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Steam System EfficienciesFebruary 18, 2004

Gregory J. Merlo & Allen Hoover

Steam System Improvements OpportunitiesAreas of Energy Loss

Energy Losses in a Steam System

– Steam Generation - 20-25%– Steam Distribution - 40-45%– Non-Utilized Condensate - 20-30%

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Steam System Improvements OpportunitiesAreas of Energy Loss

Steam Generation – 20-25%– Boiler oxygen profile– Fuel analysis– Fuel strategies– Burner control analysis– Feed water heater performance– Water Treatment– Boiler economizers– Blow down system and operation

Steam System Improvements OpportunitiesAreas of Energy Loss

Boiler Operating Efficiency– RULE OF THUMB

• Efficiency is related to the operating steam pressure/temperature.

• For each 40°F of temperature increase or decrease, 1% point of efficiency can be realized.

• Temperature at 125psig is 354°F. - Temperature at 25psig is 268°F.

• Thus if a boiler were operating with an efficiency of 80% at 125psig, it would then have an efficiency of 82% at 25psig.

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Steam System Improvements OpportunitiesAreas of Energy Loss

Steam Distribution – 40-45%

• Steam Trap Failure• Pressure Reducing (wherever possible)• Safety Relief Valves (leaking?)• Piping and Equipment Insulation

Steam System Improvements OpportunitiesSteam Trap Failure Costs

Steam Distribution– Failed Steam Traps = Energy and $ Loss

• 15psig system / drip trap / 6 months in service with steam cost @ $5.00/1,000#

• 1/4” orifice = 74#/hr x 24hrs x 180 = 319,680#/hr• Steam Cost $5.00/1,000#/hr.• 319,680#/hr x $5 /1,000 = $1,598 / trap steam loss• Assume 100 traps at 10% failure = $15,980/yr.

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Steam System Improvements OpportunitiesSteam Trap Survey Results

Steam Trap Survey ResultsTraps Tested: 3,467Trap Failures: * 110% Failed 3%Steam Cost: * * $8.95 / 1000#Annual Dollars Lost: $261,386.00Survey and Trap Replacement Cost: $ 76,000.00 Total Net Savings: $185,386.00Return on Investment: 244 %

*(Includes 76 leaks, 31 cold plugs and 3 flooded traps.)**(Area with reported steam cost of $14.44 / 1000#)

Steam System Improvements OpportunitiesSteam Trap Monitoring

Steam trap monitoring system– Detects immediately blow through steam traps– Detects immediately cold steam traps– 24/7 monitoring

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Steam System Improvements OpportunitiesAir Venting

Air in steam must be removed in order to reduce energy and optimize efficiency.

Steam System Improvements OpportunitiesCondensate Drainage

Heat ExchangersPrevention of freezing - water hammer - corrosion

• Vacuum breakers alwaysrequired on modulated steam service.

• Strainers with hoses attached indicate a drainage problem.

• Lifting of condensate on modulating systems must be eliminated.

• Drip trap stations ahead of control valves.

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Steam System Improvements OpportunitiesCondensate Return

Non-Utilized Condensate – 20-25%• Condensate Return System• Recovery of Flash Steam• Heat Recovery from Condensate

Steam System Improvements OpportunitiesCondensate Return

Condensate Heat RecoveryCondensate from building sent through PHE to preheat Domestic Water.

– Condensate at 150ºF (50gpm) inlet - 110ºF out– Cold water in at 100ºF - 140ºF out– 1M BTU recovered.– Steam cost @ $8 / 1M Btu x 8 hrs/day = $64/day

or $22,000 annually

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Steam System Improvements OpportunitiesFlash Steam Recovery

Example10,000#/hr load - 15psig 3% flash = 300#/hrCost of steam 8.00/1,000#$2.40 savings per hour.2,190 hours (1/4) year =

$5,256 flash saving opportunity

Steam System Improvements OpportunitiesUnderstanding your Steam System

Training – Fundamentals of Steam – Steam Trap Operation– Energy Conservation– Steam Trap Troubleshooting– Low Pressure Trapping– Water Hammer

Programs available at your facility or at our demonstration lab.

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Piping and Equipment Insulation Energy & Corrosion Protection

Why do we insulate?Process/Energy/Personnel/EnvironmentWhat are our Specifications?Only settings standards for K-values What are we doing to implement?Treatment or Cure?If Better is Possible/Good is not Enough!

Piping and Equipment Insulation Energy & Corrosion Protection

What is Ceramic Covering?– An effective thermal energy barrier– Temperature reducing coating with noise

reducing properties – Can be applied directly to hot surfaces without

expensive plant shut down– Easy to repair and maintain– Saves thermal energy and space– Corrosion resistant

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Piping and Equipment Insulation Energy & Corrosion Protection Benefits of Ceramic Covering

Chemical resistantOutstanding flexibility and adhesionCan be top coated with polyurethane, epoxy and waterborne coatingsComprehensively tested at independent laboratories

Piping and Equipment Insulation Energy & Corrosion Protection

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Piping and Equipment Insulation Energy & Corrosion Protection

Ceramic Limitations

Not to be applied to surfaces where the temperature is < 34oF or > 350ºF

Application should not be installed in ambient temperatures below 32°F unless surface temperature of substrate exceeds 100°F.

Piping and Equipment Insulation Energy & Corrosion Protection

Ceramic Covering Applications

Applications are endless for energy savings and corrosion protection:

– Condensate Pumps– Condensate Receivers– Flash & DA Tanks– Chillers– Water Heaters– Steam lines – Steam Traps– Boiler

– Overhead Doors– HVAC Ducting– Drain Pans in AHU– Valves/Flanges– Concrete – Indoors or Outoors

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Heat Exchangers w/Ceramic Covering

Heat Exchanger and Pipingw/Ceramic Covering

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Condensate Receiverw/Ceramic Covering

Chiller w/Ceramic Covering

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Air Conditioning Ductw/Ceramic Covering