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Area Source Boilers Energy Assessment Module 2

WEBVTT
Kind: captions
Language: en

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[MUSIC]
>> Narrator: Welcome to the Energy Assessment
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module, the second in our series on Air Toxics
Standards for Area Source Boilers.
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The goal of an energy assessment is to identify
energy saving opportunities within a boiler
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and the processes that it supports.
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Please note that the energy savings opportunities
are not required to be implemented.
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If you have an existing oil, biomass or coal-fired
unit with a heat input capacity of 10 MM Btus
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per hour or greater, you are subject to the
one-time Energy Assessment rule requirement.
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New and limited use boilers are excluded as
are facilities that operate under an energy
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management program compatible with ISO 50001
where effected units are included.
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As a reminder, the compliance date for this
requirement is March 21, 2014.
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Your energy assessment must be performed by
a qualified energy assessor.
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This person or company should have the background,
experience and expertise to evaluate energy
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savings opportunities for the types of boilers
or energy use systems located at your facility.
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The energy assessor may be either a company
employee or an outside specialist.
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For more complicated boiler or energy use
systems or facilities with multiple boilers,
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a group such as a consulting firm or a company's
engineering staff could perform the required
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assessment.
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To help you in selecting a qualified assessor,
EPA has defined a list of skill-sets and capabilities
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that the person conducting the assessment
will need to possess.
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This list can be accessed through EPA's website
at the address on your screen.
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So where does one find a qualified energy
assessor?
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We sat down with Dr. Herb Eckerlin from the
Department of Mechanical & Aerospace Engineering
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of North Carolina State University and asked.
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>> DR.
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HERB ECKLERLIN: What I would recommend that
people ask the perspective assessor for a
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resume,
education and experience.
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That would be the first thing I'd do.
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Secondly I'd ask all for a listing of the
facilities that he or she has assessed and
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also a list of contact people and contact
numbers that you would have and then thirdly,
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some sample reports.
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With that kind of information I think you're
able to make
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a reasonable judgment and then of course talking
to other folks is quite helpful.
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That's what I would recommend.
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>> NARRATOR: Once you have secured the services
of an energy assessor, you might be asked
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to provide facility information in advance
of their site visit.
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HERB ECKERLIN: Typically the information that
I would ask for, that I would recommend that
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is to be filled out is boiler operational
information in others words, the type of boiler,
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when it was built, the make, the capacity,
be a boiler horsepower or pounds of steam,
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fire tube or water tube, pressure, operating
pressure, feed water temperature, perhaps
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heat recovery if there's an economizer involved
or not, stack temperature.
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Just general boiler operation.
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And this gives the person some preliminary
information before he gets.
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He knows what to expect and it makes the whole
situation much more effective.
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Also as I've indicated in my forms the two
forms I have one is for the boilers and one
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is for the boiler house.
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In other words the boiler house information
would involve things like deaerators, condensate
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return tanks, heat recover.
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That may not be covered on the boiler form.
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>> NARRATOR: The energy assessor then schedules
a meeting and walk-through of the facility.
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The complete assessment could take anywhere
from a few hours to a day depending on the
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number of boilers and size of the facility.
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Here is what a typical energy assessment might
look like.
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The seven items that must be included as part
of your assessment are identified.
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The assessor first reviews the completed information
forms with the Boiler Plant Superintendent
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to ensure accuracy.
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HERB ECKLERLIN: The information you've completed
here indicates that the operating pressure's
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about 120 pounds?
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>> PAUL REYNOLDS: That is correct.
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>> ECKERLIN: Right.
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Feed water temperature's 233?
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>> REYNOLDS: Yes.
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>> ECKERLIN: : From the deaerator?
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For oil atomization you're using compressed
air on the smaller boilers?
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>> ECKLERLIN: And steam atomization on the
big one?
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>> REYNOLDS: That is correct.
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>> ECKERLIN: All of these boilers are pressurized
boilers which means that there's just an FD
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fan
no ID fan?
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ECKLERIN: The small boilers, the fire tube
boilers do not have any heat trap like an
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economizer?
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>> REYNOLDS.
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No.
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ECKLERLIN: But the large boiler does.
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>> ECKERLIN: Stack temperature is measured?
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>> ECKERLIN: From a previous test I notice
the temperature was perhaps on one of the
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boilers was may be five hundred degrees which
is a bit high, you know that?
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>> ECKERLIN: We, ah, that suggests to us perhaps
that there may be a heat transfer problem
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possibly scale
or possibly soot buildup on the tubes themselves.
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So that's something we probably have to look
at in the future.
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>> NARRATOR [Voice Over]: After discussing
general boiler information the assessor reviews
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plant
and auxiliary equipment, engineering plans
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and drawings and evaluates fuel usage logs.
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>> ECKERLIN: Do you wanna just quickly summarize
what you have here?
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>> REYNOLDS: Well this is just a layout of
part of our distribution coming out of this
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plant.
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We're generating the steam that goes to these
different buildings and then from those buildings
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we have the return of the condensate coming
back from those buildings.
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And the amount of condensate that we're getting
back, we're looking at how much condensate
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are we getting back at the producer end and
if we're not getting the returns that we're
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looking for, we can start pulling down to
the building to figure out which building's
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are not returning so we can kinda zero in
on where the opportunities are at.
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Well condensate is so important because if
you lose half of your condensate, you're losing
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six percent efficiency of your boiler steam
system so that's critical.
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Also I'm glad you're paying such attention
to it because condensate represents not only
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water but it represents a lot of heat coming
back.
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If we go out to the plant later we'll look
at the condensate return tank, the surge tank
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as you call it, and
see what that temperature is.
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I believe it was perhaps 160 so you have 160
coming back and that's probably almost a hundred
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degrees higher than the make-up water coming
in so that's an energy savings and then an
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another thing that people often forget is
that condensate is chemically-laden water
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so it's already been treated it's gonna save
you in chemical costs and finally, it reduces
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more condensate reduces make-up water so you
save on the water bill, the energy bill and
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the chemical bill all at once.
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So that's great.
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That's wonderful.
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Another thing that people are concerned about
is the startup and shutdown procedures on
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your boilers.
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You know thermal stresses are a big part of
rapid big problem with rapid start-up.
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What is your, specifically your step-by-step
process on startup and then shut down as you
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shift from one boiler to the next?
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>> REYNOLDS: Our startup and shutdown is more
specific to the equipment that's in those
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buildings.
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This one has the Cleaver Brooks fire-tube
boilers in them.
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>> REYNOLDS: So we, it is a single burner.
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We start a boiler at low fire and allow it
to idle to allow
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that expansion to start going through there.
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Allow it to build up the pressure within the
vessel
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before it would create enough steam pressure
to open the non-return.
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While we have another boiler
online generating the steam.
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Then we would slowly start increasing they
firing rate on the boiler we're bringing on
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the boiler that you would be taking off would
respond by backing off so we are starting
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to
decrease the amount of fuel we're putting
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in one as we're increasing the other one and
trying to make the transition that a way.
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So that kinda answers both questions at the
same time.
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But uh.
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That that makes the entire system more stable.
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>> REYNOLDS: We're not bringing something
up quick, we're not thermal shocking it.
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We're not
changing our water load going through the
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planet.
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We're trying to make it where it's just a
transition.
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>> ECKERLIN: Yeah.
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And that will extend the life of the boilers
too.
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>> ECKERLIN: Because you're not stressing
them so hard.
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>> REYNOLDS: And we're not stressing the refractory
and the things like that.
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>> ECKERLIN: Right
>> REYNOLDS: for our passes and the
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Right, right.
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Well that's and I guess for these fire tube
boilers the
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start-up period would be about two hours?
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>> REYNOLDS: Correct.
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Usually they'll warm up in about two hours
to the point that we start
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making them take on the load.
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We also usually maintain one with a steam
drum in the mud drum heater.
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>> ECKERLIN: Oh okay that's good.
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>> REYNOLDS: By doing that, we're helping
maintain the chemistry within that piece of
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equipment
and it gives those a running start trying
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to bring one on.
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Because it's already at fifty pounds of pressure
before we actually put the fire.
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>> ECKERLIN: And so that's a good deal of
heat in there.
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. .
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>> ECKERLIN: . . . there already.
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You know as well as I do that stack loss is
one of the big losses we have
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in operating a boiler and something we have
to be very cognizant of and sensitive to.
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And the two big variables there are stack
temperature and 02.
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The oxygen level in the flue gas.
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Also one thing that we haven't talked about
is when you have an increase in stack temperature
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there is the possibility that the baffle in
the back end of the boiler could break out
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or have a hole in it then those flue gases
go from the first pass to the fourth pass
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and skip the two intermediate ones and so
if you have a sudden increase in stack temperature
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it could be a baffle problem which is something
people have to be aware of.
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And so there's some opportunities there I
think that we have to look at also . . . [fade
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down]
>> NARRATOR [Voice Over]: A visual inspection
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of the boiler and related equipment is then
conducted.
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>> ECKERLIN: Paul, in the typical Energy Assessment,
one of the first things we want to do is to
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evaluate
the boiler house.
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By that I mean, how clean is it, how well
kept it is.
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That tells us a great deal about what we're
dealing with, what to expect.
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Now in a visual inspection we really want
to focus on
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three-year areas.
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One would be the steam pressure, we'll talk
about that in a moment.
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The other is the water level and thirdly the
fuel.
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So let's look at the steam pressure first.
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Up here, you see on the left hand side, you
see a pressure controller.
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That boiler here is controlled by steam pressure.
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As the pressure drops
the fuel will increase, as the pressure goes
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too high, the fuel will decrease.
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So that's very important.
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These typical industrial boilers are pressure
controlled.
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The second controller up there
has to do with a high pressure cut-off.
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In other words, this boiler is operating at
120 pounds.
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If it goes to
130 or 135, we want that fuel to cut off.
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You don't want this thing to explode, okay?
00:13:12.820 --> 00:13:13.820
So that's important.
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Those are the two functions there of that
steam pressure controller.
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One is the control itself one is the high
pressure safety.
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The second thing we want to focus on is water
level.
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That's very, very important.
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Up here, you see the water level in that glass
tube.
00:13:35.589 --> 00:13:40.180
That boiler has to maintain a certain water
level; if that water level drops, you're gonna
00:13:40.180 --> 00:13:42.610
burn up this boiler.
00:13:42.610 --> 00:13:43.610
That's not good.
00:13:43.610 --> 00:13:44.610
Okay?
00:13:44.610 --> 00:13:51.519
And if the water level goes too high, the
feedwater pump that controls cuts off.
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This is one part of the controller.
00:13:54.870 --> 00:13:59.870
If this control does not work, we have an
auxiliary water level control on the other
00:13:59.870 --> 00:14:01.460
side.
00:14:01.460 --> 00:14:03.190
So we have a backup.
00:14:03.190 --> 00:14:08.790
That tells you how important water level is
to the operation of this
00:14:08.790 --> 00:14:09.790
fire tube boiler.
00:14:09.790 --> 00:14:14.399
You have a water tube boiler there's also
a water level control on the drum.
00:14:14.399 --> 00:14:20.640
So for a water tube boiler, fire tube the
same principles apply.
00:14:20.640 --> 00:14:25.050
The third thing I want focus on is fuel flow.
00:14:25.050 --> 00:14:35.940
Here we have the controller and we're measuring
the fuel oil flow on a continuous basis.
00:14:35.940 --> 00:14:36.940
That's very important.
00:14:36.940 --> 00:14:37.940
We measure this every day.
00:14:37.940 --> 00:14:42.779
That tells us how much oil we're burning on
a gallon basis every day.
00:14:42.779 --> 00:14:48.070
It enables us to find out how effectively
this boiler is running.
00:14:48.070 --> 00:14:54.010
I notice here this is the bottom blow down
valve for the front and you have another one
00:14:54.010 --> 00:14:55.010
in the back.
00:14:55.010 --> 00:15:02.550
Could you just tell us the procedure you use
when you do the bottom blow down procedure
00:15:02.550 --> 00:15:07.980
because a lot of times people keep that valve
open an awful long time and all they're doing
00:15:07.980 --> 00:15:12.710
is dumping out water and we would like to
avoid that if possible.
00:15:12.710 --> 00:15:13.750
00:15:13.750 --> 00:15:18.860
Well again, what we're trying to do is minimize
the amount of water that we're blowing down
00:15:18.860 --> 00:15:20.730
but yet, get a good blow down.
00:15:20.730 --> 00:15:28.270
First thing that we do is we open the valve
then we take your isolation valve and slowly
00:15:28.270 --> 00:15:30.840
warm up the line.
00:15:30.840 --> 00:15:35.750
Then we close the valve, fully open your isolation
valve.
00:15:35.750 --> 00:15:41.279
Then we take that valve and we open it for
two to three seconds.
00:15:41.279 --> 00:15:43.830
And then close it back.
00:15:43.830 --> 00:15:47.509
That allows whatever was there, a quick vortex
to pull that out.
00:15:47.509 --> 00:15:49.259
>> ECKERLIN: All that said sediment.
00:15:49.259 --> 00:15:50.259
>> REYNOLDS: Sediment.
00:15:50.259 --> 00:15:56.750
We close it and whatever we've stirred up,
give it a second or two to settle down, give
00:15:56.750 --> 00:15:59.160
it another quick blow and close it.
00:15:59.160 --> 00:16:03.180
We usually do that twice on each end.
00:16:03.180 --> 00:16:09.389
We do, we're on a 12-hour shift, so we're
doing it at the first of each shift so this
00:16:09.389 --> 00:16:13.179
gets blown down twice a day.
00:16:13.179 --> 00:16:15.160
>> ECKERLIN: Both ends?
00:16:15.160 --> 00:16:17.149
>> REYNOLDS: Both ends.
00:16:17.149 --> 00:16:18.949
>> ECKERLIN: Okay that's good.
00:16:18.949 --> 00:16:19.949
That's a good procedure.
00:16:19.949 --> 00:16:29.449
Can you review for us now the all
adjustment of the air and the fuel?
00:16:29.449 --> 00:16:36.869
I think you set up the air first and you do
this I believe at low medium and high fire?
00:16:36.869 --> 00:16:37.869
00:16:37.869 --> 00:16:39.480
>> ECKERLIN: And you start at low fire?
00:16:39.480 --> 00:16:40.480
00:16:40.480 --> 00:16:47.290
And we set the air first and then tune your
fuel to the air.
00:16:47.290 --> 00:16:49.000
>> ECKERLIN: At a particular load?
00:16:49.000 --> 00:16:51.230
>> REYNOLDS: At a particular load.
00:16:51.230 --> 00:16:54.570
We have the ability to vent steam through
a muffler.
00:16:54.570 --> 00:17:02.940
So we can take a boiler with no load on it,
just idling and make that set point.
00:17:02.940 --> 00:17:07.360
We can adjust it up to 25 percent, tune there.
00:17:07.360 --> 00:17:12.760
Then go on up to 50 percent, 75 percent, full
load.
00:17:12.760 --> 00:17:16.970
Then we track it back down and go back through
it again.
00:17:16.970 --> 00:17:25.059
So then we have the ability to be getting
the curve set for our fuel from low, 25 percent,
00:17:25.059 --> 00:17:29.889
50 percent, 75 percent, and adjust it all
the way through the curve.
00:17:29.889 --> 00:17:33.230
>> ECKERLIN: Now you do that by adjusting
the cam?
00:17:33.230 --> 00:17:36.779
>> REYNOLDS: We do that by adjusting the cam.
00:17:36.779 --> 00:17:37.779
>> ECKERLIN: On the fuel?
00:17:37.779 --> 00:17:39.209
>> REYNOLDS: On the fuel.
00:17:39.209 --> 00:17:41.109
>> ECKERLIN: Ah that's good.
00:17:41.109 --> 00:17:45.080
>> REYNOLDS: So here's the temperature gage
and this is where as they're making their
00:17:45.080 --> 00:17:48.039
rounds they are able to record that.
00:17:48.039 --> 00:17:51.960
And they're also recording their steam load
and everything as they're doing it.
00:17:51.960 --> 00:17:56.600
So we can capture that data, if there's a
sudden change in it, we know that something's
00:17:56.600 --> 00:17:57.980
happened within the boiler.
00:17:57.980 --> 00:18:04.280
Or if we need to look at, a temperature may
be normal for what that load is we can start
00:18:04.280 --> 00:18:08.460
comparing that temperature at that load at
a different time.
00:18:08.460 --> 00:18:26.269
Would you like to look at the flame pattern?
00:18:26.269 --> 00:18:27.470
>> ECKERLIN: Yes, let's do that.
00:18:27.470 --> 00:18:29.470
Well a picture's worth a thousand words isn't
it?
00:18:29.470 --> 00:18:30.470
>> REYNOLDS: It is.
00:18:30.470 --> 00:18:31.470
>> ECKERLIN: It's beautiful.
00:18:31.470 --> 00:18:32.470
Very well done.
00:18:32.470 --> 00:18:38.850
Well Paul I think we're here by the condensate
tank or the surge tank as you call it.
00:18:38.850 --> 00:18:44.509
This is where the condensate comes back from
all of the facilities.
00:18:44.509 --> 00:18:53.269
That's sort of the liquid gold because it's
got energy, it's got chemicals in it, and
00:18:53.269 --> 00:19:00.380
it's water which doesn't have to be made up.
00:19:00.380 --> 00:19:01.380
What's the temperature of the condensate tank
here now?
00:19:01.380 --> 00:19:02.669
>> REYNOLDS: Well it's around 150 to 160.
00:19:02.669 --> 00:19:05.690
That is a combination of the condensate that
is being returned plus that amount of soft
00:19:05.690 --> 00:19:06.690
water that we've added to it as make-up.
00:19:06.690 --> 00:19:10.449
So this is our average temperature of the
condensate and the make-up.
00:19:10.449 --> 00:19:20.010
>> ECKERLIN: So actually then the condensate
coming back is going to be higher than that.
00:19:20.010 --> 00:19:21.139
00:19:21.139 --> 00:19:23.390
Which is very good.
00:19:23.390 --> 00:19:24.519
00:19:24.519 --> 00:19:29.909
Also I notice here in this facility that you
have the piping which is color coded.
00:19:29.909 --> 00:19:31.339
00:19:31.339 --> 00:19:34.700
>> ECKERLIN: You have the green which is the
condensate return.
00:19:34.700 --> 00:19:38.529
The yellow there is the
make-up water.
00:19:38.529 --> 00:19:42.070
Then the steam, I guess that's for some heating
here?
00:19:42.070 --> 00:19:47.019
>> REYNOLDS: The heating here and then where
we're taking it out to the distribution.
00:19:47.019 --> 00:19:51.259
But the color coding makes it much easier
to trace down lines.
00:19:51.259 --> 00:19:56.009
Otherwise you'd just be seeing a lot of pipes
up in the ceiling and it's easy to get them
00:19:56.009 --> 00:19:57.009
crossed up.
00:19:57.009 --> 00:20:03.019
The color-coding is a great, great help.
00:20:03.019 --> 00:20:04.850
>> ECKERLIN: That's something that you don't
see.
00:20:04.850 --> 00:20:08.950
I don't see very often as you go around the
country so that's a real plus here.
00:20:08.950 --> 00:20:18.720
And then behind here, you have the condensate
tank, uh pumps.
00:20:18.720 --> 00:20:21.039
Which pumps the water to the deareator.
00:20:21.039 --> 00:20:22.919
Which is up, we'll see that later.
00:20:22.919 --> 00:20:24.259
Are these variable speed pumps?
00:20:24.259 --> 00:20:25.340
>> REYNOLDS: Yes they are.
00:20:25.340 --> 00:20:37.690
So we're only using the amount of energy necessary
to achieve what we're trying to do.
00:20:37.690 --> 00:20:43.429
Which is take a volume of water from here
up to the next level.
00:20:43.429 --> 00:20:46.409
As we start making more steam, the deareator
will be using more water so this putting more
00:20:46.409 --> 00:20:49.769
water in the deareator so our equipment adjusts
according to whatever our load is.
00:20:49.769 --> 00:20:52.109
>> ECKERLIN: Are you adding any steam to this
tank at all here?
00:20:52.109 --> 00:20:53.109
>> REYNOLDS: No.
00:20:53.109 --> 00:20:55.419
All the steam is added at the deaerator.
00:20:55.419 --> 00:21:07.019
>> ECKERLIN: Paul, we have here this continuous
condensate, not condensate, blow down heat
00:21:07.019 --> 00:21:08.019
recovery.
00:21:08.019 --> 00:21:09.019
Could you pass us through that please?
00:21:09.019 --> 00:21:14.010
>> REYNOLDS: Well to maintain the chemistry
in the boiler you have a continuous blow down
00:21:14.010 --> 00:21:15.010
to maintain those solids.
00:21:15.010 --> 00:21:16.010
Of course that is boiler water that has all
the heat in it.
00:21:16.010 --> 00:21:24.289
So that water is piped to go through this
heating exchanger.
00:21:24.289 --> 00:21:38.710
That's going through one side and on the other
side of this heat exchanger we have the make-up
00:21:38.710 --> 00:21:42.249
water that would be going into our surge tank.
00:21:42.249 --> 00:21:45.961
So we are literally transferring the heat
or part of that heat of what would be being
00:21:45.961 --> 00:21:50.210
blown down to the drain and pre-heating the
water that goes to our condensate receiver.
00:21:50.210 --> 00:21:51.210
So we're capturing the heat instead of losing
it.
00:21:51.210 --> 00:21:54.509
>> ECKERLIN: That's a good energy conservation
measure that people ought to consider all
00:21:54.509 --> 00:21:55.700
of the time.
00:21:55.700 --> 00:21:56.879
>> REYNOLDS: Very good.
00:21:56.879 --> 00:22:01.240
Now we'll go up to the deaerator where this
is going.
00:22:01.240 --> 00:22:04.570
>> ECKERLIN: Well Paul here we are at the
deareator.
00:22:04.570 --> 00:22:09.379
This is the device that removes mechanically
the oxygen from the feedwater.
00:22:09.379 --> 00:22:10.509
00:22:10.509 --> 00:22:12.580
>> ECKERLIN: Ah, typically this is at low
pressure.
00:22:12.580 --> 00:22:15.839
What is the pressure of this vessel here now?
00:22:15.839 --> 00:22:18.099
>> REYNOLDS: Were probably eight to 10 pounds.
00:22:18.099 --> 00:22:22.109
>> ECKERLIN: Eight to ten pounds, and what
is the water temperature, the feedwater temperature?
00:22:22.109 --> 00:22:24.039
>> REYNOLDS: We're approaching 230.
00:22:24.039 --> 00:22:25.989
>> ECKERLIN: Approaching 230 degrees.
00:22:25.989 --> 00:22:26.989
That's sort of what it shows here.
00:22:26.989 --> 00:22:28.369
That's great.
00:22:28.369 --> 00:22:36.039
Ah, one of the problems people will often
have with deaerators is they don't operate
00:22:36.039 --> 00:22:38.769
at the proper pressure or the temperature.
00:22:38.769 --> 00:22:44.360
Sometimes they're below 212 and then it doesn't
really serve their purpose at all so it's
00:22:44.360 --> 00:22:50.610
good that you're up and above that 8 to 10
pounds, 230 so that indicates good operation
00:22:50.610 --> 00:22:52.852
in this particular instance.
00:22:52.852 --> 00:22:54.270
This is the storage section here?
00:22:54.270 --> 00:22:55.270
00:22:55.270 --> 00:22:58.640
>> ECKERLIN: We're going around the corner
now and we're going to look at the mechanical
00:22:58.640 --> 00:22:59.809
section above it, is that correct?
00:22:59.809 --> 00:23:02.519
00:23:02.519 --> 00:23:13.479
The way that we maintain the temperature is
through a PRV valve.
00:23:13.479 --> 00:23:17.340
And that is feeding the mechanical section
of the deareator.
00:23:17.340 --> 00:23:21.539
As the load goes up the water would increase
going into it.
00:23:21.539 --> 00:23:25.789
You would have a pressure drop in
the PRV valve would open up and apply more
00:23:25.789 --> 00:23:26.789
steam.
00:23:26.789 --> 00:23:34.940
As the load goes down, there'd be less water
the PRV valve would close so that way we maintain
00:23:34.940 --> 00:23:39.779
a constant pressure
on the mechanical side of the deareator and
00:23:39.779 --> 00:23:48.190
the result is the storage tank
water is at a constant level around 230.
00:23:48.190 --> 00:23:52.489
From that storage tank,
it then goes to our feedwater pump that are
00:23:52.489 --> 00:23:53.970
located in the basement.
00:23:53.970 --> 00:24:00.309
They're located there to where
the head pressure going into the suction side
00:24:00.309 --> 00:24:05.609
of the pump is maintained to keep
that hot water from flashing in the pump.
00:24:05.609 --> 00:24:11.279
And from there we can boost the water pressure
back up to where we can put it into our boiler.
00:24:11.279 --> 00:24:12.899
>> ECKERLIN: Roughly at 230 feedwater temperature.
00:24:12.899 --> 00:24:14.519
>> REYNOLDS: Water temperature entering the
boiler.
00:24:14.519 --> 00:24:31.309
>> ECKERLIN: That's a good description and
an important part of a boiler operation and
00:24:31.309 --> 00:24:37.330
mechanical removal of oxygen from the feed
water and it avoids the use of chemicals so
00:24:37.330 --> 00:24:38.330
that's so important.
00:24:38.330 --> 00:24:39.630
This is a system where you take bottom blow
down, not continuous, bottom blow down and
00:24:39.630 --> 00:24:46.850
you have to prepare it so it's acceptable
to the city.
00:24:46.850 --> 00:24:47.850
So you have to cool it.
00:24:47.850 --> 00:24:56.239
And this is the cold water coming in.
00:24:56.239 --> 00:25:03.509
Can you explain then to the folks what's happening
00:25:03.509 --> 00:25:14.990
>> REYNOLDS: The first step is to minimize
how much bottom blow down you have.
00:25:14.990 --> 00:25:21.720
So by minimizing that and having it where
it's in shorter parts, that reduces how much
00:25:21.720 --> 00:25:24.320
water weíre sending down the drain.
00:25:24.320 --> 00:25:30.889
>> ECKERLIN: That goes back to the 3 seconds
you were talking about?
00:25:30.889 --> 00:25:31.889
00:25:31.889 --> 00:25:32.889
And it's also less water that we're having
to make up for what we're blowing down.
00:25:32.889 --> 00:25:37.759
So that water comes into this accumulator
tank and as it passes through, the automatic
00:25:37.759 --> 00:25:48.649
valve will open to cool that water down for
what was entering into their sewer system.
00:25:48.649 --> 00:25:49.810
So the first step is to minimize how much
blow down we have and then to minimize how
00:25:49.810 --> 00:25:50.810
much cooling water we're using to reach the
set point.
00:25:50.810 --> 00:25:51.810
So we'll do it to where it kinda dominoes
up and dominoes down.
00:25:51.810 --> 00:25:52.810
We try to minimize what we're doing to get
the proper effect out of it and balance our
00:25:52.810 --> 00:25:53.810
water temperature.
00:25:53.810 --> 00:25:54.810
>> ECKERLIN: The important thing for people
to recognize is that this water here for cooling
00:25:54.810 --> 00:26:08.710
is only for cooling so it's costing
the university money to do that.
00:26:08.710 --> 00:26:12.072
So it's important to communicate that to the
folks upstairs.
00:26:12.072 --> 00:26:13.072
>> REYNOLDS: Right.
00:26:13.072 --> 00:26:14.072
>> ECKERLIN: Thank you.
00:26:14.072 --> 00:26:15.190
>> NARRATOR: During the plant walk-through
the assessor identifies a number of potential
00:26:15.190 --> 00:26:18.700
measures that might improve energy efficiency
of the facility.
00:26:18.700 --> 00:26:21.700
He then summarizes findings for the plant
supervisor.
00:26:21.700 --> 00:26:27.539
>> ECKERLIN: Well Paul, thank you so much
for a very interesting tour, very comprehensive
00:26:27.539 --> 00:26:28.539
tour.
00:26:28.539 --> 00:26:33.370
I just want to summarize my comments with
a few recommendations.
00:26:33.370 --> 00:26:38.789
Perhaps the first one would be in the area
of stack temperature, flue gas temperature,
00:26:38.789 --> 00:26:41.220
leaving the last point of heat recovery.
00:26:41.220 --> 00:26:44.019
That probably can be reduced.
00:26:44.019 --> 00:26:49.629
Some other things you may want to look at
would be soot on the flue gas side or scale
00:26:49.629 --> 00:26:51.509
on the water side.
00:26:51.509 --> 00:26:57.179
Another item that people often don't check
which is important are the baffles, the condition
00:26:57.179 --> 00:26:59.779
of the baffles at the back end of the boiler.
00:26:59.779 --> 00:27:06.719
If they break, the flue gases then make a
short circuit from pass 1 to pass four which
00:27:06.719 --> 00:27:11.529
would cause the temperature of that flue gas
which you're monitoring pretty well,
00:27:11.529 --> 00:27:13.360
would cause it to jump rather dramatically.
00:27:13.360 --> 00:27:16.640
In that way you're checking things you'll
catch that.
00:27:16.640 --> 00:27:18.999
That's something to be aware of.
00:27:18.999 --> 00:27:22.460
the same thing goes for oxygen in the flue
gas.
00:27:22.460 --> 00:27:27.559
That's a measure of excess air and you need
to keep close tabs on that.
00:27:27.559 --> 00:27:34.490
If the oxygen gets too high uh you'll need
a burner tune-up which cost maybe a thousand
00:27:34.490 --> 00:27:35.729
to twelve hundred dollars.
00:27:35.729 --> 00:27:38.159
That's often a good investment.
00:27:38.159 --> 00:27:41.049
Another important
item here that we have to keep in mind is
00:27:41.049 --> 00:27:46.899
whenever we're talking about stack temperature
or 02, we always have to keep in mind that
00:27:46.899 --> 00:27:51.219
that varies with load okay very load dependent.
00:27:51.219 --> 00:27:57.720
So if you're measuring 02 or stack temperature
measure it in high fire, mid-range, and low
00:27:57.720 --> 00:28:00.320
fire and see how that goes.
00:28:00.320 --> 00:28:05.539
And if you do this on a regular basis checking
stack temperature and O2 on a regular basis,
00:28:05.539 --> 00:28:07.899
do it the same load every time.
00:28:07.899 --> 00:28:08.899
That's important.
00:28:08.899 --> 00:28:14.120
Lots of times people will say, 'hey the stack
temperature's 450 today isn't that great?'
00:28:14.120 --> 00:28:18.169
Okay well it may be at low fire and that may
be the reason it's lower.
00:28:18.169 --> 00:28:24.940
So load is an important factor in both stack
temperature and O2.
00:28:24.940 --> 00:28:30.710
Also when we're doing a stack, a flue gas
analysis, pay attention to CO, the carbon
00:28:30.710 --> 00:28:32.039
monoxide.
00:28:32.039 --> 00:28:34.210
That's a measure of incomplete combustion.
00:28:34.210 --> 00:28:36.570
CO is actually a fuel.
00:28:36.570 --> 00:28:40.259
It has a heating value of 43.47 BTU's per
pound.
00:28:40.259 --> 00:28:44.259
It's not nearly what it what other fuels are
but it is a fuel.
00:28:44.259 --> 00:28:48.909
And so you want to eliminate, minimize that.
00:28:48.909 --> 00:28:53.659
Typically a guideline is to keep CO below
200 parts per million that would
00:28:53.659 --> 00:28:57.260
be acceptable, that's a rule of thumb.
00:28:57.260 --> 00:28:58.269
Condensate return.
00:28:58.269 --> 00:28:59.649
We've talked a lot about that.
00:28:59.649 --> 00:29:01.929
I think
you're doing a good job on that.
00:29:01.929 --> 00:29:06.259
As I mentioned earlier, if you lose 50 percent
of your condensate
00:29:06.259 --> 00:29:09.100
that's representing a 6-percent energy loss.
00:29:09.100 --> 00:29:10.100
00:29:10.100 --> 00:29:13.659
In addition to that you have chemical and
water losses too.
00:29:13.659 --> 00:29:18.659
So that's an important variable in your overall
operation.
00:29:18.659 --> 00:29:19.659
Bottom blow-down.
00:29:19.659 --> 00:29:25.440
You seem to have that under control on three-second
cycles, just keep up the good work in that
00:29:25.440 --> 00:29:26.990
area.
00:29:26.990 --> 00:29:31.830
One area that I think you're probably aware
of is that blow down cooler down there in
00:29:31.830 --> 00:29:33.649
the corner in the basement.
00:29:33.649 --> 00:29:37.450
You'd like to minimize using city water to
cool hot blow down.
00:29:37.450 --> 00:29:40.989
So that's an area for improvement perhaps.
00:29:40.989 --> 00:29:48.839
Steam trap maintenance by the other staff
not necessarily your operation or your responsibility.
00:29:48.839 --> 00:29:53.730
But steam trap maintenance is so important
particularly in a large facility like this
00:29:53.730 --> 00:29:59.839
where we have traps throughout the steam distribution
line and in the buildings themselves so that's
00:29:59.839 --> 00:30:02.099
important.
00:30:02.099 --> 00:30:03.169
Cold end corrosion.
00:30:03.169 --> 00:30:08.490
It's another thing to pay attention to particularly
when you're firing heavy oil that may become
00:30:08.490 --> 00:30:15.710
more of a problem later when boiler number
4 begins to play a larger role here.
00:30:15.710 --> 00:30:20.349
And cold end corrosion but you're doing something
about that by raising the feed water temperature
00:30:20.349 --> 00:30:21.349
to the economizer.
00:30:21.349 --> 00:30:22.809
So that's positive.
00:30:22.809 --> 00:30:29.460
Just be sensitive to cold end corrosion because
of the importance and the effect it has.
00:30:29.460 --> 00:30:30.460
Particularly on economizers.
00:30:30.460 --> 00:30:33.629
I go around the country and I see a lot of
economizers.
00:30:33.629 --> 00:30:38.589
And most of them are out of
service simply because of cold end corrosion.
00:30:38.589 --> 00:30:40.229
So you want to avoid that.
00:30:40.229 --> 00:30:46.109
But overall I think you've done a nice job
here and I really appreciate the tour that
00:30:46.109 --> 00:30:50.759
you've given us and I think there's room for
improvement but that's true in every facility.
00:30:50.759 --> 00:30:53.690
I want to thank you again.
00:30:53.690 --> 00:30:54.690
Appreciate it very much.
00:30:54.690 --> 00:30:56.120
>> REYNOLDS: And when will I be having your
report?
00:30:56.120 --> 00:30:57.529
>> ECKERLIN: Oh, that's an important question.
00:30:57.529 --> 00:30:58.529
In two weeks.
00:30:58.529 --> 00:30:59.529
>> REYNOLDS: Okay, very good.
00:30:59.529 --> 00:31:00.529
>> ECKERLIN: You can hold me to it okay.
00:31:00.529 --> 00:31:01.529
>> REYNOLDS: Thank you.
00:31:01.529 --> 00:31:02.529
>> ECKERLIN: Yes sir.
00:31:02.529 --> 00:31:03.529
Thank you.
00:31:03.529 --> 00:31:07.469
>> NARRATOR: Once you have received your energy
assessment, you will need to notify EPA.
00:31:07.469 --> 00:31:13.090
Initial notification of compliance status
is due by July 19, 2014.
00:31:13.090 --> 00:31:16.149
Be sure to keep your assessment with your
records.
00:31:16.149 --> 00:31:21.059
You can learn more under the reporting and
recordkeeping module in this series.
00:31:21.059 --> 00:31:25.509
Assessing your energy management practices
and program can help you identify operational
00:31:25.509 --> 00:31:31.659
and organizational strategies necessary to
support and maintain boiler efficiency.
00:31:31.659 --> 00:31:37.860
EPA, through its Energy Star program, can
help you build into your energy program critical
00:31:37.860 --> 00:31:41.210
practices that will keep your boilers operating
efficiently.
00:31:41.210 --> 00:31:46.099
EPA's EnergyStar website provides valuable
resources to help.
00:31:46.099 --> 00:31:50.820
Department of Energy, through its Advanced
Manufacturing Office, can help you understand
00:31:50.820 --> 00:31:55.330
the energy assessment process and assist you
in obtaining an assessment.
00:31:55.330 --> 00:31:58.799
DOEís energy assessment webpage provides
helpful information and resources.
00:31:58.799 --> 00:31:59.799
00:31:59.799 --> 00:32:00.799
Energy Assessment - Module 3 of 4
SCRIPT for EDIT 07/18/13
00:32:00.799 --> 00:32:01.799
9
00:32:01.799 --> 00:32:02.799
00:32:02.799 --> 00:32:03.799
Shooting Script
CLIENT: Environmental Protection Agency
00:32:03.799 --> 00:32:03.805
PRODUCER: Marsha Winstead, WinRock Productions,
LLC

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