1. IAC Student Meeting February 19, 2004 Using DOE BestPractices Steam Tools And Resources Dr. Anthony L. Wright Oak Ridge National Laboratory (wrightal@ornl.gov, 865-574-6878)

2. Sir Oliver Lyle: “The Efficient Use Of Steam” Steam Possesses Many Outstanding Qualities: –Very high heat content –Gives up heat at constant temperature –Produced from water (cheap, plentiful) –Clean, odorless, tasteless –It’s heat can be used over and over –Can generate power, then used for heating –Can be readily distributed, easily controlled 1947

3. Steam Systems Have Four Basic Components Generation, Distribution, End Use, Recovery

4. Four Key BP Steam Tools Steam System Scoping Tool Steam System Survey Guide Steam System Assessment Tool (SSAT) 3E-Plus Insulation Appraisal Software

5. Additional BP Steam Resources Steam System Sourcebook Steam Tip Sheets Steam Technical Briefs Additional BP Steam Reports “Steaming Ahead” Newsletter BP Steam Training –End User –Specialist Qualification

6. What Does A GREAT Steam System Look Like? BestPractices Steam Has Identified Key Elements Of An Excellent Steam System Steam System Scoping Tool Outlines These Key Elements Best Practice Elements Identified By Steam System Experts

7. Steam Scoping Tool Consists Of 26 Questions On Key Steam System Areas For Improvement

8. Use The Steam SYSTEM SCOPING TOOL To Assess Major Steam Best Practice Areas Steam System Profiling: –Steam costs –Benchmarking –Measurements Steam System Operating Practices: –Steam traps –Water treatment –Insulation –Leaks –Equipment Inspection Boiler Plant Operating Practices: –Boiler efficiency –Heat recovery –Dry steam generation –General boiler operation Distribution, Recovery Operating Practices: –Backpressure turbine use –Condensate recovery/use

9. Available SSST Versions Microsoft Excel Version Visual Basic Version

10. Demonstrating The Steam System Scoping Tool…

11. AVERAGE SSST RESULTS (68 Respondents, Total Average = 65%)

12. STEAM SYSTEM SURVEY GUIDE Technical Guide Covers 5 Areas: –Steam system profiling –Identifying steam properties –Improving boiler operations –Improving resource utilization –Improving steam distribution

13. Use The Survey Guide To Assess Steam Efficiency Improvements In These Areas Fuel Costs Combustion Efficiency For Different Boiler Fuels Boiler Blowdown Improvement Savings Vent Steam Use Of Backpressure Turbines vs PRVs Condensing Turbine Operation Steam Leaks Insulation Condensate Recovery

14. Steam Generation Efficiency Boiler efficiency is a major factor determining the operating costs of a steam system Several major factors impact boiler performance What are the efficiency control parameters and are they maintained at appropriate levels?

15. Identify Boiler Losses Steam Outlet Feedwater Inlet Fuel and Air Exhaust Gases

16. Classic Boiler Efficiency For a steam generating unit efficiency is defined as the heat absorbed by the steam divided by the energy input with the fuel

17. Boiler efficiency can also be determined in an INDIRECT MANNER –By determining the magnitude of the losses –The primary losses are typically Shell loss Blowdown loss Stack loss

18. New Steam Tool: Steam System Assessment Tool (SSAT) PURPOSE: –Demonstrate magnitude – energy, cost, emission savings – of key steam system improvement opportunities

19. SSAT Can Evaluate These Key Steam Improvement Initiatives Real Cost Of Steam Steam Quality Boiler Efficiency Alternative Fuels Cogeneration Opportunities Steam Turbines vs PRVs Boiler Blowdown Condensate Recovery Steam Trap Operating Efficiency Heat Recovery Vent Steam Steam Leaks Insulation Efficiency Emissions Calculations

20. Key SSAT Features Choice of 1, 2, or 3 Header Pressure Models Schematics of Model Steam Systems Estimates of Site Environmental Emissions Major Equipment Simulated: –Boiler –Back pressure turbines –Condensing turbine –Deaerator –Steam traps, leaks, insulation losses –Letdowns –Flash vessels –Feedwater preheat exchangers

22. Demonstrating The Usefulness Of SSAT… 2-Header Steam System Example: –400, 20 psig –Natural gas boiler –2,000 kW site electrical load Evaluating Steam Improvements: –Boiler efficiency change –Boiler blowdown improvements –Utilizing back pressure turbine to make on-site power

23. Demonstrating The Steam System Assessment Tool…

24. Known SSAT Areas For Improvement MP-LP Desuperheating Model Does Not Work Correctly Project To Use LP Vent Steam To Heat Deaerator Water Does Not Work Correctly DATA INPUT: –Enter NUMBERS ONLY –For example – “4” not “4%”

25. SSAT Steam Trap, Leak Assumptions Last Trap Leak ReviewLossesLosses <1 yr 3% 1% 1-2 yr 5% 2% 3-5 yr 10% 4% 6-8 yr 15% 6% 9-10 yr 30% 8% >10 yr 50% 13%

26. 3E-Plus Insulation Appraisal Software

27. Demonstrating The 3E-Plus Insulation Appraisal Software…

28. STEAM SYSTEM SOURCEBOOK Includes Three Main Sections: –Steam System Basics –Performance Improvement Opportunities –Programs, Contacts, and Resources

29. 19 Steam Energy Tips Published 1- Page Tips For Improving Steam System Areas Available On BestPractices Web Site, And In Steam Sourcebook

30. Four Steam Technical Briefs Published The Role of Heat Pumps in Industrial Steam Systems Steam Heat Transfer Solutions Process Control Schemes in Industrial Steam Systems How to Calculate the True Cost of Steam

31. Guide To Low-Emission Boiler And Combustion Equipment Selection Guidance For Choosing Low- Emission Boilers, Combustion Equipment Collaboration Between DOE, ABMA, CIBO

32. Using BP Steam Tools –1a Use Steam Scoping Tool To Self Assess Your Steam System –COLLECT steam system data –DETERMINE steam system costs –OBTAIN SSST score –IDENTIFY potential areas for improvement

33. Using BP Steam Tools –1b IDENTIFY Staff Training Needs –Many available courses offered by steam service providers, training organizations –BP Steam training opportunities End User Specialist Qualification

34. Using BP Steam Tools –2 REVIEW Available BP Steam Resource Documents – Improvement Ideas –Steam Sourcebook –Steam Tips, Tech. Briefs –Other Publications

35. Using BP Steam Tools –3 QUANTIFY Potential Steam Improvement Savings Available –Survey Guide (hand calculations) –SSAT (system-model based calculations) –3E-Plus (insulation-specific improvements)

36. For Further Information… Tony Wright, Oak Ridge National Laboratory phone: 865-574-6878; fax: 865-576-6642 email: email: wrightal@ornl.gov BestPractices Web Site Address: www.oit.doe.gov/bestpractices “Steaming Ahead” Web Site Address: www.steamingahead.org