FEATURE BOILERS DON’T LET OFF STEAM
Most manufacturers are looking for ways to reduce energy consumption, keep bills down, increase efficiency and improve productivity. What many don’t realise, however, is the important part a steam system can play in this. Marc Hough, product manager for flow control, at ERIKS UK & Ireland, explains why a poorly designed steam system could be increasing costs right under your nose
tonnes. With even a small steam system having around 50 traps, this can be an extremely costly waste of steam. In the most serious cases, high pressure
W
ithout wishing to over-generalise, steam systems are often treated as
the ‘extra’ of a manufacturing plant. They’re there to perform in the background, but you never really notice them, and they don’t get much credit for what they do. Even potential problems or failures can go unnoticed. Think about it: if other systems in your production process were running inefficiently, you’d most likely spot the issue and resolve it quickly. The problem with a steam system, however, is that the rate at which its efficiency and performance deteriorate is normally quite slow.
LEAKS AND LOSSES As a result, issues can steadily worsen over a number of years. In some cases, systems that may have gone without a formal survey for as long as five years can reveal blockages or leaks in up to 30 per cent of their steam traps when a survey is eventually carried out. Yet the reductions in efficiency, the increases in energy costs and CO2 emissions, and the changes in the speed or quality of production have been so gradual that plant operators do not notice that something is amiss until it is too late. What is perhaps more concerning is as
many as 10 per cent of steam traps may be leaking one year after system start- up. That number is likely to increase by seven per cent for every year that the system remains unchecked. The effect this can have on both processes and costs is striking. For example: a malfunctioning steam trap would lose steam at an average rate of 11kg/h, therefore total steam losses for a year will be 66 tonnes, at a cost per tonne of £25-30. Overall, that’s an annual loss of £1,650 to £1,980 and 32kW of energy, not to mention a CO2 impact of almost 10
12 MARCH 2018 | FACTORY EQUIPMENT
Marc Hough, product manager for flow control, at ERIKS UK & Ireland
leaks can prove extremely hazardous to workers, with an increased risk of scalding. The impact this can have on people and on a business’s reputation can be long-lasting. All of these costs, energy losses, unnecessary emissions and potential safety issues can be avoided by implementing a steam system audit as part of your maintenance routine.
As many as 10 per cent of steam traps
may be leaking one year after system start-up"
THE STEAM TRAP…TRAP Too many people seem to believe that a steam system’s relative simplicity means it is robust and maintenance-free. This is far from the case. System audits can reveal a number of costly and damaging problems capable of continuing, undetected, for months at a time. These can include: • Steam trap leaks • Ill-fitting steam traps, or traps that are not suited to the application
• Incorrectly fitted steam traps • Incorrect diameter pipes • Inadequate insulation of pipes and fittings
• Poor pipe layouts, which allow condensate to gather
• Water build-up, which creates water hammer and can damage the pipe bends and valves.
Some surveys have even revealed steam traps that the customer didn’t know were there. Considering that steam traps are often the weakest point of a steam system, this can prove to be a costly oversight.
TRACKING THE TRAPS A surveyor often begins a professional audit by discussing the system’s operation with the manufacturer. Existing system drawings are also reviewed. Surveyors then undertake their own mapping of the system. This involves inspecting pipework and insulation, as well as valves and steam traps. An audit is more than just a visual
inspection, however. It also involves ultrasonic and infrared thermographic measurements, which identify blockages and leaks, and assess the functionality of every system component. A thorough examination such as this not only helps plant operators to better understand their systems, but also identifies any problem areas before they cause production to halt entirely.
UNDER PRESSURE With increasing pressure to reduce energy costs, wastage and CO2 emissions, an expert steam system audit can often be a quick and easy win, with the possibility of achieving a return on investment in as little as two to four months. Undertaking an audit shouldn’t be
viewed as a one-off, however. Seven per cent of steam traps can begin failing after roughly twelve months of operation. An annual steam system audit will help to maintain your plant and keep it functioning at its optimal level. Furthermore, by partnering with a
specialist, you can benefit from expert maintenance and asset management, which in turn could mean increased reliability, enhanced safety, reduced downtime and lower operating costs for your plant. Who wouldn’t want that?
For more information on ERIKS UK & Ireland’s flow control products and services, please visit
www.eriks.co.uk/Flow-Control/4543 or call 0121 508 6000
/ FACTORYEQUIPMENT
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