ENERGY AUDIT METHODOLOGY FOR HEATERS

Presented By

Quamie Mortley PhD

Test Code for Heater Performance

Power Test Code (PTC) ASME PTC - 12.1 For Closed Heaters

HEATER PERFORMANCE
Collect the following data for Digestion Heaters Steam Flow to Digestion Heater, Injection Steam Flow, Liquor Flow rate Steam Pressure, Temperature Enthalpy and Saturation Temperature Liquor Inlet, Liquor Outlet Temperatures Condensate Temperature

HEATER PERFORMANCE
After the collecting the above data, evaluate the following Terminal temperature difference TTD

Heater drain cooler approach temperature difference DCA

Temperature rise across heater TR

Terminal temperature difference - TTD TTD = T sat T liquor outlet

Tsat - Steam saturation temperature at shell pressure (deg.C)

Tliquor out - Temperature of liquor leaving heater (deg.C)

HEATER PERFORMANCE
Heater drain cooler approach temperature difference DCA DCA = T condensate T liquor outlet

Tcondensate - Temperature of Condensate (deg.C) Tliquor out - Temperature of liquor leaving heater (deg.C)

HEATER PERFORMANCE
Temperature rise across heater TR TR = T liquor outlet T liquor inlet

Tliquor outlet - Temperature of liquor leaving heater (deg.C) Tliquor inlet - Temperature of liquor entering heater (deg.C)

HEATER PERFORMANCE DEVIATION

Check if TTD, DCA, TR are deviating from the design and actual rise in liquor temperature is low: High terminal temperature difference, TTD Excessive venting (worn vents, altered set point, vent malfunctioning) Excessive liquor flow High condensate level (tube leaks, improper setting) Header partition leaks

Non condensable gases on shell side

Excessive tube bundle pressure drop (excessive number of tubes plugged, tubes folded internally)

HEATER PERFORMANCE DEVIATION

High drain cooler approach temperature, DCA Drain cooler inlet not submerged Low condensate level (improper setting) Excessive tube bundle pressure drop (excessive number of tubes plugged / tubes folded internally)