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!