Escolar Documentos
Profissional Documentos
Cultura Documentos
WELCOME
SERVICES SBU
TO
ENERGY SAVING
OPPORTUNITIES IN
INDUSTRIES
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SAFETY OATH
SERVICES SBU
2/22/2014
WELCOME
SERVICES SBU
TO
STEAM BASICS
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SERVICES SBU
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
2/22/2014
SERVICES SBU
hf
+ hfg
STEAM USE
SERVICES SBU
Steam distillation
Hot water generation by steam sparging
Vacuum jet ejectors
Textiles plants
2/22/2014
TYPES OF STEAM
Wet Steam
Superheated Steam
Flash Steam
Flash steam is generated when condensate pressure is reduced.
SERVICES SBU
The specific heat capacity of liquid is lower at reduced pressure and the
excess heat (hf at P1 hf at P2) is converted to steam at low pressure.
The flash steam generated is calculated by formula (hf at P1 hf at P2) /
(latent heat at P2). P1 is higher pressure and P2 is lower pressure.
This steam is used in plant operating at lower pressure or sent to boiler
feed water tank for pre heating boiler feed water by direct injection.
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SERVICES SBU
Saturated Steam
Running of steam engines to do mechanical work.
As energy storage which is extracted by heat transfer.
Process heat transfer
Pipeline tracing for maintaining constant process temperatures.
Motive fluid for pumping hot steam condensate for reuse to boiler feed
water tank.
Domestic use for cooking, steam cleaning of fabrics, aircraft food
trolleys and heating of buildings.
Superheated Steam
Generation of electricity in steam turbines.
Co generation of electricity in cogeneration steam at high pressure is
first used to generate electricity and then the low pressure steam is
used for other applications
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2/22/2014
SERVICES SBU
Pressure
Heat / Enthalpy
Specific Heat
Temperature
Entropy
Thermal Conductivity
Density
Entropy
Viscosity
Sp. Volume
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
UNITS OF MEASUREMENT OF
PROPERTIES OF STEAM
SI Units
MKS
Pressure
Pa (N/m2)
kg/cm2
Temperature
oK
oC
Density
kg/m3
kg/m3
Sp Volume
m3/kg
m3/kg
Enthalpy
J/kg
kcal/kg
Sp. Heat
J/(kg.K)
kcal/(kg.oC)
Heat
kJ
kcal
Entropy
J/kg K
kcal/kg K
kcal/kgoC
SERVICES SBU
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
2/22/2014
PRESSURE 1
SERVICES SBU
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PRESSURE 2
Pressure measured in
Atmospheric Pressure
SERVICES SBU
Other units of pressure are Pa, kPa, MPa, atm, kg / cm2, mm Hg, MWC, psi.
1 atm = 14.696 psi = 1.013 bar = 101.3 kPa = 0.1013 MPa = 760 mm Hg=1.033 Kg/cm2
1 bar = 14.504 psi = 0.1 MPa = 100 kPa = 105 Pa = 0.9869 atm = 1.02 kg/cm2
1 kg/cm2 = 14.223 psi = 0.9806 bar
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2/22/2014
TEMPERATURE
SERVICES SBU
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
SI Prefixes
SERVICES SBU
Multiplication Factor
Facotr
Prefix
Symbol
1,000,000,000,000,000,000
10 18
exa
1,000,000,000,000,000
10 15
peta
1,000,000,000,000
10 12
tera
1,000,000,000
10 9
giga
1,000,000
10 6
mega
1,000
10 3
kilo
100
10 2
hecto
10
10 1
deca
da
0.1
10 -1
deci
0.01
10 -2
centi
0.001
10 -3
mili
0.000 001
10 -6
micro
10 -9
nano
10 -12
pico
10 -15
Femto
10 -18
atto
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2/22/2014
STEAM TABLE
SERVICES SBU
Bothe pressure and temperature are required to get the properties of steam
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
Col 2
Saturation Temperature, oC
Col 3
Col 4
Col 5
Col 6
Col7
SERVICES SBU
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
2/22/2014
Temp
Sp Vol
steam
Sp wt
Steam
Kg/cm2
oC
M3/kg
Kg/m3
Kcal/kg
Kcal/kg
Kcal/kg
119.62
0.9016
1.109
119.87
645.8
525.9
158.08
0.3213
3.112
159.3
657.8
498.5
10
179.04
0.1981
5.049
181.2
663
481.8
30
232.76
0.068
14.7
239.5
669.7
430.2
50
262.7
0.0402
24.85
274.2
667.3
393.1
70
284.48
0.0279
35.78
300.9
662.1
361.2
225.65
374.15
0.0031
315
501.5
SERVICES SBU
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
TRENDS
SERVICES SBU
1.
2.
3.
4.
5.
Total heat of steam does not show much change but the distribution
of total heat changes
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
2/22/2014
SERVICES SBU
250
Temperature, oC
200
150
100
50
0
1
10 11 12 13 14 15 16 17 18 19 20
SERVICES SBU
2
1.8
1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
0
1
9 10 11 12 13 14 15 16 17 18 19 20
(a)
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10
2/22/2014
APPLICATION OF STEAM
TABLE TREND
SERVICES SBU
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COMPARISON
BOILER OPERATING AT DIFFERENT
PRESSURES
Dry Steam
Wet Steam
SERVICES SBU
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11
2/22/2014
ENTROPY
SERVICES SBU
Dry saturated
Dryness fraction as high as possible
No air or non condensable gases
Right quantity at right temperature
No solids
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12
2/22/2014
SERVICES SBU
Air enters as dissolved gases in boiler feed water and at every shutdown and gets carried to
heat transfer equipment traveling ahead of steam
CO2 gets generated if bi carbonates are present in feed water which decompose at high
temperature in the boiler
CO2 gets absorbed in condensate water due to its lower temperature from atmosphere
Non condensable in steam lowers its partial pressure resulting in lowering of effective
steam temperature
= 1:6:30
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DE-AERATION..
SERVICES SBU
Oxygen and many other non-condensable gases enter the steam system through flanged
joints, rusted & leaking fittings.
Oxygen promotes corrosion of pipes and fittings. It affects the heat transfer in equipment.
The
Removal of Oxygen and Non condensable gases is termed as De-aeration.
D issolved O xyg en in p pm
32
50
65
82
10 0
Temperature in Deg C
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13
2/22/2014
SERVICES SBU
SERVICES SBU
14
2/22/2014
WELCOME
SERVICES SBU
TO
STEAM GENERATION
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STEAM GENERATION
SERVICES SBU
Source of energy
Combustion of fuel
Fuel conditioning
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15
2/22/2014
FUEL TYPES
SERVICES SBU
SOLID FUELS
Coal, Wood, Husk, Bagasse
LIQUID FUELS
Furnace Oil (FO)
Light Diesel Oil (LDO)
High Speed Diesel(HSD) LSHS / HPS
GASEOUS FUELS
Liquefied Petroleum Gas (LPG) Natural Gas (NG)
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SERVICES SBU
16
2/22/2014
LIQUID FUELS
Furnace Oil (FO)
Light Diesel Oil (LDO)
GASEOUS FUELS
Liquified Petroleum Gas (LPG)
Natural Gas (NG)
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SERVICES SBU
Solid Fuels
Composition C, H, N, S, O2, H2O, Ash
Composition H2O, Ash, Volatile matter, Fixed Carbon, GCV, NCV
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17
2/22/2014
SERVICES SBU
Liquid Fuels
Composition C, H, N, S, O2, H2O, Ash, GCV, NCV
Density, Flash point, Pour point, Sediments
Gaseous Fuels
Composition C, H, N, S, O2, H2O, Ash, GCV, NCV
(Normally N, S, O2, Ash is absent)
Density
Chemicals present like Methane, Ethane, Propane,
Butane, etc. in volume percent
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
SERVICES SBU
Site Analysis
For Moisture % as fired condition
ULTIMATE ANALYSIS
C, H, N, S, O2, Ash, GCV, NCV
18
2/22/2014
COMBUSTION OF FUELS - 1
SERVICES SBU
COMBUSTION OF FUELS - 2
SERVICES SBU
Combustion air
Minimum quantity of excess air
Pre heated combustion air if possible
19
2/22/2014
BOILER CLASSIFICATION
SERVICES SBU
PACKAGED BOILERS
SERVICES SBU
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20
2/22/2014
SERVICES SBU
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BOILER RATING
SERVICES SBU
Boiler is rated on the basis of From and At 100oC basis written as F & A
100oC
Actual output from a boiler is always less than the F & A 100oC rating
Actual output from a boiler depends upon the feed water temperature.
Higher the feed water temperature higher is the output
If a boiler is rated as 1,000 kg/h F & A 100oC it means the boiler is rated
to give output of 539.4 kcal/kg of steam
But the process conditions determine the heat load or steam requirement
in a plant
This means higher the feed water temperature lower will be the fuel
consumption
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
21
2/22/2014
Boiler rating
Operating pressure
10 kg/cm2(g)
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Description
Value
SERVICES SBU
Unit
SATURATED STEAM
0oC
30oC
85oC
110oC
539.4
539.4
539.4
539.4
kcal/kg
663.9-0
663.9-30
663.9-85
663.9-110
kcal/kg
633.9
578.9
553.9
kcal/kg
= 663.9
3
Ratio, Av/Reqd
539.4/553.9 kcal/kg
0.851
0.932
0.974
851
932
974
Kg/h
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
22
2/22/2014
Description
SERVICES SBU
Value
Unit
654.3
Kcal/kg
0oC
30oC
85oC
110oC
539.4
539.4
539.4
539.4
kcal/kg
654.3-0
654.3-30
654.3-85
654.3-110
kcal/kg
624.3
569.3
544.3
kcal/kg
Ratio, Av/Reqd
0.864
0.948
0.991
864
948
991
Kg/h
851
932
974
Kg/h
= 654.3
539.4/544.3 kcal/kg
COMMITTED TO DELIVER I DrNNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
EFFICIENCY ESTIMATION
SERVICES SBU
TWO METHODS
Direct Efficiency
Indirect Efficiency
As per some standard like BS 845 Part 1 Or ASME PTC 4.1
As per good engineering practice
Evaluate only the major losses
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23
2/22/2014
DIRECT EFFICIENCY
Efficiency
Output
Input
=
=
=
=
SERVICES SBU
Output / Input
m * cp * (hg fwt)
m * (hg fwt)
fuel cons (f) * Cal Value
m * (hg fwt)
Direct Efficiency ()
------------------F * GCV
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BOILER EFFICIENCY
SERVICES SBU
INDIRECT METHOD
Efficiency = 100 all losses
Losses are
24
2/22/2014
ESTIMATION OF LOSSES
SERVICES SBU
SERVICES SBU
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25
2/22/2014
SERVICES SBU
Total loss, Lt
Lt gr
(L1 + L2 + L3 + L4 + L5 + L6) gr
Lt net
Thermal Efficiency, E
E gr
=
100 Lt gr
E net
100 Lt net
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
SERVICES SBU
Fuel
Kgr
Knet
VCO2 Th
H2
Constant k1
Coke
0.75
0.76
20.6
0.4
70
Anthracite
0.67
0.69
19.1
3.0
65
Coal
0.62
0.65
18.4
4.0
63
0.51
0.54
15.8
11.5
54
Fuel Oil D*
0.48
0.51
15.5
13.0
53
LPG Butane
0.43
0.46
14.1
17.2
48
LPG Propane
0.42
0.45
13.8
18.2
48
Natural Gas
0.35
0.39
11.9
24.4
40
* As per BS 2869
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
26
2/22/2014
Fuel consumption
Water consumption
Steam output
Stack temperature
O2 / CO2 in flue gas from chimney
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27
2/22/2014
SERVICES SBU
FLOW METERS
WATER
TM
A ZFLO-W
SERVICES SBU
28
2/22/2014
SERVICES SBU
SERVICES SBU
5
2
3
6
10
11
15
12
13
7
14
29
2/22/2014
16
45
SERVICES SBU
D
17
5xD
SERVICES SBU
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
30
2/22/2014
SERVICES SBU
2.
Steam is formed and taken out of the boiler continuously and does not carry and dissolved solids.
3.
If operated like this quantity of solids will go on increasing and will exceed the maximum solubility
at operating temperature. Solids will start separating out and will start depositing on the heat transfer
surfaces in the form of scale.
4.
This scale is hard and can cause mechanical damage to the boiler as well as hinder heat transfer as it
is bad conductor of heat
5.
Such scale forming is to be prevented and is dine by ensuring that the quantity of dissolved solids
never exceed the maximum solubility level with adequate safety margin
6.
This limit is 3500 ppm and is achieved by draining calculated amount of boiler water continuously in
a controlled way (SABCO) or periodically manually.
7.
The quantity of water to be drained is calculated by mass balance as per the following formula;
Blow down percentage = { Feed water TDS / ( Boiler water TDS Feed water TDS) } x 100
(Page 58 Technical Memento)
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
31
2/22/2014
BLOWDOWN LOCATIONS IN
STEAM BOILER
SERVICES SBU
SERVICES SBU
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32
2/22/2014
BLOWDOWN CALCULATIONS
Feed water TDS
Permitted boiler water TDS
Percentage blow down required
200
-------------- x 100
3500 200
= 6.06%
SERVICES SBU
200 ppm
3500 ppm
0.9 x 364 =
=
328
36
kg/h
kg/h
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
Equivalent fuel
Annual fuel cost
90% is surface blow down
SERVICES SBU
364 kg/h
10 kg/cm2
185.6 kcal/kg
185.6 x 364
67558.4 kcal/h
67558.4/9650/0.88
8 kg/h
8 x 24 x 300 x 50
INR 28,80,000
INR 25,92,000
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
33
2/22/2014
Recovering this
Equivalent fuel
Money saved per year
364 x 0.9
327.6 kg/h
0.5 kg/cm2
185.6 kcal/kg
110.92 kcal/kg
531.9 kcal/kg
185.6 110.92
74.68 kcal/kg of BD water
74.68/531.9 * 100
14.04%
46 kg/h
46 x 642.8
29568.8 kcal/h
3.5 kg/h
3.5 x 24 x 300 x 50
12,60,000
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
SERVICES SBU
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
34
2/22/2014
ENERGY SAVING
OPPORTUNITIES - BOILER
SERVICES SBU
WELCOME
SERVICES SBU
TO
STEAM DISTRIBUTION
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35
2/22/2014
STEAM DISTRIBUTION
SERVICES SBU
Install header in boiler house near ground level with valves and an air
vent
Use zero leakage valves like bellow seal valves
Use NRV in steam line if more than one boilers are connected to the
header
Ensure correct size of Piping
Provide header drain arrangement every 30 m of horizontal steam pipe
run
Provide air vent, vacuum breaker and drain steam trap at the end of
steam header
Provide moisture separators at entry to each steam using plant or
critical equipment
Insulate even valves and flanges in steam lines
Use pressure reducing stations
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
SERVICES SBU
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
36
2/22/2014
SERVICES SBU
Process Design
Superheated steam
Lines sized at velocity of upto 45 m/s
Saturated steam
Lines sized at velocity of 30 m/s for long lines
Lines sized for 35 m/s for short lines
Wet Steam
Lines sized at velocity of 10 to 15m/s
Steam Header
10 to 15 m/s
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
SERVICES SBU
m = 3600 . u . a .
m
u
a
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
37
2/22/2014
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
38
2/22/2014
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
39
2/22/2014
SERVICES SBU
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
SERVICES SBU
40
2/22/2014
Valve
Size
10
12
Op
Temp
Heat
Steam Heat
Stea
m
Heat
Steam Heat
Steam
Heat
Steam Heat
Steam
oC
kcal/h
kg/h
kcal/h
kg/h
kcal/h
kg/h
kcal/h
kg/h
kcal/h
kg/h
kcal/h
kg/h
100
426
0.85
509
1.01
761
1.51
1016
2.02
1207
2.40
1525
3.03
150
915
1.82
1094
2.17
1638
3.25
2185
4.34
2596
5.15
3279
6.51
200
1578
3.13
1882
3.74
2825
6.61
3765
7.47
4473
8.88
5650
11.21
250
2444
4.85
2943
5.84
4379
8.69
5839
11.59
6933
13.76
8757
17.38
300
3566
7.08
4259
8.45
6386
12.76
8515
16.90
10113
20.07
12774
25.35
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
SERVICES SBU
41
2/22/2014
SERVICES SBU
Body
Cover
Cover Gasket
Bi-metallic Plate
Strainer
Seat
Valve
Adjustment Screw
Cover Bolts
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
SERVICES SBU
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
42
2/22/2014
SS STRAINER
SERVICES SBU
BODY
DISCHARGE
BOLT
SS COVER
SS DISC
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
SERVICES SBU
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
43
2/22/2014
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
SS COVER
SS BODY
SERVICES SBU
THERMOSTATIC CAPSULE
SS STRAINER
44
2/22/2014
SERVICES SBU
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
SERVICES SBU
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
45
2/22/2014
SERVICES SBU
SS COVER
SS BALL
SS GASKET
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
SERVICES SBU
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
46
2/22/2014
1 Moisture Separator
2 Drain Valve
3 Drain Isolation Valve
4 Steam Trap
5 Isolation Valve
6 Pressure Indicator
7 Isolation Valve
8 Strainer
9 Control Valve
10 GATE Valve
SERVICES SBU
11 Globe Valve
12 Globe Valve
13 Globe Valve
14 Pressure Indicator
15 Safety Valve
16 Pr. Transmitter
17 Pr. Indicator Controller
18 E to P converter
19 AFR
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
WELCOME
SERVICES SBU
TO
STEAM UTILISATION
&
CONDENSATE RECOVERY
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47
2/22/2014
STEAM UTILISATION
SERVICES SBU
STEAM UTILISATION
SERVICES SBU
Direct Heating
Total enthalpy of steam available for heating which is higher that
latent heat
Product gets contaminated
Product gets diluted
No steam traps are required
Condensate can not be recovered for re use
Indirect heating
Only latent heat available for heating which is lesser than total
enthalpy of steam
Most of the industries use indirect method of heating
Condensate can be recovered for re use provided same heat
transfer area is not used for heating and cooling like coil in a
reactor
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48
2/22/2014
STEAM TRAPS
SERVICES SBU
Steam traps are automatic valves which work on the principle of difference in
property of steam
Thermodynamic trap
Thermodynamic property
Float trap
Buoyancy
Thermostatic trap
Bimetallic trap
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SERVICES SBU
49
2/22/2014
SOURCE OF CONDENSATE
SERVICES SBU
SERVICES SBU
50
2/22/2014
TTS-FS-SS
SERVICES SBU
BSP 3/8 1
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TBM
SERVICES SBU
51
2/22/2014
EXPECTATIONS FORM A
STEAM TRAP
SERVICES SBU
Criteria
Desired
Float &
Therm
ostatic
Vent
Thermodynami
c
Thermostatic
Inv erted
Bucket
Condensate Discharge
Continuous
Continuous
Intermittent
Continuous
Intermittent
Service Life
High
High
Lower
High
High
Wear Resistance
High
High
Low
Lower
Lower
Corrosion Resistance
High
High
High
High
High
High
Low
High
Low
High
Venting Capability
High
High
Lower
High
Lower
Good
Good
Poor
Good
Poor
Good
Good
Poor
Good
Good
Good
Good
Poor
Good
Good
10
Immediate
Immediate
Delayed
Delayed
Immediate
11
Good
Poor
Poor
Fair
Good
12
Physical size
Small
Intermediate
Small
Small
Large
13
Good
Fair
Poor
Poor
Good
14
Mechanical failure
Open / Closed
Closed
Open
Design Based
Open
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SERVICES SBU
3.
4.
52
2/22/2014
SERVICES SBU
S.No.
Application
Service Factor
Remarks
Boiler Header
Steam Separators
Tracing Lines
Submerged Coils
Jacketed Kettles
10
Evaporators
11
Flash tanks
12
Platen Presses
13
Rotating Cylinders
14
Air Heaters
15
Radiators
16
17
VAM
Note:
If the operating pressure differential varies to a very low value increase the safety factor
RECOMMENDED STEAM
TRAPS FOR EQUIPMENT
SERVICES SBU
Float tarps
With thermostatic vent
These are the normal traps
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53
2/22/2014
SERVICES SBU
SERVICES SBU
54
2/22/2014
SERVICES SBU
BODY
SS DISC
SS SEGMENT
SERVICES SBU
CENTERING
HOOP SS
55
2/22/2014
A steam trap blowing live steam will make a low pitch whistle
When a test valve is provided you can open it and observe the operation
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
Pressure,
kg/cm2
Loss, kg/h
Trap Size
15
20
25
40
50
1.17
2.34
3.25
7.30
12.99
20.29
6.49
14.61
25.97
40.58
3.51
9.74
21.91
38.96
60.87
4.67
12.99
29.22
51.94
81.16
5.84
16.23
36.52
64.93
101.45
7.01
19.48
43.83
77.92
121.74
8.18
22.73
51.13
90.90
142.03
9.35
25.97
58.44
103.89
162.32
10.52
29.22
65.74
116.87
182.62
10
11.69
32.46
73.05
129.86
202.91
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56
2/22/2014
TRAP PROBLEMS
SERVICES SBU
Water hammer
water hammer can destroy thermostatic element or crush ball float
Dirt
Dirt can plug strainer or lodge on the pin or seat. Dirt can plug the vent
hole in bucket traps causing them to fail shut
Pressure rating
the trap seat pressure rating must be higher than the maximum steam
pressure or the trap will fail closed
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SERVICES SBU
Heat recovery
Fuel saving
Thermal de-aeration
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57
2/22/2014
SERVICES SBU
SERVICES SBU
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58
2/22/2014
Flash Vessel
SERVICES SBU
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ECONOMICS OF CONDENSATE
RECOVERY
SERVICES SBU
59
2/22/2014
SERVICES SBU
Boiler
1. Efficient burner operating at low excess air so that we
get low excess air and high CO2 in flue gas
2. Instruments for O2, and stack temperatures
3. Fuel flow meters for liquid / gaseous fuel, steam flow
meter and water flow meter
4. Boiler performance monitoring system
5. Boiler surface blow down control and heat recovery
system
6. Heat recovery units for extracting heat from flue gas
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SERVICES SBU
1.
2.
3.
4.
5.
60
2/22/2014
WELCOME
SERVICES SBU
TO
CASE STUDIES ON ENERGY SAVING
EQUIPMENT
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CASE STUDIES
SERVICES SBU
61
2/22/2014
CONVENTIONAL
PISTON
BELLOW SEAL
Primary seal
Gland packing
Piston Rings
Metallic bellows
Stem Leakage
Starts on wearing of
piston rings
No leaksge
Replacement cost
Low
High
NA
Maintenance Cost
Very high
High
Nil
Equipment downtime
Very high
High
Nil
Packing Replacement
Very often
Nil
Media Loss
High
Nil
Safety
Valve life
Low , months
> conventional
High - Years
Initial cost
Low
High
High
Cost of ownership
Very high
High
Low
PLANT
NO.
TOTAL
VALVES
LEAKING
VALVES
% LEAKING
VALVES
TOTAL
STEAM
LEAKAGE,
KG
STEAM
LOSS PER
VALVE, KG
4.8
174
10
5.72
48
133
14
10.32
37
2.7
124
14
11.58
29
2.02
491
125
25.36
254
2.04
241
51
21.34
122
2.37
253
75
29.46
91
1.22
160
18
11.25
51
2.83
333
65
19.54
123
1.89
168
36
21.46
79
2.19
10
49
12
23.65
48
4.14
11
1101
197
17.85
313
1.59
12
321
63
19.76
128
2.02
13
164
12
7.28
43
3.6
14
568
37
6.54
64
1.72
15
198
18
9.24
41
2.24
62
2/22/2014
SERVICES SBU
1.
2.
3.
63
2/22/2014
SERVICES SBU
A process requires 25,000 kg/h of water to be heated from 30oC to 75oC. Steam
is available at 10 kg/cm2 as well as 3.5 kg/cm2. Select the steam pressure
Case 1:
=
=
478.3 kcal/kg
25,000 x 1 x (75 30) / 478.3
2,352 kg/h
=
=
506.7 kcal/kg
25,000 x 1 x (75 30) / 506.7
2,220 kg/h
2352 2220
Money Saved
=
=
Case 2:
= 132 kg/h
SERVICES SBU
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
64
2/22/2014
USE OF TEMPERATURE
CONTROLLERS
SERVICES SBU
80 30
50oC
T (Overheating)
85 30
55oC
1000 x (55/50)
1100 kg/h
1100 1000
100 kg/h
20,40,000
SERVICES SBU
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
65
2/22/2014
CASE STUDY 4
USE OF BIMETALLIC STEAM TRAP IN PLACE OF THERMODYNAMIC TYPE
For Thermax Chemical @ 6 bar
Legend
to
M1
Description
Time at start up
Mass of water initially
Unit
HH: mm
kg
T1
t1
M2
Deg C
HH: mm
kg
T2
Tc
Em
Lm
T
Lm
Time at end
Mass of water at end
31
11:45
16.85
Deg C
54
40
Deg C
158.826
158.826
Kcal / kg
659.3636364 659.3636364
Kg
0.24
min
15
15
0.97
0.14
Kg / Hr
SERVICES SBU
kg/hr
0.03482795
0.84
Description
Time at start up
Mass of water initially
Unit
HH: mm
kg
T1
t1
M2
Deg C
HH: mm
kg
T2
Tc
Em
Lm
T
Lm
Time at end
Mass of water at end
22
0:45
2.98
Deg C
75
54
Deg C
142.92
142.92
653.4
653.4
Kcal / kg
Kg
0.21 0.101529541
min
Kg / Hr
30
30
0.41
0.20
kg/hr
0.21
SERVICES SBU
0.017 kg
0.87 Rs. / kg
Rs. 870
0.87 x 1000
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66
2/22/2014
SERVICES SBU
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
BLOWDOWN CALCULATIONS
SERVICES SBU
0.9 x 364 =
=
328
36
kg/h
kg/h
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
67
2/22/2014
Equivalent fuel
Annual fuel cost
90% is surface blow down
SERVICES SBU
364 kg/h
10 kg/cm2
185.6 kcal/kg
185.6 x 364
67558.4 kcal/h
67558.4/9650/0.88
8 kg/h
8 x 24 x 300 x 50
INR 28,80,000
INR 25,92,000
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
Recovering this
Equivalent fuel
Money saved per year
364 x 0.9
327.6 kg/h
0.5 kg/cm2
185.6 kcal/kg
110.92 kcal/kg
531.9 kcal/kg
185.6 110.92
74.68 kcal/kg of BD water
74.68/531.9 * 100
14.04%
46 kg/h
46 x 642.8
29568.8 kcal/h
3.5 kg/h
3.5 x 24 x 300 x 50
12,60,000
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
68
2/22/2014
SABCO SCHEMATIC
SERVICES SBU
CONTACT DETAILS
SERVICES SBU
V K TRAMA
MOBILE 09890040272
E MAIL vktrama@yahoo.co.in
Sushama Garud
Mobile 02066155577
E mail info.c&hservices@thermaxindia.com
COMMITTED TO DELIVER INNOVATIVE ENERGY SOLUTIONS
69
2/22/2014
SERVICES SBU
THANK YOU
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70