Industrial Energy Efficiency


            TOMSK POLYTECHNIC UNIVERSITY











                G.N. Klimova, E.A. Shutov, I.V. Sharapova






INDUSTRIAL ENERGY EFFICIENCY



Recommended for publishing as a study aid by the Editorial Board of Tomsk Polytechnic University














Tomsk Polytechnic University Publishing House 2015

      UDC 658.26.004.18(075.8)
      BBC 31.29-5:31.280.7я73
           K49


      G.N. Klimova

K49 Industrial Energy Efficiency: study aid / G.N. Klimova, E.A. Shu-tov, I.V. Sharapova ; Tomsk Polytechnic University. - Tomsk : TPU Publishing House, 2015. - 163 p.




             This book considers issues, reviewed by the courses “Industrial Energy Efficiency and Energy Audit”, “Optimization and Energy Saving Practices”, “Energy and Resource Saving Practices for Industrial and Utility Facilities.” The structure of power saving regulatory and legal framework is described herein, as well as organization and implementation of energy inspections for consumers, main energy efficiency increase in electrical energy supply systems of industrial enterprises, revenue metering of electrical energy in different voltage systems, calculation and performance analysis for industrial enterprise energy efficiency assessment.
             Developed for students trained in the field 13.04.02 “Electrical and Power Engineering”.

                                                         UDC 658.26.004.18 (075.8)
                                                         BBC 31.29-5:31.280.7я73



Reviewers

Deputy Head of Perspective Development Section, LLC “Gorseti” (Gorseti, LLC)
T.N. Khmelenko

Chief Power Engineer of LLC “Svet XXI veka” (Modern Illuminants, LLC)
A.I. Prudnikov





                                        © Tomsk Polytechnic University, 2011
                                        © Klimova G.N., Shutov E.A.,
                                          Sharapova I.V., 2011
                                        © Design. Tomsk Polytechnic University Publishing House, 2015

TABLE OF CONTENTS


BASIC TERMS AND DEFINITIONS ...................................................5
INTRODUCTION .................................................................11
CHAPTER 1.   ENERGY EFFICIENCY REGULATORY AND LEGAL FRAMEWORK ................14
CHAPTER 2.   CONTRACTUAL RELATIONS BASIS .....................................17
    2.1.  Terms of Agreement Conclusion.......................................18
    2.2.  Justification of the declared active power maximum .................19
    2.3.  Setting the norms of electrical energy losses ......................19
         2.3.1. Calculation of electrical energy losses in transformers when evaluating a design average power factor.............................20
               2.З.1.1. Losses in double-wound transformers....................20
               2.З.1.2. Losses in triple-wound transformers...................21
         2.З.2. Electrical energy losses in overhead and cable power lines ....2З
         2.З.З. Method of average loads.......................................25
CHAPTER З.   TARIFFS FOR ELECTRICAL ENERGY ...................................29
    З.1.  Electrical Energy Pricing Principles ...............................29
         З.1.1. Cost of service for regional consumers........................29
         З.1.2. Types of electrical energy tariffs............................З0
    З.2.  Method for consumer electricity tariff calculation .................З4
CHAPTER 4.   ENERGY INSPECTIONS...............................................З9
    4.1.  Energy inspection management .......................................40
    4.2.  Types of energy inspections.........................................40
    4.З.  Energy inspection procedure ........................................42
CHAPTER 5.   ENERGY BALANCES FOR INDUSTRIAL AND ENERGY ENTERPRISES ............47
    5.1.  Types of electrical balances .......................................49
         5.1.1. Electrical balance for a shop.................................5З
         5.1.2. Plant-wide electrical balance.................................54
         5.1.З. Energy and financial balance .................................55
CHAPTER 6.   INDUSTRIAL ELECTRICAL ENERGY EFFICIENCY .........................59
    6.1.  Reduction of electrical energy losses in the networks................59
         6.1.1. Reduction of power losses by phase load leveling .............61
         6.1.2. Increase of transformer efficiency............................62
         6.1.З. EE saving by networks reconstruction .........................62
    6.2.  Efficient mode of transformer operation ............................6З
    6.З.  EE saving by increasing the working machines load ..................65

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     6.4. EE saving by means of electric drive ................................68
         6.4.1. EE saving by reducing the no-load run of motors..................68
         6.4.2. EE saving by replacing the underloaded electric motors with motors of a lower power .........................................71
     6.5. Power factor and its technical and economic significance ............73
         6.5.1. General requirements to reactive power factor calculation .....74
         6.5.2. Causes and effects of a low power factor.......................75
         6.5.3. Ways of power factor increase .................................78
               6.5.3.1. Natural ways of power factor increase .................78
               6.5.3.2. Artificial ways of power factor increase.................80
     6.6. EE saving during pumping units operation ............................88
     6.7. EE saving during ventilation units operation ..........................93
     6.8. EE saving during electric furnaces operation ..........................96
         6.8.1. Electric resistance furnaces ....................................96
         6.8.2. Arc steel furnaces ..............................................97
     6.9. EE saving in the lighting systems ................................. 103
CHAPTER 7.   ELECTRICAL ENERGY METERING AT INDUSTRIAL FACILITIES .............116
     7.1. Electronic EE meters ...............................................117
     7.2. Accuracy of EE meter readings ......................................118
     7.3. Connection circuits for single-phase meters.........................119
7.4. Three-phase meter connection circuits in 380/220 V electrical installations............................................................121
     7.5. Three-phase meter connection circuits in electrical installations over 1000 V..............................................................125
CHAPTER 8.   GENERAL INFORMATION ABOUT COMMERCIAL RELATIONS MANAGEMENT IN THE OREM MARKET ................................................130
     8.1. Wholesale market of EE and power (OREM) ............................130
     8.2. OREM Agreements.....................................................131
     8.3. Electrical energy market structure analysis ........................135
CHAPTER 9.   ENERGY COMPONENT OF CONSUMER BASKET FOR TOMSK REGION ..144
     9.1. Justification of CB data for calculation of energy demand per capita ..144
     9.2. Estimation of energy input, required for manufacture of CB product set .145
     9.3. Variation of energy demand, depending on factors, effecting its value .149
REFERENCES ......................................................................157
ANNEX 1 ......................................................................161

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                TERMS AND DEFINITIONS





     Actual energy losses (reported losses) - a difference between energy volume, delivered to the grid and sold energy, calculated according to ratio of the amount of bills paid to a certain period of time.
     Bilateral contract of electrical energy purchase-sale - the agreement, according to which a provider obliges to supply electrical energy to a buyer, meeting the obligatory requirements, in a certain amount and of certain quality, and a buyer obliges to accept and pay for the electrical energy under the terms of contract, concluded in compliance with wholesale market rules and principal regulations of retail market functioning.
     Commercial losses of energy - a difference between supplied and useful consumed energy. They are conditioned by metering system imperfection, diversity and inaccuracy of meter readings, metering instrumentation error, irregular payments for energy consumption, the unaccounted consumers and theft.
     Domestic energy-using appliance - products, which functional purpose assumes using energy resources, power requirements of which does not exceed twenty one kW of electrical energy, for heat energy - 100 kW and which can be applied for personal, family, household and similar needs.
     EE provider of last resort (hereinafter - provider of last resort) - a commercial organization, which duty, according to the current Federal legislation, or by constructive obligation is to conclude the sales and purchase agreement for electrical energy with any applying consumer of electricity or with a person, acting on behalf and for the benefit of electrical energy consumer and willing to purchase electrical energy.
     Efficiency factor (EF) - a factor of energy consumption efficiency. It is found as a ratio of supplied power to total consumed power.
     Electrical energy consumers - entities, purchasing electrical energy for their own domestic and/or industrial needs [1].
     Electrical energy consumers with controlled load - the category of electrical energy consumers, which due to operation modes (electrical energy consumption) have effect on the electrical energy quality, reliability of operation of the Unified Energy System of Russia and due to this render paid services on contractual basis regarding recovery of the Unified Energy System of Russia in case of emergency situation. The specified consumers can also provide other agreed services on contractual basis.
     Electrical energy supply - a range of measures and engineering facilities to provide consumers with electrical energy.

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     Electrical equipment of labor - a ratio of electrical energy amount, used in a production process, to a number of workers.
     Electromagnetic compatibility - an adjustment capability of electrical devices, generating electromagnetic fields, for joint work, at which the arising electromagnetic interference does not exceed the specified level and does not interfere with operation of each device.
     Energy (output) parameter - a parameter of energy carrier consumption by a unit, depending on a secondary load amount.
     Energy balance - a balance of production, processing, transportation, conversion, distribution and consumption of all types of energy and energy resources.
     Energy component of a product cost - a share of produced goods cost, spent on purchase and consumption of fuel and energy resources.
     Energy efficiency - characteristics, showing a ratio of useful effect from energy resources use to energy resources input, consumed for the purpose of such effect, in relation to a product, production process, legal entity and individual entrepreneur.
     Energy efficiency - implementation of organizational, legal, engineering, processing, economic measures and other measures, aimed at reduction of used energy resources volume and keeping the respective useful effect from their use (including the volume of produced goods, performed activities and rendered services).
     Energy efficiency class - a characteristic of the product, reflecting its energy efficiency.
     Energy efficiency factor - an absolute or specific value of energy resources consumption, required for manufacture of any product, stipulated by the regulating documents.
     Energy inspection - is a collection and processing of information about using of energy resources to obtain reliable information about volume of energy resources used, energy efficiency factors, to reveal the energy-saving potential and energy efficiency increase with the results reflected in the energy certificate.
     Energy intensity of product (specific consumption) - an economic and statistical factor, determined according to a ratio of consumed energy resources volume to manufactured products in kind.
     Energy performance agreement (contract) - agreement (contract), the subject of which means actions performed by Contractor, aimed at energy saving and energy efficiency increase of used energy resources for the Customer.
     Energy producer - is a commercial organization, regardless of its organizational and legal form, producing and supplying electrical and heat

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energy in the grids for further transformation, transmission, distribution and sale to consumers.
     Energy resource - an energy carrier, which energy is used or may be used for conduct of an economic or other activity, as well as the type of energy (atomic, heat, electrical, electromagnetic energy or any other type of energy).
     Energy sales organizations organizations, which perform selling of produced or purchased electrical energy to other entities as the main activity.
     Energy saving reserve (potential) - amount of consumed fuel or energy potential economy, estimated by experts, from any implemented energysaving measures.
     Energy security a protectability of the State, region, enterprise and a person from the threat of energy and energy resources deficiency in the amount and quality, required for vital activity of current and future generations.
     Energy supply reliability - capability to perform the assigned functions and keep the performance criteria within conditions, stipulated by regulating documents.
     Entities of electric power engineering sector - entities, which engage in activities in the electric power engineering sector, including generation of electrical, heat energy and power, purchase and sale of electrical energy and power, power supply to consumers, rendering of services on electrical energy transmission, operational dispatch management in the electric power sector, sale of electrical energy (power), organization of purchase and sale of electrical energy and power.
     Estimated losses of energy - losses, conditioned by energy consumption for heating, thermodynamic cycle imperfection, which are calculated according to the well-known physical regularities and operation mode parameters.
     Fuel and energy consumption standard - a regulated amount of fuel and energy consumption for the given enterprise, process, products, works and services.
     Fuel and Energy Resource (FER) - a set of all natural converted types of fuel and energy, which are currently used in economic activities. Energy carrier which is currently used or may be (usable) applied in future.
     Gross Domestic Product (GDP) - a generalizing statistical factor, expressing a total cost of domestically manufactured products in market prices.
     Gross National Product (GNP) - an economic index, expressing a total cost of final goods and services in market prices. It includes the cost of goods and services consumed by population, public purchases, capital investments and balance of payments.

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     Market price - price for goods, formed at the goods market without federal influence on the price.
     Monitoring - observation, evaluation and forecast of the object under study in view of varying external environmental factors or internal processes, and people’s economic activity.
     Non-productive consumption of energy resources - energy resources losses, caused by violation of federal standards requirements for equipment, design criteria, process regulations or mismanagement.
     Operating generating capacity - a part of the maximum available capacity of facilities for electrical and heat energy generation, excluding the capacity of industrial power facilities, taken out of service for maintenance according to established procedure.
     Organizations with the participation of government or municipality -legal entities, where a share (contribution) of the Russian Federation, a constituent entity of the Russian Federation, a municipality in charter capitals makes more than 50 percent and (or) regarding which the Russian Federation, a constituent entity of the Russian Federation, of a municipality are entitled to exercise more than 50 % of the votes directly or indirectly, which fall within voting stocks (shares), constituting charter capitals of such legal entities as the state or municipal unitary enterprises, state or municipal institutions, state-owned companies and corporations, as well as legal entities which property belongs to the state-owned corporations either by over 50 % of stocks or shares in charter capital.
     Power consumers - entities, purchasing power, including for their own domestic and/or industrial needs, and/or for further sale, entities, selling electrical energy in retail markets, entities, selling electrical energy in the territories, where electric power systems of foreign states are located.
     Prices (tariffs) in electric power engineering sector - the system of price rates, according to which payments for electrical energy (power) are settled, also for services, provided in wholesale and retail markets (hereinafter - prices (tariffs)) [2, 3].
     Reference fuel - a conventional physical unit, applied for proportioning of different fuel types, using the factor which equals to the ratio of 1 kg fuel heat content of this kind to heat content of 1 kg reference fuel, which is equal to 29.3076 J/kg (7000 kcal/kg).
     Regulated activities - activities, performed by entities of natural monopolies, communal organizations, in regard of which the price (tariff) regulation is exercised according to the Russian Federation legislation.
     Regulated price - price for goods (tariff), formed at the goods market with the direct federal influence on the price, including setting of its limit or fixed size.

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     Regulation period - a time interval (quarter, six months, a year), taken for calculation of indices, included in the tariff-setting offers for electrical and heat power, and payment amounts for services.
     Renewable energy sources - solar, wind and water energy (including energy of waste waters), except for cases of such energy use in pumped-storage power stations, tidal energy, wave energy of water bodies, including reservoirs, rivers, seas, oceans, geothermal energy using the natural subsurface heat transfer agents, low-potential geothermal energy, energy of air, water with special heat carriers, biomass, including specifically grown plants for obtaining energy, among them trees, as well as production and consumer wastes, excluding wastes from raw hydrocarbons, biogas, landfill gas from production and consumer wastes, and gas emitted in coal mines.
     Retail markets of electrical energy (hereinafter - retail markets) - the area of electrical energy distribution beyond the wholesale market with participation of electrical energy consumers.
     Revenue metering of electrical energy (power) - a process of electrical energy metering and defining a volume of power, accumulation, storage, processing, transfer of these readings results and formation, including by means of calculation, data about amount of generated and consumed electrical energy (power) for purposes of mutual settlement payments for provided electrical energy and power, as well as for related services.
     Secondary energy resource - an energy resource obtained as production and consumer waste or potential of products, wastes, intermediate and by-products, generated as a result of a production process or operation of equipment which functions are not related to production of the respective energy resource.
     Social norm of electrical energy (power) consumption - a specific amount (volume) of electrical energy (power), which is consumed by population and equivalent categories of consumers, within boundaries of which and above which electrical energy (power) delivery is done at varying regulated prices (tariffs) [2, 3].
     Specific energy (fuel) consumption - a factor, found by ratio of actually consumed fuel amount (in physical terms or in reference units) to amount of actually manufactured products of this kind.
     Standardization - an activity of regulating documents development and approval, which stipulate a complex of norms, rules, provisions and requirements, obligatory for design development, manufacture, construction, reconstruction and operation of equipment, processes and devices.
     Unaccounted consumption of fuel and energy resources - consumption of fuel and energy resources (FER) by enterprises, organizations or indi

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viduals without metering devices, or using defective and low-quality meters, including such readings that can be falsified easily.
     Wholesale market agents - legal entities, which obtained according to current Federal law procedure the right to participate in relations, connected with electrical energy and/or power distribution in wholesale market, in compliance with the wholesale market rules, approved by the Government of the Russian Federation.
     Wholesale market of electrical energy and power (hereinafter -wholesale market) - is the area of special products distribution - electrical energy and power within the Unified Energy System of Russia in the boundaries of the common economic zone of the Russian Federation with participation of major producers and major buyers of electrical energy and power, as well as other parties, which have obtained the status of wholesale market entities and acting based on the wholesale market regulations. Criteria of referring to electrical energy producers and buyers to the category of major producers and major buyers are set by the Government of the Russian Federation.

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                INTRODUCTION





     The issues of rational and efficient consumption of fuel and energy resources (FER) acquire more important value.
     Calculation methods for electrical energy losses in electric equipment, electrical energy saving by improvement of engineering processes, process equipment productivity increase, etc., given in this book, only cover general industrial units.
     Application of electrical energy is versatile and it is practically impossible to provide for all possible saving measures, that is why activities, carried out for most industrial facilities, are recommended in this textbook.
     Great attention to rational use of electrical energy, fuel and energy resources, is also given at the government level. Main trends of the Federal Energy Efficiency Policy are given in Federal Law No. 261 ‘On Energy Conservation and Energy Efficiency Increase and about Amendments to Certain Legislative Acts of the Russian Federation’ approved by the State Duma on November 11, 2009 [4].

    Main trends of the Federal Energy Efficiency Policy

     Goal of the energy efficiency policy of Russia consists in the maximum efficient use of natural energy resources and energy sector potential for a sustainable development of the economy, increase of population life quality and contribution to strengthening of its foreign economic position.
     Objectives of the Russian Federation Energy Strategy up to 2030 are determined by major domestic and external challenges of the forthcoming long-term period [5].
     A major domestic challenge consists in necessity for an energy sector of the country to implement its most important role of transition to innovative way of economy development within the Concept framework. The guaranteed meeting of domestic demand for energy resources should account for the following requirements:
     J Provision of welfare standards by Russia that correspond to those of the developed economies;
     J Achievement of research and engineering leadership of Russia for a number of major trends, providing its competitive advantages and national, including energy, security;
     J Transformation of the country’s economy structure in favor of less energy-consuming industries;
     J Transition of the country from raw materials export towards resource-innovative development with a quality renovation of power sector (both fuel and non-fuel) and related sectors;


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     J Rational reduction of fuel and energy complex share in total volume of investment in the country economy along with increase of absolute volume of investment in energy sector, required for development and accelerated modernization of the sector and growth of its activity scale;
     J Necessity to increase energy efficiency and reduce energy intensity of economy to the level of countries with similar natural and climate conditions (Canada, Scandinavian countries);
     J Gradual limitation of fuel and energy complex load on the environment and climate by reducing the pollutants emission, polluted wastewater discharge, and greenhouse gases emission, reduction of production wastes and energy consumption.
     A major external challenge consists in the necessity to address the threats, related to the world energy markets instability and volatility¹ of world prices for energy resources, as well as provision of energy sector contribution to increase of its foreign economic activity and strengthening of Russia’s position in the global economic system. It means that the following shall be provided for:
     J Achievement of sustainable results of foreign economic activity in the area of fuel and energy complex in conditions of the increasing global competition for resources and sales markets;
     J Minimization of negative effects of a global economic crisis and using it for a complete renovation diversification of economy structure in favor of less energy-consuming industries, stimulation of a Russian energy sector transition to an accelerated innovative development and a new technological pattern;
     J Increase of a strategic presence of Russia in the markets of high-technology products and intellectual services in the energy sector, including due to deployment of globally oriented specialized enterprises;
     J Geographic and product diversification of the Russian energy export in conditions of steady and expanding supply of energy resources to largest world consumers;
     J Rational reduction of a fuel-energy resources share in the Russian export structure, transition from selling the primary raw and energy resources abroad towards selling the products of advanced processing, as well as development of petroleum products, produced by foreign refineries, owned by the Russian oil companies;
     J Development of major hubs of international energy infrastructure in the territory of Russia, using new energy technologies.

¹ Волатильность (от английского volatility) - статистический показатель, характеризующий тенденцию рыночной цены или дохода изменяться во времени.

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