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Reliability Improvement Programs in Steam Distribution and Power Generation Systems
Abstract
This paper will present alternatives to costly corrective
maintenance of the steam trap and condensate return system,
and the paybacks associated with instituting a program
of planned maintenance management of that system.
Energy costs can be reduced by 10% and maintenance costs
by 20%, while achieving other tangible improvements in
the reliability and efficiency of the system.
Recent studies have shown that more than 40% of all installed
steam traps and 20% of certain types of valves need
some form of corrective action. The majority of all high
backpressure problems in condensate return systems are
due to poor design criteria. in expandlng or retrofitting
existing return systems. By instituting a maintenance
management program, a 95% reliability can be gained
within two to four annual maintenance cycles. The associated
operational problems can be greatly reduced.
The maintenance management concept involves: 1) centralized
project management; 2) diagnostic and inspection
expertise; 3) system troubleshooting; 4) data analysis, reporting
and recommendations; 5) maintenance repairs and
follow-up; and 6) software and data base management.
Several case studies, in which the concept has been successfully
applied, will be presented.
Energy costs, which have been on the rise for the past ten
years, have now leveled off due to global supply and demand
issues. But that is not true of the costs to maintain
capital equipment such as steam distribution and power
generation systems. Those costs continue to rise.
If the basic principles of maintenance management are
applied, when upgrading poorly maintained steam systems,
those upgraded systems can be a fast payback of savings
in energy, manpower and inventory. Three major areas
where the savings can be gained are the steam traps,
valve and condensate return systems. Such systems can
be found in power generation, steam distribution, and in
all types of durable and non-durable industrial productions.
Collections
Citation
Petto, S. (1987). Reliability Improvement Programs in Steam Distribution and Power Generation Systems. Energy Systems Laboratory (http://esl.eslwin.tamu.edu). Available electronically from https : / /hdl .handle .net /1969 .1 /92841.