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 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