Page 52 - Boiler plant and distribution system optimization manual

Chapter 4

Basic Boiler Plant Efficiency

This chapter is designed to show the logical the losses by another 20%. It can get quite expen-
steps that should be followed to find basic boiler sive when this circle of losses is escalated by poor
plant efficiency. It covers the basic steps for plant conditions in the distribution system.
survey and testing to identify sources of losses in Figure 4.2 points out an interesting fact
the plant and distribution system. about the real value of fuel savings. When con-
In figure 4.1 the typical cost of 1,000 pounds sidering where the money comes from to pay fuel
of steam [approximately 1 million Btus] is shown. bills, boiler and distribution system optimiza-
Boiler plant operations are fairly fixed. Optimiz- tion should have a very high priority because the
ing boiler efficiency will often offer a good op- money that pays the fuel bill comes from compa-
portunity for improved efficiency and fuel dollar ny profits. It is not unusual to be able to identify
savings. The typical distribution system wastes a a savings of $50,000 a year in a typical plant. The
great deal of energy, about double a boiler’s loss- real question is, how does this relate to profits? If
es. When the distribution system wastes energy, there is a 5% profit one million dollars will have
the boiler load goes up accordingly compounding to be invested in raw materials, production, mar-

Figure 4.1—Typical cost factors for I,000 pounds of steam. The boiler plant operational
costs are fairly constant and predictable. The steam system losses are unpredictable and
can be very large depending on conditions.

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