Clayton Armstrong 2011-02-22 GSK Aranda SP - steam&condensat
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GSK Manufacturing
Aranda de Duero, SPAIN
STEAM AND CONDENSATE ENERGY AUDIT REPORT
PROJECT N° 30275
1
Emission
E. Morin
R. Ivanov
04/02/2011
Item
Description
Established
Checked out
Date
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 2 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
TABLE OF CONTENTS
1 Executive summary ................................................................................................................... 4
2 Steam budget and summary of potential savings ...................................................................... 6
3 Optimisation project n°1: Reduce Boilers Blowdown rate ......................................................... 8
3.1 C URRENT SITUATION .............................................................................................................................. 8
3.2 O PTIMIZATION ....................................................................................................................................... 9
3.3 S AVINGS CALCULATION ........................................................................................................................ 10
3.4 I NVESTMENTS ...................................................................................................................................... 11 4 Optimisation project n°2: Reduce flash steam losses from feedwater tank ............................. 12
4.1 C URRENT SITUATION ............................................................................................................................ 12
4.2 O PTIMIZATION ..................................................................................................................................... 15
4.3 S AVINGS CALCULATION ........................................................................................................................ 16
4.4 I NVESTMENT ........................................................................................................................................ 19 5 Optimisation project n°3: Improve steam ancillaries insulation ............................................... 21
5.1 C URRENT SITUATION ............................................................................................................................ 21
5.2 O PTIMIZATION ..................................................................................................................................... 22
5.3 S AVINGS CALCULATION ........................................................................................................................ 22
5.4 I NVESTMENTS ...................................................................................................................................... 23 6 Optimisation project n°4: Replace failed steam traps.............................................................. 24
6.1 C URRENT SITUATION ............................................................................................................................ 24
6.2 O PTIMIZATION ..................................................................................................................................... 25
6.3 S AVINGS CALCULATION ........................................................................................................................ 25
6.4 I NVESTMENT ........................................................................................................................................ 26 7 Summary of deviations noticed during the audit ...................................................................... 27
7.1 S TEAM GENERATION ............................................................................................................................ 27
7.2 S TEAM DISTRIBUTION ........................................................................................................................... 28
7.3 S TEAM USERS ..................................................................................................................................... 29
7.4 C ONDENSATE RETURN ......................................................................................................................... 32 8 Complete check list of all verifications done during the audit ................................................... 33
9 Recommended complementary studies................................................................................... 35
9.1 A DDITIONAL ENERGY - SAVING OPTIMISATIONS ........................................................................................ 35
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 3 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
9.2 A DDITIONAL OPERATIONAL OPTIMISATIONS ............................................................................................ 36 10 Appendix N°1: Determination of the January 2011 boiler house efficiency .............................. 37
11 Appendix N°2: Steam Pressure Controlled Heat Exchangers at Low Load.............................. 40
11.1 C URRENT SITUATION ............................................................................................................................ 40
11.2 O PTIMIZATION ..................................................................................................................................... 43
11.3 S AVINGS ............................................................................................................................................. 45
11.4 I NVESTMENTS ...................................................................................................................................... 45
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 4 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
Executive summary
1
The energy audit conducted from January 17 th till January 20 th 2011 by Armstrong covers the 4 parts
of the steam loop: boiler house, steam distribution, steam consumption and condensate return.
GSK factory located at Aranda de Duero, in Spain, produces medicines as liquids, aerosols and
tablets.
Steam is mainly used by:
- Coils to produce hot air for fluid bed dryers, coating machines (GLATT) and dehumidifier
(Munters)
- Heat exchangers for sanitization, hot water production, pure steam generation
- Double jackets for reactors heating
Steam is distributed at 7 barg from the new boiler house since one year. The former boiler house is
now stopped. All steam is distributed from the Eagle building to tunnel 2 area and tunnel 1 area.
Steam pressure is then locally reduced to 6, 4 or 2 barg.
Steam is produced by 2 steam generators (Clayton), gas-fired, with a capacity of 3 tons/hr.
The average steam production of the boiler house during the audit is estimated at 0,9 tons/hr. The
steam consumption was low due to the stop of activities in the Eagle Building.
As an indicator, if we use some figures recorded in the old boiler house 2 years ago, your average
steam consumption was about 2 tons/hr.
Our calculations based upon data collected during the audit show a current steam price of 29,5 €
per ton, and an annual steam budget estimated at 133 300 €.
The steam and condensate lines are generally correctly sized.
Insulation of steam ancillaries can be improved.
The steam distribution system is under trapped, especially in front of control valves, resulting in a
serious risk of steam leaks caused by corrosion, erosion and water hammering.
All Condensate that could be recovered is sent back to the boiler house using 3 pumping traps units.
Condensate return ratio was calculated to be 70% during the audit.
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 5 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
In order to identify steam leaks, operational problems etc., a steam trap survey was carried out ; in
total 98 traps were tested. The trap survey showed 15% of failed traps (leaking and plugged).
The savings calculated for optimization projects in this report were based upon engineering
assumptions, observations and standard engineering practices.
We estimate the potential energy savings of at least 9% of the estimated steam budget, which
represents a yearly saving of about 377 MWh, 72 tons of CO2 and 11 850 € (see projects 1-3-4).
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 6 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
2 Steam budget and summary of potential savings
The former boiler house (Energy Central 1) was equipped by meters for all energies (gas, water,
steam, condensate) and data were recorded in a global supervision system.
However the new boiler house (Energy Central 2) is not as well equipped. There are only 1 water
meter and 2 gas meters (one for each steam generator) but data is not regularly reported.
Therefore we cannot know your gas consumption for the last 12 months and we cannot calculate
your steam production for the previous year.
Nevertheless, based upon the utility figures during our visit on site in January 2011, we can
estimate:
Boilers steam generation:
• Total yearly steam generation:
3472 MWh (4516 t/year)
• Steam cost:
38.4 €/MWh (29.5 €/t)
• Total yearly steam budget:
133 300 €/year
• Efficiency estimated:
86% (see calculation in appendix n°1)
Basic data considered:
• Gas unit costs :
25 €/MWh hhv
• Gas High Heating Value : 42.1 MJ/Nm³
• Electricity unit costs : 0.064 €/kWh
• Water costs :
o 0.35 €/m³ for city water
o 9000 €/year for Chemicals
o Total = 5 €/m³
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 7 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
Summary of identified energy-saving optimizations and their estimated yearly results:
Note: projects n°1, 3 and 4 should be prioritized as it is simple solutions easy to implement with a
payback time close to 1 year :
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 8 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
3 Optimisation project n°1: Reduce Boilers Blowdown rate
3.1 Current situation
Water impurities and chemicals concentrate (due to evaporation) in a Clayton system as in any
other steam boiler.
To avoid boiler problems, water must be periodically discharged or “blown down” from the boiler to
control the concentrations of suspended and total dissolved solids in the boiler.
The importance of boiler blowdown is often overlooked. If the blowdown rate is too high, you waste
energy (water, fuel, chemicals). If high concentrations are maintained, (too low blowdown) it may
lead to scaling, reduced efficiency, and could lead to water carryover into the steam compromising
the steam quality (wet steam).
Comparing to conventional firetubes steam boilers, Clayton Steam Generators have reduced
blowdown because of two factors:
• Steam Generator is a forced circulation boiler and can tolerate relatively high TDS levels in
the feedwater – as high as 8550 ppm (normal range is 3000-6000 ppm)
• Water that is blowndown is separator trap return water that has been concentrated in the
separator by a factor of, typically, 4 to 5.
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 9 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
Because condensate from Clayton separator returns to the feedwater tank, the feedwater will be
concentrated and "cycled up" as in normal boiler water. In other words, the feedwater in the
feedwater tank will have the same composition as the coil water.
Therefore the blowdown rate is calculated with the following formula:
% Blowdown = C make-up water
(C Feedwater – C make-up water )
Where :
C Feed water = the measured TDS concentration in the feedwater tank C make-up water = the measured TDS concentration in the make-up water
- The blowdown system installed on the 2 Clayton in the new boiler house is automatic: the
valve opens every 2 hours during 4 minutes.
According to Nalco monthly water analysis since June 2010, average TDS concentration values are:
- Feed water =50 ppm
- Make up water = 1520 ppm
Therefore your average blowdown rate is 3.4 %
3.2 Optimization
According to the water treatment manual from Clayton, the following water conditions must be
maintained in the feedwater (boiler water) at all operating times:
• Zero hardness
• pH 10.5–11.5 (normal range), maximum of 12.5
• Oxygen free with an excess sulfite residual of 50–100 ppm
• Maximum TDS of 8,550 ppm (normal range 3,000-6,000)
• Maximum dissolved iron of 5 ppm
• Free of suspended solids
• Maximum silica of 120 ppm with the proper OH alkalinity
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 10 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
According to your water analysis, TDS concentration is half of the lowest value recommended by
Clayton. Therefore you could reduce at least by 2 the blowdown rate.
The easiest solution is to change the duration of blowdown valves opening defined in the BMS
system. In agreement with Nalco, you can reduce the blowdown duration to 2 minutes every 2 hours
for example.
Another solution consists in installing a TDS probe on the feedwater line and control the blowdown
valve continuously.
3.3 Savings calculation
Reduce Blowdown rate
Existing
Proposed
Savings
Make-up water TDS
ppm
50,0
50,0
Feedwater TDS
ppm
1520,0
3000,0
Blowdown rate
%
3,40
1,69
1,71
Water savings
Existing
Proposed
Savings
Steam production of the boiler
kg/h
1000,0
1000,0
Blowdown flow
kg/h
34,0
16,9
17,1
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 11 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
Treated Water unit costs
€/m3
5,0
5,0
Water costs
€/yr
1063
530
533
Fuel savings
Existing
Proposed
Savings
Sensible heat Blowdown
kj/kg
721,0
721,0
Sensible heat make up water
kj/kg
50,0
50,0
Sensible heat differential
kj/kg
671,0
671,0
Energy used
kj/h
22823
11373
11450
Boiler efficiency
%
86,0
86,0
Operating hours
hr
6240
6240
Fuel used
MWh/yr
46,0
22,9
23,08
Fuel unit costs
€/MWh
25,0
25,0
Fuel costs
€/year
1150
573
577
CO2 savings
Existing
Proposed
Savings
Energy used
Gj/yr
166 50,6
83
83
CO2 emissions
kg CO2/GJ
50,6
50,6
CO2 produced
t/yr
9,5
4,7
4,7
Total savings
Existing
Existing
Proposed
€/yr
Total costs
2211
1102
1109
Total energy saved by reducing the blowdown rate is estimated at 1110 €/year .
3.4 Investments
No investment is required to change the blowdown frequency on the BMS System.
However we estimate the budget to install a TDS controlled blowdown valve at 9000 €.
Payback time for this optimization would be more than 7 years.
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 12 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
4 Optimisation project n°2: Reduce flash steam losses from feedwater
tank
4.1 Current situation
In the new boiler house, 7 barg saturated steam is produced by 2 Clayton generators.
The principle of steam production is the following:
Make-up water and return condensate are blend in the feedwater tank. Feedwater is pumped into
the heating coil, flowing through the spiral single passage section of the coil in a direction opposite
of the combustion gases, where it is rapidly heated to steam temperature. As the fluid leaves the
generator section, it passes through helically wound water wall section, into the separator nozzle in
the steam separator. The centrifugal force in the nozzle separates dry steam from excess water,
which returns to the lower section in the separator. Steam is delivered through the steam discharge
outlet located at the top of the steam separator. The excess water is returned to the feedwater
through the steam trap.
This system allows delivering 99% dry steam within a short time.
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 13 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
In order to keep the coil wet at all operating conditions and assure a very good steam quality, a
minimum of 20% excess water is required.
This part of excess water is heated from feedwater tank temperature to saturation (170°C/7 barg)
and evacuated by the steam trap at the separator outlet. This condensate is then sent to the
atmospheric feedwater tank.
Consequently a part of condensate will vaporize from 7 to 0 barg generating 13.5% of flash steam in
the feedwater tank.
Condensate from separator going back to the feedwater tank is useful to maintain the feedwater at
high temperature (90°C minimum required).
We indeed observed that the average temperature in the tank is above 95°C.
Therefore, no extra-steam is needed to maintain the temperature.
However the feedwater tank is still overheated.
Usually, condensate from separator is connected to the bottom of the feedwater tank (under the
water level) using a sparger tube :
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 14 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
This configuration allows maximizing the heat usage and insures a good homogenization of
feedwater temperature in the tank.
However in the new boilerhouse, condensate is connected to the top of the feedwater tank :
Consequently, flash steam generated is not completely condensed and is evacuated through the
vent to the atmosphere.
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 15 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
Excess feedwater load
In theory, a minimum of 20% excess water is required for a good operation of the steam generator.
This percentage is set and the feedwater pump has a fixed pumping rate.
It is possible to check if the amount of excess water is in a normal range as it is directly linked to the
amount of condensate evacuated from the steam trap.
The Clayton booklet explains how :
We did measure the opening time for the steam trap when the Clayton was at 25-30% load. I was
about 10 minutes per hour. This value is too high considering the explanation above. We therefore
conclude that the amount of excess water set is too high (about 40%) and so is the amount of flash
steam generated in the feedwater tank.
4.2 Optimization
To prevent from too much flash steam loss at the feedwater tank vent we recommend to:
1. Check with your Clayton distributor if a technician can reduce the amount of excess
water pumped to run properly the generators
2. Move condensate connections from the top to the bottom of the feedwater tank using
a sparger tube : it will help to have an homogeneous feedwater temperature in the
tank
3. Recover condensate heat to preheat combustion air up to 50°C. The solution consists
in installing a coil to heat combustion air using a part of condensate from Clayton
separator.
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 16 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
4.3 Savings calculation
Considering our observations and measurement on site, we can estimate the cost of this flash
steam loss:
Fuel savings
Existing
% of revaporisation (7 to 0 barg)
13,5%
Flash steam flow estimated
ton/h
0,066
safety factor
10%
Energy loss
kW
37
operating hours
hr
6240
yearly Energy used
MWh/year
232
boiler efficiency
%
86
Fuel used
MWh/year hhv
300
Fuel unit costs
€/MWh hhv
25
Fuel costs
€/year
7506
CO2 savings
Existing
Energy used
Gj/yr
1081
CO2 emissions
kg CO2/GJ
50,6
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 17 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
CO2 produced
t/yr
55
Water savings
Existing
Flash steam flow estimated
kg/h
0,066
safety factor
10%
Yearly water lost
m³/year
371
Water unit costs
€/m3
5,0
Water costs
€/yr
1853
In conclusion, we estimate the total potential savings at 9360 €/year .
1. Solution 1 : reduce excess feed water rate on the pump
Considering your installation, the Clayton specialist technician will decide how much it is possible to
reduce the amount of excess water pumped.
The following table shows savings calculation if the rate is decreased by 10% :
Fuel savings
Existing
Proposed
Savings
Feewater flow
m³/hr
1,1
1,1
Excess feedwater rate
%
40%
30%
10%
Excess water flow / condensate
m³/hr
0,44
0,33
0,11
% of revaporisation (7 to 0 barg)
13,5%
13,5%
Flash steam flow estimated
ton/h
0,059
0,045
0,015
Energy loss
kW
37
28
9
operating hours
hr
6240
6240
yearly Energy used
MWh/year
232
174
58
boiler efficiency
%
86
86
Fuel used
MWh/year hhv
300
225
75
Fuel unit costs
€/MWh hhv
25
25
Fuel costs
€/year
7506
5629
1876
CO2 savings
Existing
Proposed
Savings
Energy used
Gj/yr
1081
811
270
CO2 emissions
kg CO2/GJ
50,6
50,6
CO2 produced
t/yr
55
41
14
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 18 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
Water savings
Existing
Proposed
Savings
Flash steam flow estimated
kg/h
0,059
0,045
0,015
Yearly water lost
m³/year
371
278
Water unit costs
€/m3
5,0
5,0
Water costs
€/yr
1853
1390
463
The total savings would be 2340 €/year .
2. Solution 2 : Move the condensate connections to the bottom of the tank with a sparger tube
The modification will imply an increase of the feedwater temperature pumped to the generators.
We estimate this increase at 5°C. The efficiency gain on steam production will be about 0.5%.
Boiler efficiency
Existing
Proposed
Savings
Feedwater temperature °C
93,0
98,0
Boiler efficiency
%
86,0
86,5
0,5
Fuel savings
Existing
Proposed
Savings
yearly Energy used
GJ/yr
12499,2
12499
Boiler efficiency
%
86,0
86,5
0,5
Fuel used
MWh/yr hhv
4486
4460
25,93
Fuel unit costs
€/MWh hhv
25,0
25,0
Fuel costs
€/year
112145
111496
648
CO2 savings
Existing
Proposed
Savings
Energy used
Gj/yr
16149
16055
93
CO2 emissions
kg CO2/GJ
50,6
51
CO2 produced
t/yr
817
812
5
Savings are poor (less than 1000 €) because steam production is very low. If the steam demand
increases, savings will follow.
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 19 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
3. Solution 3 : preheat combustion air using hot condensate
The preheating of combustion air from ambient to 50°C will lead to an efficiency improvement by
1.5%:
Boiler efficiency
Existing
Proposed
Savings
Intake air temperature (average)
°C
18,0
50,0
Stacks temperature
°C
120,0
120,0
Oxygene content
%
7,0
7,0
Boiler efficiency
%
86,0
87,5
1,5
Fuel savings
Existing
Proposed
Savings
yearly Energy used
GJ/yr
12499,2
12499
Boiler efficiency
%
86,0
87,5
1,5
Fuel used
MWh/yr hhv
4486
4409
76,90
Fuel unit costs
€/MWh hhv
25,0
25,0
Fuel costs
€/year
112145
110222
1922
CO2 savings
Existing
Proposed
Savings
Energy used
Gj/yr
16149
15872
277
CO2 emissions
kg CO2/GJ
50,6
51
CO2 produced
t/yr
817
803
14
4.4 Investment
1. Solution 1 : reduce excess feed water rate on the pump
Budgetary cost for this project is estimated under 1000 €.
Payback time for this optimization is less than 6 Months.
2. Solution 2 : Move the condensate connections to the bottom of the tank with a sparger tube
Budgetary cost for this project is 3000 €.
Payback time for this optimization is about 55 Months.
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 20 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
3. Solution 3 : preheat combustion air using hot condenste
Budgetary cost for this project is 13 100€.
Including:
- Air ducts, condensate coil, valves, controls
- Installation work
At level of steam generation seen during the audit, payback time for this optimization is about 82
Months.
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 21 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
5 Optimisation project n°3: Improve steam ancillaries insulation
5.1 Current situation
Not only for safety reason, must hot surfaces have effective insulation to
prevent excessive heat loss by radiation. The basic function of insulation
is to retard the flow of unwanted heat transfer. There is more chance of
part of steam to condense during distribution if the pipelines are not
properly insulated.
There is a closely interrelated efficiency between boilers and their
distribution systems. The losses occurred in the distribution systems have
a significant impact on boiler operations. When these losses are minimized, boiler plant efficiency is
improved.
We observed some valves and filters on steam lines which are not insulated in your steam
distribution system.
The following table shows the non-insulated equipments identified during the audit:
Location
Ancillaries length or
DN
Pressure
loss
type
number
(mm)
(barg)
(W)
Boiler house (Eagle)
Back Pressure valves
valve
2
80
7
2106
Eagle building
2nd floor South
valve
2
100
7
2796
Pressure Reducing Station
strainer
1
100
7
1398
Pressure Reducing Station
valve
1
100
4
1137
GLATT 6115
valve
2
32
4
745
2nd Floor North Lavado
valve
1
32
4
373
2nd Floor North Lavado
valve
1
40
4
425
4th floor south
valve
3
40
2
1069
4th floor south
strainer
1
40
2
356
Tunnel 2 aera
1st floor VP37
valve
1
50
6
618
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 22 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
VP43
valve
1
50
6
618
near VP43
strainer
1
50
6
618
VP44
valve
1
40
4
425
to MDU1500
strainer
1
40
4
425
Glatt sala 544 - VP56
valve
2
32
6
869
Glatt sala 544 - VP56
strainer
1
32
6
435
Glatt sala 531 - VP50
valve
1
32
4
373
Glatt sala 535 - VP38
valve
1
32
6
435
Glatt sala 535 - VP38
strainer
1
32
6
435
Tunnel 1 aera
VP16
valve
1
65
3
614
VP4
valve
1
65
3
614
The total radiation loss is calculated at 16882 W.
5.2 Optimization
We recommend installing insulated jackets on all ancillaries located in
steam lines above DN25. These jackets are easy to remove in case of
maintenance operations.
5.3 Savings calculation
SAVINGS Calculation
Total radiation losses
16882 W
Operating hours
6240 h
Annual loss (time corrected)
105,3 MWh/yr
Steam production efficiency
86,0% (lhv)
Annual primary energy loss
122,5 MWh lhv/yr
Annual primary energy loss
135,6 MWh hhv/yr
Fuel cost
25,00 €/MWh
Annual financial loss
3391 €/yr
CO2 emissions
24,7 t CO2/year
Savings calculated are 3400 €/year .
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 23 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
5.4 Investments
Budgetary cost for this project is 6000 €.
Including:
- On site measurement to prepare tailor-made manufacturing of the jackets
- Supply of insulation jackets
- Installation
Payback time for this optimization is less than 21 Months.
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 24 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
6 Optimisation project n°4: Replace failed steam traps
6.1 Current situation
A full trap survey was done during our audit. There are 98 steam traps identified and listed on your
steam system drawings. 15 of the installed traps were failing (13 leaking, 2 plugged) and 34 could
not be tested as the units were out of service.
The details of the trap survey and its results are available on SteamStar trap management online
platform.
Here are the access parameters of this trap survey:
Login : beatriz.herrero@gsk.com
Full Name : Beatriz Herrero Gonzalo
Password : B34Tr1ZH3Rr3
Website : www.steamstar.com
Summary of results:
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 25 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
6.2 Optimization
We recommend replacing all steam traps indentified as failed.
Leaking steam traps mean losses of steam. It may also reduce condensate evacuation from process
by creating a back-pressure in the return lines.
Besides, steam in condensate return lines may generate water hammers which can damage your
installation and ancillaries (valves, pressure reducing valve, heat exchangers).
Blocked traps compromise steam quality and cause corrosion and erosion of steam lines and
auxiliaries, resulting in high maintenance costs and increased down time due to system failures.
These traps should be individually evaluated and should be cleaned or replaced by correctly sized
and installed traps.
Some of failed traps were not installed properly (reversed or inclined).
We also noticed a wrong selection for traps n°14-34-35, the pressure differential available is 4.5
barg whereas the steam pressure is 7 barg.
6.3 Savings calculation
Fuel savings
Existing
Steam losses calculated by Steamstar kg/h
50,450
Energy loss
kW
29
operating hours
hr
6240
yearly Energy used
MWh/year
179
boiler efficiency
%
86
Fuel used
MWh/year hhv
231
Fuel unit costs
€/MWh hhv
25
Fuel costs
€/year
5780
CO2 savings
Existing
Energy used
Gj/yr
832
CO2 emissions
kg CO2/GJ
50,6
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 26 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
CO2 produced
t/yr
42
Water savings
Existing
Steam losses
kg/h
50,450
Yearly water lost
m³/year
315
Water unit costs
€/m3
5,0
Water costs
€/yr
1574
Total savings would be 7350 €/year .
6.4 Investment
The budgetary cost for replacing all failing traps is 8000 €.
Including:
- Equipments supply (traps)
- Installation by a mechanical contractor
- Project management
Payback time for replacing all failing traps, including blocked traps, is 13 Months .
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 27 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
7 Summary of deviations noticed during the audit
7.1 Steam generation
Steam is produced by the Energy Central 2 since 2010. This new boiler house is not well monitored
yet.
Gas meters data on the 2 steam generators are not read regularly. As natural gas is also used for
hot water boilers in the Energy Central 1, it is not possible at the moment to know exactly fuel
consumption used to produce steam.
The make-up water meter is reported every day during the daily maintenance (decalcify water).
Some other data are measured and reported to the BMS System:
However some of these probes do not work properly (stacks temperatures, steam temperature) and
only steam pressure is recorded (trends available).
Consequently it is not possible to check on a regular basis the good functioning of the new boiler
house.
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 28 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
Gas meters should at least be reported once per month. The best would be to connect meters to the
BMS system (same for water) and record values.
We also recommend you to check if the steam and condensate flowmeters used in the old boiler
house cannot be moved to the new steam production system.
7.2 Steam distribution
Missing condensate drain points
Poor drainage of steam lines will cause accumulation of condensate in the steam distribution
system, thus causing a serious safety hazard for water hammering.
Also on many locations there are no drip legs installed on steam lines in front of control valves. In
some situations there are several meters vertical steam line above a control valve, without a drain
point (especially for Munters feed). When these valves are in a closed position condensate will
accumulate in front of these control valves, and sub-cool. This sub-cooled condensate is aggressive
(low PH) and will cause corrosion of the valves and piping. Also there is a risk for thermo shock and
water hammering. Furthermore accumulated condensate will compromise steam quality and cause
early wear of piping and ancillaries due to erosion.
« Low point »
Steam line size between Eagle and Tunnel 1&2
We have checked the steam line size for the connection between Eagle and Tunnel 1&2.
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 29 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
Steam is distributed at 6 barg in a DN65 pipe. As steam velocity should not exceed 30 m/s in the
pipe, the maximum steam flow you could sent safely to Tunnel 1&2 is 1220 kg/hr.
Steam lines DESIGN
Steam pressure
6 Bar(g)
X value
1,00
Line diameter DN
65
Flow
1220 kg/h 30,0 m/s
Steam velocity
max 30,0 m/s
Steam temperature
164,9 °C
specific volume Steam enthalpy Sensible heat
0,27 m3/kg 2763 kJ/kg 697 kJ/kg 2066 kJ/kg
X= 1,00
Latent heat Latent input
X= 1,00
700,1 kW
Currently it is not a problem as your real steam consumption for these areas is lower. However, if for
some reason the steam demand is increased you have to be aware of this limit.
7.3 Steam users
Main steam users are the GLATT systems and the dehumidifier Munters which need hot air.
The factory use 8 GLATT and 9 Munters in the whole site.
-GLATT systems (for coating machines and fluid bed dryers)
Each air handling unit is equipped with 2 or 3 steam coils.
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 30 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
The first one is called the “anti-freezing” coil. It is used to pre-heat outside air to 20-30°C.
Often the control valve is a thermostatic one and it is not protected by a drain point upfront.
Therefore this valve may leak rapidly.
Besides, considering the low temperature setting, the steam load in the coil may be low and there
may not be enough pressure to push condensate in the return line. This condition leads to flooded
coils which decrease the heat efficiency and generate slight water hammers. (see appendix n°2 for
detailed explanation)
The second and third steam coils are used to heat the air to 75-85°C. Most of them are equipped
with an automatic ON/OFF valve upfront the control valve. This prevent from steam leaks. However,
we highly recommend installing a steam trap in front of control valves which are installed in “low
point” to prevent from water hammering.
.
The GLATT equipments installed in the Eagle building are also equipped with start-up steam traps.
This steam traps open only with a pressure differential less than 1.5 barg. It allows evacuating
condensate to the sewer when steam pressure is less than back-pressure.
We observed that finally the valves after these steam traps are closed because you lose too much
condensate to the sewer. To avoid this situation you could install a system to push condensate in
the return at any operating condition (see appendix n°2).
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 31 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
-Dehumidifier Munters (for air conditioning)
The Munters system uses a desiccant rotor to remove humidity from outside air.
This desiccant rotor needs to be regenerated using hot air.
The air is heated by a steam coil up to 125°C.
Steam pressure needed is 4.25 barg (indicated in Munters datasheet).
Steam feeding lines are well equipped with control valves and automatic ON/OFF valves.
However there is no drainage point before all valves. Consequently, when the valve is closed,
condensate accumulates in steam line.
- Steam pressure levels
Many pressure reducing stations are installed on steam distribution lines.
However the steam pressure level is not always adapted to the need.
Munters dehumidifiers are designed to use 4.25 barg, but we have seen some equipment fed with 4
barg or even 2 barg steam. Therefore the desiccant regeneration may not be efficient and the
humidity control hazardous.
For GLATT dryers, steam pressure levels are also various:
- WSG120-sala 531, GLATT1350-sala 535 = 3 barg
- GLATT-sala 544 = 4.5 barg
- WSG120-sala 602, Climatiz.Recubrid.- sala 607 = 5 barg
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 32 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
- GLATT 6115-6102-6106, Eagle = 4 barg
Steam pressure levels should be adjusted considering these parameters:
Hot air temperature needed
The lower the steam pressure, the higher the latent heat which is transferred in
the coil
The lower the pressure, the higher the specific volume (attention to be paid to
steam pipe size)
If steam pressure is less than condensate return back-pressure, you may cause
condensate accumulation inside the coil.
-Linea AVAMYS (2 double jacketed reactors)
We observed that there is only one steam trap for the 2 condensate outlets of reactors.
This configuration can only work if the reactors do not run in the same time; otherwise you may have
troubles to evacuate condensate from one of the reactors to the return line.
7.4 Condensate return
Condensate from Tunnel 1 area is collected and sent to Tunnel 2 area with an old pumping-trap.
The condensate header and the pump have been relocated recently and the steam trap on the
motive steam line has not been re-installed. We recommend you to insert the steam trap again to
prevent from rapid erosion and steam leaks on the check valve at the pump steam inlet.
In a general way, there is no high back pressure in condensate return lines as you use 3
atmospheric condensate pumps. In Tunnel 1 and Eagle they are located at the same level or under
steam users. Thus condensate back-pressure is close to 0.
However in tunnel 1, some steam users located on the first floor are “under” the condensate pump
installed on the second floor. Therefore these steam users may be more sensitive to condensate
return back-pressure.
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 33 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
8 Complete check list of all verifications done during the audit
Potential optimisation
Status
Comments
STEAM GENERATION
Steam pressure setting
OK
7 barg is good compromise. 6 barg would certainly
be too low for distribution (lines sizing restrictions)
Feed water temp. to the boilers
OK
93°C measured on the feedwater pump. Clayton
requires a minimum of 90°C
Stack temperature in front of
NA
Not possible to measure on Clayton boilers.
economizer
Stack temperature after economizer
OK
Refer to combustion analysis or temperatures
reported in the BMS system (when repaired)
Combustion air temperature
To be improved
Ambient
Oxygen rate
OK
5-7% depending on the firing rate
Boiler sizing
OK
Boiler blow down rate
To be improved
Could be reduced to fit with Clayton
recommendations
Refer to optimization project n°1
Deaerator pressure
NA
Atmospheric feedwater tank
Feed-water pre-heating
NA
Boiler stand-by time and volatility of
OK
Clayton steam generators have a good response
steam demand
for these conditions
Boiler blow-down recovery
NA
Blowdown is too low at current steam demand to
recover energy within 5 years payback
STEAM AND CONDENSATE AUDIT
Project N°30275
Date: 04/02/2011
GSK MANUFACTURING Aranda, Spain
Page 34 of 45
Established by E. Morin
To the attention of Ms. Beatriz Herrero-Gonzalo
STEAM DISTRIBUTION
External leaks of steam or condensate
OK
No leak has been observed during the audit
from pipes, flanges, etc.
System design, trapping points etc.
To be improved Steam lines have all been interconnected to
distribute steam in both ways (from and to Eagle).
Steam line between Eagle and tunnels 1 and 2 is
undersized for high steam demands.
It misses many trapping points in front of control
valves and in “low points”.
Insulation
To be improved Refer to optimization project n°3
Steam quality
To be improved Steam quality is good at the outlet of the boiler
house but is progressively decreased by the lack of
drip legs in front of steam users
Steam pressure level
To be improved There are many pressure reducing stations. The
pressure level is not always adapted to the steam
usage.
Water hammering
OK
No water hammering has been observed in the
distribution lines
STEAM USERS
Condensate drainage and air venting
OK
from heat exchangers
Steam traps
To be improved 15% failed traps identified
Some traps are wrongly mounted (inclined,
reversed)
CONDENSATE AND FLASH STEAM RECOVERY
Condensate recovered
OK
Sizing of condensate return lines
OK
Flash steam recovery
To be improved Flash steam could be recovered on condensate
receivers. A vent condenser exists in tunnel 2 but is
not used anymore.
Water hammering
OK
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