IL IOF Steam Presentation

Steam Systems
Technology Concept
Steam System Background
Primary industrial energy source
process heating pressure control mechanical drive space heating
Significant consumer of natural gas

Over 45% of all fuel burned by U.S. manufacturers is consumed to raise steam. DOE Best Practices
$$$
Great energy & cost savings potential!
US DOE Industries of the Future Workshop Series
Why Use Steam?
Extremely Uniform Heating Absolute Temperature Limit on Heated Surfaces High Heat Delivery Fast Recovery from Cold Spots Heats Unusually Shaped Heat Exchangers Uniformly
Classes of Steam
Low Pressure Heating Steam 15 psig
Used Mainly for Space Heating Systems and Single Effect

Absorption Chillers Actual Code is More Restrictive
Medium Pressure Steam: 15-150 psig

Heating
Used in Hospitals, District Steam Systems, Some Industrial Strictly Industrial and Power Generating Applications Increase in Expense with Each Higher Class
High Pressure: Above 150 psig
Each Class has Piping and Valve Requirements
Steam System Operation
Generation Distribution End Use Condensate Recovery & Feed Water

Systems
Generation
Boilers
Fire-tube or water-tube
Heat recovery
generators
Turbine exhaust Furnace exhaust
Typical Boiler
Generation
Water tube
fuel burned within combustion chamber combustion gas surrounds water tubes within vessel
Fire tube
fuel burned in combustion chamber combustion gases flow through tubes water surrounds tubes
Generation
Fire tube
Scotch Marine most

popular Two, three, and four pass designs Constant pressure with wide load fluctuations Steam pressure limited to under 350 psig Preferred between 3,500 to 35,000 lbs/hr (120 Bhp 1,200 Bhp)
Generation
Water tube
Fuel burned within combustion

chamber Combustion gas surrounds water tubes within vessel Low water content allows rapid steam production Capable of high pressure and superheated steam Preferred ranges are below 3,500 lbs/hr (120 Bhp) and above 35,000 lbs/hr (1,200 Bhp)
Source: Cleaver Brooks
Generation
Modular Boilers
Array of smaller boilers meet
load more effectively without cycling Improved combustion efficiency Reduced jacket losses Fin tube design less durable Piping and controls important Mostly for commercial markets
Source: ES Magazine March, 2001
Generation
Heat recovery steam

generators (HRSGs)
Create steam using a heat

exchanger in a hot gas flow
Can produce superheated
steam Can produce high pressure steam
Turbine exhaust Furnace exhaust
Distribution & End Users
Distribution Systems
Distribution lines Pressure reduction

Pressure reduction valve Backpressure turbine
End Use Components
Heat exchangers Mechanical drives Steam

sparging/injection equipment
Recovery & Feed Water
Condensate Recovery System
Steam traps Collection tanks Flash steam recovery Pumps Deaerator Economizer
Feed Water System
Steam System Schematic
Typical Applications
Steam is not commonly used for space

heating only
hot water systems are less maintenance intensive
Exceptions
Hospitals need steam for sterilizers Older district heating systems Industrial plants which require process steam
Efficient Steam Systems
Proper performance yields
Low operating costs Minimal downtime Reduced emissions Effective process control
Effective maintenance is the best strategy!!
Why make a change?
Great energy & cost savings potential!

Save energy (20% or more)
$$$
Reduce downtime Eliminate maintenance crises Improve process control Minimize safety hazards
Why make a change?
INEFFICIENT STEAM SYSTEM
Why make a change?
EFFICIENT STEAM SYSTEM
Technology Common System Improvements
Benchmarking
Profile your existing system Calculating the cost of steam ($/ thousand lbs)
Separating process boiler load from seasonal heating Steam System Assessment Tool (US DOE) Fuel Water Chemicals
Rough estimate: Total Steam Cost ($/MMBtu) = Fuel Cost ($/MMBtu) x 130%
DOE steam cost estimating resource:

http://www.oit.doe.gov/bestpractices/steam/pdfs/tech_brief_true_cost.pdf
Common Problem Areas
Incorrect air/fuel ratio combustion inefficiency Lack of insulation Insufficient trap maintenance Steam leaks No heat recovery Insufficient water treatment/blowdown issues Frequent boiler cycling Water hammer Poor record keeping
Gas usage Steam production
Air/Fuel Ratio Combustion Efficiency
In theory . . .
AIR (O2 & N2)
PERFECT COMBUSTION
FUEL (C2H)
EXHAUST (CO2, H2O & N2)
Air/Fuel Ratio Combustion Efficiency
In the real world . . . Excess air introduced to prevent incomplete combustion
AIR (O NN 2 && 2) ) AIR (O 2 2 Combustion FUEL (C2H)
EXCESS O2
EXHAUST (CO2, H2O & N2)
Left over oxygen carries heat away from boiler

Steam System Exercises Air/Fuel Ratio
Optimum combustion air = increased efficiency
Too much air = excess heat loss in stack Too little air = wasted fuel
Worksheet example (use boiler chart on next slide):
Steam System Exercises Air/Fuel Ratio
Net Stack Temp = Stack temp reading ambient air temp
Insulation
Lack of insulation unnecessary heat loss Wet insulation heat loss
Condensate return lines need insulation too. 3E Plus available at www.pipeinsulation.org
*Based on 8,000 hours of operation, 85% efficient boiler, mineral fiber insulation with
all purpose jacket
Insulation
What about insulating valves? Removable insulation is available
Savings energy savings (btu/hr) hours fuel cost
Steam traps
Expect 15% to 30% failure every 3 to 5 years Easily tested using ultrasonic equipment Steam trap example problem
GO TOSupplemental Steam Trap Info
Steam Leaks
Easy to find Hard to fix

Steam Leak Rates Through Holes (lbm/hr) Orifice Diameter (inches) 1/32 1/16 3/32 1/8 5/32 3/16 7/32 1/4 9/32 5/16 11/32 3/8 13/32 7/16 15/32 1/2 Steam Pressure (psig) 2 0.31 1.25 2.81 4.5 7.8 11.2 15.3 20 25.2 31.2 37.7 44.9 52.7 61.1 70.2 79.8 5 0.49 1.97 4.44 7.9 12.3 17.7 24.2 31.6 39.9 49.3 59.6 71 83.3 96.6 111 126 10 0.7 2.8 6.3 11.2 17.4 25.1 34.2 44.6 56.5 69.7 84.4 100 118 137 157 179 15 0.85 3.4 7.7 13.7 21.3 30.7 41.9 54.7 69.2 85.4 103 123 144 167 192 219 25 1.14 4.6 10.3 18.3 28.5 41.1 55.9 73.1 92.5 114 138 164 193 224 257 292 50 1.86 7.4 16.7 29.8 46.5 67 91.2 119 151 186 225 268 314 365 419 476 75 2.58 10.3 15.4 41.3 64.5 93 126 165 209 258 312 371 436 506 580 660 100 3.3 13.2 29.7 52.8 82.5 119 162 211 267 330 399 475 557 647 742 844 125 4.02 16.1 36.2 64.3 100 145 197 257 325 402 486 578 679 787 904 1028 150 4.74 18.9 42.6 75.8 118 170 232 303 384 474 573 682 800 928 1065 1212 200 6.17 24.7 55.6 99 154 222 303 395 500 617 747 889 1043 1210 1389 1580 250 7.61 30.4 68.5 122 190 274 373 487 617 761 921 1096 1286 1492 1713 1949 300 4.05 36.2 81.5 145 226 326 443 579 733 905 1095 1303 1529 1774 2037 2317
The table can also be used to determine steam losses through steam traps that have failed open.
Heat recovery options
Vent Condensers
Economizer/ Recuperator
Blowdown Heat Recovery

Economizers and Recuperators
Recuperators
Recover heat to
combustion air Require steady boiler loading
Economizers
Recover heat to
boiler feed water Require continuous feed water flow
Boiler Recuperator
Boiler Recuperator
Boiler efficiency indirectly proportional to stack temp Causes of excess stack temps:
Excess air Fouled waterside surfaces Fouled fireside surfaces Overfiring Insufficient heat transfer surface High steam pressure
Only insufficient heat transfer surface or high pressure justify a

recuperator:
Excess air - adjust air/fuel ratio Fouled surfaces - can be detected by visual inspection Overfiring Flue temp must be at least 50F over the minimum allowable
Boiler Recuperator
Boiler conditions:
450F stack temperature 80 inlet air 4% O2 in stack Current natural gas consumption: 67,286 MMBtu/year Current natural gas cost: $5.90/MMBtu Net stack temp: 450 - 80 = 370 Net stack temp w/recuperator: 280F New efficiency current efficiency = efficiency gain 83.0% - 80.7% = 2.3%
To find the potential savings from a recuperator:
continued
Boiler Recuperator continued
Energy Savings:
= current use x (1- (old efficiency/new efficiency)) = 67,286 MMBtu x (1 (0.807 / 0.830)) = 1,865 MMBtu/yr = energy savings x energy cost = 1,865 MMBtu/yr x $5.90/MMBtu = $11,000/yr
Cost savings:
Vent Condensers
Recover flash steam or fugitive steam
Condensate tanks Deaerators
Blowdown Heat Recovery
Vent
Requires continuous midCondensate Return
Boiler
Mid-drum blow down Mud-drum blow down
Fee d Water
Deaerator
Flash Steam
drum blow down Intermittent mud-drum blow down can be accommodated
Approximate Savings:
Flash Separator
Blow Down
Prehe ate d fe ed wate r Heat Exchange r
% energy savings blowdown % 0.4
Make up Water
Water treatment/blowdown issues
Typical steam system

Blowdown <10% feed water
Systems with high quality water treatment

Blowdown <5% feed water
Reducing blowdown saves
Energy Water costs Chemical costs
Boiler Short Cycling
Boiler cycle:
Pre-purge fan removes combustible gases from boiler Firing interval Post-purge gases removed again Idle period
Problem: heat is removed during purges
Short cycling
Occurs when an oversized boiler quickly satisfies heat
demands Boiler shuts down until next demand
Causes:
Boiler oversized for expansions that never happened Energy conservation measures have reduced heat
demand Space heating based on design-basis temperature conditions Space heating sized for quick recovery from night setbacks
Illustration of a typical boiler short-cycling:
Green areas represent energy that will be wasted while the boiler is not firing but the fan is in pre-purge or post-purge phase.
Illustration of an improved boiler cycle:
Note the reduction in wasted energy from eliminating short-cycling.

Replacement and alternative technologies
Backpressure Turbines
pressure Require
Replace pressure reducing valves Produce electrical power by reducing steam

>5,000 lbs/hr steam flow >100 psig pressure drop across turbine
IAC implementation trends and analysis
Application of New Technologies/Concepts
Combustion analysis testing equipment Removable valve insulation Trap analysis with ultrasonic equipment Steam flow metering Gas sub-metering Continuous blow down and conductivity metering Exhaust stack economizers Modular boiler systems Direct contact water heaters
Technology - Next Steps
How to start
Steps in evaluating your system Best Practices Monitoring needs Implementation
TREAT STEAM LIKE A FOURTH UTILITY!
Steps in evaluating your system
Utility bill analysis Steam trap inventory Combustion testing Ensure all insulation is in good shape Optimize boiler blowdown Monitor boiler cycling during periods of low demand Check for applications for new technologies
Natural Gas Utility Profile

30,000
Heating Load
25,000
Gas Use (MMBtu)
20,000
15,000
Process Load
10,000
5,000
Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May
Best Practices
Combustion testing (quarterly) Steam trap testing (annually)
Inventory / maintenance history
Steam leak reporting mechanism for all staff Insulation standards formalized
Benchmarking
Monitoring needs
Monitor and track boiler system data
Daily Natural Gas Usage (meter on each boiler) Daily Steam Production (meter on boiler water feed) Daily Water Usage (meter on make-up water feed) Chemical Costs (compare to water usage)
Boiler cycles Stack temperature
Implementation of Improvements
Improving system performance
Assessing the entire system (supply and demand) Identifying opportunities Quantifying benefits and costs Implementing most feasible projects
Implementation requires participation
Production staff Maintenance staff Management staff
ISO 14000
Formalized method for identifying and documenting

process improvements Can be used for benchmarking Proper use can lead to significantly reduced energy costs All program goals are set by company
Assessing your current system
In house assessment
GO TO Assessment Resources Listing
Tools Tools available available from from US US DOE DOE Steam Steam Challenge Challenge Program Program
US DOE Industrial Assessment Centers Energy Resources Center @ UIC
Private energy service companies

Steam equipment manufacturers
Assessment Resources
Energy Resources Center @ UIC www.erc.uic.edu - can provide

BACK
expertise in industrial steam systems, also will perform energy assessments for industrial clients. Industrial Assessment Centers http://www.oit.doe.gov/iac/ - will provide energy assessments (including steam systems) free of charge to qualified industrial clients. US DOE Steam Challenge Program http://www.oit.doe.gov/bestpractices/steam/ - provides a wide range of technical assistance materials, tools, and services to the industrial market. National Association of Energy Service Companies http://www.naesco.org/ - trade organization of companies that will perform energy audits and finance improvements. Steam System Survey Guide http://www.oit.doe.gov/bestpractices/steam/pdfs/steam_survey_guide.p df - guide to assessing industrial steam systems. Rutgers IAC Self Assessment Guide http://iac.rutgers.edu/manuals/selfassessment.pdf - guide to assessing industrial plants for energy efficiency.

IL IOF Steam Presentation

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Steam Systems

Steam System Background

Primary industrial energy source

process heating pressure control mechanical drive space heating

Significant consumer of natural gas

Great energy & cost savings potential!

US DOE Industries of the Future Workshop Series

Why Use Steam?

US DOE Industries of the Future Workshop Series

Low Pressure Heating Steam 15 psig

Used Mainly for Space Heating Systems and Single Effect

Medium Pressure Steam: 15-150 psig

High Pressure: Above 150 psig

Each Class has Piping and Valve Requirements

US DOE Industries of the Future Workshop Series

Steam System Operation

Generation Distribution End Use Condensate Recovery & Feed Water

US DOE Industries of the Future Workshop Series

Turbine exhaust Furnace exhaust

US DOE Industries of the Future Workshop Series

US DOE Industries of the Future Workshop Series

Scotch Marine most

US DOE Industries of the Future Workshop Series

Fuel burned within combustion

Source: Cleaver Brooks

US DOE Industries of the Future Workshop Series

Array of smaller boilers meet

Source: ES Magazine March, 2001

US DOE Industries of the Future Workshop Series

Heat recovery steam

Create steam using a heat

Can produce superheated

steam Can produce high pressure steam

Turbine exhaust Furnace exhaust

US DOE Industries of the Future Workshop Series

Distribution & End Users

Distribution lines Pressure reduction

Pressure reduction valve Backpressure turbine

End Use Components

Heat exchangers Mechanical drives Steam

US DOE Industries of the Future Workshop Series

Recovery & Feed Water

Condensate Recovery System

Feed Water System

US DOE Industries of the Future Workshop Series

Steam System Schematic

US DOE Industries of the Future Workshop Series

Steam is not commonly used for space

hot water systems are less maintenance intensive

US DOE Industries of the Future Workshop Series

Efficient Steam Systems

Proper performance yields

Effective maintenance is the best strategy!!

US DOE Industries of the Future Workshop Series

Why make a change?

Great energy & cost savings potential!

US DOE Industries of the Future Workshop Series

Why make a change?

INEFFICIENT STEAM SYSTEM

US DOE Industries of the Future Workshop Series

Why make a change?

EFFICIENT STEAM SYSTEM

US DOE Industries of the Future Workshop Series