Boilers
Cameron Raszler
Author
01/29/2021
Added
56
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Description
Top IAC Recommendation Series: Boilers
Searchable Transcript
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- [00:00:07.060]The purpose of a boiler is to heat feedwater
- [00:00:09.720]and turn it into steam.
- [00:00:11.380]Steam can then be used to run equipment,
- [00:00:13.780]transfer heat to other processes,
- [00:00:15.990]or perform additional tasks.
- [00:00:18.200]In the transfer of this steam through the steam network,
- [00:00:20.830]there are often leaks that develop,
- [00:00:22.350]which should be fixed promptly to minimize wasted energy.
- [00:00:25.980]The National IAC Database lists an average annual savings
- [00:00:29.580]of $29,500 for repairing steam leaks.
- [00:00:33.970]Steam traps provide a way to drain condensate
- [00:00:36.370]after steam has lost its energy and become water.
- [00:00:39.550]When working properly,
- [00:00:41.020]they prevent steam from exiting the system,
- [00:00:43.110]which saves money by preventing waste of this resource.
- [00:00:46.320]If steam shops have not been properly
- [00:00:48.090]inspected and maintained,
- [00:00:49.630]steam can leak into the condensate return lines.
- [00:00:52.640]The frequency at which steam traps should be inspected
- [00:00:55.220]depends on the pressure in the system.
- [00:00:57.060]For high pressure systems with 150 PSIG or higher,
- [00:01:01.070]a weekly to monthly inspection is suggested.
- [00:01:03.830]For medium pressure systems, ranging from 30 to 150 PSIG,
- [00:01:08.230]inspections should be monthly to quarterly.
- [00:01:10.700]For systems with low pressures, under 30 PSIG,
- [00:01:14.010]annual inspections are sufficient.
- [00:01:15.890]Some food processing facilities may utilize a boiler
- [00:01:19.430]to produce hot water instead of steam.
- [00:01:22.090]In these cases,
- [00:01:23.200]the recommendation to repair steam leaks doesn't apply.
- [00:01:26.110]The following recommendations are applicable for facilities
- [00:01:29.210]that use a boiler for either of these purposes.
- [00:01:32.280]As a boiler operates,
- [00:01:33.670]it produces hot gas that is expelled through a waste stack.
- [00:01:37.810]This gas can be used to preheat feedwater
- [00:01:40.350]through the use of an economizer.
- [00:01:42.760]When the cold feed water is preheated,
- [00:01:44.720]less energy has to be used to heat it up and create steam.
- [00:01:48.520]Warmer feedwater also reduces
- [00:01:50.250]the thermal shock on the boiler,
- [00:01:51.770]which can cause stress to the system
- [00:01:53.450]and lead to deterioration over time.
- [00:01:56.310]Industrial assessment centers have recommended
- [00:01:58.620]that food processing facilities implement the use
- [00:02:01.120]of a boiler economizer 163 times
- [00:02:04.280]with an average savings of $31,500.
- [00:02:08.180]So how do you know if your facility
- [00:02:09.700]would benefit from adding an economizer?
- [00:02:12.720]If your boiler exceeds 100 boiler horsepower,
- [00:02:15.690]operates at a pressure of 75 PSIG or higher,
- [00:02:19.360]and is significantly loaded all year long,
- [00:02:21.700]it would be a great candidate to retrofit an economizer.
- [00:02:25.400]Before measuring the stack temperature,
- [00:02:27.400]make sure all other boiler improvements have been made.
- [00:02:30.360]Adding an economizer to an inefficient system
- [00:02:32.830]would only be partially beneficial.
- [00:02:35.160]Optimize the system first,
- [00:02:36.870]and then see if an economizer would be beneficial.
- [00:02:39.940]The third recommendation commonly made about boiler systems
- [00:02:43.010]is to analyze the flue gas for a proper air to fuel ratio.
- [00:02:47.030]This recommendation has an average annual savings
- [00:02:49.830]of $12,000.
- [00:02:52.380]Two to three percent of oxygen
- [00:02:53.960]with a small amount of combustibles
- [00:02:55.750]is the ideal conditions for most systems.
- [00:02:58.410]This measurement can be done through the use of
- [00:03:00.530]inexpensive gas-absorbing test kits.
- [00:03:03.990]More costly probes can be purchased
- [00:03:05.950]in the range of 500 to $1,000
- [00:03:08.430]and are owned by many vendors
- [00:03:09.960]and industrial assessment centers.
- [00:03:12.230]It is recommended that a facility purchase one of these
- [00:03:14.760]computer-based analyzers
- [00:03:16.260]if their annual fuel costs exceed $50,000.
- [00:03:19.760]Join us in the next video
- [00:03:20.950]to see the most common recommendations
- [00:03:23.050]food processors are given regarding electricity efficiency.
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