Heating Plant Overall for CEOs

STEAM PLANT EXECUTIVE SUMMIT

FOR HEATING PLANTS

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BENCHMARKS

PLANT EFFICIENCY

STEAM / HOT WATER COSTS

STEAM / HOT WATER USAGE

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PLANT EFFICIENCY

Total gas therms in 2012 7,862,240 JANUARY 107,125,000

Total #6 oil gallons in 2012 120,310 FEBRUARY 93,949,000

MARCH 66,638,000

Btu/therm 100,000 Gas APRIL 43,566,000

Btu/gallon 153,200 #6 OIL MAY 24,490,000

JUNE 20,354,000

Total gas Btu’s in 2012 786,224,000,000 JULY 18,606,000

Total oil Btu’s in 2012 18,431,492,000 AUGUST 17,926,000

SEPTEMBER 19,735,000

Total fuel BTU’s in 2012 804,655,492,000 OCTOBER 42,128,000

NOVEMBER 59,510,000

DECEMBER 92,882,000

Total Steam Pounds Produced 606,909,000

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STEAM / HOT WATER COSTS

2012 2012 #’S OF STEAM

GAS $5,951,725.39 55.9% JANUARY 107,125,000

OIL $381,382.70 3.6% FEBRUARY 93,949,000

WATER $99,919.35 0.9% MARCH 66,638,000

CHEMICALS $44,307.85 0.4% APRIL 43,566,000

PAYROLL $3,343,997.63 31.4% MAY 24,490,000

PARTS $150,463.49 1.8% JUNE 20,354,000

REPAIRS $327,183.87 3.1% JULY 18,606,000

ELECTRIC $306,000.00 2.9% AUGUST 17,926,000

SEPTEMBER 19,735,000

$10,649,288.13 100.0% OCTOBER 42,128,000

NOVEMBER 59,510,000

DECEMBER 92,882,000

PARKCHESTER

$/Mpound $17.47 Total Steam Pounds Produced 606,909,000

STEAMBTU’s

HOT WATER

LEAKY TRAPS

HEATING

PROCESS

STEAM AND HOT WATER USE

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PLANT EFFICIENCY

BOILER EFFICIENCY

SEQUENCING OF OPERATIONS

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BOILER EFFICIENCY

O2

WASTE HEAT RECOVERY

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A furnace operates at 2,400° F flue gas temperature. The optimum ratio is 10% excess air (2.1% O2 in flue gases), but tests show an actual ratio of 25% excess air (4.5% O2 in flue gases). The chart shows an actual available heat of 22% compared to an ideal of 29%.

FUEL SAVINGS = 100 X ((29 – 22) / 29) = 24%

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WASTE HEAT RECOVERY

ECONOMIZERS

FLUE GAS HEAT RECOVERY SYSTEM

BLOW DOWN HEAT EXCHANGERSAIR PREHEATERS

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PLANT EFFICIENCY

SEQUENCING OF OPERATIONS

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USING LESS

OPERATIONAL DASHBOARD

STEAM TRAPS

INSULATIONOPERATING STANDARDS

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OPERATIONAL DASHBOARD

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In a plant where the value of steam is $10.00 per thousand pounds ($10.00/1,000 lb), an inspection program indicates that a trap on a 150-pound-per-square-inch-gauge (psig) steam line is stuck open. The trap orifice is 1/8th inch in diameter. The table shows the estimated steam loss as 75.8 pounds per hour (lb/hr). After the failed trap is repaired, annual savings are:

ANNUAL SAVINGS = 75.8 IB/HR X 8,760 HR/YR X $10.00/1,000 lb=$6,640

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INSULATION

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OPERATIONAL STANDARDS

Heating Plant Overall for CEOs

Engineering

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