 - 37 48 122 - - 697 - 30 - 123 - - 498 - 23 49 124 - - 399 - 18 59 125 - - 3100 - 15 - 126 - - 2101 - 11 54 127 - - 1102 - 9 27 128 - - 1103 - 7 30 129 - - 1104 - 5 57 130-140 - - <1105 - 4 43

Source: Appendix 1, CoP 3 – Occupational Noise V 3.1 June 2018

Table 6: Occupational Noise Level Limits

140

Appendix -B: Gap Analysis Checklists

General Requirements

SI. No. Particulars Details1 Industry Name 2 Industry License No. 3 Location 4 Year of Establishment 5 ISG Key Team

Members DetailsEnergy Specialist Environmental

Professional Process Expert

Subject Matter Expert (Not Mandatory)

8 Final List of Products and Raw Materials

Prepare a list of Final Products and associated Raw Materials

9 Operational Production Capacity

The list production capacity of each product for every quarter

10 Plant Layout

Energy

SI. No. Particulars Details1 Mass Balance Diagram 2 Energy Balance Diagram Schematic Energy Flowchart within Process3 Single Line Diagrams (Electrical) SLD needs to be updated the latest changes 4 Connecting Load5 Load Schedule6 End Load Voltage: 220kV/33kV/11kV/6.6kV/3.3kV/690V/415V7 Major Loads of the Plant8 High-End Motor Details9 High-End Pump Details 10 MV Panels Details Number of MV Panel and details listed11 LV Panels Details Number of LV Panel and details listed12 Number of Capacitor Bank (Contactor,

Thyristor or IGBT):

a. Brand of Capacitor Bank: b. Model of Capacitor Bank: c. KVar Rating:

141

d. With or without detuned filter or shunt reactor:

13 VFD’s for Electrical Application (Motors, Pumps, Compressors, Cranes, Lifts, Hoists) with Details (Step, Make, Model, Year of Installation)

14 Harmonic filters, Active/Passive (Panel, where installed, model/type if available)

15 Voltage stabilizers: a. If yes then brand, models and rating:

16 Generator Detail in case of Captive Power Plant (excl. Backup Power)

17 Large Rectifier Loads: Yes/No (DC End Loads, such as Electrolyser)

a. If yes, the Load Capacity b. kVA Rating

18 Sub-Metering Process Line Electricity Consumption Sub Metering

19 Monthly Electricity Consumption As per ADDC bills

Keep the Record for the last 3 years

20 Natural Gas Bills Keep the Record for the last 3 years21 Monthly Diesel Consumption (kl) Only Process Related Consumption Required22 Monthly Heavy Oil Consumption Only Process Related Consumption Required23 Other Sources of Energy Generation De-

tails (e.g. Renewable Sources, Generator etc.)

24 HVAC & Refrigeration/Ammonia Plant (if any)

a. Number of Chillers b. Water/Air Cooled/Others Chillers: c. Brand: d. Model: e. Tonnage: f. Year of Installation: g. Number of FAHU h. Number of AHU

Energy

SI. No. Particulars Details

142

i. Number of FCU j. Evaporative Cooling Towers - specifica-tion kW.th/kW.ele.

k. VFDs for HVAC Application CHW/Coolant Circuits

l. Calorifiers Electrical/LPG/HFO/Diesel (Cons. In case of non-electrical for last 12 months)

24 SCADA System (and BMS, as feasible and concerning major loads): Yes/ No

a. If yes, does the SCADA System integrate the following features: -

b. Electrical Consumption: Yes/No c. Main Electrical Loads Controls: Yes/No d. Power Quality: Yes/No

e. HVAC/Refrigeration Systems: Yes/No f. Temperature and Relative Humidity: Yes/No

g. Do Thermostats provide dp/wbt (Dew Point or Wet Bulb Temperature) controls/set points: Yes/No

h. Plant Lighting Controls: Yes/No i. Motor Control Centre (MCC) Cabinet, incl. VFD Status

k. Process Water and other major liquid processes

25 Building thermal efficiency: a. Main Production/Workshop Building Cooled? Yes/No

b. Main Production Sites Envelope Specs: Roof, Walls, est. u-values

c. Are main sites corrugated/GI steel sheet-ed roofs with PU/Sandwich insulation 50mm-100mm: Yes/No

Energy


143

d. Any Cool Roof/Cool Walls and other thermal efficiency measures implemented: Yes/No

e. Window Films installed (Sky Lights and Window Areas > 300 sq.m)

26 Street Lightning Details What type of streetlights industry is using (e.g. LED, Halogen, CFL)

27 Admin Building Lightning Details What type of streetlights admin building is using (e.g. LED, Halogen, CFL)

28 Plant and Warehouse Lighting Details What type of streetlights admin building is using (e.g. LED, Halogen, CFL)

Water

SI. No. Particulars Details1 Water Balance Diagram Schematic Water Flowchart within Process2 Monthly Fresh Water Consumption

Data - ADDC BillsFor the Last Three Years

3 Monthly Treated Wastewater Details (From ETP and RO)

4 Monthly Treated Wastewater (Recycled) Used in Process

5 RO Plant and ETP Specifications 6 Sub-Metering Process Line Water Consumption Sub Metering

Energy


144

GHG Emission

SI. No. Particulars Details1 Annual Stack Monitoring Report 2 Annual GHG Emission Report

Air Quality

SI. No. Particulars Details1 Indoor Air Quality Report (At Fix Loca-

tions)For Last 3 Years

2 List of Pollution Control Technologies Installed in the Plant

For Stack Pollution and Ambient Air Pollution

Indoor Noise Level

SI. No. Particulars Details YI Y2 Y31 Indoor Air Quality Report (At Fix Locations) For Last 3 Years

Waste

SI. No. Particulars Details1 Monthly Non-Hazardous Waste Genera-

tion RecordTadweer Monthly Manifest Data (Excel Sheet)

2 Monthly Hazardous Waste Generation Record

Tadweer Monthly Manifest Data (Excel Sheet)

3 List of Bi Products 3 Quarterly Bi-Product Generation Record 4 Annual Waste Reduction Report Record From 2017

145

IT Dashboard is a web-based sustainability tracking and benchmarking tool primarily designed for existing industrial manufacturing entities. IT Dashboard helps you track and assess Sustainability KPIs performance within industrial manufacturing entities. After creating an account, users enter sustainability data into your IT Dashboard account to monitor its own sustainability performance, assess ISG KPIs over time, and identify potential opportunities for savings.

Industries partnered with IDB for sustainability performance reporting can request user account to measuring their sustainability performance.

In general, industry would require reporting their sustainability performance on Monthly, quarterly and half yearly basis as follows:

Appendix-C: IT Dashboard

Sr. No. KPI's Unit Sample Values Unit Full Forms

1 Production Ton 1000 Tones2 Electricity kWh 150000 Kilo-watt hour3 Fresh Water m3 10000 Meter cube or cubic meter4 Diesel lit 2000 Litre5 Natural Gas/Fuel

GasMMSCF 2500000 Million Standard Cubic Feet

6 LPG MBTU 3500 Thousand British Thermal Unit7 Waste 7.1 Non-Hazardous kg 4750 Kilogram7.2 Hazardous kg 1200 Kilogram

No. of Entries Indoor Air Monitoring Parameter

Units Units

Min Input Max Input 2 10 PM2.5 µg/m3 microgram per meter cube2 10 PM10 µg/m3 microgram per meter cube2 10 NO2 µg/m3 microgram per meter cube2 10 SO2 µg/m3 microgram per meter cube2 10 VOC's µg/m3 microgram per meter cube

Half Yearly Inputs for Industries

Monthly Inputs for Industries

146

No. of Entries Noise Monitoring Units Units Full Forms

Min Input Max Input Reading 2 10 LAeq dB (A) decibal2 10 LAeq dB (A) decibal

CO2-eq Ton

Stack ID Name XYZ Sample ValuesStack Flow m3/Hr. Cu.meter/hour 15CO2 % percent (%) percent of CO2 from total emission 9%Operation Hours Hr. annual operation hours for stack 2000CO2 density kg/m3 kg/m3 of CO2 1.98

130

Stack Flow m3/Hr. Cu.meter / hour 15 CO2 % percent (%) percent of CO2 from total emission 9%

Operation Hours Hr. annual operation hours for stack 2000

CO2 density kg/m3 kg/ m3 of co2 1.98

Typical Results:

Web Ref: Tableau

Appendix - D: Due Diligence Tool

It is an independent Microsoft Excel-based decision-making tool for the industries to carry out due diligence of any proposed sustainability measure. It has several features as:

Typical Results:

Half Yearly Inputs for Industries

147

Appendix - D: Due Diligence Tool It is an independent Microsoft Excel-based decision-making tool for the industries to carry out due diligence of any proposed sustainability measure. It has several features as:

• An interactive tool

• Operational industries can perform as-is analysis of various parameters related to sustainability KPI such as

° Administration & Process Building envelope performance

° Building Lighting Performance

° Process equipment energy efficiency

° Process wastewater efficiency

° Waste and by-product utilization

• With a few data input to the tool, the industry can arrive on a high-level energy and water saving potential

• Tool allows operating industries to identify the sustainability measures that could possibly worked on.

• Provides a qualitative feedback on the indoor environmental performance of manufacturing process building and warehouse.

131

v

Appendix - E

Table-1 Industry Building Envelope

An interactive tool

Operational industries can perform as-is analysis of various parameters related to sustainability KPI such as

o Administration & Process Building envelope performance

o Building Lighting Performance

o Process equipment energy efficiency

o Process wastewater efficiency

o Waste and by-product utilization

With a few data input to the tool, the industry can arrive on a high-level energy and water saving potential

Tool allows operating industries to identify the sustainability measures that could possibly worked on.

Provides a qualitative feedback on the indoor environmental performance of manufacturing process building and warehouse.

Sustainability Benchmark AssessmentFramework for As-is Evaluation

KPIs Achievable Savings Benefits

GHG Emissions

Building FabricSavings: 10% 10% IRR: 20% 0.3

1. Reduce the Energy Bills Waste

0.2

Building LightingSavings: 9% 0.090232684 IRR: 30% 0.3 1. Reduce the Energy Bills 2. Reduce the GHG Emissions 3. Helping to meet the industrial sustianbility goals Occupational Noise

Savings: 7% to 15% 7% 15%

Process Equipment 3Water Savings: 28% 0.2 IRR: 30% 0.3 6. qeoiruqpoeirIndoor Air

28.00%

1. Save the cost of

1. Save the cost of

Note:

Building Fabric

1. Reduce the Energy Bills 2. Reduce the GHG Emissions 3. Helping to meet the industrial sustianbility goals 4. Contribution to UAE Sustainability Development Goals

Savings: 10%

Water

1. Save the cost of water by treating and reusing in process2. Reduce the GHG Emission3. Reduce the Air Pollution

Savings: 28%

Building Lighting Savings: 9%

Waste1. Save the cost of waste disposal 2. Reduce the GHG emissions 3. Reduce the air pollution

Diversion from Landfill: 20%

Process Equipment Savings: 7% to 15%

Sustainability Benchmark AssessmentFramework for As-is Evaluation

KPIs Benefits

tCO2 Emissions Reduction Annually: 20%20%

GHG Emissions

Waste Diversion from Landfill: 20%0.2 IRR: 30% 0.3

20%

Occupational Noise Savings: 20%0.2 IRR: Below Prescribed Standard: 30%1. In

Below Prescribed Standard: 30% 0

Indoor Air Savings: 0%1. Re

Below Prescribed Standard: 5% 01. Reduct

Targets

Indoor Air1. Reduction in the overall Carbon footprint of Abu Dhabi Industrial Sector. 2. Set the becnhmar for the peer indistries. 3. "Green Product" special recognization in the

Occupational Noise

1. Increase the productivity of company staff 2. Comply with regulatory standards 3. Set the benchmark for the peer industries

Below Prescribed Standard: 5%

Below Prescribed Standard: 30%

GHG EmissionstCO2 Emissions Reduction Annually: 20%

1. Reduction in the overall Carbon footprint of Abu Dhabi Industrial Sector. 2. Set the becnhmar for the peer indistries. 3. "Green Product" special recognization in the local and internation market.

148

Appendix-E: ISG Standards & Guideline Values

Industry Envelope Element Parameter Requirements

Industry Structure (Non-Conditioned Space)External Walls U – value (Max) 0.45 W/m2KRoof U – value (Max) 0.42 W/m2K

Industry Structure (Conditioned Space)

External Walls U – value (Max) 0.32 W/m2KRoof U – value (Max) 0.20 W/m2KFloors U – value (Max) 3.73 W/m2K

Industry Structure (Conditioned and Non-Conditioned Space)

Vertical Glazing

U – value (Max) 1.9 W/m2KShading Coefficient (Max) 0.26SHGC (Max) 0.23VLT (Min) 25 %

Skylight (maximum 3% of Roof Area)

Note

This is not applicable to GRP skylights

U – value (Max) 3.80 W/m2K

Shading Coefficient (Max) 0.35

SHGC (Max) 0.30VLT (Min) 60 % to 70%

Table 1: Industry Building Envelope

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Infrared Thermography

Applicable Standard BS EN 13187:1999 Thermal performance of buildings. Qualitative detection of thermal irregularities in building envelopes. Infrared method

ISO 18436-7:2014 Condition monitoring and diagnostics of machines — Requirements for qualification and assessment of personnel— Part 7: Thermography

Specialist Qualification

Thermographer afflicted to • Infraspection Institute, USA• British Institute of Non-Destructive Testing, UK• Any other equivalent international organizationQualified Level I Thermographer (ISO 18436-7:2014 or equivalent international standard)

Typical Table of Infrared Thermography Test Report

Chapter Content1. Introduction All details necessary to identify the building/envelope tested; the purpose

of the test as per BS EN 13187:1999; post address and estimated date of construction of the building.

2. Test Object • description of which parts of the building were subject to the test• envelope area; • a detailed description of temporarily sealed openings, if any.

3. Test Data4. Conclusion and Recommendation5. Test Professional/ Agency Qualification

Name and address of organization/individual carrying out the test and details of the credentials permitting them to do so.

Blower Door TestingApplicable Standard • Technical Standard L2 - Measuring Air Permeability of Building

Envelopes (Non-Dwellings)

Specialist Qualification • Minimum of 2 years’ experience in Envelope testing and verificationTypical Table of Contents of Blower Door Test Report

Chapter Content

Table 2: Air Tightness / Envelope Tightness Guideline

150

1. Introduction All details necessary to identify the building/envelope tested; the purpose of the test as per BS EN 13829:2001; post address and estimated date of construction of the building.

2. Test Limitation/ Deviation

Deviation from the test condition defined in Technical Standard L2 - Measuring Air Permeability of Building Envelopes (Non-Dwellings)

3. Test Object • description of which parts of the building were subject to the test;• envelope area;• documentation of test calculations so that the stated results can be

verified;• the general status of openings on the building envelope, latched,

sealed, open, etc.;• a detailed description of temporarily sealed openings, if any;• the type of heating, ventilating and air conditioning system.

4. Apparatus and procedure

• equipment and technique employed.

5. Test Condition • Day of test• Weather data Temperature, Relative Humidity, Wind speed and

direction

6. Test data • zero-flow pressure differences ΔP0,1+ , ΔP0,1- , ΔP0,2+ , ΔP0,2- , ΔP0,1 and ΔP0,2 for pressurization and depressurization test;

• External and internal temperatures before and after the test;• barometric pressure before and after the test.• differential pressure on the lowest and highest floor at the highest

flow rate• achieved if required.• table of induced pressure differences and corresponding air flow

rates.air leakage graph, with the value of correlation coefficient r²;• the airflow coefficient Cenv , the airflow exponent, n, and the air

leakage coefficient CL, for both pressurization and depressurization tests determined by the method indicated;

• Air permeability result and test target

7. Conclusion and Recommendation

8. Test Professional/ Agency Qualifica-tion

• Name and address of organization/individual carrying out the test and details of the credentials permitting them to do so (UKAS Accreditation number, ATTMA registration number of the professional).

151

Table 3 : Minimum HVAC System Performance Criteria (EER)

Unitary Air Conditioners

Condensing Units

S.No Capacities Minimum Efficiency

Full Load, EER Full Load, CoP IPLV

1 < 150 TR >9.562 >2.803 >12.52 >150 TR >9.562 >2.803 >12.75

Air Cooled Chillers

152

Internal Lighting -Area Method

S.No Chiller Type Capacities Minimum Efficiency

Full Load, CoP

IPLV

1 Water cooled, electrically operat-ed, positive displacement (rotary screw & scroll)

150 TR >4.45 >5.20

≥150 TR and < 300TR >4.90 >5.60

≥ 300 TR >5.50 >6.15

2 Water cooled, electrically operat-ed, centrifugal

150 TR >5.00 >5.25

≥150 TR and < 300TR >5.55 >5.90

≥ 300 TR >6.10 >6.40

Water Cooled Chillers

10

13

14

11

3

14

11

9

15

BUILDING TYPE

153

Table 4 : Recommended Light Power Densities

Internal Lighting

Common Space Types LPD (W/m2)

Office-Enclosed 12Office-Open Plan 12Conference/Meeting/Multi-purpose

14

Classroom/Lecture/Train-ing

15

Lobby 14Audience/Seating Area 10For Religious Buildings 18For Sports Arena 4For Transportation 5Atrium-First Three Floors 6Atrium-Each Additional Floor

2

Dining Area 10Food Preparation 13Laboratory 15Restrooms 10Dressing/Locker/Fitting Room

6

Corridor/Transition 5Stairs-Active 6Active Storage 9Inactive storage 3Electrical/Mechanical 16Workshop 20

Building Specific Space Types LPD (W/m2)

Automotive-Service/Repair 8ManufacturingLow Bay (<25 ft Floor to Ceiling Height)

13

High Bay (.25 ft Floor to Ceiling Height)

18

Detailed Manufacturing 23Equipment Room 13Control Room 5WarehouseFine Material Storage 15Medium/Bulky Material Storage 10Parking Garage – Garage Area 2

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Table 5: Minimum Performance Criteria For Sanitary Wares

Fixture type Requirements Remarks

Water Closets 3.0 l/flush Half flush type6.0 l/flush Full flush type

Urinals 0.5 l/flush or Sensor-based urinal systems are also accept-able.Waterless

Wash Basin Mixture/ Faucets / Sink Mixer / Bath Mixer

6.0 l/min. At 413.7 Kpa reference pressure

Hand Showers 9.5 l/min. At 551.6 Kpa reference pressureBidet/ trigger spray 6.0 l/min. At 413.7 Kpa reference pressure

Notes

1. The table provides an outline/guidance on the flow and flush fixture requirements to be used in the project. This, however, does not stop a project from seeking higher efficiencies.

2. It should be ensured that laundry equipment, dishwashers etc. that have not been mentioned in the above table are selected from energy star/equivalent accredited products for achieving maximum water savings

Notes

a. The light power densities indicated above are improvements over those levels mentioned in ASHRAE 90.1-2019.

b. Submissions should comprise LPD tables for the project comprising the proposed values in relation to IDB specified values for different areas

S.No Area / Zone Light Power Density (LPD) W/ m2

1 Canopies and overhangs 5.0

External Lighting

155

Product Type Maximum grams of VOC per litre of adhesive or sealant, less water and exempt compounds

Indoor Carpet Adhesive 50Carpet Pad Adhesive 50Wood Flooring Adhesive 100Rubber Flooring Adhesive 60Sub-floor adhesive 50Ceramic tile adhesive 65Cove base adhesive 50Plasterboard and wall panel adhesive 50Multipurpose construction adhesive 70Structural glazing adhesive 100Architectural sealants 250

Product Category Type** Phase II (g/l)*

Interior matt walls and ceilings (Gloss <25 @60º)

WBSB

30 30

Interior glossy walls and ceilings (Gloss >25 @60º)

WBSB

100 100

Interior trim and cladding paints for wood and metal

WB SB

130 300

Interior trim varnishes and wood stains, including opaque wood stains

WBSB

130400

Interior minimal build wood stains WB SB

130 700

Primers WB SB

30 350

Table 6: VOC Limits

Adhesives and sealants

Paints and Coatings

156

Product Category Type** Phase II (g/l)*

Binding Primers WB SB

30 750

One-pack performance coatings WB SB

140 500

Two-pack reactive performance coatings for specific end-use such as floors

WBSB

140500

Multi-colored coatings WB SB

100 100

Decorative effect coatings WB SB

200 200

*g/l of ready to use product** WB = Water-Based, SB = Solvent Based

S.N.o Emission Source Unit Emission Factor

1 Abu Dhabi Grid Emission Factor kg CO2-eq/kWh 0.42

2 Diesel kg CO2-eq /lit 2.68

3 Natural Gas kg CO2-eq /SFC 54.90

4 Desalinated Water kg CO2-eq /m3 2.03933

5 Transportation kg CO2-eq /trip-kg 0.129

Table 7: GHG Emission Factors

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Documents

INDUSTRIAL SUSTAINABILITY GUIDELINE