Acknowledgements

Improving Steam System Performance: A Sourcebook for Industry was developed under the BestPractices activity for the U. S. Department of Energy’s (DOE) Industrial Technologies Program (ITP). BestPracticesundertook this project as a series of sourcebook publications. Other topics in this series include: compressed air systems, pumping systems, fan systems, process heating, and motor and drive systems.For more information about DOE’s BestPractices, see ITP and BestPractices in the Where to Find Help section of this publication.

ITP, Lawrence Berkeley National Laboratory, and Resource Dynamics Corporation wish to thank the staff atthe many organizations that so generously assisted in the collection of data for this Sourcebook. TheAlliance to Save Energy, the Council of Industrial Boiler Operators, the National Insulation Association,and the North American Insulation Manufacturers Association provided valuable assistance in develop-ing, compiling, and reviewing this publication.

The BestPractices Steam activity appreciates the participation of the Steam Technical Subcommittee.Special thanks are extended to its co-chairs, Dr. Anthony Wright, Oak Ridge National Laboratory, and Glenn Hahn, Spirax Sarco, an Allied Partner, for providing extensive technical guidance and reviewthroughout the preparation of this publication. The efforts of these program and committee partici-pants are greatly appreciated.

Additionally, the contributions of the following participants are appreciated for their review of and suggestions for this Sourcebook:

Deborah Bloom, Nalco CompanySean Casten, Turbosteam CorporationBruce Gorelick, Enercheck SystemsRobert Griffin, Enbridge Gas Distribution, CanadaDr. Greg Harrell, Energy, Environment and Resources Center, University of Tennessee-KnoxvilleThomas Henry, Armstrong ServiceCarroll Hooper, Steam Solutions, Inc.James Kumana, Kumana and AssociatesAndrew W. Larkin, Trigen Energy CorporationLloyd Mason, Condensate Return SpecialistsGil McCoy, EERE Information CenterKelly Paffel, Plant Support & Evaluations, Inc.W. Randall Rawson, American Boiler Manufacturers Association Douglas Riley, Millennium Chemical Thomas Scheetz, BASFJohn Todd, Yarway Corporation

Prepared for: The United States Department of EnergyIndustrial Technologies Program

Prepared by: Lawrence Berkeley National LaboratoryWashington, DCResource Dynamics CorporationVienna, VA

Cover photo credit: NREL/PIX 05559. The Leathers geothermal power plant located in the Salton Sea, California. Photo by Warren Gretz.

Acknowledgements i

Table of Contents ii

List of Figures and Tables iii

Quick Start Guide

Section 1: Steam System BasicsWhy Steam? 3

Steam System Operation 3

Generation 5

Distribution 11

End Use 15

Recovery 21

Section 2: Performance Improvement OpportunitiesOverview 25

Systems Approach 25

Common Performance Improvement Opportunities 25

BestPractices Steam System Performance Tools 26

Steam System Training 28

Overview of Financing Steam System Improvements 29

Section 3: Where to Find HelpThe Industrial Technologies Program and BestPractices 33

Directory of Contacts 36

Resources and Tools 37

AppendicesAppendix A: Glossary of Terms 57

Appendix B: Steam Tip Sheets 61

Appendix C: Guidelines for Comment 101

Contents

iiA Sourcebook for Industry

1

3

25

33

55

iii Improving Steam System Performance

List of FiguresFigure 1. Steam System Schematic 4

Figure 2. Firetube Boiler 5

Figure 3. Watertube Boiler 6

Figure 4. Thermostatic Steam Trap with a Bellows Element 13

Figure 5. Thermostatic Steam Trap with a Bimetallic Element 13

Figure 6. Inverted Bucket Steam Trap 14

Figure 7. Float and Thermostatic Steam Trap 14

Figure 8. Thermodynamic Disc Steam Trap 14

Figure 9. Shell and Tube Heat Exchanger 18

Figure 10. Components of a Plate and Frame Heat Exchanger 18

Figure 11. Configuration of a Jacketed Kettle Heat Exchanger 18

Figure 12. Thermocompressor Operation 20

Figure 13. Condensate Receiver Tank and Pump Combination 22

Figure 14. Flash Steam Recovery Vessel 23

List of TablesTable 1. Key IOF Steam End-Use Equipment 16

Table 2. Common Performance Improvement Opportunities for the Generation,Distribution, and Recovery Parts of Industrial Steam Systems 26

1

This Sourcebook is designed to provide steamsystem users with a reference that describes the basic steam system components, outlinesopportunities for energy and performanceimprovements, and discusses the benefits of a systems approach in identifying and imple-menting these improvement opportunities. The Sourcebook is divided into three main sections as outlined below.

This Sourcebook is not intended to be a compre-hensive technical guide on improving steam systems, but rather a document that makes usersaware of potential performance improvements,provides some practical guidelines, and directsthe user to helpful resources. A systems approachanalyzes the supply and the demand sides of thesystem and how they interact, essentially shiftingthe focus from individual components to totalsystem performance. The cost-effective operationand maintenance of a steam system requireattention not only to the needs of individualpieces of equipment, but also to the system as awhole. Often, operators are so focused on theimmediate demands of the equipment, theyoverlook the broader question of how systemparameters affect the equipment.

� Section 1: Steam System BasicsFor users unfamiliar with the basics of steam systems, or for users seeking a refresher, a brief discussion of the terms, relationships, and important system design considerations is provided. Users already familiar with industrialsteam system operation may want to skip thissection. This section describes steam systemsusing four basic parts: generation, distribution,end use, and recovery.

� Section 2: Performance Improvement Opportunities

This section discusses important factors thatshould be considered when industrial facilitiesseek to improve steam system performance andto lower operating costs. This section also providesan overview of the financial considerations relat-ed to steam system improvements. Additionally, this section discusses several resources and toolsdeveloped through the U. S. Department of Energy’s (DOE) BestPractices Steam activities toidentify and assess steam system improvementopportunities.

� Section 3: Where to Find HelpThis section provides a directory of associationsand other organizations involved in the steamsystem marketplace. This section also provides a description of the BestPractices Steam activities, a directory of contacts, and a listing of availableresources and tools, such as publications, software,training courses, and videos.

� AppendicesThe Sourcebook includes three appendices.Appendix A is a glossary defining terms used insteam systems. Appendix B contains a series ofsteam system tip sheets. Developed throughDOE’s BestPractices Steam activities, these tipsheets discuss common opportunities that industrial facilities can use to improve perform-ance and reduce fuel use. Appendix C providesguidelines for submitting suggested changes andimprovements to the Sourcebook.

A Sourcebook for Industry

Quick Start Guide

Quick Start Guide