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  • Keep an Eye on Your Steam Traps - Automatically

    Although steam traps fail every day, a comprehensive steam trap management program at most facilities doesn't exist. Even the best programs only inspect them once a year or every other year, resulting in high rates of lost energy. At Campbell-Sevey, we recommend a proactive approach to monitoring steam traps using Armstrong’s SteamEye®. With SteamEye you know instantly when a steam trap fails, allowing you to immediately correct it.

    SteamEye keeps an eye on your steam traps 24 hours a day, every day, allowing you to reduce labor and energy costs by detecting leaks automatically.

    How SteamEye Works

    SteamEye uses a radio frequency (RF) wireless transmitter mounted at each steam trap to detect their operating state. That operating state is then transmitted wirelessly to a central receiver that can then alert system operators of trap failure.

    SteamEye technology is on 24/7 — constantly reporting the status of your steam traps for optimum energy system management and savings. It can be installed on high pressure traps in service without shutting off the steam, and its remote, wireless operation addresses the labor costs and safety issues associated with manual monitoring.

    Range of the RF Signal

    In outdoor installations where the transmitter is within the line of sight of the receiver, the typical range is 1,200 feet. In facilities where the signal must travel through walls or floors, the range varies. Typically, the signal range is approximately 300 feet. If the receiver is out of the range of a transmitter, repeaters can be placed between the transmitter and receiver to “repeat” the signal from transmitter to receiver.

    Eliminate Steam Trap Monitoring Problems

    Armstrong's SteamEye, together with their Sage energy management application, help eliminate traditional trap monitoring and management problems and dramatically improve your system efficiency. 

    Contact Campbell-Sevey for a Steam Trap Survey and to learn more about Steam Trap Monitoring Programs.

  • Improve Heat Exchanger Efficiency with Mixers and Turbulators


    In many conventionally designed heat exchangers, efficiency is limited due to a small temperature difference at the heat exchange surface. For instance, in a shell and tube exchanger, liquid usually flows through the tube. The outer layer of liquid has greater exposure to the walls of the tubing, therefore it experiences higher heat transfer than liquid in the core and can form a barrier, sharply inhibiting thermal exchange. This can happen for a variety of reasons, but low velocity is the most common one.

    To maximize efficiency in these applications, one option Campbell-Sevey can recommend is the use of static mixers or turbulators within heat exchangers.

    Static Mixers

    A static mixer consists of a rod with mixer elements, such as half-circle discs, to agitate the fluid. The flow of liquid is directed radially toward the pipe walls and back to the element, regardless of velocity. As a result, fluids are completely mixed to eliminate differences in temperature and improve thermal transfer.

    One notable element to consider when adding static mixers is that pressure drop will be higher. The team at Campbell-Sevey can help you determine how that may affect your system based on your process.

    Twisted Tape Turbulators

    Twisted tape turbulators are a cost effective way to enhance the heat transfer in the tubes for some of these applications as well. Unlike a static mixer, twisted tape turbulators are thin, flat metal sheets in a helical shape. They are inserted into the tubes and break up the laminar flow of fluids, enhancing heat transfer efficiency.

    The larger the temperature difference is at the heat exchange surface, the more efficient the heat exchanger is, and the smaller the heat exchanger can be, reducing capital cost. Additionally, whether you use static mixers or twisted tape turbulators, both can help extend equipment life by eliminating hot and cool spots that can cause thermal stress.

    For more information on improving your system and heat exchanger efficiency, contact the team at Campbell-Sevey.

  • Test Your Knowledge: What Are the Effects of Air Trapped in a Coil?

    In a typical Air Heating Coil piping configuration, traps are used to handle condensate and air. What are the effects of air in a coil?

    1. Excess Steam Pressure
    2. Cold Spots
    3. Thermal Vacuum
    4. Water Hammer
    5. Elevated Condensate

    The answer is...


    Cold Spots AND Water Hammer

    Cold spots are formed when pockets are air are trapped in the coil, creating a decrease in heating efficiency. 


    Air can also trap pockets of condensate that move through the coil as "slugs", causing water hammer. 


    To remove air, Thermostatic Air Vents are typically installed on the coil outlet. 


    Float and Thermostatic Traps are also used on the coil discharge. F&T traps are always the first choice for modulating variable pressure coils. 

    For information on how to improve steam system efficiency, contact the team at Campbell-Sevey or attend our Steam Energy Conservation Seminar.

  • CS Insight: Campbell-Sevey Goes Curling


    For fun at Campbell-Sevey, we regularly do team-building events for our staff. This spring we decided to do something unique. 

    Since not everyone golfs or skates well enough to play hockey, and bowling had already been done, we instead headed to the Minnesota Curling Center in Chaska, MN for a few hours of curling. 

    Curling is one of the fastest growing sports in the Midwest. Everyone at Campbell-Sevey had heard of it, watched it, or knew someone who had done it, but few had tried it themselves. Turns out, it's harder than it looks and it's way more fun doing it than just watching it. 

    After some practice sliding the stones and laughing at each other, we set up teams and did a little round robin tournament. While some did better than others, everyone had a blast!

    Of course, afterward we all headed to the Crooked Pint at the curling club for a bit of bragging and a lot more laughs. It was a great time, a learning experience, and a fun way to connect as a team. 


  • Steam Tip 12: Flash High-Pressure Condensate to Regenerate Low-Pressure Steam

    Low-pressure process steam requirements are usually met by throttling high-pressure steam, but a portion of the process requirements can be achieved at low cost by flashing high-pressure condensate. Flashing is particularly attractive when it is not economically feasible to return the high-pressure condensate to the boiler. In the table below, the quantity of steam obtained per pound of condensate flashed is given as a function of both condensate and steam pressures. 

    Example 

    In a plant where the cost of steam is $8.00 per million Btu ($8.00/MMBtu), saturated steam at 150 pounds per-square-inch-gauge (psig) is generated, and a portion of it throttled to supply 30-psig steam. Assuming continuous operation, determine the annual energy savings of producing low-pressure steam by flashing 5,000 pounds per hour (lb/hr) of 150-psig condensate. The average temperature of the boiler makeup water is 70°F. 

    From the table above, when 150-psig condensate is flashed at 30 psig, 10.3% of the condensate vaporizes. 

    • Low-Pressure Steam Produced = 5,000 lb/hr x 0.103 or 515 lb/hr

    From the ASME Steam Tables, the enthalpy values are: 

    • For 30-psig saturated steam = 1,171.9 Btu/lb
    • For 70ºF makeup water = 38.0 Btu/lb

     Annual Savings are obtained as follows:

    • 515 lb/hr x (1,171.9–38.0) Btu/lb
    • x 8,760 hr/yr 
    • x $8.00/MMBtu]/10Btu/MMBtu 
    • = $40,924 

    Proximity Is a Plus 

    The source of high-pressure condensate should be relatively close to the low-pressure steam usage to minimize piping and insulation costs. 

    Match Availability and Use 

    The economics of heat recovery projects are most favorable when the waste steam heat content is high and the flow is continuous. Seasonal space heating is not the most desirable end use. 

    For resources and suggested actions download the complete Steam Tip sheet from the U.S. Department of Energy

  • Featured Product: Armstrong 1500 Series Control Valve

    Control valves are a key component in any pressure or temperature control application. With the increasing cost of fuel, delivering media in the most efficient way increases productivity by delivering the required pressure or temperature while avoiding excessive consumption. Precision control also provides repeatability and safety for any process.

    Armstrong's Python 1500 Series Control Valves are globe-style two-way single-seated valves that are ideally suited to deliver accurate and efficient control of most steam and liquid applications that are found in a variety of manufacturing and institutional environments. Made of carbon steel, the body of the 1500 series has top entry trim and a bolted bonnet for easy access to all internal parts for in-line inspection, maintenance, and trim replacement. 

    The 1500 Series Also Offers:

    • Two pneumatic actuator sizes
    • Pneumatic actuators have been designed with six springs to allow lower hysteresis and higher performance
    • Pneumatic actuators tested to three million cycles
    • Reverse and direct acting actuators that are field reversible
    • Both PTFE chevron seals and graphoil packing
    • Teflon packing is live spring-loaded for long service life and less maintenance
    • Parabolic equal percentage trims for accurate control
    • Additional trims such as perforated unbalanced, multi-hole balanced, soft seats for class VI shut off, and micro trims are available.
    • Metal to metal seats and plugs rated for Class IV shut off
    • 17-4 PH h900 plugs for long service
    • 50:1 turn down
    • Electric actuators
    • On/Off and modulating characteristics

     For insight into what type of control valve is best suited to your application, contact the team at Campbell-Sevey

     

  • Test Your Knowledge: How much more efficient is steam compared to hot air?

    Air, water and steam are three media commonly used to distribute heat to process loads. However, steam has several advantages compared to hot air and hot water. These advantages include.

    • the heat carrying capacity of steam is much greater than air or water
    • steam provides its own locomotive force.
    • steam provides heat at a constant temperature

    How much more efficient is steam compared to hot air? If 100 psig steam were condensed in a heat exchanger, the mass flow rate of steam required to transfer 1,000,000Btu/hr of heat would be about 1,135 lb/hr. 

    If the temperature of hot air dropped by 100 F as it passed through a heat exchanger, the mass flow rate of air to transfer the same amount of heat with the same temperature difference would be about ________?

    1. 4,800 lb/hr
    2. 10,000 lb/hr
    3. 23,200 lb/hr
    4. 38,500 lb/hr

    And the answer is...

    38,500 lb/hr or about 34 times as much as steam. Here are the calculations to see for yourself: 

    • Msteam = Q / hfg = 1,000,000 Btu/hr / 881 Btu/lb = 1,135 lb/hr
    • Mwater = Q / (cp x dt) = 1,000,000 Btu/hr / (1 Btu/lb-F x 100 F) = 10,000 lb/hr
    • Mair = Q / (cp x dt) = 1,000,000 Btu/hr / (0.26 Btu/lb-F x 100 F) = 38,500 lb/hr

    The higher flow rates required by water and air require pipes and ducts with larger diameters than steam pipes, which increases first cost and heat loss. In addition, air and water do not propel themselves. Thus, hot air and water distribution systems require fans or pumps, whereas a steam distribution system does not require any additional propulsion for outgoing steam and a very small pumping system for returning the condensate to the boiler. 

    Finally, because steam condenses at a constant temperature, 100-psig steam could heat a process stream to a maximum temperature of 338 F which is the temperature of the steam. On the other hand, the temperature of water and air decrease as heat is transferred; thus, if the heat in these examples was delivered by a cross-flow heat exchanger, the maximum temperature of the process stream would be 100 F less than the incoming temperature of the air or water. 

    Because of these advantages, steam is the most widely used heat-carrying medium in the world.


  • The Value of a Great Partnership? In This Case Over $35,000

    Recently Campbell-Sevey joined CenterPoint Energy in handing a $35,061 rebate check to one of our valued customers for the energy saving projects they've invested in recently. They documented a remarkable energy efficiency cost savings of 9%! Plus, the projects created a safer, longer lasting system. Here is a brief overview of the recent projects.

    The facility is used for primary research and development and comprises over half of a million square feet of space. The original facility was built in 1958, with multiple additions constructed over the years. These latest two energy-saving projects involved performing a steam trap survey with follow-up steam trap replacements of failed traps. An insulation survey of the steam piping was then performed and custom removable, reusable insulation blankets were installed on the valves, steam traps, and strainers throughout the facility. Typically, this is equipment that remains uninsulated for the life of a building. One small mechanical room experienced a significant 10 degree drop in temperature. This is a room that was historically quite warm and is now comfortable in which to work.

    Campbell-Sevey has had a long relationship with the customer to ensure the facility operates at peak efficiency. With our superior knowledge of steam, air and water systems we can find the right products and solutions to fit their specific requirements. Here is a list of many of the products Campbell-Sevey has provided to the site:

    • Steam Generation
      • Water-tube boiler
      • Tray-type deaerator
      • Surge tank
      • Stack heat recovery economizer with rebate
      • Stack
      • Direct-fired make-up air heater
    • Distribution
      • Insulation with rebate
      • Multiple steam trap surveys with rebates
      • Steam traps and rebates
      • Steam trap valve stations with rebates
      • Wireless safety valve monitors
      • Wireless steam trap/safety valve monitoring system
      • Strainers
      • Steam filters
      • Safety and relief valves
      • Check valves
      • Actuated ball valves
      • Separators
      • Steam pressure regulators
      • Control valves
      • Piston-style steam shut-off valves
    • Utilization
      • Water heater skids
      • Shell and tube heat exchangers
    • Condensate Return
      • Flash tanks
      • Condensate return pump skids

    The value of partnerships with energy system experts like Campbell-Sevey is in having a partner you trust provide you the best products at the best value so you reap the highest returns on your investment through peak efficiency. That is exactly what this customer has done. And with partners like Campbell-Sevey and CenterPoint Energy, they'll reap those returns for decades to come.

    Contact the team at Campbell-Sevey to learn how we can best serve your needs and maximize your energy savings. 

     

  • Steam Tip 11: Use Vapor Recompression to Recover Low-Pressure Waste Steam

    Low-pressure steam exhaust from industrial operations such as evaporators or cookers is usually vented to the atmosphere or condensed in a cooling tower. Simultaneously, other plant operations may require intermediate-pressure steam at 20 to 50 pounds per square inch gauge (psig). Instead of letting down high-pressure steam across a throttling valve to meet these needs, low-pressure waste steam can be mechanically compressed or boosted to a higher pressure so that it can be reused. 

    Vapor recompression relies upon a mechanical compressor or steam jet ejector to increase the temperature of the latent heat in steam to render it usable for process duties. Recompression typically requires only 5% to 10% of the energy required to raise an equivalent amount of steam in a boiler. 

    Example 

    Consider a petrochemical plant that vents 15-psig steam to the atmosphere. At the same time, a process imposes a continuous requirement on the boiler for 5,000 pounds per hour (lb/hr) of 40-pounds-per-square-inch-gauge (psig) steam. If 15-psig waste steam is recompressed to 40 psig by an electrically driven compressor, the compression ratio is: 

    • Compression Ration = [(40 + 14.7)/(15 + 14.7)] = 1.84

    Interpolating from the table above, the compressor requires 63.5 Btu/lb of delivered steam. Assuming that electricity is priced at $0.06/kWh, the annual cost of driving the compressor is: 

    • Compression Operating Cost = [63.5 Btu/lb x 5,000 lb/hr x 8,760 hr/yr x $0.06/kWh]/ 3,413 Btu/kWh = $48,895

     If an equivalent quantity of 40-psig steam (enthalpy for saturated steam is 1,176 Btu/lb) were to be supplied by an 80% efficient natural-gas-fired boiler, the steam production costs with fuel priced at $8.00 per million Btu ($8.00/MMBtu) and 70°F feedwater (enthalpy is 38 Btu/lb) are: 

    • Steam Production Costs = [5,000 lb/yr x (1,176 – 38) Btu/lb x 8,760 hr/yr x $8.00/MMBtu]/(0.80 x 10Btu/MMBtu) = $498,444 
    • Annual Vapor Recompression Cost Savings: $498,444 - $48,895 = $449,549 

    Conduct a Pinch Analysis 

    Based on the actual application, there may be other options to vapor recompression. The industry best practice is to conduct a pinch analysis on the steam system to reveal cost-effective alternatives and optimize steam use by eliminating inefficiencies. 

    Contact Campbell-Sevey

    For more information on how Vapor Recompression and other ways to recover steam loss, contact the team at Campbell-Sevey.

    Adapted from an Energy TIPS fact sheet that was originally published by the Industrial Energy Extension Service of Georgia Tech. Click to download the complete tip sheet along with suggested actions and resources. 

  • Campbell-Sevey Videos Reach 50,000 Views

    If you haven't seen our library of industry-related demonstration videos in our Knowledge Center yet, you are missing out on a valuable resource. The library contains nearly 40 videos that recently reached over 50,000 views including videos on:

    • Coils
    • Condensing Heat Recovery
    • Expansion Joints
    • Humidifiers
    • Pressure Reducing Valves
    • Shell and Tube Exchangers
    • Steam Traps
    • and more!

    Here are a few titles to check out:

    • Float and Thermostatic Steam Trap
    • The Proper Use of a Vacuum Breaker in a Steam System
    • Steam Distribution Coil
    • Condensing Heat Recovery System
    • How Expansion Joints Work
    • Shell and Tube Heat Exchanger

    Click to see the our complete library of videos. If you have suggestion for a product you'd like to see demonstrated on a video, let us know. 




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Products We Carry

GENERATION
  • Hot Water Boilers
  • Watertube Steam Boilers
  • Firetube Steam Boilers
  • Deaerators
  • Heat Recovery Steam Generators (HRSG’s)
  • Automatic Recirculation Valves
  • Economizers
  • Gas-Fired Water Heaters
  • Gas-Fired Humidifiers
  • Boiler/Generator Flue Stacks
  • Continuous Emissions Monitors (CEMS)
DISTRIBUTION
  • Pressure Reducing Valves
  • Safety and Relief Valves
  • Control Valves
  • Pressure Independent Control Valves
  • Expansion Joints, Guides, Anchors
  • Flash Tanks
  • Flow Meters
  • Balancing Valves
  • Check Valves
  • Separators
  • Pumps
  • Pressure Booster Systems
  • Piston Valves
UTILIZATION
  • Heating/Cooling Coils
  • Plate and Frame Heat Exchangers
  • Shell and Tube Exchangers
  • Water Heaters
  • Steam Humidifiers
  • Vacuum Systems
  • Condensers
  • Steam Traps
  • Wireless Steam Trap Monitors
  • Tube Bundles
  • Direct Gas-Fired Space Heaters
  • Direct Gas-Fired Make-Up Air Units
  • Unit Heaters
  • Strainers
  • Air Vents
  • Liquid Drainers
  • Heat Transfer Packages
  • Digital Water Mixing Valves
  • Air Cooled Condensers/Dry Coolers
  • Steam Filters
RETURN
  • Electric Condensate Pumps
  • Steam/Air-Powered Condensate Pumps
  • Packaged Condensate Pump Skids