In a recent Hydrocarbon Processing article, Improving the sustainability of steam production, Emerson’s Marcio Donnangelo and Tim Dwyer share their insights on the crucial role of efficient heat transfer in process manufacturing. They explore the challenges industries face with steam distribution systems, particularly the impact of problems with steam traps and their impacts on heat exchangers on energy efficiency and sustainability. Steam trap sub-optimal performance or failures can lead to significant energy losses, increased operational costs, and a higher carbon footprint.
Marcio and Tim emphasize that when steam traps fail, they either remain open, leaking steam and wasting energy, or close, preventing proper heat exchange. Either scenario affects the efficiency of the entire system. The cumulative effect of multiple failing traps across a plant can result in substantial energy waste, translating to higher operational costs and a significant increase in CO2 emissions.
For a steam trap fail-open condition:
…steam loss is a link in a direct energy loss chain. The boiler must work harder to compensate for the loss, so it consumes more fuel and creates more emissions since most boilers burn oil or natural gas. Leaking steam can also lead to a shortage and system pressure sag, requiring additional boilers and leading to even more emissions.
For steam traps supporting heat exchangers that fail to close:
…steam cannot flow through the heat exchanger sufficiently to deliver the heating step that the process needs. Some steam might be flowing, but condensate backed into the heat exchanger reduces the working exchange surface area. Whatever the situation, the process fluid is not being heated sufficiently. Operators observing the effect in the control room may assume it is caused by fouling because the results are similar
To address these challenges, they advocate for implementing automated, continuous monitoring solutions. The Rosemount 708 wireless acoustic transmitter and temperature sensors can be strategically installed to monitor steam trap performance in real time. These sensors detect anomalies in steam trap operation, such as leaking or cold traps, enabling operators to proactively address issues promptly before they escalate into more significant problems.
Rosemount 708 wireless acoustic transmitter feeding Plantweb Insight Steam Trap advanced analytics application to assess steam trap health proactively.
One key advantage of this energy-saving solution is its wireless nature, making it easier and more cost-effective to deploy across large, complex plants. The data collected by these sensors is fed into the Plantweb Insight Steam Trap advanced analytics application, which can provide insights into system performance, predict failures, and suggest maintenance actions. This proactive approach to steam trap management improves energy efficiency and aligns with sustainability goals by reducing the carbon footprint.
Marcio and Tim also explain the importance of integrating these monitoring solutions into a broader digital transformation strategy. Plants can optimize their heat transfer processes by leveraging Emerson’s automation and digitalization tools, reduce waste, and operate more sustainably. This is particularly important as industries face increasing pressure to reduce emissions and operate more efficiently in a competitive global market.
Read the article for more on this solution for effective steam trap management in process manufacturing and production processes. With these advanced monitoring solutions, plants can ensure their heat transfer systems operate efficiently, reduce energy waste, and contribute to broader sustainability efforts.
Visit the Wireless Steam Trap Monitoring section on Emerson.com to learn more.
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