GlaxoSmithKline - Armstrong International · 12-05-2011 · Memphis, TN STEAM AND CONDENSATE AUDIT...

©2011 Armstrong Service, Inc.

GlaxoSmithKline Memphis, TN

STEAM AND CONDENSATE AUDIT REPORT

Project No: ASIR-10138-02-0411

Prepared for:

Alan Stewart – Project Engineer, Global Manufacturing & Supply PO Box 13167, Memphis, TN 38113

Phone: 901-415-1326

May 12, 2011

Prepared By:

Armstrong Service Inc 8615 Commodity Circle, Suite 17

Orlando FL-32819

Ph: 407-370-3301 / Fax: 407-370-3399

STEAM AND CONDENSATE AUDIT

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To the attention of Mr. Alan Stewart

Prepared by N. Iordanova

© 2011 Armstrong Service, Inc.

NOTICE This proposal has been submitted to GlaxoSmithKline (GSK) Memphis, TN in confidence and it contains trade secrets, as well as privileged information, and/or proprietary work product of Armstrong Service, Inc. (ASI). In consideration of the receipt of this Proposal and the information and data herein, Recipient agrees that it will use this document and the information contained herein only for internal use and only for the purpose of evaluating a business transaction with Armstrong. Recipient agrees that it will not disclose this Proposal or any part thereof to any third parties and Recipient may only disclose this document to those employees involved in the evaluation of a business transaction with Armstrong, on an as need basis. Recipient may make only those copies needed for such internal review. Upon conclusion of business discussions, this document and all copies shall be returned to Armstrong upon its or their request.


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TABLE OF CONTENTS

EXECUTIVE SUMMARY .......................................................................................................... 4

1 STEAM BUDGET AND SUMMARY OF POTENTIAL SAVINGS ....................................... 6

2 OPTIMIZATION PROJECTS ............................................................................................. 8

2.1 OPTIMIZATION PROJECT # 1: OPTIMIZE COMBUSTION AND STACK LOSSES - STEAM BOILER .... 8

2.2 OPTIMIZATION PROJECT # 2: OPTIMIZE COMBUSTION AND STACK LOSSES – HOT WATER BOILER

14

2.3 OPTIMIZATION PROJECT # 3: BLOWDOWN REDUCTION......................................................... 18

2.4 OPTIMIZATION PROJECT # 4 REMOVE IDLE PIPING ............................................................... 21

2.5 OPTIMIZATION PROJECT # 5 INSTALL REMOVABLE INSULATION ............................................. 23

2.6 OPTIMIZATION PROJECT # 6/6A: HOT WATER OPTIMIZATION - DUAL SALT ............................ 26

2.7 OPTIMIZATION PROJECT # 7: HOT WATER OPTIMIZATION – SANITARY AND NON-SANITARY HW

33

2.8 OPTIMIZATION PROJECT # 8: HOT WATER OPTIMIZATION – DOMESTIC HW .......................... 38

3 CHECK LIST VERIFICATIONS COMPLETED DURING THE AUDIT .............................. 42

4 RECOMMENDED ADDITIONAL STUDIES ..................................................................... 44

4.1 OPTIMIZATION PROJECT # 9 STEAM TRAPS .......................................................................... 44

4.2 HEAT RECOVERY FROM THE OVEN’S EXHAUST ............................................................................ 48

4.3 NEW BOILER INSTALLATION EVALUATION ..................................................................................... 50

5 ADDITIONAL OBSERVATIONS AND RECOMMENDATIONS ........................................ 52

5.1 PIPING PRACTICES AND STEAM TRAPS INSTALLATION .................................................................. 52

6 CLOSING ........................................................................................................................ 54

7 APPENDIX INSULATION - Details and calculations .................................................... 55


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EXECUTIVE SUMMARY During the period of March 28th thru April 1st of 2011, ASI conducted an energy audit of the steam system (generation, distribution, and users), and condensate return at the GSK facility in Memphis, Tennessee. ASI estimated the potential energy savings of more than 13% of the current yearly steam and hot water budget ($247,225 NG or 14,292,000 kWh, 27,300 klbs steam), which represents an annual estimated saving of 6,403 MMBTU natural gas or 1,875,413 kWh, and overall (natural gas and electricity) 317 tons of CO2, and $37,038. The electrical consumption will be increased by 58,743 kWh per year. GSK has already implemented many energy savings projects, i.e.:

• Hot exhaust air heat recovery from compressor’s cooling is used as a combustion air for the steam boiler.

• Heat pipe installation on a regeneration service air (before steam coil) on dehumidification systems

• Installation of removable insulation on equipment requiring access for maintenance More projects are expected to be implemented in the next months or year, i.e.:

• Process and utility consumption improvement with the installation of a new mixer for the Dual Salt production

• Automated chemicals fed to the boiler feed water system

• Hot Water heating temperature reset based on outside air temperatures

• Moving some of the hot water wash stations closer to the hot water generation areas It was mutually decided between GSK and ASI that the opportunities for further improvements (cost savings, safety and reliability) are in the following areas:

• The boiler rooms, where the steam and hot water is generated and the equipment is concentrated in one location, represent significant opportunities. Although the system is very efficient, improvements can be made in the boilers tuning and the blowdown reduction. The expected savings from these improvements are 3.1% of the annual fuel consumption.


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• The steam distribution systems always provide opportunities for energy, reliability and safety improvements. Insulation project has been implemented, but there are still areas for improvements. Additional 0.8% savings are expected from insulation and idle lines removal. A steam trap survey is recommended to evaluate the savings due to failed traps, which are expected to be not less than 2% of the steam (not included in this report).

• Steam Users: - The hot water generation is one of the major users of steam. The generation capacities, the distribution, as well as the location of the users lead to inconsistent and unreliable water temperatures, which not only impede the process operations, but are also a safety hazard for the operators. GSK’s request was to emphasize on these projects as a safety and reliability issue. The energy savings are 9.2%. Some of the obsolete NG fired hot water generation equipment will be reinstated to operate, which will save some capital investment. - The six ovens at Dual Salt are the largest steam users in the plant, consuming more than 50% of the steam in the plant. They operate year round with short interruptions between the cycles, while charging and discharging the product inside. A heat recovery was attempted as a project, but due to the size of the duct and the limited air flow, as well the fact that they will be replaced by a newer process in the next couple of years, the project is not recommended

The condensate return does not represent a saving opportunity as all of it is returned to the boiler room. As the steam is distributed at low 13 psig pressure, the flash steam from the condensate (2.8%) is not an issue, nor can it be recovered.


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1 STEAM BUDGET AND SUMMARY OF POTENTIAL SAVINGS Total Annual Steam Generation - 27,300 klbs/yr (12,407 tons) Steam Cost - $6.36/klbs ($14.00/ton) Annual Natural Gas Fuel Budget - $247,225. Estimated Fuel for Steam generation- $163,169, or 66% from total. Below is the summary of identified energy-saving improvements and their estimated annual benefits.

The above savings are calculated based on utility data and costs for the most recent 12 months, and information gathered during the audit. For the systems in which information was not available, engineering assumptions were made based on observations and standard engineering practices. The investment costs are estimated based on data and experience from similar projects ASI has implemented in the past.


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Utility data and costs for the past 12 months.

The natural gas is metered by Constellation Energy for the entire plant. There are two boilers in operation year round. The steam boiler consumes approximately 66% of the NG, and the rest is used by the hot water boiler for building heating purposes. .


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2 OPTIMIZATION PROJECTS 2.1 OPTIMIZATION PROJECT # 1:

Optimize Combustion and Stack Losses - Steam Boiler

Current System Description and Observed Deficiency The plant operates two boilers, one steam and one hot water. The steam boiler is CB200-150ST, and it operates year round to satisfy the process steam needs. The load is generally stable throughout the year varying between 45% and 60% of the burner capacity, averaging 52%, without drastic demand swings triggered by process users. The largest users are the 6 ovens at Dual Salt, but there are never two units that start at the same time and the steam load is not largely affected by starts or stops of operation. The seasonal change is also minimal, as the environment conditions of a majority of the plant is strictly controlled for temperature and relative humidity. The heating load in the winter is close to summer time load due to the steam use for dehumidification purposes. This boiler is fired on NG. The fuel /air ratio is controlled through a mechanical linkage system. There is no oxygen trim system installed. Combustion analysis and tune-ups are performed every year. A combustion test was performed by ASI, which shows more than sufficient air supply and respectively excess oxygen in the flue gases.


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The boiler is not equipped with an economizer, but the flue gas temperature is low and an economizer is not recommended. Flue gas temperatures vary, as observed, from 305°F to 312°F, depending on the firing loads. The combustion air is supplied preheated to 115°F f rom the compressor cooling system. This energy saving project was implemented last year. There is a steam meter installed on the main headers, but there is no separate meter for the NG supply. The boiler’s operation and efficiencies were analyzed for the present conditions, based on the data regarding excess O2%, CO ppm and stack temperature from the last combustion analysis. The radiation losses from the boiler are also included in the following table. .


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GSK is looking to install smaller boiler(s) closer to the users. ASI recommends investigating further options as the largest steam user will be eliminated in 2 to 3 years and the new production equipment would not need as large amounts of steam as the present. Changes in the domestic and process hot water generation are also going to affect the decision and sizing of a new boiler. Discussion Essentials of low excess air boiler operation: Combustion is a chemical reaction in which a

fuel constituent reacts with oxygen to release heat. As a result, all fuels need oxygen, and the natural available oxygen source is air. However, air contains nitrogen that has no role in the combustion reaction except absorption of a portion of the released heat of reaction. Every cubic foot of oxygen brings four cubic feet of nitrogen along with it. This unwanted nitrogen leaves

the boiler stack as a part of waste gases, taking with it a portion of the heat released from the fuel. Hence, the quantity of unwanted nitrogen has to be kept at a minimum by controlling the excess oxygen level in stack gases. There is a belief that maintaining higher excess oxygen than the recommended level ensures complete combustion. This belief is not always true. In some cases badly aligned burners can operate inefficiently (despite high excess oxygen) and have presence of excess oxygen, carbon monoxide, and unburned fuel in stack gases. Therefore maintaining higher excess oxygen than the recommended levels will not help in maintaining efficient boiler operation. The optimum excess air level depends on the type of fuel and burner design. In general, gas burners are designed to operate at 10 - 15% excess air (2% to 3% oxygen in the exhaust flue gas). The recommended excess air level by the burner manufacturer already includes a safety margin. Any additional margin, if maintained, simply lowers the boiler efficiency. The table below provides some general information on typical control limits.


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Optimization The overall conclusion is that the losses from combustion can be reduced and the overall boiler efficiency increased. The path to achieve this can take many directions, the main being:

- Tighter tune up with the existing mechanical linkage - Automated control

Boiler tune up and lower excess air level operation: At proper alignment of the burners, the low excess air level at the boilers can be achieved through the following steps:

1. Stabilize the boiler at given operating load. Note: A minimum of three firing levels are required: low, medium and high.

2. Verify the present combustion conditions with a portable flue gas analyzer capable of measuring Oxygen, Combustibles and CO in stack gases.

3. If Combustibles and CO are not present, in small steps adjust the fuel/air ratio to reduce air supply.

4. Verify the combustion conditions again after 10 minutes of stable boiler condition.

5. If Combustibles are not present, repeat steps 3 and 4 until the oxygen in the stack gas reaches the level recommended by the manufacturer (see table above, 3% for high fire and max 7% at low fire).

A combustion management system incorporating fuel air ratio control, lead/lag sequencing, continuous inline data acquisition and remote control could be installed for even more stable and consistent results, but is not recommended due to the high payback period.


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Savings Properly mixing the fuel and air in the combustion zone and lowering the oxygen (excess air) in the boilers flue gas from the present level down to 4.5% O2 will increase the boiler efficiency and will save $1,589 annually. The savings are calculated based on the past 12 months NG

consumption and the respective calculated efficiencies.

Estimated Investment and Payback The investment to tune-up the boilers is already a part of the annual O&M budget. No additional expense is required.


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Detailed Calculations


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2.2 OPTIMIZATION PROJECT # 2:

Optimize Combustion and Stack Losses – Hot Water Bo iler

Current System Description and Observed Deficiency The hot water boiler is CB760-200, and it operates year round to satisfy the plant winter heating and summer reheating needs. The load is generally stable throughout the year varying between 12% and 50% of the burner capacity, depending on the season. Hot water is generated at 180°F (SP=185°F) and returned at 160°F. A three wa y valve controls the mixing percent between the flow of re-circulated and hot boiler water through the system.

This boiler is fired on NG. The fuel /air ratio is controlled through a mechanical linkage system. There is no oxygen trim system installed. Combustion analysis and tune-ups are performed every year. A combustion test throughout the entire boiler load range was performed by ASI, which shows more than sufficient air supply and respectively excess oxygen in the flue gases.


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The boiler is not equipped with an economizer, but the flue gas temperature is low and an economizer is not recommended. Flue gas temperatures vary, as observed, from 200°F to 275°F, depending on the firing loads. Discussion The discussion about combustion basics described in the previous project is identical and fully applicable to this project.


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Optimization The overall conclusion is that the losses from combustion can be reduced and the overall boiler efficiency increased. The path to achieve this is the same as in Project#1 A combustion management system is not recommended due to the high pay back period. Savings Properly mixing the fuel and air in the combustion zone and lowering the oxygen (excess air) in the boiler flue gas from the present level down to 6% O2 will increase the boiler efficiency and will save $1,910 annually. The savings are calculated based on the past 12 months NG

consumption and the respective calculated efficiencies. Estimated Investment and Payback The investment to tune-up the boilers is already a part of the annual O&M budget. No additional expense is required.


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Blowdown Reduction

Current System Description and Observed Deficiency The continuous blowdown (BD) control is manually adjusted and estimated at approximately 14.5%. Chemicals are added manually to the boiler feed water. The water treatment Consulting Service Report from Chemtreat shows:

- Boiler water conductivity at 3518 µmhos/cm before neutralization and 2115 µmhos/cm neutralized. Present recommended limits for boiler water conductivity are between 1800 µmhos/cm and 2200 µmhos/cm.

- Conductivity of the make-up water (MUW) after the softeners - 146 µmhos/cm, - The condensate conductivity - 7 µmhos/cm. - The feedwater (FW) conductivity - 509 µmhos/cm.

As the boiler feed water is a mixture between MUW and condensate, the high level of conductivity is suspected to be due to chemical addition. The blowdown percent was calculated based on the above data.


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Discussion In the generation of steam, most water impurities are not evaporated with the steam and thus concentrate in the boiler water. The concentration of impurities is usually regulated by the adjustment of a continuous blowdown valve, which controls the amount of water (and with it the concentrated impurities) removed from the steam drum. Too little blowdown will result in sludge deposits and carryover. Too much BD creates excessive removal of hot water resulting in increased boiler fuel, feedwater, and chemical consumption. Therefore, establishing optimum BD levels to maintain acceptable boiler water quality and minimize hot water loss is a significant energy conservation opportunity. ASME guidance document suggests for low pressure, fire tube boilers, water conductivity ranges up to 7000 µmhos/cm without neutralization. The boiler presently operates at much lower limit, as well as the recommended range is low. This Chemtreat recommended range may be discussed in more details to understand the reasons behind it, otherwise the boiler water conductivity limits may be increased. Optimization The high conductivity of the feed water was addressed by GSK and will be improved by the addition of automated chemicals supply. If the feed water conductivity is maintained at the MUW levels, which is higher than normally seen in boiler plants, and the conductivity in the boiler is maintained at the same level as it is now (at the upper recommended limit), the BD will be reduced down to 4.2%. Additional space for improvement of the blowdown percent is available if the boiler water conductivity is increased.


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If the feed water quality does not improve with the automated chemicals supply, ASI recommends the water treatment company investigating the reason for this event, as it is not common. Savings The implementation of this project will save $5,425 annually including fuel, water and sewer charges. Estimated investment and Payback The automated chemical addition is already approved as a project and there is no expected additional investment. The payback is immediate.


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2.4 OPTIMIZATION PROJECT # 4 Remove Idle Piping

Current System Description and Observed Deficiency

During the survey, one pipe in near the Roll Compaction area was identified to be active, while the steam user was removed long ago. The pipe was properly trapped at the end and the condensate returned to the condensate receiver.

More pipes like this can be identified after the Triple Salt process was stopped, but as this area is going to serve the new Dual Salt Mixers, no more examples are provided in the report.

Discussion Abandoned long piping runs lead to thermal losses and requires continuous maintenance. If not drained properly, they also create a potential for water hammer in the system. Optimization ASI recommends all steam & condensate piping not in use to be removed, blanked or isolated and the lines to be drained.


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This will not only save energy, but will also create an opportunity for the rest of the steam and condensate systems to function properly. Savings The implementation of this project will save $141 annually.

Estimated investment and Payback

Budgetary cost for this project is estimated to be $200.

- Included:

• Pipe removal, or materials to blank the pipe, or install an isolation valve.

• Installation by GSK maintenance labor The payback of this installation is expected to be around 1.4 year.


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2.5 OPTIMIZATION PROJECT # 5 Install Removable Insulation


There were few hot surfaces in the plant that had missing or defective insulation, most being valves and fittings or other equipment requiring frequent access for maintenance or repair. The list of the observed bare surfaces, their location and approximate length, as well as summary of heat losses and associated savings are included in a separate Appendix Insulation - Details and Calculations. Discussion The basic reasons for insulation are:

• Energy savings: Insulation is primarily used to conserve energy by reducing heat loss to the atmosphere or reducing heat gain from the surrounding;

• Safety/Personnel protection: Protecting plant personnel from burns by keeping surface temperatures below 140oF.

Insulating steam and hot water piping does not only mean the main piping. The unions, flanges, and valve bodies should be the target of insulation because of their extended surface areas. The heat losses in the steam distribution lines contribute to an increase in the steam load. Condensate lines and receivers should also be insulated to ensure maximum heat recovery. Optimization ASI recommends insulating all bare surfaces above 140ºF, including steam and hot water valves, fittings, and piping. Areas with frequent maintenance should be insulated with removable insulation. The equipment and areas with missing insulation were identified and documented with a picture for easier identification. ASI recommends considering the insulation on a case by case manner and prioritize based on system pressure and actual hours of operation.


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Savings The implementation of this project will save $1,787 annually.

The overall savings from this project are presented in the table below.

The pictures and lists of the observed bare pipes, valves, flanges and fittings, and their locations are included in the detailed tables in an Appendix at the end of this report: Based on these data GSK personnel needs to prioritize and to define the most beneficial areas for insulation. To help the plant personnel with evaluating the energy loss from bare valves, ASI built an energy loss matrix for the most common pressure of the steam and for the variety of valve sizes existing in the plant. The table is built based on the present steam pricing, and should be accordingly adjusted.

Low Pressure Valves


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Estimated investment and Payback Budgetary cost for this project is $3,600. Included:

• Equipment supply (removable insulation)

• Installation by plant personnel. Additional cost will occur if a mechanical contractor is used.

The payback of this installation is expected to be around 2 years. Priority should be given to the steam bare surfaces, year round operations and to the outside locations, if any, which have the quickest payback.


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2.6 OPTIMIZATION PROJECT # 6/6a:

Hot Water Optimization - Dual Salt


A Patterson-Kelly (P-K) Heater is located in the South penthouse. The hot water target temperature is 180°F.

P-K Heater South Penthouse Solenoid Valve open to drain all the time. The P-K heater supplies hot water to 4 users – 3 hose stations and the Dual Salt Mixer. The hot water is routed through the jacket of the mixer to maintain the process temperature (process is exothermic at the beginning) and drained to the sewer outside of the room. The main reason for draining the hot water was reportedly due to leaks from pinch holes between the jacket and the mixer. Due to inconsistent hot water temperatures, many times the operators cannot achieve the desired temperatures at the jacket and are forced to restrict the flow at the P-K heater, which is located 300 ft away. The two hose stations, at Cool Orange and the Mezzanine, are used once per day for less than an hour. They are also used to boost the circulation and opened to drain during a start-up of the mixer.


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The wash down hose in the Dual Salt is used once per month for an hour when the mixer needs to be cleaned. It never operates at the same time with the jacket hot water circulation, as it’s used only during cleaning. Based on the average listed below water consumption the following annual steam, fuel and water usage was calculated.


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Optimization ASI recommends;

• installing an instantaneous hot water heat exchanger (Flo-Rite Temperature 535PP, see cut sheet at the end of this project), at close proximity to the Dual salt mixer (up on the wall outside the room).

• connecting the hoses at the Mezzanine and the Cool Orange to the new system through the existing piping. There will be no recirculation system between the new heat exchanger and the two hoses. Water temperature is not critical for these locations.

• if the water quality in the jacket is good (a new mixer is available for installation, no pinch holes), there are two options for further optimization. The first option is to install a recirculation pump and a mixing head at the Flo-Rite and circulate the water through it, with little addition of heat to the circuit, as needed. The second option would be a heat exchanger to be installed to recover the heat from the drained water by preheating the fresh incoming water before the Flo-Rite. These two options both provide significant opportunities for heat/steam and water/sewer savings.

Piping arrangement for hot and cold water supply to the mixer. The new location of the heat exchanger would be in this vicinity. The operation under the new conditions is reflected in the tables below:


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Savings The savings from this project are calculated in two stages:

- First, the installation of the new heater close to the main user - $6,209 - Second, and more beneficial, if a recirculation is established through the jacket of the

Dual Salt Mixer and majority of the heat, water and sewer are saved – additional $19,546 per year.

The saving calculations details are shown in the following table.

Estimated Investment and Payback Budgetary estimated cost for this project is:

• First stage - $59,400, 9.6 years pay back.

• Second stage – additional $20,000, one year pay back.

• Combined estimate – $79,400, payback 3.1 years.


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Included:

• Data collection of condensate and water quality, flows and capacity of present mixer.

• No additional piping design. Piping by contractor

• Equipment supply (HW instantaneous heater, and heat recovery heat exchanger or pump).

• Installation of equipment, support, relocation of piping (by a mechanical contractor)

• Project management and start-up The payback of this installation is expected to be 3.1 years.


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Hot Water Optimization – Sanitary and Non-Sanitary HW


A P-K Heater supplies HW to the sanitary wash room. The sanitary hot water target temperature is 185°F, which is rarely precisely ach ieved. Connected to this system are two hoses, the Old maintenance room and the BC blending, and one new sink. The temperatures of the water at the point of use vary around +/- 25°F (observed 160°F and 210°F).

P-K Heater Sanitary Dual Flo-Rite Temperature – Non-sanitary. The Non-sanitary system uses two Flo-Rite Temp heat exchangers. Connected to this system is only one hose in the room below. The temperatures of the water at the point of use varies between 180°F and 202°F (as observed). Both of these systems represent a safety hazard for the employees as the temperatures are not consistent and could go above 200°F at any time the system is not in use and the water stays stagnant in the heaters. Details about expected water usage are presented in the table below:


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In the Tripple salt area there is a new Direct contact gas fired heater, AFD 4000, which was recently installed but not used since the process was shut down. The heater has a 4,000,000 BTU/hr heating capacity (66 gpm with a 100°F temper ature rise). The AFD is located approximately 350 ft away from the sanitary wash room.

Optimization ASI recommends;

• using the AFD as a main hot water supply to both Sanitary and non-sanitary wash rooms

• as the maximum achievable temperature will be not higher than 185°F, installing a booster electrical heater will be required. The heater will be capable of raising the water temperature with up to 20°F, to make sure that 190° F is achieved at the point of use.

• as the present systems are not connected, new piping needs to be installed between the AFD 4000 and the two hot water generation points at the moment. From this point onthe existing piping system will be used.


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• no recirculation system will be installed, as the hot water usage at both sanitary and non-sanitary washrooms are used once or twice per day, and the losses of the circulation would be higher than the heat needed to initially heat up the piping during usage.

The temperature of the water should never exceed the 190°F at the point of use. The operation under the new conditions is reflected in the tables below:


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Savings The savings from this project will be $189, but the safety and the reliability of the system will be improved. The saving calculations details are shown in the following table.

Estimated Investment and Payback Budgetary estimated cost for this project is $71,300

Included:

• No additional piping design. Piping routed by contractor


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• Equipment supply (electrical HW heater, 144kW. The existing AFD4000 and pump are going to be used as they are, without changes.

• Installation of equipment, support, tie-in to existing piping (by a mechanical contractor)

• Project management and start-up The payback of this installation is not acceptable from energy savings point of view, but the project should be considered as a safety and reliability improvement.


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Hot Water Optimization – Domestic HW


There are 15 sinks in the wash rooms around the plant, all of them supplied by the Flo-Rite Heat exchanger in the South Penthouse.

Flo-Rite South Penthouse – Domestic HW. All of these sinks are used as needed for a combined time of not more than an hour per day.


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Optimization ASI recommends installing electric heaters at the point of use, combining 2 to 3 sinks together with one heater, as the existing piping infrastructure dictates. The present HW generation system would be abandoned and all the losses related to distribution eliminated. The maintenance expenses will be also decreased. The operation under the new conditions are reflected in the tables below:


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Savings The heat loss and hot water run time is expected to be much less, if this project is implemented, but the savings will be only $248, as the electrical cost for heating is higher than the steam heating. The saving calculations details are shown in the following table.

Estimated Investment and Payback Budgetary estimated cost for this project is $6,000

Included:

• No additional piping design.

• Equipment supply (electrical HW heaters, 3kW or as needed). Installation of equipment, support, tie-in to existing piping (by a mechanical contractor)

• No project management and start-up. The payback of this installation is expected to be 24 years.


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3 CHECK LIST VERIFICATIONS COMPLETED DURING THE AUD IT


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4 RECOMMENDED ADDITIONAL STUDIES

4.1 OPTIMIZATION PROJECT # 9 Steam Traps


There are around 120 steam traps installed presently at the plant. A complete steam trap survey was performed in 2008 by the Armstrong Rep. The results from this trap survey show that a total of 69 traps were checked (the rest were out of service) and 3.3% of the traps have been identified as failed in blowing through (BT- 4 trap), or Plugged (PL – 1 trap) condition. The results are presented in the Executive Summary Reports from Steam Star:

- Condition Summary - Trap Type Summary - Application Summary - Manufacturer Summary - Annualized Loss Summaries - a total breakdown of estimated steam and monetary loss


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During the survey, the following system deficiencies were observed:

• Improper installation of a steam trap (“master” traps) • Improper installation of a steam trap (tilted, not vertically installed traps)

Details of the observed deficiencies are shown in the Section 5 - Additional Observations and Recommendations. Discussion The basic reasons for steam trap surveys and subsequent actions, i.e. repairs or replacements are:

• Energy savings: blowing through and leaking traps are wasting 100% of the fuel, water and chemicals used in the process of steam generation;


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• Reliability and performance improvements: Undersized traps, plugged traps, or bad piping practices lead to energy and performance inefficiency, low steam quality, losses and safety concerns. Equipment becomes damaged (water-hammered and/or corroded) thus prompting increased manpower for maintenance and opportunity for failures.

Best Practices Recommended Testing Schedule for Steam Traps For maximum trap life and steam economy, a regular schedule should be set up for trap testing and preventive maintenance. Trap size, operating pressure and importance determine how frequently traps should be checked.

Optimization In order to maintain a low steam trap failure rate, ASI recommends establishing a preventive maintenance program to manage the entire steam trap population. This requires that all traps are tagged and recorded to maintain a steam trap inventory. Scheduled surveys should be performed to ensure that all traps are properly operating and to identify failures and prevent losses as soon as possible. ASI recommends, after the complete (100% of the trap population) steam trap survey, repairing/replacing all identified failed steam traps. The details of the trap survey and its results would be available on SteamStar trap management online platform, accessible via the GSK – Armstrong dedicated web site. Recommendations for steam trap replacement, as needed, will be based on steam operating conditions and specific application.


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Savings

The savings from the repair/replacement of the failed steam traps will be calculated as a result of the complete Steam Trap Survey. The steam savings consists of a reduced amount of purchased steam and contributes to a reduction in the CO2 emissions. The savings will be calculated based on the type of trap, orifice size, trap application and inlet steam pressure. The steam cost is based on the provided utility costs. The replacement or repair of the failed traps after a steam trap survey normally saves between 2% to 5% of the purchased steam, which corresponds to $3,200 to $8,200 annually. To define the exact benefits a complete steam trap survey will be needed.

Estimated investment and Payback

Complete steam trap survey cost - $4,000. This includes a survey and a one-time $500 fee for Steam Star access. Steam traps repair cost will be defined after the 100% steam trap population survey. The payback of the trap repairs is expected to be between 1 and 2 years.


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4.2 Heat Recovery from the Oven’s exhaust

There are 6 ovens, 3 old and 3 new, to dry the product after the mixing takes place in the Dual Salt Mixer. The cars are loaded inside, and the air is circulated and heated to 185°F. The fresh air supply is taken from the hallway where the ovens are located and it has a constant temperature of around 70°F year round. The flow is not known. The exhaust flows are manually adjusted through the duct dampers. The air leaving the system is hot (185°F) and moist, and contains fine particles of powder from the product.

For some of the old ovens it was reported that the heat up time is longer than the others and sometimes it takes up to 45 minutes to achieve the target 185°F temperature If the incoming air is preheated by the exhaust air, the heat up cycle time will be significantly decreased. The ovens are the bottleneck for the process, as the mixer can produce higher outputs, and the entire process as a whole can generate more yield if the ovens heat up faster.


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The existing ovens are expected to be obsolete in 2.5 to 3 years when the new mixers/dryers would be installed.


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4.3 New Boiler Installation Evaluation

In 2008, SSR Ellers Inc. performed a feasibility study regarding an on-site installation of small LP at-point-use Patterson-Kelly boilers to replace the existing steam boiler. In the long term, GSK would like to reduce or eliminate the steam usage. Present steam users are:

• Dual Salt Ovens – 6 units

• Hot Water Generation – 4 units

• AHUs dehumidification units – 6 units

• AHU Heating coils – 5 units Boiler’s Manpower Requirements and Efficiency Rating Based on the codes and regulations to avoid the increase of labor cost (certified operator or stationary engineer), a LP condensing boilers with 90% to 97% efficiency were proposed for installation in 2008. Savings The maximum expected present heat generation efficiency is 82.7%. For 12 months a total of 48,765 MMBTUs were used. The following savings are a comparison of the fuel consumption at different boiler efficiencies.


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Any other conditions in between can be easily calculated. The savings of this project are highly dependent on the actual steam demand and the natural gas cost. Confirmed numbers for natural gas and detailed investment estimates need to be performed to evaluate further this opportunity: It is recommended to re-evaluate it after the other projects are implemented and the steam demand has a more defined load pattern.


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5 ADDITIONAL OBSERVATIONS AND RECOMMENDATIONS

This chapter will cover observed deficiencies not related to energy savings but are vital for the safe and reliable operation of the plant. 5.1 Piping Practices and Steam Traps Installation During the survey, the following piping practices and deficiencies were observed:

Location Problem – Discuss - Recommend Picture

Oven

Trap installed at the same elevation as the coil bottom. No drop down after the coil. This piping arrangement prevents the condensate to leave the coil immediately and backs up water to the coil. As water has less heat transfer compared to steam, it will take longer for the air to be preheated. This oven has the worst start-up time and this could be a contributing factor. The elbow out of the coil should be down 90° before the pipe turns horizontal to the trap.

Non-Sanitary

HX

Two HE, one trap – master trapping.

This arrangement prevents the two HXs to function equally efficient, as

there will be always one of them having condensate back-up in it,

while the other operate.

If the system will stay, install second trap at the other HX.


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New mixer

One trap serves 4 jackets - master trapping. The fact that the present trap is down and far away from any of the jackets helps, but it is not a proper piping practice. Install one trap per jacket to prevent water accumulation.

Obsolete HX for the summer reheat

Tilted IB As the IB trap operates at the gravity principal, having a tilted trap will prevent the bucket inside to settle down and will create BT r leaking conditions at the trap. Repipe to true vertical trap installation, to prevent the bucket from sticking to the wall.

AHU Coil

Tilted IB Same as above


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6 CLOSING

ASI appreciates the opportunity to assist GSK with this steam and condensate audit and welcomes the opportunity to be GSK’s energy services partner and provider. We are pleased to report there is potential for significant cost savings in the facility and propose to work with the facility in further development into definitive projects for these findings. A more detailed analysis will confirm payback criteria, and potentially identify additional savings opportunities. Please contact Armstrong Service to define the next steps.


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7 APPENDIX INSULATION - Details and calculation s

Location Description Picture

Boiler room

DA – 2” Pressure Reducing Valve, 2”

Unions

Hallway

Ovens – 1.5” Valve

Hallway

Ovens – 2.5” Elbows

Hallway

Ovens – 1.5” Control Valve


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Hallway

Ovens – 1.5” Control Valve, 1.5” Valve, 1.5”

Unions

Hallway

Ovens – 1.5” Control Valve, 1.5” Valve, 1.5”

Unions

Sanitary

P-K Heater – 2” Strainer, 2” Elbow, 2” Union, 2”

Control Valve, 2” flange, 6” Bottom Heat Exchanger

Non-

sanitary

6” Control Valve Heads


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AHU 17A

1.5” Unions, 1.5” Strainer, 1.5” Pipe

AHU 17B


AHU 17A


AHU 18B

5” x 16” Coil,


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AHU 18B

1.5” Elbows, 1.5” Unions

AHU 19B 1.5” Unions

AHU 19A

1.5” Unions

Near AHU

19A

1.5” Pipe


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Near AHU

19B

3” Valve

Stick Pack

1

2” Valve, 2” Unions, 2” Pipe, 2” Strainer

Roll

Compaction

Reheat Coil – 2” Valve, 2” Unions, 2” Pipe

South

Penthouse

P-K Heater – 2.5” Flanges, 2.5” Control Valve, 2.5” Pipe, 12” Bottom Heat

Exchanger


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Roof

Buffalo AHU, Zones 1 thru 8 – Each has:

1” Unions, 1” Valve, 1” Strainer, 1” Pipe, 1”

Control Valve

Roof Buffalo AHU – 2” Control Valve, 2” Unions

AHU

AHU after Cold Room – 2” Control Valve, 2” Valve, 2” Pipes, 2” Elbow, 2” Tee, 2”

Strainer

HW Boiler

3-way Valve – 6” Control Valve


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HW Boiler

Return Valve – 6” Valve

Oven #3

Steam Supply – Unions, Elbows

New mixer jacket on doors and

port

Door – d5’ x 3” Discharge Area – d2’ x 6” Charging Port – d2’ x 3” Filter Housing – d4’ x 14”

FW Pumps

Supply/Return – 1.25” Pipe, 1.25” Strainer


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GlaxoSmithKline - Armstrong International · 12-05-2011 · Memphis, TN STEAM AND CONDENSATE AUDIT...

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