Managing An Energy Efficient

Steam Distribution System

Campbell-Sevey, Inc.

May 12, 2015

Steam System Topics

1. Steam Traps 2. Importance of Regular Trap Monitoring 3. Automatic Trap Monitoring 4. Condensate Return 5. Valve Insulating Blankets

Typical Steam System

Typical Steam System

Steam Trap Functions

A Steam Trap Must Provide:

1. Trap Live Steam 2. Remove Condensate 3. Remove Air and Non-Condensable Gas

Steam Trap Concepts

When Steam Trap Provides All Functions, System Can Achieve:

1. Fast heat-up 2. No water hammer 3. Maximum equipment temperature for

increased performance 4. Maximum fuel economy 5. Maximum equipment longevity 6. Minimum maintenance

Steam Trap

Management Discussion

• Putting Dollars and Cents to Steam Trap Failure: - Steam trap management is becoming increasingly important - The value of steam - Focus on energy savings and cost avoidance

• Manual Trap Monitoring: - Comprehensive survey reports - Returns steam system to intended purpose - Minimizes energy loss

• Wireless Monitoring System: - Tool for monitoring steam traps, PRV’s, condensate tanks and pumps, safety relief valves - Components – Design principles

Steam Trap Management

Is Becoming

Increasingly Important

• The value of steam • Focus on energy savings and cost avoidance

What Is The Cost of Steam?

2003 Steam Rate

($8.76/1,000 lb)

Annual Usage = 1,493,800,000 lb

Total Annual Cost = $13,087,843

Energy Cost of a Failed

Steam Trap?

$210

$458

$622

$742 $733

$1,055

$0

$200

$400

$600

$800

$1,000

$1,200

15 psi (5/32") 50 psi (5/32") 125 psi (1/8") 200 psi (7/64") 400 psi (5/64") 600 psi (3/32")

Steam Pressure (Orifice Size In)

US

Do

llars

Dollar Loss in 1 month

What Is The Cost of Undetected

Steam Trap Failure?

Energy Losses!

Pressurized return lines

Unexpected down time

Compromised or loss of

product

Failure of auxiliary equipment

such as PRV’s, electric

condensate pumps, and

control valves

Emergency labor requirements

Typical Steam System Program

Issues of Today

• Facilities struggle to maintain focus on steam trap management because of other facility priorities • Labor in most facilities is limited – workers are asked to do more with less • Tracking energy savings and cost avoidance on a continual basis does not exist due to lack of available tools

Long-Term Objectives

• An effective steam trap management program must be sustainable over the long-term to achieve results • The program must be benchmarked – manage what is measured

0

5

10

15

20

25

30

1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006

Perc

en

tag

e (

%)

Trend of % Steam Trap Failure

What is SteamEye®?

• Radio Frequency 24/7 steam trap monitoring system designed to effectively allocate labor, and promote energy savings • The trap population can be viewed from any computer in the company network • When a steam trap reports as failed, action can be taken to mitigate losses and reduce additional steam system issues

Components of a SteamEye®

Systems

• RF Transmitters - Measures cold and blow through conditions

• Repeaters

- Where needed

• Gateway

Components of a SteamEye®

Systems

Typical RF Facility Layout

• 1200 feet line of site • Average distance is 300 – 500 feet in most facilities

Gateway

• Allows users to access from any network computer • Can be programmed to link with BAS and DCS systems • Can automatically communicate with the SteamStar database • Works like a computer; CPU, web server, battery back up • Can page or email three people when a steam trap fails

Condensate Return

• Utilizes all valuable BTU’s within the steam system • Effective recovery of condensate reduces: - Fuel/Energy costs associated with producing steam - Boiler water make-up and sewage treatment - Boiler water chemical treatment • Protects the environment • Saves you money

Electric Centrifugal Pumps

Receiver

Motor

Pump

Float switch

Inlet

Overflow

Vent

Condensate Return

• Excellent for returning cold condensate

• Inexpensive for initial purchase - cost of running wire

• Cast iron or steel receivers

• Typically sized 3:1

• Non-standard packages available - elevated receivers • higher temp. condensate - duplex units - control panel

• Must be used in vented systems

Methods of Condensate Return

Continued…

Receiver

Pump

Inlet Check Valve

Outlet Check Valve

Mechanical Pumps

Mechanical Pumps

• Operates with spring assisted float mechanism • Utilizes steam, air or inert gas as motive • Can be used in: - Vacuum systems - Sump applications - Vented systems - Closed systems • Pre-packaged, pre-piped units available • Designed for quick, single trade installation - Non-standard packages available • Non-electric - Can be used in explosion proof areas - Can be used in remote locations

Mechanical Pumps

• Investment cast stainless steel internals - Wear and corrosion resistance - Provides long service life • Externally replaceable vent and motive seats • Inconel X-750 springs - Provides stress chloride resistance - More reliable than standard stainless steel springs - 3 Year Warranty - Typical

Pipe Insulation

Pipe Insulation Including

Valves

Reusable Thermal &

Acoustical Insulation Covers -

Applications

• Piping Systems • Turbines • Exhaust Systems • Equipment • Pumps • Man-Way Doors • Instrument Covers • Solar Applications • Acoustical Applications • Tube Wrap

TEP, Inc. “Energy Wrap”

Advantage

• Energy Conservation • Personnel Protection • Freeze Protection • Fire Protection • Labor / Material Savings • Sound Attenuation • Reduced Room Temperature • Maintaining Process Control Temperature • Reduced Operation Cycles of Equipment • Reduction in Waste Material

$ Payback Analysis

• TEP Inc.'s Energy Wrap Systems make it easy to save energy and lower emissions, which in turn saves customers money.

• Energy Wrap systems often reduce heat loss by 90% or more, and typical paybacks are 12 months or less.

• On hot applications Energy Wrap offers 95% insulation efficiencies, allowing customers to produce more and spend less.

• No matter the process temperature, TEP Inc. has a solution that will save both energy and money.

Steam System Review

1. Steam Traps 2. Importance of Regular Trap Monitoring 3. Automatic Trap Monitoring 4. Condensate Return 5. Valve Insulating Blankets

Questions?

Thank you!