Energy efficiency tip of the day (Steam systems low efficiency problems)
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Steam system low efficiency Problems
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Transcript of Energy efficiency tip of the day (Steam systems low efficiency problems)
SteamsystemlowefficiencyProblems
Reasonsforlowefficiency
BoilersFrequenton-offcycles
Results
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
SolutionChecksteamtrapsanddrainsatsystemstartupandoperation
Goodselectionforsteamtrapstype
Applyregularmaintenanceplanforsteamtraps
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
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
