The Steamgard Process
- 1. Project Goals
- 2. System Evaluation & Analysis
- 3. Installation & Retrofit
- 4. Measurement & Verification
- 5. Extended Warranty
We identify the chronic problems in your facility associated with traditional mechanical steam traps that can be solved through our technology and engineering expertise.
A team of experts establish project goals by identifying many of the persisting issues that occur in virtually all steam system applications. The solutions we provide result in lower energy usage, reduced operating expenses, reduced steam consumption and maintenance costs, and increased equipment efficiency.
An essential part of this first step is gathering data that typically includes information about:
- Existing operating conditions
- Fuel consumption, production and weather profiles
- Boiler system operating procedures
- Current maintenance practices, schedules and costs
- Design vs. actual throughput limits at unit and plant level
- Steam processing problems perceived at operator and management levels
An expert and experienced Steamgard engineering team, using tools that can range from infrared thermal spectrography to an ultrasound recorder to a high temperature pyrometer, conducts a thorough inspection of your steam system. We start in the boiler room and follow all steam lines in the facility to locate steam-using equipment and evaluate how all components of the steam system work together.
Control valves, check valves, piping and other elements are evaluated. Steam traps in the system are thoroughly tested and tagged.
After completing a thorough system review, we process the information gathered and prepare an expert analysis, which includes primary Energy Conservation Measures (ECMs). Frequently, we suggest Secondary Energy Conservation Measures (SECM’s) for your consideration.
The Steamgard evaluation of the system and processes, presented in a comprehensive report, contains a detailed analysis of cost savings and project payback expectations. The report can include suggestions for corrections or modifications to your system that can add value to or upgrade the facility’s operations. With its supporting data, photographs, calculations, charts and graphs, our report is presented to you as a working document. We review it with you and the information and your feedback becomes the blueprint for installation and retrofitting.
A representative payback calculation helps you make an informed decision about the long and short-term value of your investment.
Factors we identify in calculating the payback include:
- Excess steam consumption caused by failed mechanical steam traps
- Excess energy costs due to excessive steam consumption
- Reduced maintenance costs
- Increased process/equipment efficiency
Our expert installation and retrofit teams of engineers, field supervisors and steam technicians are trained to ensure efficient and high quality installations with minimum operational interruptions. Our team is flexible and work can be performed when it is least likely to have impact on day-to-day operations–nights, weekends or holidays. An experienced engineer who serves as Project Manager and the Crew Supervisor review the site before starting work.
A comprehensive environmental, safety and health program is followed to ensure project safety.
If installation services are conducted by your maintenance personnel or outside contractors, Steamgard can provide personnel training and supervision, in addition to helping with commissioning the project.
As the work is being completed, we review our progress regularly to minimize your time for walkthroughs, punch lists and final acceptance.
Our engineers are accustomed to utilizing the United States Department of Energy’s and industry procedures to measure performance and verify the value of our projects.
From the applied engineering phase, a model of steam consumption and system operating parameters is produced. During measurement and verification, both consumption patterns and operating parameters are reviewed to estimate the results. We visit the site to review operations and gather data and develop a new consumption model for comparison with the original. For example, if steam is produced for heating only, a linear regression of therms consumed as a function of Heating Degree Days (HDD) can estimate the rate of savings and project actual savings.
The performance of the Steamgard system is guaranteed for five years and can be extended. Although the system requires minimal maintenance, we are pleased to provide long-term inspection/testing and maintenance services to you, at your request. These services, available throughout North America, feature a response time of 48 hours or less.