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1<br />Steam System<br />Management<br />
2<br />cutting steam wastage and lowering operating costsfor steam and condensate systemsby John Herbert<br />
3<br />John Herbert<br />Principal Engineer<br />International Knowledge<br />20+ years Industrial and process Steam syste...
4<br />Process Steam <br />A properly designed and operated steam installation provides industry with a powerful source of...
5<br />Why Audit?<br />Increasing Business Risk:<br />Energy Security <br />Fuel costs, water, and tariffs are rising<br />
6<br />Why Audit?<br />Environmental Risk:<br />Environmental reporting becoming “Standard”<br />Carbon Taxation at the bo...
7<br />Why Audit?<br />Consumers Awareness:<br />Pollution arising from industry is increasingly a buyer concern<br />Impa...
How?<br />What is a Steam System Management Audit, essentially it’s an inspection process that:<br />Tracks down deficienc...
Approach<br />A steam systemis sub divided into four categories:<br />1. Generation<br />boiler plant, fuel, water, etc.<b...
10<br />
1. Generation<br />Review the steam generation plant and equipment to optimise operations: <br />fuel efficiency<br />oper...
12<br />1. Generation<br />Boiler Plant Efficiency<br />Poor Steam Header<br />
1. Generation<br />13<br />Raw Water Meter<br />Blowdown<br />
2. Distribution<br />Review the distribution systems to ensure that the energy content in the steam reaches the end user p...
2. Distribution<br />Poor design, installation and operation reduces the steam quality:<br />wet steam (lower latent energ...
16<br />2. Distribution<br />Trapped condensate<br />Missing insulation<br />Poor installation<br />
17<br />2. Distribution<br />No Insulation<br />Thermal insulation missing<br />Steam leak<br />
18<br />2. Distribution<br />Alignment<br />Low  point<br />Low  point<br />
3. Trapping<br />Efficient steam trapping prevents energy waste, and encourages air removal to optimise heat transfer to t...
20<br />3. Trapping (process)<br />Trap Leakage <br />Trap Leakage<br />
4. Condensate<br />Efficiently collecting and returning hot (non contaminated) condensate to the central plant is vital to...
4. Condensate<br />Returning condensate is to the boiler is vital saving:<br />Energy<br />Raw Water<br />Chemical Treatme...
23<br />4. Condensate<br />80%<br />70%<br />60%<br />or less? <br />Condensate Receiver<br />
24<br />4. Condensate<br />Condensate pressure main <br />No Insulation<br />Missing insulation<br />
5. Other<br />Safe operation of steam systems is important, safety issues highlighted<br />25<br />Safe discharge pipe <br...
26<br />O&M Record<br />
Plant Management<br />Many installations don’t have a current drawing(s) for the steam installation!<br />RIGHT:  An examp...
28<br />Energy  Analysis<br />
29<br />The Audit Process…..<br />Data Collection<br />Utility bills<br />Site Inspection, steam trap audit<br />Analysis ...
30<br />Finding the Energy and Cost Savings $$$<br />Roadmap to savings, three lanes:<br />Housekeeping<br />Little or no ...
31<br />Boilers cannot <br />maintain load<br />
32<br />Finding the Energy and Cost Savings $$$<br />Following energy and management analysis, Kelcroft charts help explai...
Report<br />A suggested table of content could include:<br />Introduction (brief, scope)<br />Description of Steam System ...
Kelcroft’s Steam Management <br />depth of experience and expertise <br />helps you lower the cost of <br />doing business...
35<br />Kelcroft<br />Kelcroft E&M Limited<br />Unit 518 , 5/F, Hope Sea Industrial Centre <br />26 Lam Hing Street, Kowlo...
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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.

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Steam Systems Management by John Herbert

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

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