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IAC Student Meeting February 19, 2004 Using DOE BestPractices Steam Tools And Resources

IAC Student Meeting February 19, 2004 Using DOE BestPractices Steam Tools And Resources. Dr. Anthony L. Wright Oak Ridge National Laboratory (wrightal@ornl.gov, 865-574-6878). Sir Oliver Lyle: “The Efficient Use Of Steam”. Steam Possesses Many Outstanding Qualities: Very high heat content

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IAC Student Meeting February 19, 2004 Using DOE BestPractices Steam Tools And Resources

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

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

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

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

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

  6. What Does A 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

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

  8. 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 Use The Steam SYSTEM SCOPING TOOL To Assess Major Steam Best Practice Areas

  9. Available SSST Versions • Microsoft Excel Version • Visual Basic Version

  10. Demonstrating The Steam System Scoping Tool…

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

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

  13. 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 Use The Survey Guide To Assess Steam Efficiency Improvements In These Areas

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

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

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

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

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

  19. 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 SSAT Can Evaluate These KeySteam Improvement Initiatives

  20. 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 Key SSAT Features

  21. 2-Header Steam System Example: 400, 20 psig Natural gas boiler 2,000 kW site electrical load Evaluating Steam Improvements: Boiler efficiency change Boiler blowdown improvements Utilizing back pressure turbine to make on-site power Demonstrating The Usefulness Of SSAT…

  22. Demonstrating The Steam System Assessment Tool…

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

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

  25. 3E-Plus Insulation Appraisal Software

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

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

  28. 1- Page Tips For Improving Steam System Areas Available On BestPractices Web Site, And In Steam Sourcebook 19 Steam Energy Tips Published

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

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

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

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

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

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

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

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