Training Manual on Energy Efficiency - APO Asian Productivity ...

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<strong>Training</strong> <strong>Manual</strong> on Energy Efficiency for Small and Medium Enterprises • Superheated: 50–70 m/sec • Saturated: 30–40 m/sec • Wet or Exhaust: 20–30 m/sec The steam piping should be sized based on permissible velocity and the available pressure drop in the line. A higher pipe size will reduce the pressure drop and thus the energy cost. However, higher pipe size will increase the initial installation cost. By use of smaller pipe size, even though the installation cost can be reduced, the energy cost will increase due to higher-pressure drop. Thus, optimum sizing is necessary. (Pressure drop change is inversely proportional to the 5th power of diameter change.) Pipe redundancy Pipe redundancy is to be avoided in steam distribution since it leads to significant losses. All redundant pipelines must be eliminated; this could reduce steam distribution losses significantly Drain points 3.7 TIPS ON STEAM PIPING SIZING AND LAYOUT Pipe sizing Proper sizing of steam pipelines helps in minimizing pressure drop. The velocities for various types of steam are: Drain points help in removing water in the pipes due to condensation of steam. The presence of water in steam is undesirable as it causes water hammer, leading to damage to steam pipes and eventually leakages. Steam traps must be provided at the drain points to avoid leakage of steam. 3.8 MAINTENANCE OF STEAM TRAPS The key functions of steam traps are: • to discharge condensate once it is formed; • to prevent steam from escaping; and • to discharge air and non-condensable gases. Steam trap performance is very important for fuel economy in all steam-use systems and is one of the major energy efficiency opportunities which can yield surprising results. • Traps that are open, meaning those draining steam and condensate, result in loss of energy and direct loss of condensate (the purest form of water) and significant economic loss as boiler operating costs increase. • Traps that are closed, or become blocked, result in reduced heating capacity of steam heating equipment, and direct loss of production, which is undesirable. - 24 -
3.9 GOOD PRACTICES FOR EFFICIENT STEAM UTILIZATION 3.9.1 Steam leakage quantification Energy Efficiency in Steam Distribution and Utilization Some tips for steam trap monitoring and maintenance are presented here: • Dirt is one of the most common problem areas. Dirt, scale, or foreign material finds its way to the traps and often damages the valve seat, preventing it from closing properly and leading to leakages. • Strainers provided for handling dirt and other material before it reaches the traps must be maintained properly. • Sight glasses, fitted after the traps, permit visual identification of blowing traps and need to be properly taken care of. • If the trap selected is not the appropriate type and size for the given application, significant losses take place. • Inverted bucket and thermodynamic traps should have intermittent condensate discharge. • Float and thermostatic traps should have a continuous condensate discharge. • Flash steam and leaking steam are not the same. Leaking steam is continuous, like an exhaust, while flash steam is intermittent and like a cloud. • A regular schedule of maintenance should be adopted, to repair and replace defective traps in the interest of fuel economy. • Mechanisms within the traps produce sonic and ultrasonic sounds due to passage of condensate and steam. Using suitable listening devices, ranging from a simple screwdriver, a mechanic’s stethoscope, or an ultrasonic trap tester, a trap monitoring system can be established in an industry. • Similarly, temperature sensing by contact and non-contact devices can help to monitor trap performance. Steam leakage is a visible indicator of waste and must be avoided. Regular leakage monitoring and rectification is one of the major steam economy measures. A simple graph (see Figure 3-2) can be used for estimating steam leakage. The plume is the visible jet of steam issuing from the point of leakage. And, irrespective of pressure, the length of plume helps us to quantify steam loss in kg per hour. - 25 -
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Annex S. No. Enconomic Opportunity
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