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Heat Exchanger Stall. Condensate Return. Hotter boiler feed water temperatures Minimizes the amount of chemicals required to treat boiler feed water Eliminates environmental concerns Minimizes water usage which is critical in some areas - PowerPoint PPT Presentation
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©2005 Armstrong International, Inc.
Heat Exchanger Stall
2““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
Condensate Return
Let’s take a look at a savings analysis...
•Hotter boiler feed water temperatures
•Minimizes the amount of chemicals required to treat boiler feed water
•Eliminates environmental concerns
•Minimizes water usage which is critical in some areas
•Condensate is a tangible item which can be measured in the form of a savings analysis
•Effective return can lower overall costs which can impact profitability
3““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
A. Condensate Load A= 2000 lb/hrB. Annual hours of operation B= 5000 hrsC. Total Water Cost = (C1+C2) C1. Untreated water and sewage .002 $/gal C2. Water treatment chemicals .003 $/gal
C= .005 $/galD. Make-up water preheating requirements D1. Condensate return temperature 200 °F D2. Make-up water temperature 60 °F D = (D1-D2) x 1.0 BTU/lb / °F D= 140 BTU/ lb
E. Steam cost E= 5.00 $/1000 lb
F. Savings in water costs(A) x 2000 x (B) 5000 x (C) .005
8.34 lb/gal F= 5,995 $/yr
G. Savings for preheating make-up water *(BTU/lb from direct steam injection)
(A) 2000 x (B) 5000 x (D) 140 x (E) 5.00*1000 x 1000 G= 7,000 $/yr
H. Cost of steam to run Armstrong Pump Trap3 x (A) 2000 x (B) 5000 x (E) 5.00 *1000 x 1000 H= 150 $/yr
I. Total annual savings = (F+G+H) F. Savings in water costs 5,995 $/yr G. Savings for preheating make-up water +7,000 $/yr H. Cost of steam to run Armstrong Pump Trap - 150 $/yr
I= 12,845 $/yrJ. Payback of pump purchase Payback = $5,063 (cost of pump package)
12,845 J= .39 yrs
4““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
25 psig Steam 25 psig Steam MainMain
Modulating Modulating Control Valve 0 Control Valve 0 – 25 psig– 25 psig
5““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
Effects of “Stall”
• Inadequate condensate drainage
• Water hammer
• Frozen coils
• Corrosion due to Carbonic Acid formation
• Poor temperature control
• Control valve hunting (system cycling)
• Reduction of heat transfer capacity
6““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
Factors Contributing to Stall
• Oversized equipment
• Conservative fouling factors
• Excessive safety factors
• Large operating ranges
• Back pressure at steam trap discharge
• Changes in system parameters
7““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
25 psig Steam 25 psig Steam MainMain
Modulating Modulating Control Valve 0 Control Valve 0 – 25 psig– 25 psig
8““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
What is the “Stall” Solution?
• Use a bigger steam trap ?• Use a vacuum breaker ?• Implement a safety drain ?• Install a Positive-Pressure system ?• Use an electric pump?
9““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
Finding “Stall”
Where does Stall occur?
• Air heating coils• Shell & tube heat exchangers• Plate & frame heat exchangers• Absorption chillers• Kettles• Any type of heat transfer equipment that has
Modulating Control
10““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
11““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
12““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
Product Product RangeRange
• Single pump capacities from 350 lb/hr to 73,000 lb/hr
• Flash recovery vessels
• Electric condensate pumps
13““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
Rescue Cap™Rescue Cap™
• Fits Spirax Sarco PPC/PPF pumps
• Watson McDaniel
• Spence
• Hoffman PCS
• Gestra FPS23
• Johnson
• Clark Reliance
14““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
Armstrong Stainless Steel Sump EjectorArmstrong Stainless Steel Sump Ejector
• Replaces standard electric sump pumps (must have high pressure steam available
• For steam pits, tunnels and enclosed spaces where ground or rain water can accumulate and requires pumping
• Can be used in any application where the water temperature will not exceed 140°F
• Great for locations that run underground steam lines where the drip traps are in tunnels or manholes
15““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
Armstrong AFT Vertical Flash VesselsArmstrong AFT Vertical Flash Vessels
• Excellent for providing low velocity flash steam with no water carryover
• ASME Sec. VIII U stamped to 150 PSI (other pressures upon request)
16““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
Packaged Packaged SolutionsSolutions
• Standard Packages
• Custom Fabrications
• ASME Packages
• Low Boy Solutions
• Vented Systems
• Closed-loop Systems
• Process Water Packages
and more…Closed-loop Low-Boy Receiver PackageClosed-loop Low-Boy Receiver Package
17““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
Common Industry Applications
Modulating Control
• Jacketed KettlesJacketed Kettles
• Process Air HeatingProcess Air Heating
• Tank HeatersTank Heaters
• Shell & Tube ExchangersShell & Tube Exchangers
• Process Media (water, oil, food etc.)Process Media (water, oil, food etc.)
Any steam consuming process heat exchanger Any steam consuming process heat exchanger utilizing…utilizing…
18““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong
““Expect many Expect many enjoyable experiencesenjoyable experiences!”!”David M. ArmstrongDavid M. Armstrong