A2A Training Modules 4 to 5.2

8/20/2019 A2A Training Modules 4 to 5.2

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This module explains the concept of an energy balance. It is an important methodology

that the tool uses to derive the breakdown of energy among the different end-uses

within a plant. This background theory will help you understand the way the technical

assessment tools works, and why it requires the information it does for the various fuels

and equipment. In the exercise you will perform an energy balance manually. The toolkit

does the calculations automatically, but the exercise will ensure a good understanding of

the concept.

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Study boundary The boundary of the study is defined by the energy purchased and utilized within the

process of Ammonia production

Energy purchased and sold Energy purchased accounts for energy utilized as a fuel only. Energy used for

feedstock production (such as ammonia) is not utilized in the energy balance, but inthe energy intensity determination to be discussed in module 8

On-site energy generation, such as renewable energy from wind, solar, biomass isincluded

Energy sold or sent to another process train is accounted for in the assessment, onlyif it uses one of the purchased fuels to generate it (eg. Natural gas generating steam,of which some is used and the remaining sent to another process train)

Utilized energy Equipment capacity, operating hours and number of equipment define the utilized

energy The variable conditions such as the operation of maximum capacity is required Equipment with large capacity are detailed and for smaller pieces of equipment,

such as ½ hp motors, the averages of the operating hours and capacities arepreferred

For smaller or numerous equipment with similar characteristics, averages ofequipment load, such as on-off time, partial load applied to motors are used todetermine the average capacity or average operating hours

Losses during equipment operation are not included in this study

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This figure shows the flow of energy within the study boundary.

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For the Energy Balance, it is important to ONLY list energy used as fuel, and EXCLUDE

energy used as feedstock in the production of ammonia.

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The energy balance accounts for where the energy flows within a plant. As the graph

demonstrates the energy entering the plant (on the left) is equal to the amount of

energy used by various equipment within a plant (on the right). The energy balance uses

this comparison of purchased energy to energy consumed to determine the energy

used by each end-use or equipment type. The following slides explain that process in

detail.

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• The energy content of the purchased fuel is evaluated against the energy consumed by

each end use.

• The adjustment factor is the ratio of energy consumed to energy purchased.

• The adjustment factor is calculated for each fuel type

• Once the adjustment factor is determined, the gaps in the energy consumed by

inventory of equipment can be noted.

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The lower heating value (LHV) is required to determine the fuel energy content to use in

the Energy Balance tab. The LHV for some fuels may vary in energy content so the

default values in the toolkit can be overwritten if necessary.

The sold energy is the summation of the energy content of the sold fuels. For sold

energy products such as steam, the energy value of the steam is allocated to the type of

fuel used to generate the steam, with an adjustment applied to account for the

conversion of fuel to steam. This adjustment is assumed to be 0.9, which is typical of

boilers and reformer conversion.

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•Self-generated energy is the total steam and electricity generated on-site.

•Net-imported energy is the net purchased energy minus self-generated energy

•The energy used by fuel type is determined by summing the energy use per equipment

end-use for that fuel type.

The adjustment factor is the ratio of net imported fuel to utilized fuel for each fuel, and

should always be less than one.

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The adjustment factor is the ratio of net imported fuel to utilized fuel for each fuel, and shouldalways be less than one because of the following assumptions:

•Equipment is assumed to be 100% efficient.•The hours of operation are applied directly to operating time without adjustment forload factors applied to equipment.

•Equipment capacity is assumed to be the rated capacity.

If the adjustment factor is much greater than one, the following should be reviewed to addressthis:

•Review quantity of purchased energy (may be too high).•Review the hours of operation of equipment using the fuel with the discrepantadjustment factor.

•Review the capacity rating of equipment using the fuel with the discrepant adjustmentfactor.

•Review the quantity of equipment using the fuel with the discrepant adjustment factor.•Review the firing time and efficiency of equipment where this is reported, such as forboilers and ovens.•Investigate whether all equipment using this fuel have been accounted for.

When the adjustment factor is close to one, then all purchased energy is being accounted for byall reported equipment.

If the adjustment factor

for steam as a fuel is much greater or less than one, review thefollowing:

•That the source of the steam has been correctly identified in TA2•That the fuel used as steam has not been generated using another source fuel

accounted for elsewhere (e. g. natural gas generated steam) and therefore added twicein the energy balance

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Link:

02 A2A Training module 4 activity

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Notes:

- useful conversion factors are provided on the same worksheet.

- Enter answers into shaded cells in Tab A.4.1

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Note: results are also shown in tab B 4.1 of the Excel workbook

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In previous modules you have learned some of the theory and methodology used by the

toolkit. In this module you will start using the toolkit as if you are doing an assessment

for a plant. There will be a demonstration of how to fill in the technical assessment, and

an exercise in which you will receive information from a hypothetical plant, and use that

information to fill in the technical assessment.

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The purpose of the technical best practice (TBPs) assessment is to determine which TBPs

are implemented at the plant, and to develop benchmarks for the plant. The

benchmarks highlights the areas where opportunities exist to implement TBPs, and

indicate the potential that still exist to implement TBPs.

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The technical best practice (TBPs) assessment is part of the first step in the Continuous

Improvement Cycle.

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The Energy Technical Assessment questionnaire collects information on energy

purchased and the energy used by equipment in the plant. The questionnaire includes

questions pertaining to the overall energy use, production, characteristics of the

equipment, and the presence of energy efficiency measures. The Excel workbook

includes the following sections:

•Section A gathers general information regarding the facility production and

procurement of energy.

•Section B is specifically related to generic equipment, such as cooling, heating and

motive power.

•Section C outlines types of heating, ventilation and air conditioning systems specifically

associated with occupancy comfort.

•Section D is an overview of system practices, other major energy consuming

equipment, and the implementation of emerging technologies.

•Section E collects data on ammonia production practices only.

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This is the index as seen on the tab labeled “Index”. Click the description to navigate

directly to that tab.

The end uses referred to in the Index Table are:

•Process: Energy end uses applicable to the manufacturing processes and generic to

different manufacturing plants.

•Comfort: Energy end uses that support the comfort of the employees, such as lighting,

space heating and cooling, and air ventilation to maintain appropriate air quality for

employees.

•Other: Energy end uses applicable to processes not covered by “process” and

“comfort” end uses, and non-generic energy end uses specific to the processes in a

specific manufacturing sector.

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Link:

Module 5.1 Video

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There may be numerous pieces of equipment under each type, and it is recommended

to categorize this by size. Up to six ranges of equipment sizes can be entered, by

providing weighted average equipment capacity values and average hours of operation

for each range.

For example, if there are 25 motors ranging in size from 0.3 to 0.5 kW, operating

between 500 to 6000 hours per year, the average range of equipment capacity would

be:

Average range [kw] = ∑ (motor power *kw]) x (motor hours of operation [h])

∑ (hours of operation *h+)

The hours of operation entry would be the average hours for all the motors in that

range.

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Boilers require special consideration when grouping together. As can be seen in the

boiler section of TA3, since boiler type /economizer must be selected from a drop-down

menu, if there is more than one boiler for that line, they must be of the same

type/economizer.

However, it is rare that you will need to group boilers together, since there is sufficient

space to enter information for four boilers and facilities rarely have more than four.

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Links:

03 A2A Training module 5.1 activity

04 A2A Training module 5.1 activity – incomplete assessment

Notes:

- The technical assessment is partially filled in, but not complete. You must use the

missing information found on Tab A 5.1.1 to complete the technical assessment.

- For the pumps: Two sizes ranges are missing in the TBP assessment. You must group

the pumps together into size ranges, and calculate weighted values of the pump ratings,and finally enter this into the correct cells in the assessment

- For the boilers: Five boiler sizes are given, therefore two of the boilers must be

grouped together and weighted values of boiler ratings must be calculated. Also, for the

economizer entry, you must decide if "ntf" or "no economizer" must be selected.

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Now that you have completed the training activity for module 5.1 on your own, the

answers and issues will be reviewed.

Some of the Technical Assessment that require data entry will be shown in the

subsequent slides. You can also open the completed assessment to see the filled-in

assessment:

05 A2A Training module 5.1 activity - Completed Assessment

The solutions to the weighted average calculation are shown in Tab B 5.1.1 of “03 A2A

Training module 5.1 activity”

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The purchased energy information should be entered on tab TA2 as shown above.

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The boiler section is filled in as shown. The 17.6 MW boiler is a weighted average of the

15MW and 20MW closed fire tube boiler (see the weighted average calculations on tab

B 5.1.1 of “03 A2A Training module 5.1 activity”).

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This screen shows the second table of boiler information to be entered.

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After reviewing all of the tabs of the technical assessment, these are some of the issues

that could be found that should be brought up with plant personnel.

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The issues found on the energy balance tab (TA 11) are shown in this slide.

The high adjustment factor for natural gas indicates that the plant purchased much more

natural gas than is being accounted for by the equipment natural gas consumption. This

is an issue that should be discussed with plant personnel. It may be that some

equipment was missed, equipment capacities or hours were incorrect, the quantity of

natural gas purchased was incorrect, or other reasons.

The energy balance showed that gasoline was purchased, however no equipment was

entered that uses gasoline. This is another issue that should be discussed with the plant.

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This module explains the ammonia specific components of technical assessment, and

the ammonia specific library.

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The ammonia subsector energy use and best practice assessment is presented in section

E of the Energy Technical Assessment questionnaire. Up to five such types of equipment

can be detailed, in order of energy use.

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Link:

Module 5.2 Video

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The library organizes energy efficiency technical best practices by end use and several

process levels. Each energy savings measure is entered in a separate tab with its

associated parameters, providing the energy savings, the fuel type saved, and a detailed

description of the measure along with the reference sources of information.

This section is intended to provide more detail and supplement Module 3. The focus will

be specifically on the Ammonia library.

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Profile type: each measure is classified as either technology, operating, behavioural or maintenance.

Level (1 to 5): further describe each measure based on which part of the plant and which category of equipment the

measure is relevant to. This allows the user to filter the measure list on the Index tab by a variety of criteria.

Relative implementation cost: each measure is rated as high, medium or low to indicate the relative cost ofimplementation: •High – there would be significant investment to implement the measure. A detailed economic feasibility studywould generally be required. Most measures in this category would involve the replacement of large equipment, orlarge retrofit projects.•Medium – may involve inexpensive equipment replacement or retrofits. An economic feasibility study is generallyadvisable.•Low – little or no capital cost would be required. Often involves behavioural changes and only a rudimentaryeconomic assessment may be needed.

Relative implementation difficulty: each measure is rated as high, medium or low to indicate the relative difficulty ofimplementation:•High – the implementation of the measure involves complex change to the plant. The measure may involve redesign,and a detailed engineering feasibility assessment would be required.•

Medium –

may involve small equipment replacement or simple retrofits. A less extensive technical feasibilityassessment is usually required.•Low – relatively easy to implement the opportunities and most often involves maintenance related opportunitiesand/or behavioural changes. Technical feasibility studies are generally not required.

Energy type: four energy types are listed: natural gas, electricity, refined petroleum products, and other. Measuresavings are shown for each fuel type. As illustrated in Exhibit 20 (boiler economizer), some measures show savingsfor more than one energy type. This indicates that there are multiple energy source options for the given end-use;the savings will be calculated for the energy source selected in the Technical Assessment, not all of the energysources listed in the library. For the measures which may save other types of energy than those listed, the fuel type isentered in the “Other fuel” line.

Savings percentage: the amount of energy that would be saved for that particular fuel type. The savings is given as apercentage of the end-use consumption (not the total plant energy use). Savings are dependent on site specificconditions and the savings indicated in the measure library provides only typical values, or ranges of savings forimplementation of a specific measure, as guidance. These values are reported in literature or obtained from industrialexperts. Savings are provided per opportunity and are not additive. Furthermore, interactive effects will reduce thetotal potential savings if more than one opportunity is implemented.

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Description: explanation of the measure, and the means by which the measure saves

energy.

Reference Sources: the source of the savings percentage and measure life.

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Links to libraries:

08 A2A Training module 5.2 activity - Ammonia Library

09 A2A Training module 5.2 activity - Generic Library

The questions shown in the slide are also found in tab A 5.2.1 in the exercise file:


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Links:

05 A2A Training module 5.1 activity - Completed Assessment

09 A2A Training module 5.2 activity - Generic Library


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Note: the potential energy savings is calculated automatically by the report card (as will

be seen in a subsequent module), however, it is important to understand the

calculations and origins of the numbers used.

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Documents

A2A Training Modules 4 to 5.2