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A large-scale energy audit is underway at AVISMA. GCE-Energy LLC, an independent auditor, is involved to carry out comprehensive inspection of power, heat and water supply systems followed by issue of the guidelines on improving energy efficiency.

In February 2015, the enterprise launched the Energy Efficiency Program. Its first stage scheduled for 2015-2018 will consist in deep analysis of energy sources consumption with further implementation of the ISO 50001 energy management system.

One of the program priorities is to cut energy sources costs which, due to the process specifics, account for substantial part of AVISMA’s budget. In order to reach this target, in September 2016 the enterprise signed a contract with GCE-Energy, an audit company from St. Petersburg, to conduct a comprehensive energy audit that will last 6 months.

The power supply system is the first to be inspected. In October, GCE’s experts Mikhail Bozhkov and Vitaly Khvoynitsky performed visual inspections of the workshops and electrical equipment and studied related documents. Now it is time for instrumental measurement on power supply and distribution networks at AVISMA sites located in Ivakinsky Karier and Chaika Recretional Resort.

The auditors measure energy quality and loads on the process units with the help of portable power quality analyzers PEK.

In Russia, quality of electrical energy is measured in accordance with the GOST first passed in 1967 and last revised in 2013. Today it is called the Customs Union Standard 32144 “Power Quality Indices” and sets the following criteria: voltage fluctuations, harmonics and flicker measurements.

At AVISMA the auditors measure such factors as voltage unbalance, unsinusoidality, waveform distortion, AC failures and overvoltages. The last two parameters are quite in line with the standards whereas unbalance and unsinusoidality leave much to be desired.

Mikhail BOZHKOV, auditor

- AVISMA employs three potlines, ore-thermal furnaces and chlorination units. When operating, this equipment immediately consumes huge amounts of electricity. Since the output of the power network is limited and the transformers ate two-phase ones, sudden and considerable take-out of power results in distortion of phases. Such a problem is not attributed exclusively to your facilities – production of titanium remains extremely power-consuming all over the world.

Another scope of work is expert review of power supply reliability. At the first stage, the experts examine documents regarding the number of power sources, flexibility of the power supply system and power flow diagrams. They have also looked through the statistics of electrical failures at AVISMA.

According to the auditors’ preliminary conclusion, the power supply system of the enterprise is highly reliable and is in line with the applicable standards. The experts noted significant advantages such as energy efficiency programs and staff advanced training schedules, timely replacement of worn out equipment and intensive modernization of lighting in the workshops which has so far resulted in replacement of almost all fluorescent bulbs for LED lamps.

The auditors assume that the highest energy saving potential at the enterprise is in water recycling. Theoretically, volume and temperatures of recycled water are enough for it to be further re-used for production needs.

Vitaly KHVOYNITSKY, auditor:

- Recycled water can be used in heat pumps for waste energy generation. Then it comes to the question how this energy can be transferred and then used for, say, heating or hot water supply of the workshops while reducing hot water purchase from external providers. We are now working on this option together with the Engineering Department. We are going to make technical calculations, develop draft design scope. If this scheme turns out to be workable, we will propose it for an experiment in one of the workshops.

Energy savings can also be achieved by installing variable frequency drives on the non-intensively used equipment. An efficient method is to use infrared heaters in process areas (first of all, storages and shelters) instead of conventional heating.

Alexandr VILLER, Senior Energy Efficiency Engineer at AVISMA:

- The plant has rather high buildings where staff mostly works at the ground level. With the conventional central heating, heat goes up while the lower floors remain cold. When workshop gates are open, heat quickly infiltrates as well. Infrared heaters enable to spread heat evenly and keep it longer.

Apart from this, location of the heat source inside the workshop excludes heat losses through heating networks. Now we are choosing the rooms where these changes will be the most reasonable.

Such equipment was installed in some warehouses and spongy titanium production line during modernization of power substations at AVISMA.

Visits of heat, water and gas supply experts are scheduled for January 2017. The first stage of the energy audit is due to be completed in February 2017. Once the instrumental measurements data are processed, the auditors from St. Petersburg will issue a summary report and recommendations of definite energy saving measures.

After review of the recommendations by AVISMA engineers, these guidelines will be turned into a long-term energy efficiency program.

Source: newspaper “Mettalurg”, issue no.48

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