Tereos in Spain trusts KLINGER for energy audits, saving CO2 emissions and 4-5% on annual expenditures with twice-yearly steam trap audits
Energy efficiency in fluid control offers great potential: Tereos in Spain trusts KLINGER’s team of specialists to find expensive steam leaks.
While installing KLINGER valves and gaskets is an important first step towards creating a leaner, greener fluid control business, savvy customers don’t stop there. Expert energy audits by veteran KLINGER representatives generate a multitude of data, providing customers with increased energy efficiency and decreased CO2 emissions, in addition to reduced water and fuel consumption. Suggested improvements help customers allocate resources in the most efficient manner, spot potential problems before they start, and design a system that will operate at peak parameters.
Contacts mentioned in the article:
Ivan Gadea, Regional Sales Director at KLINGER Spain
Javier Torres, Technical Sales for KLINGER in Zaragoza
Ivan Gadea, Regional Sales Director for KLINGER Spain, began a steam development strategy 6 years ago in order to improve KLINGER’s offerings to energy audit customers. With his 17 years of experience in the field, Ivan was uniquely positioned to combine his field experience with his work in sales management in order to design a flexible package of training, testing, and product promotion that is readily customized to each plant’s needs.
„Equipment that is not designed or calculated correctly automatically means a waste of energy. Every waste of energy means a loss of competitiveness.“
Ivan Gadea, Regional Sales Director at KLINGER Spain
Steam traps mean loss of money
On average, the annual energy loss of a steam leak costs approximately 800 euros per trap, with around 30% of the average system’s traps experiencing leaks at any given time. With a standard mid-sized chemical plant featuring 600 steam traps, this amounts to an annual loss of 144,000 euros. Such a needless increase in operating expenses can be mitigated through a KLINGER energy audit.
The most popular KLINGER energy audit service is a twice-yearly steam trap energy audit, which was the option chosen by food, chemical and paper conglomerate Tereos for their Zaragoza plant in Spain. Tereos got in touch with KLINGER’s regional sales manager, who referred them to Ivan for a discussion about their facility’s particular audit needs. The team conferred and eventually agreed upon an eight-point audit, which scrutinized everything from system design and installation to product sizes and materials.
Fact box
8 point plan for the energy audit
1. Correct design and sizing of the steam and condensate line
2. Determine whether there is a recovery line for uncontaminated condensates
3. Check steam leaks inside the line and outside
4. S.T.E.A. (Steam Trap Energy Audit) inspection of steam traps by means of an ultrasonic system. Check the operation of the equipment and also if it is the correct size and model, if the assembly is well done.
5. Visual inspection of the air elimination equipment of the steam installation
6. Correct lagging of lines and pipe elements
7. Possibility of flash steam recovery in low pressure equipment through flash steam tanks
8. Use of steam at the correct pressure (review of reducing stations)
How to save energy costs
The team started with a visual assessment of the steam and condensate line for product choice and line size, also verifying that the system contained a recovery line for uncontaminated condensates. The inside and outline of the lines were checked for steam leaks, and all steam traps were inspected ultrasonically. This specialized tool system checks the operation of all of the equipment, as well as ensuring that the size, model, and installation are chosen and completed properly for the system needs. Further inspection examined the air elimination equipment, as well as the lines and pipe elements for correct lagging. Flash steam tanks and reducing stations were also reviewed for proper installation and material condition.
Ivan discusses audit findings with Tereos staff
Alejandro Escribano has been Mechanical Maintenance Manager at Tereos for 15 years and oversaw the KLINGER audit to analyze and improve the Tereos facility. Not only does the audit provide valuable feedback for the plant to improve operational cost and efficiency, but subcontracting the audit saves money even in itself.
„The devices used to check the leakage of the steam traps are very expensive. It costs less for Tereos to call KLINGER for service once or twice per year.“
Alejandro Escribano, Mechanical Maintenance Manager at Tereos
Bundling the use of these highly specialized tools with KLINGER professional advice creates more value for Tereos than would purchasing the devices on their own.
Ivan checks different points from the outside of the steam trap looking for steam leaks
Eliminating corrosion damage
A KLINGER audit also allows the customer to benefit from industry knowledge as a whole, giving KLINGER the opportunity to pay it forward by using past system difficulties as teachable moments. One common issue that KLINGER audits examine for is group trapping, a budget friendly system design choice that can end up costing more in the long run. When the condensate from multiple pieces of equipment is discharged through a single larger trap, the differences in load and outlet pressure can cause damage due to condensate accumulation, water hammer, corrosion damage, and uneven drainage. Each piece of equipment should be discharged through an individual steam trap and a corresponding check valve, in order to sustain individual operating pressure conditions.
Energy efficiency is a win-win
After thorough inspection and measurement of the system, Ivan and his team provided Tereos with a detailed audit report. This document walks the staff through the system step by step, pointing out devices that would benefit from updates or changes, and explaining the thought process behind each suggestion. Photographs and diagrams back up findings with clear data, providing measurements for each device. Specific devices are flagged for further inspection at a later date, allowing Tereos to build their own internal calendar for preventative maintenance in the future. As supply chain issues continue to plague the manufacturing industry, a clear schedule for product replacement is essential in order to ensure that product stock is available for repair or replacement.
Ivan together with Javier Torres, the Technical Sales from KLINGER in Zaragoza, discussing problems in the steam lines.
By following through on the KLINGER audit suggestions, Tereos will be able to realize a future savings of approximately 4 to 5% on the Zaragoza plant’s annual expenditures, while also running a cleaner, more efficient operation. Though the cost savings will certainly be a benefit to Tereos, the improvement to energy efficiency is a win for everyone, as greener manufacturing practices help us all to build a better future.
Fact box
Did you know …
… that KLINGER Spain has been a leading company in Fluid Control (valves, accessories and sealing technologies) since 1970?
... that Maintenance Repair Operations (MRO) for industrial plants are one of the core business operations of KLINGER Spain?
... that KLINGER Spain’s facilities in Valencia include a LogisticsCenter and a complete Service Center, which provides a wide variety of added services such as a ValveAutomation Center, Valve Repair and AssemblyCenter, KLINGER GasketManufacturing Center and a Technical Office?
What is the steam audit process? KLINGER will meet with your team to discuss the current state of your system and any problems or concerns you may have. After inspection and measurements, KLINGER will analyze the results and compare them to appropriate metrics and historical data. If necessary, KLINGER will recommend alterations or upgrades to improve system efficiency and integrity.
What problems can a steam audit solve? One common problem in steam systems is roughing, or reddish-brown iron deposits that grow on the heat-transfer surfaces of columns, vessels, and piping. A steam audit can identify these areas, determine the extent of the corrosion, and suggest corrective actions to reduce or remove the corrosion.
How do teams stay current on steam technology? KLINGER provides seminars and training courses to keep your team up to date with the latest steam system research and development. These events may take place at one of KLINGER’s fully equipped learning centers or on your own work site.
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