002 energy management

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Energy Management

Energy Management System, Energy Auditing and

Implementation techniques for Power Industries.

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Definition & Objectives• 1. The judicious & effective use of energy to maximise profits

(minimise costs) and enhance competitive position.• 2.The strategy of adujusting and optimising energy, using

systems and proceedures to reduce energy requirements per nit of output while holding constant or reducing total costs of producing the output.

The objective of energy management is to Achieve & maintain optimum energy procurement and

utilsation, and To minimise energy cost / waste without affecting production

& quality. To minimise environmental effects.

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Management

• Management :- In all business and organizational activities is the act of coordinating the efforts of people to accomplish desired goals and objectives using available resources efficiently and effectively. Management comprises-

• Planning, Organizing, Staffing, Leading or directing, and controlling an organization for the purpose of accomplishing a goal.

• Resourcing :- deployment of human resources, financial resources,

• technological resources, and

• natural resources.

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Management Functions• Management functions are Universal.• They are applicable everywhere.• Originated from the Army.

• Forecasting• Planning• Organizing (Staffing)• Commanding• Coordinating• Controlling

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ISO 50001 – En.M.S.

• Using energy efficiently --• Helps organizations to save money.• Helps to conserve resources and• Helps to tackle climate change. • ISO 50001 supports organizations in all sectors

to use energy more efficiently,• through the development of an energy

management system (EnMS).

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ISO 50001 - Energy management

• ISO 50001 is based on the management system model of continual improvement.

• Which is also used for other well-known standards such as ISO 9001 or ISO 14001.

• This makes it easier for organizations to integrate energy management into their overall efforts-

• To improve quality and environmental management.

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ISO 50001:2011 provides• A framework of requirements for

organizations to:• Develop a policy for more efficient use of

energy• Fix targets and objectives to meet the policy• Use data to better understand and make

decisions about energy use• Measure the results• Review how well the policy works, and • Continually improve energy management.

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Purpose• The purpose of this ISO is to enable organizations-• To establish the systems and processes necessary to improve

energy performance,• Including energy efficiency, use and consumption. • Implementation of this International Standard is intended to lead

to reductions in greenhouse gas emissions • and reduce other related environmental impacts and• reduce energy cost through systematic management of energy. • This ISO is applicable to all types and sizes of organizations,

irrespective of geographical, cultural or social conditions.• Successful implementation depends on commitment from all

levels and functions of the organization, • and especially from top management.

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PDCA – Plan – Do - Check - Act

• This ISO is based on the PDCA continual improvement framework and incorporates energy management into everyday organizational practices, as illustrated in Figure.

• For energy management, the PDCA approach can be outlined as follows:

• — Plan: conduct the energy review and establish the baseline, energy performance indicators (EnPIs), objectives, targets and action plans necessary to deliver results that will improve energy performance in accordance with the organization's energy policy;

• — Do: implement the energy management action plans;• — Check: monitor and measure processes and the key

characteristics of operations that determine energy performance against the energy policy and objectives, and report the results;

• — Act: take actions to continually improve energy performance and the EnMS.

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Terms and definitions

• For the purposes of this document, the following terms and definitions apply.

• 3.1 boundaries• physical or site limits and/or organizational limits as

defined by the organization• EXAMPLE:• A process; a group of processes; a site; an entire

organization; multiple sites under the control of an organization.

• A Section in a TPS, Entire TPS, Entire Genco.

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• 3.2 Continual improvement• recurring process which results in enhancement of

energy performance and the energy management system• Note 1 to entry: The process of establishing objectives

and finding opportunities for improvement is a continual process.

• Note 2 to entry: Continual improvement achieves improvements in overall energy performance, consistent with the organization's energy policy.

• 3.3 Correction• action to eliminate a detected nonconformity (3.21)• Note 1 to entry: Adapted from ISO 9000:2005, definition

3.6.6.

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• 3.4 Corrective action• action to eliminate the cause of a detected

nonconformity (3.21)• Note 1 to entry: There can be more than one cause

for a nonconformity.• Note 2 to entry: Corrective action is taken to prevent

recurrence whereas,• Preventive action is taken to prevent occurrence.• Note 3 to entry: Adapted from ISO 9000:2005,

definition 3.6.5• 3.5 energy• Electricity, fuels, steam, heat, compressed air, and

other like media

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• 3.6 Energy baseline• Quantitative reference(s) providing a basis for comparison

of energy performance. (Heat rate, Sp.F.O.C., Auxy.Consmn)• Note 1 : An energy baseline reflects a specified period of

time.• Note 2 : An energy baseline can be normalized using

variables which affect energy use and/or consumption, • e.g. production level, degree days (outdoor temperature),

etc.• Note 3 : The energy baseline is also used for calculation of

energy savings, as a reference –• before and after implementation of energy performance

improvement actions.

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• 3.7 Energy consumption• Quantity of energy applied• 3.8 Energy efficiency• ratio or other quantitative relationship between an

output of performance, service, goods or energy, and an input of energy

• EXAMPLE:• Conversion efficiency; energy required/energy used;

output/input; theoretical energy used to operate/actual energy used to operate.

• Note 1: Both input and output need to be clearly specified in quantity and quality, and be measurable.

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• 3.9 Energy Management System ( EnMS)• set of interrelated or interacting elements to establish an

energy policy and energy objectives, and processes and procedures to achieve those objectives

• 3.10 Energy Management Team• person(s) responsible for effective implementation of the

EnMS activities and for delivering energy performance improvements

• Note 1 : The size and nature of the organization, and available resources, will determine the size of the team. The team may be one person, such as the management representative.

• 3.11 Energy Objective:- Specified outcome or achievement set to meet the organization's energy policy related to improved energy performance

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• 3.12 Energy Performance• measurable results related to energy efficiency (3.8),

energy use (3.18) and energy consumption (3.7)• 3.13 Energy Performance Indicator, EnPI• Quantitative value or measure of energy

performance, as defined by the organization• 3.14 Energy Policy• Statement by the organization of its overall

intentions and direction of an organization related to its energy performance, as formally expressed by top management

• Note 1 : The energy policy provides a framework for action and for the setting of energy objectives and energy targets.

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• 3.15 Energy Review• Determination of the organization's energy

performance based on data and other information, leading to identification of opportunities for improvement

• Note 1 : In other regional or national standards, concepts such as identification and review of energy aspects or energy profile are included in the concept of energy review.

• 3.16 Energy services• activities and their results related to the provision

and/or use of energy.

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• 3.17 Energy Target• Detailed and quantifiable energy performance requirement,

applicable to the organization or parts thereof, that arises from the energy objective and that needs to be set and met in order to achieve this objective

• 3.18 Energy use• manner or kind of application of energy• EXAMPLE:• Ventilation; lighting; heating; cooling; transportation;

processes; production lines.• 3.19 Interested party• Person or group concerned with, or affected by, the energy

performance of the organization

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• 3.20 Internal Audit• systematic, independent and documented process for

obtaining evidence and evaluating it objectively in order to determine the extent to which requirements are fulfilled

• 3.21 Non Conformity (NC) non-fulfilment of a requirement

• 3.22 Organization-- Company, corporation, firm, enterprise, authority or institution, or part or combination thereof, whether incorporated or not, public or private, that has its own functions and administration and that has the authority to control its energy use and consumption

• Note : An organization can be a person or a group of people.

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• 3.23 Preventive action:- action to eliminate the cause of a potential nonconformity .

• 3.24 Procedure :- Specified way to carry out an activity or a process

• Note 1 : When a procedure is documented, the term “written procedure” or “documented procedure” is frequently used.

• 3.25 Record:- Document stating results achieved or providing evidence of activities performed

• Note 1 : Records can be used, for example, to document traceability and to provide evidence of verification, preventive action and corrective action.

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• 3.26 Scope:- Extent of activities, facilities and decisions that the organization addresses through an EnMS, which can include several boundaries

• 3.27 Significant energy use :- Energy use accounting for substantial energy consumption and/or offering considerable potential for energy performance improvement

• .3.28 Top management :- Person or group of people who directs and controls an organization at the highest level.

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E.A. of a TPS

COAL TO ELECTRICITY PROCESS

Energy Audit ?

• Use of Energy in efficient way.

• Misuse of Energy

• Points of loss.

• Controllable loss.

STEAM CYCLE FOR 210 MW UNIT

THERMAL PROCESS LOSSES

A. Plant on-line instruments with few audit instruments Accuracy around 3.0%.

B. Accurately calibrated instruments as per ASME-PTC-6 for steam turbine & ASME-PTC-4-1 for Boilers.

Accuracy around 0.5 %ERROR OF PROCEDURE OF ENERGY AUDIT OTHER THAN

ASME-PTC-6 for steam turbines and ASME – PTC-4.1 for boiler

- Error in Boiler Energy Audit – around 2.0%– Error in steam turbine Energy Audit – around 3.0%Total error because of Instrumentation & Procedure 6.0%

EFFECT OF INSTRUMENTATION ON ENERGY AUDITS

Contd….

IMPORTANCE OF ACCURACY IN ENERGY AUDITS

– 1.0% Deviation in Heat Rate means 25000 tons of coal loss/annum for 200 MW Unit or approx Rs. 5 crores / year (4000Kcal coal GCV & Rs.2000/ton coal cost)

Cost of Energy Audit B =Rs.12-14 Lakhs. And Energy Audit A =Rs. 6 - 8 Lakhs.

Extra payment of Rs.6.0 lakhs is justified in view of results.

SHORT FALL LOSS IN CRORES PER ANNUM

TURBINE CYCLE HEAT RATE 1.0 % 5.0

TG OUTPUT 1.0% 5.0

BOILER EFFICIENCY 1.0% 1.75

AUX. POWER CONSUMPTION 5.0 % 2.5

NOTE: TG CYCLE HEAT RATE IS TAKEN AS 2000 KCAL / KWh COAL CV IS TAKEN AS 4000 KCAL / Kg PRICE OF COAL TAKEN AS Rs. 2000 / t LOSS INCREASES WITH MACHINE SIZE

ECONOMIC ASPECTS OF INEFFICIENT MACHINES (210 MW UNIT)

CONFORMITY FOR ENERGY AUDITS

FOLLOW TEST CODES

• ASME PTC - 6 For Steam Turbines

ASME PTC - 4.1 or BS- 845: 1987 for Boilers

CALIBRATION LAB• Govt. Accredited i.e. NABL Labs

SCHEMATIC DIAGRAM OF BOILER

Water cycle

Fuel cycle

Air & flue gas cycle

Steam cycle

Ash/ rejects cycle

TYPICAL BOILER LOSSES

BOILER SPECIFICATION

SOME CRITICAL FACTORS AFFECTING BOILER PERFORMANCE

• -Fuel;-Heating Value, Moisture Contents, Ash Composition, Ash Contents,& Volatile Matter.

• -Operational Parameter:-Level of Excess Air, & operating Condition of Burner Tilt Mechanism.

• -Design:-Heating input per plan area, Height of Boiler, Platens & pendants heat transfer Surfaces, Burner & wind Box design.

Coal Quality IMPACTS• -Low heat value fuel results in over firing of fuel causing more heat

availability for super heater and re-heater thus more attempration spray requirement. Hence increase in THR, overloading of ash handling system, fans and increased soot blowing

• -Moisture content increase causes increase in heat transfer to S.H, and R.H. Hence again increase in attempration spray and THR.

• -Ash composition and contents increases damage to pressure parts surfaces because of melting behavior of low fusion ash temperature of blended coal in particular.

• -In consistency in fired fuel characteristics results in variation in excess air requirement thereby increasing stack loss and hence boiler efficiency reduction, overloading of ID Fan and ultimately unit load limitation.

• -High heat value causes more radiant heat transfer to water walls thereby leaving lesser heat for super heater and re-heater.So above problems are minimised.

IMPACTS contd… -Normally excess air ranges from 15% to 30% of

stoichiometric air. • -High O2 % and presence of CO at ID Fan outlet are

indicator of air in leakages and improper combustion in furnace.

• -Poorly effective damper control also is the cause of higher SEC of fans both primary and secondary.

• -The quality and purity of feed water and make up water is also required to be maintained in a meticulous way by limiting blow down losses to nearly 1% and by checking the passing and leakages of valves. However, maximum 3% of flow can be taken as make up for these causes including soot blowing requirements.

• -Soot blowing is dependent on ash contents and is unit specific. Intelligently devised soot blowing can result in saving the fuel. Continued………

IMPACTS contd…• -Cascading effects on efficiency, loading and

availability because of following systems and equipments performance also needed to be looked into. The systems are:-Fuel receiving, preparation and handling systems.Pulverizing systemAir HeaterFansElectrostatic PrecipitatorFly ash handling systemBottom ash handling systemWaste disposal system

STUDY OF VARIOUS BOILER ASPECTS

Coal quality - composition and calorific value

Coal milling aspects

Combustion and excess air

Reheaters

Heat recovery units – Economisers, air preheaters, etc

Insulation aspects

Operation and maintenance features which affect the energy efficiency

Boiler blow down aspects

Soot blowing aspects

Condition & status of boiler and their internals

Feed water system aspects

Air and flue gas system aspect

STUDY OF VARIOUS BOILER ASPECTS

Heat Rate Losses in Boiler

3

8

5

1

4 3

10

1

2

3

4

5

6

7

8

9

1HRH TEMPERATURE MS TEMPERATURE

MS PRESSURE R/H SPRAY

EXCESS O2 EXIT GAS TEMPERATURE

BOTTOM ASH

STEPS INVOLVED IN BOILER ENERGY AUDIT

Data collection

Observations and Analysis

Exploration for energy conservation measures

Report preparation

DATA COLLECTION- BOILER

DATA COLLECTION- BOILER contd…

DATA COLLECTION- AIR PREHEATER (APH)

Particulars

EXHAUST GAS TEMPERATURE PROFILE

Temperature location

COAL PARAMETERS

HEAT BALANCE OF BOILER

(Flue gas)

Collect recommended feed water & boiler water limits

Mills and Burners Performance

Mill specifications

Design coal parameter

Collect the information of soot blowers

OTHER INFORMATION COLLECTION

INSTRUMENTS REQUIRED

Power Analyser: Used for measuring electrical parameters such as kW, kVA, pf, V, A and Hz

Temperature Indicator & Probe

Stroboscope: To measure the speed of the driven equipment and motor

Sling hygrometer or digital hygrometer

Anemometer

Available On line instruments at the site

( Calibrated )

INSTRUMENTS REQUIRED contd…

Digital Manometer of suitable range and appropriate probes for measurement of pressure head and velocity head

Additional pressure gauges with appropriate range of measurement and calibrated before audit

Flue gas analyzers / orsat apparatus

Infrared pyrometers

Pressure gauges

Steam trap tester / Ultra sonic leak detectors

MEASUREMENTS & OBSERVATIONS TO BE MADE

(DURING AUDIT PERIOD)

analysis

- Fly ash & bottom ash

Fans, Pumps

OBSERVATIONS AND ANALYSIS

System familiarization and operational details:Availability factor, PLF, Coal consumption (tons and kg/kWh),Oil consumption in ml/kWh, Boiler efficiency & Others

Plant observation & past data:


Operating efficiency of the boiler:The test method employed is based on the abbreviated efficiency by theloss method (or indirect method) test, which neglects the minor lossesand heat credits, which are covered in full text version. The major lossescovered are: Heat loss due to dry flue gas losses Heat loss due to moisture in fuel

Heat loss due to hydrogen (moisture of burning hydrogen)

Heat loss due to combustibles in refuse

Heat loss due to radiation

Un accounted losses as per the contract with the Boiler Supplier

Indirect method is also called as heat loss method. The efficiency can be arrived at, by subtracting the heat loss fractions from 100. The standards do not include blow-down loss in the efficiency determination process


Measurement Locations:

( O2, CO2, CO )


(Time)


Coal Ultimate Analysis

COMPUTATION OF BOILER LOSSES 1. Dry flue gas loss:

Where C%BA – % of carbon in bottom ash

C%FA - % of carbon in fly ash

Bash – Bottom ash qunatiity in kg

Fash – Fly ash quantity in kg

FGT – flue gas temperature at APH outlet in 0 C

ABT – Ambient temperature in C

Cp= specific heat of flue gas in Kcal/kg C = 0.23

COMPUTATION OF BOILER LOSSES 2. Loss due to unburnt carbon in ash:

)%()%(,

/

,

BAshBACFAshFACGCVfuelofGCV

kgkcalincarbonofvalueCalorific

LashincarbonunburnttodueLoss uca

GCV

ABTFGTM

LfuelinmoisturetodueLoss mf

100584)(45.0(,

3. Loss due to moisture in fuel:

4. Loss due to hydrogen in fuel:

GCV

ABTFGTH

LfuelinhydrogentodueLoss hf

100584)(45.0(

9, 2

Where H2 – kg of H2 in 1 kg of fuel

COMPUTATION OF BOILER LOSSES 5. Loss due to moisture in air:

GCVABTFGThumidityAASLairinmoistureintodueLoss ma

100)(45.0,

Where AAS=Actual mass of air suppliedHumidity = humidity of air in kg/kg of dry air

GCV1005744

%CO%COC%CO

L,xidecarbonmonotodueLoss2

co

GCV100

574428h/kginnconsumptiofuel10ppminCO

L,monoxidecarbontodueLoss

6

co

6. Loss due to CO in flue gas:

TYPICAL BOILER HEAT BALANCE

BOILER

Boiler Efficiency (Heat in Steam)

Heat loss due to dry flue gas

Dry Flue Gas LossHeat loss due to wet flue gas

Heat loss due to moisture in fuel

Heat loss due to unburnts in residue

Heat loss due to moisture in air

Heat loss due to radiation & other unaccounted loss

5.5%

4.2%

1%

0.3%

1%

1%

87%

100%Heat fromFuel

BOILER EFFICIENCY EVALUATION

COCO

CO

COMBUSTION CONTROL, EXCESS AIR AND COLD AIR INGRESS

While conducting the study, the following need to be verified:

Present excess air and comparison with PG test or design value

Combustion control systems installed and status of operation,

calibration systems

Monitoring and controlling mechanism for oxygen, excess air and reporting systems in place

Effect of excess air on boiler performance

Excess air with respect to boiler load variation

Cold air infiltration in to the system – observe the present method of measurement, estimation, frequency of measurement for estimating the losses and control mechanisms initiated. The air ingress also increases load on the ID fan and hinders the capacity of the boiler

Air Preheater Analysis

PRESSURE : -78mmwcTEMPERATURE : 150 oCO2 : 4.8%

PERFORMANCE OF AIR PREHEATERS

Air leakage estimation in APH:The following gives the air leakage in to the (APH) system ifthe Oxygen % is measured at the entry and exit of the APH

Alternatively, if the CO2% is measured in the exhaust gases then the air

leakage is estimated by


Gas side efficiency: The gas side efficiency is defined as the ratio of the temperature drop, corrected for leakage, to the temperature head and expressed as percentage.

Temperature drop is obtained by subtracting the corrected gas outlet temperature from the inlet. Temperature head is obtained by subtracting air inlet temperature from gas inlet temperature.


Theoretical

Total air = PA+ SA+ Seal air tph

Operation and Mtce Controllable Variables Affecting Boiler Performance

• Superheater Steam Outlet Temperature• Reheater Steam Outlet Temperature• Air Heater Leakage• Superheater spray• Reheater Spray• High Primary airflows• Pulveriser Coal Reject• High Carbon Content in Fly Ash• High Carbon Content in Bottom Ash• Furnace Exit Gas Temperature

Operation and Mtce Controllable Variables Affecting Boiler Performance

• Economiser Exit Gas Temperature• Airheater Exit gas Temperature• Boiler air in leakage• Auxliary Power Consumption of Fans,Mills and Soot Blowers• Excess Oxygen in Flue Gas• Cycle Losses due to Leaking Vent and Drain Valves• Soot Blowing Optimization• Mill Air In Leakage on Suction Mills• Steam Purity Problems

EXPLORATION OF ENERGY CONSERVATION OPPORTUNITIES

Boilers:Steam and water parameters ( flow, pressure and temperature ) Air and gas parameters ( flow, pressure and temperature ) Burners operation Primary and secondary air ratios and temperatures Air infiltration in to boilers Unburnt loss reduction Combustion control – boiler excess air, O2 Measurement inaccuracy or unbalance Dry flue gas loss Insulation Air infiltration to flue gases Water quality, Blow down and its control

EXPLORATION OF ENERGY CONSERVATION OPPORTUNITIES

Coal quality and performance of coal mills Super heater and reheater performance Super heater temperature, slagging of furnace water walls and tubes Fouling on the pendant and horizontal convection tubes, soot blowers performance Boiler control systems Limitation on Performance of associated equipments (pumps, fans, heaters, soot blowers, mills, etc) affecting boiler loading and efficiency Loading on ID, FD and PA fans Operation of dampers /inlet guide vanes / speed controllers of fans Fouling of boiler heating surfaces Installation of energy saving retrofits DM water consumption

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002 energy management

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