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Steam Boiler Economiser
Valveforce are proud to offer steam boiler economisers designed to enhance the efficiency and performance of your steam systems.
With our extensive expertise and cutting-edge technology, we are dedicated to providing innovative solutions that not only save energy but also reduce costs and environmental impact. Whether you are seeking to optimize your existing steam boiler or looking for a complete system overhaul, Valveforce is here to deliver reliable and sustainable solutions tailored to your specific needs.
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Steam Boiler Economiser Explained
Purpose
Having passed through a steam boiler, flue gases should not be considered as spent and simply vented off to atmosphere. Alternatively, the energy from these hot gases should be used to improve the thermal efficiency of the steam raising equipment itself, and recover significant energy.
To improve steam boiler efficiency, steam boiler economisers can be fitted between the boiler smoke box and chimney through which the hot flue gases are passed and boiler feedwater heated. This heat exchange process, via a boiler economiser, ensures that feedwater arrives at the boiler at a higher temperature, and it is estimated that a 10°C temperature increase of the boiler feedwater will improve boiler efficiency by approximately 2%.
So with flue gases typically venting at 230°C, an economiser will cool these to approximately 140°C which in turn will increase feedwater temperatures by 25°C. This therefore means a fuel consumption reduction of around 5% for the same boiler output which is a significant cost saving.
If you design or modify a steam boiler economiser, it will take less energy to raise the required volume of steam or generate more steam using the same amount of energy.
Why Install Steam Boiler Economisers?
Integrated Solution
Many steam boilers were designed when fuel costs were relatively cheap. However, with fuel costs rising faster than capital costs, boiler economisers should be considered for many new and existing boiler installations.
A steam boiler economiser is often considered as additional plant for steam raising systems. However, an economiser should be considered an integral part of a complex steam solution and therefore be designed as such.
Benefits
The benefits of specifying and installing steam boiler economisers are clear:
- Reduced emissions
- Improved fuel economy
- Enhanced boiler efficiency
- Lower thermal stress of the boiler shell
- Promotes improved internal circulation
- Capital outlay usually recovered in less than 12 months
Steam Boiler Economiser Services
Specification & Design
Valveforce steam boiler economiser solutions are designed to conform to the Pressure Equipment Directive (PED), BS EN 12952 and are UKCA and/or CE marked accordingly.
To ensure the most economical design, boiler economisers are manufactured from carbon steel, with highly-durable extended fins welded to the economiser single tube design, which ensures feedwater flows uniformly through the element to eliminate hotspots, sludge build-up and scaling.
Additionally, Valveforce can reverse engineer boiler economisers so replacements can be fabricated on a like-for-like basis. This ensures modifications to steam boiler plant and on-site works are minimised and the project delivered as effortlessly and affordably as possible
Looking for a new or replacement steam boiler economiser, contact Valveforce now to discuss your requirements on 0121 711 1908 or contact us via our enquiry form.
Advanced Material Selection for Durability
Understanding the importance of operating conditions, Valveforce selects materials for your economiser that offer high corrosion resistance and thermal conductivity, ensuring long-term durability and performance under varying temperature and pressure conditions.
Efficient Design for Maximum Heat Recovery
Our economiser designs focus on maximising heat recovery without significantly increasing backpressure, ensuring the efficiency gains justify your investment. Valveforce's approach balances operational costs with substantial efficiency improvements.
A 10°c increase in feedwater temperature will give you an efficicency improvement of 2%.
Installation & Commissioning
Seamless Compatibility with Boiler Systems
Valveforce ensures your economiser is perfectly compatible with your existing boiler system, optimising capacity, design pressure, and temperature. Our experts meticulously assess flue gas volume and characteristics to guarantee a match that enhances your system's efficiency.
Strategic Installation for Optimal Performance
Valveforce installs your economiser in the prime location to capture the hottest flue gases, ensuring easy access for maintenance and accommodating future expansions. Our strategic placement enhances heat recovery and ensures maintenance efficiency.
Comprehensive Water Treatment Program
To combat scaling and corrosion, Valveforce implements rigorous water treatment programs. Our water treatment services safeguard your economiser's integrity and efficiency.
Design Considerations for Thermal Expansion
Valveforce accommodates thermal expansion through careful economiser design and installation, using proper supports and expansion joints to prevent stress and damage, ensuring a seamless integration with your boiler system.
Overhaul & Repair
Corrosion
Corrosion is a formidable enemy to economisers, compromising tube integrity and system reliability. Valveforce employs advanced techniques to combat corrosion, extending the life of your economiser through protective coatings and material upgrades designed to withstand harsh conditions.
Scaling
Accumulated mineral deposits can choke your economiser's efficiency. Our service includes meticulous cleaning and maintenance protocols to remove scaling, restoring optimal heat transfer and preventing overheating risks.
Fouling
Soot and particulate matter can cloud your system's efficiency. Valveforce's cleaning solutions ensure your economiser surfaces are pristine, enhancing heat transfer and reducing unnecessary fuel consumption.
Thermal Stress
Valveforce's experts are adept at diagnosing and rectifying issues caused by thermal stress, implementing measures to mitigate rapid temperature fluctuations and ensure the longevity of your economiser tubes.
Flow Imbalance
Our comprehensive assessments identify and correct flow imbalances, ensuring even distribution of flue gases and water to prevent localised overheating and wear, safeguarding against premature failures.
Leakage
Leakages are more than just a nuisance; they're a threat to efficiency and system health. Valveforce promptly addresses leaks, employing state-of-the-art techniques to seal and secure your economiser, maintaining system integrity and performance.
Material Failure
High temperatures and pressures demand much from economiser materials. Valveforce's maintenance service includes thorough inspections and replacements using superior materials that resist fatigue and withstand extreme conditions, ensuring durability and reliability.
Control System Malfunction
Issues with control systems wouldn't lead to damage as they are simply measuring temperature on both sides. Valveforce's control system services including replacement parts where practical ensure your economiser operates flawlessly, with accurate sensors, responsive actuators, and reliable controllers for optimal performance and protection.
Maintenance & Service
Initial Assessment and Planning Site Survey
Site Survey: Conduct a site survey to assess the condition of the economizer and surrounding equipment. This includes checking access routes, scaffolding requirements, and safety hazards.
Scope Definition: Define the scope of the service, including the specific maintenance and overhaul activities required based on the economizer’s current condition.
Preparation of Tools and Materials: Ensure that all necessary tools, replacement parts, cleaning materials, and safety equipment are on hand.
Shutdown and Safety Precautions
System Shutdown: Safely shut down the boiler and economizer system according to standard operating procedures. Ensure all residual pressure is released, and the economizer is allowed to cool.
Isolation and Lockout/Tagout (LOTO): Isolate the economizer from the rest of the system. Implement LOTO procedures to prevent accidental re-energization.
Safety Briefing: Conduct a safety briefing with all personnel involved in the maintenance, emphasizing the importance of PPE, hazard identification, and emergency procedures.
Visual and Functional Inspection
External Inspection: Inspect the external surfaces of the economizer for signs of damage, corrosion, and wear. Look for leaks, cracks, and other physical defects.
Internal Inspection: Access the internals of the economizer, inspecting tubes, fins, headers, and other components for scaling, soot buildup, corrosion, and mechanical damage.
Operational Check: Review the performance data and logs for the economizer prior to shutdown to identify any performance issues like reduced heat transfer or increased pressure drop.
Cleaning
Soot Blowing: If the economizer is fitted with soot blowers, these should be operated before shutdown to remove loose soot from the surfaces.
Manual Cleaning: Manually clean the economizer tubes and fins to remove soot, ash, and scale deposits. Use appropriate tools such as brushes, scrapers, or high-pressure water jets.
Chemical Cleaning: If necessary, apply chemical cleaners to remove stubborn deposits. This process must be done carefully, following environmental and safety guidelines.
Component Inspection and Replacement
Tube Inspection and Replacement: Inspect the tubes for signs of pitting, corrosion, and wear. Replace tubes that are excessively damaged or have reached the end of their service life.
Header and Manifold Inspection: Check the headers and manifolds for corrosion, erosion, and thermal stress damage. Replace any compromised components.
Gaskets and Seals: Inspect and replace gaskets, seals, and any other components prone to wear and tear, ensuring that they are of the correct specification.
Valve and Control System Check: Inspect all control systems, including bypass valves and pressure relief valves. Replace or recalibrate as needed.
Pressure Testing
Hydrostatic Testing: Conduct a hydrostatic test to ensure the integrity of the economizer after reassembly. The test pressure should be higher than the normal operating pressure but within safe limits.
Leak Detection: During the hydrostatic test, carefully inspect all welds, joints, and tubes for leaks or any signs of pressure loss.
Reassembly
Careful Reassembly: Reassemble the economizer components, ensuring that all parts are correctly aligned and secured. Pay special attention to sealing surfaces and gasket placements.
Torque Specifications: Tighten bolts and fasteners to the manufacturer’s recommended torque settings to avoid issues during operation.
Final Inspection and Functional Testing
Final Visual Inspection: Perform a thorough final visual inspection to ensure everything is properly reassembled and that no tools or materials are left inside the economizer.
Functional Testing: Gradually bring the economizer back online and perform functional tests, monitoring key parameters such as temperature differentials, pressure drops, and flow rates.
Performance Verification: Compare the current performance data with historical data to ensure that the economizer is operating at optimal efficiency.
Documentation and Reporting
Service Report: Prepare a detailed service report outlining all maintenance and overhaul activities performed. Include findings from inspections, parts replaced, test results, and any recommendations for future maintenance.
Record Keeping: Ensure that all documentation is stored securely for future reference and that the service log for the economizer is updated.
Recommissioning
System Integration: Once the economizer has passed all tests and inspections, integrate it back into the steam system. Gradually increase the load to ensure stability.
Monitoring: Closely monitor the economizer during the initial hours of operation post-overhaul, watching for any signs of leaks, abnormal noises, or performance issues.
Post-Service Support
Training: Provide training to the maintenance team on the updated operational procedures and any new components installed during the overhaul.
Scheduled Follow-Up: Schedule a follow-up inspection after a specified period to ensure the economizer is functioning correctly and to address any potential issues.
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