Steam Leakage Quantification and Cost - UE Systems

1 1 swagelok EnergySwagelok EnergySteam LeakageQuantification and CostKelly PaffelTechnical ManagerSwagelok EnergySwagelok EnergySTEAM LEAKAGES team leaks have a negative affect on Steam plant operations. Energy losses Increase in Emissions Loss of reliability Production issues SafetySwagelok EnergySwagelok EnergyENERGY LOSSES Energy losses can be as high as 19% (or even higher in a few cases) of the total Steam energy production cost . $ 1,000, fuel cost for the boiler operation (yearly) $ 190, energy loss2 swagelok EnergySwagelok EnergySTEAM Leakage CORRECTION Has the greatest payback of all items in the Steam system. Most leaks can be corrected with out capital cost . Great than: Steam traps repair or replacement Steam trap failure will typically only lose the latent energy sensible energy is typically still recovered.

2 Insulation EnergySwagelok EnergySTEAM VS. COMPRESSED AIR Steam leak = $ 3, 100 psig 1/8 $ per thousand lbs. Compressed air = $ 2, 100 psig 1/8 $ per KwhSwagelok EnergySwagelok EnergyESTIMATING Steam Leakage Size of the leak diameter Equation are based on a prefect orifice Steam pressure (P1) Down stream will alwaysbe atmospheric or zero (P2)Leak 3 swagelok EnergySwagelok EnergyBASICSP1 = ?P2 = 0 swagelok EnergySwagelok EnergyBASICS OF Leakage Leak will not be a perfect orifice A constant has to be used in the equation to compensate for this factorP1 = ?P2 = 0 swagelok EnergySwagelok EnergyBASICSP1 = ?P2 = 04 swagelok EnergySwagelok EnergyBASICSP1 = 50 psigP2 = 06 VolumeP1 = 50 psigP2 = 06 VolumeTest results indicate not a significant difference between the plume when varying the orifice size.

3 Pressure varying has a significant EnergySwagelok EnergyBASICS Plume length is (highly) depended on pressure Volume is depended on orifice diameter and pressure swagelok EnergySwagelok Energy1/8 Steam LEAKAGE1/8" LeakPressureSteam Loss (pph) cost / HourDays / YearCost / $8, $3, $2, $1, $1, $ $ EnergySwagelok Energy3/8 Steam LEAK3/8" LeakPressureSteam Loss (pph) cost / HourDays / YearCost / $74, $32, $23, $15, $12, $8, $5, EnergySwagelok EnergyCALCULATIONS A variation of the Napier equation for flow through a orifice Many different variations Most equations are very aggressive in the flow rates Steam Loss = x PaX D2 is a constant (to compensate for imperfect orifice Pa(pressure absolute) D2 (Diameter squared) swagelok EnergySwagelok EnergyDistance: 6 Valve size: Valve opening: 1/3 leakPressure: 140 psigCost: $ 14, EnergySwagelok EnergyDistance: 14 Valve size: Valve opening: 3/4 3/16 leakPressure: 150 cost : $ 11, EnergySwagelok EnergyDistance: 40 Leak: 3/16 Pressure: 250 cost .)

4 $ 18, EnergySwagelok EnergyCRACKS IN LINESBest guessExtremely hard to determine diameter of the orifice7 swagelok EnergySwagelok EnergySwagelok EnergySwagelok EnergySTEAM HOSE LEAKAGES wagelok EnergySwagelok EnergySTEAM LEAKS8 swagelok EnergySwagelok EnergyWHAT CAUSES Steam LEAKS Piping/tubing Connections Threaded connections Expansion and contraction CO2corrosion Erosion Steam Component Failures Valves Steam traps EnergySwagelok EnergyTHREADED CONNECTIONS Expansion and contraction from Steam system start up and shut downs CO2 Corrosion or carbonic acidSwagelok EnergySwagelok EnergyTubingPipe Threaded Connections9 swagelok EnergySwagelok EnergyCO2 CORROSION Leaks will be created by corrosionSwagelok EnergySwagelok

5 EnergyEROSION A small leak today will be a larger leak tomorrow Steam will wire draw or erode the material causing a larger leakSwagelok EnergySwagelok EnergyEMISSIONS10 swagelok EnergySwagelok EnergyRELIABILITY Valve selections Isolation valves are purchased already have internal Leakage occurring Packing on standard valvesSwagelok EnergySwagelok EnergyVALVE PACKING PROBLEMS Valve failure causes issues with productions areasSwagelok EnergySwagelok EnergyVALVES11 swagelok EnergySwagelok EnergyVALVE FAILURESS wagelok EnergySwagelok EnergyPRODUCTION ISSUES Leaks will create pressure loss in the system Lower pressures = lower temperatures, which create problems in the tracer systemSwagelok EnergySwagelok EnergySAFETY Steam will create safety issues Personnel injury Burns Fog conditions (visibility) Steam condenses to condensate creates water in the air Colder climates the condensate will freeze and cause a hazard condition12 swagelok EnergySwagelok EnergySOLUTIONS TO PREVENT Steam Leakage NO.

6 1 CHANGE MUST OCCUR Product selection System design Installation design Operation SOP s Root cause analysis has to be part of the programSwagelok EnergySwagelok EnergySOLUTIONS TO PREVENT Steam Leakage NO. 1 CHANGE MUST OCCUR Tube connectors and welded joints vs. threaded connections Valves that will eliminate packing Leakage Valves that do not excessive leak internally Stainless steel vs. carbon steelSwagelok EnergySwagelok EnergyTubing vs. Threaded Systems Tubing/tubing connectors Eliminate threaded connections Threads are used so the plant does not have to weld13 swagelok EnergySwagelok EnergyStandard Pipe ConnectionsSwagelok EnergySwagelok EnergySteam System Using TubingSwagelok EnergySwagelok EnergySTEAM LOSSES We can no longer accept Steam losses14 swagelok EnergySwagelok EnergyTODAY S Steam SYSTEM OPERATIONS No Steam leaks No Steam loss to atmosphereSwagelok Energy 2008 swagelok CompanySwagelok Energy AdvisorsWorld-Class Services Standardized training programs Customized training programs In-plant Steam system audits Steam and condensate system design Project management and consulting services Engineering Support ServicesMission StatementProvide

7 World class energy services to help swagelok customers optimize their in-plant Steam and condensate Energy 2008 swagelok CompanyE