Steam Theory 1. Basics of Steam What is Steam? Principal Applications for Steam Types of Steam Flash Steam How to Read a Steam Table 2. Steam Heating Heating with Steam Steam Heating Mechanism Overall Heat Transfer Coefficient What is Vacuum Steam? Tracing the Causes of Heat Maintenance Issues 3. Basics of Steam Traps What is a Steam Trap? The History of Steam Traps #1 The History of Steam Traps #2 How Mechanical Traps Work: A Look at their Mechanism and Merits How Disc Traps Work: A Look at their Mechanism and Merits How Bimetal-Type Thermostatic Steam Traps Work: A Look at their Mechanisms and Merits 4. Steam Trap Selection Steam Trap Selection: How Application Affects Selection Steam Trap Selection: Understanding Specifications Steam Trap Selection: Safety Factor and Life Cycle Cost Traps and Orifices Part 1 Traps and Orifices Part 2 Casting vs. Forging Applications of Different Types of Steam Traps Don't Get Steamed : Selecting Steam Trap Design Understanding Steam Traps Compare Two Fixed Orifice Venturi Products to a Variable Orifice Free Float Steam Trap 5. Steam Trap Problems Is My Trap Leaking Live Steam? Temperature Control Trap Precautions Trap Installation Orientation Trap Back Pressure Double Trapping Group Trapping Steam Locking Air Binding My Steam Trap Is Good - Why Doesn't It Work? 6. Steam Trap Management Introduction to Steam Trap Management Steam Trap Losses - what it costs you A Guide to Steam Trap Testing Implement a Sustainable Steam Trap Management Program Impact Plant Performance by Improving the Steam System 7. Water Hammer Water Hammer: What is it? Water Hammer: The Mechanism Water Hammer: Cause and Location Water Hammer: In Steam Distribution Lines Water Hammer: In Equipment Water Hammer: In Condensate Transport Piping Identifying Water Hammer Using a Thermal Camera Mitigation of Water Hammer in Vertical Flashing Condensate Transport Piping Stop Knocking Your Condensate Return Steam Trap Management: Do Something; Anything. Please! 8. Risk Mitigation Steam System Optimization and Risk Mitigation Risk Based Methodology for Industrial Steam Systems Why Bad Things Happen to Good Steam Equipment Beware of the Dangers of Cold Traps Steam System Winterization: How to Protect Your Plant 9. Steam Quality Wet Steam vs. Dry Steam: The Importance of the Steam Dryness Fraction Separators and their Role in the Steam System Clean & Pure Steam Temperature Problems Caused by Air Removing Air from Steam Equipment Air Vents for Steam Steam Quality Considerations 10. Steam Distribution Best Practices for Condensate Removal on Steam Lines Installation Tips for Steam Traps on Steam Mains Erosion in Steam and Condensate Piping Corrosion in Steam and Condensate Piping Allocate New Plant Focus to Steam System Design—Part 1 11. Condensate Recovery Introduction to Condensate Recovery Returning Condensate and When to Use Condensate Pumps Condensate Recovery: Vented vs. Pressurized Systems Condensate Recovery Piping What is Stall? Methods of Preventing Stall Cavitation in Condensate Pumps Steam Heat Exchangers are Underworked and Over-Surfaced Allocate New Plant Focus to Steam System Design—Part 2 Optimize Reboiler Performance via Effective Condensate Drainage Vent Away Condensate Pump Frustrations in a Flash 12. Energy Efficiency Tips to improve steam plant efficiency Advice on Winter Preparation for Steam Systems Insulating Traps Steam Compressors Why Save Energy? Management Strategies for Conserving Energy Recovering Steam Clouds and Waste Heat Waste Heat Recovery Boiler Energy Saving Tips Steam Line Energy Saving Tips Steam-Using Equipment Energy Saving Tips Preventing Steam Leaks Handle Steam More Intelligently Optimize the Entire Steam System Use Available Data to Lower System Cost 13. Compressed Air / Gas Removing Condensate from Compressed Air Preventing Clogging of Air Traps Air Compressor Energy Saving Tips Improving Compressed Air Quality and Countermeasures Against Leaks 14. Other Valves Types of Manual Valves Bypass Valves Check Valve Installation and Benefits Pressure Reducing Valves for Steam Tips to improve steam plant efficiency TLV Euro Engineering (Cheltenham, UK) TLV Euro Engineering has revealed five steps that industrial businesses can take to improve their steam plant efficiency. In many industries, steam plants now provide a crucial energy source, delivering reliable high-quality steam for the production process. However, rising gas prices and a need to reduce CO2 emissions has led to an increasing focus on the efficiency of steam plants. While there are many ways to improve efficiency they often involve considerable investment (e.g., the wholesale change of steam traps), so before embarking on any large capital project, it is worth taking a closer look at the system itself by following these five steps to improve efficiency. Before you begin It is a good idea to estimate the cost of steam generation beforehand. All the calculations quoted here are based on a plant running 24/7 for 50 weeks a year, with a steam cost of GBP 20.00. For the best results, you need to ascertain the steam cost for your site. Approximate steam costs can be calculated easily by taking the fuel costs and calorific value and applying a rough figure for boiler efficiency. For a more accurate approach, the amount of steam generated, fuel costs, water costs, water treatment costs, and boiler maintenance costs can also be taken into account. Step 1: Do a Steam Trap Survey First, a steam trap survey can easily identify leaking or faulty traps and provide significant potential savings. For example, it is not unusual for a site with 100 steam traps to find that 15-20 are leaking. A leaking steam trap could be losing you up to GBP 2,000 per year, so the potential annual loss - and therefore the potential saving - is in the region of GBP 35,000. Replacing the traps could provide payback in months rather than years. The same survey will also identify blocked traps, which can significantly reduce process efficiency, affect steam quality, and impact on the safety of the system. In a recent example, TLV Euro Engineering was contracted to provide regular steam trap surveys using its Trapman® TM5 testing equipment at all 13 UK-based BOCM Pauls animal feed sites. To gain ISO14001 accreditation, each site needed to monitor energy usage to improve efficiency and reduce energy. TLV was asked to carry out a steam survey. They needed to not only determine whether a trap was correctly working or not, but also to accurately quantify the steam losses in traps that were leaking. A total of 552 traps were tested of which 89 (16 per cent) were leaking. This was estimated to be costing BOCM Pauls GBP 95,000 and generating 435 tons of CO2. Step 2: Understand the Value of Condensate Second, as the cost of steam rises with the increase in energy prices, so does the value of condensate. Here are some factors to take into account when calculating the value of condensate: heat energy, water charges, the cost of water treatment, and effluent charges. Based on typical costs of GBP 3.00 or GBP 4.00 per ton, a small steam-powered process discharging 1,000 liters of unrecovered condensate per hour would be costing approximately GBP 24,000 per year. In contrast, the savings made by the installation of an efficient condensate return system with associated pipe modifications could lead to a positive return on investment less than six months down the line. Step 3: Insulate your Steam System Third, although the cost of insulation can be high, the potential savings can deliver a rapid return on investment. Programs are available to calculate the standing losses from un-lagged steam pipes. All that is required to establish a realistic estimate is a simple site survey to identify piping size and steam pressure. As an example of the benefits, a process running 24/7 (10barg, 20C) can reach annual losses of up to GBP 4,500 for just 10m of un-lagged internal pipe. Step 4: Look for Steam Leaks Fourth, a 1mm hole in your steam main could be costing GBP 500 per year. A 2in isolation valve leaking steam could be costing GBP 750 per year. Walk around your steam system and closely inspect valve stems, safety valves, flanges and unions for steam leaks. You will probably be surprised how many you find. Step 5: Start Steam Metering Finally, steam metering itself will not directly save energy, but for good housekeeping it is an essential discipline. Metering from the boiler house provides the most accurate steam consumption statistics for a typical working day, and can also be a useful troubleshooting tool. For example, a rise in oil consumption without a corresponding rise in steam production can point to a problem with the boiler. Conclusion There are potentially thousands of pounds (£) of savings to be made by following these five simple steps. For the best results you may need the help of a steam specialist company, but elements of a preliminary audit can be carried out in-house. Based on the findings, a steam management program should be developed and established to help improve the system. Taking it Further After having improved system efficiency with an in-house management program, it can become more difficult to find opportunities to save energy. The next stage may require greater capital outlay, but larger savings could also be made. One example is energy loss related to venting large amounts of flash steam into the atmosphere. Recovering and using this steam can result in significant savings. If you have a process running at 1 to 1.5 barg, you may be able to utilize the flash steam for this application, but care needs to be taken to make sure that flash steam requirements are in line with the flash being generated. If you do not have a suitable use for the flash steam, there may be opportunities to use it to preheat boiler feedwater. Alternatively, a steam compressor uses plant steam mixed with flash steam to generate steam at a more useful pressure. Improved boiler operation can in turn show a marked improvement in efficiency. Regular servicing and maintenance; correct blow-down; the use of modulating burners instead of traditional on/off burners; and sequencing systems for multiple steam and hot-water boiler installations can all help to maximize boiler efficiency. In addition, variable-speed drives on the blower and an economizer to utilize waste heat in the flue gas can also help to increase the efficiency of the boiler. Finally, look at the way steam is used around your site, as steam pressure and quality can have a significant bearing on the efficiency of particular processes. Vent Away Condensate Pump Frustrations in a Flash Advice on Winter Preparation for Steam Systems Also on TLV.com Free Float® Steam Traps for High Temperature, High Pressure Use Free Float® Steam Traps for Steam Mains and Tracer Lines Steam and Condensate Training Seminars Engineering Calculator