The document discusses energy management in power industries. It defines energy management and its objectives as the judicious use of energy to maximize profits and competitiveness while minimizing costs and environmental impacts. The key aspects covered include ISO 50001 energy management systems, management functions, conducting energy audits and reviews of systems like boilers. It emphasizes establishing an energy baseline, setting targets and objectives, measuring and reviewing performance, and continually improving energy efficiency.

1. Energy Management
Energy Management System,
Energy Auditing and
Implementation techniques for
Power Industries.
1

2. 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.
2

3. Management
3
• 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.

4. Management Functions
• Management functions are Universal.
• They are applicable everywhere.
• Originated from the Army.
• Forecasting
• Planning
• Organizing (Staffing)
• Commanding
• Coordinating
• Controlling
4

5. 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).
5

6. 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.
6

7. 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.
7

8. 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.
8

9. 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 performance9

10. 10

11. 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.
11

12. • 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.
12

13. • 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 13

14. • 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.
14

15. • 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.
15

16. • 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
16

17. • 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 17

18. • 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.
18

19. • 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
19

20. • 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.
20

21. • 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.
21

22. • 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.
22

23. E.A. of a TPS
23

24. COAL TO ELECTRICITY PROCESS

25. Energy Audit ?
• Use of Energy in efficient way.
• Misuse of Energy
• Points of loss.
• Controllable loss.

26. STEAM CYCLE FOR 210 MW UNIT

27. THERMAL PROCESS LOSSES

28. 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….

29. 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.

30. 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)

31. 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

32. SCHEMATIC DIAGRAM OF BOILER
Water cycle
Fuel cycle
Air & flue gas
cycle
Steam cycle
Ash/ rejects
cycle

33. TYPICAL BOILER LOSSES

34. BOILER SPECIFICATION

35. 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.

36. 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.

37. 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………

38. 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 system
Air Heater
Fans
Electrostatic Precipitator
Fly ash handling system
Bottom ash handling system
Waste disposal system

39. 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

40. 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

41. Heat Rate Losses in Boiler
3
8
5
1
4 3
1
0
1
2
3
4
5
6
7
8
9
1
HRH TEMPERATURE MS TEMPERATURE
MS PRESSURE R/H SPRAY
EXCESS O2 EXIT GAS TEMPERATURE
BOTTOM ASH

43. STEPS INVOLVED IN BOILER ENERGY AUDIT
 Data collection
 Observations and Analysis
 Exploration for energy conservation
measures
 Report preparation

44. DATA COLLECTION- BOILER

45. DATA COLLECTION- BOILER contd…

46. DATA COLLECTION- AIR PREHEATER (APH)
Particulars

47. EXHAUST GAS TEMPERATURE PROFILE
Temperature location

48. COAL PARAMETERS
HEAT BALANCE OF BOILER
(Flue gas)

49.  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

50. 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 )

51. 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

52. MEASUREMENTS & OBSERVATIONS TO BE MADE
(DURING AUDIT PERIOD)
analysis
- Fly ash & bottom ash
Fans, Pumps

53. 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:

54. OBSERVATIONS AND ANALYSIS
Operating efficiency of the boiler:
The test method employed is based on the abbreviated efficiency by the
loss method (or indirect method) test, which neglects the minor losses
and heat credits, which are covered in full text version. The major losses
covered 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

55. OBSERVATIONS AND ANALYSIS

56. OBSERVATIONS AND ANALYSIS
Measurement Locations:
( O2, CO2, CO )

57. OBSERVATIONS AND ANALYSIS
(Time)

58. OBSERVATIONS AND ANALYSIS
Coal Ultimate Analysis

59. OBSERVATIONS AND ANALYSIS

60. 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

61. COMPUTATION OF BOILER LOSSES
2. Loss due to unburnt carbon in ash:
)%()%(
,
/
,
BAshBACFAshFAC
GCVfuelofGCV
kgkcalincarbonofvalueCalorific
LashincarbonunburnttodueLoss uca
GCV
ABTFGT
M
LfuelinmoisturetodueLoss mf
100
584)(45.0(,
3. Loss due to moisture in fuel:
4. Loss due to hydrogen in fuel:
GCV
ABTFGT
H
LfuelinhydrogentodueLoss hf
100
584)(45.0(
9
, 2
Where H2 – kg of H2 in 1 kg of fuel

62. COMPUTATION OF BOILER LOSSES
5. Loss due to moisture in air:
GCV
ABTFGThumidityAASLairinmoistureintodueLoss ma
100
)(45.0,
Where AAS=Actual mass of air supplied
Humidity = humidity of air in kg/kg of dry air
GCV
1005744
%CO%CO
C%CO
L,xidecarbonmonotodueLoss
2
co
GCV
100
574428h/kginnconsumptiofuel10ppminCO
L,monoxidecarbontodueLoss
6
co
6. Loss due to CO in flue gas:

63. TYPICAL BOILER HEAT BALANCE
BOILER
Boiler Efficiency (Heat in Steam)
Heat loss due to dry flue gas
Dry Flue Gas Loss
Heat 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
from
Fuel

64. BOILER EFFICIENCY EVALUATION
COCO
CO

65. 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

66. Air Preheater Analysis
PRESSURE : -
78mmwc
TEMPERATURE : 150
oC
O2 : 4.8%

67. PERFORMANCE OF AIR PREHEATERS
Air leakage estimation in APH:
The following gives the air leakage in to the (APH) system if
the 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

68. PERFORMANCE OF AIR PREHEATERS
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.

69. PERFORMANCE OF AIR PREHEATERS
Theoretical
Total air = PA+ SA+ Seal air tph

70. 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

71. 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

72. 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

73. 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

74. chittatosh_bhattacharya@rediffmail.com

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