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Energy efficiency tip of the day (Steam systems low efficiency problems)

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Steam system low efficiency Problems
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Page 1: Energy efficiency tip of the day (Steam systems low efficiency problems)

SteamsystemlowefficiencyProblems

Page 2: Energy efficiency tip of the day (Steam systems low efficiency problems)

Reasonsforlowefficiency

Page 3: Energy efficiency tip of the day (Steam systems low efficiency problems)

BoilersFrequenton-offcycles

Page 4: Energy efficiency tip of the day (Steam systems low efficiency problems)

Results

Page 5: Energy efficiency tip of the day (Steam systems low efficiency problems)

Results Lossofenergyatstartupcycles

Page 6: Energy efficiency tip of the day (Steam systems low efficiency problems)

Solution

Boilercontinuousoperationatgoodload

Adjuststeamconsumersloadtokeepboilerloadaboveminimumturn-downratio

Reviewboilersloadsharingandcontrolconcept

Page 7: Energy efficiency tip of the day (Steam systems low efficiency problems)

Boileroperationatlowerpressurethandesignpressure

Page 8: Energy efficiency tip of the day (Steam systems low efficiency problems)

Results

Page 9: Energy efficiency tip of the day (Steam systems low efficiency problems)

Lossofefficiencyatlowpressure

Increaseradiationandconvectionlosses

Lowerqualitysteamproduced(foamformation)

Page 10: Energy efficiency tip of the day (Steam systems low efficiency problems)

Possibilityofsteampriming(watercarryover)withloadchange

Page 11: Energy efficiency tip of the day (Steam systems low efficiency problems)

Solution

Page 12: Energy efficiency tip of the day (Steam systems low efficiency problems)

OperateBoileratpressureclosetodesignpressure

Adjustboilerpressuretodesignandadjuststeampressureatconsumersidewithletdownvalve

Checkfeasibilityofusingletdownorextractionturbineinsteadofletdownvalvestorecovertheenergy

Page 13: Energy efficiency tip of the day (Steam systems low efficiency problems)

Highsteamvelocityinpipes(morethan30m/s)

Page 14: Energy efficiency tip of the day (Steam systems low efficiency problems)

Happenswhenweaddmoresteamquantitieswithoutconsideringexistingsteampipessize

Page 15: Energy efficiency tip of the day (Steam systems low efficiency problems)

Results

Noiseandvibrationinsteamlines

Causeofwater-hammerifcondensationhappens

Pipeserosion

Page 16: Energy efficiency tip of the day (Steam systems low efficiency problems)

Solution

Checktheexistingsteamvelocityinyoursteamnetworkandplanforanyrequiredde-bottleneck.

Considertochecksteamnetworkpipingsizebeforeaddinganewadditionalamountofsteammorethandesign

Page 17: Energy efficiency tip of the day (Steam systems low efficiency problems)

Water-hammerandcondensation

Page 18: Energy efficiency tip of the day (Steam systems low efficiency problems)

Startupcondensatenotremoved

Page 19: Energy efficiency tip of the day (Steam systems low efficiency problems)

ResultsNoiseandvibrationinsteamlines

SteamleaksPipingjointsfailure

Page 20: Energy efficiency tip of the day (Steam systems low efficiency problems)

SolutionChecksteamtrapsanddrainsatsystemstartupandoperation

Goodselectionforsteamtrapstype

Applyregularmaintenanceplanforsteamtraps

Page 21: Energy efficiency tip of the day (Steam systems low efficiency problems)

Solution

Ensureremovingcondensatefromsteampipes

Checksteamtrapsanddrainsatsystemstartupandoperation

Goodselectionforsteamtrapstype

Applyregularmaintenanceplanforsteamtraps

Page 22: Energy efficiency tip of the day (Steam systems low efficiency problems)

Defectedsysteminsulation

Page 23: Energy efficiency tip of the day (Steam systems low efficiency problems)

ResultsLossofenergy

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

Page 24: Energy efficiency tip of the day (Steam systems low efficiency problems)

Solution

Ensuregoodinsulationisinplace

Checktheconditionofsysteminsulationandapplyanymaintenancerequiredimmediately

ConsiderInsulationupgradeforoldsystems

Applythermalscanningtodetectdefectedareas

Page 25: Energy efficiency tip of the day (Steam systems low efficiency problems)

Presenceofairandnoncondensablegasesinsteamsystem

Page 26: Energy efficiency tip of the day (Steam systems low efficiency problems)

Results

Poorheattransfer

Corrosionduetoaciditywithcondensate

Reducegeneratedsteamtemperature

Page 27: Energy efficiency tip of the day (Steam systems low efficiency problems)

Solution

Insureairremovalfromsystem

Usesystemairventsasperstandardoperatingprocedures.

Regularcheckforsteamtraps

Page 28: Energy efficiency tip of the day (Steam systems low efficiency problems)

Commonresult

Page 29: Energy efficiency tip of the day (Steam systems low efficiency problems)

Highoperationalandmaintenancecost

Page 30: Energy efficiency tip of the day (Steam systems low efficiency problems)

QuantifiedenergysavingopportunitiesforBoilers

Page 31: Energy efficiency tip of the day (Steam systems low efficiency problems)

ImprovedoperationandmaintenanceofboilersUpto5%

Page 32: Energy efficiency tip of the day (Steam systems low efficiency problems)

ImprovedwatertreatmentandboilerwaterconditioningUpto2%

Page 33: Energy efficiency tip of the day (Steam systems low efficiency problems)

Totaldissolvedsolids(TDS)controlandboilerblowdownUpto2%

Page 34: Energy efficiency tip of the day (Steam systems low efficiency problems)

BlowdownheatrecoveryUpto4%

Page 35: Energy efficiency tip of the day (Steam systems low efficiency problems)

Boilerandburnermanagementsystems,digitalcombustioncontrolsandoxygentrimUpto5%

Page 36: Energy efficiency tip of the day (Steam systems low efficiency problems)

EconomisersUpto5%

Page 37: Energy efficiency tip of the day (Steam systems low efficiency problems)

Combustionairpre-heatingUpto2%

Page 38: Energy efficiency tip of the day (Steam systems low efficiency problems)

360ProactiveEngineerwww.360ProcativeEngineer.com

Page 39: Energy efficiency tip of the day (Steam systems low efficiency problems)

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


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