Steam Systems Management by John Herbert

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Managing steam systems yields energy and cost savings that benefit your business and the environment.

Managing steam systems yields energy and cost savings that benefit your business and the environment.

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  • The anatomy of a steam system, four categories:Steam Generation -Exam the boiler plant efficiency, fuel switching, dual fuel;Steam distribution -Exam the steam headers and distribution piping systems, considering air venting and condensate flowsTrapping - Steam traps prevent wasting steam, exam type, location, and operation;Condensate recovery - Exam volume flow, set targets for condensate recovery
  • Review the steam generation plant and equipment to optimise operations: fuel efficiencyoperation and controlsdual fuel firing / fuel switchingmaintain water quality for boiler operationoptions for removal of non-condensablesoptions for heat recovery
  • If its not metered it’s never improved!
  • Review the distribution systems to ensure that the energy content in the steam reaches the end user process with minimum losses. Poor installation causes long term problems and early equipment failures, increasing the cost of ownership.
  • Whether through poor design, installation or operation steam quality is important to deliver the energy created at the boiler plant to the process/end user. Wet steam (lower latent energy content) impacts productivity and operations. And Non-condensables also disrupt heat transfer lowering efficiency
  • Efficient steam trapping prevents energy waste, and encourages air removal to optimise heat transfer to the process/end userSteam leaking into condensate lines can also preventing condensate return to central plant
  • Efficiently collecting and returning hot (non contaminated) condensate to the central plant is vital to lower energy cost As the percentage of condensate returned increases the cost for fresh water and chemical treatment is reduced
  • Many owners don’t have a record of the steam installation - Kelcroft created Steam schematic Drawing for client

Transcript

  • 1. 1
    Steam System
    Management
  • 2. 2
    cutting steam wastage and lowering operating costsfor steam and condensate systemsby John Herbert
  • 3. 3
    John Herbert
    Principal Engineer
    International Knowledge
    20+ years Industrial and process Steam systems experience
    Energy Efficiency expertise
  • 4. 4
    Process Steam
    A properly designed and operated steam installation provides industry with a powerful source of energy
  • 5. 5
    Why Audit?
    Increasing Business Risk:
    Energy Security
    Fuel costs, water, and tariffs are rising
  • 6. 6
    Why Audit?
    Environmental Risk:
    Environmental reporting becoming “Standard”
    Carbon Taxation at the border(EU)
    Pollution arising from energy is increasing community concern
  • 7. 7
    Why Audit?
    Consumers Awareness:
    Pollution arising from industry is increasingly a buyer concern
    Impacts on the community monitored
  • 8. How?
    What is a Steam System Management Audit, essentially it’s an inspection process that:
    Tracks down deficiencies and waste
    Identifies energy and cost saving opportunities
    Delivers optimised the operation of the steam system for the owner
    8
  • 9. Approach
    A steam systemis sub divided into four categories:
    1. Generation
    boiler plant, fuel, water, etc.
    2. Distribution
    Piping, pressure reducing valves (prv), insulation
    3. Trapping
    Efficiency trapping equipment
    4. Condensate
    Recover condensate
    9
  • 10. 10
  • 11. 1. Generation
    Review the steam generation plant and equipment to optimise operations:
    fuel efficiency
    operation and controls
    dual fuel firing / fuel switching
    maintain water quality for boiler operation
    options for removal of non-condensables
    options for heat recovery
    11
  • 12. 12
    1. Generation
    Boiler Plant Efficiency
    Poor Steam Header
  • 13. 1. Generation
    13
    Raw Water Meter
    Blowdown
  • 14. 2. Distribution
    Review the distribution systems to ensure that the energy content in the steam reaches the end user process with minimum losses.
    14
  • 15. 2. Distribution
    Poor design, installation and operation reduces the steam quality:
    wet steam (lower latent energy content) impacts productivity and operations
    Non-condensablesdisrupt heat transfer lowering efficiency
    15
  • 16. 16
    2. Distribution
    Trapped condensate
    Missing insulation
    Poor installation
  • 17. 17
    2. Distribution
    No Insulation
    Thermal insulation missing
    Steam leak
  • 18. 18
    2. Distribution
    Alignment
    Low point
    Low point
  • 19. 3. Trapping
    Efficient steam trapping prevents energy waste, and encourages air removal to optimise heat transfer to the process/end user
    Steam leaking into condensate lines can also preventing condensate return to central plant
    19
  • 20. 20
    3. Trapping (process)
    Trap Leakage
    Trap Leakage
  • 21. 4. Condensate
    Efficiently collecting and returning hot (non contaminated) condensate to the central plant is vital to lower energy cost
    As the percentage of condensate returned increases the cost for fresh water and chemical treatment is reduced
    21
  • 22. 4. Condensate
    Returning condensate is to the boiler is vital saving:
    Energy
    Raw Water
    Chemical Treatment
    22
  • 23. 23
    4. Condensate
    80%
    70%
    60%
    or less?
    Condensate Receiver
  • 24. 24
    4. Condensate
    Condensate pressure main
    No Insulation
    Missing insulation
  • 25. 5. Other
    Safe operation of steam systems is important, safety issues highlighted
    25
    Safe discharge pipe
    missing
  • 26. 26
    O&M Record
  • 27. Plant Management
    Many installations don’t have a current drawing(s) for the steam installation!
    RIGHT: An example of new schematic drawing created by Kelcroft >>
    27
  • 28. 28
    Energy Analysis
  • 29. 29
    The Audit Process…..
    Data Collection
    Utility bills
    Site Inspection, steam trap audit
    Analysis of Data
    Written Report
    Energy analysis
    Record Photographs
    Charts
  • 30. 30
    Finding the Energy and Cost Savings $$$
    Roadmap to savings, three lanes:
    Housekeeping
    Little or no capital cost
    training, signage
    O&M
    Operating improvements with minor cost
    Capital Works
    Major capital expenditure,
    Plant replacement upgrade
  • 31. 31
    Boilers cannot
    maintain load
  • 32. 32
    Finding the Energy and Cost Savings $$$
    Following energy and management analysis, Kelcroft charts help explain the findings visually
    Depending on the project, gap and sensitivity analysis
  • 33. Report
    A suggested table of content could include:
    Introduction (brief, scope)
    Description of Steam System including:
    Generation
    Distribution
    Trapping
    Condensate Return
    Management and Operation
    Energy Analysis
    Heat and condensate recovery
    Conclusions and Recommendations
    Findings
    Schedule of EMM (Energy Management Measures) work for each category
    Where defects found recommend remedial work
    Appendix – photographs, charting, etc.
    33
  • 34. Kelcroft’s Steam Management
    depth of experience and expertise
    helps you lower the cost of
    doing business in Asia
    34
  • 35. 35
    Kelcroft
    Kelcroft E&M Limited
    Unit 518 , 5/F, Hope Sea Industrial Centre
    26 Lam Hing Street, Kowloon Bay,
    Kowloon, Hong Kong SAR
    tel. 電話 :+(852) 2335 9830
    fax 傳真: +(852) 2335 9862
    web: http://www.kelcroft.com.hk
    email: info@kelcroft.com.hk