© 2010 Armstrong International Pvt. Ltd.
Steam And Condensate Engineering Audit
for
Stiefel, a GSK company Rua Prof. Joao Cavalheiro Salem 1081/1301
Bonsucesso, Guarulhos – SP - BRASIL
Prepared for
Mr. Ricardo Carminato
[28th Mar’11 to 1st Apr’11]
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 2 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
www.armstronginternational.in
Executive Summary
Armstrong conducted a Steam System Engineering Audit at Stiefel, a GSK company, Sao
Paulo, Brasil during the period of Mar 28 – Apr 01, 2011. The objective of the study was to
identify opportunities for decreasing energy waste (reducing carbon footprint), improving
reliability, decreasing maintenance costs and improving safety. Opportunities identified are
summarized in Table 1.
The energy audit conducted by Armstrong covers the 4 parts of the steam loop: boiler house,
steam distribution, steam consumption and condensate return.
The Boiler house had scope for improvement in reducing the blowdown and reducing the pre
heating temperature of furnace oil. The combustion analysis conducted during audit indicated
that the boiler was operating at good efficiency levels by maintaining close to best in class
excess air levels but was under a cycling loading which resulted in high radiation losses. Also
the flue gas exhaust temperature was close to 200oC which further reduced the steam
generation efficiency.
In general the steam distribution system was found good. The insulation was satisfactory and
there were no major steam leaks which is a indicator of a very good maintenance program
being in place. The main drawback of the distribution system is the absence of flow meters. The
plant does not have meter on steam, water or fuel.
The plant utilises steam for a majority of heating applications either for heating water or for
product heating in the production process. The production process is a batch operation and
some processes run only a couple of times a year. The condensate recovery from the plant is
intermittent due to batch process. As discussed during the kick off meeting, the major issue to
concentrate on was to find initiatives that will lead to energy and carbon dioxide emission
reduction with low capital investment.
We estimate the potential energy savings of 40.26% of the current yearly fuel bill for steam
and compressed air generation which represents a yearly saving of about 126 tons of CO2 and
94.3 KBRL.
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 3 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
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Sr.
No.
Description
Financial
Savings
BRL./year
Estimated
Investment
BRL
Simple
Payback
[RANGE in
years ]
CO2
Emission
Reduction
[ton/year] Safe
ty
Main
ten
ance
Pro
cess
1 Replace steam to water
heating by direct water
heater
69400 200000 2.88 115 X X X
2 Reduce steam generation
pressure
908 Nil Immediate 1.9 X X
3 Reduce boiler blowdown 1190 Nil Immediate 2.3 X
4 Increase temperature of
feed water
System Benefit
10000 NA Nil X
5 Reduce Furnace oil pre
heating temperature
91 Nil Immediate 0.11 X X
6 Install pumping trap on
RTR-08, RTR-07, RTR-06
System Benefit
20000 NA Nil X
7 Install Heat recovery unit
on compressor
22803 32000 1.40 7 X
8 Install Steam, water, and
Fuel meter for boiler
System
Benefit
20000 NA Nil X X
TOTAL Savings: 94392 BRL /year
(40.26% of total Steam Generation and Compressor Fuel Budget)
TOTAL Fuel Savings: 38.39 ton /year of Furnace Oil
TOTAL CO2 Emissions Reductions: 126 ton/year
Table 1 : Optimisations Identified during Audit
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 4 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
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Note: Values marked as NA imply a requirement of in-depth review to ascertain confirm saving potential Savings are calculated on only heat recovery basis. Savings are based on the data furnished by the plant head and data collected during the study period. Investment considered for the payback calculations are based on budgetary prices of the items considered
and may change depending upon implementation time & the prevailing market situation. At an Audit level investments are calculated with an accuracy of ±25%.
The above investment and saving estimates are developed according to standard engineering
practices and are based on Armstrong’s extensive experience in steam and utility systems.
More accurate investment estimates will be available after the scope of work to be done by
AIPL is defined and jointly agreed upon by both GSK and AIPL as well as upon completion of
Detailed Engineering Design.
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 5 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
www.armstronginternational.in
Acknowledgement
An Engineering Audit is a venture between Energy Experts and Plant Experts to define
opportunities for optimization. The contribution of the plant’s team is extremely important in this
venture. We sincerely acknowledge the contribution of the following dignitaries and site
engineering personnel whose co-operation helped to conclude to the quality of the data analysis
and conclusions.
Mr.Waldimir Benetti
Mr. Aluizio Aaujo Silveira
Mr. Cesar Peixoto de Carvalho
Mr. Luiz Dias
Mr. Jarbas Mingorance
Mr. Ed Carlos
We are also thankful to the other staff members who were actively involved while collecting the
data and conducting the field trials.
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 6 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
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Table of Contents
1 PLANT AND UTILITIES OVERVIEW 8
2 STEAM AND CONDENSATE SYSTEMS OVERVIEW 10
2.1 STEAM GENERATION 10 2.2 STEAM DISTRIBUTION 13 2.3 STEAM USAGE 14 2.4 CONDENSATE COLLECTION AND RETURN 17 2.5 STEAM TRAPS 17 2.6 STEAM COST CALCULATIONS 18
3 ENERGY CONSERVATION MEASURES 20
3.01 ECM 1: REPLACE STEAM TO WATER HEATING BY DIRECT WATER HEATING 20 3.02 ECM 2: REDUCE STEAM GENERATION PRESSURE 24 3.03 ECM 3: REDUCE BOILER BLOWDOWN 27 3.04 ECM 4: INCREASE FEED WATER TEMPERATURE 30 3.05 ECM 5: REDUCE FURNACE OIL TEMPERATURE 32 3.06 ECM 6: INSTALL PUMPING TRAP ON RTR-08, RTR-07 AND RTR-06 33 3.07 ECM 7: INSTALL HEAT RECOVERY UNIT ON COMPRESSOR 36 3.08 ECM 8: INSTALLATION THE FLOW METERS IN SOME LINES. 40
4 CONCLUSIONS AND RECOMMENDED NEXT STEPS 42
5 ATTACHMENT 45
5.1 BOILER INDIRECT EFFICIENCY TEST RESULTS 47 5.2 TRAP SURVEY REPORT 51
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 7 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
www.armstronginternational.in
1.0 PLANT AND UTILITIES OVERVIEW
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 8 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
www.armstronginternational.in
1 Plant and Utilities Overview
The Stiefel, a GSK company, manufacturers healthcare and pharmaceutical products at the
Guarulhos plant.
Major utilities used in the plant are furnace oil, Diesel, compressed air, electricity and water.
There are no meters to measure or record the steam generated in the previous year; similarly
there is no metered data for fuel and water consumption. The fuel readings are taken on an day
to day basis on the level maintained in the tank.
Based on the data available with the plant the total furnace oil consumption during previous year
is 115450 litres which accounts for approximately 158 KBRL. The compressed air is generated
by an 60 HP air compressor for which the electricity consumption is approximately calculated as
76.3 KBRL.
Energy content and CO2 emissions considered for the different fuels used in the plant are
summarized in Table 2 : Heating Values and CO2 Emissions
Fuel
Heating Value CO2 emissions
HHV Units Qty Units
Furnace oil 10900 kCal/kg 0.26788 kg CO2/kWh
Electricity --- --- 0.089 kg CO2/kWh
Table 2 : Heating Values and CO2 Emissions
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 9 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
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2.0 STEAM AND CONDENSATE SYSTEM OVERVIEW
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 10 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
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2 Steam and Condensate Systems Overview 2.1 Steam generation
I. Boilers Description The Stiefel plant boiler house consists of a two Furnace oil / Diesel fired fire tube boiler which
generates steam at 9 barg and saturation temperature to provide steam to process. One boiler
is under continous operation whereas the other boiler is standby. During audit boiler no.2 was
not operational due to maintenance related to burner control, so the efficiency could not be
tested. The boiler uses diesel as a startup fuel and furnace oil as primary fuel. The boiler is not
equipped with flue gas exhaust heat recovery equipments like Air Pre Heater (APH) and
Economizer; so the final stack temperature at outlet is measured as 200˚C.
More details about the boilers are provided in following table:
Boilers # Units 1 1
Manufacturer Tenge Tenge
Type WT/FT FT FT
Rated Capacity kg/h 3200 2000
Rated Pressure kg/cm2g 10.5 10.5
Rated Temperature oC Sat. Sat.
Operating Pressure kg/cm2g 9 9
Operating Temperature oC Sat. Sat.
Main Fuel Used FO FO
Back-up Fuel Diesel Diesel
O2 Trim Yes/No No No
Economizer Yes/No No No
Air Preheater Yes/No No NO
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 11 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
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Boilers # Units 1 1
VFD on FD Fan Yes/No No No
VFD on ID Fan Yes/No/NA NA NA
Modulated Blowdown Yes/No No No
Table 3 : Steam Boilers Details
II. Indirect Boiler Efficiency
During the study, Armstrong took stack gas measurements to determine the boiler operating
efficiencies. The measurements are summarized below:
Boiler 1
Fuel Used
Furnace Oil
Load % 30--50% Load
O2 in Stack % 4.69
CO2 in Stack % 12.5
Ambient Temperature C 28
Stack Temperature C 200
CO ppm 00
Radiation losses % 3
Indirect Efficiency (HHV) % 82
III. Direct Boiler Efficiency
As mentioned earlier as there are no flow meters to estimate the steam flow and since the boiler
is under cyclic loading it is not possible to determine exact steam generation for determining the
direct efficiency of the boiler.
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
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III. Boiler Insulation The insulation surface temperature of both the boilers was found to be okay. The average
surface temperature on the front surface was measured as 59C and that at the sides 53C,
back 45C with an ambient temperature of 36C. There was no visible insulation damage. The
average surface temperature was found to be 56C.
IV. Boiler Feed Water System
The raw water from bore well is stored in a storage tank and from there routed to reverse
osmosis (RO) plant. The water from these treatment plants is transferred to storage tank where
condensate from plant is also added. From here the boiler feed water pumps water to de-
aerator. The boiler feed water tank does not have steam injection and the average temperature
is close to 55oC. Also the boiler water is dosed with a chemical prior to feeding it to boiler.
The water analysis report is tabulated below:
Conductivity (μS/cm)
Treated Water 0.92
Treated + Condensate 175
Raw water 92
Condensate 5.8
Boiler 595
Table 4 : Water Analysis Report
The test results show that the boiler water treatment was within limit parameters and the
condensate was free of any major contamination.
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 13 of 51
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V. Boiler Blowdown The boiler do not have automatic blowdown control system and the manual practice of once a
hour blowdown is followed. It was observed that there is no practise of testing the conductivity
or TDS of water samples; only the PH of the water samples is tested.
It is recommended to check TDS of the boiler every 8 hours to monitor the heath of water in
boiler.
The present manual blowdown system is inconsistent in maintaining the blowdown and depends
on operator’s judgement with no parameter being monitored or controlled.
2.2 Steam distribution
I. Steam Distribution Network
During audit, the 3.2 TPH boiler was operated at 30 to 50% load to match the plant steam load.
There are no steam flow meters in the distribution network too.
The overall insulation was found in good condition and there were no major steam leaks except
for one near the kitchen hot water PHE control valve.
The condensate drains are correctly designed with adequate strainers and moisture seperators
before the pressure reducing stations and equipment temperature control valves.
II. Steam Lines Sizing
During our Audit we have checked the sizing of the main distribution lines, results are tabulated
in Table 5
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 14 of 51
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Sr.
No
Line Description Line
Size
NB
Pr.,
Kg/cm2
g
Flow
(Max)
T/hr
Velocity
m/s
ΔP
Kg/cm2
per 30m
Remark
1. Boiler to Distribution
header 250 9 3.5 3.9 0.001 Ok
2. Main distribution line 150 9 3.5 10.7 0.01 Ok
3. Line to PHE 80 3 0.8 20.5 0.03 Ok
4 Line to Fuel oil tank 50 9 0.5 13.8 0.05 Ok
Table 5 : Sizing of Main Steam Lines
2.3 Steam usage
As discussed earlier, Stiefel has steam generation mainly for water and product heating. A
majority of the applications are for low grade heating (less than 70oC) which can be replaced by
an efficient water heating system.
The product heating is done in jacketed vessels which operate on a batch process which is
inconsistent and varies from twice each day to once a month. Due to such random operation the
boiler operation is cyclic and cannot be averaged for operation.
2.3.1 Steam users
Based on the data given by the plant and observations made during visit, an estimate of steam
consumption is tabulated below:
Overall Steam Consumption (Kg/Week)
COSMETICS 1908 Production
CREAMS 1689 Production
Water Heating 22365 Kitchen, plate heat exchangers
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
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COSMETICS CONSUMPTION (Kg/Week)
RTR-05 341 Equipment
RTR-07 1229 Equipment
RTR-06 322 Equipment
MIS 03 16 Equipment
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
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CREAMS CONSUMPTION (Kg/Week)
RTR-08 1287.10726 Equipment
RTR-09 386.132178 Equipment
RTR-04 16.0888407 Equipment
OTHER AREAS CONSUMPTION (Kg/Week)
KITCHEN 400 PHE
AIR CONDITIONING 2327.462717 PHE
DYNAFLO 1000 Mixer
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
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2.4 Condensate collection and return
During the audit it was observed that the steam traps on the equipments pump condensate to
the common condensate header. Most of the condensate lines have a compressed air purging
which flushes out condensate from the equipment at the end of the batch. There are no
mechanical or electrical pumps for pumping of the condensate.
2.4.1 Condensate Return Rate
The condensate return rate on an average is approximately 80% of the total steam generation
as all the equipments excepts the steam / water mixers are indirect heating applications.
2.5 Steam Traps
During the trap survey 38 steam trap locations were checked with ultrasonic steam trap leak
detector to validate working, selection and installation. The summary of trap survey is as below
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
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A few traps were closed with bypass open as the traps were waterlogged during process. This
is not a good practice as opening of bypass means leaking of live steam and the correct solution
is to replace the failed steam traps.
2.6 Steam Cost Calculations
Due to no record of steam generation, based on non accurate steam consumption the steam
cost is calculated as 123.4 BRL/ton.
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 19 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
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3.0 ENERGY CONSERVATION MEASURES
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
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3 Energy Conservation Measures
3.01 ECM 1: Replace steam to water heating by direct water heating
Current System Description and Observed Deficiency
During the Audit, it was observed that the major steam consumption in the plant was for water
and process heating application. The heating temperature required in most of the applications
was less than 80oC and either a plate heat exchanger or a portable steam water mixer was used
for heating water with steam. In the process (production) steam was used in jacketed vessels to
heat the product from ambient temperature to 70oC / 80oC.
There is no application which requires the product or water above the atmospheric evaporation
temperature of water.
As discussed in earlier steam generation section, the boiler is under cyclic loading and
operating at an efficiency of approximately 75%. The steam generated in boiler then is made
available to the point of use in the plant at required pressures maintained by the individual
pressure reducing valves.
Since the operating pressure for the jacketed vessels and other indirect heat exchangers is very
low and the back pressure due the elevation of the condensate header acting at the outlet of the
trap, the condensate undergoes sub-cooling thereby contributing to the energy loss.
Technical Discussion
Presently, the boiler operates at 75% efficiency, which means out of the total fuel energy fired in
the boiler only 75% transforms into usable steam energy. This boiler generates steam at 10 bar-
g which has to be carried to the process plant where applications require steam at a pressure
lower than 3.5 bar-g. During this process there is a distribution loss of another 1% to 5%
depending on insulation health and leaks. Further the heat transfer loss in the heat exchanger
accounts for another 1% to 2%. Thus by the time the fuel energy get available to the water it
loses a significant amount of its energy content.
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
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Majority of the losses explained above can be avoided if fuel energy is directly utilised for
heating the water by a high efficiency water heater. The gas based water heater can generate
hot water at efficiency close to 99.7% and the distribution losses are less than 1% due to low
temperature and low pressure distribution which significantly reduces insulation loss and leak
losses. Since the water gets directly used for heating or CIP there is heat exchanger required
for this system.
Fig: Existing system V/S Improved System
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
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Recommended Optimisation
Armstrong recommends
Replacing steam based water heating by direct hot water
Installing a high efficiency direct fired hot water generator
Estimated Benefit:
The estimated benefits by reducing excess air are as below:
Replace steam by direct water heating
Hot water Required 2000 kg/h
Temp of hot water 80 Deg C
Inlet water temp 25 Deg C
Heat required 110000 kcal/kg
System efficiency 72%
Fuel Required 14 kg/h
Improved system efficiency 96%
Natural gas required Required 13 kg/h
Savings 14 R$/hour
Annual Monetory saving 69462 R$/year
Present CO2 emission 237623 kg/year
Future CO2 emission 122335 kg/year
CO2 emission reduction 115 ton/year
The implementation of this optimisation will lead to an annual carbon dioxide emission reduction
of 115 MT/year.
The above savings are calculated based on replacement of direct water consumption
applications like kitchen, CIP, cleaning stations, sanitation, etc. The flow rate (2000 kg/h) is an
estimated flow. If the hot water is used for process heating in jacketed vessels, the savings will
be higher. A study to quantify exact requirement of hot water should be done prior to
implementation of this project.
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
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Estimated Investment and Payback:
The implementation of this energy conservation measure would require an investment of
approximately 200000 BRL which include:
High efficiency direct water heater
Installation
Piping modification
The payback for this optimisation measure would be approximately 2.88 years.
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
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3.02 ECM 2: Reduce steam generation pressure
Current System Description and Observed Deficiency
The boiler generates steam at 9 bar-g whereas all the steam applications like water heat
exchangers, jacketed process vessels, etc utilise steam at less than 3 bar-g. The steam
distribution from boiler to the plant is at steam generation pressure and the pressure is reduced
at the equipment.
The velocity and pressure drop calculation for existing maximum steam load of 3500 kg/h reveal
that there will be no significant pressure drop and the steam velocities will be less than 20 m/s.
Technical Discussion
The reduction in steam pressure and temperature:
Will reduce fuel consumption - total heat in steam at 9 bar-g is 3 kcal/kg more than
the total heat in steam at 6bar-g.
Will reduce the standby losses, radiation losses and losses associated with the flash
steam and steam leaks in the pipe joints, valves and fittings.
Will increase the temperature differential between the combustion gases and water,
which increases the heat transfer and boiler efficiency. Since the facility currently
does not have stack economizers to capture energy from stack losses, the reduction
of steam pressure will have a positive impact.
Will decrease scale formation and oxygen corrosion. Scale formation and oxygen
corrosion rise dramatically with boiler pressure. Oxygen corrosion in high-pressure
systems causes pitting on the boiler tubes, which ultimately lead to pinhole leaks.
Scale also reduces heat transfer and efficiency.
Recommended Optimisation
Armstrong recommends
Reducing the steam generation pressure
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
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In order to avoid the potential pitfalls, while implementing this proposal, it is required:
- All PRV’s to be studied (identified and capacity confirmed) for the new conditions. If
needed PRV’s to be replaced or adjusted for the new conditions.
- The steam traps capacities to handle condensate in the steam plant upstream from the
pressure reducing valves to be checked and replaced if needed.
- The boiler feed water pump pressure discharge to be adjusted for the new conditions to
avoid cavitations because of a potential increase in pump flow rates (gpm). This will
also result in some electrical energy savings, which have not been considered in the
calculations.
The pressure reduction should be decreased in 0.5 bar-g intervals. It is required to monitor the
system response for 24 hours to observe steam quality and capacity PRV and pipes. Assuming
the PRV’s are not considered suitable for the lower pressures, replacement/upgrade for the new
conditions will need to be done.
Estimated Benefit:
The estimated benefits by reducing boiler pressure are as below:
Reduce Steam Generation pressure
Fuel Cost 1.66 $R/kg
Boiler efficiency 75%
Steam generation 4227 kg/day
Steam pressure 9 barg
Steam Enthalpy 663 kcal/kg
Feed water enthalpy 55 kcal/kg
Fuel Calorific Value 10900 kcal/kg
Fuel consumption 315 kg/day
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
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Enthalpy at 6 barg 660
Fuel consumption 313 kg/day
Fuel saving 2 kg/day
Annual Operation 312 days
Annual Fuel Saving 547 kg/year
Annual Monetory Saving 908 $R/kg
Energy Savings 6937 kWh
CO2 Savings 1.9 ton/year
The implementation of this measure will lead to an annual reduction in BPF consumption by
approximately 547 kg/year. The total CO2 reduction will be approximately 1.9 ton/year.
Estimated Investment and Payback:
The implementation of this energy conservation measure does not require any investment
except for some man-hours during the trial period.
The payback for this optimisation measure would be Immediate.
Note: If it is observed that the existing PRV’s are not capable for the pressure reduction, then it
is recommended to generate steam at higher pressure as the investment for new PRV’s will
have long payback.
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 27 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
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3.03 ECM 3: Reduce Boiler Blowdown
Current System Description and Observed Deficiency
The boiler has a intermittent manual blowdown which was found to be inconsistent and operator
depended. It was observed that the operators depending upon their judgement gave a
blowdown ranging from 3 to 6 seconds per hour. During analysis it was observed that the
present blowdown was higher than that required for the current water parameters.
Technical Discussion
Even with the best pretreatment programs, boiler feed water contains some degree of impurities
such as suspended and dissolved solids. As water evaporates, these impurities are left behind
and accumulate inside the boiler. The increasing concentration of dissolved solids leads to
carryover of boiler water into the steam, causing damage to piping, steam traps and even
process equipment. The increasing concentration of suspended solids forms sludge, which
impairs boiler efficiency and heat transfer capability.
To avoid boiler problems, water must be periodically discharged or “blowdown” from the boiler
to control the concentrations of suspended and total dissolved solids in the boiler water. Surface
water blowdown is often done continuously to reduce the level of dissolved solids, and bottom
blowdown is performed periodically to remove sludge from the bottom of the boiler.
If the blowdown rate is too high, energy (water, fuel, chemicals) is wasted. If high
concentrations are maintained, (too low blowdown) it may lead to scaling, reduced efficiency,
and to water carryover into the steam compromising its quality (wet steam)
The ASME guidelines "Consensus on Operating Practices for the Control of Feed water and
Boiler Water Quality in Modern Industrial Boilers," shown in the tables below, are frequently
used for establishing optimum blow down rate.
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 28 of 51
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Water Chemistry for Water tube Boilers - ASME Guidelines
Recommended Optimisation
Armstrong recommends
Reducing the blowdown
It is recommended to install a automatic blowdown controller for maintaining the correct
blowdown, but since the steam generation and operational hours are very low, this measure
cannot be economically justified.
So a fixed orifice of 3mm is recommended to be placed into the blowdown line which will
maintain the boiler water TDS within required parameters.
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 29 of 51
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Estimated Benefit:
The estimated benefits by reducing blowdown are as below:
Reduce Boiler Blowdown
Present Blowdown 320 kg/day
Boiler conductivity 4477 μs/cm
Feed water conductivity 175 μs/cm
Steam generation 4227 kg/h
Blowdown required 172 kg/day
Heat in blowdown 182 kcal/kg
Enthalpy in feed water 55 kcal/kg
Energy Saving 18799 kcal/day
Fuel Saving 2.3 kg/day
Annual monetory Saving 1190 R$/year
The implementation of this measure will lead to an annual reduction in BPF consumption by
approximately 717 kg/year. The total CO2 reduction will be approximately 2.3 ton/year.
Estimated Investment and Payback:
The implementation of this energy conservation measure does not require any major investment
except for Orifice Plate and Labour
The payback for this optimisation measure would be Immediate.
Note: It is advised to consult the water treatment chemical supplier and ensure that this initiative
will not have any adverse effect on the boiler.
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 30 of 51
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3.04 ECM 4: Increase feed water temperature
Current System Description and Observed Deficiency
During audit it was noticed that the boiler feed water temperature was approximately 60oC and
the feed water tank did not have any steam injection practice to increase the feed water
temperature. The condensate return from the plant was mixed with the treated make up water at
room temperature prior to feeding to boiler.
Technical Discussion
In the de-aerator, dissolved gases, such as oxygen and carbon dioxide, are expelled by
preheating the feed water before it enters the boiler. All natural waters contain dissolved gases
in solution. Certain gases, such as carbon dioxide and oxygen, greatly increase corrosion.
When heated in boiler systems, carbon dioxide (CO2) and oxygen (O2) are released as gases
and combine with water (H2O) to form carbonic acid, (H2CO3). Removal of oxygen, carbon
dioxide and other non-condensable gases from boiler feed water is vital to boiler equipment
longevity as well as safety of operation. Carbonic acid corrodes metal reducing the life of
equipment and piping. It also dissolves iron (Fe) which when returned to the boiler precipitates
and causes scaling on the boiler and tubes. This scale not only contributes to reducing the life of
the equipment but also increases the amount of energy needed to achieve heat transfer.
Removal of oxygen and carbon dioxide can be accomplished by heating the boiler feed water,
which reduces the concentration of oxygen and carbon dioxide in the atmosphere surrounding
the feed water. Below graph shows concentration of Oxygen at different feed water
temperature.
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 31 of 51
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Above graph shows that present Dissolved Oxygen level in feed water is in the range of 7 ppm
to 8 ppm at 30 C, with thermal de-aeration it can be reduced to below 2 ppm by increasing the
feed water temperature above 95 oC. This will increase the boiler tubes life & reduce down time,
tube leaks problems.
Recommended Optimisation
Armstrong recommends purging of steam into the feed water tank so as to maintain the feed
water temperature above 950C.
Estimated Benefits:
The implementation of this optimisation measure would lead to system benefits and reduced
maintenance cost. Some of the key benefits are:
Improved boiler steam generation capacity
Reduced oxygen in feed water
Prolong life of boiler tubes
Reduced maintenance downtime
Estimated Investment:
To preheat investment is estimated as BRL 10,000 which includes:
Piping
Steam Injector
Temperature Control Valve
Instrumentation
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 32 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
www.armstronginternational.in
3.05 ECM 5: Reduce Furnace oil temperature
Current System Description and Observed Deficiency
During audit it was noticed that the furnace oil tank was heated to temperature above 85oC
which resulted in generation of furnace oil fumes from the tank. These fumes not only are
resulting in loss of fuel but also not good for human health. It also may lead to fire hazard if the
temperature reaches close to flash point of the oil.
Technical Discussion
For maintaining the viscosity of furnace oil, it is required to pre heat the furnace oil. This pre-
heating helps in pumping of the oil as well as in better combustion of the oil in the burner.
Excessive heating beyond a certain temperature may lead to health and safety hazards.
Recommended Optimisation
Armstrong recommends maintain the furnace oil temperature close to 80oC.
Estimated Benefits:
The implementation of this optimisation measure would lead to system benefits, safety and
health. A little monitory saving can also be achieved by reduction in steam consumption for
heating:
Reduce Furnace Oil Temperature
Present FO temp 87 deg C
Recommended Temp 80 deg C
FO flow 98133 kg/year
Specific heat of FO 0.52 kcal/kg K
Heat saving 357202 kcal/year
Fuel Saving 55 kg/year
Monetory saving 91 R$/year
Estimated Investment:
There is no investment required for this initiative and payback is Immediate.
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 33 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
www.armstronginternational.in
3.06 ECM 6: Install Pumping trap on RTR-08, RTR-07 and RTR-06
Current System Description and Observed Deficiency
During audit it was noticed that the bypass line of the trap on RTR-08 was open and the
condensate along with steam passing. It was then understood from operator that the
condensate does not get discharged from the trap and so the bypass line is kept open.
The jacketed vessel RTR-08 heats the product usually to 90oC and for this purpose utilises
steam which is controlled by a temperature control valve. The condensate formed has a back
pressure of approximately 0.5 barg due to the elevation of the condensate return line.
Other jacketed vessels viz., RTR-07 and RTR-06 have an auxiliary air purging arrangement
which ensures that the condensate is flushed out from the jacketed vessels and do not face a
situation of stalling of condensate. But the operators have a practise of opening the bypass line
at the start-up so as to drain out any steam. This practice leads to energy loss which is difficult
to quantify but is not a good engineering practise.
Technical Discussion
Stall occurs primarily in heat transfer equipment where the steam pressure is modulated to
obtain a desired output (i.e. product temperature). The pressure range of any such equipment
(coils, shell and tube, etc.) can be segmented into two distinct operational modes: Operating
and Stall.
Operating: In the upper section of the pressure range, the operating pressure (OP) of the
equipment is greater than the back pressure (BP) present at the discharge of the steam trap.
Therefore a positive pressure differential across the trap exists, allowing for condensate to flow
from the equipment to the condensate return line.
Stall: In the lower section of the pressure range, the operating pressure (OP) of the equipment
is less than or equal to the back pressure (BP) present at the discharge of the steam trap.
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 34 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
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Therefore, a negative or no pressure differential exists; this does not allow condensate to be
discharged to the return line, and the condensate begins to collect and flood the equipment.
Recommended Optimisation
Armstrong recommends installing a pump and trap (mechanical steam operated pump)
combination package for recovering condensate from RTR-08, RTR-07, RTR-06 and reduce the
energy loss.
Estimated Benefits:
The implementation of this optimisation measure would lead to system benefits and reduced
maintenance cost. Some of the key benefits are:
Continuous drain of condensate
Mechanical pump so safe in inflammable area
Reduced maintenance downtime
Better heat transfer
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 35 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
www.armstronginternational.in
Estimated Investment:
To preheat investment is estimated as BRL 20000 which includes:
Piping
Pumping trap (Pump Trap combination)
Installation
Labour
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 36 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
www.armstronginternational.in
3.07 ECM 7: Install Heat recovery unit on compressor
Current System Description and Observed Deficiency
During the Audit, it was observed that the facility has two 60 HP air compressors. One of the
unit is continuously operational whereas the other acts as an standby which turns ON when
there is a increased demand.
The existing compressors are oil cooled type and there is no heat recovery on them. The hot air
blast is open to atmosphere.
Technical Discussion
Air compressors account for significant amount of electricity used in industries. Air compressors
are used in a variety of industries to supply process requirements, to operate pneumatic tools
and equipment, and to meet instrumentation needs. Only 10 – 30% of energy reaches the point
of end-use, and balance 70 – 90% of energy of the power of the prime mover being converted
to unusable heat energy and to a lesser extent lost in form of friction, misuse and noise.
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 37 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
www.armstronginternational.in
(Source: BEE, INDIA)
The compressing of air gives off heat. The heat energy is concentrated in the decreasing
volume of air. To maintain proper operating temperatures, the compressor must transfer excess
heat to a cooling media before the air goes out into the pipe system. As much as 90 percent of
that heat can be recovered for use in operation which can supplement or replace the electricity,
gas or oil needed to create hot water for washrooms, or direct warm air into a workspace,
warehouse, loading dock, or entryway, the savings can really add up. The energy recovered by
means of a closed loop cooling system (for water cooled compressors) is advantageous to the
compressor's operating conditions, reliability and service life due to an equal temperature level
and high cooling water quality to name but a few. The temperature level of the recovered energy
determines the possible application areas and thereby the value. In the highest temperature
levels (from oil free compressors) the degree of recovery is the greatest. The highest degree of
efficiency is generally obtained from water cooled installations where the compressor discharge
cooling water can be connected directly to a continuous process heating requirement.. Surplus
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 38 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
www.armstronginternational.in
energy can then be effectively utilized all year round. Most new compressors from the major
suppliers can be adapted to be supplemented with standard equipment for recovery.
Energy recovery from air cooled compressor installations will not always give heat when it is
required and perhaps not in sufficient quantities. The quantity of recovered energy will vary if the
compressor has a variable load. In order for recovery to be possible a corresponding energy
requirement is needed, which is normally met through an ordinary system supply. Recovered
energy is best utilized as additional energy to the ordinary system, so that the available energy
is always utilized when the compressor is running.
Recommended Optimisation
Armstrong recommends
Installing a heat recovery unit
Estimated Benefit:
The estimated benefits by reducing excess air are as below:
Source: Atlas Copco Manual
Based on the information provided by Atlas Copco heat recovery manual, the estimated benefits
by installing a heat recovery unit are:
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 39 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
www.armstronginternational.in
Compressor Heat Recovery
Hot water flow 402 kg/h
Rise in temp 70 Deg C
Heat recovery (80%) 22512 kcal/h
Annual Fuel saving 13747 kg/h
Monitory Saving 22803 $R/year
CO2 saving 7.0 ton/year
The implementation of this measure will lead to a annual reduction in BPF consumption by
approximately 13 ton/year. The total CO2 reduction will be approximately 7 ton/year.
Estimated Investment and Payback:
The implementation of this energy conservation measure would require an investment of
approximately 32000 BRL which include:
Heat recovery equipment – 23000 BRL
Installation & Piping modification – 7000 BRL
Storage tank – 2000 BRL
The payback for this optimisation measure would be approximately 1.40 years.
Note: The quote for price of heat recovery unit was provided from Atlas Copco
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 40 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
www.armstronginternational.in
3.08 ECM 8: Installation the flow meters in some lines.
Current System Description and Observed Deficiency
During the audit, it was observed that there are no flow meters installed on the steam, water line
and the fuel line. The plant presently cannot measure the production, consumption and
distribution this resources in the plant. Because of this fact there is no way to make exact
calculations for efficiency, track the expenditure or verify opportunities for savings or even
implement programs that help to decrease the consumption.
Technical Discussion
For the good operation of any plant, the control over the utilities is of utmost importance, in this
case the utilities being steam, water and fuel. It’s necessary to meaure with a flow meter each
lines, to establish a control and define, if it’s possible to reduce the consumption or the
efficiency of the equipments, that aren’t the best. The installation the flow meters in water line,
fuel line and steam line contribute to set up a base to develop the programs for checking
consumption, possible leaks, loss and savings that would be present in the different lines. .
Recommended Optimization
Armstrong recommends the installation the flow meter in different sections of the plant and the
main headers for distribution of steam and water. The same applies for the fuel line.
Estimated Benefits
The benefits of implementation of this optimization are various, beginning from establish
measures that help to know that efficiency and use correct of the resources (fuel, water and
steam).
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 41 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
www.armstronginternational.in
4.0 CONCLUSION AND RECOMMENDED NEXT STEPS
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 42 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
www.armstronginternational.in
4 Conclusions and Recommended Next Steps The Steam and Condensate Engineering Audit has defined a total potential of 2,77,74,206
Rs./year savings that are summarized in the following table.
Sr.
No
Description
Elec
MWh
Fuel
ton /y
Water
KL /y
Financial
Savings
Rs./year
CO2 Emiss.
Reduction
[ton/year]
1** Replace steam to water
heating by direct water heater
NA 23.32 NA 69400 115
2 Reduce steam generation
pressure
NA 0.5 NA 908 1.9
3* Reduce boiler blowdown NA 0.7 46 1190 2.3
4* Increase temperature of feed
water
NA NA NA NA NA
5* Reduce Furnace oil pre
heating temperature
NA 0.05 NA 91 0.11
6* Install pumping trap on RTR-
08, RTR-07, RTR-06
NA NA NA NA NA
7 Install Heat recovery unit on
compressor
NA 13.7 NA 22803 7
8* Install Steam, water, and Fuel
meter for boiler
NA NA NA NA NA
TOTAL NA 38.27 19 94392 126.31
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 43 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
www.armstronginternational.in
The savings only include utilities savings. Maintenance, safety and process optimizations are
not represented in those numbers.The projects recommended (indicated with an *) are simple
and do not need any further engineering. Armstrong would be glad to prepare a proposal for
their implementation.
The project marked ** (ECM 1) to be implemented only after implementation of ECM 7.
The other projects will need a step of further engineering to define the exact solution and refine
the investments in order to be able to provide a turnkey proposal.
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 44 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
www.armstronginternational.in
Confidentiality Notice
This engineering audit report has been submitted to M/s. Stiefel, a GSK company, Recipient, in
confidence and it contains trade secrets, as well as privileged information, and/or proprietary
work product of Armstrong International Pvt. Ltd. (AIPL), In consideration of the receipt of this
report and the information and data herein, Recipient agrees that it will use this document and
the information contained herein only for internal use and only for the purpose of evaluating a
business transaction with Armstrong Recipient agrees that it will not disclose this report or any
part thereof to any third parties and Recipient may only disclose this document to those
employees involved in the evaluation of a business transaction with AIPL, on a need basis.
Recipient may make only those copies needed for such internal review. Upon conclusion of
business discussions, this document and all copies shall be returned to AIPL upon its or their
request.
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
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Project ID: 90020 Page 45 of 51
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5 Attachment
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 46 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
www.armstronginternational.in
Attachment 5.1 Boiler Indirect Efficiency Test Results
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 47 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
5.1 Boiler Indirect Efficiency Test Results
BOILER HOUSE SIMULATION BOILER 1
Boiler operating hours (incl. hot stand-by hours) 8,760 hours/year
1. Fuel power input %LHV
Fuel type: 60 Oil No.6 (bunker C) %HHV
Fuel consumption during operating hours 75.0 l/h
Boiler capacity 3.2 ton/h (=2.2MW)
Specific weight of the fuel 0.86 kg/l
Fuel consumption 64.1 kg/h
Lower heating value (LHV) 40880 kJ/kg
Higher heating value (HHV) 43399 kJ/kg
Fuel unit costs 50 €/MWh HHV (= 0.52€/l)
Fuel power input (LHV) 728.2 kW 100%
Fuel power input (HHV) 773.1 kW
Steam pressure 9 Bar(g) / 179.9°C sat.
Enthalpy steam 2777 kJ/kg
Temperature feed water to the boiler/eco 65.0 °C
Enthalpy feed water 272 kJ/kg
Heat added to feedwater 2505 kJ/kg
Max. theoretical steam production 1.05 ton/h (=0.9 ton/h actual)
2.1 - Combustion losses (dry)
Temperature stack after boiler 200 °C
Temperature ambient air 30 °C
Excess air 27.0 %
Oxygen % flue gas (Dry volume) 4.69 %
Specific Stack flow (dry) 12.82 Nm3/kg fuel
Total stack flow (dry) 822.1 Nm3/h
Total stack flow (wet) 906.3 Nm3/h
Specific heat stack 1.40 kJ/Nm³.K -7.0%
Energy loss in dry stacks 54.50 kW -7.5%
2.2 - Losses due to moisture in fuel
Moisture in Stack 0.000 kg/kg fuel
Specific heat water in fuel 4.18 kJ/kg.K
Specific heat water in stacks 1.8643 kJ/kg.K
Energy losses due to moisture in fuel 0.0 kW on HHV 0.0%
Energy losses due to moisture in fuel 0.0 kW on LHV 0.0%
2.3 - Losses due to H2 of Fuel
Moisture in Stack 0.972 kg/kg fuel
Specific heat water in fuel 4.18 kJ/kg.K
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 48 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
Specific heat water in stacks 1.8643 kJ/kg.K
Energy losses due to moisture in fuel 47.6 kW on HHV -6.2%
Energy losses due to moisture in fuel 4.3 kW on LHV -0.6%
3. Cycling losses (burner starts)
Hot standby time during operating hours 90 %
Min. burner capacity 1000 kW
Boiler water volume 5.00 m3
Burner on/off pressure differential 1.00 Bar(g)
Purge cycle time 120 sec
Minimum nr. burner starts 0.00 per hour 0.0%
Heat loss purging air 0.00 kW 0.0%
4.1 Economizer (non condensing)
Temperature stack after economizer 200 °C
Economizer inlet water temperature 65.0 °C
Economizer outlet water temperature 65.0 °C
Heat transfer efficiency 100%
0.0%
Power recovered by economizer 0.0 kW 0.0%
4.2 Air preheating from external source (Top of boiler house)
Combustion air required 13.56 Nm3/kg fuel
Total combustion air flow 1017.1 Nm3/h
Normal combustion air temperature 30.0 °C
Preheated combustion air temperature 25.0 °C -0.2%
Power recovered by air preheating -1.8 kW -0.3%
4.3 Air preheat system (closed loop heat recovery from stack after eco)
Temperature stack after air preheater 200 °C
Preheated combustion air temperature 30.0 °C
Energy taken from the stack 0.0 kW
Heat transfer efficiency 100%
0.0%
Power recovered by air preheat system 0.0 kW 0.0%
5. Radiation losses
Boiler AverageLoad 1.62 %
Water Tube Radiation Losses (as per Abma) #N/A %
Fire Tube Radiation Losses (Manufacturer Data) #N/A % Radiation losses considered in calc. 3.0 % -2.8%
Radiation losses 21.8 kW -3.0%
6. Blow down
Conductivity boiler feed water 200.0 µs/cm
Conductivity boiler water 3000.0 µs/cm
Boiler water lost by blow down + carry over 7.1 % of steam output (15cycles)
Boiler feed water flow 0.980 ton/h
Boiler water lost by blow down + carry over 0.065 ton/h
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 49 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
Ratio of blow down vs carry over 100% blowdown
Carry over 0.000 ton/h
X-value of the steam from the boiler 1.000
Blow down flow remaining 0.065 ton/h
Enthalpy blow down water 763 kJ/kg
Temperature make up water 25.0 °C
Enthalpy make up water 104.5 kJ/kg
Total Blow Down losses (Boiler + Deaerator) 11.9 kW -1.2%
Blow down losses compensated by boiler only 8.9 kW -1.2%
7. Boiler Efficiency and Fuel Costs
Net power output in steam from the boiler 636.8 kW ( 5578 MWh)
Net dry steam production boiler (x=1) 0.915 ton/h = 8015 t/year
Net wet steam production boiler 0.915 ton/h
Boiler efficiency on LHV 87.45 %
Boiler efficiency on HHV 82.37 %
Annual Fuel costs 338,597 €/year Fuel costs / ton dry steam 42.25 €/ton
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 50 of 51
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Attachment 5.3 Trap Survey Report
Energy Audit for Steam & Condensate System Date: 28-Mar -11
to 01-Apr-11
Stiefel, a GSK Company – SP - BRAZIL Revision 00
Project ID: 90020 Page 51 of 51
For the Attention: Mr. Ricardo Carminato Prepared by P Ternikar
5.2 Trap Survey Report
ARMSTRONG INTERNATIONAL PRIVATE LIMITEDP – 46, Eighth Avenue, Domestic Tarrif Area,Mahindra World City, Anjur Village, Natham Sub,Chengalpattu 603 002India
4/1/11
Sao Paulo, SP
Prepared by:
GSK, Guarulhos
Steam Trap Survey
For:
General Summary
The General Summary reviews the Scope of Work, final reports, and steam losses associated with this steam trap survey.
ARMSTRONG INTERNATIONAL PRIVATE LIMITEDP – 46, Eighth Avenue, Domestic Tarrif Area,Mahindra World City, Anjur Village, Natham Sub,Chengalpattu
Date: 4/1/11To: GSK, Guarulhos Sao Paulo, SPRe: Steam Trap Survey
Between 3/28/11 and 4/1/11 ARMSTRONG INTERNATIONAL PRIVATE LIMITED conducted a steam trap survey at yourfacility.38 in service traps were tested. All failed or defective traps were tagged with a red and white tag for ease in fieldidentification. The field investigation and computer analysis reveals that 2.6% of the in-service traps were found to be defective. Thefailed traps wasting steam resulted in an estimated annualized loss of 31,622 kg of steam and a corresponding monetaryloss of 3,902 BRL. The following is a breakdown of defective traps as a percentage of the total in-service traps:
Blow Thru 0.0%Leaking 0.0%Plugged 0.0%Rapid Cycling 2.6%Flooded 0.0%Cold 0.0% Total 2.6%
Refer to the defective trap report for a complete listing of all failed traps. We thank you for the opportunity to assist in your energy conservation efforts and steam maintenance program. If we canbe of any further service, or if you wish to discuss any aspects of this report, please do not hesitate to contact us.
STEAM TRAP SURVEY SCOPE OF WORK & TECHNICAL SPECIFICATIONS
AT THE JOB SITE
1. All steam traps are located, identified, and tagged with a stainless steel or aluminum tag and clip.
2. Each trap is tested to determine its operating condition. The method used shall include ultrasonic listening and visual inspection where possible (the customer should supply a means to reach traps that are difficult to access, e.g. ladders, forklifts, etc.).
3. A temporary red and white paper tag is attached to each FAILED trap in addition to the stainless steel or aluminum tag.
4. Note is made of specific problems. Some examples are: water hammer, poor or improper insulation, steam leaks in piping or valves, improper installation of traps, and other steam related problems.
5. On-the-job-training is provided to those plant personnel who are helping our Technicians with the survey. One plant maintenance person should accompany each survey team.
6. Trap Survey—Log Sheet Data:
a. Tag Number b. Location c. Elevation d. Manufacturer and Model Number e. Connection Size f. Pressure
i. Pressure In (P.I) – actual steam pressure leading to the trap ii. Pressure Out (P.O.) – actual steam pressure leaving the trap
g. Application (Drip, Tracer, Coil, Process, Air Vents, Liquid Drainer) h. Equipment (Unit Heater, Radiator, Humidifier, etc.) i. Piping (Direction, Valve-In, Strainer, Valve-Out) j. Trap Condition (Operating Mode) k. Comments
Note: All personnel testing traps are certified, factory trained technicians.
Recommended Steam Trap Testing
Procedures
Armstrong International, Inc.
STEAM TRAP TESTING
A combination of testing methods is used in accurately predicting the operating condition of a trap. We recommend the use of an ultrasonic listening device with visual observation when possible. When an atmospheric discharge is not possible, the use of the ultrasonic listening device can be used to determine the operating condition of the steam trap. Temperature measurement cannot show the operating condition of the trap. It is merely a sign of corresponding saturation steam pressure upstream of the trap and pressure on the condensate return system downstream of the trap. Determining the amount of back pressure in the condensate system helps to quantify the amount of live steam lost through a failed trap. The ultrasonic listening device gives a fairly clear understanding of how the trap is operating. A normally operating inverted bucket trap emits a definite burst of sound when the bucket sinks and opens the trap valve, thereby discharging condensate until entering steam floats the bucket and closes the valve. In the presence of extremely low loads, the bucket is heard as a continuous clattering sound. This is sometimes called a “dribbling trap.” This is still a normal operating steam trap with no steam loss. This could also be a sign of an oversized trap, therefore requiring a smaller or restrictive orifice. The normal operating sounds of a float and thermostatic trap are difficult to distinguish as it is a constant flow device with no cycle rate. By shutting off the inlet valve, letting condensate collect, and then releasing a large condensate load to the trap, the trap is heard opening and then modulating down the steady state flow. The thermostatic air vent in a float and thermostatic trap often opens rather infrequently to release air, making its working condition difficult to determine. A thermostatic steam trap has a cycle, but it is much more gentle in nature than the inverted bucket or disc trap. A sub cooling thermostatic steam trap is similar in operation to the float trap. It may have either a bellows or a bimetallic spring as the actuation device, opening and closing the trap according to the set temperature differential.
STEAM TRAP TESTING (Continued)
A final determination of the operation of a steam trap is visual. This test can only be done if there is an atmospheric discharge or test valve. If there is a test valve after the trap, close off the valve to condensate return and open the test valve to the atmosphere. The steam trap will now act as an atmospheric discharge trap. If there is high back pressure in the condensate return system, some generic types of steam traps operate differently when discharging to the atmosphere than to the condensate return system. Therefore it is important to know how the different generic types of traps operate under varying conditions. Opening a test valve ahead of the trap can also determine if the trap is backing up condensate. The actual piping arrangement with the application can give some insight as to freezing problems, formation of vacuum, back pressure and poor piping configurations that may affect the operation of the trap. Use a systems approach when testing steam traps. There are times when, after further investigation, what seems to be a defective trap is actually a piping or application problem. Armstrong International, Inc. Three Rivers, MI Phone: +1 (269) 273-1415 Fax: +1 (269) 278-6555 Web: http://www.armstrong-intl.com
Executive Summary Report
The Executive Summary Report includes the following information:
• Condition Summary - a listing of steam traps by operating mode • Trap Type Summary - a listing of steam traps by generic type • Application Summary - a listing of steam traps by application • Manufacturer Summary - a listing of steam traps by
manufacturer • Annualized Loss Summaries - a total breakdown of estimated
steam and monetary loss
STEAM TRAP EXECUTIVE SUMMARYGSK, Guarulhos - Energy Audit
Survey Date: 3/28/11 - 4/1/11
TRAP TYPE SUMMARY TOTAL ANNUALIZED SUMMARIES
Generic Type Population
Count% of Total Failure
CountIn Service
Failure
DC Disc 20 52.6% 1 5.0% Steam Loss (kg) 31,622FL Float 14 36.8% 0 0.0% Monetary Loss (BRL) 3,902Other 4 10.5% 0 0.0% Fuel used to generate lost steam
(kWh/yr)
31,023
CO2 Emissions (kg) 8,340Totals: 38 100% 1 2.6% SOx Emissions (kg) 208,055
NOx Emissions (kg) 24,295
MANUFACTURER SUMMARY CONDITION SUMMARY
Manufacturer Population
Count% of Total Failure
CountIn Service
FailureCondition Population
Count% of Total
SPI Spirax Sarco 34 89.5% 1 2.9% NT Not Tested 6 15.8%Other 4 10.5% 0 0.0% OK Good 31 81.6%
RC Rapid Cycling 1 2.6%Totals: 38 100% 1 2.6%
Totals: 38 100%
APPLICATION SUMMARY
Application Population
Count% of Total Failure
CountIn Service
Failure
CL Coil 2 5.3% 0 0.0%DR Drip 24 63.2% 1 4.2%PR Process 12 31.6% 0 0.0%
Totals: 38 100% 1 2.6%
STEAM TRAP EXECUTIVE SUMMARYGSK, Guarulhos - Energy Audit
Survey Date: 3/28/11 - 4/1/11
TRAP TYPE SUMMARY
CONDITION SUMMARY
APPLICATION SUMMARY
Generic Type PopulationCount
% of Total FailureCount
In ServiceFailure
Condition PopulationCount
% of Total Application PopulationCount
% of Total FailureCount
In ServiceFailure
DC Disc 20 52.6% 1 5.0% NT Not Tested 6 15.8% CL Coil 2 5.3% 0 0.0%FL Float 14 36.8% 0 0.0% OK Good 31 81.6% DR Drip 24 63.2% 1 4.2%Other 4 10.5% 0 0.0% RC Rapid Cycling 1 2.6% PR Process 12 31.6% 0 0.0%
Totals: 38 100% 1 2.6% Totals: 38 100% Totals: 38 100% 1 2.6%
MANUFACTURER SUMMARYGSK, Guarulhos - Energy Audit
Survey Date: 3/28/11 - 4/1/11
MANUFACTURER SUMMARY
MANUFACTURER SUMMARY
Manufacturer Population Count % of Total Failure
CountIn Service Failure
SPI Spirax Sarco 34 89.5% 1 2.9%Other 4 10.5% 0 0.0%
Totals: 38 100% 1 2.6%
Defective Trap Report
The Defective Trap Report includes the following information:
• Blow Through, Leaking and Rapid Cycling Traps - a listing of defective traps wasting steam with a condition of BT, LK or RC
• Plugged and Flooded Traps - a listing of defective traps not wasting steam but backing up condensate due to a failed closed (PL) or flooded (FL) condition
PMO
Months/Year
Months/Year
Months/Year
Months/Year
Months/Year
Months/Year
GSK, Guarulhos
Superheat
Superheat
Superheat
Superheat
Superheat
Comments
Comments
Comments
Comments
Comments
1
Process
Val
ve O
ut
PipingLine Sz
1C
Critical Trap
Critical Trap
Critical Trap
Critical Trap
Critical Trap
Receiver
Receiver
Receiver
Receiver
Receiver
MFR Pressure
0 bar15.0
Location
Location
Location
Location
Location
Location
15.0
Model
Frequency
Frequency
Frequency
Frequency
Frequency
Conn Size
1
Application
H41.4 bar
Drip
Route No.
Route No.
Route No.
Route No.
Route No.
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Do not monitor
Do not monitor
Do not monitor
Do not monitor
Do not monitor
Conductive
Conductive
Conductive
Conductive
Conductive
12
123.40 BRL
SPI
Customer
Steam Loss/Yr
NO15.0
Coil
X
5
Condition
Recommendation
Recommendation
Recommendation
Recommendation
Recommendation
Socket-Weld
Outside
Outside
Outside
Outside
Outside
Dis
char
ge
3,902 BRL
Conn Type
Conn Type
Conn Type
Conn Type
Conn Type
Condensate
Installed Date
Installed Date
Installed Date
Installed Date
Installed Date
9.0
Steam Cost
Drain near Boiler enteranceTank 02
Date
Date
Date
Date
Date
Date
TD52
Sup
ply
31,622 kg/yr
Elevation
Elevation
Elevation
Elevation
Elevation
12
RC
Out Out
12
Load
Page
Lift
Follow up
Follow up
Follow up
Follow up
Follow upNPT Pipe Thread
Equip
006 2
Ricardo CarminatoDEFECTIVE TRAP REPORTTechnician
Energy Audit
Str
aine
rInsulation
Val
ve In
Tracer
Check Valve
Check Valve
Check Valve
Check Valve
Check Valve
Dire
ctio
n
Steam
Annual Cost
4/1/11
Temp Alarm
Temp Alarm
Temp Alarm
Temp Alarm
Temp Alarm
Transmitter
Transmitter
Transmitter
Transmitter
Transmitter
Tag#
Tag#
Tag#
Tag#
Tag#
DR C
12
In In
1
Appendix
The Appendix includes the following reference information:
Terminology –a glossary of terms used on survey reports.
Trap Condition Reference –descriptions for each trap conditionreported.
TERMINOLOGY
TERMS DESCRIPTION DEFINITION
TAG NUMBER Trap identification no. A sequence of up to 15alphanumeric characters.
LOCATION Trap location General description of the traplocation, i.e. Building, Floor, Room,etc.
INSIDE/OUTSIDE Whether the trap is locatedwithin a protective structure oris exposed to the elements.
I=Inside, O=Outside
ELEVATION Elevation of the trap Height above/below the floor/groundsurface
MFG Trap manufacturer A three character designation of thetrap manufacturer (e.g.ARM=Armstrong)
MODEL Trap model number The model number designated bythe trap manufacturer.
TYPE Generic type of trap Type designated by single letter, e.g.IB=Inverted Bucket.
CONN SIZE Connection size Connection size of the trap (notnecessarily the same as the pipesize).
INSPECTIONFREQUENCY
Trap inspection schedule Recommended number of times thetrap should be tested in months,(e.g. every ___ months).
TERMINOLOGY(Continued)
TERMS DESCRIPTION DEFINITION
EQUIPMENT Equipment beingserviced
Actual equipment being serviced by the steam trap, e.g.Unit Heater.
P –I Pressure In The gauge pressure or nominal pressure on the inletside of the trap.
P –O Pressure Out The gauge pressure or nominal pressure on the outletside of the trap (also called Back Pressure)
SUP Supply side of trap Supply side pressure in terms of C=Constant SupplyPressure; M=Modulating Supply Pressure
RETURN Discharge side of trap Discharge side of trap is either C=Closed or O=Open toatmosphere
APP Application Application serviced by trap, e.g. DR=Drip Trap, etc.
TIME INSERVICE
Amount of annual use The number of hours the trap is under load, expressed inmonthsper year (e.g. 2,160 hours = 3 months).
PIPING Direction of piping H=Horizontal, V=Vertical, etc.
V –I Valve In Type of valve on inlet side of trap (0=None, 1=on/off,2=2 or 3 way valve)
V –O Valve Out Type of valve on outlet side of trap (0=None, 1=on/off,2=2 or 3 way valve)
STR Strainer Type of strainer ahead of trap, 0=None; 1=Inline;2=Inline w/blowdown valve
COND.LOAD
Condensate Load Actual load of condensate at the trap.
COND. LIFT Condensate Lift Actual height condensate must be lifted to overheadreturn.
TERMINOLOGY(Continued)
TERMS DESCRIPTION DEFINITION
INSUL Insulation Type Actual type of insulation surroundingpipes and traps, e.g. Asbestos,Calcium Silicate, etc.
CONN. TYPE Connection Type Actual trap connection, e.g.SCR=Screwed, FLG=Flanged, etc.
SUPERHEAT Superheat present Indicates whether superheat ispresent at the trap.
SD Shutdown required Indicates that system or plantshutdown must be initiated to repairthe failed trap.
LINE SIZE IN Line size in Nominal size of the inlet line/pipe
LINE SIZE OUT Line size out Nominal size of the outlet line/pipe
TRAP CONDITION
ABBREVIATION DESCRIPTION DEFINITION
OK Good Trap Trap in normal operating mode.
BT Blow Through Trap has failed in an open mode withmaximum steam loss. Trap shouldbe repaired or replaced.
LK Leaking Trap has failed in a partially openmode with a steam loss ofapproximately 25% of maximum.Trap should be repaired or replaced.
RC Rapid Cycling Disc trap going into failure mode.
PL Plugged Trap has failed in a closed positionand is backing up condensate. Trapshould be repaired or replaced.
FL Flooded Trap is assumed to be undersizedand unable to handle thecondensate load. Trap should bereplaced with proper size.
OS Not in Service The steam supply line is off and thetrap is not in service.
NT Not Tested Trap in service but not tested due toinaccessibility, unable to reach, toohigh, etc.
CD Cold A SteamEye trap sensor hasreported a low temperature reading.
FT Fault A SteamEye trap sensor hasreported a monitoring fault condition.
ARMSTRONGTHEORETICAL STEAM LOSS CALCULATIONS (IP UNITS)
The basic formulas used to estimate the live steam loss of defective traps are as follows:
MASONEILAN’S FORMULA
)())(.( oiV PPPC 12 = Blow Through
Where: CV = Flow Coefficient
∆P = Pi –Po
Pi = Inlet Pressure (psia)
Po = Outlet Pressure (psia)
NAPIER’S FORMULA
))()(.( 04351 APi
Where: A0 = Area of Orifice
These are general formulas used in determining steam loss through and orifice. Basedon data compiled in the field as well as actual test data from our lab in Michigan, certainchanges have been made to these formulas.
In addition to inlet pressure, back pressure, and orifice size, piping configurations,severity of failure, and condensate load influence the quantity of steam loss through atrap. Consequently, service and very light condensate loads as found in drip and tracerservice and the much higher condensate loads associated with coil and processapplications.
Back pressure, service time and modulating conditions are incorporated in thecalculations. Naturally, some information such as how many months a trap operates peryear is determined by data supplied by plant personnel.
ARMSTRONGADJUSTED STEAM LOSS CALCULATIONS (IP UNITS)
Given from trap survey log sheet:
P.I. = Inlet pressure (psig)P.O. = Outlet pressure (psig)
Step 1: Convert pressures to psia:
P.I. + 14.7 = Pi, actual inlet pressure (psia)P.O. + 14.7 = Po, actual outlet pressure (psia)
Step 2: Determine Po , outlet pressure(psia) to be used in calculations:
If Po ≥0.5 Pi, then use Po
If P0 < 0.5 Pi, then use 0.5 Pi
Step 3: Determine ∆P using Pi and Po found in step 2:
∆P = Pi –Po
Step 4: Calculate steam flow or blow through (lb/hr):
)())(.( oiV PPPCW 90 for coil & process applications
)())(.( oiV PPPCW 41 for tracer & drip applications
Where: W = Steam flow or blow through (lb/hr)CV = Flow coefficientPi = Inlet pressure (psia)Po = Outlet pressure (psia)∆P = Pi –Po
STEAM LOSS CALCULATION EXAMPLES (IP UNITS)
A. Coil Application
Given: P.I = 100 psigP.O. = 0 psigCV = 32.1
Step 1: Pi = 100 + 14.7 = 114.7Po = 0 + 14.7 = 14.7
Step 2: 1307114714
..
. < 0.5, therefore
Po = (0.5)(Pi) = (0.5)(114.7) = 57.35
Step 3: ∆P = Pi –Po = 114.7 –57.35 = 57.35
Step 4: 869235577114355713290 ,)..(.).)(.( W lb/hr
B. Drip Application
Given: P.I = 100 psigP.O. = 60 psigCV = 32.1
Step 1: Pi = 100 + 14.7 = 114.7Po = 60 + 14.7 = 74.7
Step 2: 6507114774
...
≥0.5, therefore
Po = 57.35
Step 3: ∆P = Pi –Po = 114.7 –74.7 = 40
Step 4: 912377471144013241 ,)..().)(.( W lb/hr
STEAM LOSS CALCULATION EXAMPLES (IP UNITS)(Continued)
C. Tracer Application
Given: P.I = 100 psigP.O. = 45 psigCV = 32.1
Step 1: Pi = 100 + 14.7 = 114.7Po = 45 + 14.7 = 59.7
Step 2: 5207114759
...
≥0.5, therefore
Po = 59.7
Step 3: ∆P = Pi –Po = 114.7 –59.7 = 55
Step 4: 401475971145513241 ,)..().)(.( W lb/hr
Log Sheet Data
The Log Sheet Data is a complete listing of all trap data as recorded by technicians.
PMO
C
Months/Year
Months/Year
Months/Year
Months/Year
Months/Year
Months/Year
GSK, Guarulhos
Superheat
Superheat
Superheat
Superheat
Superheat
DR
OK
C
Comments
Comments
Comments
Comments
Comments
1
NO
Process
9.0
TD52
004
Val
ve O
ut
Piping
NO
Line Sz
20.0
0 bar
0 bar
2
OK
1
9.0
20.0
C
Critical Trap
Critical Trap
Critical Trap
Critical Trap
Critical Trap
002
Receiver
Receiver
Receiver
Receiver
Receiver
MFR Pressure
C
1 bar
SPI
15.0
10.0 bar
2BPF tank 02
Location
Location
Location
Location
Location
Location
15.0
Drain near Boiler enteranceTank 01
Model
Frequency
Frequency
Frequency
Frequency
Frequency
Conn Size
Socket-Weld
8
Application
1
H41.4 bar
X
Drip
1
Route No.
Route No.
Route No.
Route No.
Route No.
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Do not monitor
Do not monitor
Do not monitor
Do not monitor
Do not monitor
1C
Conductive
Conductive
Conductive
Conductive
Conductive
12
SPI
Customer
20.0
C
NO
41.4 bar
15.0
Coil
Socket-Weld
20.0
X
12
Condition
H
Recommendation
Recommendation
Recommendation
Recommendation
Recommendation
H
Socket-Weld
Outside
Outside
Outside
Outside
Outside
20.0
Dis
char
ge
Conn Type
Conn Type
Conn Type
Conn Type
Conn Type
Condensate
Installed Date
Installed Date
Installed Date
Installed Date
Installed Date
12
9.0
12
BPF tank 01
1X
FT14C-10
Near Boiler
TD52
Date
Date
Date
Date
Date
Date
OK
OK
0 bar
TD52
Sup
ply
1
Elevation
Elevation
Elevation
Elevation
Elevation
0 bar
DR
12
Out Out
12
9.0
9.0
FT14C-10
Load
NO20.0
Page
15.0
Lift
15.0
Follow up
Follow up
Follow up
Follow up
Follow up
2
Socket-Weld
SPI
Equip
001 2
10.0 bar
Ricardo Carminato
C
2003
SPI
15.0
SPI
TRAP SURVEY DATA LOGTechnician
Energy Audit
CL
C
Str
aine
r1
X
41.4 bar
OK
C1
CL
Insulation
15.0V
alve
In
Tracer
Check Valve
Check Valve
Check Valve
Check Valve
Check Valve
Dire
ctio
n
20.0
Steam
20.0
4/1/11
12
Temp Alarm
Temp Alarm
Temp Alarm
Temp Alarm
Temp Alarm
Transmitter
Transmitter
Transmitter
Transmitter
Transmitter
Tag#
Tag#
Tag#
Tag#
Tag#
DR C
NO
H
12
Socket-Weld
005
12
In In
1X
H
1
Near BPF service tank
PMO
C
Months/Year
Months/Year
Months/Year
Months/Year
Months/Year
Months/Year
GSK, Guarulhos
Superheat
Superheat
Superheat
Superheat
Superheat
DR
C
Comments
Comments
Comments
Comments
Comments
2
NO
Process
High Elevation
9.0
TD52
009
DR
Val
ve O
ut
Piping
NO
Line Sz
20.0
0 bar
0 bar
2
OK
1
9.0
15.0
C
Critical Trap
Critical Trap
Critical Trap
Critical Trap
Critical Trap
007
Receiver
Receiver
Receiver
Receiver
Receiver
MFR Pressure
C
0 bar
SPI
15.0
41.4 bar
2Boiler House
Location
Location
Location
Location
Location
Location
15.0
Boiler House
Model
Frequency
Frequency
Frequency
Frequency
Frequency
Conn Size
Socket-Weld
8
Application
1
H41.4 bar
X
Drip
1
Route No.
Route No.
Route No.
Route No.
Route No.
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Do not monitor
Do not monitor
Do not monitor
Do not monitor
Do not monitor
1C
Conductive
Conductive
Conductive
Conductive
Conductive
12
123.40 BRL
SPI
Customer
20.0
Steam Loss/Yr
C
NO
41.4 bar
15.0
Coil
Socket-Weld
20.0
X
5
Condition
H
Recommendation
Recommendation
Recommendation
Recommendation
Recommendation
H
Socket-Weld
Outside
Outside
Outside
Outside
Outside
15.0
Dis
char
ge
3,902 BRL
Conn Type
Conn Type
Conn Type
Conn Type
Conn Type
Condensate
Installed Date
Installed Date
Installed Date
Installed Date
Installed Date
12
9.0
12
Main Header
1X
TD52
Steam Cost
Drain near Boiler enteranceTank 02
TD52
Date
Date
Date
Date
Date
Date
OK
OK
0 bar
TD52
Sup
ply
31,622 kg/yr
DR
1
Elevation
Elevation
Elevation
Elevation
Elevation
0 bar
DR
12
RC
Out Out
12
9.0
9.0
TD52
Load
NO20.0
Page
20.0
Lift
15.0
Follow up
Follow up
Follow up
Follow up
Follow up
2
Socket-Weld
SPI
Equip
006 2
41.4 bar
Ricardo Carminato
C
2008
SPI
20.0
SPI
TRAP SURVEY DATA LOGTechnician
Energy Audit
C
Str
aine
r1
X
41.4 bar
C1
Insulation
15.0V
alve
In
Tracer
Check Valve
Check Valve
Check Valve
Check Valve
Check Valve
Dire
ctio
n
20.0
Steam
20.0
Annual Cost
4/1/11
12
Temp Alarm
Temp Alarm
Temp Alarm
Temp Alarm
Temp Alarm
Transmitter
Transmitter
Transmitter
Transmitter
Transmitter
Tag#
Tag#
Tag#
Tag#
Tag#
DR C
NO
H
12
Socket-Weld
NT010
12
In In
1X
H
1
main Header
PMO
C
Months/Year
Months/Year
Months/Year
Months/Year
Months/Year
Months/Year
GSK, Guarulhos
Superheat
Superheat
Superheat
Superheat
Superheat
DR
C
Comments
Comments
Comments
Comments
Comments
3
NO
Process
9.0
014
DR
Val
ve O
ut
Piping
NO
Line Sz
15.0
0 bar
* TLV (3)
0 bar
2
OK
1
9.0
15.0
C
Critical Trap
Critical Trap
Critical Trap
Critical Trap
Critical Trap
012
Receiver
Receiver
Receiver
Receiver
Receiver
MFR Pressure
C
0 bar25.0
41.4 bar
2Near Kitchen area
Location
Location
Location
Location
Location
Location
*
Near Kitchen area
Model
Frequency
Frequency
Frequency
Frequency
Frequency
Conn Size
Socket-Weld
8
Application
1
H*
X
Drip
1
Route No.
Route No.
Route No.
Route No.
Route No.
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Do not monitor
Do not monitor
Do not monitor
Do not monitor
Do not monitor
1C
Conductive
Conductive
Conductive
Conductive
Conductive
12
*
Customer
25.0
C
NO
41.4 bar
25.0
Coil
Socket-Weld
15.0
X
12
Condition
NT
H
Recommendation
Recommendation
Recommendation
Recommendation
Recommendation
H
Socket-Weld
Outside
Outside
Outside
Outside
Outside
Dis
char
ge
Conn Type
Conn Type
Conn Type
Conn Type
Conn Type
Condensate
Installed Date
Installed Date
Installed Date
Installed Date
Installed Date
12
9.0
12
Near Kitchen area
1X
Sector do TC para aguagelada
TD52
Date
Date
Date
Date
Date
Date
OK
high Elevation
0 bar
*
Sup
ply
DR
1
Elevation
Elevation
Elevation
Elevation
Elevation
0 bar
DR
12
Out Out
12
9.0
9.0
TD52
Load
NO25.0
Page
25.0
Lift
Follow up
Follow up
Follow up
Follow up
Follow up
2
Socket-Weld
SPI
Equip
011 2
Ricardo Carminato
C
2013
25.0
SPI
TRAP SURVEY DATA LOGTechnician
Energy Audit
C
Str
aine
r1
X OK
C1
Insulation
15.0V
alve
In
Tracer
Check Valve
Check Valve
Check Valve
Check Valve
Check Valve
Dire
ctio
n
15.0
Steam
15.0
4/1/11
12
Temp Alarm
Temp Alarm
Temp Alarm
Temp Alarm
Temp Alarm
Transmitter
Transmitter
Transmitter
Transmitter
Transmitter
Tag#
Tag#
Tag#
Tag#
Tag#
DR C
NO
NT
H
12
Socket-Weld
015
12
In In
1X
H
1
Near Kitchen area
PMO
C
Months/Year
Months/Year
Months/Year
Months/Year
Months/Year
Months/Year
GSK, Guarulhos
Superheat
Superheat
Superheat
Superheat
Superheat
DR
OK
C
Comments
Comments
Comments
Comments
Comments
4
NO
Process
9.0
TD52
019
DR
Val
ve O
ut
Piping
NO
Line Sz
15.0
0 bar
0 bar
2
OK
1
9.0
15.0
C
Critical Trap
Critical Trap
Critical Trap
Critical Trap
Critical Trap
017
Receiver
Receiver
Receiver
Receiver
Receiver
MFR Pressure
C
0 bar
SPI
15.0
41.4 bar
2Drip leg
Location
Location
Location
Location
Location
Location
15.0
Drip leg
Model
Frequency
Frequency
Frequency
Frequency
Frequency
Conn Size
Socket-Weld
8
Application
1
H41.4 bar
X
Drip
1
Route No.
Route No.
Route No.
Route No.
Route No.
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Do not monitor
Do not monitor
Do not monitor
Do not monitor
Do not monitor
1C
Conductive
Conductive
Conductive
Conductive
Conductive
12
SPI
Customer
15.0
C
NO
41.4 bar
15.0
Coil
Socket-Weld
15.0
X
12
Condition
H
Recommendation
Recommendation
Recommendation
Recommendation
Recommendation
H
Socket-Weld
Outside
Outside
Outside
Outside
Outside
15.0
Dis
char
ge
Conn Type
Conn Type
Conn Type
Conn Type
Conn Type
Condensate
Installed Date
Installed Date
Installed Date
Installed Date
Installed Date
12
9.0
12
Drip leg
1X
TD52
Drip leg
TD52
Date
Date
Date
Date
Date
Date
OK
OK
0 bar
TD52
Sup
ply
DR
1
Elevation
Elevation
Elevation
Elevation
Elevation
0 bar
DR
12
Out Out
12
9.0
9.0
TD52
Load
NO15.0
Page
15.0
Lift
15.0
Follow up
Follow up
Follow up
Follow up
Follow up
2
Socket-Weld
SPI
Equip
016 2
41.4 bar
Ricardo Carminato
C
2018
SPI
15.0
SPI
TRAP SURVEY DATA LOGTechnician
Energy Audit
C
Str
aine
r1
X
41.4 bar
OK
C1
Insulation
15.0V
alve
In
Tracer
Check Valve
Check Valve
Check Valve
Check Valve
Check Valve
Dire
ctio
n
15.0
Steam
15.0
4/1/11
12
Temp Alarm
Temp Alarm
Temp Alarm
Temp Alarm
Temp Alarm
Transmitter
Transmitter
Transmitter
Transmitter
Transmitter
Tag#
Tag#
Tag#
Tag#
Tag#
DR C
NO
H
12
Socket-Weld
020
12
In In
1X
H
1
Drip leg
PMO
C
Months/Year
Months/Year
Months/Year
Months/Year
Months/Year
Months/Year
GSK, Guarulhos
Superheat
Superheat
Superheat
Superheat
Superheat
DR
OK
C
Comments
Comments
Comments
Comments
Comments
5
NO
Process
9.0
TD52
024
DR
Val
ve O
ut
Piping
NO
Line Sz
15.0
0 bar
0 bar
2
OK
1
9.0
15.0
C
Critical Trap
Critical Trap
Critical Trap
Critical Trap
Critical Trap
022
Receiver
Receiver
Receiver
Receiver
Receiver
MFR Pressure
C
0 bar
SPI
15.0
41.4 bar
2Drip leg
Location
Location
Location
Location
Location
Location
15.0
Drip leg
Model
Frequency
Frequency
Frequency
Frequency
Frequency
Conn Size
Socket-Weld
8
Application
1
H41.4 bar
X
Drip
1
Route No.
Route No.
Route No.
Route No.
Route No.
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Do not monitor
Do not monitor
Do not monitor
Do not monitor
Do not monitor
1C
Conductive
Conductive
Conductive
Conductive
Conductive
12
SPI
Customer
15.0
C
NO
41.4 bar
15.0
Coil
Socket-Weld
15.0
X
12
Condition
H
Recommendation
Recommendation
Recommendation
Recommendation
Recommendation
H
Socket-Weld
Outside
Outside
Outside
Outside
Outside
15.0
Dis
char
ge
Conn Type
Conn Type
Conn Type
Conn Type
Conn Type
Condensate
Installed Date
Installed Date
Installed Date
Installed Date
Installed Date
12
9.0
12
Drip leg
1X
TD52
Drip leg
TD52
Date
Date
Date
Date
Date
Date
OK
OK
0 bar
TD52
Sup
ply
DR
1
Elevation
Elevation
Elevation
Elevation
Elevation
0 bar
DR
12
Out Out
12
9.0
9.0
TD52
Load
NO15.0
Page
15.0
Lift
15.0
Follow up
Follow up
Follow up
Follow up
Follow up
2
Socket-Weld
SPI
Equip
021 2
41.4 bar
Ricardo Carminato
C
2023
SPI
15.0
SPI
TRAP SURVEY DATA LOGTechnician
Energy Audit
C
Str
aine
r1
X
41.4 bar
OK
C1
Insulation
15.0V
alve
In
Tracer
Check Valve
Check Valve
Check Valve
Check Valve
Check Valve
Dire
ctio
n
15.0
Steam
15.0
4/1/11
12
Temp Alarm
Temp Alarm
Temp Alarm
Temp Alarm
Temp Alarm
Transmitter
Transmitter
Transmitter
Transmitter
Transmitter
Tag#
Tag#
Tag#
Tag#
Tag#
DR C
NO
H
12
Socket-Weld
025
12
In In
1X
H
1
Drip leg
PMO
C
Months/Year
Months/Year
Months/Year
Months/Year
Months/Year
Months/Year
GSK, Guarulhos
Superheat
Superheat
Superheat
Superheat
Superheat
OK
C
Comments
Comments
Comments
Comments
Comments
6
NO
Process
3.0
FT552
029
Val
ve O
ut
Piping
NO
Line Sz
20.0
0 bar
* TLV (3)
0 bar
2
1
3.0
20.0
C
Critical Trap
Critical Trap
Critical Trap
Critical Trap
Critical Trap
027
Receiver
Receiver
Receiver
Receiver
Receiver
MFR Pressure
C
0 bar
SPI
15.0
8.3 bar
2Cosmetics section - TREVIARTR-10
Location
Location
Location
Location
Location
Location
*
Cosmetics section - TREVIARTR-07
Model
Frequency
Frequency
Frequency
Frequency
Frequency
Conn Size
Socket-Weld
8
Application
1
H*
X
Drip
PR 1
Route No.
Route No.
Route No.
Route No.
Route No.
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Do not monitor
Do not monitor
Do not monitor
Do not monitor
Do not monitor
1C
Conductive
Conductive
Conductive
Conductive
Conductive
12
*
Customer
20.0
C
NO
8.3 bar
15.0
Coil
Socket-Weld
20.0
X
12
Condition
NT
H
Recommendation
Recommendation
Recommendation
Recommendation
Recommendation
H
Socket-Weld
Outside
Outside
Outside
Outside
Outside
20.0
Dis
char
ge
Conn Type
Conn Type
Conn Type
Conn Type
Conn Type
Condensate
Installed Date
Installed Date
Installed Date
Installed Date
Installed Date
12
9.0
PR
12
Cosmetics section - TREVIARTR-06
1X
FT552
TC de Placa 21 K 40 A
FT552
Date
Date
Date
Date
Date
Date
Equipment not operational
NT0 bar
*
Sup
ply
1
Elevation
Elevation
Elevation
Elevation
Elevation
0 bar
12
Out Out
12
3.0
3.0
FT552
Load
NO20.0
Page
20.0
Lift
20.0
Follow up
Follow up
Follow up
Follow up
Follow up
2
Socket-Weld
SPI
Equip
026 2
8.3 bar
Ricardo Carminato
C
2028
SPI
20.0
SPI
TRAP SURVEY DATA LOGTechnician
Energy Audit
C
Str
aine
r
PR
1X
8.3 bar
OK
C1
PR
Insulation
20.0V
alve
In
Tracer
Check Valve
Check Valve
Check Valve
Check Valve
Check Valve
Dire
ctio
n
20.0
Steam
20.0
NT
4/1/11
12
Temp Alarm
Temp Alarm
Temp Alarm
Temp Alarm
Temp Alarm
Transmitter
Transmitter
Transmitter
Transmitter
Transmitter
Tag#
Tag#
Tag#
Tag#
Tag#
DR C
NO
H
12
Socket-Weld
030
12
In In
1X
H
1
Cosmetics section - TREUMIS 03
PMO
C
Months/Year
Months/Year
Months/Year
Months/Year
Months/Year
Months/Year
GSK, Guarulhos
Superheat
Superheat
Superheat
Superheat
Superheat
OK
C
Comments
Comments
Comments
Comments
Comments
7
NO
Process
3.0
FT553
035
Val
ve O
ut
Piping
NO
Line Sz
20.0
0 bar
0 bar
2
OK
1
3.0
20.0
C
Critical Trap
Critical Trap
Critical Trap
Critical Trap
Critical Trap
032
Receiver
Receiver
Receiver
Receiver
Receiver
MFR Pressure
C
0 bar
SPI
20.0
10.0 bar
2Cosmetics section - TREURTR-009
Location
Location
Location
Location
Location
Location
40.0
Cosmetics section - TREURTR-002
Model
Frequency
Frequency
Frequency
Frequency
Frequency
Conn Size
Socket-Weld
8
Application
1
H10.0 bar
X
Drip
PR 1
Route No.
Route No.
Route No.
Route No.
Route No.
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Do not monitor
Do not monitor
Do not monitor
Do not monitor
Do not monitor
1C
Conductive
Conductive
Conductive
Conductive
Conductive
12
SPI
Customer
20.0
C
NO
4.5 bar
20.0
Coil
Socket-Weld
20.0
X
12
Condition
H
Recommendation
Recommendation
Recommendation
Recommendation
Recommendation
H
Socket-Weld
Outside
Outside
Outside
Outside
Outside
20.0
Dis
char
ge
Conn Type
Conn Type
Conn Type
Conn Type
Conn Type
Condensate
Installed Date
Installed Date
Installed Date
Installed Date
Installed Date
12
3.0
PR
12
Cosmetics section - TREURTR-004
1X
FT553
Cosmetics section - TREU5000 l
FT553
Date
Date
Date
Date
Date
Date
OK
OK
0 bar
FT10-10
Sup
ply
1
Elevation
Elevation
Elevation
Elevation
Elevation
0 bar
12
Out Out
12
3.0
3.0
FT553
Load
NO20.0
Page
20.0
Lift
20.0
Follow up
Follow up
Follow up
Follow up
Follow up
2
Socket-Weld
SPI
Equip
031 2
4.5 bar
Ricardo Carminato
C
2033
SPI
20.0
SPI
TRAP SURVEY DATA LOGTechnician
Energy Audit
C
Str
aine
r
PR
1X
10.0 bar
OK
C1
PR
Insulation
20.0V
alve
In
Tracer
Check Valve
Check Valve
Check Valve
Check Valve
Check Valve
Dire
ctio
n
20.0
Steam
20.0
4/1/11
12
PR
Temp Alarm
Temp Alarm
Temp Alarm
Temp Alarm
Temp Alarm
Transmitter
Transmitter
Transmitter
Transmitter
Transmitter
Tag#
Tag#
Tag#
Tag#
Tag#
C
NO
H
12
Socket-Weld
036
12
In In
1X
H
1
Cosmetics section - TREU300 l
PMO
Months/Year
Months/Year
Months/Year
Months/Year
Months/Year
Months/Year
GSK, Guarulhos
Superheat
Superheat
Superheat
Superheat
Superheat
OK
Comments
Comments
Comments
Comments
Comments
8
Process
3.0
FT10-4.5
Val
ve O
ut
Piping
NO
Line Sz
0 bar
2
OK
1
20.0
C
Critical Trap
Critical Trap
Critical Trap
Critical Trap
Critical Trap
34
Receiver
Receiver
Receiver
Receiver
Receiver
MFR Pressure
C
0 bar20.0
4.5 bar
Location
Location
Location
Location
Location
Location
20.0
Model
Frequency
Frequency
Frequency
Frequency
Frequency
Conn Size
8
Application
H4.5 bar
Drip
PR 1
Route No.
Route No.
Route No.
Route No.
Route No.
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Shutdown Req'd
Do not monitor
Do not monitor
Do not monitor
Do not monitor
Do not monitor
Conductive
Conductive
Conductive
Conductive
Conductive
12
SPI
Customer
C
NO20.0
Coil
Socket-Weld
20.0
X
12
Condition
Recommendation
Recommendation
Recommendation
Recommendation
Recommendation
H
Socket-Weld
Outside
Outside
Outside
Outside
Outside
Dis
char
ge
Conn Type
Conn Type
Conn Type
Conn Type
Conn Type
Condensate
Installed Date
Installed Date
Installed Date
Installed Date
Installed Date
12
3.0
Oral section - TREU RTR-001
1X
Oral section - TREU RTR-002
Date
Date
Date
Date
Date
Date
OK
FT553
Sup
ply
Elevation
Elevation
Elevation
Elevation
Elevation
0 bar
12
Out Out
12
3.0
FT10-4.5
Load
Page
25.0
Lift
40.0
Follow up
Follow up
Follow up
Follow up
Follow upNPT Pipe Thread
SPI
Equip
037 2
Ricardo Carminato
238
SPI
25.0
TRAP SURVEY DATA LOGTechnician
Energy Audit
C
Str
aine
r
PR
4.5 bar
C1
Insulation
Val
ve In
Tracer
Check Valve
Check Valve
Check Valve
Check Valve
Check Valve
Dire
ctio
n
Steam
20.0
4/1/11
PR
Temp Alarm
Temp Alarm
Temp Alarm
Temp Alarm
Temp Alarm
Transmitter
Transmitter
Transmitter
Transmitter
Transmitter
Tag#
Tag#
Tag#
Tag#
Tag#
C
NO
12
Socket-Weld 12
In In
1X
H
1
Cosmetics section - TREURTR-008