SteamsystemlowefficiencyProblems

Reasonsforlowefficiency

BoilersFrequenton-offcycles

Results

Results Lossofenergyatstartupcycles

Solution

Boilercontinuousoperationatgoodload

Adjuststeamconsumersloadtokeepboilerloadaboveminimumturn-downratio

Reviewboilersloadsharingandcontrolconcept

Boileroperationatlowerpressurethandesignpressure

Results

Lossofefficiencyatlowpressure

Increaseradiationandconvectionlosses

Lowerqualitysteamproduced(foamformation)

Possibilityofsteampriming(watercarryover)withloadchange

Solution

OperateBoileratpressureclosetodesignpressure

Adjustboilerpressuretodesignandadjuststeampressureatconsumersidewithletdownvalve

Checkfeasibilityofusingletdownorextractionturbineinsteadofletdownvalvestorecovertheenergy

Highsteamvelocityinpipes(morethan30m/s)

Happenswhenweaddmoresteamquantitieswithoutconsideringexistingsteampipessize

Results

Noiseandvibrationinsteamlines

Causeofwater-hammerifcondensationhappens

Pipeserosion

Solution

Checktheexistingsteamvelocityinyoursteamnetworkandplanforanyrequiredde-bottleneck.

Considertochecksteamnetworkpipingsizebeforeaddinganewadditionalamountofsteammorethandesign

Water-hammerandcondensation

Startupcondensatenotremoved

ResultsNoiseandvibrationinsteamlines

SteamleaksPipingjointsfailure

SolutionChecksteamtrapsanddrainsatsystemstartupandoperation

Goodselectionforsteamtrapstype

Applyregularmaintenanceplanforsteamtraps

Solution

Ensureremovingcondensatefromsteampipes

Checksteamtrapsanddrainsatsystemstartupandoperation

Goodselectionforsteamtrapstype

Applyregularmaintenanceplanforsteamtraps

Defectedsysteminsulation

ResultsLossofenergy

Example(1.5Kgofsteam/hr/mofpipeiscondensedbyloosingenergywithoutinsulation)(at7barsteamsystem)

Solution

Ensuregoodinsulationisinplace

Checktheconditionofsysteminsulationandapplyanymaintenancerequiredimmediately

ConsiderInsulationupgradeforoldsystems

Applythermalscanningtodetectdefectedareas

Presenceofairandnoncondensablegasesinsteamsystem

Results

Poorheattransfer

Corrosionduetoaciditywithcondensate

Reducegeneratedsteamtemperature

Solution

Insureairremovalfromsystem

Usesystemairventsasperstandardoperatingprocedures.

Regularcheckforsteamtraps

Commonresult

Highoperationalandmaintenancecost

QuantifiedenergysavingopportunitiesforBoilers

ImprovedoperationandmaintenanceofboilersUpto5%

ImprovedwatertreatmentandboilerwaterconditioningUpto2%

Totaldissolvedsolids(TDS)controlandboilerblowdownUpto2%

BlowdownheatrecoveryUpto4%

Boilerandburnermanagementsystems,digitalcombustioncontrolsandoxygentrimUpto5%

EconomisersUpto5%

Combustionairpre-heatingUpto2%

360ProactiveEngineerwww.360ProcativeEngineer.com

SteamsystemlowefficiencyProblems

Reasonsforlowefficiency

BoilersFrequenton-offcycles

Results Lossofenergyatstartupcycles

Solution

Boilercontinuousoperationatgoodload

Adjuststeamconsumersloadtokeepboilerloadaboveminimumturn-downratio

Reviewboilersloadsharingandcontrolconcept

Boileroperationatlowerpressurethandesignpressure

Results

Lossofefficiencyatlowpressure

Increaseradiationandconvectionlosses

Lowerqualitysteamproduced(foamformation)

Possibilityofsteampriming(watercarryover)withloadchange

Solution

OperateBoileratpressureclosetodesignpressure

Adjustboilerpressuretodesignandadjuststeampressureatconsumersidewithletdownvalve

Checkfeasibilityofusingletdownorextractionturbineinsteadofletdownvalvestorecovertheenergy

Highsteamvelocityinpipes(morethan30m/s)

Happenswhenweaddmoresteamquantitieswithoutconsideringexistingsteampipessize

Results

Noiseandvibrationinsteamlines

Causeofwater-hammerifcondensationhappens

Pipeserosion

Solution

Checktheexistingsteamvelocityinyoursteamnetworkandplanforanyrequiredde-bottleneck.

Considertochecksteamnetworkpipingsizebeforeaddinganewadditionalamountofsteammorethandesign

Water-hammerandcondensation

Startupcondensatenotremoved

ResultsNoiseandvibrationinsteamlines

SteamleaksPipingjointsfailure

Solution

Ensureremovingcondensatefromsteampipes

Checksteamtrapsanddrainsatsystemstartupandoperation

Goodselectionforsteamtrapstype

Applyregularmaintenanceplanforsteamtraps

Defectedsysteminsulation

ResultsLossofenergy

Example(1.5Kgofsteam/hr/mofpipeiscondensedbyloosingenergywithoutinsulation)(at7barsteamsystem)

Solution

Ensuregoodinsulationisinplace

Checktheconditionofsysteminsulationandapplyanymaintenancerequiredimmediately

ConsiderInsulationupgradeforoldsystems

Applythermalscanningtodetectdefectedareas

Presenceofairandnoncondensablegasesinsteamsystem

Results

Poorheattransfer

Corrosionduetoaciditywithcondensate

Reducegeneratedsteamtemperature

Solution

Insureairremovalfromsystem

Usesystemairventsasperstandardoperatingprocedures.

Regularcheckforsteamtraps

Commonresult Highoperationalandmaintenancecost

QuantifiedenergysavingopportunitiesforBoilers

ImprovedoperationandmaintenanceofboilersUpto5%

ImprovedwatertreatmentandboilerwaterconditioningUpto2%

Totaldissolvedsolids(TDS)controlandboilerblowdownUpto2%

BlowdownheatrecoveryUpto4%

Boilerandburnermanagementsystems,digitalcombustioncontrolsandoxygentrimUpto5%

EconomisersUpto5%

Combustionairpre-heatingUpto2%

360ProactiveEngineerwww.360ProcativeEngineer.com