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Metal Plating Plant- Welded Header Repair and Fuel Savings Update
This plant does government work exclusively so we won't post its name or precise location. It has a row of tanks into which the work is dipped from an overhead gondola. The tanks contain various chemicals and those requiring heat have steam coils in their bottoms. The first pic is a view of their tank line.
The original installation consisted of an overhead steam main and overhead dry return running from the boiler room to the end of the tank line. Air and water left the coils through bucket traps mounted at about the rim level of the tanks (4 feet above ground), then lifted past check valves via steam pressure another 8 feet to the dry return.
Not only did they have to maintain 10-12 PSI in the boiler to accomplish this, but the check valves would close if vacuum formed in a coil. In one case, a coil developed a leak and the vacuum pulled some of the solution from the tank into the coil. This made for an interesting service call.
Our solution was to run a new 2-inch dry return below the tank rims, with the trap discharges draining by gravity into the new line. Check valves were no longer needed. The new line terminates in a small Hoffman condensate transfer pump which lifts the water into the original overhead return. From there it flows to the boiler-feed pump. We did this work last year and hadn't been back until yesterday
The second two pics show the overhead piping. Note all the plugged tees in the overhead return- these were where the coils originally discharged.
We repiped the end-of-main trap also, so it would drain to the transfer pump rather than up into the overhead return.
All Steamed Up, Inc.
"Reducing our country's energy consumption, one system at a time"
Steam, Vapor & Hot-Water Heating Specialists
Oil & Gas Burner Service
Baltimore, MD (USA) and consulting anywhere.https://heatinghelp.com/find-a-contractor/detail/all-steamed-up-inc