PROCEEDINGS: DATE: SUBJECT AREAS: THEME: Your Physical ... · Boldt – A Solid Foundation 123 years in construction services A culture built on strong values One of the nations largest

C O N S U L T I N G S O L U T I O N S / T E C H N I C A L S O L U T I O N S / C O N S T R U C T I O N S O L U T I O N S

PROCEEDINGS: 2012 Healthcare Engineering Society of Northern Illinois (HESNI) Annual Conference

DATE: May 3-4, 2012

SUBJECT AREAS: Operations; design, and compliance

THEME: Your Physical Plant – Internal/External Cares and Concerns

ABSTRACT: Physical plants have needs associated with their overall performance from an efficiency level as well as a quality, cost and compliance perspective. We typically look at the boiler room as a box without forethought as to what we are doing to the facility it supports or what the facility is returning to the boiler room. This presentation will address the concepts of looking at the production setting (boiler room) and distribution/end user as one in order to maintain harmony and balance throughout the entire system.

KEY TOPIC POINTS:

Operating the cash register we call the physical plant Why do we operate at the pressures we do? Steam verses hot water Efficiency gains in the boiler room Distribution issues End users Return system Summer verses winter loads(operating at a lower pressure) Preventative maintenance practices

TAKE AWAY POINTS:

Identifying areas for potential energy improvement Benchmarking energy cost savings for project initiatives Heighten awareness of how the entire system operates as one Best practices for equipment selection and operation Discuss alternate management techniques for operation/maintenance of plant

Internal/External Cares and Concerns

Your Physical Plant

May 4, 2012

Introductions

Boldt – A Solid Foundation

123 years in construction services

A culture built on strong values

One of the nations largest builders

Honesty, fairness, hard work, performance and a love of construction are what we value

Jay Ehrfurth, P.E.

• Director of Project Development - Power

• 9+ years with State of Wisconsin - DOA

• State Chief Power Plant Engineer

• 16 years with Georgia Pacific – Green Bay

• Power Plant Superintendent

• Power Plant Maintenance Manager

• Project Manager

• 5 years with Rouman & Associates

• Consulting Engineer – Utilities & HVAC

• 1 year with WE Energies

• Point Beach Nuclear Plant - Operations

Agenda

• Plant 101

• Operating Pressure/Temperatures

• Your Physical Plant the Cash Register

• Internal Concerns

• External Concerns

• Distribution Issues

• End Users

• Return System

• Summer verses Winter Loads

• Preventative Maintenance Practices

Plant 101

Plant 101

• In one day, more people come in close proximity to a boiler or pressure vessel than the number of people who fly each year in the United States.”

Donald E. Tanner, Executive Director, National Board - NB Bulletin/Fall 2002

Unique World

Boilers and support equipment operate at pressures and temperatures that are inherently dangerous.

Plant 101

• Mother Nature always wins. Physics, chemistry, mechanics, etc

• Everything wants to balance out. Force items into a position they don’t want to be at; hold then do work before a return back to its original state.

• Everything is relative. Differentials, can be to much of a good thing

• Steam, chilled water and electricity are generated on demand and cannot be stored. Requires plant operations to “swing” immediately and constantly with system demands.

Laws of the Boiler Room

Plant 101

• Boiler at 100 psi

• 8.5” by 11” = 93.5 IN2

• 93.5 IN2 x 100 LBS/IN2 =

• 9,350 pounds force or ~ 4.75 tons

• Boiler at 15 psi – “Low Pressure”

• 8.5” by 11” = 93.5 IN2

• 93.5 IN2 x 15 LBS/IN2 =

• 1,402.5 pounds force or ~ ¾ of a ton

System Forces

Plant 101

It is a known engineering fact that a given volume of water, under pressure at or above 212 degrees will instantaneously flash and grow in volume to occupy a space greater than 1,600 times its original volume.

Potential Energy

• Dynamite expands >900 times in volume

• Where would we encounter water above atmospheric pressure?

Operating Pressures/Temperatures

Why do we operate at the pressures we do?

0 Psig 15 Psig 100 Psig

Sat Temp 212oF 250oF 338oF

-32 -32 -32

Sensible Heat 180 218 306

Latent Heat 970 946 882

Total Energy 1,150 1,164 1,188

Volume(FT3/#) 27 14 4

BTU =

1 # H2O

1 oF




-32 -32 -32



Total Energy 1,150 1,164 1,188

Volume(FT3/#) 27 14 4

BTU =

1 # H2O

1 oF




-32 -32 -32



Total Energy 1,150 1,164 1,188

Volume(FT3/#) 27 14 4

4”8”12”




-32 -32 -32



Total Energy 1,150 1,164 1,188

Volume(FT3/#) 27 14 4




-32 -32 -32



Total Energy 1,150 1,164 1,188

Volume(FT3/#) 27 14 4


End user needs it– Pick a pressure, get a temperature

No pumps

More delivered energy per volume

Smaller line sizes; pipe, hangers, insulation

Smaller boiler

Ability to add energy from waste streams

Ability to create superheated steam

Potential Benefits


Desuperheater

Steam

Water

PRV Station

Saturation Pressure/Temperature

Curve

Your Physical Plant the Cash Register

Operating the cash register we call the Physical Plant

Operating the cash register we call the Physical Plant

ONE FOR ONE ONE FOR SOMETHING LESS

COST AVOIDANCEENERGY EFFICIENCY

• Reduce Demand• Boiler Efficiency• Boiler Cycling• Condensate Return• Water – RO Systems

• BAS - Setbacks• Trap surveys• System losses• Economizers• Insulation

Internal Concerns

Internal Concerns

Fuel, 74%

Chemicals, 0.50%

Water, 0.75%

Sewer, 1.50%Electricity, 2.50% Equipment, 9.75%

Labor, 10%

Total Cost Factors For 1,000 Pounds of Steam

Internal Concerns

Definitions:

Efficiency: “The ratio of the effective or useful output to the total input of any system”

Combustion Efficiency: The effective use of fuel to the burner.

Boiler Efficiency: The effective use of heat to the boiler.

Boiler Room Efficiency: The effective use of steam in the boiler room.

System Efficiency: The effective use of steam from the time it leaves the boiler room and until it returns to the boiler room.

Internal Concerns

– Tune burner

– Boiler controls

– Oxygen trim(O2)

– Casing leaks, refractory

– Efficient dispatching

– Feedwater economizer

– Water treatment

– Soot blowing

– DA tank operation

– Feedwater pump recirculation

– Blowdown heat recovery

– Combustion air make-up

– Compressed air system

Burner Zone:

Boiler Zone:

Boiler Room Zone:

Internal Concerns

Item Principle of Operation Efficiency Improvement

Economizer

Firetube Turbulators

Combustion Controls

Oil & Gas Burners

Insulation

Blowdown System

Condensate Return

Transfer energy from flue gas to feedwater

Increase turbulence in secondary passes.

Improve fuel/air ratio and O2

Improve fuel/air ratio and O2

Reduce heat transfer

Transfer waste heat and/or reduce flow

Reduce make-up water

1% for each 40oF decrease in stack gas temperatures or 1% for each 10oF increase in feedwater temperature

Same as economizer

0.25% increase for each 1% decrease in O2

0.25% increase for each 1% decrease in O2

Dependent on surface temperatures

1-3% dependent on blowdown quantity and operating temperatures

12 – 15%

External Concerns

External Concerns

Distribution Issues

Proper insulation

Lines properly pitched and dripped

Steam trap surveys

Hangers adequately installed and maintained

Anchors still in fixed position

Expansion still compensated for

Tightness of flanges and gaskets

Lines properly sized– Facility expansion turned branch into main

Pressure reducing valve stations and safety relief valves

External Concerns

End Users

Pressure reducing valve stations and superheated steam

Proper operation of desuperheating valves

Control valve operation

Proper dripping and trap selection

Inactive equipment

Coil or heat exchangers – yellow metals

Water treatment – neutralizing amines

Proper freeze protection – vacuum breaker

External Concerns

Return System

Return temperatures and entrained air

Water treatment chemicals

Steam trap discharging and gravity flow

Condensate receivers and full return

Proper insulation practices

Piping materials

Iron and copper returned to boiler system

Corrosion coupons

Summer verses Winter Loads

Summer verses winter loads

• Displays peaks and when they occur

• Displays valleys and when they occur

• Displays system anomalies

• Displays viabilities in load

• Helps to define boiler needs on a seasonal basis

Summer verses winter loads

• Displays load duration over the year

• Filters out system peaks and valleys

• Easy to overlay anticipated growth

• Allows an understanding of boiler stacking(dispatching)

• Helps to define boiler loading and turndown needs

Preventative Maintenance Practices

Preventative maintenance practices

Be in Business Means Having Problems!

Avoiding Costs Means Solving Problems!

Avoiding a Lot of Costs Means Solving a Lot of

Problems Fast!

Use people and processes first to solve problems,then supplement and

support with technology!

Preventative maintenance practices

Mechanical Integrity

Identify equipment covered– Relief and venting system/devices– Emergency systems– Controls(sensors, alarms, interlocks)

Written maintenance procedures

Maintenance training– Overview of systems and hazards– Procedures perform task in a safe manner

» Lockout/Tagout» Confined space

Inspection and testing– Required by law– Required by Code

Quality assurance– Close the loop

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PRESENTOR: Jay Ehrfurth, PE Director of Project Development – Power The Boldt Company

SPEAKER BIO: Jay Ehrfurth, P.E.

Mr. Ehrfurth is currently employed with The Boldt Company as Director of Project Development-Power. In this role, Jay supports the repair, modification or construction of centralized heating/power facilities as found in hospitals, industrial, higher educational campuses, airports, institutions and correctional facilities.

Before joining Boldt, Jay served as the State Chief Power Plant Engineer and team leader for the Wisconsin Department of Administration’s Division of State Facilities, Heating Plant Engineering group for 9+ years. This group of engineers and professionals monitor central plant performance, statewide fuel purchasing, plant emissions, and manages construction projects for 35+ state owned heating/cooling/power plants. These plants combined are capable of generating over 5,000,000 lbs per hour of steam, over 15 MW of electricity and over 71,000 tons of cooling.

Prior to that, Jay worked for Georgia-Pacific(Fort Howard) for 16 years in various positions from engineering to maintenance supervisor to power plant management, overseeing the operational portion of a 1,200,000 lbs per hour 900F/900psig coal fired plant with 90+ MWs of electrical generation. Served as part of a start-up team for a green field plant site in Georgia with CFB boilers and two 20MW CT’s with HRSG.

Jay also spent 5 years with a consulting engineering firm in the Fox River Valley as their power and utility engineer mainly performing consulting duties to the pulp and paper industry. Jay is a Licensed Professional Engineer in the State of Wisconsin and holds an ASOPE-Master Chief’s license, NIULPE-Chief’s License and ASOPE-Technical Instructor credential.

Jay is on the board of directors for the Wisconsin Boiler Inspectors Association (WBIA), American Society of Power Engineers (ASOPE) – Wisconsin Region 2, American Society of Power Engineers (ASOPE) – National and various program advisory boards for Wisconsin area Technical Colleges.

PROCEEDINGS: DATE: SUBJECT AREAS: THEME: Your Physical ... · Boldt – A Solid Foundation 123 years in construction services A culture built on strong values One of the nations largest

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