Steam And Condensate Engineering Audit Stiefel, a GSK company

© 2010 Armstrong International Pvt. Ltd.

Steam And Condensate Engineering Audit

for

Stiefel, a GSK company Rua Prof. Joao Cavalheiro Salem 1081/1301

Bonsucesso, Guarulhos – SP - BRASIL

Prepared for

Mr. Ricardo Carminato

[28th Mar’11 to 1st Apr’11]

Energy Audit for Steam & Condensate System Date: 28-Mar -11

to 01-Apr-11

Stiefel, a GSK Company – SP - BRAZIL Revision 00

Project ID: 90020 of 51

For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar

www.armstronginternational.in

Executive Summary

Armstrong conducted a Steam System Engineering Audit at Stiefel, a GSK company, Sao

Paulo, Brasil during the period of Mar 28 – Apr 01, 2011. The objective of the study was to

identify opportunities for decreasing energy waste (reducing carbon footprint), improving

reliability, decreasing maintenance costs and improving safety. Opportunities identified are

summarized in Table 1.

The energy audit conducted by Armstrong covers the 4 parts of the steam loop: boiler house,

steam distribution, steam consumption and condensate return.

The Boiler house had scope for improvement in reducing the blowdown and reducing the pre

heating temperature of furnace oil. The combustion analysis conducted during audit indicated

that the boiler was operating at good efficiency levels by maintaining close to best in class

excess air levels but was under a cycling loading which resulted in high radiation losses. Also

the flue gas exhaust temperature was close to 200oC which further reduced the steam

generation efficiency.

In general the steam distribution system was found good. The insulation was satisfactory and

there were no major steam leaks which is a indicator of a very good maintenance program

being in place. The main drawback of the distribution system is the absence of flow meters. The

plant does not have meter on steam, water or fuel.

The plant utilises steam for a majority of heating applications either for heating water or for

product heating in the production process. The production process is a batch operation and

some processes run only a couple of times a year. The condensate recovery from the plant is

intermittent due to batch process. As discussed during the kick off meeting, the major issue to

concentrate on was to find initiatives that will lead to energy and carbon dioxide emission

reduction with low capital investment.

We estimate the potential energy savings of 40.26% of the current yearly fuel bill for steam

and compressed air generation which represents a yearly saving of about 126 tons of CO2 and

94.3 KBRL.


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Sr.

No.

Description

Financial

Savings

BRL./year

Estimated

Investment

BRL

Simple

Payback

[RANGE in

years ]

CO2

Emission

Reduction

[ton/year] Safe

ty

Main

ten

ance

Pro

cess

1 Replace steam to water

heating by direct water

heater

69400 200000 2.88 115 X X X

2 Reduce steam generation

pressure

908 Nil Immediate 1.9 X X

3 Reduce boiler blowdown 1190 Nil Immediate 2.3 X

4 Increase temperature of

feed water

System Benefit

10000 NA Nil X

5 Reduce Furnace oil pre

heating temperature

91 Nil Immediate 0.11 X X

6 Install pumping trap on

RTR-08, RTR-07, RTR-06

System Benefit

20000 NA Nil X

7 Install Heat recovery unit

on compressor

22803 32000 1.40 7 X

8 Install Steam, water, and

Fuel meter for boiler

System

Benefit

20000 NA Nil X X

TOTAL Savings: 94392 BRL /year

(40.26% of total Steam Generation and Compressor Fuel Budget)

TOTAL Fuel Savings: 38.39 ton /year of Furnace Oil

TOTAL CO2 Emissions Reductions: 126 ton/year

Table 1 : Optimisations Identified during Audit


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Note: Values marked as NA imply a requirement of in-depth review to ascertain confirm saving potential Savings are calculated on only heat recovery basis. Savings are based on the data furnished by the plant head and data collected during the study period. Investment considered for the payback calculations are based on budgetary prices of the items considered

and may change depending upon implementation time & the prevailing market situation. At an Audit level investments are calculated with an accuracy of ±25%.

The above investment and saving estimates are developed according to standard engineering

practices and are based on Armstrong’s extensive experience in steam and utility systems.

More accurate investment estimates will be available after the scope of work to be done by

AIPL is defined and jointly agreed upon by both GSK and AIPL as well as upon completion of

Detailed Engineering Design.


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Acknowledgement

An Engineering Audit is a venture between Energy Experts and Plant Experts to define

opportunities for optimization. The contribution of the plant’s team is extremely important in this

venture. We sincerely acknowledge the contribution of the following dignitaries and site

engineering personnel whose co-operation helped to conclude to the quality of the data analysis

and conclusions.

Mr.Waldimir Benetti

Mr. Aluizio Aaujo Silveira

Mr. Cesar Peixoto de Carvalho

Mr. Luiz Dias

Mr. Jarbas Mingorance

Mr. Ed Carlos

We are also thankful to the other staff members who were actively involved while collecting the

data and conducting the field trials.


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Table of Contents

1 PLANT AND UTILITIES OVERVIEW 8

2 STEAM AND CONDENSATE SYSTEMS OVERVIEW 10

2.1 STEAM GENERATION 10 2.2 STEAM DISTRIBUTION 13 2.3 STEAM USAGE 14 2.4 CONDENSATE COLLECTION AND RETURN 17 2.5 STEAM TRAPS 17 2.6 STEAM COST CALCULATIONS 18

3 ENERGY CONSERVATION MEASURES 20

3.01 ECM 1: REPLACE STEAM TO WATER HEATING BY DIRECT WATER HEATING 20 3.02 ECM 2: REDUCE STEAM GENERATION PRESSURE 24 3.03 ECM 3: REDUCE BOILER BLOWDOWN 27 3.04 ECM 4: INCREASE FEED WATER TEMPERATURE 30 3.05 ECM 5: REDUCE FURNACE OIL TEMPERATURE 32 3.06 ECM 6: INSTALL PUMPING TRAP ON RTR-08, RTR-07 AND RTR-06 33 3.07 ECM 7: INSTALL HEAT RECOVERY UNIT ON COMPRESSOR 36 3.08 ECM 8: INSTALLATION THE FLOW METERS IN SOME LINES. 40

4 CONCLUSIONS AND RECOMMENDED NEXT STEPS 42

5 ATTACHMENT 45

5.1 BOILER INDIRECT EFFICIENCY TEST RESULTS 47 5.2 TRAP SURVEY REPORT 51


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1.0 PLANT AND UTILITIES OVERVIEW


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1 Plant and Utilities Overview

The Stiefel, a GSK company, manufacturers healthcare and pharmaceutical products at the

Guarulhos plant.

Major utilities used in the plant are furnace oil, Diesel, compressed air, electricity and water.

There are no meters to measure or record the steam generated in the previous year; similarly

there is no metered data for fuel and water consumption. The fuel readings are taken on an day

to day basis on the level maintained in the tank.

Based on the data available with the plant the total furnace oil consumption during previous year

is 115450 litres which accounts for approximately 158 KBRL. The compressed air is generated

by an 60 HP air compressor for which the electricity consumption is approximately calculated as

76.3 KBRL.

Energy content and CO2 emissions considered for the different fuels used in the plant are

summarized in Table 2 : Heating Values and CO2 Emissions

Fuel

Heating Value CO2 emissions

HHV Units Qty Units

Furnace oil 10900 kCal/kg 0.26788 kg CO2/kWh

Electricity --- --- 0.089 kg CO2/kWh

Table 2 : Heating Values and CO2 Emissions


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2.0 STEAM AND CONDENSATE SYSTEM OVERVIEW


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2 Steam and Condensate Systems Overview 2.1 Steam generation

I. Boilers Description The Stiefel plant boiler house consists of a two Furnace oil / Diesel fired fire tube boiler which

generates steam at 9 barg and saturation temperature to provide steam to process. One boiler

is under continous operation whereas the other boiler is standby. During audit boiler no.2 was

not operational due to maintenance related to burner control, so the efficiency could not be

tested. The boiler uses diesel as a startup fuel and furnace oil as primary fuel. The boiler is not

equipped with flue gas exhaust heat recovery equipments like Air Pre Heater (APH) and

Economizer; so the final stack temperature at outlet is measured as 200˚C.

More details about the boilers are provided in following table:

Boilers # Units 1 1

Manufacturer Tenge Tenge

Type WT/FT FT FT

Rated Capacity kg/h 3200 2000

Rated Pressure kg/cm2g 10.5 10.5

Rated Temperature oC Sat. Sat.

Operating Pressure kg/cm2g 9 9

Operating Temperature oC Sat. Sat.

Main Fuel Used FO FO

Back-up Fuel Diesel Diesel

O2 Trim Yes/No No No

Economizer Yes/No No No

Air Preheater Yes/No No NO


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Boilers # Units 1 1

VFD on FD Fan Yes/No No No

VFD on ID Fan Yes/No/NA NA NA

Modulated Blowdown Yes/No No No

Table 3 : Steam Boilers Details

II. Indirect Boiler Efficiency

During the study, Armstrong took stack gas measurements to determine the boiler operating

efficiencies. The measurements are summarized below:

Boiler 1

Fuel Used

Furnace Oil

Load % 30--50% Load

O2 in Stack % 4.69

CO2 in Stack % 12.5

Ambient Temperature C 28

Stack Temperature C 200

CO ppm 00

Radiation losses % 3

Indirect Efficiency (HHV) % 82

III. Direct Boiler Efficiency

As mentioned earlier as there are no flow meters to estimate the steam flow and since the boiler

is under cyclic loading it is not possible to determine exact steam generation for determining the

direct efficiency of the boiler.


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III. Boiler Insulation The insulation surface temperature of both the boilers was found to be okay. The average

surface temperature on the front surface was measured as 59C and that at the sides 53C,

back 45C with an ambient temperature of 36C. There was no visible insulation damage. The

average surface temperature was found to be 56C.

IV. Boiler Feed Water System

The raw water from bore well is stored in a storage tank and from there routed to reverse

osmosis (RO) plant. The water from these treatment plants is transferred to storage tank where

condensate from plant is also added. From here the boiler feed water pumps water to de-

aerator. The boiler feed water tank does not have steam injection and the average temperature

is close to 55oC. Also the boiler water is dosed with a chemical prior to feeding it to boiler.

The water analysis report is tabulated below:

Conductivity (μS/cm)

Treated Water 0.92

Treated + Condensate 175

Raw water 92

Condensate 5.8

Boiler 595

Table 4 : Water Analysis Report

The test results show that the boiler water treatment was within limit parameters and the

condensate was free of any major contamination.


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V. Boiler Blowdown The boiler do not have automatic blowdown control system and the manual practice of once a

hour blowdown is followed. It was observed that there is no practise of testing the conductivity

or TDS of water samples; only the PH of the water samples is tested.

It is recommended to check TDS of the boiler every 8 hours to monitor the heath of water in

boiler.

The present manual blowdown system is inconsistent in maintaining the blowdown and depends

on operator’s judgement with no parameter being monitored or controlled.

2.2 Steam distribution

I. Steam Distribution Network

During audit, the 3.2 TPH boiler was operated at 30 to 50% load to match the plant steam load.

There are no steam flow meters in the distribution network too.

The overall insulation was found in good condition and there were no major steam leaks except

for one near the kitchen hot water PHE control valve.

The condensate drains are correctly designed with adequate strainers and moisture seperators

before the pressure reducing stations and equipment temperature control valves.

II. Steam Lines Sizing

During our Audit we have checked the sizing of the main distribution lines, results are tabulated

in Table 5


to 01-Apr-11





Sr.

No

Line Description Line

Size

NB

Pr.,

Kg/cm2

g

Flow

(Max)

T/hr

Velocity

m/s

ΔP

Kg/cm2

per 30m

Remark

1. Boiler to Distribution

header 250 9 3.5 3.9 0.001 Ok

2. Main distribution line 150 9 3.5 10.7 0.01 Ok

3. Line to PHE 80 3 0.8 20.5 0.03 Ok

4 Line to Fuel oil tank 50 9 0.5 13.8 0.05 Ok

Table 5 : Sizing of Main Steam Lines

2.3 Steam usage

As discussed earlier, Stiefel has steam generation mainly for water and product heating. A

majority of the applications are for low grade heating (less than 70oC) which can be replaced by

an efficient water heating system.

The product heating is done in jacketed vessels which operate on a batch process which is

inconsistent and varies from twice each day to once a month. Due to such random operation the

boiler operation is cyclic and cannot be averaged for operation.

2.3.1 Steam users

Based on the data given by the plant and observations made during visit, an estimate of steam

consumption is tabulated below:

Overall Steam Consumption (Kg/Week)

COSMETICS 1908 Production

CREAMS 1689 Production

Water Heating 22365 Kitchen, plate heat exchangers


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COSMETICS CONSUMPTION (Kg/Week)

RTR-05 341 Equipment



MIS 03 16 Equipment


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CREAMS CONSUMPTION (Kg/Week)

RTR-08 1287.10726 Equipment



OTHER AREAS CONSUMPTION (Kg/Week)

KITCHEN 400 PHE

AIR CONDITIONING 2327.462717 PHE

DYNAFLO 1000 Mixer


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2.4 Condensate collection and return

During the audit it was observed that the steam traps on the equipments pump condensate to

the common condensate header. Most of the condensate lines have a compressed air purging

which flushes out condensate from the equipment at the end of the batch. There are no

mechanical or electrical pumps for pumping of the condensate.

2.4.1 Condensate Return Rate

The condensate return rate on an average is approximately 80% of the total steam generation

as all the equipments excepts the steam / water mixers are indirect heating applications.

2.5 Steam Traps

During the trap survey 38 steam trap locations were checked with ultrasonic steam trap leak

detector to validate working, selection and installation. The summary of trap survey is as below


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A few traps were closed with bypass open as the traps were waterlogged during process. This

is not a good practice as opening of bypass means leaking of live steam and the correct solution

is to replace the failed steam traps.

2.6 Steam Cost Calculations

Due to no record of steam generation, based on non accurate steam consumption the steam

cost is calculated as 123.4 BRL/ton.


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3.0 ENERGY CONSERVATION MEASURES


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3 Energy Conservation Measures

3.01 ECM 1: Replace steam to water heating by direct water heating

Current System Description and Observed Deficiency

During the Audit, it was observed that the major steam consumption in the plant was for water

and process heating application. The heating temperature required in most of the applications

was less than 80oC and either a plate heat exchanger or a portable steam water mixer was used

for heating water with steam. In the process (production) steam was used in jacketed vessels to

heat the product from ambient temperature to 70oC / 80oC.

There is no application which requires the product or water above the atmospheric evaporation

temperature of water.

As discussed in earlier steam generation section, the boiler is under cyclic loading and

operating at an efficiency of approximately 75%. The steam generated in boiler then is made

available to the point of use in the plant at required pressures maintained by the individual

pressure reducing valves.

Since the operating pressure for the jacketed vessels and other indirect heat exchangers is very

low and the back pressure due the elevation of the condensate header acting at the outlet of the

trap, the condensate undergoes sub-cooling thereby contributing to the energy loss.

Technical Discussion

Presently, the boiler operates at 75% efficiency, which means out of the total fuel energy fired in

the boiler only 75% transforms into usable steam energy. This boiler generates steam at 10 bar-

g which has to be carried to the process plant where applications require steam at a pressure

lower than 3.5 bar-g. During this process there is a distribution loss of another 1% to 5%

depending on insulation health and leaks. Further the heat transfer loss in the heat exchanger

accounts for another 1% to 2%. Thus by the time the fuel energy get available to the water it

loses a significant amount of its energy content.


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Majority of the losses explained above can be avoided if fuel energy is directly utilised for

heating the water by a high efficiency water heater. The gas based water heater can generate

hot water at efficiency close to 99.7% and the distribution losses are less than 1% due to low

temperature and low pressure distribution which significantly reduces insulation loss and leak

losses. Since the water gets directly used for heating or CIP there is heat exchanger required

for this system.

Fig: Existing system V/S Improved System


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Recommended Optimisation

Armstrong recommends

Replacing steam based water heating by direct hot water

Installing a high efficiency direct fired hot water generator

Estimated Benefit:

The estimated benefits by reducing excess air are as below:

Replace steam by direct water heating

Hot water Required 2000 kg/h

Temp of hot water 80 Deg C

Inlet water temp 25 Deg C

Heat required 110000 kcal/kg

System efficiency 72%

Fuel Required 14 kg/h

Improved system efficiency 96%

Natural gas required Required 13 kg/h

Savings 14 R$/hour

Annual Monetory saving 69462 R$/year

Present CO2 emission 237623 kg/year

Future CO2 emission 122335 kg/year

CO2 emission reduction 115 ton/year

The implementation of this optimisation will lead to an annual carbon dioxide emission reduction

of 115 MT/year.

The above savings are calculated based on replacement of direct water consumption

applications like kitchen, CIP, cleaning stations, sanitation, etc. The flow rate (2000 kg/h) is an

estimated flow. If the hot water is used for process heating in jacketed vessels, the savings will

be higher. A study to quantify exact requirement of hot water should be done prior to

implementation of this project.


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Estimated Investment and Payback:

The implementation of this energy conservation measure would require an investment of

approximately 200000 BRL which include:

High efficiency direct water heater

Installation

Piping modification

The payback for this optimisation measure would be approximately 2.88 years.


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3.02 ECM 2: Reduce steam generation pressure


The boiler generates steam at 9 bar-g whereas all the steam applications like water heat

exchangers, jacketed process vessels, etc utilise steam at less than 3 bar-g. The steam

distribution from boiler to the plant is at steam generation pressure and the pressure is reduced

at the equipment.

The velocity and pressure drop calculation for existing maximum steam load of 3500 kg/h reveal

that there will be no significant pressure drop and the steam velocities will be less than 20 m/s.


The reduction in steam pressure and temperature:

Will reduce fuel consumption - total heat in steam at 9 bar-g is 3 kcal/kg more than

the total heat in steam at 6bar-g.

Will reduce the standby losses, radiation losses and losses associated with the flash

steam and steam leaks in the pipe joints, valves and fittings.

Will increase the temperature differential between the combustion gases and water,

which increases the heat transfer and boiler efficiency. Since the facility currently

does not have stack economizers to capture energy from stack losses, the reduction

of steam pressure will have a positive impact.

Will decrease scale formation and oxygen corrosion. Scale formation and oxygen

corrosion rise dramatically with boiler pressure. Oxygen corrosion in high-pressure

systems causes pitting on the boiler tubes, which ultimately lead to pinhole leaks.

Scale also reduces heat transfer and efficiency.



Reducing the steam generation pressure


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In order to avoid the potential pitfalls, while implementing this proposal, it is required:

- All PRV’s to be studied (identified and capacity confirmed) for the new conditions. If

needed PRV’s to be replaced or adjusted for the new conditions.

- The steam traps capacities to handle condensate in the steam plant upstream from the

pressure reducing valves to be checked and replaced if needed.

- The boiler feed water pump pressure discharge to be adjusted for the new conditions to

avoid cavitations because of a potential increase in pump flow rates (gpm). This will

also result in some electrical energy savings, which have not been considered in the

calculations.

The pressure reduction should be decreased in 0.5 bar-g intervals. It is required to monitor the

system response for 24 hours to observe steam quality and capacity PRV and pipes. Assuming

the PRV’s are not considered suitable for the lower pressures, replacement/upgrade for the new

conditions will need to be done.

Estimated Benefit:

The estimated benefits by reducing boiler pressure are as below:

Reduce Steam Generation pressure

Fuel Cost 1.66 $R/kg

Boiler efficiency 75%

Steam generation 4227 kg/day

Steam pressure 9 barg

Steam Enthalpy 663 kcal/kg

Feed water enthalpy 55 kcal/kg

Fuel Calorific Value 10900 kcal/kg

Fuel consumption 315 kg/day


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Enthalpy at 6 barg 660

Fuel consumption 313 kg/day

Fuel saving 2 kg/day

Annual Operation 312 days

Annual Fuel Saving 547 kg/year

Annual Monetory Saving 908 $R/kg

Energy Savings 6937 kWh

CO2 Savings 1.9 ton/year

The implementation of this measure will lead to an annual reduction in BPF consumption by

approximately 547 kg/year. The total CO2 reduction will be approximately 1.9 ton/year.


The implementation of this energy conservation measure does not require any investment

except for some man-hours during the trial period.

The payback for this optimisation measure would be Immediate.

Note: If it is observed that the existing PRV’s are not capable for the pressure reduction, then it

is recommended to generate steam at higher pressure as the investment for new PRV’s will

have long payback.


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3.03 ECM 3: Reduce Boiler Blowdown


The boiler has a intermittent manual blowdown which was found to be inconsistent and operator

depended. It was observed that the operators depending upon their judgement gave a

blowdown ranging from 3 to 6 seconds per hour. During analysis it was observed that the

present blowdown was higher than that required for the current water parameters.


Even with the best pretreatment programs, boiler feed water contains some degree of impurities

such as suspended and dissolved solids. As water evaporates, these impurities are left behind

and accumulate inside the boiler. The increasing concentration of dissolved solids leads to

carryover of boiler water into the steam, causing damage to piping, steam traps and even

process equipment. The increasing concentration of suspended solids forms sludge, which

impairs boiler efficiency and heat transfer capability.

To avoid boiler problems, water must be periodically discharged or “blowdown” from the boiler

to control the concentrations of suspended and total dissolved solids in the boiler water. Surface

water blowdown is often done continuously to reduce the level of dissolved solids, and bottom

blowdown is performed periodically to remove sludge from the bottom of the boiler.

If the blowdown rate is too high, energy (water, fuel, chemicals) is wasted. If high

concentrations are maintained, (too low blowdown) it may lead to scaling, reduced efficiency,

and to water carryover into the steam compromising its quality (wet steam)

The ASME guidelines "Consensus on Operating Practices for the Control of Feed water and

Boiler Water Quality in Modern Industrial Boilers," shown in the tables below, are frequently

used for establishing optimum blow down rate.

http://www.gewater.com/handbook/boiler_water_systems/Table13-2.jsp

http://www.gewater.com/handbook/boiler_water_systems/Table13-2.jsp


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Water Chemistry for Water tube Boilers - ASME Guidelines



Reducing the blowdown

It is recommended to install a automatic blowdown controller for maintaining the correct

blowdown, but since the steam generation and operational hours are very low, this measure

cannot be economically justified.

So a fixed orifice of 3mm is recommended to be placed into the blowdown line which will

maintain the boiler water TDS within required parameters.


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Estimated Benefit:

The estimated benefits by reducing blowdown are as below:

Reduce Boiler Blowdown

Present Blowdown 320 kg/day

Boiler conductivity 4477 μs/cm

Feed water conductivity 175 μs/cm

Steam generation 4227 kg/h

Blowdown required 172 kg/day

Heat in blowdown 182 kcal/kg

Enthalpy in feed water 55 kcal/kg

Energy Saving 18799 kcal/day

Fuel Saving 2.3 kg/day

Annual monetory Saving 1190 R$/year

The implementation of this measure will lead to an annual reduction in BPF consumption by

approximately 717 kg/year. The total CO2 reduction will be approximately 2.3 ton/year.


The implementation of this energy conservation measure does not require any major investment

except for Orifice Plate and Labour

The payback for this optimisation measure would be Immediate.

Note: It is advised to consult the water treatment chemical supplier and ensure that this initiative

will not have any adverse effect on the boiler.


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3.04 ECM 4: Increase feed water temperature


During audit it was noticed that the boiler feed water temperature was approximately 60oC and

the feed water tank did not have any steam injection practice to increase the feed water

temperature. The condensate return from the plant was mixed with the treated make up water at

room temperature prior to feeding to boiler.


In the de-aerator, dissolved gases, such as oxygen and carbon dioxide, are expelled by

preheating the feed water before it enters the boiler. All natural waters contain dissolved gases

in solution. Certain gases, such as carbon dioxide and oxygen, greatly increase corrosion.

When heated in boiler systems, carbon dioxide (CO2) and oxygen (O2) are released as gases

and combine with water (H2O) to form carbonic acid, (H2CO3). Removal of oxygen, carbon

dioxide and other non-condensable gases from boiler feed water is vital to boiler equipment

longevity as well as safety of operation. Carbonic acid corrodes metal reducing the life of

equipment and piping. It also dissolves iron (Fe) which when returned to the boiler precipitates

and causes scaling on the boiler and tubes. This scale not only contributes to reducing the life of

the equipment but also increases the amount of energy needed to achieve heat transfer.

Removal of oxygen and carbon dioxide can be accomplished by heating the boiler feed water,

which reduces the concentration of oxygen and carbon dioxide in the atmosphere surrounding

the feed water. Below graph shows concentration of Oxygen at different feed water

temperature.


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Above graph shows that present Dissolved Oxygen level in feed water is in the range of 7 ppm

to 8 ppm at 30 C, with thermal de-aeration it can be reduced to below 2 ppm by increasing the

feed water temperature above 95 oC. This will increase the boiler tubes life & reduce down time,

tube leaks problems.


Armstrong recommends purging of steam into the feed water tank so as to maintain the feed

water temperature above 950C.

Estimated Benefits:

The implementation of this optimisation measure would lead to system benefits and reduced

maintenance cost. Some of the key benefits are:

Improved boiler steam generation capacity

Reduced oxygen in feed water

Prolong life of boiler tubes

Reduced maintenance downtime

Estimated Investment:

To preheat investment is estimated as BRL 10,000 which includes:

Piping

Steam Injector

Temperature Control Valve

Instrumentation


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3.05 ECM 5: Reduce Furnace oil temperature


During audit it was noticed that the furnace oil tank was heated to temperature above 85oC

which resulted in generation of furnace oil fumes from the tank. These fumes not only are

resulting in loss of fuel but also not good for human health. It also may lead to fire hazard if the

temperature reaches close to flash point of the oil.


For maintaining the viscosity of furnace oil, it is required to pre heat the furnace oil. This pre-

heating helps in pumping of the oil as well as in better combustion of the oil in the burner.

Excessive heating beyond a certain temperature may lead to health and safety hazards.


Armstrong recommends maintain the furnace oil temperature close to 80oC.

Estimated Benefits:

The implementation of this optimisation measure would lead to system benefits, safety and

health. A little monitory saving can also be achieved by reduction in steam consumption for

heating:

Reduce Furnace Oil Temperature

Present FO temp 87 deg C

Recommended Temp 80 deg C

FO flow 98133 kg/year

Specific heat of FO 0.52 kcal/kg K

Heat saving 357202 kcal/year

Fuel Saving 55 kg/year

Monetory saving 91 R$/year


There is no investment required for this initiative and payback is Immediate.


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3.06 ECM 6: Install Pumping trap on RTR-08, RTR-07 and RTR-06


During audit it was noticed that the bypass line of the trap on RTR-08 was open and the

condensate along with steam passing. It was then understood from operator that the

condensate does not get discharged from the trap and so the bypass line is kept open.

The jacketed vessel RTR-08 heats the product usually to 90oC and for this purpose utilises

steam which is controlled by a temperature control valve. The condensate formed has a back

pressure of approximately 0.5 barg due to the elevation of the condensate return line.

Other jacketed vessels viz., RTR-07 and RTR-06 have an auxiliary air purging arrangement

which ensures that the condensate is flushed out from the jacketed vessels and do not face a

situation of stalling of condensate. But the operators have a practise of opening the bypass line

at the start-up so as to drain out any steam. This practice leads to energy loss which is difficult

to quantify but is not a good engineering practise.


Stall occurs primarily in heat transfer equipment where the steam pressure is modulated to

obtain a desired output (i.e. product temperature). The pressure range of any such equipment

(coils, shell and tube, etc.) can be segmented into two distinct operational modes: Operating

and Stall.

Operating: In the upper section of the pressure range, the operating pressure (OP) of the

equipment is greater than the back pressure (BP) present at the discharge of the steam trap.

Therefore a positive pressure differential across the trap exists, allowing for condensate to flow

from the equipment to the condensate return line.

Stall: In the lower section of the pressure range, the operating pressure (OP) of the equipment

is less than or equal to the back pressure (BP) present at the discharge of the steam trap.


to 01-Apr-11





Therefore, a negative or no pressure differential exists; this does not allow condensate to be

discharged to the return line, and the condensate begins to collect and flood the equipment.


Armstrong recommends installing a pump and trap (mechanical steam operated pump)

combination package for recovering condensate from RTR-08, RTR-07, RTR-06 and reduce the

energy loss.

Estimated Benefits:

The implementation of this optimisation measure would lead to system benefits and reduced

maintenance cost. Some of the key benefits are:

Continuous drain of condensate

Mechanical pump so safe in inflammable area

Reduced maintenance downtime

Better heat transfer


to 01-Apr-11






To preheat investment is estimated as BRL 20000 which includes:

Piping

Pumping trap (Pump Trap combination)

Installation

Labour


to 01-Apr-11





3.07 ECM 7: Install Heat recovery unit on compressor


During the Audit, it was observed that the facility has two 60 HP air compressors. One of the

unit is continuously operational whereas the other acts as an standby which turns ON when

there is a increased demand.

The existing compressors are oil cooled type and there is no heat recovery on them. The hot air

blast is open to atmosphere.


Air compressors account for significant amount of electricity used in industries. Air compressors

are used in a variety of industries to supply process requirements, to operate pneumatic tools

and equipment, and to meet instrumentation needs. Only 10 – 30% of energy reaches the point

of end-use, and balance 70 – 90% of energy of the power of the prime mover being converted

to unusable heat energy and to a lesser extent lost in form of friction, misuse and noise.


to 01-Apr-11





(Source: BEE, INDIA)

The compressing of air gives off heat. The heat energy is concentrated in the decreasing

volume of air. To maintain proper operating temperatures, the compressor must transfer excess

heat to a cooling media before the air goes out into the pipe system. As much as 90 percent of

that heat can be recovered for use in operation which can supplement or replace the electricity,

gas or oil needed to create hot water for washrooms, or direct warm air into a workspace,

warehouse, loading dock, or entryway, the savings can really add up. The energy recovered by

means of a closed loop cooling system (for water cooled compressors) is advantageous to the

compressor's operating conditions, reliability and service life due to an equal temperature level

and high cooling water quality to name but a few. The temperature level of the recovered energy

determines the possible application areas and thereby the value. In the highest temperature

levels (from oil free compressors) the degree of recovery is the greatest. The highest degree of

efficiency is generally obtained from water cooled installations where the compressor discharge

cooling water can be connected directly to a continuous process heating requirement.. Surplus


to 01-Apr-11





energy can then be effectively utilized all year round. Most new compressors from the major

suppliers can be adapted to be supplemented with standard equipment for recovery.

Energy recovery from air cooled compressor installations will not always give heat when it is

required and perhaps not in sufficient quantities. The quantity of recovered energy will vary if the

compressor has a variable load. In order for recovery to be possible a corresponding energy

requirement is needed, which is normally met through an ordinary system supply. Recovered

energy is best utilized as additional energy to the ordinary system, so that the available energy

is always utilized when the compressor is running.



Installing a heat recovery unit

Estimated Benefit:

The estimated benefits by reducing excess air are as below:

Source: Atlas Copco Manual

Based on the information provided by Atlas Copco heat recovery manual, the estimated benefits

by installing a heat recovery unit are:


to 01-Apr-11





Compressor Heat Recovery

Hot water flow 402 kg/h

Rise in temp 70 Deg C

Heat recovery (80%) 22512 kcal/h

Annual Fuel saving 13747 kg/h

Monitory Saving 22803 $R/year

CO2 saving 7.0 ton/year

The implementation of this measure will lead to a annual reduction in BPF consumption by

approximately 13 ton/year. The total CO2 reduction will be approximately 7 ton/year.


The implementation of this energy conservation measure would require an investment of

approximately 32000 BRL which include:

Heat recovery equipment – 23000 BRL

Installation & Piping modification – 7000 BRL

Storage tank – 2000 BRL

The payback for this optimisation measure would be approximately 1.40 years.

Note: The quote for price of heat recovery unit was provided from Atlas Copco


to 01-Apr-11





3.08 ECM 8: Installation the flow meters in some lines.


During the audit, it was observed that there are no flow meters installed on the steam, water line

and the fuel line. The plant presently cannot measure the production, consumption and

distribution this resources in the plant. Because of this fact there is no way to make exact

calculations for efficiency, track the expenditure or verify opportunities for savings or even

implement programs that help to decrease the consumption.


For the good operation of any plant, the control over the utilities is of utmost importance, in this

case the utilities being steam, water and fuel. It’s necessary to meaure with a flow meter each

lines, to establish a control and define, if it’s possible to reduce the consumption or the

efficiency of the equipments, that aren’t the best. The installation the flow meters in water line,

fuel line and steam line contribute to set up a base to develop the programs for checking

consumption, possible leaks, loss and savings that would be present in the different lines. .

Recommended Optimization

Armstrong recommends the installation the flow meter in different sections of the plant and the

main headers for distribution of steam and water. The same applies for the fuel line.

Estimated Benefits

The benefits of implementation of this optimization are various, beginning from establish

measures that help to know that efficiency and use correct of the resources (fuel, water and

steam).


to 01-Apr-11





4.0 CONCLUSION AND RECOMMENDED NEXT STEPS


to 01-Apr-11





4 Conclusions and Recommended Next Steps The Steam and Condensate Engineering Audit has defined a total potential of 2,77,74,206

Rs./year savings that are summarized in the following table.

Sr.

No

Description

Elec

MWh

Fuel

ton /y

Water

KL /y

Financial

Savings

Rs./year

CO2 Emiss.

Reduction

[ton/year]

1** Replace steam to water

heating by direct water heater

NA 23.32 NA 69400 115

2 Reduce steam generation

pressure

NA 0.5 NA 908 1.9

3* Reduce boiler blowdown NA 0.7 46 1190 2.3

4* Increase temperature of feed

water

NA NA NA NA NA

5* Reduce Furnace oil pre

heating temperature

NA 0.05 NA 91 0.11

6* Install pumping trap on RTR-

08, RTR-07, RTR-06

NA NA NA NA NA

7 Install Heat recovery unit on

compressor

NA 13.7 NA 22803 7

8* Install Steam, water, and Fuel

meter for boiler

NA NA NA NA NA

TOTAL NA 38.27 19 94392 126.31


to 01-Apr-11





The savings only include utilities savings. Maintenance, safety and process optimizations are

not represented in those numbers.The projects recommended (indicated with an *) are simple

and do not need any further engineering. Armstrong would be glad to prepare a proposal for

their implementation.

The project marked ** (ECM 1) to be implemented only after implementation of ECM 7.

The other projects will need a step of further engineering to define the exact solution and refine

the investments in order to be able to provide a turnkey proposal.


to 01-Apr-11





Confidentiality Notice

This engineering audit report has been submitted to M/s. Stiefel, a GSK company, Recipient, in

confidence and it contains trade secrets, as well as privileged information, and/or proprietary

work product of Armstrong International Pvt. Ltd. (AIPL), In consideration of the receipt of this

report 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 report 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 AIPL, on a 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 AIPL upon its or their

request.


to 01-Apr-11





5 Attachment


to 01-Apr-11





Attachment 5.1 Boiler Indirect Efficiency Test Results


to 01-Apr-11




5.1 Boiler Indirect Efficiency Test Results

BOILER HOUSE SIMULATION BOILER 1

Boiler operating hours (incl. hot stand-by hours) 8,760 hours/year

1. Fuel power input %LHV

Fuel type: 60 Oil No.6 (bunker C) %HHV

Fuel consumption during operating hours 75.0 l/h

Boiler capacity 3.2 ton/h (=2.2MW)

Specific weight of the fuel 0.86 kg/l

Fuel consumption 64.1 kg/h

Lower heating value (LHV) 40880 kJ/kg

Higher heating value (HHV) 43399 kJ/kg

Fuel unit costs 50 €/MWh HHV (= 0.52€/l)

Fuel power input (LHV) 728.2 kW 100%

Fuel power input (HHV) 773.1 kW

Steam pressure 9 Bar(g) / 179.9°C sat.

Enthalpy steam 2777 kJ/kg

Temperature feed water to the boiler/eco 65.0 °C

Enthalpy feed water 272 kJ/kg

Heat added to feedwater 2505 kJ/kg

Max. theoretical steam production 1.05 ton/h (=0.9 ton/h actual)

2.1 - Combustion losses (dry)

Temperature stack after boiler 200 °C

Temperature ambient air 30 °C

Excess air 27.0 %

Oxygen % flue gas (Dry volume) 4.69 %

Specific Stack flow (dry) 12.82 Nm3/kg fuel

Total stack flow (dry) 822.1 Nm3/h

Total stack flow (wet) 906.3 Nm3/h

Specific heat stack 1.40 kJ/Nm³.K -7.0%

Energy loss in dry stacks 54.50 kW -7.5%

2.2 - Losses due to moisture in fuel

Moisture in Stack 0.000 kg/kg fuel

Specific heat water in fuel 4.18 kJ/kg.K

Specific heat water in stacks 1.8643 kJ/kg.K

Energy losses due to moisture in fuel 0.0 kW on HHV 0.0%

Energy losses due to moisture in fuel 0.0 kW on LHV 0.0%

2.3 - Losses due to H2 of Fuel

Moisture in Stack 0.972 kg/kg fuel

Specific heat water in fuel 4.18 kJ/kg.K


to 01-Apr-11




Specific heat water in stacks 1.8643 kJ/kg.K

Energy losses due to moisture in fuel 47.6 kW on HHV -6.2%

Energy losses due to moisture in fuel 4.3 kW on LHV -0.6%

3. Cycling losses (burner starts)

Hot standby time during operating hours 90 %

Min. burner capacity 1000 kW

Boiler water volume 5.00 m3

Burner on/off pressure differential 1.00 Bar(g)

Purge cycle time 120 sec

Minimum nr. burner starts 0.00 per hour 0.0%

Heat loss purging air 0.00 kW 0.0%

4.1 Economizer (non condensing)

Temperature stack after economizer 200 °C

Economizer inlet water temperature 65.0 °C

Economizer outlet water temperature 65.0 °C

Heat transfer efficiency 100%

0.0%

Power recovered by economizer 0.0 kW 0.0%

4.2 Air preheating from external source (Top of boiler house)

Combustion air required 13.56 Nm3/kg fuel

Total combustion air flow 1017.1 Nm3/h

Normal combustion air temperature 30.0 °C

Preheated combustion air temperature 25.0 °C -0.2%

Power recovered by air preheating -1.8 kW -0.3%

4.3 Air preheat system (closed loop heat recovery from stack after eco)

Temperature stack after air preheater 200 °C

Preheated combustion air temperature 30.0 °C

Energy taken from the stack 0.0 kW

Heat transfer efficiency 100%

0.0%

Power recovered by air preheat system 0.0 kW 0.0%

5. Radiation losses

Boiler AverageLoad 1.62 %

Water Tube Radiation Losses (as per Abma) #N/A %

Fire Tube Radiation Losses (Manufacturer Data) #N/A % Radiation losses considered in calc. 3.0 % -2.8%

Radiation losses 21.8 kW -3.0%

6. Blow down

Conductivity boiler feed water 200.0 µs/cm

Conductivity boiler water 3000.0 µs/cm

Boiler water lost by blow down + carry over 7.1 % of steam output (15cycles)

Boiler feed water flow 0.980 ton/h

Boiler water lost by blow down + carry over 0.065 ton/h


to 01-Apr-11




Ratio of blow down vs carry over 100% blowdown

Carry over 0.000 ton/h

X-value of the steam from the boiler 1.000

Blow down flow remaining 0.065 ton/h

Enthalpy blow down water 763 kJ/kg

Temperature make up water 25.0 °C

Enthalpy make up water 104.5 kJ/kg

Total Blow Down losses (Boiler + Deaerator) 11.9 kW -1.2%

Blow down losses compensated by boiler only 8.9 kW -1.2%

7. Boiler Efficiency and Fuel Costs

Net power output in steam from the boiler 636.8 kW ( 5578 MWh)

Net dry steam production boiler (x=1) 0.915 ton/h = 8015 t/year

Net wet steam production boiler 0.915 ton/h

Boiler efficiency on LHV 87.45 %

Boiler efficiency on HHV 82.37 %

Annual Fuel costs 338,597 €/year Fuel costs / ton dry steam 42.25 €/ton


to 01-Apr-11




Attachment 5.3 Trap Survey Report


to 01-Apr-11




5.2 Trap Survey Report

ARMSTRONG INTERNATIONAL PRIVATE LIMITEDP – 46, Eighth Avenue, Domestic Tarrif Area,Mahindra World City, Anjur Village, Natham Sub,Chengalpattu 603 002India

4/1/11

Sao Paulo, SP

Prepared by:

GSK, Guarulhos

Steam Trap Survey

For:

General Summary

The General Summary reviews the Scope of Work, final reports, and steam losses associated with this steam trap survey.

ARMSTRONG INTERNATIONAL PRIVATE LIMITEDP – 46, Eighth Avenue, Domestic Tarrif Area,Mahindra World City, Anjur Village, Natham Sub,Chengalpattu

Date: 4/1/11To: GSK, Guarulhos Sao Paulo, SPRe: Steam Trap Survey

Between 3/28/11 and 4/1/11 ARMSTRONG INTERNATIONAL PRIVATE LIMITED conducted a steam trap survey at yourfacility.38 in service traps were tested. All failed or defective traps were tagged with a red and white tag for ease in fieldidentification. The field investigation and computer analysis reveals that 2.6% of the in-service traps were found to be defective. Thefailed traps wasting steam resulted in an estimated annualized loss of 31,622 kg of steam and a corresponding monetaryloss of 3,902 BRL. The following is a breakdown of defective traps as a percentage of the total in-service traps:

Blow Thru 0.0%Leaking 0.0%Plugged 0.0%Rapid Cycling 2.6%Flooded 0.0%Cold 0.0% Total 2.6%

Refer to the defective trap report for a complete listing of all failed traps. We thank you for the opportunity to assist in your energy conservation efforts and steam maintenance program. If we canbe of any further service, or if you wish to discuss any aspects of this report, please do not hesitate to contact us.

STEAM TRAP SURVEY SCOPE OF WORK & TECHNICAL SPECIFICATIONS

AT THE JOB SITE

1. All steam traps are located, identified, and tagged with a stainless steel or aluminum tag and clip.

2. Each trap is tested to determine its operating condition. The method used shall include ultrasonic listening and visual inspection where possible (the customer should supply a means to reach traps that are difficult to access, e.g. ladders, forklifts, etc.).

3. A temporary red and white paper tag is attached to each FAILED trap in addition to the stainless steel or aluminum tag.

4. Note is made of specific problems. Some examples are: water hammer, poor or improper insulation, steam leaks in piping or valves, improper installation of traps, and other steam related problems.

5. On-the-job-training is provided to those plant personnel who are helping our Technicians with the survey. One plant maintenance person should accompany each survey team.

6. Trap Survey—Log Sheet Data:

a. Tag Number b. Location c. Elevation d. Manufacturer and Model Number e. Connection Size f. Pressure

i. Pressure In (P.I) – actual steam pressure leading to the trap ii. Pressure Out (P.O.) – actual steam pressure leaving the trap

g. Application (Drip, Tracer, Coil, Process, Air Vents, Liquid Drainer) h. Equipment (Unit Heater, Radiator, Humidifier, etc.) i. Piping (Direction, Valve-In, Strainer, Valve-Out) j. Trap Condition (Operating Mode) k. Comments

Note: All personnel testing traps are certified, factory trained technicians.

Recommended Steam Trap Testing

Procedures

Armstrong International, Inc.

STEAM TRAP TESTING

A combination of testing methods is used in accurately predicting the operating condition of a trap. We recommend the use of an ultrasonic listening device with visual observation when possible. When an atmospheric discharge is not possible, the use of the ultrasonic listening device can be used to determine the operating condition of the steam trap. Temperature measurement cannot show the operating condition of the trap. It is merely a sign of corresponding saturation steam pressure upstream of the trap and pressure on the condensate return system downstream of the trap. Determining the amount of back pressure in the condensate system helps to quantify the amount of live steam lost through a failed trap. The ultrasonic listening device gives a fairly clear understanding of how the trap is operating. A normally operating inverted bucket trap emits a definite burst of sound when the bucket sinks and opens the trap valve, thereby discharging condensate until entering steam floats the bucket and closes the valve. In the presence of extremely low loads, the bucket is heard as a continuous clattering sound. This is sometimes called a “dribbling trap.” This is still a normal operating steam trap with no steam loss. This could also be a sign of an oversized trap, therefore requiring a smaller or restrictive orifice. The normal operating sounds of a float and thermostatic trap are difficult to distinguish as it is a constant flow device with no cycle rate. By shutting off the inlet valve, letting condensate collect, and then releasing a large condensate load to the trap, the trap is heard opening and then modulating down the steady state flow. The thermostatic air vent in a float and thermostatic trap often opens rather infrequently to release air, making its working condition difficult to determine. A thermostatic steam trap has a cycle, but it is much more gentle in nature than the inverted bucket or disc trap. A sub cooling thermostatic steam trap is similar in operation to the float trap. It may have either a bellows or a bimetallic spring as the actuation device, opening and closing the trap according to the set temperature differential.

STEAM TRAP TESTING (Continued)

A final determination of the operation of a steam trap is visual. This test can only be done if there is an atmospheric discharge or test valve. If there is a test valve after the trap, close off the valve to condensate return and open the test valve to the atmosphere. The steam trap will now act as an atmospheric discharge trap. If there is high back pressure in the condensate return system, some generic types of steam traps operate differently when discharging to the atmosphere than to the condensate return system. Therefore it is important to know how the different generic types of traps operate under varying conditions. Opening a test valve ahead of the trap can also determine if the trap is backing up condensate. The actual piping arrangement with the application can give some insight as to freezing problems, formation of vacuum, back pressure and poor piping configurations that may affect the operation of the trap. Use a systems approach when testing steam traps. There are times when, after further investigation, what seems to be a defective trap is actually a piping or application problem. Armstrong International, Inc. Three Rivers, MI Phone: +1 (269) 273-1415 Fax: +1 (269) 278-6555 Web: http://www.armstrong-intl.com

Executive Summary Report

The Executive Summary Report includes the following information:

• Condition Summary - a listing of steam traps by operating mode • Trap Type Summary - a listing of steam traps by generic type • Application Summary - a listing of steam traps by application • Manufacturer Summary - a listing of steam traps by

manufacturer • Annualized Loss Summaries - a total breakdown of estimated

steam and monetary loss

STEAM TRAP EXECUTIVE SUMMARYGSK, Guarulhos - Energy Audit

Survey Date: 3/28/11 - 4/1/11

TRAP TYPE SUMMARY TOTAL ANNUALIZED SUMMARIES

Generic Type Population

Count% of Total Failure

CountIn Service

Failure

DC Disc 20 52.6% 1 5.0% Steam Loss (kg) 31,622FL Float 14 36.8% 0 0.0% Monetary Loss (BRL) 3,902Other 4 10.5% 0 0.0% Fuel used to generate lost steam

(kWh/yr)

31,023

CO2 Emissions (kg) 8,340Totals: 38 100% 1 2.6% SOx Emissions (kg) 208,055

NOx Emissions (kg) 24,295

MANUFACTURER SUMMARY CONDITION SUMMARY

Manufacturer Population


CountIn Service

FailureCondition Population

Count% of Total

SPI Spirax Sarco 34 89.5% 1 2.9% NT Not Tested 6 15.8%Other 4 10.5% 0 0.0% OK Good 31 81.6%

RC Rapid Cycling 1 2.6%Totals: 38 100% 1 2.6%

Totals: 38 100%

APPLICATION SUMMARY

Application Population


CountIn Service

Failure

CL Coil 2 5.3% 0 0.0%DR Drip 24 63.2% 1 4.2%PR Process 12 31.6% 0 0.0%

Totals: 38 100% 1 2.6%

STEAM TRAP EXECUTIVE SUMMARYGSK, Guarulhos - Energy Audit

Survey Date: 3/28/11 - 4/1/11

TRAP TYPE SUMMARY

CONDITION SUMMARY

APPLICATION SUMMARY

Generic Type PopulationCount

% of Total FailureCount

In ServiceFailure

Condition PopulationCount

% of Total Application PopulationCount

% of Total FailureCount

In ServiceFailure

DC Disc 20 52.6% 1 5.0% NT Not Tested 6 15.8% CL Coil 2 5.3% 0 0.0%FL Float 14 36.8% 0 0.0% OK Good 31 81.6% DR Drip 24 63.2% 1 4.2%Other 4 10.5% 0 0.0% RC Rapid Cycling 1 2.6% PR Process 12 31.6% 0 0.0%

Totals: 38 100% 1 2.6% Totals: 38 100% Totals: 38 100% 1 2.6%

MANUFACTURER SUMMARYGSK, Guarulhos - Energy Audit

Survey Date: 3/28/11 - 4/1/11

MANUFACTURER SUMMARY

MANUFACTURER SUMMARY

Manufacturer Population Count % of Total Failure

CountIn Service Failure

SPI Spirax Sarco 34 89.5% 1 2.9%Other 4 10.5% 0 0.0%

Totals: 38 100% 1 2.6%

Defective Trap Report

The Defective Trap Report includes the following information:

• Blow Through, Leaking and Rapid Cycling Traps - a listing of defective traps wasting steam with a condition of BT, LK or RC

• Plugged and Flooded Traps - a listing of defective traps not wasting steam but backing up condensate due to a failed closed (PL) or flooded (FL) condition

PMO

Months/Year

Months/Year

Months/Year

Months/Year

Months/Year

Months/Year

GSK, Guarulhos

Superheat

Superheat

Superheat

Superheat

Superheat

Comments

Comments

Comments

Comments

Comments

1

Process

Val

ve O

ut

PipingLine Sz

1C

Critical Trap

Critical Trap

Critical Trap

Critical Trap

Critical Trap

Receiver

Receiver

Receiver

Receiver

Receiver

MFR Pressure

0 bar15.0

Location

Location

Location

Location

Location

Location

15.0

Model

Frequency

Frequency

Frequency

Frequency

Frequency

Conn Size

1

Application

H41.4 bar

Drip

Route No.

Route No.

Route No.

Route No.

Route No.

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Do not monitor

Do not monitor

Do not monitor

Do not monitor

Do not monitor

Conductive

Conductive

Conductive

Conductive

Conductive

12

123.40 BRL

SPI

Customer

Steam Loss/Yr

NO15.0

Coil

X

5

Condition

Recommendation

Recommendation

Recommendation

Recommendation

Recommendation

Socket-Weld

Outside

Outside

Outside

Outside

Outside

Dis

char

ge

3,902 BRL

Conn Type

Conn Type

Conn Type

Conn Type

Conn Type

Condensate

Installed Date

Installed Date

Installed Date

Installed Date

Installed Date

9.0

Steam Cost

Drain near Boiler enteranceTank 02

Date

Date

Date

Date

Date

Date

TD52

Sup

ply

31,622 kg/yr

Elevation

Elevation

Elevation

Elevation

Elevation

12

RC

Out Out

12

Load

Page

Lift

Follow up

Follow up

Follow up

Follow up

Follow upNPT Pipe Thread

Equip

006 2

Ricardo CarminatoDEFECTIVE TRAP REPORTTechnician

Energy Audit

Str

aine

rInsulation

Val

ve In

Tracer

Check Valve

Check Valve

Check Valve

Check Valve

Check Valve

Dire

ctio

n

Steam

Annual Cost

4/1/11

Temp Alarm

Temp Alarm

Temp Alarm

Temp Alarm

Temp Alarm

Transmitter

Transmitter

Transmitter

Transmitter

Transmitter

Tag#

Tag#

Tag#

Tag#

Tag#

DR C

12

In In

1

Appendix

The Appendix includes the following reference information:

Terminology –a glossary of terms used on survey reports.

Trap Condition Reference –descriptions for each trap conditionreported.

TERMINOLOGY

TERMS DESCRIPTION DEFINITION

TAG NUMBER Trap identification no. A sequence of up to 15alphanumeric characters.

LOCATION Trap location General description of the traplocation, i.e. Building, Floor, Room,etc.

INSIDE/OUTSIDE Whether the trap is locatedwithin a protective structure oris exposed to the elements.

I=Inside, O=Outside

ELEVATION Elevation of the trap Height above/below the floor/groundsurface

MFG Trap manufacturer A three character designation of thetrap manufacturer (e.g.ARM=Armstrong)

MODEL Trap model number The model number designated bythe trap manufacturer.

TYPE Generic type of trap Type designated by single letter, e.g.IB=Inverted Bucket.

CONN SIZE Connection size Connection size of the trap (notnecessarily the same as the pipesize).

INSPECTIONFREQUENCY

Trap inspection schedule Recommended number of times thetrap should be tested in months,(e.g. every ___ months).

TERMINOLOGY(Continued)


EQUIPMENT Equipment beingserviced

Actual equipment being serviced by the steam trap, e.g.Unit Heater.

P –I Pressure In The gauge pressure or nominal pressure on the inletside of the trap.

P –O Pressure Out The gauge pressure or nominal pressure on the outletside of the trap (also called Back Pressure)

SUP Supply side of trap Supply side pressure in terms of C=Constant SupplyPressure; M=Modulating Supply Pressure

RETURN Discharge side of trap Discharge side of trap is either C=Closed or O=Open toatmosphere

APP Application Application serviced by trap, e.g. DR=Drip Trap, etc.

TIME INSERVICE

Amount of annual use The number of hours the trap is under load, expressed inmonthsper year (e.g. 2,160 hours = 3 months).

PIPING Direction of piping H=Horizontal, V=Vertical, etc.

V –I Valve In Type of valve on inlet side of trap (0=None, 1=on/off,2=2 or 3 way valve)

V –O Valve Out Type of valve on outlet side of trap (0=None, 1=on/off,2=2 or 3 way valve)

STR Strainer Type of strainer ahead of trap, 0=None; 1=Inline;2=Inline w/blowdown valve

COND.LOAD

Condensate Load Actual load of condensate at the trap.

COND. LIFT Condensate Lift Actual height condensate must be lifted to overheadreturn.

TERMINOLOGY(Continued)


INSUL Insulation Type Actual type of insulation surroundingpipes and traps, e.g. Asbestos,Calcium Silicate, etc.

CONN. TYPE Connection Type Actual trap connection, e.g.SCR=Screwed, FLG=Flanged, etc.

SUPERHEAT Superheat present Indicates whether superheat ispresent at the trap.

SD Shutdown required Indicates that system or plantshutdown must be initiated to repairthe failed trap.

LINE SIZE IN Line size in Nominal size of the inlet line/pipe

LINE SIZE OUT Line size out Nominal size of the outlet line/pipe

TRAP CONDITION

ABBREVIATION DESCRIPTION DEFINITION

OK Good Trap Trap in normal operating mode.

BT Blow Through Trap has failed in an open mode withmaximum steam loss. Trap shouldbe repaired or replaced.

LK Leaking Trap has failed in a partially openmode with a steam loss ofapproximately 25% of maximum.Trap should be repaired or replaced.

RC Rapid Cycling Disc trap going into failure mode.

PL Plugged Trap has failed in a closed positionand is backing up condensate. Trapshould be repaired or replaced.

FL Flooded Trap is assumed to be undersizedand unable to handle thecondensate load. Trap should bereplaced with proper size.

OS Not in Service The steam supply line is off and thetrap is not in service.

NT Not Tested Trap in service but not tested due toinaccessibility, unable to reach, toohigh, etc.

CD Cold A SteamEye trap sensor hasreported a low temperature reading.

FT Fault A SteamEye trap sensor hasreported a monitoring fault condition.

ARMSTRONGTHEORETICAL STEAM LOSS CALCULATIONS (IP UNITS)

The basic formulas used to estimate the live steam loss of defective traps are as follows:

MASONEILAN’S FORMULA

)())(.( oiV PPPC 12 = Blow Through

Where: CV = Flow Coefficient

∆P = Pi –Po

Pi = Inlet Pressure (psia)

Po = Outlet Pressure (psia)

NAPIER’S FORMULA

))()(.( 04351 APi

Where: A0 = Area of Orifice

These are general formulas used in determining steam loss through and orifice. Basedon data compiled in the field as well as actual test data from our lab in Michigan, certainchanges have been made to these formulas.

In addition to inlet pressure, back pressure, and orifice size, piping configurations,severity of failure, and condensate load influence the quantity of steam loss through atrap. Consequently, service and very light condensate loads as found in drip and tracerservice and the much higher condensate loads associated with coil and processapplications.

Back pressure, service time and modulating conditions are incorporated in thecalculations. Naturally, some information such as how many months a trap operates peryear is determined by data supplied by plant personnel.

ARMSTRONGADJUSTED STEAM LOSS CALCULATIONS (IP UNITS)

Given from trap survey log sheet:

P.I. = Inlet pressure (psig)P.O. = Outlet pressure (psig)

Step 1: Convert pressures to psia:

P.I. + 14.7 = Pi, actual inlet pressure (psia)P.O. + 14.7 = Po, actual outlet pressure (psia)

Step 2: Determine Po , outlet pressure(psia) to be used in calculations:

If Po ≥0.5 Pi, then use Po

If P0 < 0.5 Pi, then use 0.5 Pi

Step 3: Determine ∆P using Pi and Po found in step 2:

∆P = Pi –Po

Step 4: Calculate steam flow or blow through (lb/hr):

)())(.( oiV PPPCW 90 for coil & process applications

)())(.( oiV PPPCW 41 for tracer & drip applications

Where: W = Steam flow or blow through (lb/hr)CV = Flow coefficientPi = Inlet pressure (psia)Po = Outlet pressure (psia)∆P = Pi –Po

STEAM LOSS CALCULATION EXAMPLES (IP UNITS)

A. Coil Application

Given: P.I = 100 psigP.O. = 0 psigCV = 32.1

Step 1: Pi = 100 + 14.7 = 114.7Po = 0 + 14.7 = 14.7

Step 2: 1307114714

..

. < 0.5, therefore

Po = (0.5)(Pi) = (0.5)(114.7) = 57.35

Step 3: ∆P = Pi –Po = 114.7 –57.35 = 57.35

Step 4: 869235577114355713290 ,)..(.).)(.( W lb/hr

B. Drip Application


Step 1: Pi = 100 + 14.7 = 114.7Po = 60 + 14.7 = 74.7

Step 2: 6507114774

...

≥0.5, therefore

Po = 57.35

Step 3: ∆P = Pi –Po = 114.7 –74.7 = 40

Step 4: 912377471144013241 ,)..().)(.( W lb/hr

STEAM LOSS CALCULATION EXAMPLES (IP UNITS)(Continued)

C. Tracer Application


Step 1: Pi = 100 + 14.7 = 114.7Po = 45 + 14.7 = 59.7

Step 2: 5207114759

...

≥0.5, therefore

Po = 59.7

Step 3: ∆P = Pi –Po = 114.7 –59.7 = 55

Step 4: 401475971145513241 ,)..().)(.( W lb/hr

Log Sheet Data

The Log Sheet Data is a complete listing of all trap data as recorded by technicians.

PMO

C

Months/Year

Months/Year

Months/Year

Months/Year

Months/Year

Months/Year

GSK, Guarulhos

Superheat

Superheat

Superheat

Superheat

Superheat

DR

OK

C

Comments

Comments

Comments

Comments

Comments

1

NO

Process

9.0

TD52

004

Val

ve O

ut

Piping

NO

Line Sz

20.0

0 bar

0 bar

2

OK

1

9.0

20.0

C

Critical Trap

Critical Trap

Critical Trap

Critical Trap

Critical Trap

002

Receiver

Receiver

Receiver

Receiver

Receiver

MFR Pressure

C

1 bar

SPI

15.0

10.0 bar

2BPF tank 02

Location

Location

Location

Location

Location

Location

15.0


Model

Frequency

Frequency

Frequency

Frequency

Frequency

Conn Size

Socket-Weld

8

Application

1

H41.4 bar

X

Drip

1

Route No.

Route No.

Route No.

Route No.

Route No.

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Do not monitor

Do not monitor

Do not monitor

Do not monitor

Do not monitor

1C

Conductive

Conductive

Conductive

Conductive

Conductive

12

SPI

Customer

20.0

C

NO

41.4 bar

15.0

Coil

Socket-Weld

20.0

X

12

Condition

H

Recommendation

Recommendation

Recommendation

Recommendation

Recommendation

H

Socket-Weld

Outside

Outside

Outside

Outside

Outside

20.0

Dis

char

ge

Conn Type

Conn Type

Conn Type

Conn Type

Conn Type

Condensate

Installed Date

Installed Date

Installed Date

Installed Date

Installed Date

12

9.0

12

BPF tank 01

1X

FT14C-10

Near Boiler

TD52

Date

Date

Date

Date

Date

Date

OK

OK

0 bar

TD52

Sup

ply

1

Elevation

Elevation

Elevation

Elevation

Elevation

0 bar

DR

12

Out Out

12

9.0

9.0

FT14C-10

Load

NO20.0

Page

15.0

Lift

15.0

Follow up

Follow up

Follow up

Follow up

Follow up

2

Socket-Weld

SPI

Equip

001 2

10.0 bar

Ricardo Carminato

C

2003

SPI

15.0

SPI

TRAP SURVEY DATA LOGTechnician

Energy Audit

CL

C

Str

aine

r1

X

41.4 bar

OK

C1

CL

Insulation

15.0V

alve

In

Tracer

Check Valve

Check Valve

Check Valve

Check Valve

Check Valve

Dire

ctio

n

20.0

Steam

20.0

4/1/11

12

Temp Alarm

Temp Alarm

Temp Alarm

Temp Alarm

Temp Alarm

Transmitter

Transmitter

Transmitter

Transmitter

Transmitter

Tag#

Tag#

Tag#

Tag#

Tag#

DR C

NO

H

12

Socket-Weld

005

12

In In

1X

H

1

Near BPF service tank

PMO

C

Months/Year

Months/Year

Months/Year

Months/Year

Months/Year

Months/Year

GSK, Guarulhos

Superheat

Superheat

Superheat

Superheat

Superheat

DR

C

Comments

Comments

Comments

Comments

Comments

2

NO

Process

High Elevation

9.0

TD52

009

DR

Val

ve O

ut

Piping

NO

Line Sz

20.0

0 bar

0 bar

2

OK

1

9.0

15.0

C

Critical Trap

Critical Trap

Critical Trap

Critical Trap

Critical Trap

007

Receiver

Receiver

Receiver

Receiver

Receiver

MFR Pressure

C

0 bar

SPI

15.0

41.4 bar

2Boiler House

Location

Location

Location

Location

Location

Location

15.0

Boiler House

Model

Frequency

Frequency

Frequency

Frequency

Frequency

Conn Size

Socket-Weld

8

Application

1

H41.4 bar

X

Drip

1

Route No.

Route No.

Route No.

Route No.

Route No.

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Do not monitor

Do not monitor

Do not monitor

Do not monitor

Do not monitor

1C

Conductive

Conductive

Conductive

Conductive

Conductive

12

123.40 BRL

SPI

Customer

20.0

Steam Loss/Yr

C

NO

41.4 bar

15.0

Coil

Socket-Weld

20.0

X

5

Condition

H

Recommendation

Recommendation

Recommendation

Recommendation

Recommendation

H

Socket-Weld

Outside

Outside

Outside

Outside

Outside

15.0

Dis

char

ge

3,902 BRL

Conn Type

Conn Type

Conn Type

Conn Type

Conn Type

Condensate

Installed Date

Installed Date

Installed Date

Installed Date

Installed Date

12

9.0

12

Main Header

1X

TD52

Steam Cost


TD52

Date

Date

Date

Date

Date

Date

OK

OK

0 bar

TD52

Sup

ply

31,622 kg/yr

DR

1

Elevation

Elevation

Elevation

Elevation

Elevation

0 bar

DR

12

RC

Out Out

12

9.0

9.0

TD52

Load

NO20.0

Page

20.0

Lift

15.0

Follow up

Follow up

Follow up

Follow up

Follow up

2

Socket-Weld

SPI

Equip

006 2

41.4 bar

Ricardo Carminato

C

2008

SPI

20.0

SPI


Energy Audit

C

Str

aine

r1

X

41.4 bar

C1

Insulation

15.0V

alve

In

Tracer

Check Valve

Check Valve

Check Valve

Check Valve

Check Valve

Dire

ctio

n

20.0

Steam

20.0

Annual Cost

4/1/11

12

Temp Alarm

Temp Alarm

Temp Alarm

Temp Alarm

Temp Alarm

Transmitter

Transmitter

Transmitter

Transmitter

Transmitter

Tag#

Tag#

Tag#

Tag#

Tag#

DR C

NO

H

12

Socket-Weld

NT010

12

In In

1X

H

1

main Header

PMO

C

Months/Year

Months/Year

Months/Year

Months/Year

Months/Year

Months/Year

GSK, Guarulhos

Superheat

Superheat

Superheat

Superheat

Superheat

DR

C

Comments

Comments

Comments

Comments

Comments

3

NO

Process

9.0

014

DR

Val

ve O

ut

Piping

NO

Line Sz

15.0

0 bar

* TLV (3)

0 bar

2

OK

1

9.0

15.0

C

Critical Trap

Critical Trap

Critical Trap

Critical Trap

Critical Trap

012

Receiver

Receiver

Receiver

Receiver

Receiver

MFR Pressure

C

0 bar25.0

41.4 bar

2Near Kitchen area

Location

Location

Location

Location

Location

Location

*

Near Kitchen area

Model

Frequency

Frequency

Frequency

Frequency

Frequency

Conn Size

Socket-Weld

8

Application

1

H*

X

Drip

1

Route No.

Route No.

Route No.

Route No.

Route No.

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Do not monitor

Do not monitor

Do not monitor

Do not monitor

Do not monitor

1C

Conductive

Conductive

Conductive

Conductive

Conductive

12

*

Customer

25.0

C

NO

41.4 bar

25.0

Coil

Socket-Weld

15.0

X

12

Condition

NT

H

Recommendation

Recommendation

Recommendation

Recommendation

Recommendation

H

Socket-Weld

Outside

Outside

Outside

Outside

Outside

Dis

char

ge

Conn Type

Conn Type

Conn Type

Conn Type

Conn Type

Condensate

Installed Date

Installed Date

Installed Date

Installed Date

Installed Date

12

9.0

12

Near Kitchen area

1X

Sector do TC para aguagelada

TD52

Date

Date

Date

Date

Date

Date

OK

high Elevation

0 bar

*

Sup

ply

DR

1

Elevation

Elevation

Elevation

Elevation

Elevation

0 bar

DR

12

Out Out

12

9.0

9.0

TD52

Load

NO25.0

Page

25.0

Lift

Follow up

Follow up

Follow up

Follow up

Follow up

2

Socket-Weld

SPI

Equip

011 2

Ricardo Carminato

C

2013

25.0

SPI


Energy Audit

C

Str

aine

r1

X OK

C1

Insulation

15.0V

alve

In

Tracer

Check Valve

Check Valve

Check Valve

Check Valve

Check Valve

Dire

ctio

n

15.0

Steam

15.0

4/1/11

12

Temp Alarm

Temp Alarm

Temp Alarm

Temp Alarm

Temp Alarm

Transmitter

Transmitter

Transmitter

Transmitter

Transmitter

Tag#

Tag#

Tag#

Tag#

Tag#

DR C

NO

NT

H

12

Socket-Weld

015

12

In In

1X

H

1

Near Kitchen area

PMO

C

Months/Year

Months/Year

Months/Year

Months/Year

Months/Year

Months/Year

GSK, Guarulhos

Superheat

Superheat

Superheat

Superheat

Superheat

DR

OK

C

Comments

Comments

Comments

Comments

Comments

4

NO

Process

9.0

TD52

019

DR

Val

ve O

ut

Piping

NO

Line Sz

15.0

0 bar

0 bar

2

OK

1

9.0

15.0

C

Critical Trap

Critical Trap

Critical Trap

Critical Trap

Critical Trap

017

Receiver

Receiver

Receiver

Receiver

Receiver

MFR Pressure

C

0 bar

SPI

15.0

41.4 bar

2Drip leg

Location

Location

Location

Location

Location

Location

15.0

Drip leg

Model

Frequency

Frequency

Frequency

Frequency

Frequency

Conn Size

Socket-Weld

8

Application

1

H41.4 bar

X

Drip

1

Route No.

Route No.

Route No.

Route No.

Route No.

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Do not monitor

Do not monitor

Do not monitor

Do not monitor

Do not monitor

1C

Conductive

Conductive

Conductive

Conductive

Conductive

12

SPI

Customer

15.0

C

NO

41.4 bar

15.0

Coil

Socket-Weld

15.0

X

12

Condition

H

Recommendation

Recommendation

Recommendation

Recommendation

Recommendation

H

Socket-Weld

Outside

Outside

Outside

Outside

Outside

15.0

Dis

char

ge

Conn Type

Conn Type

Conn Type

Conn Type

Conn Type

Condensate

Installed Date

Installed Date

Installed Date

Installed Date

Installed Date

12

9.0

12

Drip leg

1X

TD52

Drip leg

TD52

Date

Date

Date

Date

Date

Date

OK

OK

0 bar

TD52

Sup

ply

DR

1

Elevation

Elevation

Elevation

Elevation

Elevation

0 bar

DR

12

Out Out

12

9.0

9.0

TD52

Load

NO15.0

Page

15.0

Lift

15.0

Follow up

Follow up

Follow up

Follow up

Follow up

2

Socket-Weld

SPI

Equip

016 2

41.4 bar

Ricardo Carminato

C

2018

SPI

15.0

SPI


Energy Audit

C

Str

aine

r1

X

41.4 bar

OK

C1

Insulation

15.0V

alve

In

Tracer

Check Valve

Check Valve

Check Valve

Check Valve

Check Valve

Dire

ctio

n

15.0

Steam

15.0

4/1/11

12

Temp Alarm

Temp Alarm

Temp Alarm

Temp Alarm

Temp Alarm

Transmitter

Transmitter

Transmitter

Transmitter

Transmitter

Tag#

Tag#

Tag#

Tag#

Tag#

DR C

NO

H

12

Socket-Weld

020

12

In In

1X

H

1

Drip leg

PMO

C

Months/Year

Months/Year

Months/Year

Months/Year

Months/Year

Months/Year

GSK, Guarulhos

Superheat

Superheat

Superheat

Superheat

Superheat

DR

OK

C

Comments

Comments

Comments

Comments

Comments

5

NO

Process

9.0

TD52

024

DR

Val

ve O

ut

Piping

NO

Line Sz

15.0

0 bar

0 bar

2

OK

1

9.0

15.0

C

Critical Trap

Critical Trap

Critical Trap

Critical Trap

Critical Trap

022

Receiver

Receiver

Receiver

Receiver

Receiver

MFR Pressure

C

0 bar

SPI

15.0

41.4 bar

2Drip leg

Location

Location

Location

Location

Location

Location

15.0

Drip leg

Model

Frequency

Frequency

Frequency

Frequency

Frequency

Conn Size

Socket-Weld

8

Application

1

H41.4 bar

X

Drip

1

Route No.

Route No.

Route No.

Route No.

Route No.

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Do not monitor

Do not monitor

Do not monitor

Do not monitor

Do not monitor

1C

Conductive

Conductive

Conductive

Conductive

Conductive

12

SPI

Customer

15.0

C

NO

41.4 bar

15.0

Coil

Socket-Weld

15.0

X

12

Condition

H

Recommendation

Recommendation

Recommendation

Recommendation

Recommendation

H

Socket-Weld

Outside

Outside

Outside

Outside

Outside

15.0

Dis

char

ge

Conn Type

Conn Type

Conn Type

Conn Type

Conn Type

Condensate

Installed Date

Installed Date

Installed Date

Installed Date

Installed Date

12

9.0

12

Drip leg

1X

TD52

Drip leg

TD52

Date

Date

Date

Date

Date

Date

OK

OK

0 bar

TD52

Sup

ply

DR

1

Elevation

Elevation

Elevation

Elevation

Elevation

0 bar

DR

12

Out Out

12

9.0

9.0

TD52

Load

NO15.0

Page

15.0

Lift

15.0

Follow up

Follow up

Follow up

Follow up

Follow up

2

Socket-Weld

SPI

Equip

021 2

41.4 bar

Ricardo Carminato

C

2023

SPI

15.0

SPI


Energy Audit

C

Str

aine

r1

X

41.4 bar

OK

C1

Insulation

15.0V

alve

In

Tracer

Check Valve

Check Valve

Check Valve

Check Valve

Check Valve

Dire

ctio

n

15.0

Steam

15.0

4/1/11

12

Temp Alarm

Temp Alarm

Temp Alarm

Temp Alarm

Temp Alarm

Transmitter

Transmitter

Transmitter

Transmitter

Transmitter

Tag#

Tag#

Tag#

Tag#

Tag#

DR C

NO

H

12

Socket-Weld

025

12

In In

1X

H

1

Drip leg

PMO

C

Months/Year

Months/Year

Months/Year

Months/Year

Months/Year

Months/Year

GSK, Guarulhos

Superheat

Superheat

Superheat

Superheat

Superheat

OK

C

Comments

Comments

Comments

Comments

Comments

6

NO

Process

3.0

FT552

029

Val

ve O

ut

Piping

NO

Line Sz

20.0

0 bar

* TLV (3)

0 bar

2

1

3.0

20.0

C

Critical Trap

Critical Trap

Critical Trap

Critical Trap

Critical Trap

027

Receiver

Receiver

Receiver

Receiver

Receiver

MFR Pressure

C

0 bar

SPI

15.0

8.3 bar

2Cosmetics section - TREVIARTR-10

Location

Location

Location

Location

Location

Location

*

Cosmetics section - TREVIARTR-07

Model

Frequency

Frequency

Frequency

Frequency

Frequency

Conn Size

Socket-Weld

8

Application

1

H*

X

Drip

PR 1

Route No.

Route No.

Route No.

Route No.

Route No.

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Do not monitor

Do not monitor

Do not monitor

Do not monitor

Do not monitor

1C

Conductive

Conductive

Conductive

Conductive

Conductive

12

*

Customer

20.0

C

NO

8.3 bar

15.0

Coil

Socket-Weld

20.0

X

12

Condition

NT

H

Recommendation

Recommendation

Recommendation

Recommendation

Recommendation

H

Socket-Weld

Outside

Outside

Outside

Outside

Outside

20.0

Dis

char

ge

Conn Type

Conn Type

Conn Type

Conn Type

Conn Type

Condensate

Installed Date

Installed Date

Installed Date

Installed Date

Installed Date

12

9.0

PR

12

Cosmetics section - TREVIARTR-06

1X

FT552

TC de Placa 21 K 40 A

FT552

Date

Date

Date

Date

Date

Date

Equipment not operational

NT0 bar

*

Sup

ply

1

Elevation

Elevation

Elevation

Elevation

Elevation

0 bar

12

Out Out

12

3.0

3.0

FT552

Load

NO20.0

Page

20.0

Lift

20.0

Follow up

Follow up

Follow up

Follow up

Follow up

2

Socket-Weld

SPI

Equip

026 2

8.3 bar

Ricardo Carminato

C

2028

SPI

20.0

SPI


Energy Audit

C

Str

aine

r

PR

1X

8.3 bar

OK

C1

PR

Insulation

20.0V

alve

In

Tracer

Check Valve

Check Valve

Check Valve

Check Valve

Check Valve

Dire

ctio

n

20.0

Steam

20.0

NT

4/1/11

12

Temp Alarm

Temp Alarm

Temp Alarm

Temp Alarm

Temp Alarm

Transmitter

Transmitter

Transmitter

Transmitter

Transmitter

Tag#

Tag#

Tag#

Tag#

Tag#

DR C

NO

H

12

Socket-Weld

030

12

In In

1X

H

1

Cosmetics section - TREUMIS 03

PMO

C

Months/Year

Months/Year

Months/Year

Months/Year

Months/Year

Months/Year

GSK, Guarulhos

Superheat

Superheat

Superheat

Superheat

Superheat

OK

C

Comments

Comments

Comments

Comments

Comments

7

NO

Process

3.0

FT553

035

Val

ve O

ut

Piping

NO

Line Sz

20.0

0 bar

0 bar

2

OK

1

3.0

20.0

C

Critical Trap

Critical Trap

Critical Trap

Critical Trap

Critical Trap

032

Receiver

Receiver

Receiver

Receiver

Receiver

MFR Pressure

C

0 bar

SPI

20.0

10.0 bar

2Cosmetics section - TREURTR-009

Location

Location

Location

Location

Location

Location

40.0

Cosmetics section - TREURTR-002

Model

Frequency

Frequency

Frequency

Frequency

Frequency

Conn Size

Socket-Weld

8

Application

1

H10.0 bar

X

Drip

PR 1

Route No.

Route No.

Route No.

Route No.

Route No.

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Do not monitor

Do not monitor

Do not monitor

Do not monitor

Do not monitor

1C

Conductive

Conductive

Conductive

Conductive

Conductive

12

SPI

Customer

20.0

C

NO

4.5 bar

20.0

Coil

Socket-Weld

20.0

X

12

Condition

H

Recommendation

Recommendation

Recommendation

Recommendation

Recommendation

H

Socket-Weld

Outside

Outside

Outside

Outside

Outside

20.0

Dis

char

ge

Conn Type

Conn Type

Conn Type

Conn Type

Conn Type

Condensate

Installed Date

Installed Date

Installed Date

Installed Date

Installed Date

12

3.0

PR

12


1X

FT553

Cosmetics section - TREU5000 l

FT553

Date

Date

Date

Date

Date

Date

OK

OK

0 bar

FT10-10

Sup

ply

1

Elevation

Elevation

Elevation

Elevation

Elevation

0 bar

12

Out Out

12

3.0

3.0

FT553

Load

NO20.0

Page

20.0

Lift

20.0

Follow up

Follow up

Follow up

Follow up

Follow up

2

Socket-Weld

SPI

Equip

031 2

4.5 bar

Ricardo Carminato

C

2033

SPI

20.0

SPI


Energy Audit

C

Str

aine

r

PR

1X

10.0 bar

OK

C1

PR

Insulation

20.0V

alve

In

Tracer

Check Valve

Check Valve

Check Valve

Check Valve

Check Valve

Dire

ctio

n

20.0

Steam

20.0

4/1/11

12

PR

Temp Alarm

Temp Alarm

Temp Alarm

Temp Alarm

Temp Alarm

Transmitter

Transmitter

Transmitter

Transmitter

Transmitter

Tag#

Tag#

Tag#

Tag#

Tag#

C

NO

H

12

Socket-Weld

036

12

In In

1X

H

1

Cosmetics section - TREU300 l

PMO

Months/Year

Months/Year

Months/Year

Months/Year

Months/Year

Months/Year

GSK, Guarulhos

Superheat

Superheat

Superheat

Superheat

Superheat

OK

Comments

Comments

Comments

Comments

Comments

8

Process

3.0

FT10-4.5

Val

ve O

ut

Piping

NO

Line Sz

0 bar

2

OK

1

20.0

C

Critical Trap

Critical Trap

Critical Trap

Critical Trap

Critical Trap

34

Receiver

Receiver

Receiver

Receiver

Receiver

MFR Pressure

C

0 bar20.0

4.5 bar

Location

Location

Location

Location

Location

Location

20.0

Model

Frequency

Frequency

Frequency

Frequency

Frequency

Conn Size

8

Application

H4.5 bar

Drip

PR 1

Route No.

Route No.

Route No.

Route No.

Route No.

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Shutdown Req'd

Do not monitor

Do not monitor

Do not monitor

Do not monitor

Do not monitor

Conductive

Conductive

Conductive

Conductive

Conductive

12

SPI

Customer

C

NO20.0

Coil

Socket-Weld

20.0

X

12

Condition

Recommendation

Recommendation

Recommendation

Recommendation

Recommendation

H

Socket-Weld

Outside

Outside

Outside

Outside

Outside

Dis

char

ge

Conn Type

Conn Type

Conn Type

Conn Type

Conn Type

Condensate

Installed Date

Installed Date

Installed Date

Installed Date

Installed Date

12

3.0

Oral section - TREU RTR-001

1X

Oral section - TREU RTR-002

Date

Date

Date

Date

Date

Date

OK

FT553

Sup

ply

Elevation

Elevation

Elevation

Elevation

Elevation

0 bar

12

Out Out

12

3.0

FT10-4.5

Load

Page

25.0

Lift

40.0

Follow up

Follow up

Follow up

Follow up

Follow upNPT Pipe Thread

SPI

Equip

037 2

Ricardo Carminato

238

SPI

25.0


Energy Audit

C

Str

aine

r

PR

4.5 bar

C1

Insulation

Val

ve In

Tracer

Check Valve

Check Valve

Check Valve

Check Valve

Check Valve

Dire

ctio

n

Steam

20.0

4/1/11

PR

Temp Alarm

Temp Alarm

Temp Alarm

Temp Alarm

Temp Alarm

Transmitter

Transmitter

Transmitter

Transmitter

Transmitter

Tag#

Tag#

Tag#

Tag#

Tag#

C

NO

12

Socket-Weld 12

In In

1X

H

1


Steam And Condensate Engineering Audit Stiefel, a GSK company

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Transcript of Steam And Condensate Engineering Audit Stiefel, a GSK company