Page 38 - Boiler plant and distribution system optimization manual

Optimizing Boiler Plants Establishing the Ideal Scene 23

Figure 2.4—Efficiency curve showing high ex- Figure 2.5—Efficiency curve showing high stack
cess air losses below half load. temperature losses above half load.

oxygen trim systems, heat recovery options and
such to achieve the ideal design for the plant.
The second ideal scene deals with how the
plant is operated and maintained relative to un-
necessary energy losses within the control of
plant personnel.

OPTIMIzING BOILER MANAGEMENT
Figure 2.6—A typical efficiency curve showing
moderate excess air losses at low firing rates and If tests show an annual fuel savings of
heat exchange losses at high firing rates. $100,000 were possible just by tuning up a boiler
and correcting simple maintenance problems un-
parameters and identifying them with annual fuel covered during a tune up, this fact would present
or dollar losses when they vary from the ideal. a convincing argument for additional personnel,
Once the ideal scene has been defined, loss training or technical support to insure that these
prevention can be indexed to these and other key savings are maintained. Hidden costs from main-
indicators: tenance problems can be a very expensive over-
sight.
a. Stack temperature The term management is not often discussed
b. Excess air in connection with boilers and distribution sys-
c. Percent make up water tems, probably because they are operated, but not
d. Blowdown losses managed in the sense of maintaining optimum
e. Condensate return temperature losses performance.
A good many managers feel that the efficien-
A loss prevention program is an essential cy of a plant should never change. What is missed
part of boiler plant optimization as it deals with is that they are a very dynamic energy consuming
the control of specific elements of boiler and sys- monster that must be managed. If not prevented
tem operation and maintenance. from wasting fuel, they will surely be feasting on
Thus, two ideal scenes are appropriate to your utility dollars.
any plant. The first is ideal design. Efficiency Plant engineering and maintenance staff are
measurements can be used to justify projects such often too busy or undermanned or don’t under-
as economizers, stand the magnitude of losses involved in boiler