Kazakhstan Industry Energy Audit Methodology. Paul Stevenson 2014

Transcription

1 Kazakhstan Industry Energy Audit Methodology Paul Stevenson 2014

2 Aim To propose a methodology for carrying out mandatory Energy audits of large industrial Enterprises in Kazakhstan Over time, this methodology can be developed and refined within Kazakhstan by key stakeholders: - Kazakh Government, including MINT/ KEE - Energy Auditors Association - Recognized audit training bodies 2

3 Proposed Audit Methodology Made use of existing, internationally recognized methodologies, predominantly: EN16247 (current EU methodology) ISO50002 (companion to ISO50001 currently draft only),.but tailoring detail to specific issues and needs of Kazakh industry Methodology can be further developed and refined within Kazakhstan 3

4 ENERGY AUDIT METHODOLOGY Phase 1 Site Visit Phase 2 Savings Opportunities Phase 3 Final Report Data Gathering & Management Gathering of main data prior to site visit On-site data gathering Data forms Interview & meetings Technical, operational & maintenance issues Systems assessment Design Technologies Operational sequences KPIs 4

5 Audit Methodology: Main headings 2.4 Overview of initial activities 2.5 Pre-site visit activities Planning Measurement plan 2.6 Start-up and kick-off meeting Start up meet Energy, production and other data Data Robustness checking 2.7 Site visit 2.8 Data Analysis Overview Production data and impact from product mix on energy performance Impact from starting materials on energy performance Identification of opportunities Evaluation of opportunities Criteria for deciding cost effectiveness of EE opportunity 2.9 Energy Audit Report General Audit report Closing meeting Reporting to MINT/ KEE

6 Pre visit general audit activities Recommend attention to pre site-visit activities, including: Liaisons with the site team, Understanding the process and key technologies, Gathering energy/ production/ other key data, Reviewing/ sanity checking data robustness, Performance indicators. Addresses two recurring weaknesses of energy-audits: (a) limited understanding of Enterprise processes; (b) poor quality/ non-robust data. Data robustness is important for Kazakh State Energy Register. One of the biggest recurring issues with climate change initiatives throughout World has been poor quality base year data. 6

7 Industry Energy Audits: Need good quality information! Recommend lot of attention to pre-visit activities: - gathering energy/ production/ other data; - checking data robustness and performance indicators; - understanding the site s process and key technologies. Poor quality energy and production data, combined with limited understanding of the main processes, are regular problems with Industry energy audits. Poor quality data is a recurring problem with climate change initiatives in other countries. Data robustness is also important for the Kazakh SER Establishing meaningful base-year performance indicators, ideally disaggregated to take into account main processes and product mix. These indicators are important for monitoring change over time, in a fair and meaningful manner.

8 Pre-visit energy questionnaire (PVEQ) Recommend: Standard pre-visit energy questionnaire (PVEQ) be developed for industry audits: - All basic information is collected, - Auditor is aware of what to expect and areas to focus effort. Robust, good quality basic data also useful for: Kazakh SER Greenhouse gas emissions Energy benchmarking ISO certification etc

9 Data and information gathering (1) Main sources of data Energy and production records and measurements, bills Decide what data is required What techniques will be applied to get the needed information? Level of data accuracy dependent on analytical technique in which data will be used accuracy level may affect credibility of survey results find out appropriate level, too much accuracy is not always reasonable

10 Data and information gathering (2) Permanently installed instrumentation be suspicious and constructively critical make judgement test of data reasonableness ask questions about calibration frequency/methods and instrument maintenance techniques Use portable test instruments when there is a reason to suspect a serious inaccuracy to check available figures when no data is available Communication with plant operators asking questions, listening and evaluating answers keep notes to ensure that important information will not be forgotten

11 Data and information gathering (3) To use set of data forms to organically collect data The forms are used to gain a better understanding of patterns and volumes of energy use. Cover electrical and non-electric energy supply, power demand profile, breakdown of energy consumption, annual costs for energy usage and energy management policies Forms also utilised to look for systems efficiencies, equipment s performance, operating and maintenance patterns that are likely to generate areas, which are expected to benefit most from energy efficiency studies. Preliminary assessment of existing EnMS in the enterprise (see next slides)

12 General/cross-sector technologies Lot of available information and expertize, including: Motors and drives Refrigeration systems Pump systems Fan systems Compressed air systems Lighting Boilers and steam/ hot water distribution Heat-recovery systems 12

13 Energy Auditing: Sector technologies Develop and recognize Kazakh specialists/ experts in key industry sectors: High temp Iron and Steel Non-ferrous Metals: Al, Zn, Cu, etc Smithers and Foundries Cement, Lime and MgO Glass Ceramic Process Inorganic and organic Chemicals Chlor-alkali Polymers Mineral Oil and Gas Refining Food and Drink Pulp and Paper Textiles Industry 13

14 Updated March 2012 Best available technology : Energy efficiency Raw materials Wastes arising Air / water emissions Process losses BREF Iron & Steel Over 600 pages, but can quickly find out about relevant, EE technologies and techniques 14

15 Typical audit checklists examples (1) Boilers o Check flows and return temperatures o Check steam pressures and temperatures o Check for leaks and insulation o Check burners and combustion o Check blow down arrangements o Check condensate recovery o Check flue gas temperature and composition Compressed Air System Check compressor efficiency Check for leaks Optimise inlet air duct Check I&C systems Check delivery temperature and pressure Challenge use of compressed air this is the most expensive utility

16 Typical audit checklists examples (2) Electricity o Examine and select optimal tariff structure o Meter electricity at all sectors o Check power factors o Stagger start up and check load management system o Use frequency inverters and variable speed motors Chilled water System Check COP for chillers, cooling towers and overall system Check temperature approach and lift Check scales and fouling in condenser water tubes Check refrigerant pressure Maximise free cooling o Switch off when not in use

17 Identify EE opportunities: Energy surveys Survey findings: prioritization of energy efficiency opportunities and basis for the development of the Action Plan Follow up with detailed energy audit and /or feasibility studies for the more promising opportunities There is no rigid formula. Every company should determine the type of audit that best meets its needs.

18 Energy Audit activities (1) Check operating data and consumption Analyse trends in energy use and costs Review management, operating and maintenance practices with regards to energy efficiency Make technical review of main energy intensive systems and equipment Identify opportunities and develop Action Plan C LI C

19 Energy Audit activities (2) System Optimization (SO) is a very important approach to identify energy efficiency opportunities Analysis of whole system design will achieve multiple benefits Starts at the demand for energy services at the production sites and working back through distribution to generation thereby identifying opportunities for improvement

20 Exploring energy consumption patterns: Final energy at the site Generally, compressed air, steam, hot water, etc are generated centrally and distributed around the site One of the barriers is that the interest is limited compared with core activities such as furnace, reaction vessel, kilns even when energy consumption is known Often there is little knowledge or awareness of who uses what; it is more seen as free - This is a mistake! - Identifying big users (or big mis-users) can offer substantial energy cost savings See also System Optimisation Module for more detail

21 Energy Audit activities (3) The audit will also focus on system components where appropriate The audit may also formulate recommendations for equipment upgrade or replacement For instance: High efficiency motors and pumps Installation of variable frequency drives New chillers

22 Energy Audit Approach Collection of energy consumption & production data database Analyzing energy use & identify weak points, including EnMS weaknesses Technical conception of energy conservation measures technical solutions Financial (& environmental) evaluation of measures economic efficiency Recommendation & priority list for implementation action plan

23 Investment Criteria Understood that yes/no EE investment decisions for is to be based on payback. An EE opportunity with < 8 year should be progressed, anything longer can be dismissed. RESET Experts have concerns about this criterion: 1. Optimisation before Investment 2. High risk associated with long payback. 3. Simple payback v payback on marginal extra cost. 4. Other Financial Appraisal techniques more relevant for large investments. Net present value (NPV) = better, allows larger investments to show their true, long-term savings potential. 5. Future legislation and other drivers 23

24 Energy Audit Report (1) A criticism of Kazakh Energy Audit reports has been they are very long, with large sections on the process, measurement, findings, technical graphs and detailed tables included in the body of report. The reader has difficulty extracting key points and recommendations. Recommended report template: 1. Executive summary Background and rationale for the audit. Key findings, including saving potential Summary and ranking of EE (and other) opportunities = Action Plan 2. Background/ introduction Brief description / general information about site and why the audit 3. Annual energy and production data Site energy data: total and fuel split Production data, split by main products List of main energy centres Any seasonality, e.g. much more thermal energy in winter.

25 Energy Audit Report (2) 4. Observations made during site audit Process as a whole, Site energy management, sub-metering and control; Main processes: observations/ measurements; Utilities such as CHP plant, boilers, compressed air systems, etc; Staff behavior, awareness, attitudes, etc 5. Energy saving opportunities Follows from observations; Basis for the proposed implementation programme; Measurements made and assumptions used for calculating costs and benefits; Financial appraisal of the EE opportunity; Verification methods

26 Energy Audit Report (3) 6. Conclusions and Recommendations, including Action Plan Priority based on agreed criteria for evaluating opportunities (for large or businesscritical investments, assess costs and benefits over life of the investment), Action plan should make it clear which opportunities are: (1) Energy management: therefore enabling steps; (2) No/low cost EE opportunities, including training/ awareness; (3) Investment opportunities that have been financially analyzed; (4) Investment opportunities that need further investigation by DEA. 7. Energy audit description: Appendices How done, who met What measured/ estimated, calculations made, etc. Logically, this comes after the background, but we want to avoid bulking the report and losing the flow.

27 General or Detailed Energy Audits Not all EE opportunities can be fully analysed in a General Audit, particularly technical opportunities that are likely to require large investment. In many instances, follow-up Detailed Energy Audits may be required to develop investment opportunities. Auditors and MINT need to differentiate between: (a) General Audits, which this report focuses, and (b) Detailed Energy Audits (DEAs): investment opportunities normally associated with technical equipment. Need specialist analysis before selecting the best investment.

28 Recognizing difference between General & Detailed Audits Preliminary Energy Audit Technically simple No and low cost measures detailed Energy Audit Medium and high cost measures system audits Feasibility Study Capital intensive projects complicated applications Formulation of investment plan (Action Plan) 28

29 General or preliminary energy audit Goal / target Identify energy savings opportunities Focus on no and low cost measures Identify maintenance and operational energy conservation opportunities Identify needs for more detailed analysis Duration 1 week for small & medium sized factories 1 month for large industrial facilities Preparation: Check list / questionnaire Analysis of energy use practice comparison with best practice benchmarks On site visit: Kick off meeting Walk through inspection Discussion on the findings Steps / approach Data collection and visit preparation Plant or facility visit Preparation of audit report Report: Analysis of current energy use Description of saving measures Proposals for further action

30 Detailed energy audit Goal / target thorough analysis and evaluation of energy procurement, conversion, distribution and use determine cost of operational changes Duration 1 month for small & medium sized facilities 2-3 months for large industrial facilities Steps / approach Gathering energy and production data Evaluation of data Detailed analysis of energy conservation opportunities and measures Consider organisational aspects Implementation action plan Plan the energy survey Collect basic data and information Carry out tests and sub-metering Calculate energy balances and efficiencies Identify energy saving opportunities Calculate energy savings and cost savings Calculate cost of implementation / necessary measures Review of energy purchasing cost Economic and financial appraisal Investigate responsibility structure and barriers Detailed report Priority list for implementation of measures