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energy efficiency tip of the day (efficient steam system control)

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Efficient Steam system control

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Page 1: Energy Efficiency tip of the day (Efficient Steam system control)

EfficientSteamsystemcontrol

Page 2: Energy Efficiency tip of the day (Efficient Steam system control)

TheProblem

Page 3: Energy Efficiency tip of the day (Efficient Steam system control)

Area

Page 4: Energy Efficiency tip of the day (Efficient Steam system control)

Flowcontrol

Page 5: Energy Efficiency tip of the day (Efficient Steam system control)

Problem

NoSteamflow-metersatproductionandconsumerside

Existingflowmetersarenotcalibratedregularly

Page 6: Energy Efficiency tip of the day (Efficient Steam system control)

Impact missingofimportantdataneededfor

PlantEfficiency

EnergyEfficiency

ProcessControl

CostingandCustodyTransfer

Page 7: Energy Efficiency tip of the day (Efficient Steam system control)

Solution Usesteamflowmeterswhenitisfeasible youcanonlycontrolwhatyoucanmeasure

Page 8: Energy Efficiency tip of the day (Efficient Steam system control)

Pressurecontrol

Page 9: Energy Efficiency tip of the day (Efficient Steam system control)

Atgenerationside(boilerside)

Problem Producingsteamatlowerpressure

Impact

Poorboilerefficiency

Highsteamconsumption

Highfuelconsumption

Page 10: Energy Efficiency tip of the day (Efficient Steam system control)

AtconsumersideProblem Unstablepressure(poorcontrol)

Impact Performancefluctuation

Page 11: Energy Efficiency tip of the day (Efficient Steam system control)

Solution

Atboilerside generatesteamatmaximumpressureaccepted

Atconsumerside usesuitableletdownvalves

DirectActingControlValves

PilotOperatedValves

PneumaticallyOperatedValves

Page 12: Energy Efficiency tip of the day (Efficient Steam system control)

Temperaturecontrol

Page 13: Energy Efficiency tip of the day (Efficient Steam system control)

Problem Poorinletsteamcontrol

Page 14: Energy Efficiency tip of the day (Efficient Steam system control)

Impact

Performancefluctuation

overheatingordiscomfortforapplication

Mechanicaldamage

Lossofefficiency

Page 15: Energy Efficiency tip of the day (Efficient Steam system control)

Solution usesuitabletemp.controlvalve

ManualControlValves

SelfActingControlValves

PilotOperatedValves

PneumaticallyOperatedValves

Page 16: Energy Efficiency tip of the day (Efficient Steam system control)

Condensateremoval

Page 17: Energy Efficiency tip of the day (Efficient Steam system control)

Problem Poorsteamtrapsperformance

Page 18: Energy Efficiency tip of the day (Efficient Steam system control)

Impact

Performancefluctuation

waterlogging

Lossofefficiency

waterhammerandvibration

Page 19: Energy Efficiency tip of the day (Efficient Steam system control)

Solution Considerthefollowingaspectsinselection

Thedifferentialpressure

Thesizeofthedischargeorifice

Thecondensatetemperature

Page 20: Energy Efficiency tip of the day (Efficient Steam system control)

Commonresult Highoperationalandmaintenancecost

Page 21: Energy Efficiency tip of the day (Efficient Steam system control)

Solution

Page 22: Energy Efficiency tip of the day (Efficient Steam system control)

ProposedActions

Page 23: Energy Efficiency tip of the day (Efficient Steam system control)

Checktheexistingsteamflowmetersandpreparealistofneededflowmeters

Page 24: Energy Efficiency tip of the day (Efficient Steam system control)

Prepareacalibrationplanfortheexistingsteammetersonceevery6monthsifpossible.

Page 25: Energy Efficiency tip of the day (Efficient Steam system control)

Increaseboilerpressureclosetoboilerdesignpressureandadjuststeampressureatconsumersidewithletdownvalve

Page 26: Energy Efficiency tip of the day (Efficient Steam system control)

Applyregularfunctionalsteamtrapsmaintennceprogram

Page 27: Energy Efficiency tip of the day (Efficient Steam system control)

Checkfeasibilityofusingletdownorextractionturbineinsteadofletdownvalvestorecovertheenergy

Page 28: Energy Efficiency tip of the day (Efficient Steam system control)

Checktheexistingsteaminlettemperaturetrendforsteamconsumersandevaluateyourcurrenttemp.controlsystemperformance.

Page 29: Energy Efficiency tip of the day (Efficient Steam system control)

Checktheexistingsteaminletpressuretrendforsteamconsumersandevaluateyourcurrentpressurecontrolsystemperformance.

Page 30: Energy Efficiency tip of the day (Efficient Steam system control)

360ProactiveEngineerwww.360ProcativeEngineer.com

Page 31: Energy Efficiency tip of the day (Efficient Steam system control)

EfficientSteamsystemcontrol

TheProblem

Area

Flowcontrol

Problem

NoSteamflow-metersatproductionandconsumerside

Existingflowmetersarenotcalibratedregularly

Impact missingofimportantdataneededfor

PlantEfficiency

EnergyEfficiency

ProcessControl

CostingandCustodyTransfer

Solution Usesteamflowmeterswhenitisfeasible youcanonlycontrolwhatyoucanmeasure

Pressurecontrol

Atgenerationside(boilerside)

Problem Producingsteamatlowerpressure

Impact

Poorboilerefficiency

Highsteamconsumption

Highfuelconsumption

AtconsumersideProblem Unstablepressure(poorcontrol)

Impact Performancefluctuation

Solution

Atboilerside generatesteamatmaximumpressureaccepted

Atconsumerside usesuitableletdownvalves

DirectActingControlValves

PilotOperatedValves

PneumaticallyOperatedValves

Temperaturecontrol

Problem Poorinletsteamcontrol

Impact

Performancefluctuation

overheatingordiscomfortforapplication

Mechanicaldamage

Lossofefficiency

Solution usesuitabletemp.controlvalve

ManualControlValves

SelfActingControlValves

PilotOperatedValves

PneumaticallyOperatedValves

Condensateremoval

Problem Poorsteamtrapsperformance

Impact

Performancefluctuation

waterlogging

Lossofefficiency

waterhammerandvibration

Solution Considerthefollowingaspectsinselection

Thedifferentialpressure

Thesizeofthedischargeorifice

Thecondensatetemperature

Commonresult Highoperationalandmaintenancecost

Solution ProposedActions

Checktheexistingsteamflowmetersandpreparealistofneededflowmeters

Prepareacalibrationplanfortheexistingsteammetersonceevery6monthsifpossible.

Increaseboilerpressureclosetoboilerdesignpressureandadjuststeampressureatconsumersidewithletdownvalve

Applyregularfunctionalsteamtrapsmaintennceprogram

Checkfeasibilityofusingletdownorextractionturbineinsteadofletdownvalvestorecovertheenergy

Checktheexistingsteaminlettemperaturetrendforsteamconsumersandevaluateyourcurrenttemp.controlsystemperformance.

Checktheexistingsteaminletpressuretrendforsteamconsumersandevaluateyourcurrentpressurecontrolsystemperformance.

360ProactiveEngineerwww.360ProcativeEngineer.com


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