Driving Toward Energy EfficiencyDriving Toward Energy Efficiency

Emerson Process ManagementNovaspect. Inc.

June 22 / 23, 2010

SteamSteam

Steam – Take a System ApproachSteam – Take a System ApproachSteam – Take a System ApproachSteam – Take a System Approach

Air Venting

Steam Generation

Insulation

Steam Traps Distribution Drain Traps

High Pressure Process Use

Med. Pressure Process Use

Low Pressure Process Use

Pressure Let Down

Flash Recovery / Cascade Systems

Atmospheric Flash Tank for Condensate Recovery

Make Up Water

Med. Pressure Tracing

Low Pressure Tracing

Condensate Pumping

Separation-Steam Quality-Efficiency

Local Atmospheric Flash Tank for Condensate Recovery w/Condensate Pumping

TopicsTopicsTopicsTopics

Insulation

Pressure Reduction

Flash Recovery / Cascade Systems

Steam Trapping & Steam Trap Management

Steam Leak Detection & Repair

Air Venting

Steam Using Process Equipment

Steam Tracing

Atmospheric Flash Tanks / Flash Condensing

Condensate Return

Air Venting

Steam Generation

Insulation

Steam Traps Distribution Drain Traps

High Pressure Process Use

Med. Pressure Process Use

Low Pressure Process Use

Pressure Let Down

Flash Recovery / Cascade Systems

Atmospheric Flash Tank for Condensate Recovery

Make Up Water

Med. Pressure Tracing

Low Pressure Tracing

Condensate Pumping

Separation-Steam Quality-Efficiency

Local Atmospheric Flash Tank for Condensate Recovery w/Condensate Pumping

NoteNoteNoteNote

•Today’s presentation is efficiency centric.

•Historically, projects have not been driven solely on energy savings.

•Other drivers include:

-Safety

-Throughput

-Reliability / Maintenance

Air Venting

Steam Generation

Insulation

Steam Traps Distribution Drain Traps

High Pressure Process Use

Med. Pressure Process Use

Low Pressure Process Use

Pressure Let Down

Flash Recovery / Cascade Systems

Atmospheric Flash Tank for Condensate Recovery

Make Up Water

Med. Pressure Tracing

Low Pressure Tracing

Condensate Pumping

Separation-Steam Quality-Efficiency

Local Atmospheric Flash Tank for Condensate Recovery w/Condensate Pumping

What Do You Want to Know & Why What Do You Want to Know & Why (Monitoring Points / Value)(Monitoring Points / Value)What Do You Want to Know & Why What Do You Want to Know & Why (Monitoring Points / Value)(Monitoring Points / Value)

•You can’t manage or control what you don’t measure

-Typically steam systems are under measured

•Typical measurement points serve to determine where the steam goes, how much is being used, determine where losses are occurring and to help troubleshoot system issues.

-In steam using process equipment, temperature and ΔP measurements lead to informed process and efficiency improvement decisions.

-In the distribution / condensate return system the ΔP is the condensate driver; flow and temperature measurement let you monitor and put a value to the energy being returned back to the boiler.

Air Venting

Steam Generation

Insulation

Steam Traps Distribution Drain Traps

High Pressure Process Use

Med. Pressure Process Use

Low Pressure Process Use

Pressure Let Down

Flash Recovery / Cascade Systems

Atmospheric Flash Tank for Condensate Recovery

Make Up Water

Med. Pressure Tracing

Low Pressure Tracing

Condensate Pumping

Separation-Steam Quality-Efficiency

Local Atmospheric Flash Tank for Condensate Recovery w/Condensate Pumping

Assumptions / ClarificationsAssumptions / ClarificationsAssumptions / ClarificationsAssumptions / Clarifications

100 PSIG Steam Cost / Per 1K LB 8.89Inlet Temperature / °F 40.00Fuel / Nat. Gas 4.82Water 0.64Chemical Treatment 0.05Sewer 0.38Facilities / Infrastructure / Personnel 3.00

H2O 8.35 LB/GALH2O 7.34 GAL/FT3H2O $ 0.03926 FT3H2O Sewage $ 0.0236 FT3H2O $ 0.005348774 GALH2O Sewage $ 0.00315508 GALH2O $ 0.000640572 LBH2O Sewage $ 0.000377854 LBNat. Gas $ 0.00000408 BTUChemical Trtmt $ 0.00005 LB/STM

•Cost of Steam

•Definitions

-Sensible Heat: Btu’s contained in liquid-Latent Heat: Btu’s gained at vaporization and given up at condensation-Superheat: Btu’s over and above those gained at the at vaporization – generally measured as temperature above that of saturated steam

Cost Savings through Steam Efficiency Cost Savings through Steam Efficiency Cost Savings through Steam Efficiency Cost Savings through Steam Efficiency

Gallons Wash-down Water / Day 1,000,000.00Pounds Wash-down Water / Day 8,350,000.00Wash-down Water Inlet Temperature / °F 40.00Wash-down Water Outlet Temperature / °F 150.00

Properties of 100 PSIG Steam Latent Heat of Steam / BTU per LB 880.70Cost Per 1K LB 8.89

100 PSIG Steam Load Requirement at 100% Efficiency / LB 1,042,915.67Cost to Heat 1,000,000 Gallons of Wash-down Water / Day 9,271.39$ Cost to Heat Wash-down Water / Year 3,384,057.65$

Low Quality / % Entrained Water or Air 5%Low Quality / Latent Heat of Steam / BTU per LB 836.67100 PSIG Steam Load Requirement at Reduced Efficiency / LB 1,097,805.97Cost to Heat 1,000,000 Gallons of Wash-down Water / Day 9,759.36$ Cost to Heat Wash-down Water / Year 3,562,165.95$

Cost for 5% Efficiency Loss 178,108.30$

InsulationInsulationInsulationInsulation

Prevention of radiant heat loss (condensing of steam)

100 PSIG Steam, 100’ 8”, Schedule 40 Pipe, 10 MPH Wind Speed, 40°F

•Uninsulated Pipe

-415 PPH Condensate / 365,700.9 Btu/HR

-$32,337 Annual Cost

•Insulated Pipe (2” Calcium Silicate)

-19.1 PPH Condensate / 17,097.4 Btu/HR

-$1,512 Annual Cost / $30,825 Annual Savings

-Approximate Payback = 36 days based an installed insulation cost of $3,000; 71 days based an

installed insulation cost of $6,000

InsulationInsulationInsulationInsulation

Prevention of radiant heat loss (condensing of steam)

100 PSIG Steam, 100’ 8”, Schedule 40 Pipe, 0 MPH Wind Speed, 70°F

•Uninsulated Pipe

-206 PPH Condensate / 181,654 Btu/HR

-$16,063 Annual Cost

•Insulated Pipe (2” Calcium Silicate)

-19.8 PPH Condensate / 17,426 BTU

-$1,541 Annual Cost / $14,522 Annual Savings

-Approximate Payback = 75 days based an installed insulation cost of $3,000; 151 days based an

installed insulation cost of $6,000

Pressure ReductionPressure ReductionPressure ReductionPressure Reduction

Ideally, you would produce steam at the pressure you need at the location it’s required in the quantity needed…•Higher pressure generation

-Smaller Pipe Diameter-Superheated Steam -Need for pressure reduction

•Do work during the reduction process-Generate electricity, compress air

•Elimination of superheat (process fouling)-Latent heat transfer

Flash Recovery / Cascade SystemsFlash Recovery / Cascade SystemsFlash Recovery / Cascade SystemsFlash Recovery / Cascade Systems•Condensate from higher pressure system sent to steam trap(s).

•Traps discharge into a vessel that is regulated at a pressure slightly above the lower pressure steam system.

•The portion of the condensate that “flashes” into steam is recovered into the lower pressure system.

•Lower pressure system requirements not met by the flash recovery / cascade system are supplied through supplemental let down and / or lower pressure steam production.

•This allows for multiple uses of each pound of generated steam

Flash Recovery / Cascade SystemsFlash Recovery / Cascade SystemsFlash Recovery / Cascade SystemsFlash Recovery / Cascade Systems

ValueLoad / PPH

Primary Pressure

Secondary Pressure

% of Flash Steam

PPH Flash Steam

Steam Cost

Hourly Savings Annual Savings

100,000 100 50 4.58% 4577.4 $ 8.89 $ 40.69 $ 356,471.43 100,000 50 20 4.24% 4239.5 $ 8.89 $ 37.69 $ 330,157.00

100,000 600 150 15.89% 15885.9 $ 8.89 $ 141.23 $ 1,237,136.70 100,000 150 15 16.33% 16329.9 $ 8.89 $ 145.17 $ 1,271,713.82

Steam TrappingSteam TrappingSteam TrappingSteam Trapping

Where:

-Every 100-150’, before rise, after fall, before control valve, at end of line, at steam using process equipment as appropriate.

Why:

-Condensate removal / maximum Btu latent heat per pound of steam

-Reliability (hydraulic shock, cutting valves / components)

-System Start Up

Steam Trapping – Trap EfficiencySteam Trapping – Trap EfficiencySteam Trapping – Trap EfficiencySteam Trapping – Trap Efficiency

Steam Use/HR $/1K Annual $ Population Total $ Difference

0.30

$8.89

$ 23.36

1000

$ 23,363 -

1.72 $ 133.95 $ 133,947 $ 110,584

2.53 $ 197.03 $ 197,027 $ 173,664

2.60 $ 202.48 $ 202,479 $ 179,116

3.38 $ 263.22 $ 263,222 $ 239,859

3.52 $ 274.12 $ 274,125 $ 250,762

4.14 $ 322.41 $ 322,408 $ 299,045

4.77 $ 371.47 $ 371,470 $ 348,108

Steam Trap ManagementSteam Trap ManagementSteam Trap ManagementSteam Trap Management

Total Trap Population 100.0% -Good 59.8% -Blocked 4.7% -Low Temperature 4.9% -Blowing 2.4% 1,835.19$ Leaking 11.1% 495.52$ Not in Service 16.7% -Other 0.4% -

Steam Leak Detection & RepairSteam Leak Detection & RepairSteam Leak Detection & RepairSteam Leak Detection & Repair

Hole Diameter x .7 Disch Coeff

PPH Steam Loss $/1K LBS Annual Loss

1 4411.1 8.89$ 343,520.59$ 7/8 3377.3 8.89$ 263,011.97$ 3/4 2481.3 8.89$ 193,234.71$ 5/8 1723.1 8.89$ 134,188.82$ 1/2 1102.8 8.89$ 85,882.09$ 3/8 620.3 8.89$ 48,306.73$ 1/4 275.7 8.89$ 21,470.52$ 1/8 68.9 8.89$ 5,365.68$ 1/16 17.2 8.89$ 1,339.47$ 1/32 4.3 8.89$ 334.87$

100 PSIG Steam / 100 PSID

Air VentingAir VentingAir VentingAir Venting

Removal of entrained air or inert gasses.

- Insulator / inefficient heat transfer medium

- % by volume leads to reduced BTU availability

Tell-tale

-Temperature reduction

Secondary Benefits

-Reduction of probability of hydraulic shock

-Reduction of temperature stratification (process)

Steam Using Process EquipmentSteam Using Process EquipmentSteam Using Process EquipmentSteam Using Process Equipment

High Pressure Process Use

Med. Pressure Process Use

Low Pressure Process Use

Separation-Steam Quality-Efficiency

•Use the lowest pressure that will meet the process needs.

PressureSaturation

TemperatureSensible

Heat Latent Heat Total Heat0 212 180 970 1150

15 250 218 946 116450 298 267 912 1179

100 338 309 880 1189150 366 339 857 1196300 422 399 805 1204600 489 475 728 1203900 534 529 667 1196

1500 598 614 556 11702100 644 685 444 1129

Steam Using Process EquipmentSteam Using Process EquipmentSteam Using Process EquipmentSteam Using Process Equipment

High Pressure Process Use

Med. Pressure Process Use

Low Pressure Process Use

Separation-Steam Quality-Efficiency

•Use of saturated steam for process heat exchange.

•50°F of superheat results in an additional 29 Btu per LB, or .58 Btu per degree of temperature.•The process has to shed temperature (at .58 Btu per degree) before it gets to the point of latent heat transfer by condensing at saturation temperature.

Properties of 100 PSIG Steam Saturated Steam Temperature / °F 337.9Latent Heat of Steam / Btu per LB 880.704Specific Enthalpy of Saturated Steam / Btu per LB 1189.728Specific Enthalpy of Saturated Water / Btu per LB 309.024

Superheated Steam Temperature / °F (+50°F) 387.9Latent Heat of Steam / Btu per LB 880.704Specific Enthalpy of Superheated Steam / Btu per LB 1218.616Specific Enthalpy of Saturated Water / Btu per LB 309.024

Steam Using Process EquipmentSteam Using Process EquipmentSteam Using Process EquipmentSteam Using Process Equipment

High Pressure Process Use

Med. Pressure Process Use

Low Pressure Process Use

Separation-Steam Quality-Efficiency

•Complete condensate drainage of heat exchange equipment

-Steam Trap

-Other condensate drainage method

Steam TracingSteam TracingSteam TracingSteam Tracing Med. Pressure Tracing Low Pressure Tracing

•Seasonal isolation of manifolds.

-Automated drainage scheme

•Installation best practices to ensure maximum heat transfer.

-Insulated, heat transfer cement, no air gaps

•Pay attention to ΔP across traps.

-Follow maximum tracing run guidelines

•Sensible heat for low demand / non-critical tracing.

-Instrument & instrument enclosures

•Segment Tracing Application Specifications Based on Criticality.

Atmospheric Flash Tanks / Flash CondensingAtmospheric Flash Tanks / Flash CondensingAtmospheric Flash Tanks / Flash CondensingAtmospheric Flash Tanks / Flash Condensing

•Every Btu counts

-“Waste Heat” vs. pre-heat of BFW, freeze protection

-Reduced flash venting

-More warm condensate returned for reuse

•Wrapped tubing, pipe in pipe heat exchanger, plate & frame HX

Condensate RecoveryCondensate RecoveryCondensate RecoveryCondensate Recovery

Rule of Thumb Best Practice:

• Minimum 7 turns of BFW, 13% Make-up

• Recovery of water, treatment costs, sensible heat value coupled with cost avoidance (sewage / treatment).

How

• ΔP as motive

• Local vented receiver with electric or secondary motive pressure pumps

Condensate Recovery - ValueCondensate Recovery - ValueCondensate Recovery - ValueCondensate Recovery - Value

PPH Steam Produced 500,000.00 500,000.00 500,000.00Pressure 100.00 100.00 100.00Temperature 337.90 337.90 337.90Btu/LB Sensible 309.02 309.02 309.02Btu/LB Latent 880.70 880.70 880.70Inlet H2O Temperature 40.00 100.00 190.00H2O Btu/LB Sensible 8.00 68.00 158.00

Additional Sensible Required, Btu/LB 301.02 241.02 151.02Additional Required x PPH 150,512,000.00 120,512,000.00 75,512,000.00Cost / MM Btu 4.82 4.82 4.82Additional Costs (H2O, Treatment,…) 1.07 1.07 1.07Cost 886.52$ 709.82$ 444.77$

Savings / HR -$ 176.70$ 441.75$ Savings / Year -$ 1,547,892.00$ 3,869,730.00$

Condensate Recovery - ValueCondensate Recovery - ValueCondensate Recovery - ValueCondensate Recovery - Value

Steam Value / Per 1K LB 8.89Condensate Value / Per 1K LB

BTU Value (172 Btu/LB) 0.83Water 0.64Chemical Treatment (Initial x .5) 0.03Sewer 0.38Total (without F / I / P) 1.87 21%

Next StepsNext StepsNext StepsNext StepsTake Action on Previously Identified Opportunities

Steam System Audit

-Leak Survey

-Insulation Survey

-Information “White Space”

Process Audit

Steam Trap Survey

Identify Low Hanging Fruit

Identify Costs / Losses / ROI

Prioritize

Act

Air Venting

Steam Generation

Insulation

Steam Traps Distribution Drain Traps

High Pressure Process Use

Med. Pressure Process Use

Low Pressure Process Use

Pressure Let Down

Flash Recovery / Cascade Systems

Atmospheric Flash Tank for Condensate Recovery

Make Up Water

Med. Pressure Tracing

Low Pressure Tracing

Condensate Pumping

Separation-Steam Quality-Efficiency

Local Atmospheric Flash Tank for Condensate Recovery w/Condensate Pumping

QuestionsQuestionsQuestionsQuestions

Air Venting

Steam Generation

Insulation

Steam Traps Distribution Drain Traps

High Pressure Process Use

Med. Pressure Process Use

Low Pressure Process Use

Pressure Let Down

Flash Recovery / Cascade Systems

Atmospheric Flash Tank for Condensate Recovery

Make Up Water

Med. Pressure Tracing

Low Pressure Tracing

Condensate Pumping

Separation-Steam Quality-Efficiency

Local Atmospheric Flash Tank for Condensate Recovery w/Condensate Pumping