Plant Services - December 2007 - (Page 24)

EFFICIENCY Steam Systems chiefly composed of carbon, to form on the heat transfer surfaces. This slows heat transfer, causing considerable energy loss. Soot can be mechanically removed with a flue brush. Once the soot is gone, a professional will be needed to recalibrate the burner. The payback on your investment to reduce stack temperature is quick, usually less than one year. Another cause of elevated stack temperature is scale formation on the waterside surfaces of the boiler caused by improper water treatment. The remedy might be either acid cleaning or tube replacement, depending upon the severity of the scaling condition. In either case, the fix, though more expensive than cleaning the fireside, is often paid back through energy savings in a year or less, depending upon boiler size. according to the U.S. Department of Energy (DOE). An auditor can ensure that distribution system piping is sized to produce the appropriate system pressure drops; that it’s adequately supported, guided and anchored; and that appropriate allowances are made for pipe expansion at operating temperatures. Blowdown Separators Heat Recovery Systems Inline Separators Exhaust Silencers Flash Separators Exhaust Heads Mist Separators "With Mist Eliminator Pad" Water in, water out Blowoff, Flash and Custom Manufactured ASME Code Tanks During a complete facility audit, the auditor also will investigate how the feedwater supply and condensate returns are being handled. They check to see if the water sent directly into the boiler is free of dissolved gases such as oxygen and carbon dioxide, which can cause destructive corrosion to the boiler and condensate lines. To avoid these conditions, one thing an auditor may recommend is install- The payback on your investment to reduce stack temperature is quick, usually less than one year. Survey piping In complete facility site audits, auditors survey the steam piping for energy losses through radiation and steam leaks. These manifestations of the Steamer are identifiable by the naked eye. Cutting down on steam loss through radiation is as simple as insulating the distribution system. More than half of process plants lack pipe insulation or the insulation has deteriorated to the point of uselessness. The larger the pipe diameter and greater the length, the more insulation can help in saving energy. Reducing steam leaks caused by piping corrosion and compromised flanging can be another significant energy saver. The leaks appear as wisps of condensed steam, and, once secured, result in considerable dollars saved (Table 1). Other opportunities to reduce energy costs with piping include ensuring steam mains are laid out, sized, drained and vented properly, www.PLANTSERVICES.com Tel: 814.849.7328 Fax: 814.849.4510 ing a deaerator (Figure 2) for removing dissolved oxygen and carbon dioxide from the feedwater. Auditors also will check to ensure the facility is using a water softener and that it’s working properly. Without a water softener, scale builds up in the heat exchanger, and it doesn’t take much scale to cause fuel usage to skyrocket: a quarter-inch of scale increases fuel use as much as 15%. They also will examine condensate return. For many years, condensate was dumped down the drain. In the past few years, cost pressures and environmental concerns have forced facility engineers, managers and supervisors to rethink how they handle condensate. Because condensate has already been through the steam system, it takes far less heat and fuel to turn it back into steam than it would to produce steam from an equal quantity of cold water. That’s why steam users should return the condensate back to December 2007 24 http://www.pennseparator.com http://www.PLANTSERVICES.com

Table of Contents Feed for the Digital Edition of Plant Services - December 2007

Plant Services - December 2007 Contents From the Editor: Orange Alert The PS Files: Pressed into Innovation Up and Running What Works: Samuel Adams Facility Refreshed in Cincinnati Energy Expert: Energy's "Perfect Storm" Technology Toolbox: Know Your Position Cover Story: Get a Grip on the Steamer Piping: Outside Looking In Web Hunter: Potpourri X In the Trenches: Making a Big Stink Boiler Room: Getting Educated

Plant Services - December 2007

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