1. TEAM UP! FOR STEAM AND CONDENSATE PIPING SYSTEMS SAVINGS
Thanks for coming. I’m [INSERT NAME].
I’m going to outline some simple steps and tools we can use to reduce the energy used in our steam and condensate systems.
And it all begins with you.
You’re on the front lines. We’re going to talk about teaming up with your co-workers to spot chances to cut energy use.
Together we can make a difference – for the environment and for our bottom line.
It can be as easy as
fixing a leaky steam trap.

2. Why should we care? For the environment For the bottom line
It’s easy to feel that we can’t make a difference for the environment.
But we can. Some simple changes to how we use our steam and condensate systems can add up to big energy savings that will help make this a greener place to work.

3. Why should we care? For the environment Fixing a leaky steam trap can
capture big environmental
gains.
Fixing a leaky steam trap can capture big environmental gains.
That’s because the more steam lost through our system, the more our boiler has to produce.
Our boiler uses …
[USE ONE OF THE FOLLOWING, DEPENDING ON WHAT FUEL YOU USE:]
… natural gas. We can cut almost two tonnes of carbon dioxide emissions for every 1000 cubic metres of natural gas we save.
… oil. We can cut over three tonnes of carbon dioxide emissions for every 1000 litres of oil we save.
And carbon dioxide is the major component of greenhouse gas emissions.

4. Why should we care? For the bottom line
Ten pairs of uninsulated NPS 6 flanges will cause an annual
heat loss of $1,000.
Saving energy also leaves us with more money to invest in our [company or organization].
That can help protect jobs and budgets.
Consider this small example: 10 pairs of uninsulated NPS 6 flanges will cause an annual heat loss of $1,000.
Bit by bit, saving energy can add up to substantial financial savings.

5. Where is energy wasted? Redundant pipes Steam leaks Steam trap losses
Heat loss through uninsulated
pipes and fittings
Redundant pipes serve little or no purpose, but they lose the same amount of heat per length of pipe. That’s a waste of the energy used to produce the steam. Plus, heat loss from extra piping adds to our facility’s requirements for ventilation and air conditioning.
Also, we’re less likely to check these pipes for leaks and faulty steam traps.
Steam leaks at pipe fittings, valves and traps are also a big waste of energy and money. A less obvious cost from steam leaks is that any water leaked from the system must be replaced and chemically treated.
Defective steam traps are among the chief causes of energy loss. Energy can be lost from steam traps for several reasons:
The trap fails in the open position and lets live steam escape.
We may be using the wrong type or size of trap.
We may have installed the trap in the wrong place.
The installation may be faulty.
And finally, bare or improperly insulated steam pipes are a constant source of wasted energy and wasted money.

6. What can we do? Housekeeping Low-cost opportunities Retrofits
We’ve ranked the ways we can save energy and save money into three main areas.
From simple housekeeping to retrofitting equipment, there’s a wealth of opportunities for us to generate valuable energy savings.

7. What can we do? 1. Housekeeping (cont.) Regularly inspect and maintain
steam traps.
Fix steam and condensate leaks.
Ensure good steam quality by maintaining chemical water treatment.
Simple housekeeping can turn up big energy management opportunities.
To start with, we should regularly inspect and maintain all our steam traps. Steam traps are among the chief causes of energy loss in a steam and condensate system. Steam traps often get plugged or stuck open due to a buildup of dirt, and we don’t necessarily notice.
We should also regularly check for and fix steam or condensate leaks.
We also need to ensure we’ve always got good quality steam, by maintaining our chemical water treatment.
[INSTRUCTIONS TO PRESENTER: DELETE ANY OF THESE POINTS IF THEY DO NOT APPLY TO YOUR FACILITY.]

8. What can we do? 1. Housekeeping (cont.)
Repair damaged pipe insulation.
Shut down equipment when
not needed.
Shut down steam and condensate branch systems when not needed.
Other housekeeping measures include regularly inspecting insulation and repairing any that’s damaged.
We should also shut down any equipment when it’s not needed …
… and shut down any steam and condensate branch systems when they aren’t needed.

9. What can we do? 2. Low-cost opportunities
Overhaul pressure-reducing stations.
Insulate pipes, flanges, fittings and equipment. (Three metres of uninsulated 10-centimetre steam pipe will waste more than twice as much money in steam costs per year than it would cost to insulate.)
Moving on to some low-cost ways to save money and help save the environment:
We should overhaul our pressure-reducing stations to make sure they’re as efficient as possible. Reduce system pressure as much as possible while meeting all system requirements.
Also, insulation is key. Bare or improperly insulated steam pipes are a constant source of wasted energy. That’s because they radiate heat to the surroundings, instead of transporting as much energy as possible to the steam-using equipment. Heat losses reduce the steam pressure at the equipment. This increases the boiler load, because extra steam is needed to make up the losses.
One example: A three-metre length of uninsulated 10-centimetre steam pipe will waste more than twice as much money in steam costs per year than it would cost to insulate.
[INSTRUCTIONS TO PRESENTER: DELETE ANY OF THESE POINTS IF THEY DO NOT APPLY TO YOUR FACILITY.]

10. What can we do? 2. Low-cost opportunities (cont.)
Remove redundant steam and condensate piping.
Re-pipe systems or move equipment
to shorten pipe lengths to minimize
heat loss and steam leaks.
Repair, replace or add air vents.
Optimize the location of sensors.
[suggestion: Put sensors in the best locations.]
Some other low-cost opportunities:
We should remove any redundant steam and condensate piping. It’s estimated that in older facilities, it’s possible to reduce the length of piping by 10 to
15 percent.
Where possible, we should re-pipe systems or move equipment to shorten pipe lengths. This will help minimize heat loss and steam leaks.
We should also repair, replace or add air vents where needed.
And we should optimize the location of condensate conductivity sensors. [suggestion: put condensate conductivity sensors in the best locations.]

11. What can we do? 3. Retrofits Upgrade insulation.
Eliminate steam use where possible.
Replace old steam traps or ones that are the wrong size or type.
We can also investigate upgrades by retrofitting some of our equipment. Your ideas in this area could prove to be valuable. Upgrades cost money up front, but that cost can often be paid back relatively quickly through energy savings.
Some ideas:
We could upgrade our insulation. We should look at the economic thickness of insulation – that is, we should find the best compromise between the cost of insulation and the potential energy savings.
We could also investigate where we could eliminate steam use.
And we should look into replacing old steam traps and traps that are the wrong size or type.
[INSTRUCTIONS TO PRESENTER: DELETE ANY OF THESE POINTS IF THEY DO NOT APPLY TO YOUR FACILITY.]

12. What can we do? 3. Retrofits (cont.) Optimize pipe sizes.
Oversized while undersized pipes require higher pressure, lead to higher leakage and require extra pumping energy.
One retrofit that could pay back significant savings is optimizing pipe sizes.
Oversized pipes increase our capital and insulations costs. And they lead to higher surface heat losses.
But undersized pipes require higher pressure. They also cause higher leakage losses. And they require extra pumping energy.
So we’ve got to get our pipe sizes right.

13. What can we do? 3. Retrofits (cont.) Depressurize condensate.
Recover heat from condensate.
Install a closed-loop pressurized condensate return.
Measure steam and condensate flows with a meter.
Still more retrofit ideas – these focus on the condensate that goes back to the boiler.
We could depressurize the condensate.
We could look at recovering heat from condensate.
We could install a closed-loop pressurized condensate return.
Finally, we could measure steam and condensate flows with a meter.
You may have other ideas. We want to hear them.

14. oee.nrcan.gc.ca/industrial
How can we do it?
We have the people.
We have the tools.
oee.nrcan.gc.ca/industrial
We have the people.
The fact that you’re here means we’ve already taken a giant step toward making our steam and condensate systems more energy efficient.
We need to build on this meeting. We have to encourage people who aren’t in this room to help identify energy savings.
We need your ideas – right now and in the future.
[USE THIS OPPORTUNITY TO ENCOURAGE FEEDBACK. IDENTIFY A STEAM AND CONDENSATE SYSTEM CHAMPION WHO WILL TAKE SUGGESTIONS IN THE FUTURE. CONSIDER OFFERING PRIZES AND OTHER INCENTIVES.]
We have the tools.
The NRCan fact sheet [SHOW NRCAN’s FACT SHEET] gives you an overview of energy savings related to our steam and condensate systems. It also has a checklist that we can use to evaluate our systems.

15. Thank you Together we can make it happen.
It’s good for the environment.
It’s good for the bottom line.
[ASK FOR VOLUNTEERS TO SURVEY THE FACILITY AND FILL OUT THE CHECKLIST.]