Energy Conservation Tips

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energy-conservation-tips
  • Condensate is almost 20% of the fuel energy

  • Flash Steam Holds 50% of the Energy Content of the Condensate

  • Open vessels containing heated fluids should be covered

  • Advantages of Returning Condensate to Feedwater Tank

  • Return condensate as soon as it is formed.

  • Ensure Maximum condensate is returned to the feedwater system.

  • Condensate should be recovered.

  • Mixing high pressure and low pressure condensate increases the back pressure

  • Returning condensate by trap pressure often results in reduced condensate evacuation

  • Flash steam should be separated from condensate while returning the condensate to feedwater tank.

  • Recover Flash Steam From Contaminated Condensate

  • Use Steam at Lowest Possible Pressure for Indirect Heating

  • Use Steam Traps to Drain Condensate

  • Steam line tappings for equipment must always be taken from the top of steam pipes

  • Eliminate air steam system to ensure effective heating and thus fuel savings.

  • Advantages of Steam Operated Pumps

  • Tappings for steam traps should be taken through correctly sized drain pockets.

  • Keeping the insulation dry reduces radiation loss and thus saves fuel

  • Small leaks cost big money

  • Wet steam reduces the process efficiency

  • Avoid Group Trapping

  • Avoid Sagging of Steam Lines

  • Individual trapping lowers process time and reduces steam consumption.

  • Identify stall condition and take corrective actions.

  • Recover Blowdown Heat

  • For air heating equipment use heat exchangers with finned tubes

  • Stall increases steam consumption and process time

  • Use saturated steam for indirect heat transfer applications

  • Circulation pumps are not needed for hot water and thermic fluids

  • Stall increases steam consumption and process time of the heat exchanger

  • Using multi effect evaporators in place of single effect evaporators reduces the steam consumption by about 1/3rd.

  • Utility flows should be measured accurately

  • During product drying, lumps should be broken into smaller pieces

  • Strainers should be installed correctly so that they do not become a source of wetness

  • To reduce steam consumption, a pressure reducing station should be opted for

  • On Steam heating applications controlling the temperatures to set point avoids excess steam consumption

  • For hot water systems, usie indirect heat exchangers in place of direct injection based systems

  • Insulate oil tank in the tank farm

  • Use Indirect Heating for Hot Water Generation

  • Use Saturated Heat for Utilization in the Process

  • Use Diffusers at the Point of DIscharge for Steam Traps DIscharging to Atmosphere

  • Installation of a Vacuum breaker protects the process equipment

  • Use Vacuum Breakers on Small Heat Exchangers to Avoid Stalling

  • Moisture Separators Should be Insulated

  • Installing View Glass After a Steam Trap Eases the Maintenance

  • Installation of a Vacuum breaker protects the process equipment

  • Balanced Pressure Thermostatic Steam Traps Should be Used for Tracing Applications

  • The Temperature of Furnace Oil Day Tank Should be Regulated.

  • Balanced Pressure Thermostatic Steam Traps Should be Used for Tracing Applications

  • The Temperature of Furnace Oil Day Tank Should be Regulated.

  • Correct Installation of Air Vents

  • Correct Installation of Steam Traps

  • Install moisture separators to maintain dryness of steam.

  • Correctly sized steam mains are critical.

  • Importance of correct application based steam trap selection

  • Redundant steam lines should either be removed or blinded

  • Effective control while de superheating steam is critical to avoid steam losses.

  • Accumulated condensate in steam lines can lead to noisy and damaging water hammer

  • Steam Mains should be engineered to facilitate flow of condensate by gravity to the steam trap

  • Long saturated steam distribution lines should be sized on pressure drop method.

  • Use Steam Flow Meters With Ability to Compensate for Change in the Density

  • Pipe sizing should be done correctly to avoid losses during steam distribution

  • Increase in TDS levels in the feedwater tank leads to water carry over thereby increasing fuel consumption.

  • Monitor flue gas temperatures to control stack loss.

  • Co-generation plant operations should be decided only after comparing the running cost to cost of electricity.

  • Using steam instead of thermic fluids for indirect heating is more efficient.

  • Monitoring flue gas temperature gives a good indication of the boiler operating conditions

  • Boilers efficiency should be monitored.

  • At part loads the most efficient boiler should be used.

  • Poor quality of fuel leads to poor boiler efficiency.

  • Operating boiler closer to full load improves efficiency

  • The configuration of the co-generation system is important to ensure high efficiency

  • Chemical treatment of make up water increases the TDS levels in the boiler

  • Avoid Frequent Changes to the Boiler Fuel Firing System

  • Increase the inlet air temperature to increase boiler efficiency

  • Higher feedwater temperature increases the boiler output

  • Avoid High Negative Draft in Solid Fuel Fired Boilers

  • Use saturated steam for indirect heat transfer applications.

  • Generate Steam at Higher Pressure

  • Steam is preferable to thermic fluid as heating media.

  • The TDS inside a boiler should be maintained at recommended levels

  • Maintaining high TDS levels in the boiler drum results in water carryover

  • Dissolved oxygen should be removed from the feedwater tank

  • Avoid over sizing the boiler

  • Shell type steam boilers offer better fuel efficiencies as compared to coil type boilers.

  • Boiler operation parameters should be monitored continuously

  • Co-generation plant operations should be decided only after comparing the running cost to cost of electricity

  • Feedwater tank should be sized to be 1.5 times the peak steam demand.

  • Injection of flash steam and condensate into the feedwater tank should be via a deaerator head

  • Minimize Boiler Scaling

  • High feedwater temperature drives out dissolved oxygen

  • Opting for shell type boilers over coil type boilers leads to availability of good quality steam

  • Measuring specific fuel consumption gives a true reflection of your plant efficiencies

  • Air to fuel ratio should be monitored and controlled to minimize unburnts

  • Flue gas temperatures are a good indicator of excess air

  • Safeguarding Boilers against Fuel Explosion

  • Importanceof Steam Trap Selection and SIzing

  • Use shell type boiler to recover condensate.

  • Every 6oC rise in feedwater temperature reduces the fuel bill by 1%.

  • Referencing the boiler efficiency to the GCV of the fuel rather than the NCV gives a more accurate picture

  • Black or White Smoke is an Indicator of Improper Combustion

  • Efforts should be made to minimize addition of surface moisture content in fuel.

  • Maintaining the right level of water in the feedwater tank reduces the overall boiler feedwater TD

  • The Temperature of Furnace Oil Day Tank Should be Regulated

  • To deliver the same amount of energy, the flowrate of hot water will have to be 45 times than that of steam