Steam systems have been in use since the 18th century. Learn how advanced AI technology can provide your system with modern-day efficiency and performance.
Steam is critical in a variety of process applications, but steam generation is very energy-intensive. In fact, steam systems account for about 30% of the total energy used in industrial applications for product output, according to the U.S. Department of Energy. While steam systems have been in use since the 18th century, you can apply advanced artificial intelligence (AI) technology to optimize system performance, reducing energy and maintenance costs.
How AI works
AI systems process data through complex algorithms to simulate human intelligence. AI systems learn from data patterns, produce predictions, make decisions and perform tasks autonomously. They can adapt and improve over time.
For steam systems and other types of facility systems and equipment, AI can be used for predictive maintenance, real-time monitoring and automated diagnostics. AI analyzes equipment data to predict failures, optimize maintenance schedules and detect anomalies. Using AI, you can reduce downtime, extend equipment lifetime and increase overall system reliability and efficiency.
Steaming ahead with AI
Here are some key steam system operating parameters and how AI can help optimize system performance.
Temperature impacts heat transfer efficiency, with higher temperatures typically improving system efficiency and output. By using data from Internet-of-Things (IoT) sensors placed in hard-to-reach areas, AI can track temperature trends to optimize combustion.
Pressure affects steam energy content and flow rate. Higher pressure enables more energy to be transferred at less volume, reducing heat loss. AI can optimize pressure in a steam system by analyzing real-time data, predicting demand fluctuations and automatically adjusting controls to maintain efficiency and prevent energy waste.
Dissolved solids impact steam quality and can lead to scaling and corrosion, reducing heat transfer efficiency and increasing maintenance needs. AI can monitor water chemistry in real time, predicting scaling risks and optimizing blowdown processes to maintain system efficiency.
Steam trap temperatures provide insight into performance. Trap inlet and outlet temperatures should be nearly equal. A lower outlet temperature indicates a failed trap or another issue. Strategically placed IoT sensors can monitor temperature and other parameters and send that data to a central platform that issues alerts about potential failures. AI algorithms compare real-time data with historical trends, spotting failures before they occur.
Flow rate can vary depending on the application, but it should be optimized to ensure efficient heat transfer and consistent pressure. AI would analyze real-time data — such as pressure, temperature, flow velocity and system load demand — with historical trends to optimize flow rate.
Steam technology may be centuries old, but advanced AI tools can help bring your system into the 21st century, saving energy and money while optimizing performance.