Steam is used in a variety of process applications. However, the energy cost to generate steam can be significant and much of that energy goes to waste through inefficient operation. Fortunately, you can adopt several no-cost or low-cost operational practices to improve system performance, saving energy and money.
Manage pressure
Effectively managing steam system pressure can lead to significant energy savings. Here are some operational strategies for achieving this:
- Operate the steam system at the lowest pressure that still meets process requirements. Lowering the pressure reduces energy consumption and minimizes steam leaks.
- Continuously monitor pressure levels throughout the system and adjust as needed to maintain optimal performance and efficiency.
- Ensure that steam distribution is balanced across the system to prevent pressure drops or surges that can lead to inefficiencies.
Optimize the deaerator vent rate
An improper deaerator vent rate can lead to several issues. A vent rate that is too high results in excessive steam loss. If the vent rate is too low, non-condensable gases like oxygen and carbon dioxide may not be adequately removed, leading to increased corrosion.
Monitor the vent rate regularly and measure the oxygen content in the deaerator to better understand the current performance and identify any deviations from optimal conditions. Based on the oxygen measurements, adjust the vent rate to ensure it is sufficient to remove non-condensable gases without excessive steam loss. This process often involves fine-tuning the vent valve settings.
Isolate unused steam lines
As processes change, steam demand varies, and sometimes steam is no longer needed for a particular application. However, those steam lines are still in place and contain live steam. Isolating unused lines will minimize avoidable loss of steam and reduce energy losses from piping and equipment surfaces.
Shutting off the flow of live steam in a pipe typically involves closing isolation valves strategically placed on the line to prevent any steam from entering or exiting the inactive section. Before isolating the line, ensure any existing condensate is drained from the pipe using dedicated drain valves.
Preventive maintenance pays off
To further optimize steam system efficiency and performance, take a preventive maintenance approach. Focus on anticipating and correcting potential problems. The following maintenance activities are critical to sustaining peak efficiency:
- Check steam traps frequently to ensure they are operating correctly. Malfunctioning traps can lead to steam leaks or condensate buildup, reducing system efficiency.
- Conduct routine inspections to identify and repair any leaks in the steam system. Even small leaks can lead to significant energy losses over time.
- Inspect and maintain insulation on steam lines, valves and other components. Proper insulation minimizes heat loss and maintains steam temperature and pressure for optimal efficiency.
Combining simple operational and preventive maintenance strategies can reduce steam system energy and repair costs and keep your system operating at peak performance.