Sie sind auf Seite 1von 14

3/31/2015

STEAM ENERGY CONSERVATION
STEAM
ENERGY CONSERVATION
For over 100 years Spirax Sarco has been partnering steam users and specifier’s, worldwide, to
For over 100 years Spirax Sarco has been partnering steam users and
specifier’s, worldwide, to improve the performance of their plant and
processes.
3
Business Overview - Global Presence Operating companies Sales offices Distributors 51 operating companies in 34

Business Overview - Global Presence

Operating companies Sales offices Distributors
Operating companies
Sales offices
Distributors

51 operating companies in 34 countries 1,300 direct field sales & service people for local expertise and stocks

51 operating companies in 34 countries 1,300 direct field sales & service people for local expertise
Our Heritage In 1888 Sanders Rehders and Company (Sar Co) was formed in London to
Our Heritage
In 1888 Sanders Rehders and Company (Sar Co) was formed in London to sell
steam traps and other steam related products.
Today, our worldwide steam business is part of the Spirax Sarco Engineering
plc. Group, which has been listed on the London Stock Exchange since 1959.
Spirax Sarco provides the steam expertise and solutions that can help the customers meet its
Spirax Sarco provides the steam expertise and solutions that can help the
customers meet its sustainability goals worldwide through the control and
efficient use of steam, water and other industrial fluids.
Business Overview - Manufacturing • Large component stocks to enable just in time manufacturing for

Business Overview - Manufacturing

• Large component stocks to enable just in time manufacturing for quick delivery. • Extensive
• Large component
stocks to enable
just in time
manufacturing for
quick delivery.
• Extensive product
testing including
steam testing prior
to shipment.
Large manufacturing sites: UK, USA, France, Italy, China, Brazil and Argentina Other manufacturing sites: Mexico,

Large manufacturing sites: UK, USA, France, Italy, China, Brazil and Argentina Other manufacturing sites: Mexico, Netherlands, Germany, Sweden, South Africa, India and Korea

China, Brazil and Argentina Other manufacturing sites: Mexico, Netherlands, Germany, Sweden, South Africa, India and Korea

3/31/2015

Regional Support A regional network supporting industry
Regional Support
A regional network supporting industry
Warehousing, stores, delivery, local and regional
Warehousing, stores, delivery, local and regional
STEAM WHY USET IT
STEAM
WHY USET IT
HISTORY- Indonesia A worldwide network providing local service and support 1983 – 1990 work with
HISTORY- Indonesia
A worldwide network providing local
service and support
1983
– 1990 work with many distributors
1990
– 2013 work with 2 dedicated Distributors
• PT. Petrolog Multi Usaha Mandiri
• PT. Centrindo Palmax – Medan
2014 PT. SPIRAX SARCO INDONESIA
55
- Employees
20
- Sales Engineers
6 - Service Engineers
7 - Customer Service Support & Logistic
Selection of Indonesia Clients
• Clariant Indonesia
• BASF Indonesia
• Cabot Indonesia
• Sulfindo Adi Usaha
• Amoco Mitsui PTA
• Jawa Manis Rafinasi
• Indorama Polypet
• Asahimas Chemical
• Angel Product
• Bluescope Steel Indonesia
• Pirelli Indonesia
• Krakatau Steel Indonesia
• Styrindo Chemical
• Mitshubishi Chemical
Our Solutions Products are our building blocks. A broad product range, service and expertise contribute
Our Solutions
Products are our building blocks. A broad product range, service and
expertise contribute to our ability in providing customer tailored
solutions.
Spirax Sarco – wide range of steam product solutions
Spirax Sarco has a complete range of products that cover the entire steam and condensate loop which we
design, develop, manufacture and make available to customers on a largely ex-stock basis together with
comprehensive technical advice, service and support
STEAM: Why Use It? • Steam is still the most efficient and cost effective way

STEAM: Why Use It?

• Steam is still the most efficient and cost effective way of transferring heat

• Steam is easily and readily controllable, ensuring accurate and repeatable operations

• Steam fills the heat transfer space evenly, ensuring consistent product quality.

• Steam is ideally suited to clean and sterile products/environments as it is inherently sterile.

• Steam is extremely flexible, as it can be generated in central boiler plant or localised boilers whichever suits the application.

• Steam can tie in with combined heat and power systems to provide motive power, heating, and refrigeration.

• Steam and condensate pipe sizes are usually smaller and lighter than liquid systems, minimising installation costs.

• Steam systems require no circulation pumps or circuit balancing, reducing running costs and commissioning charges.

. • Steam systems require no circulation pumps or circuit balancing, reducing running costs and commissioning
. • Steam systems require no circulation pumps or circuit balancing, reducing running costs and commissioning

3/31/2015

Type of Steam

Type of Steam

Type of Steam
Type of Steam
THE TYPICAL STEAM SYSTEM JACKETED TANK HEAT STEAM PAN COIL EXCHANGER FEED WATER CONDENSATE FEED
THE TYPICAL STEAM SYSTEM
JACKETED
TANK
HEAT
STEAM
PAN
COIL
EXCHANGER
FEED
WATER
CONDENSATE
FEED
TANK
FEED
BOILER
PUMP
Steam Distribution in Food & Beverages Clean steam generator

Steam Distribution in Food & Beverages

Clean steam generator
Clean steam generator
Steam Distribution in Food & Beverages Clean steam generator
Steam Quality Testing
Steam Quality Testing
Steam in Oil & Petrochemical Industry
Steam
in Oil & Petrochemical Industry
Pure Steam Distribution in Pharmaceutical Industry

Pure Steam Distribution in Pharmaceutical Industry

Pure Steam Distribution in Pharmaceutical Industry
Pure Steam Distribution in Pharmaceutical Industry

3/31/2015

STEAM PLANT ISSUES
STEAM
PLANT ISSUES
Flue Radiation Distribution Flash Losses Losses Losses Losses 20% 3% 5% 5% Heat Output Heat
Flue
Radiation
Distribution
Flash
Losses
Losses
Losses
Losses
20%
3%
5%
5%
Heat Output
Heat To User
75%
55%
Distribution
Condensate
Blowdown
Losses
Losses
10%
2%

THE STEAM SYSTEM LOSSES (Sankey Diagram)

Typical Losses

Fuel Input 100%
Fuel Input
100%

Boiler

Blowdown Losses Losses 10% 2% THE STEAM SYSTEM LOSSES ( Sankey Diagram ) Typical Losses Fuel
Steam System Audit

Steam System Audit

Steam System Audit
Steam System Audit
Reliability & Availability
Reliability &
Availability

PLANT ISSUES

Operating Costs
Operating
Costs
Fuel
Fuel
Legislation & Standards
Legislation &
Standards
Reliability & Availability PLANT ISSUES Operating Costs Fuel Legislation & Standards
STEAM SYSTEM AUDIT Kegiatan steam system audit merupakan evaluasi terhadap kinerja sistem uap yang ada,

STEAM SYSTEM AUDIT

Kegiatan steam system audit merupakan evaluasi terhadap kinerja sistem uap yang ada, baik secara individu maupun komprehensif, dan diikuti oleh identifikasi potensi perbaikan dan penghematan energi di bagian ruang boiler, distribusi uap, mesin pengguna uap, steam trapping, pengelolaan kondensat dan flash steam, serta sistem pengendalian proses dan monitoring.

Plant Survey Laporan Implementasi Inventarisasi Presentasi Prioritas Pengumpulan data Diskusi Biaya Assesmen
Plant Survey
Laporan
Implementasi
Inventarisasi
Presentasi
Prioritas
Pengumpulan data
Diskusi
Biaya
Assesmen
Rekomendasi
ROI
Diskusi
Potensi
Monitoring
Presentasi Prioritas Pengumpulan data Diskusi Biaya Assesmen Rekomendasi ROI Diskusi Potensi Monitoring
Steam Main Header Steam Meter Blowdown Vessel Steam Accumulator
Steam Main Header
Steam Meter
Blowdown
Vessel
Steam Accumulator

Boiler House

Feedtank/

Dearator

Make up water

Flash Steam Recovery

TDS/Turbidity Meter
TDS/Turbidity Meter

Boiler c/w Heat Pipe HE for Exhaust Heat Recovery

Dearator Make up water Flash Steam Recovery TDS/Turbidity Meter Boiler c/w Heat Pipe HE for Exhaust

3/31/2015

BOILER EFFICENCY Flue Losses Steam THE Energy BOILER Water Radiated Fuel Energy Heat Energy Blowdown
BOILER EFFICENCY
Flue
Losses
Steam
THE
Energy
BOILER
Water
Radiated
Fuel
Energy
Heat
Energy
Blowdown
Losses
BOILER EFFICENCY Flue Gas Losses • Heat lost in heating nitrogen and discharging it up

BOILER EFFICENCY

Flue Gas Losses

• Heat lost in heating nitrogen and discharging it up the flue

Air/fuel ratios

• Heat lost by burning hydrogen in the fuel and discharging steam up the flue

• Heat lost by the flue gases being too hot

Burner is producing more heat than required; maintenance Heat transfer surfaces not functioning correctly; cleaning

hot Burner is producing more heat than required; maintenance Heat transfer surfaces not functioning correctly; cleaning
T FG = 180 °C CO 2 = 10% Chimney Stack Losses
T FG = 180 °C
CO 2 = 10%
Chimney
Stack Losses

BOILER EFFICENCY

Flue Gas Losses

Calculate combustion efficiency by flue gas temperature and CO 2 content

Boiler
Boiler
Air
Air

T AMB = 20 °C

T = T FG - T AMB

efficiency by flue gas temperature and CO 2 content Boiler Air T A M B =
Flue Radiation Distribution Flash Losses Losses Losses Losses 20% 3% 5% 5% Heat Output Heat
Flue
Radiation
Distribution
Flash
Losses
Losses
Losses
Losses
20%
3%
5%
5%
Heat Output
Heat To User
75%
55%
Distribution
Condensate
Blowdown
Losses
Losses
10%
2%

THE STEAM SYSTEM LOSSES

Flue Losses

Fuel Input 100%
Fuel Input
100%

Boiler

Distribution Condensate Blowdown Losses Losses 10% 2% THE STEAM SYSTEM LOSSES Flue Losses Fuel Input 100%
Unburned Fuel Losses Useful heat Stack Losses
Unburned Fuel
Losses
Useful heat
Stack Losses

BOILER EFFICENCY

Flue Gas Losses

Fuel Combustion Process Air
Fuel
Combustion
Process
Air

We can measure CO 2 plus the exhaust gas temperature to evaluate the above losses

Fuel Combustion Process Air We can measure CO 2 plus the exhaust gas temperature to evaluate
BOILER EFFICENCY ∆∆∆∆T Flue Gas Losses ∆∆∆∆T (°C) 80 100 120 140 160 180 200
BOILER EFFICENCY
∆∆∆∆T
Flue Gas Losses
∆∆∆∆T (°C)
80
100
120
140
160
180
200
220
240
4
17.2
19.0
20.9
22.7
24.5
26.4
28.2
30.1
32.0
5
15.9
17.4
18.9
20.4
21.9
23.4
24.9
26.5
28.0
CO 2
6
15.0
16.3
17.6
18.9
20.1
21.4
22.7
24.0
25.3
%
7
14.4
15.5
16.6
17.8
18.9
20.0
21.2
22.3
23.4
8
13.9
14.9
15.9
16.9
17.9
19.0
20.0
21.0
22.0
9
13.6
14.5
15.4
16.3
17.2
18.1
19.1
20.0
20.9
CO 2 %
10
13.3
14.1
14.9
15.8
16.6
17.5
18.3
19.2
20.0
11
13.0
14.6
14.6
15.4
16.1
16.9
17.7
18.5
19.3
Percentage heat loss in flue gas for natural gas
Fuel Gas Losses = 16.6%

3/31/2015

Economiser
Economiser

BOILER EFFICENCY

Economisers

Average savings of 5% for gas fired boilers.

Economiser BOILER EFFICENCY Economisers • Average savings of 5% for gas fired boilers.
Economiser BOILER EFFICENCY Economisers • Average savings of 5% for gas fired boilers.

BOILER EFFICENCY

Boiler Shell Heat Losses

BOILER EFFICENCY Boiler Shell Heat Losses
BOILER EFFICENCY Boiler Shell Heat Losses
BOILER EFFICENCY Boiler Shell Heat Losses
Insulated steam pipe Insulated Steam Pipe

Insulated steam pipe

Insulated Steam Pipe

Insulated steam pipe Insulated Steam Pipe
Insulated steam pipe Insulated Steam Pipe
Flue Radiation Distribution Flash Losses Losses Losses Losses 20% 3% 5% 5% Heat Output Heat
Flue
Radiation
Distribution
Flash
Losses
Losses
Losses
Losses
20%
3%
5%
5%
Heat Output
Heat To User
75%
55%
Distribution
Condensate
Blowdown
Losses
Losses
10%
2%

THE STEAM SYSTEM LOSSES

Fuel Input 100%
Fuel Input
100%

Boiler

75% 55% Distribution Condensate Blowdown Losses Losses 10% 2% THE STEAM SYSTEM LOSSES Fuel Input 100%
Uninsulated Steam pipe at Boiler House Uninsulated Feedtank at Boiler House
Uninsulated
Steam pipe
at Boiler House
Uninsulated
Feedtank
at Boiler House

Thermal Imager

Uninsulated Steam pipe at Boiler House Uninsulated Feedtank at Boiler House Thermal Imager
Uninsulated Steam pipe at Boiler House Uninsulated Feedtank at Boiler House Thermal Imager
Uninsulated Steam pipe at Boiler House Uninsulated Feedtank at Boiler House Thermal Imager
Uninsulated Steam pipe at Boiler House Uninsulated Feedtank at Boiler House Thermal Imager
Uninsulated Steam pipe at Boiler House Uninsulated Feedtank at Boiler House Thermal Imager
THE STEAM SYSTEM LOSSES Typical Losses Flue Radiation Distribution Flash Losses Losses Losses Losses 20%
THE STEAM SYSTEM LOSSES
Typical Losses
Flue
Radiation
Distribution
Flash
Losses
Losses
Losses
Losses
20%
3%
5%
5%
Fuel Input
Heat Output
Heat To User
100%
75%
55%
Distribution
Boiler
Condensate
Blowdown
Losses
Losses
10%
2%

3/31/2015

BOILER EFFICENCY

Blowdown

Blowdown is required to control solids in the boiler water

Solids enter the boiler with the make- up water

As steam is generated the solids remain thus increasing their concentration

If solids are not purged they can lead to:

o

Scale Formation

o

Carryover

o

Corrosion

o

Embrittlement

are not purged they can lead to: o Scale Formation o Carryover o Corrosion o Embrittlement
37
37
Automatic TDS Control Boiler pressure (bar g) % Fuel Saved for 1% Saving in Blowdown
Automatic TDS Control
Boiler pressure
(bar g)
% Fuel Saved for 1%
Saving in Blowdown
7
0.19%
10
0.21%
17
0.25%
26
0.28%
BOILER EFFICENCY Automatic TDS Control Maximum allowable TDS Average TDS 0 12 24 Time in
BOILER EFFICENCY
Automatic TDS Control
Maximum allowable TDS
Average TDS
0
12
24
Time in hours
• Minimisation of blowdown rate: reduction in waste water, chemicals and energy loss
• Labour saving advantages from automation
• Closer control of boiler TDS levels
• Boiler maintained at design conditions
• Heat recovery savings
• Reduced maintenance issues
Boiler water TDS

BOILER EFFICENCY

Blowdown Rate Calculation

Feed Water (F) 250 ppm TDS Blowdown Rate = F × S B - F
Feed Water (F)
250 ppm TDS
Blowdown Rate =
F × S
B - F
250 × 10000
=
2500 - 250
=
1111 kg/h or 11%
× S B - F 250 × 10000 = 2500 - 250 = 1111 kg/h or
× S B - F 250 × 10000 = 2500 - 250 = 1111 kg/h or

Steam Rate (S) 10,000 kg/hr

Boiler Max TDS (B) 2500 ppm

× S B - F 250 × 10000 = 2500 - 250 = 1111 kg/h or

Boiler water TDS

Maximum allowable TDS Average TDS 0 12 24 Time in hours
Maximum allowable TDS
Average TDS
0
12
24
Time in hours

BOILER EFFICENCY

Manual Blowdown

Manual blowdown creates high and low spikes

Above max allowable levels scale forms

Below acceptable levels there is an increase in waste water

Due to spiking action levels are normally set lower so average TDS is low high waste water and energy

water • Due to spiking action levels are normally set lower so average TDS is low
CASE STUDY Steam Rate (S) 2,500 kg/hr Feed Water (F) 400 ppm TDS Boiler Max
CASE STUDY
Steam Rate (S)
2,500 kg/hr
Feed Water (F)
400 ppm TDS
Boiler Max TDS (B)
3000 3500 ppm ppm
Blowdown Rate =
F × S
B - F
400 × 2500
=
3000
- 400
Boiler Pressure
(barg)
% Fuel Saved for 1%
Blowdown Reduction
0.3-0.4%
=
384 kg/h or 15%
7,0
0,19%
Fuel Saving
10,0
0,21%
400 × 2500
=
Water Saving
Cost of water
3500
- 400
= $2.16 / m³
=
322 kg/h or 13%
= 62 kg/h blowdown saving
= 8064 hours / yr
= $1080 / yr

3/31/2015

CASE STUDY Heat Recovery from Boiler Blowdown Flash Steam 0.5 barg Cold Break Tank Blowdown

CASE STUDY

Heat Recovery from Boiler Blowdown

Flash Steam 0.5 barg Cold Break Tank Blowdown Heat To Recovery Exchanger
Flash Steam
0.5 barg
Cold Break
Tank
Blowdown
Heat
To Recovery
Exchanger

Boiler Pressure

5.0 barg

Boiler Blowdown Flash Steam 0.5 barg Cold Break Tank Blowdown Heat To Recovery Exchanger Boiler Pressure
CASE STUDY Fuel & Water Savings Flash steam recovered Running time Annual flash steam recovered
CASE STUDY
Fuel & Water Savings
Flash steam recovered
Running time
Annual flash steam recovered
= 29 kg/h
= 8064 hours
= 233,856 kg/year
Fuel Saving
Cost of steam
= $85 / 1000 kg
= ($85 × 233,856) / 1000
= $19,877 / year
Water Saving
Cost of water
= $2.16 / m³
= ((29 × 8064) / 1000) × 2.16
= $505 / year
CASE STUDY Heat Recovery Blowdown discharge rate Flash steam recovered Residual flow to heat recovery
CASE STUDY
Heat Recovery
Blowdown discharge rate
Flash steam recovered
Residual flow to heat recovery
= 322 kg/h
= 29 kg/h
= 293 kg/h
Sensible Heat Recovery
=
293 × 4.2 × (100-50)
=
61,530 kJ/h
80% boiler efficiency
= 496,177,920 kJ/yr
= $17,627 / yr
Heat savings
Assuming 40% operation
= $17,627 × 40%
= $7050 / year
Pressure Temp Specific Enthalpy (kJ/kg) Volume (barg) (°C) (m³/kg) Evaporation 0.5 112 468 2225 2694
Pressure
Temp
Specific Enthalpy (kJ/kg)
Volume
(barg)
(°C)
(m³/kg)
Evaporation
0.5
112
468
2225
2694
1.149
5.0 159
670
2086
2757
0.315
Extract from steam tables
= 670 kJ/kg
= 468 kJ/kg
= 202 kJ/kg
= 2225 kJ/kg
= 202 / 2225
= 0.09 kg flash/kg of condensate
= 9%
= 202 / 670 = 30%
= 0.09 × 322 kg/h
= 29 kg/h

CASE STUDY

Flash Steam Recovery

Enthalpy of saturated water at 5 barg Enthalpy of saturated water at 0.5 barg Surplus Enthalpy of evaporation at 0.5 barg

Proportion of flash steam

Percentage of Energy Blowdown flowrate

at 0.5 barg Surplus Enthalpy of evaporation at 0.5 barg Proportion of flash steam Percentage of
Blowdown
Blowdown

CASE STUDY

Heat Recovery from Boiler Blowdown

Flash Steam 0.5 barg Cold Break Tank Blowdown Blowdown To Recovery 100°C 50°C
Flash Steam
0.5 barg
Cold Break
Tank
Blowdown
Blowdown
To Recovery
100°C
50°C

Boiler Pressure

5.0 barg

Blowdown Flash Steam 0.5 barg Cold Break Tank Blowdown Blowdown To Recovery 100°C 50°C Boiler Pressure
CASE STUDY Heat recovery project - Flash steam

CASE STUDY

Heat recovery project - Flash steam

CASE STUDY Heat recovery project - Flash steam
CASE STUDY Heat recovery project - Flash steam

3/31/2015

CASE STUDY Savings Fuel from flash recovery Blowdown residual heat Water savings $19,877 $7,050 $1,585
CASE STUDY
Savings
Fuel from flash recovery
Blowdown residual heat
Water savings
$19,877
$7,050
$1,585
Total Savings
$28,512
Investment c.$55,000: <24mth ROI (conservative)
Plus….
Water treatment savings
Waste water treatment savings
Chemical savings
Improvement in boiler efficiency – additional fuel savings
Flue Radiation Distribution Flash Losses Losses Losses Losses 20% 3% 5% 5% Heat Output Heat
Flue
Radiation
Distribution
Flash
Losses
Losses
Losses
Losses
20%
3%
5%
5%
Heat Output
Heat To User
75%
55%
Distribution
Condensate
Blowdown
Losses
Losses
10%
2%

THE STEAM SYSTEM LOSSES

Typical Losses

Fuel Input 100%
Fuel Input
100%

Boiler

Distribution Condensate Blowdown Losses Losses 10% 2% THE STEAM SYSTEM LOSSES Typical Losses Fuel Input 100%
FUEL CONSUMPTION 1 2 3
FUEL
CONSUMPTION
1
2
3

Condensate Recovery

Reduce fuel consumption by approximately 1% for every 6°C rise in feedtank temperature

=

1% for every 6 ° C rise in feedtank temperature = FEEDTANK TEMPERATURE 1. Boiler Water

FEEDTANK

TEMPERATURE

1% for every 6 ° C rise in feedtank temperature = FEEDTANK TEMPERATURE 1. Boiler Water

1. Boiler Water

2. Feedwater

3. Condensate

1% for every 6 ° C rise in feedtank temperature = FEEDTANK TEMPERATURE 1. Boiler Water
ENERGY SAVING OPPORTUNITIES AT BOILER HOUSE 3 4 1 Burner control - Fully modulating control
ENERGY SAVING OPPORTUNITIES AT BOILER HOUSE
3
4
1
Burner control
- Fully modulating control
- Use of variable speed fan
- O2 trim
2
…can save up to
2
% thermal energy
30
% electric energy
5 Boiler insulation…
5
6
- High density and thickness
7
2 Auto TDS control
insulation lagging
- Reduces amount of boiler blow down required
-
Elimination of heat bridges
- Reduces water carryover with steam
between hot vessel and cladding
-Use of air actuated valve instead of electric
…can save up to
…can save up to
0,4 % thermal energy
5 % salts and chemicals
0,1 % thermal energy
1
6
7
Feed water control…
Water treatment…
- Use of multistage high efficiency pumps
- Reduces amount of boiler blow down required
4 Deaerator…
- Use of variable speed feed water pumps
- Avoids scaling inside the boiler which affect
3 Waste heat recovery…
- High density and thickness
- Use of modulating feed water system for
heat transfer rate between the water and the hot
- Use of flue gas economizer
insulation lagging
feed water rating matched to steam
gases
- Use of flues / air pre heater
…can save up to
demand
…can save up to
…can save up to
0,45 % thermal energy
…can save up to
5 % thermal energy
5 % thermal energy
70 % salts and chemicals
15 % electric energy
52 Increase condensate return WHY? Condensate can contain over 20% of total steam enthalpy Further
52
Increase condensate return
WHY?
Condensate can contain over 20% of total steam enthalpy
Further savings:
Water consumption
Reduced Effluent
Boiler Chemicals
Pressure
Condensate Lost
Condensate Returned
Condensate Returned
(barg)
Flash Lost
Flash Lost
Flash Recovered
10,0
72,5%
86,5%
100%
7,0
75,0%
89,1%
100%
3,5
78,3%
92,4%
100%

THE STEAM SYSTEM LOSSES

Improving Condensate Return

72,5% 86,5% 100% 7,0 75,0% 89,1% 100% 3,5 78,3% 92,4% 100% THE STEAM SYSTEM LOSSES Improving
PEMETAAN SISTEM UAP (EXISTING)
PEMETAAN SISTEM UAP (EXISTING)

3/31/2015

PEMETAAN SISTEM UAP (IMPROVEMENT) STEAM TRAPPING PENGEMBALIAN KONDENSAT
PEMETAAN SISTEM UAP (IMPROVEMENT)
STEAM
TRAPPING
PENGEMBALIAN
KONDENSAT
UAP (IMPROVEMENT) STEAM TRAPPING PENGEMBALIAN KONDENSAT FLASH STEAM 59 POMPA KONDENSAT - Pompa elektrik

FLASH STEAM

FLASH STEAM 59
FLASH STEAM 59
59
59
POMPA KONDENSAT - Pompa elektrik sentrifugal kondensat panas - Kavitasi, karena efek penguapan kondensat panas

POMPA KONDENSAT

- Pompa elektrik sentrifugal kondensat panas

- Kavitasi, karena efek penguapan kondensat panas

- Biaya perawatan lebih mahal

- Membutuhkan energi listrik

- Sering diperlukan penggantian seal

- Pompa mekanik (motive pressure pump, Ogden Pump)

- Tidak ada kavitasi, bahkan dapat bekerja pada kondisi vakum

- Biaya perawatan lebih murah

- Membutuhkan steam sebagai pendorong, 20 kg/h

- Explosion proof / hazardous

- Remote area

- Biaya perawatan lebih murah - Membutuhkan steam sebagai pendorong, 20 kg/h - Explosion proof /
Flue Radiation Distribution Flash Losses Losses Losses Losses 20% 3% 5% 5% Heat Output Heat
Flue
Radiation
Distribution
Flash
Losses
Losses
Losses
Losses
20%
3%
5%
5%
Heat Output
Heat To User
75%
55%
Distribution
Condensate
Blowdown
Losses
Losses
10%
2%

THE STEAM SYSTEM LOSSES

Typical Losses

Fuel Input 100%
Fuel Input
100%

Boiler

Distribution Condensate Blowdown Losses Losses 10% 2% THE STEAM SYSTEM LOSSES Typical Losses Fuel Input 100%
0.5 bar g Flash steam Condensate
0.5 bar g
Flash steam
Condensate

100 kg/h

FLASH STEAM

This is a natural occurrence when condensate drops in pressure after leaving a steam trap. The condensate is at steam temperature and cannot maintain this temperature at a lower pressure. This results in the condensate flashing off into steam to lose the excess heat.

Steam supply

8 bar g
8 bar g

% Flash Steam = 12% Flash steam = 12 kg/h Condensate = 88 kg/h

into steam to lose the excess heat. Steam supply 8 bar g % Flash Steam =
into steam to lose the excess heat. Steam supply 8 bar g % Flash Steam =

3/31/2015

Vent
Vent

THE STEAM SYSTEM LOSSES

Flash Steam Recovery

• Large wastage of energy in flash steam

• Loss of condensate (from flash steam)

• Unsightly discharge from the vent

• Possibility of the receiver overflowing due to pressurisation

Condensate

from Plant

To Boiler

House

from the vent • Possibility of the receiver overflowing due to pressurisation Condensate from Plant To
THE STEAM SYSTEM LOSSES Flash Steam Recovery Requirements for flash steam usage • Enough condensate

THE STEAM SYSTEM LOSSES

Flash Steam Recovery

Requirements for flash steam usage

• Enough condensate

• Use for low pressure steam

• Application needs to be close to high pressure condensate source

• Enough condensate • Use for low pressure steam • Application needs to be close to
THE STEAM SYSTEM LOSSES Flash Steam Recovery

THE STEAM SYSTEM LOSSES

Flash Steam Recovery

THE STEAM SYSTEM LOSSES Flash Steam Recovery
THE STEAM SYSTEM LOSSES Flash Steam Recovery

THE STEAM SYSTEM LOSSES

Flash Steam Recovery

 

Flash steam is recovered before it’s lost via the receiver vent

Condensate

Condensate

Energy and water saved

from Plant

No unsightly loss of flash steam from the vent pipe

Less likelihood of receiver overflowing

To Boiler

 

House

  House
steam from the vent pipe • Less likelihood of receiver overflowing To Boiler   House Recovered
Recovered Flash
Recovered
Flash
THE STEAM SYSTEM LOSSES Flash Steam Recovery Condensate Flash Condensate Feedwater

THE STEAM SYSTEM LOSSES

Flash Steam Recovery

Condensate Flash Condensate
Condensate
Flash
Condensate

Feedwater

THE STEAM SYSTEM LOSSES Flash Steam Recovery Condensate Flash Condensate Feedwater

THE STEAM SYSTEM LOSSES

Flash Steam Recovery

THE STEAM SYSTEM LOSSES Flash Steam Recovery BEFORE… …AFTER
BEFORE… …AFTER
BEFORE…
…AFTER
THE STEAM SYSTEM LOSSES Flash Steam Recovery BEFORE… …AFTER

3/31/2015

Flue Radiation Distribution Flash Losses Losses Losses Losses 20% 3% 5% 5% Heat Output Heat
Flue
Radiation
Distribution
Flash
Losses
Losses
Losses
Losses
20%
3%
5%
5%
Heat Output
Heat To User
75%
55%
Distribution
Condensate
Blowdown
Losses
Losses
10%
2%

THE STEAM SYSTEM LOSSES

Typical Losses

Fuel Input 100%
Fuel Input
100%

Boiler

Distribution Condensate Blowdown Losses Losses 10% 2% THE STEAM SYSTEM LOSSES Typical Losses Fuel Input 100%
DN50 Pipe Heat Loss = 514 W/m For 100m = 51.4 kW Condensing Rate =
DN50
Pipe
Heat Loss = 514 W/m
For 100m = 51.4 kW
Condensing Rate = 90 kg/h
Cost = ~$60,000 per annum
Insulation can reduce losses
to 1/10 th

THE STEAM SYSTEM LOSSES

Distribution Losses

Steam

7 barg

th THE STEAM SYSTEM LOSSES Distribution Losses Steam 7 barg Ambient Temperature 21 ° C ∆T
th THE STEAM SYSTEM LOSSES Distribution Losses Steam 7 barg Ambient Temperature 21 ° C ∆T

Ambient Temperature 21 °C

∆T =~150°C
∆T =~150°C

Heat emission from bare pipes

SYSTEM LOSSES Distribution Losses Steam 7 barg Ambient Temperature 21 ° C ∆T =~150°C Heat emission
KEBOCORAN UAP PANJANG FLUME Contoh : Kebocoran uap dari gasket pada sambungan pipa = 11

KEBOCORAN UAP

PANJANG FLUME
PANJANG
FLUME

Contoh : Kebocoran uap dari gasket pada sambungan pipa = 11 kg/jam dengan panjang ‘Plume’ 750 mm

sambungan pipa = 11 kg/jam dengan panjang ‘Plume’ 750 mm Kerugian biaya = 11 kg/jam x

Kerugian biaya = 11 kg/jam x Rp 600/kg x 5400 jam = Rp 36 juta/tahun

pipa = 11 kg/jam dengan panjang ‘Plume’ 750 mm Kerugian biaya = 11 kg/jam x Rp

THE STEAM SYSTEM LOSSES

Distribution Losses

THE STEAM SYSTEM LOSSES Distribution Losses
THE STEAM SYSTEM LOSSES Distribution Losses
THE STEAM SYSTEM LOSSES Distribution Losses
THE STEAM SYSTEM LOSSES Distribution Losses • Steam leaks How much are they costing you?

THE STEAM SYSTEM LOSSES

Distribution Losses

• Steam leaks How much are they costing you?

• 25 mm valve stem 8 barg 3.5 kg/h ~$1200 per annum

• mm hole, steam at 7 barg

2

9

kg/h ~$3000 per annum

• 5 m of 50 mm pipe $1500 per

annum (insulate reduce to 1/10 th )

• Incorrect installed drainage points

• Correct pipe sizing

• Condition of steam (e.g. dryness fraction)

h ) • Incorrect installed drainage points • Correct pipe sizing • Condition of steam (e.g.
THE STEAM SYSTEM LOSSES Distribution Losses: Steam Traps Failed Open Steam Trap Waste of energy/money

THE STEAM SYSTEM LOSSES

Distribution Losses: Steam Traps

Failed Open Steam Trap

Waste of energy/money Increases production costs Plumes of steam visible form vents Can cause problems in pipes Plant will still operate

Failed Closed (Cold) Steam Trap

Plant will waterlog Reduced plant output Spoilt product Under heating Safety hazard – waterhammer Freezing

Failed open steam trap with a 5 mm orifice, operating at 7 barg will lose approximately 30 kg/h. Over 260 t per annum

Failed open steam trap with a 5 mm orifice, operating at 7 barg will lose approximately

3/31/2015

THE STEAM SYSTEM LOSSES Distribution Losses: Steam Traps

THE STEAM SYSTEM LOSSES

Distribution Losses: Steam Traps

THE STEAM SYSTEM LOSSES Distribution Losses: Steam Traps
THE STEAM SYSTEM LOSSES Distribution Losses: Steam Traps
STEAM TRAP SURVEY 1. Uji kinerja steam trap dengan bantuan ultrasonic trap tester dan peralatan

STEAM TRAP SURVEY

1. Uji kinerja steam trap dengan bantuan ultrasonic trap tester dan peralatan pendukung seperti infrared

2. Uji kebocoran lain, seperti valve steam trap set

3. Tagging and numbering steam trap

4. Tabulasi steam trap

5. Pengambilan gambar setiap steam trap set, jika diperlukan

6. Mengolah dan menampilkan data dalam STMS (steam trap management system)

7. Perhitungan kebocoran steam dan emisi karbon

8. Laporan steam trap survey

dalam STMS ( steam trap management system ) 7. Perhitungan kebocoran steam dan emisi karbon 8.
dalam STMS ( steam trap management system ) 7. Perhitungan kebocoran steam dan emisi karbon 8.
steam dan emisi karbon 8. Laporan steam trap survey Sound / Ultrasonic Combined Conductivity &
Sound / Ultrasonic Combined Conductivity & Temperature
Sound /
Ultrasonic
Combined Conductivity
& Temperature

THE STEAM SYSTEM LOSSES

Trap Monitoring

& Temperature THE STEAM SYSTEM LOSSES Trap Monitoring Temperature Open Discharge Trap Monitoring S i g

Temperature

THE STEAM SYSTEM LOSSES Trap Monitoring Temperature Open Discharge Trap Monitoring S i g h t

Open Discharge

Trap Monitoring
Trap Monitoring
STEAM SYSTEM LOSSES Trap Monitoring Temperature Open Discharge Trap Monitoring S i g h t G

Sight Glass

STEAM SYSTEM LOSSES Trap Monitoring Temperature Open Discharge Trap Monitoring S i g h t G

Conductivity

STEAM SYSTEM LOSSES Trap Monitoring Temperature Open Discharge Trap Monitoring S i g h t G
S i g h t G l a s s Conductivity Flue Radiation Distribution Flash Losses
Flue Radiation Distribution Flash Losses Losses Losses Losses 20% 3% 5% 5% Heat Output Heat
Flue
Radiation
Distribution
Flash
Losses
Losses
Losses
Losses
20%
3%
5%
5%
Heat Output
Heat To User
75%
55%
Distribution
Condensate
Blowdown
Losses
Losses
10%
2%

THE STEAM SYSTEM LOSSES

Typical Losses

Fuel Input 100%
Fuel Input
100%

Boiler

Distribution Condensate Blowdown Losses Losses 10% 2% THE STEAM SYSTEM LOSSES Typical Losses Fuel Input 100%

3/31/2015

Flue Radiation Distribution Flash Losses Losses Losses Losses 15% 20% 2% 3% 5% 0% 5%
Flue
Radiation
Distribution
Flash
Losses
Losses
Losses
Losses
15%
20%
2%
3%
5%
0%
5%
4%
Heat Output
Heat To User
82% 75%
77% 55%
Distribution
Condensate
Blowdown
Losses
Losses
<1%
10%
<1%
2%

THE STEAM SYSTEM LOSSES

Ideal System

Fuel Input 100%
Fuel Input
100%

Boiler

Blowdown Losses Losses <1% 10% <1% 2% THE STEAM SYSTEM LOSSES Ideal System Fuel Input 100%
Case Study Example : Calculate the CO 2 produced from generating steam at 10 bar

Case Study

Example :

Calculate the CO2 produced from generating steam at 10 bar from a boiler supplied with Natural Gas and 80% efficient. Feedwater temperature = 30 degC

From steam tables: hg = 2781 kJ/kg For 1 kg steam, energy required = 2781 – 4,2 x 30 = 2655 kJ

Actual energy needed

= 2655/(80%)

= 3319 kJ/h

Therefore 3319 kJ = 0.922 kWh

CO2 conversion factor for Natural Gas = 0.1836 kg/kWh

Therefore CO 2 released per kg steam produced = 0.1836 x 0.922 = 0.169 kg

or 169 kg CO 2 per tonne steam

kg/kWh Therefore CO 2 released per kg steam produced = 0.1836 x 0.922 = 0.169 kg
Rusmanto Area Sales Manager rusmanto@id.spiraxsarco.com M (+62) 8156 159 711 PT. Spirax Sarco Indonesia Kawasan
Rusmanto
Area Sales Manager
rusmanto@id.spiraxsarco.com
M (+62) 8156 159 711
PT. Spirax Sarco Indonesia
Kawasan Infinia Park Blok C-99
Jl. Dr. Saharjo No. 45, Manggarai, Tebet
Jakarta Selatan 12850 - Indonesia
CARBON EMISSION

CARBON EMISSION

CARBON EMISSION
CARBON EMISSION
SUMMARY KEEPING IN THE HEAT Good design and installation Insulate efficiently Consider heat recovery KEEPING

SUMMARY

KEEPING IN THE HEAT Good design and installation Insulate efficiently Consider heat recovery

KEEPING IN THE STEAM Cure leaks Monitor steam trap operation

KEEPING IN THE WATER Return condensate for re-use Review contaminated condensate arrangements

steam trap operation KEEPING IN THE WATER Return condensate for re-use Review contaminated condensate arrangements