U.S. DEPARTMENT OF @ENERGY Energy Efficiency & Renewable Energy Steam System Efficiency Report: Steam Example 5/30/23, 12:03 PMFacility Information Company Facility Date Address Street city State Country Zip Facility Contact Name Phone Email Assessment Contact Name Phone Email ORNL ORNL Test Facility Tue May 30 2023 1 Bethel Valley Re. (Oak Ridge ™N us 37831 7. Owner (865) 576-7658, towner@omi.com D.O. Energy (123) 456-7890 AMO_ToolHelpDesk@ee.doe.govExecutive Summary Percent Savings 2) Power Cost (Sr) ‘Savings Fuol Cost (ye) Savings Make-up Water Cost (sivn) Savings ‘Annual Cost (§) ‘Annual Savings Co Implementation Cost Payback Period (months) Selected Energy Projects Modifications 2,000,000 23,896,424 440591 2e277.015 Remove Turbines * 723,027, 6.523.027 20,080,968 2,989,485 999,923 45,587 28,803,919 2,526,904 Modify High to Low Pressure Steam Turbine Modify High to Medium Pressure Steam Turbine Operations Turbine Flash Condensate % 2,266,301 266,201 22,085,733 980.692 434,200 eat 25,555,013 rasro2 Boller Header Increase Condensate Recovery * 2471.05 171,856 2276168 562,256 230;395 210,286 25,676,359 600,656 HeaderEnergy Summary ‘Annual Steam System Summary Operating Cost ° 60; Emissions (tonne CO) (602 Emissions Savings (one 03) Power (sive) Demand (KW) Generation cw) Import (kW) Fuel (yr) Total Steam Generated (the) Boiler Fuel masta) Make-up Water (si Marginal Steam Costs HP Stoam Cost (six) IMP Steam Cost (sve) LP steam Cost «six 0; Emissions (tonne Cosi) From Fuel tom Seling Electricity From Change in Electiity Imports 2e277.015 2,000,000 18,8076 13,8076 5,000 23,898,424 4102 51549 440591 367.16 176,236 210.52 $829 $76 $6.07 Remove Turbines 2ajaoaere 236,068.38 236,049.34 17523,027 18,8078 ° s9076 20,886,968 3698 asirt 999,923 320.27 167.560.214.78 saa S049 se49 191,740.93, 4430241 Flash Condensate 25,555,013 2,128.08 2128.08, 2,265,901 16,8076 13,1443 5.6533 22,855,753 3032 496.28, 434,200 3618 7a711,9004 $73 soe s3ae 2,428.08 Increase Condensate Recovery 2s.676.250 137882 1378.52 271,888 18.8078 13378 5.4296 23,278,188 400.6 503.23, 230,395 yo195 92,193,907.79 $775 $55 sast 1978.52Losses Summary Increase Condensate (wmetune) Recovery Remove Turbines Flash Condensate InpstEneray Fuel 515.49 asirt 494.28, 503.33, Water 333 2.98 328 476 Useful ay Turbine Generation igh to Low Pressure 3042 - 37.48 37.98 Turbine High fo Medium Pressure 769 = 7.39 749 Turbine Retumed ‘Steam and e807 ma 24.36 ers Condensate Process Usage High Pressure 4028 4026 4026 4026 Medium Low Pressure 17996 17996 179.96 17996 2633 26.39 26.39 26:28 Stack 7732 6776 7416 785 Blowdown ser 3.48 138 3.88 Header High Pressure Loss 053 046 os ost sn ona oa one on [ebressure 029 0.28 0.29 0.28 Turbine High o Medium Turbine - - - - Efcioney Loss igh to Low Turbine ficiency Loss Condensate cease © 3088, 28.42 47.78 46:33, Venting Losses Deaerator Vent Loss 049 043 oar 04a Non-recovered Process Losses igh Pressure s187 ‘a7 nar 5.93 Met sa0s vss sea eae Low Pressure 2275 195 nan 1138Scenario: Remove Turbines Bascine Process Usage Remove Tuthines Process Usage Me: 86.33 MMBtUrrr, me: 86.33 Meu 179.96 BLU 179.96 mMBtu he: 40.26 matuyhe Basaine Generation Remove Turbines Generation No Data for Scenario HP to MP:asain Energy Usage Unreturned condaneate:Scenario: Flash Condensate Bescine Process Usage Flash Condonsale Process Usage Me: 86.33 MMBtUrrr, me: 86.33 Meu 179.96 BLU 179.96 mMBtu he: 40.26 matuyhe Basaine Generation Flash Condensate Generation ebasain Energy Usage econmone Unrsturnes condanete: Saveur sos wnaScenario: Increase Condensate Recovery Bascine Process Usage Increase Condensate Recovery Process Usage Me: me: 86.33 MMBtUrrr, 96.39 MMe 179.96 mMBtu 179.96 BLU he: he: 40.26 matuyhe 40.26 HMBtuhr Basaine Generation Increase Condensate Recovery Generation HP to MP:asain Energy Usage “ol wwe Unreturned Condensate:Stack Loss 14.99% a Blowdown Loss 0.9% Jyh orher Losses 6.2% [Bessiee OT] Cost Savings: $0/yr seme i Pras as Pan don Pan de xe, acs Sennarine Sent Fah Loeb at ack to 109% tm mt cones 65 oat Sevege ~$2,526,904/yr ‘Omer High Pressure Header, Medium Pressre Heal, Low Pressure Header, Condens, Losses _Doaorsor Von, Condensate Flash Tank, Low Pressure Vent Include:Assessment Input Summary Gonoral Operations Data ‘Annual Operating Hours 8000, Fuel Cost (MMB) 5.78, Electricity Cost SW) 0.05, Make-up Water Cost (Sioat) Site Power Import (KW) 5000, Total Fuel Emissions urput Rate (kg ° coin Total Emissions Output Rate (kg COz/MWh) Make-up Water Temp (7) 80 0025 soror Boiler Data Baseline Fuol Type cas Ful Typical Natural Gas - US Combustion Eicency (6)85 Blowdown Rate (6) 2 Steam Temperature ("F) $88.8 1s Blowdown Flashed? No Preneat Make-up Water? No ‘Approach Temperature cw ~ Deaerator Vent Rate (1k) 0.1 Deserator Pressure (psig) 15 Remove Turbines 000 578 0.05 0.0025 5000 53.08 so1o7 50 Remove Turbines cas Typical Natural Gas - US 85 Flash Condensate 000 578 005 0.0025 5000 40107 50 Flash Condensate cas “Typical Natural Gas - US 85 2 5889 Yee 04 16 Increase Condensate Recovery ‘5000 578 0.05 .0025 ‘5000 401.07 50 Increase Condensate Recovery Gas ‘Typical Natural Gas - US 65 2 5889 No No oa 16Header Data Baseline Number ofHeaders 9 High Pressure Header Prossur (psi) 00 Process Steam Usage (kibihe) *° Condensation Recovery Rate) Heat Loss (6) os Flash Condensate Return? No Condensate Retum ‘Temperature (*F) a Medium Pressure Header Pressure (psi) 150 Process Steam Uss9® yop (ur) Condensation Recovery Rate (%) *° Heat Loss (6) on Flash Condensate into Header? Ne Desupereat Steam nto 4, Next Highest? ° Desupernaat Steam Temperate F) Low Pressure Header Pressure (psi) 20 Process Steam Usage (klbihr) aoe Condensation Recovery * Rate) Heat Loss) on Flash Condensate Into Header? Desuperteat Steam ino, ‘Next Highest? ° Desuperneat Steam Temperature (F) Remove Turbines a 600 04 No 150 150 rors 04 Ey sri 50 o4 No No Flash Condensate a 500 50 50 oa 150 150 "100.03, 50 oa Yes 2 "199.65 50 oa Yes No “Process slam usage caused am your baseline dung mada, Increase Condensate Recovery 3 500 50 8 oa 150 150 “100 a on 2 “200 18 oa No‘Turbine Data High To Low Pressure Turbine Isontropic Eicioncy (%) 85 Generation Efficiency 7) Operation Type Balance Header Operation Value + (tbh) ork, ~ Operation Value 2 (tbh) or (kw) ~ 400 High To Medium Pressure Turbine Isentropic Efficiency (%) 65 Generation Eficieney 400 Operation Type Balance Header Operation Value * (ibe) or (kw) Operation Value 2 (ibe) or (kw) Remove Turbines Flash Condensate 6 100 Balance Header cy 100 Balance Header Increase Condensate Recovery ry 100 Balance Header cy 100 Balance Header