Steam & Condensate Case Studies

Multi-year Agreement to Maintain and Optimize Steam System Utilities

Armstrong maintains and optimizes facility's 1,200 steam traps, onsite. Responsibilities include steam trap root cause analysis, repair/replace recommendations, database management, turnkey installation, steam loss reporting, and general steam condensate system upgrade recommendations.

Reducing Fuel Consumption while Increasing Condensate Return

Armstrong implements an extensive steam trap optimization program with survey, database, selection, sizing, install, repair and replacement of the company's steam trap population. Included: plant-wide steam distribution recommendations and condensate return; drip legs redesign and installation; engineering piping installations of steam distribution lines and condensate return; maintenance of pump traps, PRVs, and installation of sensing lines and condensate equipment; correction of live steam and condensate leaks; plant-wide utility piping, valves and fittings insulation; and more.

Maximizing Energy Savings through Flash Steam Recovery

Armstrong's flash steam and heat recovery solution provides a major candy manufacturer with immediate increases in energy efficiency. In addition to eliminating flash steam loss, the company is able to utilize flash steam to process water—at 100 gallons per minute—for further energy efficiencies.

Plant Expansion Without Compromising Savings and Efficiency

During a company's plant expansion, Armstrong develops a plan to provide engineering and installation of multiple, separate packaged condensate pumping systems with cycle counters, without requiring a capital payment. The food processing facility realized an annual cash savings equating to a simple return on investment (ROI) of 56%, allowing capital resources to be focused on the core business. In addition to clean and hot condensate being returned to the boiler house, the company has reinforced its “green” facility image by avoiding increases in combustion emissions and high water consumption.

Reducing Fuel Consumption While Increasing Condensate Return

Armstrong implements an extensive steam trap optimization program with survey, database, selection, sizing, install, repair and replacement of the company's steam trap population. Included: plant-wide steam distribution recommendations and condensate return; drip legs redesign and installation; engineering piping installations of steam distribution lines and condensate return; maintenance of pump traps, PRVs, and installation of sensing lines and condensate equipment; correction of live steam and condensate leaks; plant-wide utility piping, valves and fittings insulation; and more.

Condensate Contamination Mitigation

A turnkey approach to project implementation was used for the extensive scope of work, which included multiple upgrade projects as well as a complete system analysis of steam and condensate systems. Armstrong engineered and installed: condensate return and pumping system; variable frequency control on primary boiler forced draft fan; controls for monitoring multiple condensate return, and installed total organic carbon sensing to divert contaminated condensate to drain.

Steam System Optimization to Reduce Energy Consumption

Complete steam distribution optimization; implement steam trap optimization program, including: survey, database, selection, sizing, install, repair and replace steam trap population; plant-wide condensate return improvement; and more, including responsibility for all mechanical work performed by local contractors in Mexico.

Hot Water Case Studies

Process Hot Water Temperature Control

Armstrong alleviates batch process issues for a large, widely known soup company with Emech® digital control valves. These water to water mixing valves provide better than +/- 1% accuracy, while delivering real-time water temperature directly to a process monitor on the plant floor. Issues with space, reliability and process accuracy have been eliminated with the system.

Hot Water Generation Fueled by Natural Gas to Boost Energy Savings

Armstrong installs a complete hot water system to replace the outdated steam and heat exchanger currently in use at a large company's ice cream plant. Results include a calculated fuel savings of more than 30% and yearly CO2 emissions reduced by 612 tons. ROI realized within 14 months of installation.

Simultaneous Water Generation for Tank Cleaning and Process Needs

Design and specification of a hot water system that provides a tank cleaning solution. The system includes Armstrong Flo-Direct® Complete Thermal Exchange (CTE) gas-fired water heater, heat exchanger, storage tank and pumps, condensate return pump, and control valve. An integrator was included to develop a control system for automating the cleaning process. Armstrong's complete system solution not only generates and controls hot water, but also monitors and records cycle data for the tank cleaning process.

Optimization Services Case Studies

Operations and Maintenance Services through 16-year Agreement

Armstrong provides 24/7 operations and maintenance of steam, compressed air and wastewater systems with a full-time, on-site staff that includes site supervisor and five operator/technicians. Energy engineering and turnkey project management also provided.

Operations and Maintenance of Utility Systems

Facility is staffed by Armstrong utility experts, ensuring the highest level of quality, reliability and efficiency to support the plant’s construction and start-up process, while reducing overall utility costs and providing uninterrupted utility services for existing operational requirements.

Steam System Optimization to Reduce Energy Consumption

Complete steam distribution optimization; implement steam trap optimization program, including: survey, database, selection, sizing, install, repair and replace steam trap population; plant-wide condensate return improvement; and more, including responsibility for all mechanical work performed by local contractors in Mexico.

Operations and Maintenance Services Led to $2 Million in Cost Avoidance

Armstrong owns, operates, and maintains utility assets producing steam and compressed air, and maintains corresponding distribution systems throughout the facility.

Operations and Maintenance Contract to Identify Energy Savings

Armstrong's operation and routine maintenance of utilities systems for a rice manufacturing and packaging facility. Responsibilities include full-time, on-site management of steam, compressed air and waste water treatment systems.

Operations Maintenance Contract to Lower Operating Costs, Improve Safety and Boost Knowledge Base of Staff

Armstrong provides management and supervision resources required for operation and maintenance of a major cereal producer's utility systems, including generation and distribution of steam and compressed air, and water treatment. Results include lower operating costs, development of back-up and emergency processes and an improvement in site operators' knowledge and morale.

Operations and Maintenance to Drive Energy Savings and Safety

Armstrong provides renowned baby food maker with an on-site staff of utility experts. Responsibilities for operation and maintenance of utility systems includes: boilers, all associated support equipment, and steam distribution and condensate return systems; compressed air system including compressors, associated dryers, and distribution system; steam heated process hot water systems; complete facility HVAC systems; and water softeners.

Multi-year Agreement to Maintain and Optimize Steam System Utilities

Armstrong maintains and optimizes facility's 1,200 steam traps, onsite. Responsibilities include steam trap root cause analysis, repair/replace recommendations, database management, turnkey installation, steam loss reporting, and general steam condensate system upgrade recommendations.