The “virus” in steam applications – VIRUS

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This post was last edited by Fuleide on 2020-5-13 at 14:57. The “virus” in steam applications – VIRUS. The global COVID-19 pandemic that broke out in 2020 can certainly be considered a great disaster for all of humanity; to date, there have been over 3 million confirmed cases worldwide, with more than 200,000 deaths. The COVID-19 virus has not only claimed the lives of hundreds of thousands of people but will also inflict immeasurable and huge losses on the global economy. As the entire human race fights against the COVID-19 pandemic, Fred would like to take this opportunity to talk with steam users about the long-standing \"virus\" in steam applications – VIRUS – in order to remind everyone to prevent and eradicate it as soon as possible. V---Variable: It changes unpredictably. This change is reflected in several aspects: 1. Fluctuations in the pressure and temperature of the steam source, which are particularly evident in the case of externally supplied steam. For example, in a certain company’s power plant, the steam pressure fluctuates between 22 barg and 28 barg, while the temperature varies between 250°C and 350°C ； 2. Load variations, namely fluctuations in load caused by changes in the number of devices in operation and the types of products produced. For example, in a pharmaceutical company, at different stages of daily production, the steam consumption fluctuates between 1.5 tons per hour and 10 tons per hour due to changes in the equipment used ； 3. Changes in process parameters, namely variations in parameters such as temperature, pressure, and humidity required by the process. For example, in some printing and dyeing enterprises, the processing temperature is adjusted between 130°C and 200°C depending on the type of fabric. All these changes will affect the security of the system, the operational condition of the equipment, product quality, production efficiency, and steam consumption, among other things. I---Inefficient: low efficiency. Efficiency in steam applications encompasses at least two aspects – the efficiency of steam-using equipment and the efficiency of heat energy utilization. The efficiency of steam-using equipment is affected by factors such as steam superheat, steam quality, steam pressure, and the condition of the traps; of course, it also depends greatly on the equipment itself ； The efficiency of heat utilization is closely related to factors such as the layout of steam pipelines, the arrangement of equipment that uses steam, the principle of utilizing heat in a stepwise manner and as close as possible to its source, as well as the methods for recovering waste heat. Equipment efficiency is related to a company’s production efficiency, as well as its energy consumption levels ； The efficiency of heat energy utilization directly determines the effectiveness of energy conservation and consumption reduction. R---Rough: careless and not precise. At present, the steam systems in Chinese enterprises remain relatively inefficient, as evidenced by: chaotic piping layouts and oversized pipe diameters, direct use of superheated steam, generally high steam usage pressures, oversized sizes for equipment and valves, wide temperature control ranges, chaotic drainage methods, and inefficient heat recovery. Details determine the outcome. The stability, reliability, and overall operational efficiency of steam systems stem from precise technical control over every detail and high-quality standards for each device/component. U---Unreliable: Crisis of integrity. In the domestic market, the issue of integrity has always been a major obstacle to the development of small and medium-sized enterprises. In the steam energy-saving industry, which is a new sector in China, the issue of customer integrity becomes a trap that can easily ensnare energy-saving service providers, as well as a serious obstacle that hinders their development. In the projects we have worked on, although the energy-saving effects were far above the standards specified in the contracts, only about 10% of the customers paid in full as required by the contract. The remaining customers always found minor \"problems\" to nitpick over, with the aim of delaying or reducing payments; some even went so far as to distort the facts and act unreasonably. On the other hand, the current pool of energy-saving service companies is also filled with fraudsters and charlatans whose attitude and capabilities are utterly unfit to embody the concept of \"integrity\". S---Short-sighted: Short-sighted behavior. If temporary fixes that address symptoms only can be considered a contingency measure, then focusing solely on price while ignoring value is, in the case of steam systems, undoubtedly a short-sighted approach. Furthermore, with some clients who achieve energy savings far exceeding the agreed percentage and have their process-related problems resolved, yet still try every means to withhold the remaining payment for the project, this reflects not only a lack of integrity but is also a clear case of short-sightedness, as a company that does not uphold integrity can hardly succeed or sustain itself in the long term. Regarding the above content, the first three parts focus on the things themselves, while the latter two pertain to human actions; of course, the former is also under human control. The overall writing, especially the latter two parts, carries a slight critical tone. Since it’s a “virus,” it’s only natural to condemn it. Since it is called a “virus,” it indeed possesses viral characteristics. Similar phenomena are quite common, and they also spread from one company to another; this is their contagious nature ； All five elements are hidden within the enterprise’s steam system and corporate culture; it is difficult to detect them without delving deep into these aspects, which is what gives them their concealment ； There is no need to elaborate on its hazards; surely everyone is already well aware of them.