The Steamgard System® is used in various institutions around the globe.
Its benefits -- reduced energy consumption, lowered operational costs, improved productivity, enhanced safety and decades of virtually maintenance-free operation -- are especially attractive to organizations pursuing Green Initiatives and seeking long-term economic gains. Discover more about our diverse clientele.

CaseStudy-RockyFlats

THE STEAMGARD SYSTEM® technology was key to eliminating dangerous water hammer conditions at The Rocky Flats Environmental Technology Site (RFETS), an environmental cleanup site located about 15 miles northwest of downtown Denver. Recently, declassified documents relating to a series of water hammer problems that occurred in the 1990s, which resulted in injuries and a death within the federal nuclear facility, show that the STEAMGARD technology was a vital component in resolving the potentially (ongoing) hazardous situation. The report states, “They also determined the direct and root cause of these events was an equipment/material problem (defective or failed part) because valves and steam traps were not operating as designed.”

IMPROVEMENTS MADE

The facility engineers reviewed the problematic steam trap design and decided to replace the existing ‘bucket’ style steam traps with newer, more effective ‘venturi’ traps. The new steam trap is designed to drain condensate continuously and completely. These (SG) traps have no internal moving parts, which will greatly reduce trap maintenance. Hundreds of new (SG) traps were installed with a special 40-mesh stainless steel strainer insert to trap any particles or contaminants before they reach the drain nozzle. RFETS’s long- term issue with water hammer was immediately resolved after the facility’s full-conversion to THE STEAMGARD SYSTEM®. Additionally, the RFETS federal facility reported significant energy savings, reduced maintenance costs and dependable service with the Steamgard condensate removal devices.

CaseStudy-Pharnaceutical 

One of the top five global pharmaceutical companies asked Steamgard to identify thermal energy, water savings, and greenhouse gas (GHG) reduction opportunities in seven of their facilities in the United States. After detailed engineering analysis, Steamgard identified opportunities to significantly reduce their fuel bills for each site with combined make-up water savings of 11,379 K gal/yr. Additionally, their GHG footprint was reduced by 8,649 metric ton/yr.

SUMMARY OF SAVINGS


Facility

Number of Steam Traps Retrofitted

Total Annual
Energy Savings
(MMBtu/DekaTherm)

GHG Reduction
(metric ton)

Water Demand Reduction
(K gal)

East Coast
(4 Sites)

1,290

56,350

2,997

4,838

560

25,490

1,352

1,714

292

12,670

674

857

485

20,130

1,071

1,361

Midwest

560

29,220

1,554

1,672

Puerto Rico
(2 Sites)

223

13,310

706

731

74

5,545

295

206

Totals

3,484

162,715

8,649

11,379

IMPROVEMENTS MADE

  • One of the plants had severe corrosion related issues in their steam system. A review of the boiler water treatment was conducted and recommendations were made to modify the softening, de-alkalizing and amine treatment program.
  • SG additional projects were conducted in order to optimize the recovery and usage of the flash steam from the high pressure condensate.
  • Water hammer, which was being caused by the mixing of hot and colder condensate, the inadequate dripping of the primary steam supply headers and malfunctioning traps, was identified and corrected.
  • At several of the sites, a large amount of steam was being lost from safety valves downstream of pressure reducing valves (PRV). Root cause analyses were conducted and changes implemented in order to alleviate these losses. In most cases, this was primarily due to incorrectly sized PRV and the lack of complete condensate removal from the supply steam. The resulting wet steam was eroding the PRV seats and causing the valves to ‘hunt’.

1goshen hospital

Indiana University (IU) Health Goshen Hospital is a community leader committed to providing outstanding care in an innovative and dynamic environment. The Hospital operates a nationally recognized cancer center; maintains an award-winning ICU; and holds a staff of professionals consistently honored for their standard of excellence.

 

IMPROVEMENTS MADE

In 2008, IU Health Goshen Hospital replaced all its several hundred traditional steam traps with THE STEAMGARD SYSTEM®. With the successful implementation of THE STEAMGARD SYSTEM®, the re-occuring issues with malfunctioned steam traps have completely disappeared.

“We don’t have to go back to a traditional steam trap manufacturer… We have STEAMGARDs installed here, we know how simply and consistently they work, and we’re continuing relying on them in the new distribution system… Our very positive experience over the years is a result of the engineering expertise provided by STEAMGARD and the fact that THE STEAMGARD SYSTEM® is working flawlessly throughout our facility”- Vice President of Operations at IU Goshen Hospital.

 CaseStudy-Soybean

Working with a world-renowned Midwest soybean-processing mill, we established three objectives:

  • Optimize condensate flow
  • Maximize thermal efficiency
  • Eliminate losses through conventional steam traps

Before and after the project, plant operation was monitored to determine actual plant savings/process improvements. All project goals were achieved by reviewing and evaluating existing operating conditions and providing a turnkey project engineered to the facility’s specific needs.

IMPROVEMENTS MADE

All conventional steam traps were replaced with The Steamgard System®.
With overall steam consumption reduced by 9.9%, project payback was under 5½ months.

30% less BTUs consumed per pound of water evaporated.
30%
56% increase in thermal efficiency of steam coolers.
56%
80% lower extraction condensate return tank pressure.
80%

CaseStudy-Biodiesel

Recently, Steamgard has completely or partially retrofitted the condensate removal devices (steam traps) in over 35+ oilseed processing plants and worldwide refineries with the revolutionary Steamgard technology. Additional upgrades to the steam and condensate systems were also made in order to enhance efficiency and reliability of operations.

PROCESSING PLANTS / REFINERIES RETROFITTED

U.S.A 27
Brazil 4
China 3
Argentina 2
Mexico 1
Paraguay 1

IMPROVEMENTS MADE

  • The steam consumption was reduced, on average, by approximately 8% per bushel of oilseed feed (dependent upon the Plant’s configuration).
  • Many of the plants were utilizing high sparge steam (i.e., greater than 7 lb/bushel) to compensate for inefficiencies in the desolventizer toaster (DT) decks. This was leading to both excess moisture and a higher Btu usage for meal drying. Improvements in the efficiency of condensate removal from the DT decks resulted in a lower usage of sparge steam, a lower DT overhead (i.e., dome) temperature and a reduced energy for drying moisture.
  • The lack of proper air venting was resulting in a lower thermal efficiency on the rotary steam equipment. The air and non-condensable removal requirements for the major steam equipment [i.e., seed conditioner, meal dryer, 2nd stage rising film evaporator (RFE), etc.] were reviewed and air vents with an adequate capacity for the start up and normal run requirements were specified.
  • In plants utilizing a hot dehulling process, the removal of condensate was optimized from the vertical seed conditioner (VSC) decks.
  • The removal of condensate from the steam main supply headers from the boiler was reviewed and additional drip stations were installed in order to improve the quality of steam.
  • The operation of the deaerator (DA) tank was reviewed and recommendations were made in order to both ensure its proper operation and to optimize the use of oxygen scavenger in the boilers.
  • Opportunities for recovering low pressure steam from the high pressure condensate were reviewed and, where appropriate, flash tanks were recommended. The operation of the existing flash tanks was optimized to improve the quality of the low pressure steam.

CaseStudy-Marriott 

Atlanta’s premier destination – the Atlanta Marriott Marquis is home to 160,000 sq. ft of meeting space; 1,663 guest rooms and 94 suites; five restaurants and lounges, The Spa and fitness center, swimming pool and lobby.

IMPROVEMENTS MADE

An 11% energy consumption savings are directly attributed to the new STEAMGARD condensate removal devices.

The property replaced 187 steam traps throughout the building, which were designed to be an end of line after load devices and stop steam from passing through, but allow condensate to return to the boiler.

“Atlanta Marriott Marquis takes an assertive stand in protecting the environment with the implementation of additional high-tech energy saving management systems… The property replaced [their] steam traps [with]… new steam traps that have no moving parts, utilizing a venturi nozzle to separate the condensate from the steam. ”

 

Articles published:

Press-BusinessWire       Press-Bloomberg

Energy Consumption Reductions due to STEAMGARDs
11%

CaseStudy-Textile

Steamgard has helped improve efficiency and lower the rate of steam consumption for textile plants producing a wide array of products, from the lightest printed rayon to heavy denim and flannel.

Additionally, The Steamgard System®  is widely used in Carpet Mills, which produce heavier weight backing and end product, and in Bleacheries & Dye Plants that produce colored yarns for fabric.

IMPROVEMENTS MADE

Working with a world-renowned textile manufacturer, Steamgard developed and executed a condensate optimization project to achieve four goals:

  • Upgrade the quality of product by improving thermal efficiency
  • Reduce labor and material costs to service regular steam traps
  • Eliminate losses through conventional steam traps
  • Eliminate need for expensive spare inventory
Improved thermal efficiency and cut steam usage 37%.
37%

CaseStudy-PaperCompany

The Lawrence Paper Company based in Kansas, United States, has used Steamgard units with uninterrupted performance for the past 21 years.

IMPROVEMENTS MADE

  • Improved steam quality, which led to uniform surface temperature on the rolls (see IR pictures below).
  • Continuous and reliable condensate removal, which resulted in maximum hot plate temperatures under all machine operating conditions.
  • Higher quality products.
  • Reduced product rejections.
  • Even heat distribution plus higher, more uniform temperatures of the rollers enhance both the efficiency and product quality at the facility (left photo: with STEAMGARD condensate removal devices). Conversely, the low temperatures and uneven heat distribution reduce the efficiency of production equipment and increase the system’s steam consumption (right photo: with mechanical steam traps).

CaseStudy-PaperRollers

Energy consumption per ton of production reduced by 24% after conversion to STEAMGARD.
24%
Conversion to The STEAMGARD System® led to an increase of 40% on the single-wall production line.
40%

CaseStudy-Laundry

Working with a progressive commercial laundry operation, Steamgard helped the organization achieve three goals:

  • Upgrade flatwork finish quality
  • Increase productivity
  • Reduce fuel and maintenance expenses

When a mechanical steam trap failed unexpectedly, the only choice was to shutdown the line and wait for the equipment and the area to cool before it could be replaced. That’s no longer necessary, thanks to The Steamgard System.

Malfunctioning mechanical steam traps failed to remove condensate, which resulted in uneven heat distribution across the ironer rollers. To compensate, the rollers demanded excessive steam, but the temperature disparity resulted in poor flatwork finish quality.

IMPROVEMENTS MADE

By replacing more than 60 traditional mechanical steam traps on an array of equipment throughout the laundry, the firm reported:

  • Higher quality production and reduced reprocessing while using less steam.
  • Reduced natural gas costs.
Reduced therm/cwt of processed laundry by 45%
45%

Steamgard-Resort

One of a hotel’s major cost centers and opportunities for favorably impressing its guests is the kitchen. A properly functioning kitchen has an array of equipment that depends upon steam for correct food preparation, proper serving temperatures and sanitation of cooking and service items.

The hotel wanted to reduce its escalating energy and operating costs associated with its high volume kitchen operations.

IMPROVEMENTS MADE

By replacing more than 70 mechanical steam traps on an array of equipment throughout the kitchen, boiler room and other areas, the hotel reported:

  • Energy cost savings of more than $24,000 in the first year of operation
  • Improved thermal efficiency on key food preparation equipment
  • Reduce energy consumption and start-up time of equipment
  • Dependable service of condensate removal devices
Reduced start up times for sanitation equipment by 50%.
50%
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