Steam End User Training Guide

DOEBestPracticesSteamEndUserTraining

Guide

AlternateTextNarrativesand

GraphicDescriptions

June29,2010

DOE BestPractices Steam End User Training

SteamEndUserTrainingTableofContentsii

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TableofContents

Welcome ....................................................................................................................................................................................................... 3

NavigationalTutorial............................................................................................................................................................................... 6

Introduction ................................................................................................................................................................................................ 8

TechnicalModules

SteamGenerationEfficiency

EfficiencyDefinition......................................................................................................................................................30

ShellLosses.......................................................................................................................................................................42

BlowdownLosses ..........................................................................................................................................................45

StackLosses......................................................................................................................................................................73

ResourceUtilizationAnalysis............................................................................................................................................. 114

SteamDistributionSystemLosses ................................................................................................................................... 157

Conclusion.............................................................................................................................................................................................. 188

EndofCourseQuiz ............................................................................................................................................................................ 201

DOEs BestPractices Steam End User Training

WelcomeModule1

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SteamEndUserTraining

SteamEndUserTrainingWelcomeModule

Slide1SteamEndUserTraining

WelcometotheDepartmentofEnergysIndustrialTechnologiesProgramBestPracticesSteamEndUserTraining.

[SlideVisualSteamEndUserCourseWelcome]Banner:USDepartmentofEnergyEnergyEfficiencyandRenewableEnergy

USDepartmentofEnergysIndustrialTechnologiesProgram

BestPracticesSteamEndUserTraining

Slide2CourseContentsTherearesevendifferentsectionsinthistraining.Thenavigationaltutorialwillprovideyouwithabriefdemonstrationonhowtonavigatethroughthetraining.TheIntroductionwillprovideyouahistoryofthecoursedevelopment,andthenfocusonthegeneralaspectsofsteamsystemmanagementandinvestigation.Inthissectionwewillintroducethefirstofthesteamsystemsoftwaretools,whichprovidessupportinidentifyingareasofpotentialimprovement.Thiswillprepareyouformoreindepthdiscussionsintheforthcomingsectionsofthetraining.TheSteamGenerationEfficiencymodulefocusesonboilerefficiency.Inthissectionthedefinitionofboilerefficiencywillbediscussedandthevariousavenuesofboilerlosseswillbeexplored.ResourceUtilizationEffectivenesswilldiscussfuelselection,steamdemands,andcogeneration.TheSteamDistributionSystemLossesmodulewillcoversteamleaks,steamtraps,insulationissues,andcondensateloss.EverythingwillbewrappedupwiththeConclusion.Lastly,therewillbeanEndofCourseQuiz,whichwillevaluateyourknowledgeandunderstandingofthetraining.Slide3SteamAssessmentsThiscourseisstructuredlikeatypicalsteamsystemassessment.Theassessmentisdesignedtoinvestigatetheperformancecharacteristicsofthesystem,pointoutbestpractices,identifyopportunitiestoimproveperformance,andevaluatetheeconomicimpactofpotentialimprovements.


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Thistrainingwillprovideanoverviewoftypicalsteamsystems,theircomponents,operatingprinciples,managementtechniques,andpotentialimprovementopportunities.Steamsystemmodificationsoftenaffecttheentiresystemrequiringcomplicatedcalculationstoaccuratelyevaluatemass,energy,andeconomicimpacts.Thiscoursewillpointoutthevarioustoolswehaveavailabletousintheinvestigationprocess.Manyofthetoolsarethefundamentalprinciplesofphysicsthatallowustoidentifythebeforeandafterconditionsassociatedwithaspecificmodification.Additionally,theU.S.DOEhasdevelopedasophisticatedsetoftoolsthatenhanceourabilitytoaccuratelyandeffectivelyevaluatesteamsystemmodifications.Wewilldiscussthesefreetoolsthatcompletecomplicatedcalculationsandhelpyouidentify,analyze,quantify,andprioritizeenergysavingswithinyourplantssteamsystem.Slide4SteamSystemSchematicsWewilluseanexamplesteamsystemtoserveasthefocusofourinclasssteamsystemassessment.Theexamplesteamsystemrepresentsaheavyindustrysitewithtypicalcomponentsandcommonoperatingconditions.Theevaluationsandfindingsnotedinthistrainingrepresentopportunitiescommonlyidentifiedinindustrialsteamsysteminvestigations.Thissteamsystemisnotextraordinaryinanymannerincludingfuelcost,steamproduction,andoperatingconditions.Asyouwillsee,theexamplesystemoperateswiththreeboilerseachboilerconsumesadifferentfuel(naturalgas,number6fueloil,andgreenwood).Thetotalfuelexpenditureforthesiteisnominally19MillionDollarsperYear.Typicalsteamproductionis260,000poundsperhourof400psig,700Fsuperheatedsteam.Thethreeboilersdeliverhighpressuresteamtothedistributionsystemheader.Highpressuresteamservessteamloads,aswellasseveralcogenerationcomponents.Thebackpressureturbinesareconnectedtoelectricalgenerators,thusservingtoreducesteampressureandtogenerateelectricity.Pressurereducingstationsalsoassistinmanagingtheflowofsteamthroughthesystem.Asinallsteamsystemstherearemanyauxiliarycomponentssuchascondensaterecoverytanks,makeupwatertreatmentequipment,deaerator,feedwaterpumps,andmanymorecomponentsnotshownintheschematic.

[SlideVisualSteamSystemSchematic]Thisschematicrepresentsathreeheadersteamsystemincorporatingthreeboilersandmanysystemcomponents.Thesteamdistributionsystemincludesthreebackpressureturbinesandtwopressurereducingvalves.Theturbinesandpressurereducingvalvesoperatebetweenthevarioussteampressuresofthesystem.Eachsteamheaderincludesendusesteamloadswhichdischargecondensatethroughsteamtrapstotheirrespectivecondensatecollectiontanks.Condensateisultimatelycollectedinthemaincondensatereceiver,thenpumpedtoadeaerator.Thedeaeratoralsoreceivesmakeupwaterandsteamtopreheatthecollectedcondensateandmakeupwater.Thedeaeratoroutflowbecomesthefeedwaterfortheboilers.


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Slide6ResultsTheexamplesystem,whichisbasedonarealworldsteamsystem,wassubjectedtoasteamsystemassessmentusingfundamentalinvestigationtechniquesandtheU.S.DOESteamTools.Theassessmentidentifiedseveralprojectsthatwillresultinsignificantenergysavingsthatpresenteconomicallyattractiveprojects.Theassessmentidentifiedmorethan$1,300,000/yrofenergysavings,whichrepresentsmorethan7%ofthefuelinputcosttothesite.ThisSteamEndUserTrainingwillwalkyouthroughthisrealworldexampleofasteamsystemtohelpillustratehowyoucanidentifyareaswithpotentialforsavingenergyandforreducingcosts.Now,letsgetstartedsoyoucanlearnhowtoidentifyenergyefficiencyimprovementsatyoursite!


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SteamEndUserTrainiNavigationalTutorial

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SteamEndUserTrainingNavigationalTutorialModule

Slide1IntroductionHello,andwelcometotheSteamEndUserTraining.Iwouldliketotakeafewminutestoshowyouhowtonavigatethroughthetraining.Slide2TableofContents1Asyoucanseeinthetableofcontents,itisseparatedinto3differentmodules,eachonedemonstratingadifferentmajortopicintheSteamEndUserTraining:SteamGenerationEfficiency,ResourceUtilizationAnalysis,andSteamDistributionSystemLosses.Attheendofthecourse,youcantakeaninteractivequiztotestyourunderstandingofsteamsystemconceptsandimprovementopportunities.Clickonamodule,individualslide,orthequiz,tonavigatetoit.Slide6StatusIfyouclickonamodule,thesidebarwilldisplayitsindividualslides,aswellastheirtitlesandduration.Youcanclickonanyslideinordertonavigatetoit.UnderStatus,youwillseeacheckmarknexttoeachmoduleorslidethatyouhavecompleted.Atthebottom,youwillseethetotaltimeofthetraining,aswellashowmuchofthattimeyouhavecompleted.ClickonCleartogetridofallofthecheckmarks.Youcanalsoutilizethebookmarkfeature.Selectthesmallbuttonontheleftsideoftheslidetitletobookmarkaslide,Slide7Bookmarktoreturntoitlatertocompletethetrainingsession,orforreferenceorquestions.Youcanclickthebuttonagaintocancelthebookmark.Slide8Rewind/Play1Atanytimeyouhavenavigatedthecoursewiththesidebarorbottomcontrolbar,andtheaudiodoesnotbegin,doubleclickonthehighlightedsidebarslidetitle.Thehighlightidentifieswhereyouare,andtheaudioshouldrestart.Noticethetoolbarbelowthemainscreen.Rewindwilltakeyoutothebeginningofthemodulethatyouareviewing.Clickplaytocontinue,Slide10Back/Forwardandpausetopausethetraining,Backandforwardwillmovebackandforwardbetweenslides.Ifyouwanttogotwiceasfast,youcanclickon2timesFastForwardSpeed.


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Slide11FastForwardClickonitagaintoget4timesFastForwardSpeed.Youmustreturntonormalspeedtoheartheaudio,astheaudioisoffduring2timesand4timesFastforward.Slide12NormalSpeedClickonitonemoretimetogobacktothenormalspeed.Slide13SliderBar1Youcanalsonavigatetoaparticularsectionofthetrainingbydraggingthesliderbackandforward.Clickitandholddownthemousebutton.Slide15SlideNumber/Play/Pause1Itwilldisplaywhichslideyouareon,outofthetotalnumberofslidesinthemodule.Asyourepositiontheslidercursor,youwillnoticethesidebarwillhighlighttheslidecorrespondingtothecursorposition.Slide16SlideNumber/Play/Pause2Torestartthetraining,youmayclickonthecorrespondingslide(whichishighlighted),orjusthittheplaybutton,asthepausebuttonwasautomaticallyengagedwhenusingtheslider.Slide19SoundOn/Off1Also,Youcanchoosetohavethesoundonoroff.Slide21ClosedCaptioning1CCallowstheusertoturntheclosedcaptioningonoroff.ClickingtheXwillexittheprogram.ClickingIwilldisplayinformationabouttheprogram,includingtheauthorandtheauthorsemailaddress.Slide23MinimizeScreenAtthetoprightofthescreen,youcanclicktheleftbuttontominimizethewindow.Slide24MaximizeScreenClickonthemiddlebuttontomaximizeit,sothatyoucanseeitbetter.ClickontheXallthewayontherightinordertoclosethetraining.IfyouareusingInternetExplorersF11Fullscreenmode,youwontbeabletoseethebigXintheupperrightcorneruntilyouhitF11again.IfyouareusingabrowserotherthanInternetExplorer,thesebuttonswilllookdifferent.Now,letsgetstarted!


SteamEndUserTrainingIntroductionModule1

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SteamEndUserTrainingIntroductionModule

Slide1IntroductionTitlePageHello,andwelcometotheSteamSystemEndUsertraining.Inthistraining,wewillinvestigatehowtoassess,evaluate,andmanagesteamsystems.Wewillcovertheentiresteamsystem,fromoneendtotheother.Letsgetstarteddiscussingtheoriginofthecourse,theneedforthecourse,andthentheoverallcourseobjectives.

[SlideVisualIntroductionTitlePage]

DOEsBestPracticesSteamEndUserTraining

Introduction

CourseDevelopmentTheNeedfortheCourse

CourseObjectivesStarttheInvestigation

Slide2OriginalCourseThiswebbasedtrainingtoolhasbeendevelopedfromitsoriginal,instructorledclassroomsetting.Theoriginalcoursewasdesignedprimarilywiththeindustrialsectorinmindandwithanindustrialexperiencebasis.Theprimaryprinciplesareapplicabletoallsteamsystemsandeventhermalwatersystems;but,thefoundationprinciplesarebasedinheavyindustry.Thecourseisdesignedforplantpersonnel,suchasenergymanagers,steamsystemsupervisors,engineers,equipmentoperators,andotherswithsteamsystemresponsibilitiesinindustrialapplications.Nowasawebbasedtrainingtool,participantscanaccessthetraininganytimeandreturntorevisittopicsofinteresttohelpimprovetheefficiencyandperformanceoftheirsteamsystems.


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[SlideVisualDescriptionoftheInstructorledClassroomCourse]Headercontains:

IndustrialTechnologiesProgramTitleincludes:

ABestPracticesTrainingPresentationUSDepartmentofEnergy

SystemSystemsAssessmentTrainingIncludingUseoftheSteamSystemsToolSuite

Threephotographsofsteamsystems.

Photo1:alargeverticalexhaustpipeonabuildingexteriorexhaustingasteamplumefromthetopofthestack. Photo2:aseriesofsmallsteampipeswithasteampressuregauge. Photo3:Fivehorizontalrunsofsteamdistributionpipingfromacommonheader.Steamdistributionpipingisinsulatedwithan

aluminumjacketing.Apersonisstandingneartheheader.

Bottomfootercontains:USDepartmentofEnergySealUSDepartmentofEnergyEnergyEfficiencyandRenewableEnergyBringyouaprosperousfuturewhereenergyisclean,abundant,reliable,andaffordable.

Slide3CourseDeveloperThiscoursewasdevelopedbyGregHarrellandisintendedtopresentarealworldviewofhowsteamsystemsoperate,practicalevaluationtechniques,andcommonimprovementopportunities.Thiscoursehasdevelopedovermanyyearsofobservingandinvestigatingsteamsystems.ItrepresentsthecompilationofBestPracticesobservedassustainablesteamsystemmanagementmeasures.

[SlideVisualGregHarrellsCredentials]CourseDeveloperGregHarrell,Ph.D.,P.E.

Ph.D.MechanicalEngineeringThermodynamics,VirginiaTech(VPI&SU)1997

1987to1993DesignEngineer,UtilitiesProcessEngineer,BASFCorp.

Oversightforengineering,technicalactivitiesofentireutilitiesdepartment(steamproduction,electricpowergeneration,compressedairsystems,industrialrefrigerationfacilities,industrialHVACsystems,waterfiltrationfacilitiesandwastewatertreatmentplant


AtVirginiaTechMechanicalEngineeringProfessor,EnergyManagementInstitute(EMI)


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From1997to2001DirectorofTechnicalAssistanceforEMI Undergraduateandgraduatelevelthermodynamicsprofessor Directlyinvolvedinimportantaspectsofenergymanagementforindustrieslocatedworldwide Hasconductednumerousenergysurveysforindustrialclientsthroughouttheworldon6continents,in22countries,andin36of

theUnitedStates DevelopedU.S.DOEBestPracticesSteamEndUserTrainingandU.S.DOESteamSpecialistQualificationTraining PlayedmajorroleindevelopmentoftheUSDOEBestPracticesSteamToolsandauthoredSteamSystemSurveyGuide,whichhas

becomeatextforuniversitymechanicalengineeringcourses ACertifiedInstructor,CompressedAirChallenge

CurrentlyConsultantforEnergyManagementServices

Primaryrolescontinuetoincludeindustrialsystemsenergyanalysisandindividualprocessanalyses,industrialtrainingcourses,universityinstruction,energysystemmodeling,andsoftwaredevelopment

AprimaryinstructorintheNorthCarolinaStateUniversityEnergyManagementDiplomaProgram Majorsystemfocusareasboilers,steamsystems,combinedheatandpowersystems(cogeneration),gasturbines,and

compressedairsystemsSlide4QualifiedPresentersThecoursehasbeenpresentedtothousandsofparticipantsrepresentingalltypesofindustry.Thecourseinstructorsallhavemanyyearsofpracticalsteamsystemexperiencetheircareersfilledwithconductingsteamsystemassessmentthroughouttheworldinalltypesofsettings.Thiscombinationoftechnicalexpertise,realworldexperience,anddirectfeedbackfromindustrialparticipantshasresultedinthepractical,useful,andstraightforwardcourseyouseetoday.

[SlideVisualQualifiedPresentersandTheirContactInformation]

GregHarrell,Ph.D.,P.E.EnergyManagementServices341WillocksDriveJeffersonCity,Tennessee37760Phone:8657190173Email:[email protected]

RichardJendrucko,Ph.D.Consultant,IndustrialEnergyManagement458HillvaleTurnEastKnoxville,Tennessee37919Phone:8655237323Email:[email protected]


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RiyazPapar,P.E.,CEM

HudsonTechnologies14SplitRailFenceTheWoodlands,Texas77382Phone:2812980975Email:[email protected]

DebbieBloomNalcoCompany1601WestDiehlRoadNaperville,Illinois60187Phone:6303052445Email:[email protected]

StephenTerry,Ph.D.,P.E.NorthCarolinaStateUniversityIndustrialAssessmentCenterDepartmentofMechanicalandAerospaceEngineeringRaleigh,NorthCarolina27695Phone:(919)5151878Email:[email protected]

BillMoirSteamEngineeringInc.204NE117thAvenueVancouver,Washington98684Phone:(800)3466152Email:[email protected]

Slide5IndustrialEnergyJustforamomentletsexaminetheimportanceofeffectivemanagementofsteamsystems.Tostartthisdiscussion,considertheamountofenergyrequiredtooperateourindustries.ItisinterestingtonotethatintheUnitedStatesenergyisusedinthreebroadcategoriesofconsumers.Theseconsumersaresegregatedintotransportation(automobiles,trucks,andairplanes),residentialcommercial(homesandbuildings),andindustry.ItisinterestingtonotethateachofthesethreesectorsconsumeapproximatelyonethirdoftheenergyusedintheU.S.Thetransportationsectorconsumesalmostonethirdoftheenergy,whileresidentialandcommercialtogetherusesomewhatmorethanonethirdoftheenergy.Remarkably,industryaloneusesathirdofthecountrysenergy.Thesethreesectorsuseenergyinverydifferentways.Thetransportationsectorusesprimarilyliquidfuelsastheenergyresource.Residentialandcommerciallocationsusealargeamountofelectricityalongwithnaturalgasandfueloils.Industryusesabroadmixofenergyresourcesincorporatingelectricity,manyfueltypes,andotherenergyresources.Managementandsupportforthesesectorsrequireverydifferentapproaches.OnethingisveryapparentmanagingtheenergyutilizationofindustryiscriticaltothecompetitivenessoftheU.S.ontheworldstage.



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[SlideVisual2004EnergyUsePieChart]Title:2004EnergyUse*

Industry34.0%(orangeslice)Transportation28.0%(blueslice)Commercial17.0%(greenslice)Residential21.0%(yellowslice)

Footnotes:

*IncludeselectricitylossesSource:DOE/EIAMonthlyEnergyReview2004(preliminary)

Slide6EnergyConsumptionOurfocushereistheindustrialsector.Itwillbeinterestingtoustocharacterizethetypesofenergyuseintheindustrialsector.U.S.DOEisservingasanenergymanagerforindustrialsitesintheUnitedStates.FromtheperspectiveoftheU.S.DOEhelpingU.S.industrymanageenergyresourcesisadauntingchallengethereareaquarterofamillionindustrialsitesintheUnitedStates.HowcanDOEhelpaquarterofamilliondiverseusers?LikeanygoodenergymanagerDOEinvestigatedthemeasurementsthatindicatehowenergyisusedinindustrythroughoutthecountry.WhatDOEfoundisthathalfoftheenergyusedinindustrialsitesisusedbylargeindustrialsites.Thisisveryinterestingbecauselargeindustrialsitescompriseonly3percentoftheindustrialpopulation.Ifwecaninfluencetheenergyconsumptionofthissmallfractionofthetotalindustrialpopulation,thenwecaninfluenceasignificantportionofU.S.energy!Also,thetechniquesusedtoaidthelargeindustrialsitescanbereplicatedtotheremainingindustrialsites.

[SlideVisualU.S.ManufacturingPlants:BySizeBarChart}Title:U.S.ManufacturingPlants:BySize HorizontalAxis:PlantsizeandAnnualEnergyCosts

SmallPlants$2MAllU.S.Plants(nocostprovided)

VerticalAxis:NumberofU.S.Plants

Range0to250,000by50,000increments



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Chartreads:

SmallPlants$2Mhas6,802plants(orangebar)AllU.S.Plants(nocostprovided)has226,737plants(greenbar)

[SlideVisualPercentofTotalIndustri galEner yPieChart]Title:PercentofTotalIndustrialEnergy

SmallandMedium47%(yellowslice)Large53%(orangeslice)

Source:1998EIAMECS

Slide7EnergyRequirementsAsaresult,letstakealookathowenergyisusedinatypicalindustrialsite.Asyoucanseefromthechart,mostoftheenergyisgoingintoprocessheatingandsteamsystems.Bothprocessheatingandsteamsystemsconsumemorethanonethirdoftotalindustrialenergy.Itisalsoexcellenttonotethateventhoughprocessheatingandsteamsystemshavetheirdistinctdifferences,theinvestigationtechniquesandopportunitieswehaveinprocessheatingareverysimilartothoseforsteam.Ifwecanbettermanageourprocessheatingandsteamsystems,wecanhaveasignificantimpactonourenergyconsumptionandcompetitivenessintheworldmarket.Thisistheprimarydrivingforceforthiscourse;inotherwords,steamsystemsareamajorfactorintheenergyconsumptionoftheUnitedStatesandmuchoftheworld;therefore,weneedtomanagethemeffectively.

[SlideVisualTypicalEnergyRequirementsPieChart]Title:ManufacturingEnergyUsebyTypeofSystem(%)

Steam35%(blueslice)ProcessHeating38%(brightyellowslice)MotorSystems12%(peachslice)ProcessCooling1%(whiteslice)ElectroChemical2%(yellowslice)Other4%(blueslice)Facilities8%(greenslice)

Footnotes:

Note:DoesnotincludeoffsitelossesSource:DOE/EIAMonthlyEnergyReview2004(preliminary)



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Slide8CourseDivisionsThiscourseisarrangedinasimilarmannertoatypicalsteamsystemassessment.Wewillinvestigateallareasofthesteamsystem.WewillstartwiththeboileroperationsintheSteamGenerationAssessmentsectionofthecourse.Inthissectionwewillexaminetheenergyconversionefficiencyoftheboiler.Variousboilerefficiencyinvestigationmethodswillbeidentified.Boilerefficiencyimprovementavenueswillbeexploredalongwithcontrolstrategies.IntheResourceUtilizat sectionofthecoursewewilltargetsteamendusecomponents,fuelselection,steamsystembalancing,aswellascombinedheatandpoweractivities.Thesearemajorconcernsformostfacilitiesandcanpresentsignificantopportunitiesforeconomicimprovement.

ionAnalysis

TheDistributionSystemcanprovidetremendouswasteintheformofsteamleaks,steamtrapfailures,insulationrelatedlosses,andlostcondensate.Theseareaswillserveasinvestigationtargetsforourdiscussions.Slide9U.S.DOEToolsInvestigatingandanalyzingsteamsystemsrequiresasignificantamountofcomplexcalculationstoidentifytheimpactpotentials.Throughoutthistraining,wewilldemonstratethefundamentalcalculationsandinvestigationtechniquesrequiredtoevaluateeachareaandeachimprovementopportunity.TheSteamSystemSurveyGuideisacompaniondocumenttotheSteamEndUserTrainingtodiscussmajorareasofpotentialimprovementsforsteamsystemsandhowtoquantifythoseopportunitiesandisavailableforfreedownloadfromtheBestPracticesTrainingArea.AdditionaltechnicalpublicationsareprovidedforfreedownloadfromtheBestPracticesResources.Youcanreferencethesedocumentsasyouinvestigateimprovementsforyoursteamsystemsefficiencyandperformance.TheSteamSystemToolsSuiteisasetofsoftwaretoolsconstructedtoaidintheevaluationofsteamsystemprojects.ThesesoftwaretoolsareavailableforfreedownloadfromtheU.S.DOEwebsite.TheToolsSuiteincludestheSteamSystemScopingTool,whichisdesignedtoguidetheusertopotentialimprovementopportunities.Also,includedistheSteamSystemAssessmentTool,whichallowstheusertocompleteacomprehensivemass,energy,andeconomicbalanceonthesteamsystem.Thistoolisdesignedtoevaluatethesystemwideimpactsofchangesinthesteamsystem.Finally,theToolsSuitecontainsthe3EPlusInsulationEvaluationTool.Thistoolcanbeusedtoevaluateanyinsulationrelatedproject.Slide10CourseObjectives1Wearegoingtofocusourattentiononthefundamentalandpracticalaspectsofsteamsystemoperation,maintenance,andmanagement.Whatwewouldliketoaccomplishistohelpyouidentifyopportunitiesyoumayhavetoimproveyoursteamsystem,understandhowtoevaluatethetrueimpacts,andtosetapathtoimplementtheimprovements.Thefocuswillbeonthefundamentalsofsteamsystemsifthefundamentalsaremasteredthesteamsystemwillbewellmanaged.Effectivesteamsystemmanagementrequiresanexcellenttoolboxfilledwithevaluationtoolsandtechniquesthatwillenabletheskilledassessortoidentifyandquantifyimprovementopportunities.Wewillfocusontheessentialmeasurementsthatcharacterizeoperations.Wewillfocussomeattentionontheboilerandunderstandhowboilerefficiencycanbeimpactedandimproved.

DOEs BestPractices Stea

sualCourseObjectives1]

m End User Training

IntroductionModule8

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[SlideVi

BecomefamiliarwithU.S.DOEToolsSuitetoassesssteamsystems

Identifythemeasurementsrequiredtomanagesteamsystems Measureboilerefficiency Estimatethemagnitudeofspecificboilerlosses Identifyandprioritizeareasofboilerefficiencyimprovement Recognizetheimpactsoffuelselection

Slide11CourseObjectives2Wewillintroducethetopicofcogenerationandidentifythecommonaspectsofturbineoperation.Attentionwillbegiventotheenduseequipmentandpotentialopportunitiestoreducesteamdemand.Steamtrapmanagement,insulationopportunities,andcondensaterecoveryareallvitalcomponentsinsteamsystems.Theseareaswillbeinvestigated.Thereisalotofinformationtodiscuss;so,letsgetstarted.

[SlideVisualCourseObjectives2]

Characterizetheimpactofbackpressureandcondensingsteamturbines Quantifytheimportanceofmanagingsteamconsumption Identifytherequirementsofasteamtrapmanagementprogram Evaluatetheeffectivenessofthermalinsulation Evaluatetheimpactofcondensaterecovery Recognizetheeconomicimpactsofsteamsystemoperations

Slide12SteamSystem

Steamsystemscanbelargeandcomplexwithmanycomponentsandarrangementsbutmanyoftheprimarycomponentswillbecommonfromsystemtosystem.

Oneofthefirststepsincompletingasteamsystemassessmentistoidentifytheprimarycomponentsofthesteamsystem.

Boilersandtheirauxiliarycomponents,heatexchangersandotherenduseequipment,watertreatmentsystems,condensaterecoverycomponents,distributionpiping,andmanyothercomponents.Thesecomponentsmaybearrangedinasimplesystem,withasingleboiler,maybeonebackupboileroritcanbemuchmorecomplicated.

[SlideVisualSteamSystemImpactSchematic]

Thisschematicrepresentsatwoheadersteamsystemwithtwoboilersandallofthesystemcomponents.Feedwaterispreheatedbysteaminjectionfromthelowpressuresteamdistributionheader,aswellaspreheatedmakeupwaterutilizingboilerblowdownheatrecovery.


ThetopoftheschematicshowstheBoilerFeedwaterenteringthetwoboilers.Thetwoboilersareconnectedtothehighpressuresteamdistributionheader.


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Thesteamexitstwoboilersandentersthehighpressuresteamsystemdistributionheader,indicatedbyalinebelowtheboilers.

Atthefarrightofthehighpressuresteamdistributionsystem,thehighpressureendusercomponentloadsareidentifiedthrougharectangulargraphicandarrowsenteringandleavingtherectangle,indicatingheatexchangewiththecomponents.Theendusecomponentsdischargecondensatethroughasteamtrap,representedbyarectangulargraphic.Schematically,condensatepassesthroughthebottomofthetrapandrecoveredinacondensingtank.Thecondensatetankusesapump,whichisdenotedbyacircle/squarecombination,todeliverthecondensatetothemaincondensatereceiver.Themaincondensatereceiverthenpumps(denotedbyacircle/squarecombination)thecondensatetothedeaeratortankasdenotedbytworedrectangles,withthesmalleroneonthetop.Thetoprectanglealsoshowstwotriangles,eachpointedawayfromeachother,longestendsnearlytouching.Thebottomtriangleisconnectedtoacontrolvalverepresentedbyahourglassfigurewithadomeontheside,whichprovidessteamtothedeaeratorfromsteamdistributionsystemtopreheatthecollectedcondensateandmakeupwater.Makeupwateralsoschematicallyentersatthetopofthedeaeratorwiththecollectedcondensate.Theboilerfeedwaterschematicallyexitsthedeaeratorfromthebottomandispumped(denotedasacircle/squarecombination)tothefeedwaterinletsofeachboiler,nearthetoptheschematic.

Slide13SteamSystem2PressuresThesystemmayincludemultipleboilers,severalsteampressures,differenttypesoffuel,steamturbines,andmanyprocessendusers.


Thisschematicrepresentsatwopressureheadersteamsystemwithmultipleboilersandallofthesystemcomponents.Feedwaterispreheatedbysteaminjectionfromthelowpressuresteamdistributionheader,aswellaspreheatedmakeupwaterutilizingboilerblowdownheatrecovery.ThetopoftheschematicshowstheBoilerFeedwaterenteringthetwoboilers.Thetwoboilersareconnectedtothehighpressuresteamdistributionheader.


Underthehighpressuresteamdistributionline,youwillseethreeconeshapedgraphics,thatrepresentthesteamturbines.Theonenearesttotheleftisahighpressuretocondensingturbine.Thisturbinedischargestothecondenserrepresentedbythebluecirclebelowtheturbine.Therectangulargraphictotherightoftheconeshapedgraphicindicatestheelectricalgenerationcomponentofthesteamturbine.Theturbineinthemiddlereceiveshighpressuresteamandexhaustslowpressuresteamtothelowpressuresteamdistributionsystem,aswellasgenerateselectricity.Thisturbineisdenotedasredconeandrectanglecombination.Thesteamturbinetothemostrightreceiveshighpressuresteam,drivesapump(denotedasacircle/squarecombination)andisalsocalledasteamturbinedrivenpump,thendischargestothelowpressuresteamdistributionsystemheader.



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Betweenthecondensingturbineandthehightolowpressureturbine,alightbluetriangulargraphicthatrepresentsapressurereducingvalve,whichdischargestothelowpressuresteamdistributionheader,identifiedbyaredlinebelowtheturbines.Atthefarrightofthehighpressuresteamdistributionsystem,thehighpressureendusercomponentloadsareidentifiedthrougharectangulargraphicandarrowsenteringandleavingtherectangle,indicatingheatexchangewiththecomponents.Theendusecomponentsdischargecondensatethroughasteamtrap,representedbyarectangulargraphic.Schematically,condensatepassesthroughthebottomofthetrapandrecoveredinacondensingtankwhichisalsoconnectedtothelowpressuresteamdistributionsystem.Underthelowpressuresteamdistributionline,youwillseethelowpressureendusercomponentloadsidentifiedasarectangulargraphicandarrowsenteringandleavingtherectangle,indicatingheatexchangewiththecomponents.Theendusecomponentsdischargecondensatethroughasteamtrap,representedbyanotherrectangulargraphic.Schematically,condensatepassesthroughthebottomofthetrapandrecoveredinacondensatetank,inwhichsteamisventedrepresentedbyaverticalarrowleavingthetopofthetank.Thelowpressureendusercondensatetankusesapump,whichisdenotedbyacircle/squarecombination,todeliverthecondensatetothemaincondensatereceiver,whichisalargerectanglewiththreeinputsdenotedbythreearrowsatthetopoftherectangle.Thecondensateentersthismaincondensatereceivertank,afteritpassesthroughacontrolvalve,denotedasanhourglassshapewithadomeontop.Thethirdcondensateinputcomesfromthecondensatefromtheheatexchangerthatutilizesthehighpressuresteamturbine.Thecondensateleavesthisheatexchangerandisdeliveredviaapump(denotedasacircle/squarecombination)tothemaincondensatereceiver.Themaincondensatereceiverthenpumps(denotedbyacircle/squarecombination)thehighpressurecondensate,lowpressurecondensate,andthecondensingsteamturbinecondensatetothedeaeratortankasdenotedbytworedrectangles,withthesmalleroneonthetop.Thetoprectanglealsoshowstwotriangles,eachpointedawayfromeachother,longestendsnearlytouching.Thebottomtriangleisconnectedtoacontrolvalverepresentedbyaredhourglassfigurewithadomeontheside,whichprovideslowpressuresteamtothedeaeratorfromthelowpressuresteamdistributionsystemtopreheatthecollectedcondensateandmakeupwater.Preheatedmakeupwateralsoschematicallyentersatthetopofthedeaeratorwiththecollectedcondensate.Themakeupwaterispreheatedfromtheboilerblowdownandlowpressuresteam.Boilerblowdownfromeachboilerisnotedasreddashedlinesleadingtoablowdownreceivertankdenotedasaredrectangleontherightofthescreen.Flashsteamisdivertedfromtheblowdownflashvesseltothelowpressuresteamdistributionline,alsodenotedinreddashedlines.Liquidfromtheblowdownflashtankthenschematicallyentersthetopofaheatexchanger(representedasawhiteandgreenstripedrectangle).Makeupwaterisshownenteringtheheatexchangerfromtheright,afteritpassesthroughthewatertreatmentequipment,denotedastworedrectanglesfurtherontheright.Theliquidexitingtheheatexchangerissenttothedeaerator.Theheatedboilerfeedwaterschematicallyexitsthedeaeratorfromthebottomandispumped(denotedasacircle/squarecombination)tothefeedwaterinletsofeachboiler,nearthetoptheschematic.




Slide14SteamSystem3PressuresSomesystemsareevenmorecomplicatedthanthatincludingmanysteampressuresandincorporatingsteamturbinesdrivingprocesscomponentsaswellaselectricalgenerators!


Thisschematicrepresentsathreepressureheadersteamsystemwithmultipleboilersandallofthesystemcomponents.Feedwaterispreheatedbysteaminjectionfromthelowpressuresteamdistributionheader,aswellaspreheatedmakeupwaterutilizingboilerblowdownheatrecovery.



Underthehighpressuresteamdistributionline,youwillseethreeconeshapedgraphics,thatrepresentthesteamturbines.Theonenearesttotheleftisahighpressuretocondensingturbine.Thisturbinedischargestothecondenserrepresentedbythebluecirclebelowtheturbine.Therectangulargraphictotherightoftheconeshapedgraphicindicatestheelectricalgenerationcomponentofthesteamturbine.Theturbineinthemiddlereceiveshighpressuresteamandexhaustslowpressuresteamtothelowpressuresteamdistributionsystem,aswellasgenerateselectricity.Thisturbineisdenotedasredconeandrectanglecombination.Thesteamturbinetothemostrightreceiveshighpressuresteam,drivesapump(denotedasacircle/squarecombination)andisalsocalledasteamturbinedrivenpump,thendischargestothelowpressuresteamdistributionsystemheader.Betweenthecondensingturbineandthehightolowpressureturbine,alightbluetriangulargraphicthatrepresentsapressurereducingvalve,whichdischargestothelowpressuresteamdistributionheader,identifiedbyaredlinebelowtheturbines.Atthefarrightofthehighpressuresteamdistributionsystem,thehighpressureendusercomponentloadsareidentifiedthrougharectangulargraphicandarrowsenteringandleavingtherectangle,indicatingheatexchangewiththecomponents.Theendusecomponentsdischargecondensatethroughasteamtrap,representedbyarectangulargraphic.Schematically,condensatepassesthroughthebottomofthetrapandrecoveredinacondensingtankwhichisalsoconnectedtothelowpressuresteamdistributionsystem.Underthelowpressuresteamdistributionline,youwillseethelowpressureendusercomponentloadsidentifiedasarectangulargraphicandarrowsenteringandleavingtherectangle,indicatingheatexchangewiththecomponents.Theendusecomponentsdischargecondensatethroughasteamtrap,representedbyanotherrectangulargraphic.Schematically,condensatepassesthroughthebottomofthetrapandrecoveredinacondensatetank,inwhichsteamisventedrepresentedbyaverticalarrowleavingthetopofthetank.Thelowpressureendusercondensatetankusesapump,whichisdenotedbyacircle/squarecombination,todeliverthecondensatetothemaincondensatereceiver,whichisalargerectanglewiththreeinputsdenotedbythreearrowsatthetopoftherectangle.Thecondensateentersthismaincondensatereceivertank,afteritpassesthroughacontrolvalve,denotedasanhourglassshapewithadomeontop.Thethirdcondensateinputcomesfromthecondensatefromtheheatexchangerthatutilizesthehighpressuresteamturbine.Thecondensateleavesthisheatexchangerandisdeliveredviaapump(denotedasacircle/squarecombination)tothemaincondensatereceiver.




Themaincondensatereceiverthenpumps(denotedbyacircle/squarecombination)thehighpressurecondensate,lowpressurecondensate,andthecondensingsteamturbinecondensatetothedeaeratortankasdenotedbytworedrectangles,withthesmalleroneonthetop.Thetoprectanglealsoshowstwotriangles,eachpointedawayfromeachother,longestendsnearlytouching.Thebottomtriangleisconnectedtoacontrolvalverepresentedbyaredhourglassfigurewithadomeontheside,whichprovideslowpressuresteamtothedeaeratorfromthelowpressuresteamdistributionsystemtopreheatthecollectedcondensateandmakeupwater.Preheatedmakeupwateralsoschematicallyentersatthetopofthedeaeratorwiththecollectedcondensate.Themakeupwaterispreheatedfromtheboilerblowdownandlowpressuresteam.Boilerblowdownfromeachboilerisnotedasreddashedlinesleadingtoablowdownreceivertankdenotedasaredrectangleontherightofthescreen.Flashsteamisdivertedfromtheblowdownflashvesseltothelowpressuresteamdistributionline,alsodenotedinreddashedlines.Liquidfromtheblowdownflashtankthenschematicallyentersthetopofaheatexchanger(representedasawhiteandgreenstripedrectangle).Makeupwaterisshownenteringtheheatexchangerfromtheright,afteritpassesthroughthewatertreatmentequipment,denotedastworedrectanglesfurtherontheright.Theliquidexitingtheheatexchangerissenttothedeaerator.

Slide15SteamSystemComplexThesteamsystemmayincludecondensingsteamturbinesandothermajorcomponents.However,nomatterhowcomplexorsimplethesteamsystemsare,themanagementandinvestigationactivitiesarebasicallythesameweneedthesametoolsandfundamentalknowledge.


Thisschematicrepresentsathreepressureheadersteamsystemwithmultipleboilersandallofthesystemcomponents.Feedwaterispreheatedbysteaminjectionfromthelowpressuresteamdistributionheader,aswellaspreheatedmakeupwaterutilizingboilerblowdownheatrecovery.



Underthehighpressuresteamdistributionline,youwillseethreeconeshapedgraphics,thatrepresentthesteamturbines.Theonenearesttotheleftisahighpressuretocondensingturbine.Thisturbinedischargestothecondenserrepresentedbythebluecirclebelowtheturbine.Therectangulargraphictotherightoftheconeshapedgraphicindicatestheelectricalgenerationcomponentofthesteamturbine.Theturbineinthemiddlereceiveshighpressuresteamandexhaustslowpressuresteamtothelowpressuresteamdistributionsystem,aswellasgenerateselectricity.Thisturbineisdenotedasredconeandrectanglecombination.Thesteamturbinetothemostrightreceiveshighpressuresteam,drivesapump(denotedasacircle/squarecombination)andisalsocalledasteamturbinedrivenpump,thendischargestothelowpressuresteamdistributionsystemheader.Betweenthecondensingturbineandthehightolowpressureturbine,alightbluetriangulargraphicthatrepresentsapressurereducingvalve,whichdischargestothelowpressuresteamdistributionheader,identifiedbyaredlinebelowtheturbines.


Atthefarrightofthehighpressuresteamdistributionsystem,thehighpressureendusercomponentloadsareidentifiedthrougharectangulargraphicandarrowsenteringandleavingtherectangle,indicatingheatexchangewiththecomponents.Theendusecomponentsdischargecondensatethroughasteamtrap,representedbyarectangulargraphic.Schematically,condensatepassesthroughthebottomofthetrapandrecoveredinacondensingtankwhichisalsoconnectedtothelowpressuresteamdistributionsystem.


June28,2010

Underthelowpressuresteamdistributionline,youwillseethelowpressureendusercomponentloadsidentifiedasarectangulargraphicandarrowsenteringandleavingtherectangle,indicatingheatexchangewiththecomponents.Theendusecomponentsdischargecondensatethroughasteamtrap,representedbyanotherrectangulargraphic.Schematically,condensatepassesthroughthebottomofthetrapandrecoveredinacondensatetank,inwhichsteamisventedrepresentedbyaverticalarrowleavingthetopofthetank.Thelowpressureendusercondensatetankusesapump,whichisdenotedbyacircle/squarecombination,todeliverthecondensatetothemaincondensatereceiver,whichisalargerectanglewiththreeinputsdenotedbythreearrowsatthetopoftherectangle.Thecondensateentersthismaincondensatereceivertank,afteritpassesthroughacontrolvalve,denotedasanhourglassshapewithadomeontop.Thethirdcondensateinputcomesfromthecondensatefromtheheatexchangerthatutilizesthehighpressuresteamturbine.Thecondensateleavesthisheatexchangerandisdeliveredviaapump(denotedasacircle/squarecombination)tothemaincondensatereceiver.Themaincondensatereceiverthenpumps(denotedbyacircle/squarecombination)thehighpressurecondensate,lowpressurecondensate,andthecondensingsteamturbinecondensatetothedeaeratortankasdenotedbytworedrectangles,withthesmalleroneonthetop.Thetoprectanglealsoshowstwotriangles,eachpointedawayfromeachother,longestendsnearlytouching.Thebottomtriangleisconnectedtoacontrolvalverepresentedbyaredhourglassfigurewithadomeontheside,whichprovideslowpressuresteamtothedeaeratorfromthelowpressuresteamdistributionsystemtopreheatthecollectedcondensateandmakeupwater.Preheatedmakeupwateralsoschematicallyentersatthetopofthedeaeratorwiththecollectedcondensate.Themakeupwaterispreheatedfromtheboilerblowdownandlowpressuresteam.Boilerblowdownfromeachboilerisnotedasreddashedlinesleadingtoablowdownreceivertankdenotedasaredrectangleontherightofthescreen.Flashsteamisdivertedfromtheblowdownflashvesseltothelowpressuresteamdistributionline,alsodenotedinreddashedlines.Liquidfromtheblowdownflashtankthenschematicallyentersthetopofaheatexchanger(representedasawhiteandgreenstripedrectangle).Makeupwaterisshownenteringtheheatexchangerfromtheright,afteritpassesthroughthewatertreatmentequipment,denotedastworedrectanglesfurtherontheright.Theliquidexitingtheheatexchangerissenttothedeaerator.Theheatedboilerfeedwaterschematicallyexitsthedeaeratorfromthebottomandispumped(denotedasacircle/squarecombination)tothefeedwaterinletsofeachboiler,nearthetoptheschematic.

Slide16FocusAreasWhenassessingoursteamsystem,wemustevaluatethesystemasawhole;but,wewillberequiredtoanalyzemanycomponentsindividuallythendeterminetheirimpactonthesystem.Therearemanydifferentcomponentsandsubsystemsassociatedwiththesteamsystem.Weaskquestionslike,howcanweimproveboilerefficiency?Howcanwereducesteamconsumption?Whatenergyresourcesareavailabletous?Howcanweloselessenergythroughoutthesystem?



June28,2010

[SlideVisualSteamSystemFocusAreas]SteamSystemFocusAreas SteamGenerationEfficiency ResourceUtilizationEffectiveness DistributionSystemlosses

Slide17SteamGenerationEfficiencyForexample,wewillfocusourattentionontheboilerandaskquestionslike:

Whataretheperformancecharacteristicsofourboiler? Whatarethecriticalmeasurementsrequiredtomanageboilerperformance? Howcanweimpactboilerefficiency?

[SlideVisualSteamGenerationEfficiency]SteamGenerationEfficiency Boilerefficiencyisamajorfactordeterminingtheoperatingcostsofasteamsystem Severalmajorfactorsimpactboilerperformance Whataretheefficiencycontrolparameters? Aretheymaintainedatappropriatelevels?

Slide18ResourceUtilizationWefocusourattentionontheenduseequipmentandtheenergyresourcesweemployinoursystems.Weinvestigateopportunitiestorecoverenergyfromprocessunits.Wetargetopportunitiestoreducesteamuse.Significantfocusisplacedonimprovingtheperformanceofourendusesystems.Cogenerationinvestigationsidentifypotentialstoconvertsteamenergyintopower.Weinvestigateopportunitiesusealternativeenergysources.

[SlideVisualResourceUtilizationEffectiveness]ResourceUtilizationEffectiveness Steamisgeneratedformanypurposes Steamcanoftenbegeneratedfromdifferentprimaryenergysources Multipleenergyexportscanbedevelopedfromoneenergyresource Areresourcesbeingproperlyutilized? Isthesteamenduseappropriateorinappropriate?



June28,2010

Slide19SteamDistributionSystemLossesSteamsystemsareoftenverylarge,extendingintomanyprocessareas.Weexaminehowenergycanbelostfromthedistributionsystem?Wetrytoidentifyopportunitiestoreducethelosses?Wefocusattentiononrecoveringenergyfromthedistributionsystem.

[SlideVisualSteamDistributionSystemLosses]SteamDistributionSystemLosses

Thedistributionsystemcanexperiencesignificantlosses Whatarethemainavenuesofloss? Whatmethodsareavailabletoreducethelosses?

Slide20DrivingForceQuestionInmoststeamsystemsthereareopportunitiesthatwillallowenergyconsumptiontobereduced.Ifatyourfacilityideasaredevelopedtoreduceenergyconsumption,whatwillbetheprimaryreasonthattheinitiativewillbeimplemented?

[SlideVisualDrivingForce]Whatisthemaindrivingforceforchange??

Slide21DrivingForceEconomicsEconomicimpactistheprimarydrivingforceforchange.Oneofourprimaryfocalpointsinthiscourseistoidentifyhowtoaccuratelyconnectarealworldsteamsystemchangetothetrueeconomicimpactitwillprovide.

[SlideVisualDrivingForce]Whatisthemaindrivingforceforchange??

Answer:$Slide22DrivingForceMoreEnergysavings,oftenfuelsavings,aredominantpointsoffocusresultingineconomicimpact.However,wedonotwanttolosesightofothereconomicfactors;suchas,maintenanceimpacts,reliabilityfactors,siteproductivity,productquality,environmentalimpact,andpotentiallyavoidingcostlysystemmodifications.Alloftheseissueshaveeconomicconnectionssometimesitisdifficulttoestablishthetrueeconomicimpactoftheseitems.Someoftheseimpactsmayresultinincreasedcost.Wemustattempttoaccuratelyandrealisticallyidentifythetrueeconomicimpactsandimplementationcostsassociatedwithanopportunity.



June28,2010

[SlideVisualDrivingForce]

Whatisthemaindrivingforceforchange??

Answer:$ Energy Reliability Maintenance Productivity Quality Costavoidance Emissionsreductions

Slide23MeasureManagementofanyresourcerequiresmeasurements.Throughoutthiscoursewewillidentifythecriticalmeasurementsthatallowustounderstandhowoursystemsareperformingandhowmuchimprovementhasbeenorcanbeaccomplished.

[SlideVisualMeasure]Youarenotmanagingwhatyoudonotmeasure.

Slide24StarttheInvestigationEvaluatingsteamsystemsrequiresabroadrangeofknowledgeandsignificantskillsset.Itcanbeverydifficulttodeterminewherebesttostartinvestigating.Oftenobtainingabroadoverviewofthesystemandtheoperatingpracticeswillleadtoimportantinvestigationstrategies.Slide25SSST1Investigatingsteamsystemsoftenbeginswithtakingabroadviewofthesystemandidentifyingareastoinvestigatethatmayyieldfruitfulresults.TheSteamSystemScopingTool(knownasSSST)isdesignedtohelpyouidentifythesepotentiallyfruitfulareas.

[SlideVisualSteamSystemScopingTool]

SteamSystemScopingTool(SSST)OrangeBannerwithindustrialplantgraphicinbackground

OfficeofIndustrialTechnologiesBestPracticesEnergySmartTechnologyforTodaySteamSystemScopingToolVersion2.0.0December2002

DO

UnitedStatesDepartmentofEnergy

Es BestPractices Steam End User Training


June28,2010

Clickanywhereonthisframetobegintheassessment.

Slide26ScopingTool2TheSteamSystemScopingToolisavailablefreeasanExcelbasedsoftwaretool.SSSTisnotacalculationtoolorasolutionevaluationtool;rather,itisatoolusedtohelptheusertobecomemoreawareofareasofthesteamsystemthatcanbeimproved.Thetoolisbasicallyaquestionnairethatasksgeneralquestionsaboutthemanagementpracticesofthesteamsystem.Questionsareprovidedforeachareaofthesteamsystem.Theresultsofapplyingthistoolarerelativescoresfortheperceivedperformanceofeachareaofthesystem.Thesescoresprompttheusertoinvestigatecertainareasofthesteamsystemfurther.Slide27SSSTProfilingForexampletheScopingToolasksquestionsabouttheintensityoffuelandsteammeasurements.Basedontheusersinputascoreisdevelopedforeachcategory.ThescoresshownhereareaveragescoresforasectorofU.S.industry.

[SlideVisualSSSTScorecardSystemProfiling]

SUMMARYRESULTS

SCOPINGTOOLQUESTIONSPOSSIBLESCORE

TYPICALSCORE

1.STEAMSYSTEMPROFILING STEAMCOSTS SC1:MeasureFuelCostToGenerateSteam 10 7.5SC2:TrendFuelCostToGenerateSteam 10 6.9STEAM/PRODUCTBENCHMARKS BM1:MeasureSteam/ProductBenchmarks 10 5.6BM2:TrendSteam/ProductBenchmarks 10 5.7STEAMSYSTEMMEASUREMENTS MS1:Measure/RecordSteamSystemCriticalEnergyParameters

30 22.5

MS2:IntensityOfMeasuringSteamFlows 20 8.5STEAMSYSTEMPROFILINGSCORE 90 56.7STEAMSYSTEMPROFILINGSCORE 100% 63%



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Slide28SSSTSystemOperationsQuestionstargetingsteamtrapmanagementandinsulationconditionprompttheusertoinvestigatethesevitalareasofsteamsystemmanagement.Again,thescoresnotedherearereflectiveofaveragescoresforasectorofU.S.industry.

[SlideVisualSSSTScorecardSystemOperations]BM2:TrendSteam/ProductBenchmarks 10 5.7STEAMSYSTEMMEASUREMENTS MS1:Measure/RecordSteamSystemCriticalEnergyParameters

30 22.5

MS2:IntensityOfMeasuringSteamFlows 20 8.5STEAMSYSTEMPROFILINGSCORE 90 56.7STEAMSYSTEMPROFILINGSCORE 100% 63%


TYPICALSCORE

2.STEAMSYSTEMOPERATINGPRACTICES STEAMTRAPMAINTENANCE ST1:SteamTrapMaintenancePractices 40 23.9WATERTREATMENTPROGRAM WT1:WaterTreatmentEnsuringFunction 10 8.6WT2:CleaningBoilerFireside/WatersideDeposits 10 7.1WT3:MeasuringBoilerTDS,Top/BottomBlowdownRates

10 7.7

SYSTEMINSULATION IN1:InsulationBoilerPlant 10 8.6IN2:InsulationDistribution/EndUse/Recovery 20 14.0STEAMLEAKS



June28,2010

Slide29SSSTBoilerOperationsBoilerefficiencyandcontrolcomponentsareprimarypointsoffocusintheScopingTool.Boilerblowdownissuesarealsoofconcern.

[SlideVisualSSSTScorecardBoilerOperations]


TYPICALSCORE

3.BOILERPLANTOPERATINGPRACTICES BOILEREFFICIENCY BE1:MeasuringBoilerEfficiencyHowOften 10 6.3BE2:FlueGasTemperature,O2,COMeasurement 15 9.4BE3:ControllingBoilerExcessAir 10 7.1HEATRECOVERYEQUIPMENT HR1:BoilerHeatRecoveryEquipment 15 8.5GENERATINGDRYSTEAM DS1:CheckingBoilerSteamQuality 10 4.2GENERALBOILEROPERATION GB1:AutomaticBoilerBlowdownControl 5 2.6GB2:FrequencyOfBoilerHigh/LowLevelAlarms 10 8.6GB3:FrequencyOfBoilerSteamPressureFluctuations 5 3.9

BOILERPLANTOPERATINGPRACTICESSCORE 80 50.6BOILERPLANTOPERATINGPRACTICESSCORE 100% 63%



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Slide30SSSTEndUseOfcoursecondensaterecoverypracticesareamajorpointofconcern.Thetoolfocusessomeattentiontothepotentialofusingbackpressuresteamturbines.

[SlideVisualSSSTScorecardEndUse]


TYPICALSCORE

4.STEAMDISTRIBUTION,ENDUSE,RECOVERYOPERATINGPRACTICES

MINIMIZESTEAMFLOWTHROUGHPRVs PR1:OptionsForReducingSteamPressure 10 7.4RECOVERANDUTILIZEAVAILABLECONDENSATE CR1:RecoveringAndUtilizingAvailableCondensate 10 6.4USEHIGHPRESSURECONDENSATETOMAKELOWPRESSURESTEAM

FS1:RecoveringAndUtilizingAvailableFlashSteam 10 3.7DISTRIBUTION,ENDUSE,RECOVERYOP.PRACTICESSCORE 30 17.5DISTRIBUTION,ENDUSE,RECOVERYOP.PRACTICESSCORE 100% 58%

Slide31SSSTResultsTheoutputofthetoolisanoverallscoreandindividualareascores.Solutionsarenotofferedsimplyalowscorepromptstheusertoinvestigatefurtherandpotentiallyidentifyimprovementopportunities.Inmoststeamsystemsthereareinterestinginvestigationopportunitiesinseveralareas.Typicaloverallscoresforindustrialplantsareinthe60%and70%ranges.



June28,2010

[SlideVisualSSSTScorecardResults]

SUMMARYOFRESULTS

SCOPINGTOOLAREASPOSSIBLESCORE

TYPICALSCORE

STEAMSYSTEMPROFILING 90 63%STEAMSYSTEMOPERATINGPRACTICES 140 69%BOILERPLANTOPERATINGPRACTICES 80 63%DISTRIBUTION,ENDUSE,RECOVERYOP.PRACTICES 30 58%

TOTALSCOPINGTOOLQUESTIONAIRESCORE 340 222.0TOTALSCOPINGTOOLQUESTIONAIRESCORE 100% 65%

Slide32SSSTNextStepsThetoolprovidesguidanceintowheretofindadditionalinformationforaparticulararea.TheScopingToolwillpointtheusertoadditionalU.S.DOEresources.

[SlideVisualNextStepsDirectedbySSST] Focusonareasrequiringattention Investigateresources

ConsulttheU.S.DOEBestPracticeswebsite www1.eere.energy.gov/industry/bestpractices

SteamSystemSurveyGuide U.S.DOESteamTipSheets

ImprovingSteamSystemPerformance:ASourcebookforIndustry UsetheSteamSystemAssessmentTool(SSAT) UseInsulationTool(3EPlus)\

Slide33GeneralToolsManytoolsarerequiredtoevaluatesteamsystems.TheSteamSystemScopingToolisoneofmanytoolsthatcanbeemployedtoinvestigatesteamsystems.TheothertoolsintheU.S.DOESteamToolsSuitewillbeintroducedinthiscourseaswellasthefundamentaltechniquesusedtoinvestigateandmanagesteamsystems.Themostimportanttoolsarethefundamentalprinciplesofphysicsandtherealsystemmeasurementsrequiredtoemploythem.TheU.S.DOESteamToolsareextensionsofthesevitalcomponents.



June28,2010

Slide34InformationAdditionaltechnicalresourcesareavailablefromtheDepartmentofEnergy.

[SlideVisualAdditionalTechnicalResources]

Information

Programs IndustrialTechnologiesProgram(ITP) BestPracticesSteamProgram

Softwaretools

http://www1.eere.energy.gov/industry/bestpractices/steam.html

(877)3373463 http://www1.eere.energy.gov/industry/bestpractices/software.html

SteamPublications http://www1.eere.energy.gov/industry/bestpractices/techpubs_steam.html

Training

TechnicalAssistancehttp://www1.eere.energy.gov/industry/bestpractices/training.html

http://www1.eere.energy.gov/industry/bestpractices/info_center.htmlSlide35IntroductionSummarySteamsystemsarecomplexarrangementsofinterconnectedcomponentsthatrequiretremendousamountsofenergyandeconomicexpenditure.Propermanagementofasteamsystemisvitaltoeffectivelyutilizeenergyresources.Toolsareavailabletohelpinthisinvestigationandmanagementprocess.


SteamEndUserTrainingSteamGenerationModule

BoilerEfficiency1June28,2010

SteamEndUserTrainingSteamGenerationEfficiencyModule

EfficiencyDefinitionSection

Slide1SteamGenerationEfficiencyModule

Thismodulewilldiscusssteamgenerationefficiencyandtheprimaryfactorsthataffectit..Thegeneralconceptsofboilerefficiencywillbediscussed.

[SlideVisualEfficiencyDefinitionTitlePage]


Steam iencyGenerationEffic

EfficiencyDefinitionShellLosses

BlowdownLossesStackLosses

Slide2BoilerTypes

Therearemanytypesofboilers,buttheprimaryboilerdesignationsarefiretubeboilersandwatertubeboilers.Afiretubeboilerisoneinwhichthecombustiongasesareinsidethetubes.Thisschematicdepictsa3passfiretubeboiler,inwhichwehaveacombustionzone,andsmallertubesthatallowmoreheattransferfromtheexhaustgases.Firetubeboilersservedasourfirstindustrialsteamgenerators.Thelargediameterpressurevesselholdsallofthestressofthehighpressuresteam.Asindustrialrequirementsnecessitatedhigherpressuresteamandgreatersteamflowrates,thevesselhadtobecomelargerandthewallofthevesselhadtogetthickertoaccommodatethestressofgreaterpressures.Thesefactorsmadeboilermanufacturingdifficultandexpensive.Asaresult,watertubeboilersweredeveloped.Theseboilerscontainhundredsoftubesthatholdthehighpressuresteamandwater.Theserelativelysmalldiametertubescanaccommodatethestressofmuchhigherpressuresthanthelargediametervessel.

Watertubeboilersallowthecombustiongasestoprovideheattransfertothewater(andsteam)thatiscontainedinthetubesoftheboiler.Acommonwatertubeboilerarrangementwillincorporateanuppersteamdrumthatallowstheliquidwaterandsteamtoseparate.Alowerdrum,oftencalledamuddrum,willserveasthelowercollectionheaderforthetubes.Hundredsofrelativelysmalldiametertubeswillconnectthemuddrumtothesteamdrum.Asthewaterheatsandboilingoccursthefluidrisesinthetubestothesteamdrum.


eamEndUserTrainingSteamGenerationModule


St

[SlideVisualBoilerTypes(FireTubeandWaterTube)]Thisschematicdepictsa3passfiretubeboiler,inwhichwehaveacombustionzone(atthebottom),andsmallertubesthatallowmoreheattransferfromtheexhaustgases.Thepressurevesselholdsallofthestressofthehighpressuresteam.

Watertubeboilersallowthecombustiongasestoprovideheattransfertothewater(andsteam)thatiscontainedinthetubesoftheboiler.Atypicalwatertubeboilerarrangementwillincorporateanuppersteamdrumthatallowstheliquidwaterandsteamtoseparate.Alowerdrum,oftencalledamuddrum,willserveasthelowercollectionheaderforthetubes.Hundredsofrelativelysmalldiametertubeswillconnectthemuddrumtothesteamdrum.Asthewaterheatsandboilingoccursthefluidrisesinthetubestothesteamdrum.

Slide3FireTubeBoiler

Generally,firetubeboilersaredesignedforlowerpressureandlesscapacitythanwatertubeboilersbuttheiroperatingrangesoverlap.Atypicalfiretubeboilermighthaveasteamproductionrateof5,000poundsperhour,whileatypicalwatertubeboilermighthaveasteamproductionrateof200,000poundsperhour.Firetubeboilersproducesaturatedsteaminmostallcases.

[SlideVisualaFireTubeBoiler]Thisschematicdepictsa3passfiretubeboiler,inwhichwehaveacombustionzone(atthebottom),andsmallertubesthatallowmoreheattransferfromtheexhaustgases.Thepressurevesselholdsallofthestressofthehighpressuresteam.

Slide4WaterTubeBoiler

Watertubeboilerscanproducesaturatedsteamortheycanbeequippedwithasuperheaterinternaltotheboiler.Fromthestandpointsofmanagement,investigation,andimprovement,knowingthedifferencesbetweenthetwoboilertypesisnotessentialbecausetheygenerallyworkthesame.Therearenosignificantefficiencyrelatedreasonstochooseonetypeofboilerortheother.Thereasonsforchoosingoneortheotherareusuallyrelatedtotherelativecostforthegivenpressureandsteamproductionrequirements.

[SlideVisualaWaterTubeBoiler]Watertubeboilersallowthecombustiongasestoprovideheattransfertothewater(andsteam)thatiscontainedinthetubesoftheboiler.Atypicalwatertubeboilerarrangementwillincorporateanuppersteamdrumthatallowstheliquidwaterandsteamtoseparate.Alowerdrum,oftencalledamuddrum,willserveasthelowercollectionheaderforthetubes.Hundredsofrelativelysmalldiametertubeswillconnectthemuddrumtothesteamdrum.Asthewaterheatsandboilingoccursthefluidrisesinthetubestothesteamdrum.


eBoilerEfficiency3

June28,2010

SteamEndUserTraininSteamGenerationModul

g

Slide5CommonFuels

ThistablecontainsinformationconcerningthemostcommonfuelsusedintheUnitedStatesandthroughouttheword.Naturalgasandnumber2fueloilaregenerallyconsideredveryeasyfuelstoutilize.Theheavierfueloils,likenumber6fueloilareverycommon;but,aremoredifficulttohandle.Number6fueloilisgenerallyasolidatroomtemperatureandisheatedtomorethan200Ftobepumpedtotheboilerburner.Solidfuelslikecoalandgreenwoodaremuchmoredifficulttohandleandstore.Solidfuelsgenerallycontainaportionofnoncombustiblematerialcalledashthatmustbedisposedofafterthecombustionprocess.

Greenwoodisadominantfuelinthepulpandpaperindustrybecausetheygenerateasignificantamountofwastewoodmaterials.Itshouldbenotedthatgreenwoodistypicallybarkandtreecomponentsthatwererecentlyapartofalivetree.Thisfactisimportantbecauselivetreesareessentiallyhalfliquidwatergreenwoodasafuelisnominally50%liquidwater.

TheunitcostsidentifiedinthistablearereflectiveoftheaverageU.S.fuelcostsfor2005.Thisinformationisunderstandablynotcurrent;but,itisreflectiveofthecommondifferencesinfuelprices.Itiscommonfortheenergybasedcostofnaturalgastobefourtimesgreaterthantheenergybasedcostofcoalorevenmore.Fueloilpricescanbeevenhigher.Thisisadominantreasonwhyweusecoal.

Itshouldbenotedthatthereissignificantvolatilityinthefuelmarket.

[SlideVisualCommonFueltable]

TypicalFuelProperties Sales ExamplePrice HHV UnitPrice

Fuel Unit [$/s nit]alesu [Btu/lbm] [$/ u]10BtNaturalGas 10stdft 7.00 23,311 7.00Number2FuelOil gallon 1.80 19,400 12.92Number6Oil(LS) gallon 1.20 18,742 7.82Number6Oil(HS) gallon 1.00 18,815 6.62EasternCoal ton 45.00 13,710 1.64WesternCoal ton 30.00 10,088 1.49GreenWood ton 11.00 5,250 1.05

Slide6BoilerExample

Throughoutthistrainingwewilluseanexamplesteamsystemthatreflectsasteamsystemwithrealworldcharacteristics.Thisexamplesystemwillhelpusillustratetheimportanceandusefulnessoftoolsandinvestigationspresentedinthistraining.Throughoutthiscoursewewilldiscussalltheaspectsofthissteamsystem;but,wewillstartbylookingatoneoftheboilersservingthisexamplesite.

Forthisexampletheboilerisproducing100,000poundsperhour,of400PSIG,700degreeFahrenheitsteamfromthecombustionofnaturalgas.




Thisboilerisequippedwithafuelflowmeterandthecostofthefuelistakenas$10/106Btu.

[SlideVisualWaterTubeBoiler]Watertubeboilersallowthecombustiongasestoprovideheattransfertothewater(andsteam)thatiscontainedinthetubesoftheboiler.Atypicalwatertubeboilerarrangementwillincorporateanuppersteamdrumthatallowstheliquidwaterandsteamtoseparate.Alowerdrum,oftencalledamuddrum,willserveasthelowercollectionheaderforthetubes.Hundredsofrelativelysmalldiametertubeswillconnectthemuddrumtothesteamdrum.Asthewaterheatsandboilingoccursthefluidrisesinthetubestothesteamdrum.

Slide7CaseStudy

Thisdatawillprovideenoughinformationtocalculatethefuelrelatedoperatingcostoftheboiler.

[SlideVisualOperatingCost]

Boilerfiredwithnaturalgaswhichhasahigherheatingvalueof23,311Btu/lbmHHVis1,000Btu/sftSteamconditions:400psig,700FOutput:100,000lbm/hr(steady)Rating:120,000lbm/hr(maximumcontinuous)Feedwater:600psig,242FFuelsupply:149,000sft/hr(2,480sft/min)Fuelcost:$10.00/10Btu($10.0/10sft)Determinetheoperatingcostoftheboiler

Slide8BoilerOperatingCost

Thefuelrelatedoperatingcostofthisexampleboileris$13,000,000/yr.Itshouldbenotedthatthisexampleboilercanbeconsideredatypicalindustrialboiler.Thefuelisnaturalgas,whichisoneofthesimplestfuelstoburn.Itisinterestingtonotethatthecharacteristicsofthisboilerarenotextreme;inotherwords,theboilerisproducingamoderateamountofsteamundertypicalconditions.Additionally,whilethefuelcostmaynotbeexactlyrepresentativeofthefuelcostsatagivenfacilitythisexamplecostisnotextraordinary.Thecharacteristicsofthisboilerareeasilyscalabletomostboilers.Itshouldalsobenotedthattheinvestigationandimprovementtechniquesrequiredtomanagethisexampleboilerarethesametechniquesavailabletoallboilers.Alongwiththisisthefactthatthisexampleboilerisarealboilerthatappropriatelyrepresentsthetypesofopportunitiespotentiallyavailabletomanyboilers.Boilersareextremelyexpensivecomponentsthisisthereasonweareinterestedinthem.




[Slide u al ion]Vis alC culat

Kboiler=Vfuelxkfuelxoperation

Boileroperatingcostsequalsthecostoffuelperhourperhourmultipliedbythecostofthefuelpercubicfootmultipliedbythehoursofoperation

AbbreviationsK=BoilerOperatingCostsV=VolumeflowofFuelperHourk=CostofFuelperCubicFoot=Operatingperiod

Slide9OperatingCost

Thecostoffuelforatypicalboilerissolargethatevenverysmallchangesinefficiencycanrepresentsignificantcostimpact.A1%improvementinefficiencyfortheexampleboilerrepresentsapproximately$130,000/yroffuelsavings.

Thereareothercostfactorsassociatedwithboileroperationswatertreatmentcosts,auxiliaryequipmentcosts,maintenancecosts,andoperationscosts;however,thesecoststypicallycombinetobesignificantlylessthanthecostoffuelfortheboiler.Eachcostfactorshouldbeinvestigated;but,fuelcosttypicallydominates.

Inthisexampleboilerinvestigationwewillidentifyrealworldmethodsthatwillreducethefuelconsumptionofthisboilermorethan7%,whichrepresentsmorethan$1,000,000/yr.

[SlideVisualSavingsCalculation1]

0.01x$13,000,000/yr$130,000savings!

Inthisequation,KequalsBoilerOperatingCost,VequalsCostoffuelperhour,KequalsCostoffuelpercubicfoot,andTequalsHoursofOperation.

Calculationsareoftenthoughtofasacademicexercises;however,inthecaseofmanagingboilerperformanceandcost,evaluatingboilerefficiencyisoneofthemostimportantandpracticaltoolsavailabletous.Toillustratetheimportanceandusefulnessofboilerefficiency,wewillexaminetheefficiencyofanexampleboiler.Wewillalsoexplorethemajorfactorsthatimpacttheefficiencyandoperatingcostofaboiler.




[SlideVisualOperatingCost]

Boilerfiredwithnaturalgaswhichhasahigherheatingvalueof23,311Btu/lbmHHVis1,000Btu/sftSteamconditions:400psig,700FOutput:100,000lbm/hr(steady)Rating:120,000lbm/hr(maximumcontinuous)Feedwater:600psig,242FFuelsupply:149,000sft/hr(2,480sft/min)Fuelcost:$10.00/10Btu($10.0/10sft)Operatingcost:13,000,000$/yrAsmallchangeinboilerefficiency(even1%)canrepresentasignificanteconomicimpactOtheroperatingcostsinclude:WatertreatmentBoilerfeedpumpsFluegasconditioningMaintenance(personnel,services,equipment)Typicallythesecostscombinetobemuchlessthanfuelcosts

Slide10EfficiencyDefinition

Calculationsareoftenthoughtofasacademicexercises;however,inthecaseofmanagingboilerperformanceandcost,evaluatingboilerefficiencyisoneofthemostimportantandpracticaltoolsavailabletous.Toillustratetheimportanceandusefulnessofboilerefficiency,wewillexaminetheefficiencyofanexampleboiler.Wewillalsoexplorethemajorfactorsthatimpacttheefficiencyandoperatingcostofaboiler.

[SlideVisualEfficiencyDefinitionTitlePage]



Effici tionencyDefiniShellLosses

BlowdownLossesStackLosses


eamEndUserTrainingSteamGenerationModule


St

Slide11DefineBoilerEfficiency

Boilerefficiencyisawaytodeterminehowmuchfuelenergyaboilerconvertsintosteamenergy.Steamenergyisthedesiredcommodityandfuelenergyisthepurchasedcommodity.Theequationshownhereisasimplifieddescriptionoftheenergyefficiencyofaboilerexpressedintermsoffuelenergyintotheboilerandsteamenergyoutoftheboiler.

Thefuelenergysuppliedtotheboilerisdeterminedbymultiplyingthefuelflowratebythefuelenergycontent.Fuelenergycontentisdescribedintermsoftheheatingvalueofthefuel,whichisanexpressionofthethermalenergythatisreleasedwhenthefuelisburned.ThemaximumthermalenergythatcanbereleasedwhenafuelisburnedisidentifiedasthefuelHigherHeatingValueorHHVofthefuel.Thefuelheatingvalueisdeterminedbylaboratoryanalysis.

[SlideVisualEfficiencyEquation1]n =energydesiredboiler /x(100)energythatcostsTheboilerefficiencyisequaltotheenergydesireddividedbytheenergythatcosts.

Theenergydesiredistheenergyaddedtothesteamasitpassesthroughtheboiler.Steamenergyisdeterminedbymultiplyingthesteamproduction(ormassflowrate)bythespecificenergyaddedtothesteamasitpassesthroughtheboiler.Wedescribetheenergycontentofthesteamastheenthalpyofthesteam(hintheequation)enthalpyisthethermodynamicpropertydescribingtheamountofenergyresidinginthematerial.Theenergyaddedtothesteamintheboileristhedifferenceinenthalpyofthesteamleavingtheboilerversusthefeedwaterenteringtheboiler.Enthalpyvaluesareobtainedfromthermophysicalpropertydatasetsandfieldmeasurementslikesteamtemperatureandpressure.

[SlideVisualEfficiencyEquation2]n =mboiler steam(hsteamhfeedwater)/

mfuelHHVfuelBoilerefficiencyisequaltothemassflowrateofthesteammultipliedbythedifferenceintheenthalpyofthesteamandtheenthalpyofthefeedwater;,dividedbythemassflowofthefuelmultipliedbythehigherheatingvalueofthefuel.

Enthalpyenergyofasubstancethatcanbeconvertedintoheat,work,andotherformsofenergy.

Fuelenergyisdeterminedbymultiplyingthefuelconsumptionratebythefuelenergycontent,alsoknownastheheatingvalue.




Ab ationsbr vienboiler =Efficiencyoftheboiler,alsocalledcombustionefficiency,overallefficiency(dimensionless)mste =massflowrateofsteamgeneratedintheboiler(lbm/hr)ammfuel =massflowrateoffuelburned(lbm/hr)h =Enthalpyisenergycontentofasubstance(Btu/lbm)HHV =HigherHeatingValueoffuel(Btu/lbm)

AnalternateexpressionfortheenergycontentofthefuelisidentifiedastheLowerHeatingValue(LHV).Mostcommonfuelsarecomposedprimarilyofcarbonandhydrogen.Theseelementsreactwithoxygeninthecombustionprocessandprimarilyformcarbondioxideandwater.Thewaterformedinthecombustionprocessisinitiallyvapor(steam).Ifthethiswatervaporisallowedtocoolbelowitscondensationtemperaturethevaporwillcondenseliberatingheat.Thisenergyreleasefromthewatervaporrepresentsadditionalenergyavailablefromthecombustionofthefuel.ThedifferencebetweentheHigherHeatingValueandtheLowerHeatingValueistheHigherHeatingValueaccountsforthisadditionalenergyliberationwhenthewatervaporcondenses.TheLowerHeatingValuemeasuresthefuelenergyreleasewithallthecombustionproductsremaininginthevaporphase.Slide12BoilerEfficiency1Itisinterestingtoidentifytypicalboilerefficiency.Thiswillallowustocompareourboilertotypicaloperation.Ifwecanidentifybestpracticeboilerefficiencythenwecancharacterizetheoperationofourboilerpossiblyidentifyingtheimprovementpotential.Slide13BoilerEfficiency2Ifweweretoexaminemanyboilerswewouldprobablyfindthatthetypicalboilerefficiencyisinthemid80%range.Wewouldalsoseethatmanyoftheboilerswouldhavehigherefficiencythanthisandmanywouldhavelowerefficiencythanthis.But,wewouldseeveryfewboilerswithefficienciesmuchgreaterthan90%andveryfewboilerswithefficienciesmuchlowerthan70%.Greenwoodisacommonfuelinmanyindustriesmostprominentlyinthepulpandpaperindustry.Thetermgreenwoodreferstowoodproductsthathavenotbeendried.Pulpandpaperplantsharvesttreestoprocessthemintopulpandpaperproducts.Paperisnotmadefromthebarkandlimbsofthetrees.Asthetreesareharvestedthelimbs,bark,andpoorqualitymaterialsareremovedalongwithotherpartsofthetreethatcannotbeconvertedintopaper.Thisgreenwoodisfreshfromtheforestandtypicallycontainsabout50%celluloseand50%liquidwater.Greenwoodisusedasamajorfuelsourcebecauseitisreadilyavailableandislowcost.However,afuelthatiscomposedof50%liquidwaterwillburninefficientlytheliquidwaterwillboilandcarryalargeamountofenergyoutoftheboiler.Asaresult,greenwoodfiredboilerswilloperatewithlowefficiency.Itisinterestingtonotethatatypicalindustrialcoalfiredboilerwilloperatewithrelativelyhighefficiency.Thisresultsfromthefactthathydrocarbonfuelsarecomposedprimarilyofhydrogenandcarbon.Carboncombustsandformscarbondioxide.HydrogencombustsandformsH2Owater.WaterisGodsgreatestchemicalforabsorbingandtransportingenergy.Mostofourboilersburninghydrocarbonfuelsreleasewatervapor(steam)asaproductofcombustion.Asaresult,asignificantportionoftheenergyavailableinthefueliscarriedoutoftheboilerinthewatervaporthatisformedin




thecombustionprocess.Fuelscontaininglesshydrogenexhaustlesswatervaporinthefluegasesandgenerallyhavehigherefficiency.Coalsgenerallycontainsomeamountofliquidwater,someamountofash(rocks),butmostlycarbon.

Fueloilsusuallycontainmorehydrogenthancoalsbuttheytypicallycontainverylittleashandalmostnoliquidwater.Asaresult,fueloilfiredboilerswilloperatewithrelativelyhighefficiency.

Naturalgascontainsarelativelylargeamountofhydrogen.Therefore,naturalgasfiredboilerswilloperatewithefficiencieslowerthancomparablecoalandoilfiredboilers.

Therearemanyfactorsthatimpactboilerefficiencyfueltypeisoneofthem,thewaywecontrolthecombustionprocessisanother,andenergyrecoveryequipmentinstalledontheboileronemoremajorfactoreffectingefficiency.

Slide14SteamProperties

Letsreturntoourexampleboilerbecausewehaveenoughinformationtoevaluateboilerefficiency.Inordertodeterminetheenergyaddedtothesteampassingthroughtheboilerwemustusesteampropertydataoftenknownassteamtables.Fromthetemperatureandpressuremeasurementsofthesteamandfeedwaterwecanidentifytheirenthalpiesagain,enthalpyisanindicationofenergycontent.Hereyoucanseefor700degreesFahrenheitand400poundspersquareinchgage,theenthalpyofthesteamis1,362Btuperpoundofsteam.Thefeedwaterisat242degreesFahrenheitand600poundspersquareinchgagetheenthalpyofthefeedwateris210Btu/lbasshowninthetable.

Slide15Direct(Classic)EfficiencyCalculationThesteampropertydataalongwiththefuelconsumptiondatagivesusenoughinformationtocalculateboilerefficiency.Thisboilerisoperatingwithanefficiencyofabout77%.Weareexpectingatypicalnaturalgasfiredboilertooperatewithanefficiencyinthelow80%range.Thisboilerisoperatingwithanefficiencythatisbelowtheexpectedvalueweanticipatethattheremaybeopportunitiestoimprovetheperformanceofthisboiler.

[SlideVisualEnthalpy]hsteam =1,361.88Btu/lbm

hfeedwater=210.42Btu/lbmDirectEfficiencyCalculation1Enteringdataintothedirectefficiencyequation,weget77%boilerefficiency.

[SlideVisualEquations]n =mboiler steam(hsteamhfeedwater)/x(100)

m xHHVfuel fuel



Theboilerefficiencyisequaltothemassflowofthesteammultipliedbythedifferenceintheenthalpyofthesteamandtheenthalpyofthefeedwater;dividedbythemassflowofthesteammultipliedbythehighheatingvalueofthefuel.


n =(100,000lbm/hr)x(1,361.88Btu/lbm210.42Btu/lbm)x(100)boiler (149,000sft3/hr)x(1,000Btu/sft3) *basedonvolumetricflowrate(HHVunitsareBtu/sft3)Theboilerefficiencyisequalto100,000poundsperhour,multipliedby1,361.88BTUperpoundminus210.42Btuperpound;dividedbythe149,000standardcubicfeetperhourmultipliedby1,000Btuperstandardcubicfeet.Orusingfuelmassflowdata(p=0.043lbm/sft3)mfuel =(149,000sft3/hr)x(0.043lbm/sft3)=6,407lbm/hrn =(100,000lbm/hr)x(1,361.88Btu/lbm210.42Btu/lbm)x(100)boiler (6,407lbm/hr)x(23,311Btu/lbm)*basedonmassflowrate(HHVunitsareBtu/lbm)Theboilerefficiencyisequalto100,000poundsperhour,multipliedby1,361.88BTUperpoundminus210.42Btuperpound;dividedbythe6,407poundsperhourmultipliedby23,311Btuperpound.nboiler=77.1%A e ationsbbr vinboiler =Efficiencyoftheboiler,alsocalledcombustionefficiency,overallefficiency(dimensionless)mste =massflowrateofsteamgeneratedintheboiler(lbm/hr)ammfuel =massflowrateoffuelburned(lbm/hr)h =Enthalpyisenergycontentofasubstance(Btu/lbm)HHV =HigherHeatingValueoffuel(Btu/lbm)

Slide16EfficiencyCalculation

Inordertoidentifytheimprovementopportunitiesassociatedwiththisboilerweaskwhyistheefficiencynot100%?Inotherwords,ifboilerefficiencyindicatesthat77%ofthefuelenergywentintothesteam,wheredidtheother23%ofthefuelenergygo?Itwenttosupplythelossesoftheboiler.




Slide17BoilerLosses1

Whatarethetypicalboilerlosses?Wherecanfuelgootherthanintothesteam?

[GraphicalDescriptionBoilerLosses]

Thisschematicdepictsawatertubeboiler.Fuelandairentersatthelowerleftofthecombustionzone,feedwaterentersatthetopintothesteamdrumwhichconnectstothemuddrumthroughmanytubes.Themuddrumisatthebottomoftheboiler.Steamexitstheboilerfromthesteamdrumintothesuperheatersection,whichisshownatthetopoftheboiler.Thecombustiongasesleavingtheboilerthroughtheductingattheupperright.

Slide18BoilerLosses2

Eventhoughboilersareinsulatedtheiroutersurfacesarehot,indicatingtheyarenotperfectlyinsulatedandfuelenergyisbeinglost.Thisisidentifiedasthe alsoknownas .shellloss radiationandconvectionloss

Anotherlossassociatedwithoperatingaboilerisidentifiedastheblowdownloss.Inordertomaintainproperboilerwaterchemistrysomeoftheboilerwatermustberemoved.Thisisanenergylossbecausethewaterthatisdischargedhasbeenheatedwithfuelenergy.

Theexhaustgasesfromthecombustionprocessexittheboilerwithfuelenergy.Thisenergycanbeidentifiedbytheelevatedtemperatureofthegases.Buttherealsocanbeunreactedfuelorextraairintheexhaustgases.Theseexhaustgasrelatedlossesareidentifiedasthe .stackloss

Manyotherlossescanbeidentifiedforboilers;suchas,theenergycarriedfromtheboilerwithashinacoalfiredboiler.However,thethreelossesidentifiedshell,blowdown,andstackarepresentonallfiredboilersandtheyrepresentthefundamentalpointsofconcernformanagingboilerefficiency.

Slide19IndirectEfficiency

Generallymanagingboilerperformancefocusesonidentifyingandmanagingthelosses.Infact,oneofourmostimportanttoolsistoidentify,quantify,andreducetheboilerlosses.Thisisaccomplishedthroughanindirectefficiencyevaluationtechnique,whichisthetoolmostoftenusedinthefield.

Boilerefficiencyisdeterminedinanindirectmannerbyassumingtheboilerefficiencyis100percentminusallofthelosses.Eachlossisidentifiedandquantifiedinthisanalysis.

Inthenextsectionsofourtrainingwewillfocusoneachoftheselosses.Wewillexploreeachlossindetailidentifyinghowtoevaluateeachoneforourboilers.Additionallywewillidentifythefuelimpactassociatedwitheachlossandtherealworldimprovementopportunitiesthatcanbetargetedineacharea.Therealbenefitassociatedwithevaluatingboilerperformancewiththeindirectefficiencytoolisthatasboilerefficiencyisdeterminedtheroadmapforimprovementisestablished.Evaluatingtheindividuallossesnotonlycharacterizeseachlossbutitalsoaffordsustheopportunitytoidentifytheimprovementpotentialassociatedwitheach.




[ sualBoilerLosSlideVi sIndirectEfficiencyEquations]

nindirect =100percentElossesIndirectBoilerEfficiencyisequalto100%minusthesumofallboilerlosses.

nindirect =100percentshellblowdownstackmiscIndirectBoilerEfficiencyisequalto100%minustheshelllosses,minustheblowdownlosses,minusthestacklosses,minusthemiscellaneouslosses.

Abbreviationsnindirect=IndirectefficiencyElosses=SumofallLosses



ShellLosses1June28,2010


ShellLossesSection

Slide1ShellLossesModuleNext,wewillidentifythemethodsusedtoinvestigate,quantify,andcontroltheseindividuallosses.Wewillstartwithshelllosses.

[SlideVisualShellLossesTitlePage]


EfficiencyDefinition

ShellLossesBlowdownLosses

StackLosses

Slide2ShellLossMagnitudeShelllossisthefuelenergythatleavestheboilerfromitsoutersurface.Inotherwords,theoutersurfaceoftheboilerishot,whichindicatesitislosingheat.Itisdifficulttoaccuratelymeasurethethermalenergylossfromtheoutershellofaboiler.Asaresult,shelllossisgenerallyestimatedfromsomelimitedfieldmeasurements.AnexcellentandrelativelyeasyestimatingtechniqueisidentifiedintheAmericanSocietyofMechanicalEngineersPerformanceTestCode4(ASMEPTC4).

[SlideVisualShellLossesEstimationTechnique]ASMEPTC4AmericanSocietyofMechanicalEngineersPerformanceTestCode4

Inthistechniquethetemperatureofeachsurfaceoftheboilerismeasured.Typicallythismeasurementisobtainedwithaninfraredsurfacethermometer.Surfacetemperaturestypicallyrangefrom120to180degreesFahrenheit,buthotspotsgreaterthanthisrangecanexist.Hotspotscandevelopfromdamagedinsulationontheboilerordamagedrefractoryinsidetheboiler.

Theshelllossestimatingtechniqueutilizesthecharacteristictemperatureofaboilersurfaceorareaandanestimatedambientsurfaceairflowvelocity.Theseestimatesareusedtocompleteaheattransferanalysisforallofthesurfacesoftheboileryieldinganestimatefortheboilershellloss.Thistechniqueissimple;however,theresultsmustbeconsideredageneralestimate.Thetotalshelllossestimateiscomparedtothetotalfuelenergyinputtodeterminethemagnitudeoftheloss.




Slide3ShellLossItisinterestingtonotethatformostboilersthetotalenergylostfromtheshellremainsessentiallyconstantwithrespecttoboilerload.Inotherwords,theshelllossenergyflowisbasicallyconstant.Thisisnottosaythatthefractionoffuelinputenergylostfromtheboilershellremainsconstantrathertheenergyflow(Btu/hr)remainsessentiallyconstantwithrespecttoboilerload.Thisbeingthecase,theshelllossexpressedasafractionoffuelinputenergywoulddoubleastheboilertransitionsfromfullloadtohalfload.Formostwellmaintainedboilers,thefullloadshelllosswillbebetween0.1%to2%offuelinputenergy.Usually,shelllossesareminimalandthebestwaytomanageshelllossistomonitorforhotspots,damagedinsulation,andothersurfaceproblems.Typically,shelllossissuesdonottranslateintosignificantenergylossesbutsignifyinsulationorrefractoryissuesthatneedtoberepairedtoincreasethelongevityoftheboiler.Slide4ExampleBoilerSavingsForourexampleboileranASMEtypeshelllossinvestigationindicatesapproximately0.5%ofthefuelinputenergyislostthroughtheshelloftheboiler.Thisrepresentsapproximately$65,000/yroffuelenergy.Thisisarelativelysmallfractionofthefuelinputenergyandthereisverylittlethatcanbedonetosignificantlyreduceit.

OurExampleBoiler:

FromanASMEtypeinvestigationtheradiationandconvectionlossoftheexampleboilerisapproximately0.5%ofthetotalfuelenergyinputtotheboiler.

Thisrepresentsalossofapproximately$65,000/yr. Surfacetemperaturemeasurementsdidnotindicateanyhotspotsontheexampleboiler.Theinsulation,cladding,andrefractoryarein

goodcondition.Asaresult,wewilljustacceptthatthislosswilloccurandcontinueourinvestigationintootherareasofboilerefficiency.

RadiationandConvectionLoss=$13,000,000/hrx(0.5%/100)=$65,000/yr




Slide5ShellLossSummaryInsummary,shelllossisgenerallyaminorcontributortotheoverallfuelenergyloss.Directmeasurementsofboilershelllossaredifficulttocomplete;but,simplifiedestimatingtechniquesprovideexcellentinsightintothemagnitudeofboilershellloss.Shelllossshouldnotbeignoredhotspotsintheboilershellindicateproblemsthatshouldbecorrected.

[SlideVisualShellLossSummary]

ASMEPTC4AmericanSocietyofMechanicalEngineersPerformanceTestCode4 Searchforhotspots

o Damagedinsulationo Damagedrefractoryo

MeasureboilersurfacetemperatureMonitorsurfacecladdingintegrity

o

Infrared Typicalsurfacetemperatureshouldrangebetween120oFand180oF Repairrefractory Monitorsurfacecladdingintegrity Reduceboilerloadcanpresentanopportunity


BlowdownLosses1June28,2010



BlowdownLossesSection

Slide1BlowdownLossesModuleThissectionwilldiscussblowdownlossanditsaffectonboilerefficiency.

[SlideVisualBlowdownLossesTitlePage]


EfficiencyDefinitionRadiationandConvectionLossesShellLosses

Blo eswdownLossStackLosses

Slide2Blowdown

Thenexttypeoflossinvestigatedisblowdownloss.Boilerfeedwaterisverycleanwater.However,infeedwatertherearesomedissolvedchemicals.Essentiallypuresteamexitstheboilerthemajorityofthechemicalsenteringtheboilerwithfeedwaterarenotsolubleinthesteamandwillnotleavetheboilerwiththesteam.Asaresult,theconcentrationofthesechemicalsincreasesintheboiler.Elevatedconcentrationsofchemicalsresultsinmanyseriousboilerproblemsincludingfoamingresultinginliquidcarryover,scalingonthewatersideofthetubes,andloosesludgeintheboilerwater.Blowdownistheprimarymechanismthatallowsustocontrolchemicalconcentrationsintheboilerwater.Blowdownallowsustomaintainanacceptableconcentrationofdissolvedandprecipitatedchemicalsintheboiler.

Thereisanenergylossassociatedwithblowdown,becausethewaterhasbeenheatedtotheboilingpointfromfeedwaterconditions.

Slide3BoilerBlowdown

Therearetwogeneraltypesofboilerblowdown.Oneistypicallyfromthelowersectionsoftheboilercalledbottomblowdown.Theothertypeofblowdownistypicallyfromtheuppersectionsoftheboilerandiscalledsurfaceblowdown.

Bottomblowdownisactuatedbecausesomesolidswillprecipitatefromthechemicalsdissolvedinthefeedwater.Thesesolidstendtobeheavierthanwater,andthereforetendtocongregateinlowersectionsoftheboiler.Bottomblowdownisusedtoflushthesesolidsout.Bottomblowdownistypicallyasignificantflowofwaterforaveryshortperiodoftime.Theintentistosweepawayanysolidprecipitatesformedinthewater.Even


oduleBlowdownLosses2

June28,2010

thoughwhileitisoccurringitisalargeflowrate,itcontinuesforashortperiodoftime.Asaresult,thetotalflowofbottomblowdownisusuallymuchlessthanthetotalflowsurfaceblowdown.

SteamEndUserTrainingSteamGenerationM

Surfaceblowdownistypicallyamuchsmallerflowratethanbottomblowdown;however,itcontinuesforamuchlongerperiodoftimeoftencontinuously.Surfaceblowdownistheprimarymechanismusedtocontrolthedissolvedchemicalconcentrationsintheboiler.Surfaceblowdownendsupremovingmostoftheblowdownwater.

[SlideVisualBoilerBlowdown]

Thisschematicdepictsawatertubeboiler.Fuelandairentersatthelowerleftofthecombustionzone,feedwaterentersatthetopintothesteamdrumwhichconnectstothemuddrumthroughmanytubes.Themuddrumisatthebottomoftheboiler.Steamexitstheboilerfromthesteamdrumintothesuperheatersection,whichisshownatthetopoftheboiler.Thecombustiongasesleavingtheboilerthroughtheductingattheupperright.Thebottomblowdownisshownfromthebottommuddrum.Thesurfaceblowdownisshownatthetopfromthesteamdrum.

Slide4BlowdownControl

Generally,surfaceblowdowniscontrolledbasedonboilerwaterconductivity.Conductivityisadirectmeasurementthatcancontinuouslyprovideanindicationofboilerwaterquality.However,conductivitymustbecorrelatedtoindividualchemicalcontaminantsthroughperiodicwateranalysis.Conductivityandtheresultsofspecificboilerwatertestingaidinadjustingtheblowdownrate.

[SlideVisualConductivitySensor]

Thisschematicdepictsawatertubeboiler.Fuelandairentersatthelowerleftofthecombustionzone,feedwaterentersatthetopintothesteamdrumwhichconnectstothemuddrumthroughmanytubes.Themuddrumisatthebottomoftheboiler.Steamexitstheboilerfromthesteamdrumintothesuperheatersection,whichisshownatthetopoftheboiler.Thecombustiongasesleavingtheboilerthroughtheductingattheupperright.Thesurfaceblowdownisshownatthetopfromthesteamdrumwithaconductivitysensorcontrollingtheblowdownvalveposition.Theblowdownisdischargedtothesewer.

Slide5BlowdownLossEstimate

Fromtheviewoftheboiler,feedwaterenters,steamandblowdownexit.Theboileraddsfuelenergytothesteamandblowdownthatexittheboiler.Blowdownisanenergystreamthatisdischargedfromtheboiler.Blowdownistypicallyexpressedasafractionoffeedwatermassflowandcanrangefromlessthan1%tomuchgreaterthan10%dependingonwaterchemistry,boileroperatingpressure,andotherfactors.However,itshouldbenotedthat10%blowdownratedoesnotmean10%energylossblowdowndischargedfromtheboilerisnothighenergysteam,itismoderateenergywater.Fromtheperspectiveoftheboiler,theenergyaddedtotheblowdownstreamisblowdownflowratetimesthedifferenceintheenthalpyoftheblowdownandthefeedwater.Therefore,10%blowdownratecantranslateinto5%fuelenergyinput.Itshouldbenotedthattherelationshipbetweenblowdownmassfractionandblowdownenergyfractionisdependentonmanyfactorsincludingboileroperatingpressureandfeedwatertemperature.


BlowdownLosses3June28,2010


[ isua ler ow BoilerCalcSlideV lBoi Blowd nLoss ulation]

L =mblowdown blowdown(hblowdownhfeedwater)/x(100)

mfuel fuelxHHV

AbbreviationsLblowdown =Lossduetoblowdown(%)mblowdown =massflowrateofblowdown(lbm/lbm)h eed ater massflowrateoffeedwater(lbm/lbm)f w =mfuel =massflowrateofsteamgeneratedperpoundoffuelburned(lbm/lbm)h =Enthalpyisheatcontentorusefulenergyofasubstance(Btu/lbmorkJ/kg)HHV =HigherHeatingValueoffuel(Btu/lbm)

Slide6SystemLoss

Again,fromtheperspectiveoftheboiler,theenergyaddedtotheblowdownstreamisblowdownflowratetimesthedifferenceintheenthalpyoftheblowdownandthefeedwater.However,everypoundofblowdowndischargedfromthesystemismadeupwithcoldmakeupwaterasaresult;aportionofthesteamgeneratedintheboilerisusedtoheatthemakeupwatertofeedwaterconditionsinthedeaerator.Therefore,fromasystemperspective,theenergyassociatedwiththeblowdownstreamisevenlargerthanthatidentifiedfromtheboilerperspective.

[VisualDescriptionSteamSystemImpactSchematic]

Thisschematicrepresentsathreepressureheadersteamsystemwithmultipleboilersandallofthesystemcomponents.Feedwaterispreheatedbysteaminjectionfromthelowpressuresteamdistributionheader,aswellaspreheatedmakeupwaterutilizingboilerblowdownheatrecovery.ThetopoftheschematicshowstheBoilerFeedwaterenteringthetwoboilers.Thetwoboilersareconnectedtothehighpressuresteamdistributionheader.Thesteamexitstwoboilersandentersthehighpressuresteamsystemdistributionheader,indicatedbyalinebelowtheboilers.Underthehighpressuresteamdistributionline,youwillseethreeconeshapedgraphics,thatrepresentthesteamturbines.Theonenearesttotheleftisahighpressuretocondensingturbine.Thisturbinedischargestothecondenserrepresentedbythebluecirclebelowtheturbine.Therectangulargraphictotherightoftheconeshapedgraphicindicatestheelectricalgenerationcomponentofthesteamturbine.Theturbineinthemiddlere

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