Ultrasound Fundamental Technology for the Efficient Use of Process Steam. Carlos E. Garza Rivera Level II Ultrasonic Inspector No.

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1 Ultrasound Fundamental Technology for the Efficient Use of Process Steam Carlos E. Garza Rivera Level II Ultrasonic Inspector No. UET

2 World Energetic Context High fossil fuel cost, cause that industry develop dynamically energy conservation concept. The most viable solution is the proved technology implementation for designing new upgrade packages for boosting reliability, efficiency, and maximizing the operative status of our systems. The most efficient system we have, the less energy consumed in our normal operation.

3 Industry Commitment Continuous betterment Equipment and Process Reliability High Efficiency Maximum Productivity Environmental Regulations Proactive Maintenance

4 How does Steam System Contributes? Steam has been well respected by industry for being an excellent heating source by these reasons: Easy to Produce Renewable Resource (Water) Easy Distribution Pressure and Temperature Relation Easy to Control High Energy Transportation

The Steam System and the Organization -EXECUTIVES- Concerned about the best energy transfer solution to meet the strategic and financial objectives of the

5 The Steam System and the Organization -EXECUTIVES- Concerned about the best energy transfer solution to meet the strategic and financial objectives of the organization. Capital Investment Maintenance and Overhead Costs The most use that can be maid of it System Changes What does my steam system say about the company?

6 The Steam System and the Organization -MANAGEMENT- Managers tend to be practical and focused on completing a task within a budget. Does my steam systems provides me the greatest amount of practicality and expediency, at the lowest cost possible?

7 The Steam System and the Organization -TECHNICAL PERSONEL / OPERATORS- Will it break down? Phone ringing at night? When maintenance is required and how easy it is? How do I efficiently make a diagnosis on it?

8 Steam System as an Opportunity Area High importance for industry, application versatility (equipment heating, products, power generation, etc.). All the upgrade results have immediate impact in efficiency, economics, and reliability. Step forward through design conditions.

9 Steam Users

10 Good Steam System Benefits Advantage of Steam Properties Prevention of System Problems Efficiency and Reliability Prevention of Unexpected Downtime Security Economics Environmental Protection

11 Ultrasound Key Tool Non intrusive condition analysis technology, provides critical and trustful information. Several system components inspection with the same technology. Exact diagnosis, supported by analysis software. System trending, better planning.

12 What we can Inspect with Ultrasound Valves, steam traps, heat interchangers, among other components can be trustfully inspected with ultrasound.

13 Ultrasonic Valve Inspection Valves play an important role in reliability and of our process. Blocking and control of our distribution lines depend on them. Ultrasound permits us searching for leaks, blockage, and/or deficiencies of normal valve operation.

14 Easy as ABC (Right Alan?) UP10000 in Valve Application Stethoscope Module Low Frequency (About 30KHz) ABCD Method Inspection Technique Comparison Analysis in Software If it is a critical equipment we can consider having an online ultrasonic sensor for instant monitoring.

15 Data Comparison and Diagnosis A= White; B= Green; C= Blue; D= Red

Data Comparison and Diagnosis Spectral analysis can help us making a correct diagnosis of valve operation, visual comparison is an easy way of understanding

16 Data Comparison and Diagnosis Spectral analysis can help us making a correct diagnosis of valve operation, visual comparison is an easy way of understanding what's going on inside the valve. In this images we can see a direct comparison of a leaking valve and one that is working well, under the same operation conditions.

Study Case Federal Commission of Electricity Combined Cycle Central Gomez Palacio, Durango, Mexico Design Plant Data Generation Capacity 86 Mw Benefits Heat

17 Study Case Federal Commission of Electricity Combined Cycle Central Gomez Palacio, Durango, Mexico Design Plant Data Generation Capacity 86 Mw Benefits Heat Rate reduction of 115 Btu/Kw-h by EPRI quantification methods. Quantified Leaks in valves for 30,500 Lbs/Hr of Superheated steam. $2,012,000 USD Annual Savings

18 Study Case Federal Commission of Electricity Combined Cycle Central Tula, Hidalgo, Mexico Design Plant Data Generation Capacity of 200 Mw Benefits Quantified Leaks on valves for 42,750 Lbs/Hr of Superheated Steam. $3,219,200 USD Annual Savings

Steam Trap Ultrasonic Inspection Operationally talking, steam traps are not as respected as valves or other equipment, but they represent big impact on efficiency an

19 Steam Trap Ultrasonic Inspection Operationally talking, steam traps are not as respected as valves or other equipment, but they represent big impact on efficiency an energy savings. In average, a single steam trap can lose more than 50 Tons of Steam a year. Ultrasound permits us having a condition and operative analysis of each one.

20 Inspection Technique UP10000 in Steam Application Stethoscope Module Low Frequency (About 30KHz) Steam trap discharge analysis Analysis in Software Cycles, Leak levels, blockage, blowing, or other failure mode.

21 Data Comparison and Diagnosis Correct Cycle Leaking Cycle Chattering Blowing Condensate Blockage

22 Thermodynamic Trap Degradation Process 1. Good 2. 1 st Stage Leak Failure 3. 2 nd Stage Leak Failure 4. 3 rd Stage Leak Failure 5. 4 th Stage Leak Failure 6. 5 th Stage Leak Failure 7. Chattering 8. Blocked

23 Study Case Cantarell Nitrogen Plant, Del Carmen City, Campeche, Mexico Engineering study by ultrasonic inspection in 20 traps. Losses for $35,000 USD The total population of steam traps is 100. The expected economic benefits exceeds the $175,000 USD Annual. High pressure system.

Study Case Polyester Plant AKRA, Monterrey, Nuevo Leon, Mexico Energy audit in steam systems based on ultrasound. 30 traps inspected. Losses for $60,000 USD.

24 Study Case Polyester Plant AKRA, Monterrey, Nuevo Leon, Mexico Energy audit in steam systems based on ultrasound. 30 traps inspected. Losses for $60,000 USD. Steam trap population of 200. Expected economic benefits exceeds $400,000 USD annual. Quality of the products will boost, direct contact with steam, steam conditioning very important.

When it fails, ultrasound is the quickest way for finding the leaking

25 Heat Interchangers and Condensers Critical failures that lead to unexpected downtime. External online monitoring with ultrasound. When it fails, ultrasound is the quickest way for finding the leaking tubes. Think about a 100 Mw Power Plant. 1 day outage = About $120,000 USD lose daily.

Flanges Connections Orifices Steam Mains degradation They represent a complete

26 Ultrasonic Inspection of Exterior Leaks Leak search in different places and equipment of the distribution system. Flanges Connections Orifices Steam Mains degradation They represent a complete opportunity area for energy conservation. Alone they may no represent a lot, but if you add each one, now we have good money.

27 Conceptual Analysis of Betterment Plans Design Energy Consumption Steam System Analysis Integral Application of Solutions Optimization Turn Key Solution Goals Establishment

28 Conclusions Energy conservation plays a very important role in sustaining world class industry. Steam system is an opportunity area with immediate benefits after upgrades implementation. Ultrasound is a fundamental tool for making a trustful diagnosis of the condition of our system's components. World class technology as ultrasound leads to world class industry.

29 Success in every company requires efficient use of the consumed energy in their processes. That's why energy conservation is a motivational boost for making continuous upgrade projects until we become the best of the best.

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