Industries of the Future: Creating a Sustainable Technology Edge

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Boston, MA Steam Workshop April 1, 2003 Total
System Approach To Improving Steam Efficiency
Dr. Anthony L. Wright Oak Ridge National
Laboratory (wrightal_at_ornl.gov, 865-946-1353)
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How Can You Determine Available Opportunities
To Improve YOUR Steam System??
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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
• Its heat can be used over and over
• Can generate power, then used for heating
• Can be readily distributed, easily controlled

1947
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Four Key BP Steam Tools Available

• Steam System Scoping Tool
• Steam System Survey Guide
• Steam System Assessment Tool (SSAT)
• 3E-Plus Insulation Appraisal Software

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What Does A GREATSteam 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
• Microsoft Excel, Visual Basic Versions Available

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Steam Scoping Tool Consists Of 26 QuestionsOn
Key Steam System Areas For Improvement
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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

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Steam Best PracticeProfile Your Steam System

• Monitor Fuel Cost To Generate Steam
• at least quarterly
• Measure Steam/Product Benchmarks
• at least quarterly
• Monitor Critical Steam System Parameters
• steam production, fuel flow, feedwater, blowdown,
  chemical input, etc.

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Steam Best PracticeImplement Effective Steam
Trap Program

• Elements Of A Best Practice Steam Trap
  Maintenance Program
• Proper trap selection for application
• At least annual testing of traps
• Maintaining a steam trap database
• Repairing/Replacing defective traps

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Steam Best PracticeImplement Effective Water
Treatment Program

• Ensure That Water Treatment Functioning Properly
• at least daily
• Measure Conductivity (or TDS), Determine Blowdown
  Rates
• continuously, or at least once a shift

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Steam Best PracticeSystem Insulation

• Ensure That Major System Components Are Well
  Insulated
• refractory
• piping
• valves
• fittings
• vessels
• Perform Periodic Steam System Insulation Reviews

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Insulation Improvement Example
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Steam Best PracticesSteam Leaks, Water Hammer

• Identify And Quickly Repair Steam Leaks
• strive for zero leaks
• Detect And Quickly Eliminate Steam System Water
  Hammer
• strive for frequency of less than once a month

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Steam Best PracticeMaintain Effective Steam
System Operations

• AT LEAST ONCE A YEAR, Inspect
• Boiler Plant Equipment boiler, deaerator,
  feedwater tank, chemical treatment equipment,
  etc.
• Distribution Equipment piping, valves, pressure
  reducing stations, etc.
• End Use Equipment turbines, piping, heat
  exchangers, coils, air vents, vacuum breakers,
  etc.
• Recovery Equipment flash tanks, condensate
  pumps, piping, valves, fittings, etc.

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Steam Best PracticeMeasure, Trend Boiler
Efficiency Parameters

• Measure Overall Boiler Efficiency
• at least quarterly
• Measure, As Function Of Boiler Load And Ambient
  Temperature
• flue gas temperature, oxygen content, CO
  content
• Control Boiler Excess Air To Maximize Boiler
  Efficiency
• automatically

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Steam Best PracticesHeat Recovery Equipment,
Generating Dry Steam

• Evaluate Installing Heat Recovery Equipment
• Feedwater economizer
• Combustion air preheater
• Blowdown heat recovery
• Ensure That You Are Generating Dry Steam, Check
  Steam Quality
• at least quarterly

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Steam Best PracticeMinimize Steam Flow Through
PRVs

• Best Alternatives For Reducing Steam Pressure
• Generate steam at required pressure, or
  appropriately apply PRVs
• Use Backpressure Turbines in parallel with PRVs

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Steam Best PracticeCondensate And Flash Steam
Recovery

• Recover And Utilize Available Condensate
• greater than 80, if possible
• Recover And Utilize Available Flash Steam
• greater than 80, if available

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STEAM SYSTEM SURVEY GUIDE

• Technical Guide
• Covers 5 Areas
• Steam system profiling
• Identifying steam properties
• Improving boiler operations
• Improving resource utilization
• Improving steam distribution
• Published, Available On BP Web Site

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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

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New Steam Tool Now AvailableSteam System
Assessment Tool (SSAT)

• PURPOSE
• Demonstrate magnitude energy, cost, emission
  savings of key steam system improvement
  opportunities

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You Can Use SSAT To Evaluate These KeySteam
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

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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

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Steam System Assessment Tool (SSAT) Example
Screen
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Demonstrating The Usefulness Of The Steam System
Assessment Tool

• 2-Header Steam System Example
• 400, 20 psig
• Natural gas boiler
• 2,000 kW site electrical load

• Evaluated Steam Improvements
• Boiler efficiency change
• Boiler blowdown rate change
• Utilizing back pressure turbine to make on-site
  power

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Demonstrating The Steam System Assessment Tool
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3E-Plus Insulation Appraisal Software
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STEAM SYSTEM SOURCEBOOK

• Includes Three Main Sections
• Steam System Basics
• Performance Improvement Opportunities
• Programs, Contacts, and Resources
• Published, On BP Web Site

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19 Steam Energy Tips Have Been Published

• 1- Page Tips For Improving Steam System Areas
• Available On BestPractices Web Site, And In Steam
  Sourcebook

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Steam System Opportunity Assessment For Pulp And
Paper, Chemicals, Petro. Refining

• Steam Generation, Use Data
• Performance Improvements For 30 Key Steam System
  Opportunities
• Published, On BP Web Site

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Guide To Low-Emission Boiler And Combustion
Equipment Selection

• Guidance For Choosing Low-Emission Boilers,
  Combustion Equipment
• Collaboration Between DOE, ABMA, CIBO
• Published, Available On BP Web Site

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Obtaining BP Steam Tools, Resources

• BestPractices Web Site
• All tools, resources
• Decision Tools For Industry CD
• SSST, SSAT, 3E-Plus
• Other BP tools (pumps, comp. air, etc.)
• Steam Tools And Resources CD
• All tools, resources
• Steam System Assessment Tool CD

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For Further Information

• Tony Wright, Oak Ridge National Laboratory
• phone [phone] fax [phone]
• email wrightal_at_ornl.gov
• BestPractices Web Site Address
• www.oit.doe.gov/bestpractices
• Steaming Ahead Web Site Address
• www.steamingahead.org