99213SER2IT GSK Parma - pre audit report rev1

Armstrong International Italiana Via Sandro Boticelli 80 – 10 154 TORINO – Italy - www.armstrong international.eu Tel : (+39) 011-20 00 35 // Fax : (+39) 011-24 25 744

GlaxoSmithKline Parma, Italy

STEAM AND CONDENSATE PRE-AUDIT REPORT

Project N° 99213-SER2-IT REV1

CONTACT

Stefano DORIA �� +39 335 38 75 90 [email protected]

Alexandre MACRON �� +33 6 50 86 87 78 [email protected]

STEAM and CONDENSAT PRE AUDIT

Sending date

18/09/09

GSK

Parma

Project N°

99213-SER2-IT REV1

For the attention of Ing. MAGNANI Page 2 sur 23

Etablished by Controlled by Validation date

AMA 18/09/2009

SUMMARY

1. INTRODUCTION ........................................................................................................................................................... 3

2. GENERALITIES ............................................................................................................................................................. 4

3. STEAM NETWORK ...................................................................................................................................................... 5

3.1 BOILER HOUSE ............................................................................................................................................................. 5

3.2 STEAM DISTRIBUTION ................................................................................................................................................. 10

3.3 NOTES ON INSULATION ............................................................................................................................................... 11

3.4 STEAM CONSUMERS .................................................................................................................................................... 12

3.4.1. BOILER ROOM ............................................................................................................................................................. 12

3.4.2. AUTOCLAVES ............................................................................................................................................................. 14

3.4.3 MAIN WATER ROOM / SALA ACQUA PRINCIPALE .......................................................................................................... 15

3.4.4. FDF ............................................................................................................................................................................ 17

3.4.5. TECHNICAL GALLERY ................................................................................................................................................. 18

3.4.6. OHCF ........................................................................................................................................................................ 20

4. STEAM TRAPS ............................................................................................................................................................ 21

5. ENERGY COSTS ........................................................................................................................................................ 22

6. CONCLUSIONS ........................................................................................................................................................... 23


Sending date

18/09/09

GSK

Parma

Project N°

99213-SER2-IT REV1



AMA 18/09/2009

1. Introduction

Armstrong has conducted a pre-audit of steam and condensate networks at GSK facility located in

Parma.

The aim was to have an overview of your steam and condensate network in order to estimate

optimizations solutions allowing to reduce your energy consumption and to improve your installations

reliability.

This report summarizes our first remarks and conclusions.


Sending date

18/09/09

GSK

Parma

Project N°

99213-SER2-IT REV1



AMA 18/09/2009

2. Generalities

GSK Parma is specialised in sterile manufacturing.

The production works 52 weeks/year, 24 h/day, annual running time is estimated at 8 500 h/year.

Factory is using from 3 to 4 t/h of steam, for a total consumption of about 28 000 t for year 2008

(based on gas consumption).

Steam is produced at 8 barg and then reduced in the plant at the required pressure.

Steam is mainly used:

o In tubular exchangers for heating hot water loops (about 20% of the total)

o In pure steam generators

o In autoclave

o In distillation plants

Condensates recovery rate is estimated at about 70-80%.


Sending date

18/09/09

GSK

Parma

Project N°

99213-SER2-IT REV1



AMA 18/09/2009

3. Steam network

3.1 Boiler House

Water is treated by a reversed osmosis plant.

This water is sent to a first tank and then mixed with condensates in the boilers feed water tanks.

A pre-heating system of this make up water, using energy from the boilers’ blowdown, is currently

under installation.

Treated water storage and feed water tanks


Sending date

18/09/09

GSK

Parma

Project N°

99213-SER2-IT REV1



AMA 18/09/2009

Steam loss by the vent seems to be quite important. This can be due to:

- high pressure condensate flashing in the tank

- live steam coming from the network trough defective steam traps or open by pass valves (but

80% of your steam traps have already been changed)

Temperature of the feed tank during our visit was about 70°C: some modification could be considered

to recover this energy:

- by mixing properly cold water and hot condensate;

- by condensing the vent with the cold make up water

Note that the feeding in make-up water is done in ON/OFF.

Condensates collector


Sending date

18/09/09

GSK

Parma

Project N°

99213-SER2-IT REV1



AMA 18/09/2009

8 bar steam is produced by 4 Mingazzini fire tube boilers, each with a capacity of 3t/h:

- boilers 1 & 2 are equipped with air pre-heater, recovering energy from the stacks, during

our visit we have noted a temperature on stack after the exchanger of 145°C (generally

nearer from 120°C);

- boilers 3&4 with mix burner oil/gas.

A CHP plant, with a steam capacity of 1,8t/h, is under construction and should be operational in

December.

Boiler 1 with air preheater Boilers 3 & 4

You have indicated a steam consumption varying between 5 and 8t/h.

Until today, you use 2 or 3 boilers depending of the steam demand:

- in summer, one boiler at full load and a second one modulating;

- in winter, 2 boilers at full load and a third one modulating

Based on the gas consumption you gave us, we have calculated your steam production and the

average is lower than the one announced, within 3 and 4t/h.

We have calculated a steam consumption of 27 915 tons for 2008, the first months of 2009 (and the

steam flowmeter installed this spring) confirm that trend.


Sending date

18/09/09

GSK

Parma

Project N°

99213-SER2-IT REV1



AMA 18/09/2009

Monthly steam production

Hypothesis:

HHV 10,5kWh/Smc

Feed water temperature 70°C

Steam production efficiency 85%

Operation mode of boilers should be checked: to optimize the efficiency of the boiler room,.

Efficiency of stack energy recovery on boiler 1 & 2 should be controlled

Boilers 1 & 2 have to be used in priority

Period of stand-by have to be limited as much as possible and low load running have to be avoided.


Sending date

18/09/09

GSK

Parma

Project N°

99213-SER2-IT REV1



AMA 18/09/2009

Thanks to the osmosis, the blowdown rate remains limited (0.5 to 1% regarding the water analyses

communicated)

Automatic blowdown systems (conductivity probe and automatic valves) were under installation on

boilers during the preaudit.

The installation will include a flash tank and two stages of make up water pre-heating, which should

optimize the recovering of energy remaining in blowdowns.


Sending date

18/09/09

GSK

Parma

Project N°

99213-SER2-IT REV1



AMA 18/09/2009

3.2 Steam distribution

We have followed the distribution lines from to the steam consumers.

Some drip legs are installed to drain distribution lines but drainage should be added before control

valves whenever there is a low point.

Steam traps need to be installed before control valves to avoid erosion when it is closed and to avoid

water hammers at the opening.

When the valve seat is eroded, there is a permanent steam leak.

Drip leg missing on low point before control valve

Insulation on pipe and ancillaries is globally correct, but some portions of the network which have

been modified remain without protection (in the boiler room).

Furthermore, in the different workshop some ancillaries (manual or automatic valve, filters...) are not

insulated.


Sending date

18/09/09

GSK

Parma

Project N°

99213-SER2-IT REV1



AMA 18/09/2009

3.3 Notes on insulation Non-insulated piping and ancillaries radiate heat into the environment, and thus waste energy.

Due to this heat transfer (cooling) more steam will condense inside the steam piping. If this

condensate is not drained properly, it may cause water hammers in the steam lines. If this

condensate is not returned to the boiler house energy, treated water, and chemicals are lost.

Furthermore, condensate in steam lines will cause erosion and corrosion of piping and

auxiliaries (control valves and pressure reducing valves), and reduce steam quality. It is

therefore of great importance to prevent radiation losses, and drain condensate from steam

lines effectively.

As an example, see the energy loss due to lack of insulation for 8 and 3 barg steam.

Simulation of energy and financial losses due to lack of insulation

Considering the energy cost, insulating all equipments with diameter upper than 1”1/2 and steam

pressure higher than 3 bar presents an interesting payback. The annual running time must be taken in

consideration too.


Sending date

18/09/09

GSK

Parma

Project N°

99213-SER2-IT REV1



AMA 18/09/2009

3.4 Steam consumers

We have inspected the main steam consumers collecting the available data.

Steam is collected in a main header in the boiler room and then distributed to the different users.

3.4.1. Boiler room

Steam is used in the boiler room in 4 tubular heat exchangers used for 45°C hot water loops (for

buildings and offices heating). Temperature setting is increased during winter.

Drip are missing on low points before control valve stations


Sending date

18/09/09

GSK

Parma

Project N°

99213-SER2-IT REV1



AMA 18/09/2009

Connected on the Building P steam line, two hot water tanks are equipped with steam coil for heating

and temperature maintaining (55°C).

We have detected some slaps in one of the coils. Steam pressure in the coil is too low to drain

correctly condensates.


Sending date

18/09/09

GSK

Parma

Project N°

99213-SER2-IT REV1



AMA 18/09/2009

3.4.2. Autoclaves

In total, 10 autoclaves are used:

- 7 in building P

- 2 in building QA

- 1 in building SHCF

These devices use pure steam in direct injection and industrial steam in the double jackets and

compressed air/steam in a exchanger.

Nevertheless, condensate coming from industrial steam are not recovered because of very low

pressure and to avoid some condensate accumulation in heating bodies.

Autoclaves in building P are located above a basement which could allow the installation of an

atmospheric vessel and a pump to send the condensates back to the boiler room.

Steam consumption is limited (about 50kg/h/autoclave with working batch of 2 hours): the system has

to be well designed to connect several autoclaves to the same collector.


Sending date

18/09/09

GSK

Parma

Project N°

99213-SER2-IT REV1



AMA 18/09/2009

3.4.3 Main water room / Sala acqua principale

This workshop includes:

- a distillation plant

Industrial steam is used only in the first column, at 4 barg.

Condensates of this stage are recovered and sent back to the boiler room.


Sending date

18/09/09

GSK

Parma

Project N°

99213-SER2-IT REV1



AMA 18/09/2009

- 2 exchangers for temperature maintaining and 1 for sterilization

-

- 2 pure steam generators

Industrial steam is used at 6 bar (before control valve) to produced pure steam by evaporating pure

water.

Condensates are recovered.

An energy recovery could be studied on blowdowns, for example to pre heat the pure feed water

entering the evaporator. However, note that the blowdown flow remains limited (automatic valve

open5s every 30 min).


Sending date

18/09/09

GSK

Parma

Project N°

99213-SER2-IT REV1



AMA 18/09/2009

3.4.4. FDF

This room includes the same installation than the main water room: distillation plant, pure steam

generator, exchanger for water loop temperature maintaining and the LIO using pure steam.

This distillation plant is here equipped with a plate exchanger for last column blowdown cooling.

Cooling exchanger


Sending date

18/09/09

GSK

Parma

Project N°

99213-SER2-IT REV1



AMA 18/09/2009

3.4.5. Technical gallery

Several washing machines (HYDROWASH) are used in the factory, with one installed in the

technical gallery:

Each Hydrowash uses steam in a plate heat exchanger to heat up water from 15 to 70°C.

A working batch takes about 1 hour: for the 4 machines the estimation is about 500 batches per year.

Design has been done for a water flow of 1m3/h which is higher than real condition. If we consider a

water flow of 0,5m3/h, the equivalent steam consumption is about 50kg/h (/machine/batch).

You also use some deshumidifiers (MUNTERS) , however several of them are stopped (it remains 3

using steam).


Sending date

18/09/09

GSK

Parma

Project N°

99213-SER2-IT REV1



AMA 18/09/2009

Double pressure reducing station:

Energy losses due to lack of insulation on ancillaries

localisation device type time length or DN equivalent lg th P° loss lossfactor number (mm) (m) (bar relatif) (W) (€/an)

valve 1 1 65 1,5 8 1570 593strainer 1 1 65 1,5 8 1570 593

PRV valve 1 1 50 1,37 5 984 371by pass valve 1 1 65 1,5 5 1305 493

valve 1 1 50 1,37 3 798 301TOTAL 6227 2351


Sending date

18/09/09

GSK

Parma

Project N°

99213-SER2-IT REV1



AMA 18/09/2009

3.4.6. OHCF

An exchanger is used for heating and maintaining in temperature a hot water loop (50°C).

Note that this exchanger is flooded: regarding the back pressure due to the ascendant pipe after the

exchanger, the pressure in the heating body is probably not sufficient to allow a proper drainage.

Insulation campaign should be done in production workshop and technical galleries


Sending date

18/09/09

GSK

Parma

Project N°

99213-SER2-IT REV1



AMA 18/09/2009

4. Steam traps

You planned to replace progressively all steam traps by orifice traps (steam traps’ population of about

180-200 traps)..

Today, population is mainly composed of orifice and mechanical traps (F&T).

Working status of traps has to be checked regularly to avoid energy losses, maintenance or

production troubles.

A leaking trap, more than a steam loss, can generate water hammer, increase the pressure on the

return network and disturb the operation of other traps.

A blocked trap or drip leg prevent the elimination of condensate which are swept along by the steam

which can be responsible of water hammers, erosion of equipments and make heat transfers less

efficient.


Sending date

18/09/09

GSK

Parma

Project N°

99213-SER2-IT REV1



AMA 18/09/2009

5. Energy costs

You have communicated a steam cost of 30 €/t and a yearly steam consumption of about

28 000t/year based on the 2008 consumptions.

Average cost 30,00 €/t

Yearly steam consumption 28 000 tons/year

Total yearly steam cost 840 000 €


Sending date

18/09/09

GSK

Parma

Project N°

99213-SER2-IT REV1



AMA 18/09/2009

6. Conclusions

Steam and condensates installations are globally correct. Nevertheless, some particular points

could be improved:

In the boiler room:

- The flash steam lost by the vent of the feed water tank should be limited or recovered,

- Operating of boiler room will have to be adapted with the start up of the CHP plant. Efficiency

of the steam generation should be checked regularly. Steam flowmeters could easily allow to

monitor the installation’s efficiency (recording in continue of steam consumption flow, stacks

temperature...).

On the distribution network and on consumers:

- Condensate recovery rate is already correct but recovering of autoclaves’ condensate could be

studied thoroughly;

- Assisted condensate removal should be added on hot water tanks in boiler room and heat

exchanger in OHCF

- Lines are correctly equipped with drip legs but several control valve station are not protected

against condensat accumulation on low points and wet steam.

Equipped drip legs on those points will allow ensuring a good quality of steam sent to the users

and avoid eventual water hammers, corrosion of the pipes, erosion of equipments.

- Insulation on line and in the boiler room is globally correct, but ancillaries have to be equipped

in production area and technical gallery.

The potential saving can be estimated within 2 or 3% considering improvement of insulation and

recovering of the feed water tank’s vent.

We remain at your disposal to study in details these potential improvements and optimisations.

Documents

99213SER2IT GSK Parma - pre audit report rev1