Corrugator Steam

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A question that is always a major concern to steam system plant personnel; is condensate being correctly evacuated from the process and steam is not blowing through the condensate drainage devices (steam trap stations or control valves).

The use of “visual indication” will answer the above two questions regarding condensate drainage and has proven to be the most successful means to determine proper condensate evacuation.  Visual indication has been used in certain process plants for 85 years to determine the proper condensate evacuation.

In the steam and condensate system, test valves and/or sight glasses (sight windows) provide a means to check flow, identify performance, manually measure flow, and conduct line sampling. More specifically, test valves and sight glasses offer an easy, simple means to verify existing conditions within a closed condensate piping system.

Visual indicators need to installed and used to verify proper condensate drainage on all process application and critical condensate drainage locations for condensate drainage performance.  Visual indicators can used on any steam trap station application for performances.

The EPA is announcing that the period for providing public comments on the November 30, 2012, proposed ‘‘Reconsideration of Certain New Source and Startup/Shutdown  Issues: National Emission Standards for Hazardous Air Pollutants from Coal and Oil-fired Electric Utility Steam Generating Units and Standards of Performance for Fossil-Fuel-Fired Electric Utility, Industrial-Commercial-Institutional, and Small Industrial- Commercial-Institutional Steam Generating Units’’ is being extended by 7 days.

DATES: The public comment period for the proposed rule published November 30, 2012 (77 FR 71323), is extended by 7 days to January 7, 2013.

For more information, contact

Kelly Paffel

Kelly.paffel@swagelok.com

An efficient steam system will collect condensate in the plant and either return it to a deaerator, boiler feed tank, or use it in another process. A high percentage of the steam systems are modulating, where the steam pressures to the heat transfer will vary with the processes. Modulating process steam systems require condensate to flow by gravity from the heat transfer equipment to a vented condensate tank system.

Read a Best Practice on Vented Condensate Tanks:  http://www.swagelokenergy.com/download/BP38%200060-38R0.pdf

As the leaves change color it is time to start thinking about getting ready for the cold weather.  In the industrial world, that means preparing the plant’s heating systems, namely the steam tracing and heating systems.

Part of the preparation has to include starting the systems up, and starting them up safely.  It is important to remember that a large number of incidents in the steam world occur when the systems are started up, especially when the start-up procedures are not thought out, followed, or current.  It is critical to have a start-up procedure that brings the system up to operating conditions safely.  At a minimum the procedure should outline the steps to complete the start-up, how the start-up crew is going to communicate, the number of people required, as well as the safety equipment and personnel protective equipment required.

Once the system is up and running it is important to walk the system to make sure there are no obvious issues – leaks, water hammer, etc.  See Best Practices 24 & 11.

The colder weather will put a heavier load on the steam system and all its components.  It is crucial at this time of the year that the steam be at its highest quality level and the boiler be running as efficiently as possible to minimize any steam quality issues and maximize system reliability.  See Best Practices 4 & 6.

The tracing lines are the components that most people think of when discussing winterization, and it is imperative that they be running at maximum effectiveness to minimize down time due to freeze ups.  Ensure that the system has started up correctly, and that lines are not plugged or leaking. Keep tracers to 100 foot maximums, insulate the jumpers between the supply and return headers and the process piping, and ensure that the steam trap stations are running correctly – these techniques can go a long way to reduce the number of freeze-up related issues during the winter season. See best practices 9, 16, 29 and 30.

Remember that it is much easier to make repairs and take corrective action before lines start to freeze , and that your maintenance personnel will be much happier making the repairs in warmer weather!

The question arises when to use a steam motive type of pump vs. the use of electric driven pump arrangement.  The electric driven condensate pump is always for the first choice when pumping condensate for a number of reasons. 

1.)  Lower energy operational cost

2.)  Higher reliablity

Cost of operation for one year:

 Electrical = $ 2,254.37

 Steam motive = $ 6,232.00

Vendor Marketing Statement  “STALL is the condition of a modulating system where inlet pressure can no longer overcome back pressure, preventing condensate drainage and resulting in poor heat transfer and waterhammer”

Incorrect piping of heat transfer in modulating systems will cause loss of differential pressure, thus preventing proper drainage.  Corrective measurement is to correct the piping and not purchase another component that requires maintenance to overcome the incorrect piping.

See Swagelok Energy Best Practices on how to install heat transfer components correctly

The National Board has a very good paper on combustion air for the boiler room or plant.

http://www.nationalboard.org/index.aspx?pageID=164&ID=191

Does anyone have a software system for evaluating the economics of installing a Steam Thermocompressor?