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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  • 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
  • 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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