Improvement of thermal insulation and water cleaning /air ...gec.jp/gec/en/Activities/fs_newmex/2013/2013fs10_rep.pdf · “ Improvement of thermal insulation and water cleaning /air

MOEJ/GEC JCM Feasibility Study (FS) 2013

Final Report (Summary)

“ Improvement of thermal insulation and

water cleaning/air purge at power plant”

(Implemented by Kanden Plant Co., Inc.)

Study partners The Ulaanbaatar Third Power Plant Co., Ltd

Thermal Power Plant #4 Company

Mongolia Ministry of Energy

Mongolia Ministry of Environment and Green Development

Project site Mongolia/ Ulaanbaatar

Category of project Energy Efficiency Improvement

Description of project Thermal insulation installation by “Overwrapping

Insulation Method (ECO-AIM)” which is patented by Nichias

Corporation provides not only reduction of GHG emissions

but also co-benefit as reduction of atmospheric pollution.

And it does not require removing existing thermal insulation

materials that contributes reduction of disagreeable wastes.

Introduction of condenser tube cleaning using “Brush

Inset Cleaning (Rakuchin Gun Device) Method” which is

developed by Kanden Plant Co., Inc. is expected to improve

work environment and efficiency.

Reducing 50% or more of supply water consumption and

drainage is estimated as the result. And it is expected that

removal rate of foreign bodies is high thus condenser

performance is recovered due to improvement of degree of

vacuum and turbine efficiency drop is prevented.

It is studied as feasibility study by surveying The

Ulaanbaatar Third Power Plant Co., Ltd (hereinafter

described as CHP-3) & Thermal Power Plant #4 Company

(herein after described as CHP-4). Investigation for energy

efficiency improvement by thermal diagnosis of existing

thermal insulation materials in major facilities, energy

efficiency improvement by condenser tube cleaning,

feasibility of MRV, etc. are implemented then feasibility for

project is studied.

JCM

methodology

Eligibility

criteria

● Thermal insulation installation by “Overwrapping

Insulation Method”:

Criterion 1: Project activity is a thermal insulation installation

work to reduce radiation heat quantity from surfaces of

existing heat/ power supply facilities of thermal power

plants by “Overwrapping Insulation Method”.

Criterion 2: Project activity is applicable to the objectives of

existing heat/ power supply facilities.

Criterion 3: Installation method for the project is carried out

JCM Feasibility Study (FS) 2013 – Final Report

to avoid removal of existing thermal insulation materials

(asbestos, etc.). Thermal insulation material used for the

project does not contain asbestos.

Criterion 4: Thermal insulation installation works are

complied with the low on occupational safety and health.

Criterion 5: Thermal insulation material used for the project is

applicable to the temperature range between -40C and

+650C.

Criterion 6: Thermal conductivity of thermal insulation

material used for the project is not more than the values

given in the following table.

Average temperature Thermal conductivity

F C Btu･in/hr･ft2･F W/m･K

75 23.9 0.14 0.021

100 37.8 0.15 0.022

200 93.3 0.16 0.023

300 149 0.18 0.025

400 204 0.20 0.029

500 260 0.22 0.032

600 316 0.25 0.036

700 371 0.30 0.043

● Condenser cleaning work by “Brush Inset Cleaning

Method”:

Criterion 1: Reference activity is implemented by discharging

high pressure water in condenser tube cleaning during

shutdown period of the turbine unit.

Criterion 2: Project activity is to improve efficiency of

condenser tube cleaning work that is to inset a brush to

every condenser tube then shove the brush by high

pressure water using a cleaning gun.

Criterion 3: Project participants show reliable and evidenced

basis that water consumption (or drainage) of “Brush Inset

Cleaning Method (project activity)” is reduced over 50%

comparing with “Conventional Method (reference

activity)” by one of following measures.

- Preliminary demonstration activities of “Brush Inset

Cleaning Method” at thermal power plants in Mongolia

- Verified historical data at thermal power plants in Japan

Default

values


Insulation Method”：

▪ Boiler efficiency at the thermal power plant

The most conservative value (boiler efficiency = 1.0)

▪ CO2 emissions factor of coal

Default value of lignite described in “2006 IPCC Guidelines

for National Greenhouse Gas Inventory” （0.101tCO2/GJ）

▪ Pump efficiencies for fire-fighting water pump and

drainage pump


The most conservative values (pump efficiency = 0.9)

▪ Three-phase induction motor efficiencies of fire-fighting

water pump and drainage pump

The most conservative value (motor efficiency = 1.0)

● Condenser tube cleaning by “Brush Inset Cleaning

Method”:

▪ CO2 (carbon dioxide) emissions factor of electricity

supplied to the electricity grid at the thermal power plant

（EFCO2,elec-ih）

It is calculated from coal consumption per electricity unit

supplied to the electricity grid at the thermal power plantｓ

（g/kWh） and default valueｓ of CO2 emissions factor of

“Lignite” according to “2006 IPCC Guidelines for National

Greenhouse Gas Inventory” （0.101tCO2/GJ）

Calculation

of

reference

emissions



=> There are existing heat/ power supply facilities and

existing thermal insulation materials covering the facilities

at present. And another type of insulation material is

placed to cover them for the project (three-layered

structure). => It is the method to set reduction of radiation

heat quantity by overwrapping insulation method as

default and directly calculate emissions reduction using

the default value.

To find where ensures thermal balance and assess

radiation heat quantity is determined as basis for

quantification by using measured thermal data at thermal

power plant such as steam.

Only the main steam pipe is identified to calculate

radiation heat quantity by using actual measured values of

such steam at the heat/ power supply facilities installed

thermal insulation at the result of survey.

Emissions reduction of radiation heat quantity is

calculated as reduction of coal consumptions that

corresponds to reduction of boiler fuel in this

methodology. It is based on deference of heat quantity

between inlet and outlet of main steam pipe with thermal

insulation.

Other five facilities except main steam pipe (boiler,

turbine, high/ low pressure feed water heater and boiler

feed water pipe) have no actual measured data of heat

loss as above mentioned.

Therefore, reduction on those radiation heat quantities

is calculated as thermal insulation effect by means of

sampling measurement method of surface temperature

and emissivity using infrared thermographic scanning.

Each of quantification for the 5 facilities except main


steam pipe is independently executed because shapes,

surface conditions, emissive conditions and

environmental conditions of facilities are widely varied.


Method”:

Reference emissions are calculated from reference

electricity consumptions for condenser tube cleaning

works and CO2 emission factor electricity supplied to the

electricity grid by the thermal power plant.

Water consumptions and electricity consumptions have

not been monitored in “Conventional Cleaning Method” at

CHP-3 & CHP-4. And to identify electricity consumed in

condenser cleaning works is not possible because

fire-fighting pump is shared with other works.

Therefore reference emissions and project emissions

are quantified as to measure water consumptions per

condenser tube for “Brush Inset Cleaning Method” and

“Conventional Cleaning Method” during shutdown period

of turbine unit then to calculate additional electricity

consumption for fire-fighting pump and drainage pump

based on the water consumption using estimated

formulae.

Monitoring

method



1) Parameters to be monitored every monitoring period after

thermal insulation installation:

▪ Insulation installation areas at every heat/ power supply

facilities [m2]

▪ Total mass flow rate of superheated steam at outlet of

main steam pipe after thermal insulation installation [103

ton/y]

2) Parameters to be monitored only during the first

monitoring period after thermal insulation installation.

These parameters are defined as fixed values from second

monitoring period:

▪ Yearly average enthalpy of superheated steam at inlet/

outlet of main steam pipe after thermal insulation

installation [kJ/kg]

▪ Average surface temperature of each thermal insulation

material installed on heat/ power supply facility in

sampling measurement by infrared thermographic

scanning [K]

▪ Average surface temperature of each planned part of heat/

power supply facilities before thermal insulation

installation [K]

▪ Ambient temperature around each heat/ power supply

facilities before thermal insulation installation [K]


▪ Emissivity in sampling measurement by infrared

thermographic scanning before thermal insulation

installation [fraction]

3) Parameters to be monitored before thermal insulation

installation. These parameters are defined as fixed values

throughout monitoring period:

▪ Yearly average enthalpy of superheated steam at inlet/

outlet of main steam pipe before thermal insulation

installation [kJ/kg]

▪ Average surface temperature of each thermal insulation

material installed on heat/ power supply facility in

sampling measurement by infrared thermographic

scanning [K]

▪ Average surface temperature of each planned part of heat/

power supply facilities after thermal insulation installation

[K]

▪ Ambient temperature around every heat/ power supply

facilities after thermal insulation installation [K]

▪ Emissivity in sampling measurement by infrared

thermographic scanning before thermal insulation

installation [fraction]

● Condenser cleaning by “Brush Inset Cleaning Method”:

1) Parameters to be monitored during every shutdown of

turbine unit

▪ Number of times of condenser tube cleaning work of

turbine i in the thermal power plant

2) Parameters to be monitored during shutdown of turbine

unit in the first monitoring period after the start of project

▪ Water consumption of fire-fighting water pump per tube

per condenser tube cleaning work for turbine i during

shutdown of turbine unit in the first monitoring period

after the start of project

3) Parameters to be monitored during shutdown of turbine

unit

▪ Water consumption of fire-fighting water pump per tube

per condenser tube cleaning work for turbine i during

shutdown of turbine unit in the first monitoring period

before the start of project

GHG emission reductions ● Thermal insulation installation by “Overwrapping


▪ Thermal insulation installation to deteriorated or defected

parts by means of “Overwrapping Insulation Method

(ECO-AIM)” using superior thermal insulation

performance of thermal insulation material gives that

reduction of radiation heat quantity from such main steam

pipe is reduced and boiler fuel (coal) corresponding to the

heat reduction is reduced. It results that CO2 emission is


reduced.

Emissions reduction for CHP-4 is not calculated in this

report.


Method”:

▪ Condenser tube cleaning by “Brush Inset Cleaning

(Rakuchin Gun Device) Method” gives that cleaning water

consumption per time of cleaning is reduced comparing

with the conventional cleaning method and also frequency

of cleaning is reduced. It is expected that cleaning water

consumption is reduced over 50% per year and power

consumption for fire-fighting pump and drainage pump

which supply cleaning water is reduced accordingly. It

results that CO2 emission is reduced.

▪ Total values during the years of 2016 through 2025 are as

follows.

Reference eｍｉｓｓｉｏｎｓ

（estimated)

Project emissions (estimated)

Emissions reduction

(estimated)

Thermal insulation installation by “Overwrapping Insulation Method (ECO-AIM)” for represented unit in CHP-3

N/A N/A 22,600ｔ

CO2e

Condenser tube cleaning by “Brush Inset Cleaning (Rakuchin Gun Device) Method” in CHP-3 & CHP-4

50ｔCO2e 20ｔCO2e 30ｔCO2e

Environmental impacts The project activities are aimed for efficiency improvement

in thermal power plants and give just benefit as reduction of

atmospheric pollution to surrounding or remote area thus

negative effects are not occurred. And facility improvement

works give inconsiderable influence for environment such as

scaffolding works in very limited areas in the thermal power

plants thus preventive measures are not required.

Thermal insulation installation by “Overwrapping

Insulation Method (ECO-AIM)” is the method just to overwrap

the existing thermal insulation and does not require

removing the existing thermal insulation materials. Thus it

can avoid scattering the harmful existing materials

(asbestos, etc.) from the view of the occupational safety and

health.

Project planning 1. June 2015: Proposal for following JCM finance

programme project to GEC

● Efficiency improvement by means of thermal insulation


installation by “Overwrapping Insulation Method

(ECO-AIM)”:

At No.10 boiler/ No.7 high-pressure turbine in CHP-3 and

No.3 boiler in CHP-4;

1) Thermal insulation installation (CHP-3：1637m2, CHP-4：

3582m2)

2) Thermal diagnosis (before/ after thermal insulation

installation) by infrared thermographic scanning

3) Support for MRV activities

● Efficiency improvement for condenser tube cleaning by

“Brush Inset Cleaning (Rakuchin Gun Device) Method”:

At a 100MW class of representative turbine unit in CHP-4;

1) Manufacture and delivery of “Brush Inset Cleaning Device

(Rakuchin Gun Device) ”

2) Measurement for condenser performance data

3) Implementation of condenser tube cleaning by “Brush

Inset Cleaning (Rakuchin Gun Device) Method”

4) Study for energy efficiency improvement

5) Support for MRV activities

Overwrapping Insulation Method

(ECO-AIM)

180 Million

Japanese Yen

Brush Inset Cleaning (Rakuchin Gun

Device) Method

74 Million

Japanese Yen

Support Cost for MRV Activities 20 Million

Japanese Yen

▪ Initial investment amount: 274 million Japanese Yen

(including support cost for MRV activities)

▪ Annual operation and maintenance amount: 7 million

Japanese Yen

(mainly consumables for “Brush Inset Cleaning Device

(Rakuchin Gun Device) ” and support cost for MRV

activities)

* Annual operation and maintenance cost for thermal

insulation installation is basically nil.

▪ Start of local work: July 2015

▪ Work duration (lead time): Approximately 8 months

▪ Start of operation: April 2016

Promotion of Japanese

technology



It is offered that thermal insulation installation by

“Overwrapping Insulation Method (ECO-AIM)” is expected

to apply to other thermal power plants, heat supply

companies or common plants out of CHP-3 & CHP-4 by

the chief of Mongolia Ministry of Energy.


Method”:


There are needs for introduction of “Brush Inset Cleaning

(Rakuchin Gun Device) Method” in Erdenet & Darkhan

thermal power plants in case it is verified that cleaning

water (drainage) consumption by the method is reduced

over 50% against the conventional tube cleaning method

and foreign bodies in tubes are completely removed.

Sustainable development in

host country

Implementation of thermal insulation installation using a

thermal insulation material, 10mm of Pyrogel XT, by

“Overwrapping Insulation Method (ECO-AIM)” gives life

extension effect to facilities. Persistent use of thermal power

plant facilities keeping necessary capacity results saves

additional social costs. Thus it contributes sustainable

development of Mongolia.

Introduction of condenser tube cleaning by “Brush Inset

Cleaning (Rakuchin Gun Device) Method” gives reduction of

cleaning water consumption and pump power consumption

and also substantial improvement for work environment for

condenser tube cleaning.

JCM Feasibility Study (FS) 2013

“Efficiency Improvement of Thermal Insulation Installation

and Condenser Cleaning at Thermal Power Plants”

(Host Country: Mongolia)

Study Entity: implemented by Kanden Plant Co., Inc.

1. Study Implementation Scheme

Kanden Plant Co., Ltd.: Overall management of FS, finance planning, technical support for

quantification of GHG emission reduction, etc.

Suuri-keikaku Co., Ltd.: Investigation for environmental integrity, sustainable development in

host country

Japan Quality Assurance Organization:

Support for MRV structure, PDD, etc,

Climate Exparts Ltd.: Investigation for methodology&PDD, etc.

Nichias Corporation: investigation for potential of energy efficiency improvement for

thermal insulation on major facilities in CHP-3 & CHP-4 by thermal

diagnosis, etc.

EEC Co., Ltd.： Technical support considering situation in Mongolia

2. Overview of Proposed JCM Project

(1) Description of Project Contents

Thermal insulation installation by “Overwrapping Insulation Method (ECO-AIM)” which is

patented by Nichias Corporation provides not only reduction of GHG emissions but also

co-benefit as reduction of atmospheric pollution. And it does not require removing existing

thermal insulation materials that contributes reduction of disagreeable wastes.

CO2 emission is reduced in accordance that plant heat efficiency is improved by means of

“Overwrapping Insulation Method (ECO-AIM)” installed to heat/ power supply facilities such as

pipes, boiler, drum, etc. in CHP-3 & CHP-4. Thermal insulation efficiency is measured by

infrared thermographic scanning.

Condenser cleaning works in CHP-3 & CHP-4 are executed using water cleaning and long

metal bars. It is expected that “Rakuchin Gun Device” gives improvement for work environment

and efficiency by means that water cleaning and air purge is continuously executed in an action. It

is estimated to reduce 50% of supply and waste water quantity as a result.

And also removal rate of foreign bodies is high so that condenser performance is recovered by

improvement of degree of vacuum then turbine efficiency drop is prevented.

CHP-3 & CHP-4 are supposed as counterparts and owners of the project. This FS is

implemented by surveying CHP-3 & CHP-4. Investigation for energy efficiency improvement by

thermal diagnosis of existing thermal insulation materials in major facilities, energy efficiency

improvement by condenser tube cleaning, feasibility of MRV, etc. are implemented then

feasibility for JCM is studied.

(2) Situation of Host Country

The sector 5 of National Appropriate Mitigation Actions (NAMAs) submitted by United

Nations Framework Convention on Climate Change is clearly described as efficiency

improvement at existing CHP (Combined Heat Power Plants) is a nation’s policy.

Both the projects, thermal insulation installation by “Overwrapping Insulation Method

(ECO-AIM)” and condenser tube cleaning by “Bruch Inset Cleaning (Rakuchin Gun Device)

Method” for CHPs, give plant efficiency improvement that meets the policy of Mongolia.

● Regarding relevant National Appropriate Mitigation Actions (NAMAs) by least developing

country

Mongolia is a signatory to the Copenhagen Accord and submitted the relevant NAMAs list to

UNFCCC in January 2010. A concept of GHG mitigation action is included in NAMAs and it is

assumed to implement obtaining international assistance for national capacity, advanced

technology transfer and financing.

● NAMAs submitted to UNFCCC

No Sectors－Action 9

1 Energy supply－Increase renewable options

2 Energy supply―Improve coal quality

3 Energy supply―Improve efficiency of heating boilers

4 Energy supply－Improve household stoves and furnaces

5 Energy supply＝Improve Combined Heat Power (CHP) plants

6 Energy supply－Increase use of electricity for local heating in cities

7 Building－Increase building energy efficiency

8 Industry－Increase energy efficiency in industry

9 Transport－Use more fuel efficiency vehicles

10 Agriculture－Limit quantity & increase quality of live stock

11 Forestry－Improve forest management ,reduce emissions from deforestation and

forest degradation

Source：UNFCCC

3. Study Contents

(1) JCM methodology development

a. Eligibility criteria

Below table describes about CHP-3 (high-pressure unit) and it is available for CHP-4.

● Thermal insulation installation by “Overwrapping Insulation Method”:

Criterion 1: Project activity is an insulation installation work to reduce radiation heat quantity from

surfaces of existing heat/ power supply facilities of thermal power plant by “Overwrapping

Insulation Method”.

=> It is considered that there no specific problem because the description of cliterion shows

general activity of the project. activity

Criterion 2: Project activity is applicable to the objective of existing heat/ power supply facilities.


objects of the project.

Criterion 3: Installation method for the project is carried out to avoid removal of existing insulation

materials (asbestos, etc.). Thermal insulation material used for the project does not contain

asbestos.


features of “ECO-AIM” which is planned to introduce.

Criterion 4: Thermal insulation installation works are complied with the low on occupational safety

and health.

=> It is considered that ECO-AIM and Pyrogel must not be contrary to the law but further

confirmation of the low or regulations on occupational safety and health in Mongolia is

to be done to make sure. In case there is any restriction against materials containing

asbestos, it is to be described.

Criterion 5: Thermal insulation material used for the project is applicable to the temperature range

between -40℃ and +650℃.

=> It is considered that there no specific problem because the description of criterion shows

specific values of the material provided by Nichias Corporation.

Criterion 6: Thermal conductivity of insulation material used for the project is not more than the

values given in the following table.

Average Temperature Thermal Conductivity

F C Btu･in/hr･ft2･F W/m･K

75 23.9 0.14 0.021

100 37.8 0.15 0.022

200 93.3 0.16 0.023

300 149 0.18 0.025

400 204 0.20 0.029

500 260 0.22 0.032

600 316 0.25 0.036

700 371 0.30 0.043

=> It is considered that there no specific problem because the description of criterion shows

specific values of the material provided by Nichias Corporation.

● Condenser cleaning work by “Brush Inset Cleaning Method” :

Criterion 1: Reference activity is implemented by high pressure water discharging of condenser tube

cleaning during shutdown period of the turbine unit.


general activity of the project.

Criterion 2: Project activity is to improve efficiency of condenser tube cleaning by the cleaning work

that is to set a brush into every condenser tube then shove the brush by high pressure water

using a cleaning gun.


features of “Rakuchin Gun Device” which is planned to introduce.

Criterion 3: Project participants shows reliable basis with evidences that water consumption (or

drainage) of “Brush Inset Cleaning Method (project activity)” is reduced 50% or more

comparing with “Conventional Method (reference activity)” by one of following measures.

Preliminary demonstration activities of “Brush Inset Cleaning Method” at thermal power

plants in Mongolia

Verified historical data in power plants in Japan

=> Demonstration of condenser tube cleaning work by using “Bruch Inset Method” is

planned to implement after next year at thermal power plants in Mongolia.

Also Kanden Plant Co., Inc. is available to provide verified historical data at thermal

power plant in Japan.

b. Data and parameters fixed ex ante

Quantification for both of thermal insulation installation by “Overwrapping Insulation Method”

and condenser tube cleaning by “Bruch Inset Cleaning Method” is very difficult. Especially, it is

considered that argument about theoretical justification for advanced set values is required till just

before of methodology is authorized.

● Set of default values

Thermal insulation installation by “Overwrapping Insulation Method”

■ Boiler efficiency at the thermal power plants

The most conservative value (boiler efficiency = 1.0). It is not required to mention about

justification.

■ CO2 emissions factor of coal

Default value of lignite described in “2006 IPCC Guidelines for National Greenhouse Gas

Inventory” （0.101tCO2/GJ）

■ Pump efficiencies for fire-fighting water pump and drainage pump

The most conservative values (pump efficiency = 0.9). Pomp efficiency is determined as not over

90% in the “handbook for thermal and nuclear power engineer” issued by thermal and nuclear power

engineering society.

■ Three-phase induction motor efficiencies of fire-fighting water pump and drainage pump

The most conservative value (motor efficiency = 1.0). It is not required to mention about

justification.

Condenser tube cleaning by “Brush Inset Cleaning Method”

■ CO2 emissions factor of electricity supplied to the electricity grid at the thermal power plant (CO2

emissions factor of internal power at the thermal power plant) （EFCO2,elec-ih）

It is calculated from coal consumption per electricity unit supplied to the electricity grid at the

thermal power plantｓ described in energy statistics in Mongolia (Mongolia Energy Regulation

Authority) （g/kWh） and default valueｓ of CO2 emissions factor of “Lignite” according to “2006

IPCC Guidelines for National Greenhouse Gas Inventory” at present（0.101tCO2/GJ）

● Set value in advance:

Thermal insulation installation by “Overwrapping Insulation Method”

■ Average of mass enthalpy of superheated steam at inlet/ outlet point of main steam pip

To calculate (weighted by mass flow rate of superheated steam) average of mass enthalpy of

superheated steam at inlet/ outlet point of main steam pipe during a year after insulation installation

■ Average surface temperature and emissivity at expected insulation area in the heat/ power supply

facilities before insulation installation

These parameters are measured as a time of sampling by using an infrared thermography and a

thermocouple before insulation installation.

Emissivity at surface of existing facilities is approximate 0.9 and not much varied. Then it is set as

0.01 more of value for the main steam pipe and 0.01 less of value for other heat/ power supply facilities

considering conservativeness in calculation of emission reduction.

■ Ambient temperature around heat/ power supply facilities before insulation installation

Outdoor air temperature in Mongolia is much varied and influence indoor air temperature of the

thermal power plant. Ambient temperature around heat/ power supply facility is measured by a

thermometer several times before insulation installation considering seasonal variation or outdoor air

temperature. It is supposed that outdoor air temperature is provided by Mongolia Institute of

Meteorology and Hydrology. The ambient temperature is set as 0.05deg C more of value for the main

steam pipe and 0.05 less of value for other five facilities to secure conservativeness at present.

■ Surface heat conductivity rate for convection on mains steam pipe

。Indoor condition of value is set because all the heat/ power supply facilities are inside of building

of the thermal power plant. The maximum value of vertical piping （6.0 W/m2/K） is undertaken

considering conservativeness.

Condenser cleaning work by “Brush Inset Cleaning Method”

■ Reference water consumption of turbine i during a time of condenser cleaning work.

To set it from water consumption (of fire-fighting pump) of condenser tube cleaning by

“Conventional Cleaning Method” during shutdown of turbine unit before start of project.

For each turbine of the thermal power plant, performs measurement in integrating flow-meter

cleaning water of the tube of 5, from a conservative point of view, as water consumption per one of

turbine i is set to the project prior to the start of this minimum value at least.

■ Total head of the fire-fighting water pump and drainage pump

Total head of pump is sum of discharge pressure and suction pressure. Value on the nameplate can

be used for discharge pressure. It is difficult to secure conservativeness for calculation of suction

pressure. And the suction pressure is not considered to secure conservativeness for the total pressure

as an advanced set value.

■ Number of condenser water boxes of turbine i and tubes per a condenser water box of turbine i

They are the parameters to be set from specification of facilities or nameplate.

c. Calculation of GHG emissions (including reference and project emissions)

Installation of thermal insulation by “Overwrapping Insulation Method (ECO-AIM)”

The emission reductions are calculated with the following equations;

ERy= ERmpd,y+ERboiler,y+ ERturbine,y y+ ERhpfwh,y+ ERlpfwh,y+ ERbfwp,y

ERmsp,y=QSAVmsp,y,/boiler*EFCO2,coal

QSAVmsp,y,=FSmsp-out,y*(hAVEmsp-in,BWhAVEmsp-out,BWhAVEmsp-in,AW+hAVEmsp-out,AW)

ERboier,y=SHREcsvboiler*AHEboiler,y*EFCO2,coal*10-6

*8760/3.6

ERturbine,y=SHREcsvturbine*AHEturbine,y /boiler*EFCO2,coal*10-6

l*10-6

*8760/3.6

ERhpfwh,y=SHREcsvhpwsh*AHEhpfwh,y*EFCO2,coal*10-6

*8760/3.6

ERlpfwh,y=SHREcsvlpwsh*AHElpfwh,y*EFCO2,coal*10-6

*8760/3.6

ERbfwp,y=SHREcsvbfwp*AHEbfwp,y*EFCO2,coal*10-6

*8760/3.6

ERy Emission reductions in a year y tCO2/y

ERmsp,y Emission reductions due to thermal insulation effect on main steam pipe

in a year y

tCO2/y

ERboiler,y Emission reductions due to thermal insulation effect on boiler in a year y tCO2/y

ERturbine,y Emission reductions due to thermal insulation effect on turbine in a year

y

tCO2/y

ERhpfwh,y Emission reductions due to thermal insulation effect on high pressure

feed-water heater in a year y

tCO2/y

ERlpfwp,y Emission reductions due to thermal insulation effect on low pressure

feed-water heater in a year y

tCO2/y

ERbfwp,y Emission reductions due to thermal insulation effect on boiler

feed-water pipe in a year y

tCO2/y

QSAVmsp,y Heat quantity of superheated steam in main steam pipe saved by

thermal insulation installation in a year y GJ/y

FSmsp-out,y Total mass flow rate of superheated steam at outlet point of main steam

pipe in a year 10

3 ton/y

hAVEmsp-in,AW Weighted (by mass flow rate of superheated steam) average of mass kJ/kg

enthalpy of superheated steam at inlet point of main steam pipe during

one year after installation

hAVEmsp-out,A

W

Weighted (by mass flow rate of superheated steam) average of mass

enthalpy of superheated steam at outlet point of main steam pipe during

one year after installation

kJ/kg

hAVEmsp-in,BW

Weighted (by mass flow rate of superheated steam) average of Mass

enthalpy of superheated steam at inlet point of main steam pipe during

one year before installation

kJ/kg

hAVEmsp-out,B

W

Weighted (by mass flow rate of superheated steam) average of Mass

enthalpy of superheated steam at outlet point of main steam pipe during

one year before installation

kJ/kg

SHREmesmsp Specific thermal insulation effect per installation area on main steam

pipe by thermal insulation installation (based on actual measurement of

steam heat quantity)

W/m2

SHREcsvboiler Specific thermal insulation effect per installation area on boiler by

thermal insulation installation (identified in conservative manner)

W/m2

SHREcsvturbin

e

Specific thermal insulation effect per installation area on turbine by

thermal insulation installation (identified in conservative manner)

W/m2

SHREcsvhpfwh Specific thermal insulation effect per installation area on high pressure

feed-water heater by thermal insulation installation (identified in

conservative manner)

W/m2

SHREcsvlpfwh Specific thermal insulation effect per installation area on low pressure

feed-water heater by thermal insulation installation (identified in


W/m2

SHREcsvbfwp Specific thermal insulation effect per installation area on boiler

feed-water pipe by thermal insulation installation (identified in


W/m2

AHEmsp,y Thermal insulation installation area on main steam pipe by the project

in a year y

m2

AHEboiler,y Thermal insulation installation area on boiler by the project in a year y m2

AHEturbine,y Thermal insulation installation area on turbine by the project n a year y m2

AHEhpwsh,y Thermal insulation installation area on high pressure feed-water heater

by the project n a year y

m2

AHElpwsh,y Thermal insulation installation area on low pressure feed-water heater

by the project n a year y

m2

AHEbfwp,y Thermal insulation installation area on boiler feed-water pipe by the

project n a year y

m2

boiler Boiler efficiency at the thermal power plant Fraction

EFCO2,coal CO2 Emission factor of coal tCO2/GJ

Calculated emission reduction at present (CHP-3 high pressure unit): 2,206tCO2/y.

The best calculation method is to estimate emission reduction as much as possible under excluding

overestimation. However to quantify reduction effect for this project activities is very difficult thus the

validity of quantification is just to secure conservativeness.

The quantification method for this methodology takes many factors to secure conservativeness as

follows therefore it is considered as a valid quantification method;

To take boiler efficiency as a default value as the most conservative 1.0 (actual value is less than 0.9).

Emissivity and ambient temperature as advanced or second monitoring period of set values are

defined as more conservative than average values so that emission reduction becomes lower.

Insulation effect of main steam pipe is quantified based on measurement of steam heat quantity.

Heat quantities of other heat/ power supply facilities are estimated values however they are estimated

by only the surface radiation emission of quantities (not considering convection emission) so that

conservativeness is secured.

Condenser tube cleaning by “Brush Inset Cleaning (Rakuchin Gun Device) Method”

REy=

k

i 1

(ECRE,i *Ntci,y)*EFCO2,elec-ih*10-3

ECRE,i=ECfwpRE,i+ ECdwpRE,i

ECfwpRE,i=ρw*g*QVcwRE,i*Hfwp / ηfwp /ηfwppip /3600

ECdwpRE,i=ρw*g*QVcwRE,i*Hdwp / ηdwp /ηdwppip /3600

PEy=

k

i 1

(ECPJ,i *Ntci,y)* EFCO2,elec-ih*10-3

ECPJ,i=ECfwpRE,i+ ECdwpRE,i

ECfwpPJ,i=ρw*g*QVcwPJ,i*Hfwp / ηfwp /ηfwppip /3600

ECdwpPJ,i=ρw*g*QVcwRP,i*Hdwp / ηdwp /ηdwppip /3600

PEy Reference emissions in a year y tCO2/y

ECPJ,i Reference power consumption per one condenser tube cleaning work

of turbine i at the thermal plant

kWh/a

turbine/time

Ntci,y Number of condenser tube cleaning work for turbine i at the thermal

plant in a year y times/y

EFCO2,elec-ih

Emissions factor of the net power supplied to the power grid by the

thermal power plant (CO2 Emissions factor of auxiliary power at the

thermal plant)

tCO2/MWh

ECfwpPJ,i

Reference (additional) power consumption of the fire-fighting

water pump per one condenser tube cleaning work for turbine i at the

thermal plant

kWh/time

ECdwpPJ,i Reference (additional) power consumption of the drainage pump per

one condenser tube cleaning work for turbine i at the thermal plant kWh/time

ECdwpRE,i

Reference (additional) power consumption of the fire-fighting

water pump per one condenser tube cleaning work for turbine i at the

thermal plant

kWh/time

ECdwpPJ,i Reference (additional) power consumption of the drainage pump per

one condenser tube cleaning work for turbine i at the thermal plant kWh/time

QVcwRE,i Reference water consumption of the fire-fighting water pump per one

condenser tube cleaning work for turbine i

m3/a

turbine/time

QVcwPJ,i project water consumption of the fire-fighting water pump per one

condenser tube cleaning work for turbine i

m3/a

turbine/time

Hfwp Total head of the fire-fighting water pump m

Hdwp Total head of the drainage pump m

ηfwp Pump efficiency of the fire-fighting water pump Fraction

ηdwp Pump efficiency of the drainage pump Fraction

ηfwppip Efficiency of three-phase induction motor for the pump during

operation of the fire-fighting water pump

Fraction

ηdwppip Efficiency of three-phase induction motor for the pump during

operation of the drainage pump

Fraction

ρw Water density(=1.0) kg/L

g Gravity acceleration(=9.8 m/sec2

Calculated emission reduction at present: 3tCO2/y (reference emission：5tCO2/y, project emission：

2tCO2/y)

It is quantified using power reduction effect of pumps and becomes very small value.

Effective heat drop (turbine efficiency) is expected to develop 0.5% in case 1% of degree of vacuum

is improved. Total generating end output power in year 2012 was 3,328.5GWh/y, so approximate

16,600MWh/y of generating power output can be obtained in case degree of vacuum is improved 1%

and it is corresponding to approximate 15,000tCO2/y of CO2 emission reduction

Ｔo precisely ascertain improvement rate of turbine efficiency from 1% of improvement of degree of

vacuum on condenser, It is required to analyze average value data per hour (degree of vacuum, inlet/

outlet temperature of cooling water, condenser drainage temperature, etc.) by the timed data near

rated load of turbine (There are some other factors except the degree of vacuum concerning effective

heat drop under the situation apart the rated load of turbine).

However those hourly average value data are not recorded, so it is not available to be verified.

Therefore effect of improvement on degree of vacuum is not available to be analyzed then not counted

on the emission reduction amount.

The best calculation method is to estimate emission reduction as much as possible under excluding

overestimation. However under such littleness of information (necessary monitoring is not performed)

in Mongolian power plants, the validity of quantification is just to secure conservativeness.

Pump efficiencies of fire-fighting water pump and drainage pump, three-phase induction motor

efficiencies of fire-fighting water pump and drainage pump the most conservative values defined as

default values are given the most conservative values. And conservation is secured for advanced ones

therefore the quantification is considered as valid.

(2) Development of JCM Project Design Document (PDD)

“Overwrapping Insulation Method (ECO-AIM)” and “Bruch Inset Cleaning (Rakuchin Gun Device)

Method”

Requirement for introduction of this JCM project is an infrared thermography, its set of

thermocouple, a thermometer for measuring ambient temperature and an integrating flowmeters for

measuring water consumption in condenser cleaning. And items which are measured by the thermal

power plants (flow rate of main steam, temperature, pressure, etc.) besides them.

It is planned that the infrared thermography and its set of thermocouple are from the devices

possessed by Nichias Corporation at present and QA/QC for the ones are implemented by the

requirement of JIS. The infrared thermography is yet new and not implemented calibration but it is

attached a traceability certificate and a test certificate. Nichias is skillful of operation and quality

control of the devices.

The flowmeters, thermometers and pressure gauges used in CHP-3 & CHP-4 have no test

certificates and calibrations are implemented. CHP-4 has a laboratory certificate for a calibration

party so internal calibration is implemented.

And CHP-3 is not a certification party so certification for measuring equipment is yearly

implemented by the institute of standards and measures. Kind of thermometer measuring ambient

temperature and integrating flowmeters measuring water consumption of condenser cleaning is not

yet determined. QA/QC for the flowmeters, thermometers, pressure gauges and thermometer for

ambient temperature is implemented by the thermal power plants complied with the requirement of

MNS.

In case measuring equipment has no test certificate, it can not obtain valid period if it is calibrated.

Data recorded by such measuring equipment are justified just after calibration result is verified as

good that is implemented after the monitoring period.

When the first calibration after the last day of monitoring period is implemented, bias of

measurement before adjustment is identified. Recorded data is valid as acceptable in case that the bias

is within the allowance (differed from each measurement equipment or industrial standard) regulated

by the industrial standard. If the bias excesses the allowance, the measuring equipment is the same as

under malfunction, then the measured data become nil (originally, the equipment must be replaced).

For example, in case the bias before calibration excesses the allowance level when the calibration

after monitoring, the equipment has been under malfunction (recorded data are nil) and calibration

was required earlier or the equipment was required to be replaced. In such case, uncertainly of

recorded data is not identified and correction for calculated emission reduction is not possible.

Thus, calibration that always conform the allowance level of applied industrial standard is

necessary. And when measuring equipment is getting old, earlier calibration or replacement is

required.

And measuring range is also important to control measuring equipment. It is required that the

measuring equipment which authorized wider measuring range is authorized as variation range is not

deviated by watching how much measured value is varied. In case the data that are deviated from the

authorized measuring range are occurred, the manufacture of the equipment can not guarantee the

recorded. It needs to take conservative measures for emission reduction or may be not counted in some

case.

It is planned to control measuring devices and equipment as each advanced bias does not excess the

allowance level in MNS or JIS at the time of calibration in this project. It is not only a simple matter to

introduce a technology of energy efficiency improvement but also such justified equipment controls is

a very important factor to Monolia which is under developing.

(3) Project development and implementation

a. Project planning

● It is assumed that finance is provided by Trade and Development Bank of Mongolia considering the

result of survey to CHP-3 & CHP-4 and Mongolia Ministry of Energy.

● 29 January 2014: Meetings were held with CHP-3 & CHP-4 and this FS was reported then the

minutes of meeting describing cooperation and support for Kanden plant Co., Inc. were signed.

1) June 2014: Implementation of following project planning study (planning):

● Plant efficiency improvement by means of sample installation of thermal insulation by

“Overwrapping Insulation Method (ECO-AIM)” at deterioration parts and support for MRV

activities in CHP-3

● Condenser efficiency improvement by means of “Brush Inset Cleaning Device (Rakuchin Gun

Device)” and support for MRV activities in CHP-4

2) June 2015 (after determination of finance for facilities): Implementation of following JCM

finance programme project:

● Installation of thermal insulation by “Overwrapping Insulation Method (ECO-AIM)” and

condenser efficiency improvement by “Brush Inset Cleaning (Rakuchin Gun Device) Method” and

support for MRV activities in CHP-3 & CHP-4

* April 2016 (at the time of start of monitoring): Start of operation

● From late July 2014 to the middle of November 2014: Technical committee in CHP-3 & CHP-4 and

science and technology committee in Mongolia Ministry of Energy. By the middle of December

2014: Agreement and conclusion as follows;

● The middle of November 2014: Agreement of international consortium with CHP-3 & CHP-4

● The middle of December 2014: Conclusion of contract with CHP-3 & CHP-4

b. MRV structure

Participants and roles on MRV for “Overwrapping Insulation Method (ECO-AIM)” installation in

CHP-3 and “Bruch Inset Cleaning (Rakuchin Gun Device) Method” in CHP-4 are generally agreed as

in the table below.

● Participants and roles on MRV for “Overwrapping Insulation Method (ECO-AIM)” installation in

CHP-3

Participant Role

First Deputy Director (Chief

Engineer)

Overall project management

Head of Technical of Strategy

Department

・Responsible for project planning, implementation and

reporting

Technical Strategy and Monitoring

Section

・Reporting support

･Finalization and check data for reporting

･Correspondence of validation/ verification

Production Department ・Monitoring for heat quantities, heat generation/ power

generation at key points

Heat control and Automation

Shop

・Control of measuring equipment/ device (flow meter,

pressure gauge, thermometer, infrared thermography)

Mongolian Agency for

Standardization

and Metrology

・Calibration of flow measuring equipment

Joint Committee ・Registration of JCM project, determination of amount

of credit issuance

Kanden Plant Co., Inc. ・Management for JCM project

Nichias Corporation ･Advisory for JCM project installation work control

Suuri-keikaku Co., Ltd., Climate

Experts Ltd., Japan Quality

Assurance Organization

・Support for MRV project activities

・ Support for environmental impact assessment/

consultation among interested parties

EEC Co., Ltd. (Local consultants）・Data check and finalization for reporting

・Correspondence of validation/ verification

Third Party Entity Validation/ verification for PDD and monitoring report

● Participants and roles on MRV for “Bruch Inset Cleaning (Rakuchin Gun Device) Method”

installation in CHP-4

Participant Role

First Deputy Director (Chief

Engineer)

Overall project management

Head of Research & Development

Department

・Responsible for project planning, implementation and

reporting

Research & Development Section ・Reporting support

･Finalization and check data for reporting

･Correspondence of validation/ verification

Production Department ･Data collection for heat load of condenser

Joint Committee Registration of JCM project, determination of amount

of credit issuance

Kanden Plant Co., Inc. ・Management for JCM project

Suuri-keikaku Co., Ltd.,

Climate Experts Ltd.,

Japan Quality Assurance

Organization

・Support for MRV project activities

・ Support for environmental impact assessment/

consultation among interested parties

EEC Co., Ltd. (Local consultants）・Data check and finalization for reporting

・Correspondence of validation/ verification

Third Party Entity Validation/ verification for PDD and monitoring report

c. Permission and authorization for the project

Required permissions and authorization for the project are shown in the table below.

Required permissions and authorizations

Item Authority Application Documents

1. Product

Pyrogel thermal insulation

material (non-asbestos

product) and sub-materials

Mongolian Customs B/L, Invoice, Country of origin

Infrared thermography

device

Ministry of Economy,

Trade and Industry

of Japan

Export permission (Ordinance

for export and trading control,

Appendix Table 1 10-(2), 10-(4))

“Brush Inset Cleaning

Device (Rakuchin Gun

Device)” and brush

(Polyethylene)


Uninterruptible power

supply device


* It is considered that thermal insulation installation by “Overwrapping Insulation Method

(ECO-AIM)” is executed as improvement work to existing facilities based on the low on

occupational safety and health thus approval by authorities is not required. However further

confirmation of the low or regulations on occupational safety and health in Mongolia is to be done

to make sure.

d. Japan’s contribution

Thermal insulation installation by “Overwrapping Insulation Method (ECO-AIM)” which is

patented by Nichias Corporation contributes to following points.

1) It is the method which does not require removing the existing thermal insulation materials. Thus it

can avoid scattering the harmful existing materials (asbestos, etc.) from the view of the

occupational safety and health.

2) New technology what is its easiness for installation due to the sheet –like shape of material thus

skilled workers are not required for the installation work is much expected by local parties

including local insulation installation companies.

3) Used thermal insulation material, Pyrogel XT, has 1/2 or less of thermal conductivity of thermal

performance comparing with conventional types of insulation material (perlite, calcium silicate,

etc.). Its low thermal conductivity contributes to its thin thickness and it gives to avoid much

increase of section area of facility in case installing over existing insulation. And the material

allows -40deg C to +650deg C of application temperature range so that it suits for thermal power

plants in Mongolia where is very cold.

Introduction of condenser tube cleaning using “Brush Inset Cleaning (Rakuchin Gun Device)

Method” which is developed by Kanden Plant Co., Inc. contributes to following points.

1) Work time for condenser tube cleaning is shortened thus shutdown duration of power supply unit is

shortened.

2) Numbers of operators for condenser tube cleaning are reduced thus effective relocation of operators

is available.

3) It is expected that removal rate of foreign bodies is very high thus deterioration of condenser

performance is prevented due to high level of degree of vacuum recovery.

4) Over 50% of water consumption (drainage) is reduced comparing with the conventional condenser

tube cleaning method using water and a long metal rod with a stainless steel brush.

5) Installation rain coat is not required because of no splashing of cleaning water. And reduction of

work load, efficiency and cleanliness are expected.

6) Handgun gives good operability. Safety functions and good controllability make work load lower

and no requirement for skilled workers.

e. Environmental integrity

The project activities are aimed for efficiency improvement in thermal power plants and give just

benefit as reduction of atmospheric pollution to surrounding or remote area thus negative effects

are not occurred. And facility improvement works give inconsiderable influence for environment

such as scaffolding works in very limited areas in the thermal power plants thus preventive

measures are not required.

Thermal insulation installation by “Overwrapping Insulation Method (ECO-AIM)” is the method

just to overwrap the existing thermal insulation and does not require removing the existing thermal

insulation materials. Thus it can avoid scattering the harmful existing materials (asbestos, etc.) from

the view of the occupational safety and health.

f. Sustainable development in host country

Implementation of thermal insulation installation using a thermal insulation material for

industrial use (10mm of Pyrogel XT) by “Overwrapping Insulation Method (ECO-AIM)” gives life

extension effect to facilities. Persistent use of thermal power plant facilities keeping necessary

capacity results saves additional social costs. Thus it contributes sustainable development of

Mongolia.

It is offered that thermal insulation installation by “Overwrapping Insulation Method

(ECO-AIM)” is expected to apply to other thermal power plants, heat supply companies or common

plants out of CHP-3 & CHP-4 by the chief of Mongolia Ministry of Energy.

It is offered to install the thermal insulation to one of eight units of boiler and belonged pipes and

give improvement of heat efficiency. Then the installation is enlarged to apply to other seven units in

case improvement is verified.

Introduction of “Brush Inset Cleaning (Rakuchin Gun Device) Method” gives reduction of water

consumption and power consumption of pumps and much improvement for work environment of

condenser tube cleaning. In case of Erdenet thermal power plants, degree of vacuum is dropped

from 95% to 85% one or two years after condenser tube cleaning implementation due to drop of

water purity.

Under such situation, introduction of “Brush Inset Cleaning (Rakuchin Gun Device) Method”

ensures to improve energy efficiency in whole power plants. Darkhan thermal power plant shows

very positive response that they requires implementation of demonstration of “Brush Inset Cleaning

(Rakuchin Gun Device) Method” and offers immediately purchase the device when the effect is

verified.

g. Toward project realization (planned schedule and possible obstacles to be overcome)

<Planned schedule>

● 29 January 2014: Meetings were held with CHP-3 & CHP-4 and the minutes of meeting on

agreement confirmed between Mongolian side and Japanese side were signed

● June 2014: Proposal for project planning study to GEC

● Plant efficiency improvement by means of sample installation of thermal insulation by

“Overwrapping Insulation Method (ECO-AIM)” at deterioration parts and support for MRV

activities in CHP-3

● Condenser efficiency improvement by means of “Brush Inset Cleaning Device (Rakuchin Gun

Device)” and support for MRV activities in CHP-4 (approximate 8 months of implementation

duration)

● November 2014: Agreement of international consortium with CHP-3 & CHP-4

● December 2014: Conclusion of contract with CHP-3 & CHP-4

● June 2015 (after determination of finance for facilities): Proposal for following JCM finance

programme project to GEC

● Installation of thermal insulation by “Overwrapping Insulation Method (ECO-AIM)” and

condenser efficiency improvement by “Brush Inset Cleaning Device (Rakuchin Gun Device)” and

support for MRV activities in CHP-3 & CHP-4 (approximate 8 months of implementation duration)

● April 2016 (at the time of start of monitoring): Start of operation

<Possible obstacles and proposed solutions>

Major possible obstacle and proposed solutions are mentioned as in following table.

No. Possible obstacle Proposed Solution

● Improving precision of surface

temperature calculation

It is identified that there are no useful

equipment for heat measuring in CHP-4 by

the survey, so GHG emission reduction is

not calculated in the methodology for

CHP-4. Only GHG emission reduction for

a represented unit in CHP-3 is calculated

as a result.

Quantification of radiation heat

Demonstration of sample installation of

thermal insulation by “Overwrapping

Insulation Method (ECO-AIM)” is

proposed as follows.

To install sample thermal insulation at

seriously deteriorated part of steam pipe

in CHP-3 and to measuring surface

temperature before/ after installation by

infrared thermographic scanning. Then to

calculate reduction of radiation heat

quantities was undertaken by means of

sampling measurement of surface

temperature, emissivity, etc. using infrared

thermography however it was not available

because forms of facilities, states of

surface, scales, conditions of emissive,

environmental condition, etc. are not

adequately found in CHP-3 & CHP-4 of

survey.

quantity at the part by reduction of the

surface temperature.

2. Demonstration for turbine efficiency

improvement and investigation of

reference emissions

Effective heat drop (turbine

efficiency) is expected to develop 0.5% in

case 1% of degree of vacuum is improved.

Total generating end output power in year

2012 was 3,328.5GWh/y, so approximate

16,600MWh/y of generating power output

can be obtained in case degree of vacuum

is improved 1% and it is corresponding to

approximate 15,000tCO2/y of CO2

emission reduction.

Plant efficiency analysis was undertaken

using data acquired from CHP-3 & CHP-4

however degree of plant efficiency

improvement was not proved because the

reliability of data were not confirmed.

To ensure reliability for data, it is

proposed to demonstrate degree of turbine

efficiency improvement and investigate

reference drainage by means of comparing

in project planning study of condenser

tube cleaning by “Brush Inset Cleaning

Method” comparing averaged data per

hour between “Conventional Cleaning

Method” and “Brush Inset Cleaning

Method”.