Reducing Energy Losses of Steam Boilers Caused by Blowdown with Using the FMEA Method

Abstract

In this study, the boiler blowdown was systematically examined and, the risks that increase the energy loss was determined using the potential Failure Mode and Effects Analysis (FMEA) method. Risk priority numbers (RPN) were calculated for each potential risk. It was revealed that ‘Performing more blowdown than it is necessary’ has the highest priority score. Improvement opportunities were identified by using the tree diagram, which is one of the process improvement techniques. Three suggestions were developed, such as flash steam heat recovery, reduction of water conductivity using the reverse osmosis technique, and the use of both methods. Repayment periods were calculated for each investment. If the flash steam unit and reverse osmosis system are applied together, 113.5 KW/h energy can be saved. It has been demonstrated that the FMEA technique can be used in the investigation and reduction of energy loss.