Steam Systems Management by John Herbert

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Steam System
Management

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cutting steam wastage and lowering operating costsfor steam and condensate systemsby John Herbert

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John Herbert
Principal Engineer
International Knowledge
20+ years Industrial and process Steam systems experience
Energy Efficiency expertise

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Process Steam
A properly designed and operated steam installation provides industry with a powerful source of energy

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Why Audit?
Increasing Business Risk:
Energy Security
Fuel costs, water, and tariffs are rising

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Why Audit?
Environmental Risk:
Environmental reporting becoming “Standard”
Carbon Taxation at the border(EU)
Pollution arising from energy is increasing community concern

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Why Audit?
Consumers Awareness:
Pollution arising from industry is increasingly a buyer concern
Impacts on the community monitored

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
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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
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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
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1. Generation
Boiler Plant Efficiency
Poor Steam Header

1. Generation
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Raw Water Meter
Blowdown

2. Distribution
Review the distribution systems to ensure that the energy content in the steam reaches the end user process with minimum losses.
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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
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2. Distribution
Trapped condensate
Missing insulation
Poor installation

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2. Distribution
No Insulation
Thermal insulation missing
Steam leak

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2. Distribution
Alignment
Low point
Low point

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
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3. Trapping (process)
Trap Leakage
Trap Leakage

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
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4. Condensate
Returning condensate is to the boiler is vital saving:
Energy
Raw Water
Chemical Treatment
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4. Condensate
80%
70%
60%
or less?
Condensate Receiver

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4. Condensate
Condensate pressure main
No Insulation
Missing insulation

5. Other
Safe operation of steam systems is important, safety issues highlighted
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Safe discharge pipe
missing

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O&M Record

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 >>
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Energy Analysis

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The Audit Process…..
Data Collection
Utility bills
Site Inspection, steam trap audit
Analysis of Data
Written Report
Energy analysis
Record Photographs
Charts

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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

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Boilers cannot
maintain load

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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

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.
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Kelcroft’s Steam Management
depth of experience and expertise
helps you lower the cost of
doing business in Asia
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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

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Steam Systems Management by John Herbert

by John Herbert on Jun 13, 2011

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Steam Systems Management by John Herbert — Presentation Transcript