Clayton Armstrong 2011-02-22 GSK Aranda SP - steam&condensat

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