ENERGY AUDITS (SURVEYS): TECHNIQUES AND SEQUENCE GCE Energy.
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Transcript of ENERGY AUDITS (SURVEYS): TECHNIQUES AND SEQUENCE GCE Energy.
ENERGY AUDITS (SURVEYS): TECHNIQUES AND
SEQUENCE
GCE Energy
OBJECTIVES OF AN ENERGY AUDIT:
Criteria Energy audit firms Energy suppliers
1. Assessment of energy efficiency
Independent Is biased in favor of specific efficiency steps and technologies
2. Energy efficiency program development
Is not limited to pitching specific steps and technology
Is limited to specific energy efficiency technologies and
equipment
3. Implementation of energy efficiency measures
Allows you a free, tender-based choice of contractors
Is performed by the supplier which developed the program
DISTINGUISHING TRAITS OF ENERGY AUDIT FIRMS
1. Assessment of efficiency in energy consumption2. Establishing potential energy savings
3. Development of energy savings program
Drafting contract documentation
Development and review of Client questionnaire
ENERGY AUDIT SEQUENCE
Preliminary stage
Report on work performed Energy efficiency programDeliverables
Study of relevant documentation
The stage of survey proper
Analytical stage
Development of Scope of Work
Instrumentation-based survey
Analysis of findings and overall assessment of energy efficiency
DESCRIPTION OF ENERGY AUDIT SEQUENCE
ActionParticipants’ actions
GCE Energy Client
1. Development and review of Client questionnaire and Requirements Specifications
1. Questionnaire handed to Client;
5. Review of filled Questionnaire and Specifications
2. Fill out questionnaire;3. Develop Requirements
Specs;4. Questionnaire and Specs
handed over to GCE-Energy
2. Drafting оf contract documents
1. Development of project cost;2. Drafting the Contract, work
schedule, draft budget, etc.3. Signing contract paperwork.
4. Signing contract paperwork
Deliverables at end of stage:Contract (with addenda) on work performance between GCE Energy and Client
I. Preliminary stage
ActionsParticipants’ actions
GCE Energy Client
1. Collection of initial data as per the list
1. Development and submission to Client of the list of initial data;
3. Signing acceptance Statement data received;
4. Development of initial data spreadsheets
2. Collection of data per the list and submission to GCE-Energy;
3. Drafting and signing the Statement verifying initial data collection
2. Preliminary analysis of data 1. Preliminary analysis of data -
3. Development of Scope of Work and its concurrence
1. Development of Scope of Work and its coordination with the Client
2. Concurrence on coordinated Scope of Work
Deliverables at end of stage:1.Statement on initial data collection;2.Scope of work for energy audit
II. DOCUMENTED DATA SURVEY STAGE
III. INSTRUMENTAL SURVEY STAGE
ActionsParticipants’ actions
GCE Energy Client
1. Preparation for instrumental survey
1. Establishing instrumental survey scope
2. Development of survey design and rules for taking measurements
3. Concurrence with survey design and rules for taking measurements
2. Instrumental survey
2. Measuring device installation;3. Taking measurements;4. Drafting protocols on data
collected
1. Preparation of instrument installation sites;
2. Support for measurement process;
5. Concurrence on data protocol
3. Analysis of findings 1. Preliminary analysis of findings -
Deliverables at end of stage:1. Instrumental survey design and rules;2. Instrumental survey protocols
INSTRUMENTATION SURVEYPower supply system Heat supply system
Fuel-burning plantCompressor units
1)Parameters of intake and off-take feeders of sub-
stations (U-voltage, I currents, f frequency, P –active power,
Q – reactive power);
2)Operational parameters (U-voltage, I currents, f
frequency, P –active power, Q – reactive power) of high-
voltage and low-voltage electric drives of main process and
auxiliary equipment (pumps, fans, compressors, conveyors,
etc.
1)Parameters of heat transfer agents
(pressure, flow rate, temperature);
2)Surface temperature of equipment and heat
insulation devices
1)Gas dynamic parameters (pressure, flow rate,
temperature);
2)Operation profile statistics (daily, weekly, and
annual usage profiles);
3)Compressor capacity and output;
4)Heat exchanger parameters
1)Composition and temperature of waste gases;
2)Fuel parameters and consumption rates;
3)Heated medium parameters (pressure, flow
rate, temperature) upstream and downstream of the
unit;
4)Fuel-burning units’ outer surface temperatures
INSTRUMENTATION AT GCE ENERGY DISPOSAL
IV. ANALYTICAL STAGE
ActionsParticipants’ activities
GCE EnergyClient
1. Information analysis and summary
1. Analysis of information gleaned from documents and instrumental survey findings;
2. Calculation of the enterprise’s fuel and energy efficiency rates;3. Assessment of fuel and energy efficiency and energy savings (efficiency)
potential of the enterprise;4. Compilation of fuel and energy balance sheets for the enterprise
2. Development of energy efficiency program
1. Development of commercially viable measures for improved fuel and energy efficiency;
2. Cost-performance analysis for suggested measures (expert assessment of investment needed and its payback time) and their ranking by relative gains
3. Preparation of reports
1. Preparation of Energy Survey Report;2. Development of Energy Efficiency Program
Deliverables at end of stage:1.Energy Survey Report;2.Energy Efficiency Program
PRINCIPAL CALCULATIONS
For electric supply system:
For heat supply system:
For fuel-burning plant:
For compressor units:
1)Electricity losses in transmission (power lines and transformers) 0.4, 6(10), 35, 110, 220kV;
2) Per unit electricity consumption rates;
3) Efficiency of electric drives and losses in electric motors
1)Heat energy losses in supply networks and at end-user points;
2)Heat consumption by energy supply facilities
1)Performance efficiency rate of units and boilers;
2)Heat energy losses;
3)Per unit heat consumption rates
1)Compressor performance efficiency (isothermic, adiabatic, and polytropic);
2)Electricity consumption rates per output unit;
3)Losses of air in networks and at end-used points
CALCULATION OF LOSSES IN TRANSFORMERS
Loads as % of installed capacity
Transformer losses as % of installed capacity
Estimated values:
With three transformers in operation
06.2005 12.2005 06.2006 12.2006 06.2007
Daily losses, kW*h/day 137 145 149 162 126
Loss rate* 2,42% 1,56% 1,41% 1,28% 3,02%
Load level 15,62% 18,71% 20,85% 25,29% 8,14%
Annual losses, MW*h/year 56 55 55 56 54
ESTIMATE OF ELECTRICAL EFFICIENCY OF A PUMPING STATION
Over the last 12 months unit electricity consumption rate increased (with higher throughput). That is due to increased throughput and sub-optimal pump operation mode
0%
2%
4%
6%
8%
10%
12%
1,06 3,06 5,06 7,06 9,06 11,06 1,07 3,07 5,07 7,07
month, year
Standard energy consumption rates in nickel production
Type of productEnergy resources
Electricity,kWh/ton
Heat energy,Gcal/ton
Compressed air,m3/ton
Oxygen,m3/ton
Gas,m3/ton
Electrolysis-deposited nickel
2683 1,6 - - -
Agglomerate 57,8 - - - 9,34Filtered concentrate 17,4 - 19875 - -
Crude nickel anodes 670 - - 1,2 -
Standard natural gas consumption rates for different nickel production technologies
Product Total output, tonsUnit fuel consumption rate, m3/ton
Nickel from fahlstein (slate) 6 589 450
Nickel from agglomerate 3 523 1 610
Nickel production
STANDARD ENERGY CONSUMPTION RATES AND ENERGY EFFICIENCY INDICATORS
PULP-AND-PAPER MANUFACTURING
Machine Heat energy,
Gcal/ton
Electric energy,
kWh/ton
Papermaking machine № 1 2,07 680
Papermaking machine № 3 5,03 1288
Papermaking machine № 8 1,47 675
Unit energy consumption by papermaking machine
Manufacturing of:Heat energy,
Gcal/ton
Electric energy,
kWh/ton
Paper 1,76 693
Wood pulp - 1380
Cellulose 2,73 368
Unit energy consumption in manufacturing of specific products
CompanyElectricity
consumption, 1000 kW/h
Electric network losses
1000 kW/h %
Udmurtneft 989 560 79 800 8,1%
Rosneft 144 804 16 774 11,6%
Company Heat consumption,
Gcal
Heat losses
Gcal %
Omsk caoutchuk 1 983 120 76 208 3,8%
Azot 4 071 615 255 351 6,3%
Heat losses in heat supply networks
ENERGY LOSSES IN ELECTRICITY NETWORKS
Managerial steps
Engineering and technology-related measures
а) Low-cost measures:– Improvement (optimization) of operational modes of main process, power supply, and auxiliary equipment;– Installation of compensating devices in electrically-powered units; б) Cost-intensive measures:– Switchover to alternative energy or fuels;– Upgrading or overhauling main process and power supply equipment;– Introduction of new energy-efficient technologies;– Rehabilitation of the plant’s power supply systems;– Making use of better-quality energy products;– Development of in-house energy sources, including utilization of secondary fuel and heat sources and energy
recovery.в) Introduction or upgrading of systems for cost controls and managerial (engineering) oversight and accounting of energy
resource usage with linkage to specific products and services into which they go
– Introduction or enhancement of plant energy management system;– Development of information system in support of more efficient energy use and energy savings;– Introduction or strengthening of incentives package for energy efficiency;– Development or revision of standards documentation, technical guidelines, job briefs, techniques for energy
consumption analysis, forecasting, and planning, and the like;
ENERGY EFFICIENCY MEASURES BY TYPE
Financial steps– Depending on domestic legislation
SAMPLE SEGMENT OF ENERGY EFFICIENCY PROGRAM FOR A METALLURGICAL PLANT
Recommended efficiency measures
Energy savings/yearInvestment
required, 1000 $Payback period,
yearsFuel and energy 1000 $
1. In electric supply systems1.1.Reactive power compensation at 6(10)kV 1 273,6 MW*h 52,5 24,0 0,451.2.Introduction of 0.4kV smooth startup devicesВ 790,6 MW*h 47,4 155,4 3,31.3.Introduction of frequency-modulated drives 1768,5 MW*h 106,1 385,3 3,632. In heat supply system 2.1.Fine-tuning heat pipeline networks 2 816 MW*h 100,0 200,0 2,02.2.Replacement of heat piping insulation 3 000 Gcal 39,2 144,2 3,73. In fuel supply system3.1. Repairs to recuperators of circular furnaces № 1 and № 2, roller furnace № 4, and heating furnace with walking trusses
5 mln m³397,2 120,0
0,36
3.4. Sealing of process space of circular furnace 1,5 mln m³ 119,2 40,0 0,343.5. Efficient loading of the plant’s fuel-burning equipment 18 mln m³ 1429,9 - -4. In air supply system 4.1. Upgrading flow-through sections of three К250 compressors with rotor installation 648 MW*h 26,7 160,0 6
Annual energy consumption:Fuel– 223 531 tons of coal equivalent
Electricity – 1 050 479 MW*h
Output - 1 754 thousand tons of metal products and blanksAnnual energy costs - 57108000 $
Total savings: 2 698 280 $ - fuel - 32 720 tce - 14,6 % - 2 208 000 $ - electricity - 30 475 MW/h - 3,0 % - 1 352 000 $
1) Installation of air heater (recuperator) at gas flue feeding gas for combustion cuts gas consumption by roughly 10 to 15%;2) Installation of the system for automatic combustion control coupled with high-speed burners, electric ignition and flare control system, and pulse feeding of air and gas into the furnace. This provides for better combustion control, reduces the role of operating personnel, and cuts gas consumption by 3 to 4 %;3) Replacement of commonly used wall lining with fiber-ceramic one. This increases radiation component of heat exchange by 20 to 30% thus speeding up the heating of blanks while cutting fuel consumption and reducing dross formation on treated blanks. Gas savings due to new lining may reach 30 %
EXAMPLES OF ENERGY EFFICIENCY STEPS IN METALLURGICAL TECHNOLOGY
For electric steel smelters1) Equipping electric steel smelters with gas burners intensifies heating and metal melting with concomitant
decline of electric consumption by 10 to 15 % ;2) Installation of gas recovery device at waste gas flue captures the energy of waste gases. That provides additional heat energy that may be used in affiliated production or as heat source for utility purposes
For gas fired smelters
1) Heat recovery from air-steam mix (ASM) exiting paper-making units. Installation of heat capture unit and a scrubber provides for recovery of up to 70% of ASM heat energy for main production process needs;
2) Lowering vacuum levels downstream from evaporation plant through rehabilitation of condensate system. A 10% temperature drop inside the condenser yields a 10% reduction in unit rate of steam consumption;
3) Efficient use of secondary energy sources (bark, sludge, lye). Introduction of advanced technology for burning such secondary fuels meets up to 20% of overall heat generation requirements.
EXAMPLES OF APPLICATION OF ENERGY EFFICIENCY MEASURES IN PULP-AND-PAPER PRODUCTION
Industrial sectorsPotential energy savings, %
Fuel Heat energy Electricity
Pulp-and-paper mills Up to 1 13 - 16 3 - 5
Oil refineries 11 - 12 13 - 14 2 - 3
Metallurgical plants 13 - 15 2 - 4 2 - 3
Ore dressing factories 8 - 9 Up to 1 2 - 4
Chemical plants Up to 1 13,50 7 - 9
ENERGY SAVINGS POTENTIAL BY INDUSTRIAL SECTOR
THANK YOU FOR YOUR TIME!