Rusaud - Motiva · B. Energy audit of the DH network and peak and spare boiler plants (audit to be...

9.11.2009 Pöyry Energy / DH / Olkinuora

RusaudGood Practices and Results of the Finnish

Energy Audit Programmes

Energy Auditing of District Heating SystemsEnergy Audit training Day 9.11.09


CONTENT

District Heating Energy Audit Models

Data collection and site inspection

District heating, in general

Differences between the Nordic system and Russian system

Measurements that should be implemented

Analyses and report writing

Typical results

Results from Finland

Corresponding results from Russia

Discussion


District Heating Energy Audit ModelsA. Energy audit of the whole DH system and all energy production

plants that are connected to it (audit to be based on models 1&2)

B. Energy audit of the DH network and peak and spare boiler plants (audit to be based on model 1)

When base load plants are CHP-plants and belonging to the Energy Sector Saving Agreement, or

Heat is not produced by the DH Company, but purchased

C. B + system optimization (audit to be based on model 1)Provided that annually sold heat > 16 GWh

1. Energy Audit Model for District Heating Sector (Motiva/SKY ry. 2002, author Electrowatt-Ekono Oy/Pöyry Energy Oy)

2. Power Plant Energy Analysis model (Motiva/Finenergy ry. 2002, author Electrowatt-Ekono Oy/Pöyry Energy Oy)


Energy Audit Report

Prehandlingof raw

materialSmelting

Tin-bath

Cooling Washingand

checking

Cuttingand

bundling

Continuedhandling

electr. water

soda

sandlime

Na2SO4

natural gas

electr.

O2

coolingwarter

combustion gas

electr.

N2H2

N2

cooling.air

coolingwater

waterelectr. electr.

a-powder

air Regen.

waste heatboiler

heating water

combustion gas

chruched aggregate

electr.

hot air

SO2electr.

natural gas

compr.air

stock

recycling material from clients

copr. air

natural gasDelivering

+ stock

compr. air

compr.air

compr. air

compressedair

coolingair

electr.

hotair

drying air heat

App.

6. Process5. Process

services4. Building

3. Consumption,costs2. Basic info

TABLE 1

Cons.now

Savingpot.

Invest.

Electr.

Fuels

Water

Total

0 1 2 3-4 5-

Savings€

1. Summary- text- tables 1,2- econ.prof.- Sankeydiagram

- processblock diagr.

Kauppa- ja teollisuusministeriöntukema energiakatselmushankeDNro: 333/954/93Päätöksen pvm 30.12.1993

J P - T A L O T E K N I I K K A

ENERGY ANALYSES REPORT

Company Ltd

Helsinki5.9.1999

Company Oy

Jaakko Pöyry Group

TABLE 2

Savingmeasur. 1Savingmeasur. 2

::

Savings€

Invest.€

Pay backperiod

Total

PL 27, 00131 HELSINKIPuh. 09 - 46911

Fax. 09 - 4691 311

17730 [kW]

10620 [kW]

6900 [kW]

4000 [kW]

3600 [kW]

2600 [kW]

1630 [kW]

1400 [kW]

1380 [kW]

1320 [kW]

1300 [kW]

1220 [kW]

1110 [kW]

550 [kW]

530 [kW]

520 [kW]

260 [kW]

220 [kW]

220 [kW] 200 [kW]190 [kW]

30 [kW]

50 [kW]

80 [kW] 65 [kW]

Melting

Float bath

Air coolingLighting

Raw material

Nitrogen factory

Natural gas

Water cooling

Heat recovery boiler

Heat recovery

Direct process removals

Compressed air

Oxygen burner

Room

Other

Lehr

Electricity

Ventilation

3165 [kW]

preprocessing

Prehandlingof raw

materialSmelting

Tin-bath

Cooling Washingand

checking

Cuttingand

bundling

Continuedhandling

electr. water

soda

sandlime

Na2SO4

natural gas

electr.

O2

coolingwarter

combustion gas

electr.

N2H2

N2

cooling.air

coolingwater

waterelectr. electr.

a-powder

air Regen.

waste heatboiler

heating water

combustion gas

chruched aggregate

electr.

hot air

SO2electr.

natural gas

compr.air

stock

recycling material from clients

copr. air

natural gasDelivering

+ stock

compr. air

compr.air

compr. air

compressedair

coolingair

electr.

hotair

drying air heat


TAULUKKO 2YHTEENVETO ENERGIANSÄÄSTÖTOIMENPITEISTÄ

Paataulun CO2-versio 1.0 16.5.2003

TOIMENPITEEN SÄÄSTÖ TMA INVES- CO 2 SÄÄSTÖ SÄÄSTÖ SÄÄSTÖ

KUVAUS YHTEENSÄ TOINTI VÄHENEMÄ LÄMPÖ SÄHKÖ VESIYHTEENSÄ energia CO 2 kustannukset energia CO 2 kustannukset vesi kustan-

energia muut energia muut nuksetno EUR/a a EUR t MWh/a t EUR/a EUR/a MWh/a t EUR/a EUR/a m3/a EUR/a12

3456789

10

11121314151617181920212223242526

YHTEENSÄ 0 0 0 0 0 0 0 0 0 0 0 0 0

Energy saving measure Saving Investment

Saving Potential

Heat Electricity Water

CO2 emission reduction

Total

Pay-backperiod


Example: Energy Balance as a Sankey Diagram


Audit report content

3 Basic Information3.1 Presentation Of The Company/Business Unit3.2 District Heating Activity Of The Company/Business Unit3.3 Organisation Of The Company/Business Unit3.4 Energy Consumption Of The Company/Business Unit3.5 Production And Acquisition Of Heat3.6 District Heating Customers3.7 District/Local Heating Networks3.8 Parameters Of The Entire Operation Of The Company/Business Unit



4 Conservation Possibilities In Production And Acquisition Of Heat4.1 Heating Plant 1

4.1.1 Comparison Of Parameters4.1.2 Profitability Of The Conservation Measures

4.2 Heating Plant Using Domestic (Renewable) Fuel4.3 Heating Plants Using Light Or Heavy Fuel Oil4.4 Heating Plants Using Natural Gas4.5 Purchasing Of Heat4.6 Other Heat Production Methods4.7 Efficiency Of Running The District Heating System (System Optimisation)



5 Efficiency Measurements5.1 Measuring Methods And Description Of The Measurements

5.1.1 Method 15.1.2 Method 2

5.2 Results Of The Measurements5.2.1 Heating Plant 15.2.2 Heating Plant 2



6 Conservation Possibilities In The District Heating Networks6.1 Pumping Of The District Heating Water6.2 Heat Losses Of The District Heating Network6.3 Reduction Of The Consumption Of Additional Water6.4 Reconstruction Of The Existing Network



7 Customer-Specific Conservation Possibilities7.1 Conservation Achieved Through Energy And Equipment Audits7.2 Conservation Achieved Through Monitoring Of Cooling7.3 Maintenance Of Energy Meters7.4 Training And Advisory Activities7.4.1 Energy Consumption Monitoring Reports7.4.2 Operation Training7.4.3 Energy Conservation Related Training7.4.4 Consumption control7.5 Developing district heat pricing to motivate conservation

8 Other Conservation Opportunities


CHP Plant

BuildingBuildingBuildingBuilding

BuildingBuilding

Boiler plant

BuildingBuilding

BuildingBuilding

BuildingBuilding

BuildingBuilding

BuildingBuilding

BuildingBuilding

BuildingBuilding

BuildingBuilding

Boiler plantHOB

SubstationsOwned and operated by the

Client

Heat transmission and distribution 120/70 °C operated by Energy Co.

HOB Plant

Heat metering and building level substations

Heat productionOperated by Energy Co.




Scheme of a Typical Russian Large Integrated DH System

CHP plant

Heat production

Building

Building

Building

Building

Heat transmission (primary) network 130 (150) /70 °C, hot water

Group substations

Secondary network Heat distribution 90/70 °C

Building

Building

Building

Building

Domestic hot water (DHW) supply

Heat exchangers for - space heating - DHW Possible Heat exchanger for - space heating

Heat only boiler plant

Heat production

Industrial Customer

Building Building

Secondary network Heat distribution 90/70 °C

Industrial Steam Consumer

Industrial Steam Consumer

Steam supply

This scheme represents the typical Russian large integrated DH systemThis systems allow for high utilization of CHP


Key advantages of District Heating

To Consumer• Small space requirement and safe operation• Easy to control and operate• Affordable cost and long term price stability

To Utility and Environment• Flexibility for fuel changes, possibility to

optimise fuel mix• Low emissions• District Heating is together with Combined Heat

and Power the most energy efficient way of heating


District Heating – a Clean and Economical Solution

• A district heating (DH) system supplies buildings with centrally generated heat.

• Centralised heat production enables the use of the most economical and environmentally benign fuel and manner of production.

• Combined heat and power (CHP)production utilises the maximumamount of useful energy from the fuel burned.

Losses

Losses

Cogeneration Separategeneration

HeatDemand

PowerDemand

Combined-cycleCHP plant

Heat-onlyBoiler plant

Combined-cyclecondensingpower plant

Primary energysaving in cogeneration

= 135 – 100100

%= 35%

= 135%

100


Breakdown of Production Costs


Typical production costs of district heating by fuels in Finland

Typical cost balance of heat generation

-60

-40

-20

0

20

40

60

80

100

Natural gas Oil Peat Wood Natural gas120 MWe

Coal 68 MWe Peat 62 MWe Wood 62 MWeCos

ts, E

UR

/MW

hhea

t

Fuel costs excl. taxExcise taxCO2-emission allow ancesCapital costsO&MValue of pow er+subsidyTotal production costs of heat

CHP, 120 MWtHOBs, 30 MWt

Two-component tariff structure for consumer

Capacity charge (€/MW)fixed costsconnected load

Energy charge (€/MWh)variable costsenergy consumption, MWhequal costs component 0

500

1000

1500

2000

2500

3000

3500

4000wages

operation costs

amortization

financial costs

fuel

electric energy

maintenance variable costs


Responsibilities of Different Operators in DH System


Types of Heat Suppliers

• Heating companies owned by municipalities• Normally, administrative management of these types

of heating enterprises is mainly assumed by the local public utility or construction administration.

• These types of suppliers typically procure their heat supply from large scale CHPs or HOBs

• Heating companies owned by big enterprises and development companies

• This category typically owns regional HOB and networks. Such companies are not usually financially supported by the municipality.

• In a region or city, there could by over 100 such heat suppliers

• Heating agencies under ancillary departments of various organizations (i.e. hospitals, schools, etc.) are usually very small and thus belong to the decentralized small boiler category

• Being related to the economic status of the institutions and not to the heating enterprise itself, the heating quality is usually relatively low

• Numerous such producers in each region or city

• The typical case in this category of heating company is that a building developer, or a group of building developers together, owns the buildings and the heating systems in connection to these buildings.

• These types of DH companies typically buy their heat from a small scale HOBs

• Numerous such producers in each region or city

Type 1. A heating company Type 1.B heating company

Type 2. Ancillary service Type 3: Non-governmental developer


Ownership of Heating Assets

Management of Heating Assets per Type of DH Company

Transmission ConsumerCHP HOB DSB Assets Substation for CHP Secondary Network Installation

Type 1A OwnershipOperation

Type 1 B OwnershipOperation

Type 2 OwnershipOperation

Type 3 OwnershipOperation

OwnMay own

OperateMay Operate

Production Assets Distribution Assets


Major Differences Between Finnish and Eastern European DH Systems

2. The systems are constructed and operated based on sound economical criteria

2. The systems are not always constructed and operated based on sound economical criteria

1. General status of DHDH is good business for the owners of

DH companiesSource of income for municipalities and

other ownersSignificant public interest -> operations

well recorded and data availableInvoicing based on real consumptionClear property rights and responsibilities

1. General status of DH DH companies subsidized by

municipalities and/or the stateTraditionally a part of social securityLow public interest -> partially operations

poorly recorded and limited amount of data available

Invoicing based on norms and standardsDistribution of property rights and

responsibilities is not clear

Modern / Nordic DH systemEastern European DH system


Major Differences Between Finnish and Eastern European DH Systems

4. DH is competitive against other heating methods in terms of price and quality

4. DH has problems in open competition against other heating methods in terms of price and especially quality

3. Consumer driven (Variable flow ) schemeSatisfied clientsNeed to economic O&MAttracts new customer of DHEnsures continuous cash flows

3. Production driven (constant flow) schemeNon satisfied clients Poor reputation of DH Inefficient O&M



Major Differences Between Finnish and Eastern European DH Systems, Heat production

Higher annual production efficiency 86%-92% (depends on fuel)

Low annual production efficiency of old production facilities 40%-80% depending on fuel and type of boiler or plant. New large scale production plants have relatively good annual production efficiencies

CHP, bio-fuels and industrial “waste”heat widely utilized for DH

CHP capacity not fully utilized

DH systems normally supplied by large CHP plants and/or boiler plants

Systems with coal/gas/oil fired small scale block boilers widely applied to supply relatively small DH systems



Major Differences Between Finnish and Eastern European DH Systems, Heat production

Design temperature of DH water is 120 °C (typically max 115 °C is applied in operation)

Original design supply temperature 150 °C according to Soviet / Eastern European criteria, but today no more than 130-135 °C is fed to DH networks

Flue gas cleaning arranged even for the smaller production units

Flue gas cleaning on unsatisfactory level at small scale production units

Satisfactory water quality due to proper water treatment equipment

Due to non-appropriate water treatment equipment and quality program at production plants water quality is not always on the satisfactory level -> risk to corrosion and other problem



Major Differences Between Finnish and Eastern European DH Systems, Heat transmission and distribution

Due to heat exchangers for space heating all buildings hydraulically separated from primary network

All buildings not hydraulically separated from secondary or even primary network

DHW always prepared through DH for residential customers

DHW not always prepared through DH for residential buildings

No group substations, but building level compact substations with heat exchangers for space heating and domestic hot water (DHW)

In case of larger systems group substations for space heating with or without heat exchangers

Primary networks, no large secondary networks

Large secondary networks beyond group substations



Major Differences Between Finnish and Eastern European DH Systems, Heat transmission and distribution

Clear property rights and responsibilities Distribution of property rights and responsibilities related to secondary networks and consumer installations is not clear

Heat meters exist -> invoicing based on measures consumption

Heat metering not widely applied -> invoicing based on floor area and norms & standards



Major Differences Between Finnish and Eastern European DH Systems, Heat transmission and distribution (continued)

Annual heat losses vary from 5% to 13% in average

High annual total (primary + secondary) thermal heat losses (25%- 50%, or even more ). Heat losses are caused by leaks, improper or wet insulation, too large pipe diameters in respect of the heat load and insufficient quality of piping material and installations.

Leaks: In average total volume of DH water changes once a year, which is annual make-up water demand

Leaks: Average annual make-up water demand of Eastern European DH systems is high e,g. 8 – 30 (or even more) times of total water volume in DH network



Major Differences Between Finnish and Eastern European DH Systems, Heat transmission and distribution (continued)

There are no large secondary networks in modern Nordic systems

Please note: Technical condition of secondary network is much worse than primary network

Modern Nordic DH networks (and consumer ) are designed and operated according to sound economic criteria by using standardized, commercially and technically proven technology. DH companies, heat producers, heat consumers and, to some extent, governmental authorities strictly control and supervise the quality of equipment and installation works

In Eastern Europe DH networks (and consumer installations, too) are not always constructed and operated based on sound economic criteria, and over-dimensioning of the main components of the DH system is common. Additionally, quality of the equipment and their installation varies and is not always up to a satisfactory level.



•Only one plant controls pressure difference and heat output. The other plant(s) shall be on fixed (MW, Gcal/h, m3/h) output mode

p of controlling plant is based on the p monitored from the network •All plants shall be provided with speed controlled DH pumps.•Enables maximal utilisation of CHP capacity

Preliminary ideas for reconstruction investments

Operation of two or more plants in the integrated DH network


Example: heat accumulator

With accumulatorWithout accumulator

Fuel100

Powernet37

Heat

36

Los-ses14

Fuel100

Motor

Powernet43

Heat

41

Los-ses16

Losses< 0.1

Accu.

To accumulator

5Heat

11

13

Motor

87HOB

Heat0

HOB

Losses2


Efficiency and production of 13 HOBs

HOB Combustion and calculated annual plant efficiency, year 1998

50 %

55 %

60 %

65 %

70 %

75 %

80 %

85 %

90 %

95 %

100 %

Name of HOB

Ann

ual P

lant

Effi

cien

cy

0

20000

40000

60000

80000

100000

120000

140000

160000

180000

200000

Calculated annual plant efficiency 83,1 % 81,0 % 75,7 % 79,3 % 72,5 % 71,1 % 86,0 % 77,6 % 82,0 % 81,5 % 61,8 % 69,9 % 69,7 % 79,4 % 76,2 %

Combustion efficiency 91,5 % 90,8 % 92,2 % 93,6 % 82,1 % 78,5 % 91,1 % 91,2 % 88,6 % 91,8 % 88,3 % 80,0 % 80,0 % 87,7 %

1998 Heat delivery 65023 27211 26265 108746 8787 1179 37789 19733 48952 16564 6275 11528 13816 391867 30144

9MR "Sormov

o"

Center " Sormov

o"

Quartal Engels

Pr. Sojuzny

Ivan Romano

ff st.

School No 52

Vodoprovodnaya

st.

Rekord Factory

Murashkinskaya

st.

17th Quartal

Bezrukova st.

Krasnich Sor st.

Gastello st. Total Average


Energy Efficiency in Power Plants: Typical Saving Measure Areas

• Trimming of steam parameters (live steam, extraction and back-pressure steam, feed water tank pressure, feed water valve pressure difference, etc.)

• High and low-pressure pre-heater problems• Optimal operation of reduction stations and auxiliary condensers• Heat recovery to save steam or maximize power production• Preheating of fuels, air and make-up water to increase plant efficiency• Optimization of gas turbine operation• Changes in turbine extraction steams to produce more electricity• Optimization of boiler blow downs and soot blows• Energy savings of auxiliary equipment, such as pumps and fans• Replacing more expensive energy consumed with less expensive energy when

applicable (electricity replaced with steam, steam replaced with hot water, etc.)• Recycling exhaust water back to process


Results of Selected Power Plant Energy Efficiency Analyses

16

12

12

14

7

25

13

24

20

26

Nr. of profitable saving measures

9 260023 7307030 2101 2901,8370PP10 (mu)

31 22014 45056 940-36055 7201 6101,11 150PP9 (mu)

10 590052 4402 400-4 4601 6401,31 270PP8 (in)

18 970021 56055018 7708900,91 020PP7 (in)

Not reported

0-2 84012013 0202100,6380PP6 (in)

Not reported

034 010500-6 4904401,3330PP5 (in)

-1904 950-9405905 4951100,7160PP4 (in)

4 730258 770-8 1001 47040 6601 5900,82 060PP3 (in)

38 21026 140129 3101 790-14 9104 1802,31 840PP2 (in)

-2 4609 070-35 03013 00062 7308 5603,42 500PP1 (in)

CO2reduction (t/a)

Water Savings (m3/a)

Savings in Fuels (MWh/a)

Electr. Saving (MWh/a)

Power gener. change (MWh/a)

Investment (k€)

Payback time (a)

Savings (k€/a)


Case: Identifying a Saving Measure

• Client: Municipal District Heating Power Plant• Situation: Everything seems to be ok according to the power plant operation

monitoring system, no reason for further studies• Next step in analysing project: Heat and mass balance simulation model of the

process based on the turbine accuracy measurements• Problem: Balance calculations of the simulation model give different values than on-

line measurements• Further energy balance studies show that energy of the extraction steam is not

completely transferred to feed water Identification of a leakage in the drain

valve of a high-pressure pre-heater • Solution: Repairing of the drain valve

Power production increase 4 100 MWh/aFuel consumption increase 4 400 MWh/aNet income increase 52 000 €/a


General Quality Criteria for DH Operation in Finland (according Finnish District Heating Association)

Key figure and quality criteria

Quality level 1 2 3 4 5 6Exellent < 6 < 0.7 < 0.08 < 1 < 0.6 < 0.4Good 6-9 0.7-1.2 0.08-0.16 1-2 0.6-1.2 0.4-0.8Reasonable 9-12 1.2-1.7 0.16-0.24 2-3 1.2-1.8 0.8-1.2Weak > 12 > 1.7 > 0.24 > 3 > 1.8 > 1.2

Explenations:1 = Annual heat loss in heat distribution, %2 = Consumption of additional DH water / Total volume of DH network3 = Number of failures, pcs / km4 = Annual O&M cost / total pipe length, €/m5 = Average interruption time in heat delivery per customer, h/a (outside heating season 1.5-30.9)6 = Average interruption time in heat delivery per customer, h/a (within heating season 1.10-30.4)


Benchmarking resultsEnergy consumption for DH Pumping and Network Heat Losses

10

20.8

10.2

17

0

5

10

15

20

25

Upps

ala

Oden

se

Klage

nfurt

Helsin

ki

Buda

pest

Bres

ciaBe

rlin

Lapp

eenra

nta

Sorm

ovsk

aya

Sorm

ovsk

aya,

targe

t

Cities

kWhe

l/MW

hth

%

Heat Losses (%) Pump energy kWhel/MWhth


Technical Features of District HeatingAverage annual operational benchmarks of a modern (Finnish) DH systems as a function of size of system

2.61.881.661.651.250.970.98Connected load / Tot. network length, MW/km

5.918.275.827.786.937.7310.55

Electricity for heat transmission / produced heat, kWh/MWh

1.270.930.881.391.341.251.25Make-up water demand / total network volume

84.1 %83.5 %83.3 %81.4 %79.9 %77.5 %77.9 %Total annual efficiency, %

88.6 %91.6 %92.1 %90.3 %90.0 %87.5 %88.4 %Annual production and purchase efficiency, %

5.1 %8.8 %9.6 %9.9 %11.2 %11.4 %11.9 %Network heat losses ,%

L > 1000 MW

200 MW < L < 1000 MW

80 MW < L < 200 MW

30 MW < L < 80 MW

10 MW < L < 30 MW 5 MW < L < 10 MW

L < 5 MW

Size of the system in respect of the connected load (L)


Example: pump energy

Value of additional cost for pumpingHeat density > 2.5 GWh/km, Cost of electricity 60 EUR/MWh

0

50

100

150

200

250

300

350

400

100 600 1100 1600 2100

Heat Supply, GWh/a

Val

ue o

f add

ition

al p

umpi

ng e

nerg

y, 1

000

EU

R/a

Specific pumping energy consumption0,8 %Specific pumping energy consumption0,7 %Specific pumping energy consumption0,6 %


Example: Inverter to condensate pump after DH2 exchanger

• Present situation:– DH2 water level is controlled by throttling condensate flow– Pump is oversized for normal operation

• Suggestion:– Inverter to be installed for speed control of the pump motor

• Changes:– Via inverter the electricity consumption is lowered

• Investment:– Inverter, installation and some equipment (estimate 8 000 €)

• Annual savings potential: 5 000 €/a (in electricity)• Pay-pack period: 1,6 a• CO2 emission reduction:


Actual cooling rates in DH-Net

Temperature Difference in the DH-Net, year 1998

0

10

20

30

40

50

60

70

-30 -25 -20 -15 -10 -5 0 5 10 15 20

Toutdoor

delt

a T actual

graffik


Transmission Networks

0

0.2

0.4

0.6

0.8

1

1.2

0 5 10 15 20Reduction of return temperature [K]

Rel

ativ

e ch

ange

heat lossespumping energy

Lower return temperatures –lower losses and pumping energy

• Constant flow and high temperature networks• Necessary replacement with pre-insulated pipelines • Lower temperatures - lower heat losses and reduction of energy for pumping.


Environmental analysis

CO2 emissions

0

20000

40000

60000

80000

100000

120000

2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

Year

tons

Baseline Project

Benefits of the project


The cleanliness of Helsinki’s air has steadily improved, due to the change, beginning in the 1950’s, from individually heated buildings to the centralised district heating system now serving over 90% of the city’s structures.

Heat and power production in Helsinki is based on CHP.

An Example of Environmental Benefits of DH


Illustrative examples between Eastern European and Nordic/modern DH pipelines


Illustrative examples between Eastern European (left) and Nordic (right) DH consumer substations


Illustrative examples between Eastern European (left) and modern (right) DH heat production plants

Rusaud - Motiva · B. Energy audit of the DH network and peak and spare boiler plants (audit to be...

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