Energy efficiency tip of the day (Steam systems low efficiency problems)
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Transcript of Energy efficiency tip of the day (Steam systems low efficiency problems)
![Page 1: Energy efficiency tip of the day (Steam systems low efficiency problems)](https://reader034.fdocuments.net/reader034/viewer/2022052302/58cede3f1a28abd4098b6aa3/html5/thumbnails/1.jpg)
SteamsystemlowefficiencyProblems
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Reasonsforlowefficiency
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BoilersFrequenton-offcycles
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Results
![Page 5: Energy efficiency tip of the day (Steam systems low efficiency problems)](https://reader034.fdocuments.net/reader034/viewer/2022052302/58cede3f1a28abd4098b6aa3/html5/thumbnails/5.jpg)
Results Lossofenergyatstartupcycles
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Solution
Boilercontinuousoperationatgoodload
Adjuststeamconsumersloadtokeepboilerloadaboveminimumturn-downratio
Reviewboilersloadsharingandcontrolconcept
![Page 7: Energy efficiency tip of the day (Steam systems low efficiency problems)](https://reader034.fdocuments.net/reader034/viewer/2022052302/58cede3f1a28abd4098b6aa3/html5/thumbnails/7.jpg)
Boileroperationatlowerpressurethandesignpressure
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Results
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Lossofefficiencyatlowpressure
Increaseradiationandconvectionlosses
Lowerqualitysteamproduced(foamformation)
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Possibilityofsteampriming(watercarryover)withloadchange
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Solution
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OperateBoileratpressureclosetodesignpressure
Adjustboilerpressuretodesignandadjuststeampressureatconsumersidewithletdownvalve
Checkfeasibilityofusingletdownorextractionturbineinsteadofletdownvalvestorecovertheenergy
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Highsteamvelocityinpipes(morethan30m/s)
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Happenswhenweaddmoresteamquantitieswithoutconsideringexistingsteampipessize
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Results
Noiseandvibrationinsteamlines
Causeofwater-hammerifcondensationhappens
Pipeserosion
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Solution
Checktheexistingsteamvelocityinyoursteamnetworkandplanforanyrequiredde-bottleneck.
Considertochecksteamnetworkpipingsizebeforeaddinganewadditionalamountofsteammorethandesign
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Water-hammerandcondensation
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Startupcondensatenotremoved
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ResultsNoiseandvibrationinsteamlines
SteamleaksPipingjointsfailure
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SolutionChecksteamtrapsanddrainsatsystemstartupandoperation
Goodselectionforsteamtrapstype
Applyregularmaintenanceplanforsteamtraps
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Solution
Ensureremovingcondensatefromsteampipes
Checksteamtrapsanddrainsatsystemstartupandoperation
Goodselectionforsteamtrapstype
Applyregularmaintenanceplanforsteamtraps
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Defectedsysteminsulation
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ResultsLossofenergy
Example(1.5Kgofsteam/hr/mofpipeiscondensedbyloosingenergywithoutinsulation)(at7barsteamsystem)
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Solution
Ensuregoodinsulationisinplace
Checktheconditionofsysteminsulationandapplyanymaintenancerequiredimmediately
ConsiderInsulationupgradeforoldsystems
Applythermalscanningtodetectdefectedareas
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Presenceofairandnoncondensablegasesinsteamsystem
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Results
Poorheattransfer
Corrosionduetoaciditywithcondensate
Reducegeneratedsteamtemperature
![Page 27: Energy efficiency tip of the day (Steam systems low efficiency problems)](https://reader034.fdocuments.net/reader034/viewer/2022052302/58cede3f1a28abd4098b6aa3/html5/thumbnails/27.jpg)
Solution
Insureairremovalfromsystem
Usesystemairventsasperstandardoperatingprocedures.
Regularcheckforsteamtraps
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Commonresult
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Highoperationalandmaintenancecost
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QuantifiedenergysavingopportunitiesforBoilers
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ImprovedoperationandmaintenanceofboilersUpto5%
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ImprovedwatertreatmentandboilerwaterconditioningUpto2%
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Totaldissolvedsolids(TDS)controlandboilerblowdownUpto2%
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BlowdownheatrecoveryUpto4%
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Boilerandburnermanagementsystems,digitalcombustioncontrolsandoxygentrimUpto5%
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EconomisersUpto5%
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Combustionairpre-heatingUpto2%
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360ProactiveEngineerwww.360ProcativeEngineer.com
![Page 39: Energy efficiency tip of the day (Steam systems low efficiency problems)](https://reader034.fdocuments.net/reader034/viewer/2022052302/58cede3f1a28abd4098b6aa3/html5/thumbnails/39.jpg)
SteamsystemlowefficiencyProblems
Reasonsforlowefficiency
BoilersFrequenton-offcycles
Results Lossofenergyatstartupcycles
Solution
Boilercontinuousoperationatgoodload
Adjuststeamconsumersloadtokeepboilerloadaboveminimumturn-downratio
Reviewboilersloadsharingandcontrolconcept
Boileroperationatlowerpressurethandesignpressure
Results
Lossofefficiencyatlowpressure
Increaseradiationandconvectionlosses
Lowerqualitysteamproduced(foamformation)
Possibilityofsteampriming(watercarryover)withloadchange
Solution
OperateBoileratpressureclosetodesignpressure
Adjustboilerpressuretodesignandadjuststeampressureatconsumersidewithletdownvalve
Checkfeasibilityofusingletdownorextractionturbineinsteadofletdownvalvestorecovertheenergy
Highsteamvelocityinpipes(morethan30m/s)
Happenswhenweaddmoresteamquantitieswithoutconsideringexistingsteampipessize
Results
Noiseandvibrationinsteamlines
Causeofwater-hammerifcondensationhappens
Pipeserosion
Solution
Checktheexistingsteamvelocityinyoursteamnetworkandplanforanyrequiredde-bottleneck.
Considertochecksteamnetworkpipingsizebeforeaddinganewadditionalamountofsteammorethandesign
Water-hammerandcondensation
Startupcondensatenotremoved
ResultsNoiseandvibrationinsteamlines
SteamleaksPipingjointsfailure
Solution
Ensureremovingcondensatefromsteampipes
Checksteamtrapsanddrainsatsystemstartupandoperation
Goodselectionforsteamtrapstype
Applyregularmaintenanceplanforsteamtraps
Defectedsysteminsulation
ResultsLossofenergy
Example(1.5Kgofsteam/hr/mofpipeiscondensedbyloosingenergywithoutinsulation)(at7barsteamsystem)
Solution
Ensuregoodinsulationisinplace
Checktheconditionofsysteminsulationandapplyanymaintenancerequiredimmediately
ConsiderInsulationupgradeforoldsystems
Applythermalscanningtodetectdefectedareas
Presenceofairandnoncondensablegasesinsteamsystem
Results
Poorheattransfer
Corrosionduetoaciditywithcondensate
Reducegeneratedsteamtemperature
Solution
Insureairremovalfromsystem
Usesystemairventsasperstandardoperatingprocedures.
Regularcheckforsteamtraps
Commonresult Highoperationalandmaintenancecost
QuantifiedenergysavingopportunitiesforBoilers
ImprovedoperationandmaintenanceofboilersUpto5%
ImprovedwatertreatmentandboilerwaterconditioningUpto2%
Totaldissolvedsolids(TDS)controlandboilerblowdownUpto2%
BlowdownheatrecoveryUpto4%
Boilerandburnermanagementsystems,digitalcombustioncontrolsandoxygentrimUpto5%
EconomisersUpto5%
Combustionairpre-heatingUpto2%
360ProactiveEngineerwww.360ProcativeEngineer.com