FEAT RE FEA ATURE


BOILERS PUMPS & V LVS & VALVE S S, P,


DONT LET OFF STEAM DON’’T LET OFF STEAM.. .  Incorrect diameter pipes


Most manufacturers are looking for ways to reduce energy consumpti n, keep bi s dow productivity. W at m


crease efficiency and i don t realise,


control at ERIKS steamsystemca


n play in this. M rc H ugh product m systemcould be increasing costs right under your nose W


ithout wishing to over-generalise, steam systems are often treated as


the “extra” of a manufacturing plant. They’re there to performin 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. As a result issues can s teadily 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 n otice that something is amiss until it is too late. What is perhaps more concerning: as many as 10 per cent of steam traps may


,


per cent for every year th up. That number is likely be leaking one year after


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 st eam losses for a year will be 66 tonnes, at a cost per tonne of £25-30. Overall, that’s an annual loss of £1650 to £1980 and 32kWof energy, not tomention a CO2 impact of almost 10 tonnes. With even a small steamsystem having around 50 traps, this can be an extremely costly waste of steam.


, 18 18 APRI MA 201 APRIL/MAY 2018 | IRISH MAN RISH MANUFAC ACTURI RING


to increase by 7 system start-


at the system THE STE M TR P…TR 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 steamtraps, or traps that are not suited to the application  Incorrectly fitted steam traps


www.eriks.ie


ERIKS UK & Ireland www.eriks.ie


T: 00353 1856 8540 / HSIRI IRISHMANUF MANUFACTURING FACTURING


st m nufacturers are looki g 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


prove


ver, is the important part a ger for flow


UK & Ireland explains w y a poorly designed steam


 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 pip e 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 costl y oversight.


TRACK NG THE CKINGI HE TRAPS APS


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 o f every system component.


,


In the most serious cases, high pressure 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


part of your mai implementing a


steam system audit as ntenance routine .


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. 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 in a s little as two to four months.


Undertaking an audit shouldn’t be


viewed as a one-off, however. 7 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 increase d reliability, enhanced safety, reduced downtime and lower operating costs for your plant. Who wouldn’t want that?


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