GlaxoSmithKline - Armstrong International · 1/28/2011 · ©2011 Armstrong Service, Inc. GlaxoSmithKline St. Louis, MO STEAM AND CONDENSATE AUDIT REPORT Project No: ASIR-10126-01-1210

©2011 Armstrong Service, Inc.

GlaxoSmithKline St. Louis, MO

STEAM AND CONDENSATE AUDIT REPORT

Project No: ASIR-10126-01-1210

Prepared for:

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

Phone: 901-415-1326

January 28, 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) St. Louis, MO 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 ....................................... 7

2 OPTIMIZATION PROJECTS ............................................................................................. 9

2.1 OPTIMIZATION PROJECT # 1: COATER EXHAUST TO SUPPLY AIR HEAT RECOVERY ................. 9

2.2 OPTIMIZATION PROJECT # 2: HOT WATER HEATING AND DISTRIBUTION OPTIMIZATION. ......... 15

2.3 OPTIMIZATION PROJECT # 3 INSTALL REMOVABLE INSULATION ............................................. 18

2.4 OPTIMIZATION PROJECT # 4: WINTER HEATING OPTIMIZATION ............................................. 21

3 CHECK LIST VERIFICATIONS COMPLETED DURING THE AUDIT .............................. 24

4 RECOMMENDED ADDITIONAL STUDIES ..................................................................... 26

4.1 OPTIMIZATION PROJECT # 5 STEAM TRAPS .......................................................................... 26

4.2 RO WATER HEATING .................................................................................................................. 31

4.3 NEW BOILER INSTALLATION EVALUATION ..................................................................................... 32

5 ADDITIONAL OBSERVATIONS AND RECOMMENDATIONS ........................................ 35

5.1 BEST PIPING PRACTICES AND STEAM TRAPS INSTALLATION ......................................................... 35

6 CLOSING ........................................................................................................................ 44

7 APPENDIX INSULATION - Details and calculations .................................................... 45


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EXECUTIVE SUMMARY During the period of January 11th and 12th of 2011, ASI conducted an energy audit of the steam system (distribution, and users), and condensate return at GSK, St. Louis, Missouri. ASI estimated the potential energy savings of more than 25.0% of the current yearly steam

budget ($157,991 / 6,758 klbs, or 2,365,758 kWh), which represents an annual estimated saving of 1,710 klbs steam or 598,702 kWh, 320 tons of CO2, and $39,983. There is no steam generation facility on site. The steam is purchased at 160 psig (±5 psig) from Trigen, and the building distribution system is fed from two separate lines; one for the Main building and one for Building 7. Meters are installed at both locations. The steam is distributed to three major systems: as purchased at 160 psig, reduced down to 60 psig at the north station and seasonal. During the audit the seasonal steam was not turned on yet. The main steam user is the Oscal Coater, which consumes 48% of the total steam delivered to the site and 80% of the hourly load, when in operation. The other users are multiple air handling units (AHUs) and unit heaters (UH), a roof top unit (RTU), an autoclave, a wash in place (WIP) for the coater and two hot water (HW) heating systems serving the south and the north areas. The dryers are equipped with electric heaters and one of them uses preheated air from the cooling system of the air compressors. Another heat recovery system is applied for building heating by using the heat rejected from the compressor of the low temperature chiller. Trigen does not accept returned condensate, so it is drained at several locations in the building. Many of the drains use additional cooling water to reduce the temperature below the acceptable level before discharge to the sewer. After the first day walkthrough it was mutually decided between GSK and ASI that the major opportunities for further improvements (cost savings and reliability) were in the following areas:

• Oscal Coater

• Building heating system, related to the AHUs served by the chilled water loop.

• Hot water systems – South in the basement and North on 4th floor, working independently at the moment.


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• The steam distribution systems, insulation, and steam traps, which always provide opportunities for energy, reliability and safety improvements.

Based on the ASI audit a minimum of 21% of the savings are expected from the users ,

related to heat recovery and operation and piping practices improvements. The majority of these savings will be achieved with the continuous heat recovery from the Oscal Coater, where the exhaust air will be used to preheat the supply air to the process. Due to constructability restraints the heat recovery will take place only during the winter, saving more than 13% of the steam purchased by GSK. The other projects, HW heating and building heating are related to reducing the energized piping and equipment in the building, while achieving the same or better air and HW quality at delivery points. Both HW systems were looked at for conversion to a single loop with recirculation to achieve energy savings and consistent HW temperatures at the users. The condensate was also considered for heat recovery before it’s drained to the sewer. The new HW recirculation loop and the fresh make-up city water will be preheated by condensate providing for 8.8% savings. As the chilled water loop is successfully used for the building heating, it is proposed to keep this loop running continuously, with an option to increase the water temperatures when needed, therefore completely avoiding the use of the steam heated coils in the AHUs. Savings from the present system are significant, and no additional savings are reported for project #4 Steam heater installation. The steam heater would be a sustainable addition to the present arrangement to assure complete coverage of the winter months under this heating arrangement. There is potential for additional energy savings related to the steam distribution. In general,

the steam distribution system is fairly well maintained. An insulation survey was performed internally by the plant last year. During the ASI study a 6% savings was identified from insulation improvements. Approximately half of them, 3%, are expected to be added to the

overall savings, as some of the seasonal and north end systems may not be turned on at all this winter. The savings in Project #3 Insulation are reported only for GSK’s consideration if these steam systems become energized in the future. A steam trap survey needs to be performed to


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define the steam traps present condition. A significant improvement is needed in the piping practices to achieve better steam quality, safety and reliability of the system. Many drip legs and drip traps are missing, undersized or not properly located, leading to wet steam, water hammer, damaged and leaking equipment. Steam leaks were not observed anywhere in the plant as they are immediately addressed by plant personnel. A new 15 HP boiler installation proposal was considered last year and provided for further evaluation to ASI. The savings of this project are highly dependent on the actual steam demand and the natural gas cost. It is recommended to re-evaluate the project after the other projects are implemented and the steam demand has a more defined load pattern. Multiple steam meters are installed in the plant and the collection and analysis of their readings and data will be one of the defining factors for the future of this project. Additional investment evaluation needs to be performed, too. Also, based on the present steam and electrical costs, it’s financially more beneficial for GSK to use electricity for heating purposes, instead of steam.


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1 STEAM BUDGET AND SUMMARY OF POTENTIAL SAVINGS Total annual steam purchased - 6759 klbs/yr (3,067 tons) Steam Cost - $23.38/klbs ($51.52/ton) Annual Steam Fuel Budget - $157,991. 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 past 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.


Utility data and costs for the past 12 months. The steam is metered by Trigen at the two inlets to the plant, Main Building and Building 7, and at four locations by GSK. The readings from the Trigen meters are presented in the table below (past 12 months).

After analysis of the cost of steam and its usage in the plant, it more beneficial to use electricity, than steam, as it is shown in the following table.

Conversions used for calculations


GSK St. Louis, MO


Utility data and costs for the past 12 months.

gen at the two inlets to the plant, Main Building and Building 7, and locations by GSK. The readings from the Trigen meters are presented in the table below

After analysis of the cost of steam and its usage in the plant, it was concluded that financially it’s more beneficial to use electricity, than steam, as it is shown in the following table.

for calculations

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gen at the two inlets to the plant, Main Building and Building 7, and locations by GSK. The readings from the Trigen meters are presented in the table below

was concluded that financially it’s more beneficial to use electricity, than steam, as it is shown in the following table.


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2 OPTIMIZATION PROJECTS 2.1 OPTIMIZATION PROJECT # 1:

Coater Exhaust to Supply Air Heat Recovery

Current System Description and Observed Deficiency The Coater is the largest steam user in the plant, consuming an estimated 48% of the purchased steam. Outside air with average flow rate of 9,500 cfm is conditioned (dehumidified, if needed, to a dew point of less than 13°C (55.4°F ), and heated up to 66°C (151°F) and supplied to the coater. After the process, the moist and hot air at 51°C (124°F) is routed to a dust collector, exhaust fan and discharged to the outside of the plant between the two building. A sensor is installed after the dust collector to assure the air does not contain any particles larger than 5 microns. The heat coils of the AHU are fed with steam from the high pressure (HP) steam header and reduced to 40 psig. The control of steam to the heating coils and the temperature of the supply air is based on the exhaust air temperature with set points between 46°C (115°F) and 55°C (131°F). The condensate is routed to the basement next to the condensate receiver and discharged to the sewer.

A separate meter is installed on the steam supply line to the Coater and its readings during the visit varied between 1,200 and 1,300 lbs/hr at 20°F outside air temperature (OAT). The


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readings of the meter correspond to the calculated values of steam required to heat the air flow. A summary of the average steam consumption for the year is shown in the table below, and a detailed monthly calculation is presented at the end of the project.

Discussion Hot exhaust air contains a lot of wasted energy. It is beneficial to use/return this energy back into the process with heat recovery equipment. When the hot and cold ducts are located next to each other or in close proximity, the heat pipes could recover more than 50% of the energy from the exhaust air while preheating the fresh outside air. As the humidity of the supply air needs to be maintained below certain level, during the summer a chilled water cooling coil is used to reduce the air temperature to 13°C (55°F), and remove the moisture. The air stream is subsequently reheated to 66°C (151°F). Heat pipes can successfully be used to alleviate some of the chilled water load and the reheat, if there is space available within the AHU to install additional equipment. In GSK St. Louis, the AHU configuration does not allow for this type of installation and the heat recovery will be limited.


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Optimization

ASI recommends installing a heat pipe between the exhaust and supply air ducts in the Bin storage area outside of the Coater Mechanical room. The heat pipe will be used during the winter and other months when the OA humidity levels are below the 13°C (55°F) dew point. The rest of the time a by-pass will be open and the air will be supplied at outside temperature to the cooling coil.

The maximum expected pressure drop is 0.58“ WC in the supply duct and 0.61” WC in the exhaust duct. Another option for a full time heat recovery was also evaluated, but not recommended due to the extended pay pack. If a chilled water coil (new, outside of the AHU) is installed in front of the heat pipe heat recovery, then the heat pipe can be used year round. As the savings during the summer are half the savings during the cold winter months, and the investments are almost double, this option was not further developed. Savings Increasing the supply air temperatures by 4°C (40°F ) to 16°C (60°F), starting from outside temperatures, between -18°C (0°F) to 16°C (60°F), w ill save $20,700 annually. The savings are

Proposed Location Options for Heat Pipe Installation


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calculated based on heat recovery during 1/3 of the time through those months with temperatures below 16°C (60°F), dry bulb and 13°C ( 55°F), wet bulb. A slight increase in electrical consumption by the fans is deducted from the savings. Savings based on average monthly temperatures

Estimated Investment and Payback The budgetary cost for this project is $84,200. Included in the project:

• Detailed Design, including process and equipment data confirmation and construction feasibility.

• Equipment supply (heat pipe, face and by-pass dampers with actuators, drip pans and piping up to 30 ft to a drain location). The existing supply and exhaust fans are expected to be able to handle the above listed additional pressure drops.

• Duct modifications and support for new equipment by a mechanical contractor

• Existing fan’s adjustments.

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


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Detailed Calculations Savings based on BIN data


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Savings based on average monthly data


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2.2 OPTIMIZATION PROJECT # 2:

Hot Water Heating and Distribution Optimization.

Current System Description and Observed Deficiency There are two separate HW systems serving independently the South and the North areas of the plant. None of them has a recirculation loop which explains the long time lapse from opening a valve to receiving the hot water at a specific location.

South HW Heaters in the Basement North HW Heater on 4th floor Based on average water consumption the following annual steam usage was calculated.


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Optimization ASI recommends; - reconnecting the two systems and providing a new recirculation line to provide consistent water temperatures at delivery points. - installing heat recovery heat exchangers to use the hot condensate to reheat the recirculation loop and to preheat fresh make-up city water before it enters the steam heaters.


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Savings The savings from the heat recovery of the condensate are expected to cover at least 80% of the used heat and will be $13,973 per year. The saving calculations details are shown in the following table.

Estimated Investment and Payback Budgetary cost for this project is $58,700.

Included:

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

• Additional piping design

• Equipment supply (new tank with coils). Recirculation pump is available on site. The North heater will be used as a heat exchanger for the recirculation loop reheat by condensate

• Installation of equipment, relocation and piping, by a mechanical contractor

• Project management The payback of this installation is expected to be 4.2 years.


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2.3 OPTIMIZATION PROJECT # 3 Install Removable Insulation

Current System Description and Observed Deficiency

There were several 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 the subsequent tables. 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 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. As some of the systems were not energized during the audit and may not be used regularly in the future, 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 $10,600 annually, if the seasonal steam system is

energized (2000 hr/yr) as well as any other usage of steam is restored (presently substituted by the Chilled Water heating). As mentioned before, the actual savings will differ based on the actual hours of operation at each location. 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 three most common pressures of the steam and for the variety of valve sizes existing in the plant. The tables are built based on the present steam pricing, and should be accordingly adjusted.

High Pressure Valves


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Medium Pressure Valves

Low Pressure Valves

Estimated investment and Payback Budgetary cost for this project is $20,000. 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 HP steam bare surfaces, year round operations and to the outside locations, if any, which have the quickest payback.


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2.4 OPTIMIZATION PROJECT # 4:

Winter Heating Optimization

Current System Description and Observed Deficiency The majority of the AHUs in the plant operate on heating only (winter) or cooling only (summer) mode. Since last winter, an energy saving modification was made to reduce the steam consumption for heating purposes. The cooling tower water is presently used as a heat source to reheat the chilled water loop, which circulates through the system and provides heating through the chilled water coils (substitutes for the steam heating). During December, there were several days with single digit temperatures, but this present system, circulating 70°F water, was managing to supply enough heat to the building and to avoid the start up of the steam heating. In the previous years, the conventional system for cooling was through coils using a chilled water loop, and for heating, steam heated coils. Discussion Each heating system has inherent distribution losses. The steam heating systems lose between 2% and 6% of its efficiency in the distribution, while water heating systems lose between 0% and 1%, especially if the heating water is at temperatures lower than 100°F. Steam piping surface has a temperature of around 120°F when insu lated, and close to steam saturation temperature when not insulated. By keeping the steam piping not energized (cold), additional savings will occur due to reduced hours of insulation losses, associated with missing or damaged insulation. There is a noticeable difference in the steam consumption between the winter months at the beginning of the year, and the winter months of November and December, when the new arrangement was in operation.


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Optimization ASI recommends installing a steam heating arrangement on the chilled water loop, to be able to increase the temperature of the circulated water by 10°F and avoid the use of the steam heating system.


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The set point temperature of the system needs to be additionally discussed and defined as needed. The design temperature for heating (99.6% of the time) for St. Louis is 2F. Savings The implementation of this project will assure the use of the chilled water loop throughout the entire winter and contributes to the sustainability of the previous improvement. As described in the discussion section, GSK already has significant savings from the new operation. Additional energy savings should be reported only if the seasonal steam system is on.

Estimated Investment and Payback The budgetary cost for this project is $141,000. Included in the project:

• Additional design, including process and equipment data confirmation and construction feasibility.

• Equipment supply (water heat exchanger, steam control valve, water mixing thermostatic valve). The existing chilled water circulation pumps are expected to be able to handle the additional pressure drops. The existing expansion tank and water pressurization system will be used.

• Piping modifications and support for tie-ins to new equipment by a mechanical contractor

• Project management and start-up There is no payback associated with this installation.


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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 # 5 Steam Traps

Current System Description and Observed Deficiency

There are around 70 steam traps installed presently at the plant. The last complete steam trap survey was performed in 2005. A total of 76 traps were checked and 20% of the traps have been identified as failed in blowing through (BT- 6 traps), leaking (LK – 5 traps), or Plugged (PL – 4 traps) 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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Detailed data related to the steam traps and their performance is available on the Steam Star website. During the survey, the following system deficiencies were observed:

• Missing or undersized drip legs or traps • Improper installation of a steam trap (“master” traps) • Drip on the side of the pipe • Take-off off the side and bottom of the main • Obstructed safety relief valves vent lines (safety)

Details of the observed deficiencies are shown in the Section 5 - Additional Observations and Recommendations.


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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;

• 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.


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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. Frequent checks to steam traps are seldom possible because of the steam trap locations (i.e. crawl space) or shortage of manpower, and traps fail in-between surveys. ASI suggests the installation of SteamEye to all the High Pressure and Medium Pressure steam traps, as they are the steam traps that waste the most energy. SteamEye will show an alarm for failed traps as soon as failure occurs, minimizing the potential energy loss. 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 $3,000 to $7,500 annually. To define the exact benefits a complete steam trap survey will be needed.

Estimated investment and Payback

Complete steam trap survey cost - $1,500. 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.


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The payback of the trap repairs is expected to be between 1 and 2 years. Priority should be given to the HP steam traps, which have the quickest payback or can create additional problems to the system when discharging to a low pressure header.


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4.2 RO Water heating

The city water flow to the RO system is at ambient temperature. For the RO system to operate at its best efficiency the water is preheated by steam up to 20°C (68°F). For this low level of heat it is beneficial to consider heat recovery from another heat source, instead of using live steam. In relatively close proximity to this system are the compressors for the chillers, which all require cooling, as well as the 70 °F winter heatin g chilled water loop. For each gpm of RO water the expected savings are around $1,300 per year.


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4.3 New Boiler Installation Evaluation

In 2010 Barns&McDonnell (B&MD) performed a feasibility study about an on-site installation of a small low pressure (LP) boiler to offset some base load portion of the purchased steam from Trigen. Boiler Rating and Output Capacity Based on the codes and regulations to avoid the increase of labor cost (certified operator or stationary engineer), a LP 15 psig, 15 HP boiler was recommended. The steam output from the boiler was calculated at “approximately 518 lb/hr, or 64% of the average steam needed to run the facility”, as per B&MD. This calculation was made without considering the unit “horse power” (HP) is a measure of BTU “from and to atmospheric pressure” and cannot be

converted directly in pounds of steam. Another consideration is the boiler cannot operate 100% of the time at 100% capacity. The continuous output of a boiler is at 85% of its capacity. As per the calculation below, the 15 HP boiler will be capable of 407 lbs/hr continuous output.

Boiler Operation- System load


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The study was based on the average monthly numbers for 2009, and did not consider the actual operation of the system, with and without the Oscal Coater, as well as the steam system natural fluctuations. The next chart shows the +/- 50% fluctuations of the average, which represent a conservative area of operation for any steam system and plant. When the Oscal Coater is in operation (1/3 of the year), the small LP boiler will be fully utilized. When the coater is not in operation, 5,840 hrs of the year, the small LP boiler will be fully utilized only portion of the time and its average usage is expected to fluctuate around 300 lbs/hr. If the trend of this winter’s loads continue, the boiler usage would be limited to less than 150 lbs/hr.

Savings The following savings are calculated based on 300 lbs/hr use during 5,840 hrs (2/3 of the year) and 407 lbs/hr use during 2920 hr (1/3 of the year), for a total of 2,939 klbs/yr, or 43.5% of the total purchased steam. The B&MD reported savings of 64%. The maximum expected system efficiency is 78%, and the minimum natural gas price is $8.00/MMBTU


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If a lowest expected efficiency is 75% and the highest NG price is $11.50/MMBTU (same as last year report), the savings are as follows:

Any other conditions in between can be easily calculated. Additional operating and maintenance costs also need to be deducted from the fuel savings. These are:

- Make-up Water - Chemicals - Pumping cost –Feed water, Condensate - Combustion Air Blower - Maintenance

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 Best Piping Practices and Steam Traps Installation During the survey, the following piping practices and deficiencies were observed:

• Missing / undersized drip legs- AHU 101, 103, RO heater

AHU 101. AHU 103 Missing drip leg before control valves


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AHU 101. Undersized drip leg. Needs to be same size as pipe diameter. See attached drawing for details.

RO system – steam heater. Undersized drip leg. Needs to be same size as pipe diameter. See attached drawing for details. The drip leg captures condensate only when it is properly located and sized. An undersized drip leg can cause the condensate to be pooled out of it (venturi “piccolo” effect).


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• Drip on the side of the pipe – AHU 106, WIP, main distribution

AHU 106. Drip leg take-off at 45° of the pipe, sho rt undersized. Condensate is not going to enter this drip leg

Wash in Place. Drip leg take-off at 90° on the sid e of the pipe. Condensate is not going to enter this drip leg, nor the trap. Water hammer condition is observed during start-up.

Proposed Drip trap re-piping


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End of Seasonal Main distribution pipe in the basement. Drip trap take-off from the center line of the pipe. In order for the condensate to enter the trap, the entire line needs to be flooded.

• Steam supply take-off from Drip leg – Main building 3rd floor

A best piping practice recommendation is to take off the steam from the top of the headers, in order to have dry steam supply. In the above bottom take-off, the probability to have wet steam (condensate entrainments with the steam) is extremely high.

See attached drawing for proper drip leg and drip trap re-piping


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• Missing Trap – RTU1 (roof)

RTU 1 on Roof. It is suspected that there is no trap installed on this coil, unless it’s hidden under the insulation. To prevent freezing, another steam trap is installed on the vertical supply line to the CV and connected to the discharge after the coil. This trap is not going to have condensate unless the entire line is flooded. As there is no condensate, it would not open to warm the pipe downstream of the coil. Condensate cooler is also installed to cool down the discharged condensate and by-pass steam.


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Date: 1/28/2011

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• “Master” trapping – AHU 104, 105, 116

AHU 104. Two coils are discharging to a single trap, “master trap”. As the steam shortcuts the upper coil, the bottom coils stays flooded and corrodes. Proper heat exchange and air temperatures are also hard to maintain. It this particular AHU, the bottom coil is already isolated due to leaks.

- AHU 105. Same master trap arrangement. It is recommended to install a trap for each coil to assure timely and proper condensate drain out of the coil and prevent leaks and freezing, when outside.


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• Safety relief valves (SRV)

AHU 114. The SRV discharge vent is connected to a radiator trap downstairs. Many SRVs discharge to the same area or room where the equipment and AHUs are installed. In case of steam releaf, there will be no safe access to the equipment or piping in question. Any safety relief valve should have a non-obstructed free vent pipe and should discharge to a safe location, where no harm can be done in case of sudden steam relief.


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Date: 1/28/2011

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Discussion The above listed deficiencies 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. Essentials of installing drip legs The drip legs are main components of the steam distribution system, assuring the quality of the steam at the point of usage.

They are provided to:

• Let condensate escape by gravity from the fast moving steam

• Store condensate until the pressure differential can discharge through the steam trap The drip legs are installed at various intervals (max 300 ft), changes in elevation, and low spots or natural drainage points such as:

• Main headers

• Ahead of risers

• End of mains

• Ahead of valves or regulators or equipment The condensate will be captured in the drip leg, when it is properly sized. A correctly sized drip leg must have sufficiently large diameter to catch droplets of condensate moving above it. A

Steam

Droplets

Steam Line

Steam +condensateDrip Leg

Condensate


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drip leg that is undersized can actually cause a venturi “piccolo” effect where pressure drop pulls condensate out of the trap and drip leg.

The correct size of a drip leg depends on the diameter of the supply pipe. For proper sizing see the following drawing.

Essentials of sizing drip traps If the steam trap size is not correctly calculated, the result will be:

• If undersized , the steam trap will not handle the released condensate and the

drained equipment or line will be flooded. Condensate can back up and cause unsafe water hammer.

• If oversized , it may result in:

1. Waste of live steam, 2. Back pressure in the return lines, which could disturb the function of other

parts of the system.


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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 next steps.


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7 APPENDIX INSULATION - Details and calculation s

Location Description Picture

Main Bldg. Forklift Repair Shop

UH – 1” Pressure Reducing Valve, Strainer,

Pipe, Union, Elbow

Main Bldg. Basement – South

HW HTR Area

Distribution and Supply 1.25” - Valve, Elbow,

Strainer, Union, Pressure Reducing Valve, Pipe

4” – Pipe 2” – Pipe, Valve, Pressure

Reducing Valve,

Main Bldg. North End Basement

1.5” Pressure Reducing Valve

Main Bldg. 1st Floor

Distribution 2” – Valve, Pipe, Tee 1.25” – Pipe, Elbow


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AHU 101 1.25” – Pressure Reducing

Valve 1.5” – Union, Strainer,

Valve


AHU 101 1.5” – Control Valve,

Elbow, Union


Distribution to 2nd Floor 1.5” - Pipe

Main Bldg. 2nd Floor

AHU 105 1.5” – Valve, Union,

Pressure Reducing Valve, Elbow, Pipe, Tee

1.25” – Control Valve


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AHU 104 1” – Pipe, Pressure

Reducing Valve, Control Valve

Main Bldg. South End

AHU 103 1” – Pipe, Pressure

Reducing Valve, Control Valve

Main Bldg. 3rd Floor

AHU 107 2” – Pipe, Tee, Valve,

Control Valve


Distribution 3” - Pipe


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Distribution to AHU 116 and 108

2” – Valve, Pipe 1” - Pipe


Mezzanine

AHU 108 1” – Union, Valve, Pipe,

Control Valve, Pipe


Meter 1” - Pipe


Coater – Preheat 2” – Control Valve, Pipe,

Elbow


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Coater – Heat Coils 1.25” – Valve, Union,

Control Valve, Union, Tee

Bldg. 1 3rd Floor

Behind the Coater AHU 3” Pipe


AHU 106 1” – Pressure Reducing Valve, Strainer, Union, Control Valve, Union


RO HTR 1.5” Strainer

1” Control Valve



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WIP (CIP) 2” – Flange, Pipe, Valve, Strainer, Control Valve

3” – Pipe, Flange 7” SS Heat Exchanger

Bldg. 1 4th Floor

North HW Heater 2” Strainer

0.5” Pressure Reducing Valve

Bldg. 1 4th Floor

AHU 109 & Meter 1.5” – Pipe

1” - Control Valve

Main Bldg. 4th Floor

AHU 117 1.5” – Pipe, Valve, Elbow 1” – Union, Control Valve


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Bldg. 1 4th Floor

under the ceiling

Distribution to RTU 1 1” – Valve, Pressure Reducing Valve, Pipe

Bldg. 1 4th Floor

Autoclave 4” Filter 1” Pipe

Main Bldg. Roof

RTU 1 1” – Control Valve, Union,

Strainer, Elbow, Valve

Bldg. 7 Basement

Main Inlet 2” – Valve, Elbow

1” Meter Main to UH

2” Valve


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Bldg. 7 1st Floor

Distribution to AHU 115 1.25” – Strainer, Valve, Union, Elbow, Pressure

Reducing Valve 2.5” Pipe

Bldg. 7 1st Floor

AHU 115 and UH 2” – Pipe, Valve, Strainer

Bldg. 7 1st Floor

AHU 114 MUDA .75” – Valve, Strainer, Tee, Union, Pressure Reducing Valve, Pipe, Control Valve


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Detailed Calculations


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Documents

GlaxoSmithKline - Armstrong International · 1/28/2011 · ©2011 Armstrong Service, Inc. GlaxoSmithKline St. Louis, MO STEAM AND CONDENSATE AUDIT REPORT Project No: ASIR-10126-01-1210