Steam End User Training Guide

DOEBestPractices
SteamEndUserTraining
Guide
AlternateTextNarratives
and
GraphicDescriptions
June29,2010
DOE BestPractices Steam End User Training
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
TableofContentsii
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DOEs BestPractices Steam End User Training
WelcomeModule
Slide1SteamEndUserTraining
WelcometotheDepartmentofEnergysIndustrialTechnologiesProgramBestPracticesSteamEndUserTraining.
[SlideVisualSteamEndUserCourseWelcome]
Banner:
USDepartmentofEnergy
EnergyEfficiencyandRenewableEnergy
USDepartmentofEnergys
IndustrialTechnologiesProgram
BestPractices
Slide2CourseContents
Therearesevendifferentsectionsinthistraining.Thenavigationaltutorialwillprovideyouwithabriefdemonstrationonhowtonavigatethroughthe
training.TheIntroductionwillprovideyouahistoryofthecoursedevelopment,andthenfocusonthegeneralaspectsofsteamsystemmanagement
andinvestigation.Inthissectionwewillintroducethefirstofthesteamsystemsoftwaretools,whichprovidessupportinidentifyingareasofpotential
improvement.Thiswillprepareyouformoreindepthdiscussionsintheforthcomingsectionsofthetraining.TheSteamGenerationEfficiencymodule
focusesonboilerefficiency.Inthissectionthedefinitionofboilerefficiencywillbediscussedandthevariousavenuesofboilerlosseswillbeexplored.
ResourceUtilizationEffectivenesswilldiscussfuelselection,steamdemands,andcogeneration.TheSteamDistributionSystemLossesmodulewill
coversteamleaks,steamtraps,insulationissues,andcondensateloss.EverythingwillbewrappedupwiththeConclusion.Lastly,therewillbeanEnd
ofCourseQuiz,whichwillevaluateyourknowledgeandunderstandingofthetraining.
Slide3SteamAssessments
Thiscourseisstructuredlikeatypicalsteamsystemassessment.Theassessmentisdesignedtoinvestigatetheperformancecharacteristicsofthe
system,pointoutbestpractices,identifyopportunitiestoimproveperformance,andevaluatetheeconomicimpactofpotentialimprovements.
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WelcomeModule1
Thistrainingwillprovideanoverviewoftypicalsteamsystems,theircomponents,operatingprinciples,managementtechniques,andpotential
improvementopportunities.
Steamsystemmodificationsoftenaffecttheentiresystemrequiringcomplicatedcalculationstoaccuratelyevaluatemass,energy,andeconomic
impacts.Thiscoursewillpointoutthevarioustoolswehaveavailabletousintheinvestigationprocess.Manyofthetoolsarethefundamental
principlesofphysicsthatallowustoidentifythebeforeandafterconditionsassociatedwithaspecificmodification.Additionally,theU.S.DOEhas
developedasophisticatedsetoftoolsthatenhanceourabilitytoaccuratelyandeffectivelyevaluatesteamsystemmodifications.Wewilldiscussthese
freetoolsthatcompletecomplicatedcalculationsandhelpyouidentify,analyze,quantify,andprioritizeenergysavingswithinyourplantssteam
system.
Slide4SteamSystemSchematics
Wewilluseanexamplesteamsystemtoserveasthefocusofourinclasssteamsystemassessment.Theexamplesteamsystemrepresentsaheavy
industrysitewithtypicalcomponentsandcommonoperatingconditions.Theevaluationsandfindingsnotedinthistrainingrepresentopportunities
commonlyidentifiedinindustrialsteamsysteminvestigations.Thissteamsystemisnotextraordinaryinanymannerincludingfuelcost,steam
production,andoperatingconditions.
Asyouwillsee,theexamplesystemoperateswiththreeboilerseachboilerconsumesadifferentfuel(naturalgas,number6fueloil,andgreenwood).
Thetotalfuelexpenditureforthesiteisnominally19MillionDollarsperYear.Typicalsteamproductionis260,000poundsperhourof400psig,700F
superheatedsteam.
Thethreeboilersdeliverhighpressuresteamtothedistributionsystemheader.Highpressuresteamservessteamloads,aswellasseveral
cogenerationcomponents.Thebackpressureturbinesareconnectedtoelectricalgenerators,thusservingtoreducesteampressureandtogenerate
electricity.Pressurereducingstationsalsoassistinmanagingtheflowofsteamthroughthesystem.
Asinallsteamsystemstherearemanyauxiliarycomponentssuchascondensaterecoverytanks,makeupwatertreatmentequipment,deaerator,
feedwaterpumps,andmanymorecomponentsnotshownintheschematic.
[SlideVisualSteamSystemSchematic]
Thisschematicrepresentsathreeheadersteamsystemincorporatingthreeboilersandmanysystemcomponents.Thesteamdistribution
systemincludesthreebackpressureturbinesandtwopressurereducingvalves.Theturbinesandpressurereducingvalvesoperatebetween
thevarioussteampressuresofthesystem.Eachsteamheaderincludesendusesteamloadswhichdischargecondensatethroughsteamtraps
totheirrespectivecondensatecollectiontanks.Condensateisultimatelycollectedinthemaincondensatereceiver,thenpumpedtoa
deaerator.Thedeaeratoralsoreceivesmakeupwaterandsteamtopreheatthecollectedcondensateandmakeupwater.Thedeaeratoroutflow
becomesthefeedwaterfortheboilers.
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WelcomeModule2
Slide6Results
Theexamplesystem,whichisbasedonarealworldsteamsystem,wassubjectedtoasteamsystemassessmentusingfundamentalinvestigation
techniquesandtheU.S.DOESteamTools.Theassessmentidentifiedseveralprojectsthatwillresultinsignificantenergysavingsthatpresent
economicallyattractiveprojects.Theassessmentidentifiedmorethan$1,300,000/yrofenergysavings,whichrepresentsmorethan7%ofthefuel
inputcosttothesite.
ThisSteamEndUserTrainingwillwalkyouthroughthisrealworldexampleofasteamsystemtohelpillustratehowyoucanidentifyareaswith
potentialforsavingenergyandforreducingcosts.
Now,letsgetstartedsoyoucanlearnhowtoidentifyenergyefficiencyimprovementsatyoursite!
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WelcomeModule3
NavigationalTutorialModule
Slide1Introduction
Hello,andwelcometotheSteamEndUserTraining.Iwouldliketotakeafewminutestoshowyouhowtonavigatethroughthetraining.
Slide2TableofContents1
Asyoucanseeinthetableofcontents,itisseparatedinto3differentmodules,eachonedemonstratingadifferentmajortopicintheSteamEndUser
Training:SteamGenerationEfficiency,ResourceUtilizationAnalysis,andSteamDistributionSystemLosses.Attheendofthecourse,youcantakean
interactivequiztotestyourunderstandingofsteamsystemconceptsandimprovementopportunities.
Clickonamodule,individualslide,orthequiz,tonavigatetoit.
Slide6Status
Ifyouclickonamodule,thesidebarwilldisplayitsindividualslides,aswellastheirtitlesandduration.
Youcanclickonanyslideinordertonavigatetoit.
UnderStatus,youwillseeacheckmarknexttoeachmoduleorslidethatyouhavecompleted.Atthebottom,youwillseethetotaltimeofthe
training,aswellashowmuchofthattimeyouhavecompleted.
ClickonCleartogetridofallofthecheckmarks.
Youcanalsoutilizethebookmarkfeature.Selectthesmallbuttonontheleftsideoftheslidetitletobookmarkaslide,
Slide7Bookmark
toreturntoitlatertocompletethetrainingsession,orforreferenceorquestions.Youcanclickthebuttonagaintocancelthebookmark.
Slide8Rewind/Play1
Atanytimeyouhavenavigatedthecoursewiththesidebarorbottomcontrolbar,andtheaudiodoesnotbegin,doubleclickonthehighlightedsidebar
slidetitle.Thehighlightidentifieswhereyouare,andtheaudioshouldrestart.
Noticethetoolbarbelowthemainscreen.Rewindwilltakeyoutothebeginningofthemodulethatyouareviewing.Clickplaytocontinue,
Slide10Back/Forward
andpausetopausethetraining,
Backandforwardwillmovebackandforwardbetweenslides.Ifyouwanttogotwiceasfast,youcanclickon2timesFastForwardSpeed.
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NavigationalTutorial1
Slide11FastForward
Clickonitagaintoget4timesFastForwardSpeed.
Youmustreturntonormalspeedtoheartheaudio,astheaudioisoffduring2timesand4timesFastforward.
Slide12NormalSpeed
Clickonitonemoretimetogobacktothenormalspeed.
Slide13SliderBar1
Youcanalsonavigatetoaparticularsectionofthetrainingbydraggingthesliderbackandforward.Clickitandholddownthemousebutton.
Slide15SlideNumber/Play/Pause1
Itwilldisplaywhichslideyouareon,outofthetotalnumberofslidesinthemodule.Asyourepositiontheslidercursor,youwillnoticethesidebarwill
highlighttheslidecorrespondingtothecursorposition.
Slide16SlideNumber/Play/Pause2
Torestartthetraining,youmayclickonthecorrespondingslide(whichishighlighted),orjusthittheplaybutton,asthepausebuttonwas
automaticallyengagedwhenusingtheslider.
Slide19SoundOn/Off1
Also,Youcanchoosetohavethesoundonoroff.
Slide21ClosedCaptioning1
CCallowstheusertoturntheclosedcaptioningonoroff.ClickingtheXwillexittheprogram.ClickingIwilldisplayinformationaboutthe
program,includingtheauthorandtheauthorsemailaddress.
Slide23MinimizeScreen
Atthetoprightofthescreen,youcanclicktheleftbuttontominimizethewindow.
Slide24MaximizeScreen
Clickonthemiddlebuttontomaximizeit,sothatyoucanseeitbetter.
ClickontheXallthewayontherightinordertoclosethetraining.IfyouareusingInternetExplorersF11Fullscreenmode,youwontbeabletosee
thebigXintheupperrightcorneruntilyouhitF11again.IfyouareusingabrowserotherthanInternetExplorer,thesebuttonswilllookdifferent.
Now,letsgetstarted!
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NavigationalTutorial2
IntroductionModule
Slide1IntroductionTitlePage
Hello,andwelcometotheSteamSystemEndUsertraining.Inthistraining,wewillinvestigatehowtoassess,evaluate,andmanagesteamsystems.We
willcovertheentiresteamsystem,fromoneendtotheother.
Letsgetstarteddiscussingtheoriginofthecourse,theneedforthecourse,andthentheoverallcourseobjectives.
[SlideVisualIntroductionTitlePage]
DOEsBestPractices
Introduction
CourseDevelopment
TheNeedfortheCourse
CourseObjectives
StarttheInvestigation
Slide2OriginalCourse
Thiswebbasedtrainingtoolhasbeendevelopedfromitsoriginal,instructorledclassroomsetting.
Theoriginalcoursewasdesignedprimarilywiththeindustrialsectorinmindandwithanindustrialexperiencebasis.Theprimaryprinciplesare
applicabletoallsteamsystemsandeventhermalwatersystems;but,thefoundationprinciplesarebasedinheavyindustry.
Thecourseisdesignedforplantpersonnel,suchasenergymanagers,steamsystemsupervisors,engineers,equipmentoperators,andotherswithsteam
systemresponsibilitiesinindustrialapplications.
Nowasawebbasedtrainingtool,participantscanaccessthetraininganytimeandreturntorevisittopicsofinteresttohelpimprovetheefficiencyand
performanceoftheirsteamsystems.
IntroductionModule1
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[SlideVisualDescriptionoftheInstructorledClassroomCourse]
Headercontains:
IndustrialTechnologiesProgram
Titleincludes:
ABestPracticesTrainingPresentation
SystemSystemsAssessmentTraining
IncludingUseoftheSteamSystemsToolSuite
Threephotographsofsteamsystems.
Photo1:alargeverticalexhaustpipeonabuildingexteriorexhaustingasteamplumefromthetopofthestack.
Photo2:aseriesofsmallsteampipeswithasteampressuregauge.
Photo3:Fivehorizontalrunsofsteamdistributionpipingfromacommonheader.Steamdistributionpipingisinsulatedwithan
aluminumjacketing.Apersonisstandingneartheheader.
Bottomfootercontains:
USDepartmentofEnergySeal
EnergyEfficiencyandRenewableEnergy
Bringyouaprosperousfuturewhereenergyisclean,abundant,reliable,andaffordable.
Slide3CourseDeveloper
ThiscoursewasdevelopedbyGregHarrellandisintendedtopresentarealworldviewofhowsteamsystemsoperate,practicalevaluationtechniques,
andcommonimprovementopportunities.Thiscoursehasdevelopedovermanyyearsofobservingandinvestigatingsteamsystems.Itrepresentsthe
compilationofBestPracticesobservedassustainablesteamsystemmanagementmeasures.
[SlideVisualGregHarrellsCredentials]
CourseDeveloperGregHarrell,Ph.D.,P.E.
Ph.D.MechanicalEngineeringThermodynamics,VirginiaTech(VPI&SU)1997
1987to1993DesignEngineer,UtilitiesProcessEngineer,BASFCorp.
Oversightforengineering,technicalactivitiesofentireutilitiesdepartment(steamproduction,electricpowergeneration,
compressedairsystems,industrialrefrigerationfacilities,industrialHVACsystems,waterfiltrationfacilitiesandwastewater
treatmentplant
IntroductionModule2
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AtVirginiaTechMechanicalEngineeringProfessor,EnergyManagementInstitute(EMI)
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
compressedairsystems
Slide4QualifiedPresenters
Thecoursehasbeenpresentedtothousandsofparticipantsrepresentingalltypesofindustry.Thecourseinstructorsallhavemanyyearsofpractical
steamsystemexperiencetheircareersfilledwithconductingsteamsystemassessmentthroughouttheworldinalltypesofsettings.Thiscombination
oftechnicalexpertise,realworldexperience,anddirectfeedbackfromindustrialparticipantshasresultedinthepractical,useful,andstraightforward
courseyouseetoday.
[SlideVisualQualifiedPresentersandTheirContactInformation]
GregHarrell,Ph.D.,P.E.
EnergyManagementServices
341WillocksDrive
JeffersonCity,Tennessee37760
Phone:8657190173
Email:gregharrell@emscas.com
RichardJendrucko,Ph.D.
Consultant,IndustrialEnergyManagement
458HillvaleTurnEast
Knoxville,Tennessee37919
Phone:8655237323
Email:drj@utk.edu
IntroductionModule3
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RiyazPapar,P.E.,CEM
HudsonTechnologies
14SplitRailFence
TheWoodlands,Texas77382
Phone:2812980975
Email:rpapar@houstontech.com
DebbieBloom
NalcoCompany
1601WestDiehlRoad
Naperville,Illinois60187
Phone:6303052445
Email:dbloom@nalco.com
StephenTerry,Ph.D.,P.E.
NorthCarolinaStateUniversity
IndustrialAssessmentCenter
DepartmentofMechanicalandAerospaceEngineering
Raleigh,NorthCarolina27695
Phone:(919)5151878
Email:sdterry@eos.ncsu.edu
BillMoir
SteamEngineeringInc.
204NE117thAvenue
Vancouver,Washington98684
Phone:(800)3466152
Email:BillMoir@steamengineering.com
Slide5IndustrialEnergy
Justforamomentletsexaminetheimportanceofeffectivemanagementofsteamsystems.Tostartthisdiscussion,considertheamountofenergy
requiredtooperateourindustries.ItisinterestingtonotethatintheUnitedStatesenergyisusedinthreebroadcategoriesofconsumers.These
consumersaresegregatedintotransportation(automobiles,trucks,andairplanes),residentialcommercial(homesandbuildings),andindustry.Itis
interestingtonotethateachofthesethreesectorsconsumeapproximatelyonethirdoftheenergyusedintheU.S.Thetransportationsectorconsumes
almostonethirdoftheenergy,whileresidentialandcommercialtogetherusesomewhatmorethanonethirdoftheenergy.Remarkably,industryalone
usesathirdofthecountrysenergy.
Thesethreesectorsuseenergyinverydifferentways.Thetransportationsectorusesprimarilyliquidfuelsastheenergyresource.Residentialand
commerciallocationsusealargeamountofelectricityalongwithnaturalgasandfueloils.Industryusesabroadmixofenergyresourcesincorporating
electricity,manyfueltypes,andotherenergyresources.Managementandsupportforthesesectorsrequireverydifferentapproaches.Onethingisvery
apparentmanagingtheenergyutilizationofindustryiscriticaltothecompetitivenessoftheU.S.ontheworldstage.
IntroductionModule4
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[SlideVisual2004EnergyUsePieChart]
Title:2004EnergyUse*
Industry34.0%(orangeslice)
Transportation28.0%(blueslice)
Commercial17.0%(greenslice)
Residential21.0%(yellowslice)
Footnotes:
*Includeselectricitylosses
Source:DOE/EIAMonthlyEnergyReview2004(preliminary)
Slide6EnergyConsumption
Ourfocushereistheindustrialsector.Itwillbeinterestingtoustocharacterizethetypesofenergyuseintheindustrialsector.U.S.DOEisservingasan
energymanagerforindustrialsitesintheUnitedStates.FromtheperspectiveoftheU.S.DOEhelpingU.S.industrymanageenergyresourcesisa
dauntingchallengethereareaquarterofamillionindustrialsitesintheUnitedStates.HowcanDOEhelpaquarterofamilliondiverseusers?Like
anygoodenergymanagerDOEinvestigatedthemeasurementsthatindicatehowenergyisusedinindustrythroughoutthecountry.WhatDOEfoundis
thathalfoftheenergyusedinindustrialsitesisusedbylargeindustrialsites.Thisisveryinterestingbecauselargeindustrialsitescompriseonly3
percentoftheindustrialpopulation.
Ifwecaninfluencetheenergyconsumptionofthissmallfractionofthetotalindustrialpopulation,thenwecaninfluenceasignificantportionofU.S.
energy!Also,thetechniquesusedtoaidthelargeindustrialsitescanbereplicatedtotheremainingindustrialsites.
[SlideVisualU.S.ManufacturingPlants:BySizeBarChart}
Title:U.S.ManufacturingPlants:BySize
HorizontalAxis:PlantsizeandAnnualEnergyCosts
SmallPlants<$100K
MidSizePlants$100K$2M
LargePlant>$2M
AllU.S.Plants(nocostprovided)
VerticalAxis:NumberofU.S.Plants
Range0to250,000by50,000increments
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Chartreads:
SmallPlants<$100Khas104,299plants(yellowbar)
MidSizePlants$100K$2Mhas115,636plants(yellowbar)
LargePlant>$2Mhas6,802plants(orangebar)
AllU.S.Plants(nocostprovided)has226,737plants(greenbar)
[SlideVisualPercentofTotalIndustrialEnergyPieChart]
Title:PercentofTotalIndustrialEnergy
SmallandMedium47%(yellowslice)
Large53%(orangeslice)
Source:1998EIAMECS
Slide7EnergyRequirements
Asaresult,letstakealookathowenergyisusedinatypicalindustrialsite.Asyoucanseefromthechart,mostoftheenergyisgoingintoprocess
heatingandsteamsystems.Bothprocessheatingandsteamsystemsconsumemorethanonethirdoftotalindustrialenergy.Itisalsoexcellenttonote
thateventhoughprocessheatingandsteamsystemshavetheirdistinctdifferences,theinvestigationtechniquesandopportunitieswehaveinprocess
heatingareverysimilartothoseforsteam.Ifwecanbettermanageourprocessheatingandsteamsystems,wecanhaveasignificantimpactonour
energyconsumptionandcompetitivenessintheworldmarket.Thisistheprimarydrivingforceforthiscourse;inotherwords,steamsystemsarea
majorfactorintheenergyconsumptionoftheUnitedStatesandmuchoftheworld;therefore,weneedtomanagethemeffectively.
[SlideVisualTypicalEnergyRequirementsPieChart]
Title:ManufacturingEnergyUsebyTypeofSystem(%)
Steam35%(blueslice)
ProcessHeating38%(brightyellowslice)
MotorSystems12%(peachslice)
ProcessCooling1%(whiteslice)
ElectroChemical2%(yellowslice)
Other4%(blueslice)
Facilities8%(greenslice)
Footnotes:
Note:Doesnotincludeoffsitelosses
Source:DOE/EIAMonthlyEnergyReview2004(preliminary)
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Slide8CourseDivisions
Thiscourseisarrangedinasimilarmannertoatypicalsteamsystemassessment.Wewillinvestigateallareasofthesteamsystem.Wewillstartwith
theboileroperationsintheSteamGenerationAssessmentsectionofthecourse.Inthissectionwewillexaminetheenergyconversionefficiencyofthe
boiler.Variousboilerefficiencyinvestigationmethodswillbeidentified.Boilerefficiencyimprovementavenueswillbeexploredalongwithcontrol
strategies.
IntheResourceUtilizationAnalysissectionofthecoursewewilltargetsteamendusecomponents,fuelselection,steamsystembalancing,aswellas
combinedheatandpoweractivities.Thesearemajorconcernsformostfacilitiesandcanpresentsignificantopportunitiesforeconomicimprovement.
TheDistributionSystemcanprovidetremendouswasteintheformofsteamleaks,steamtrapfailures,insulationrelatedlosses,andlostcondensate.
Theseareaswillserveasinvestigationtargetsforourdiscussions.
Slide9U.S.DOETools
Investigatingandanalyzingsteamsystemsrequiresasignificantamountofcomplexcalculationstoidentifytheimpactpotentials.Throughoutthis
training,wewilldemonstratethefundamentalcalculationsandinvestigationtechniquesrequiredtoevaluateeachareaandeachimprovement
opportunity.
TheSteamSystemSurveyGuideisacompaniondocumenttotheSteamEndUserTrainingtodiscussmajorareasofpotentialimprovementsforsteam
systemsandhowtoquantifythoseopportunitiesandisavailableforfreedownloadfromtheBestPracticesTrainingArea.
AdditionaltechnicalpublicationsareprovidedforfreedownloadfromtheBestPracticesResources.Youcanreferencethesedocumentsasyou
investigateimprovementsforyoursteamsystemsefficiencyandperformance.
TheSteamSystemToolsSuiteisasetofsoftwaretoolsconstructedtoaidintheevaluationofsteamsystemprojects.Thesesoftwaretoolsareavailable
forfreedownloadfromtheU.S.DOEwebsite.TheToolsSuiteincludestheSteamSystemScopingTool,whichisdesignedtoguidetheusertopotential
improvementopportunities.Also,includedistheSteamSystemAssessmentTool,whichallowstheusertocompleteacomprehensivemass,energy,and
economicbalanceonthesteamsystem.Thistoolisdesignedtoevaluatethesystemwideimpactsofchangesinthesteamsystem.Finally,theTools
Suitecontainsthe3EPlusInsulationEvaluationTool.Thistoolcanbeusedtoevaluateanyinsulationrelatedproject.
Slide10CourseObjectives1
Wearegoingtofocusourattentiononthefundamentalandpracticalaspectsofsteamsystemoperation,maintenance,andmanagement.Whatwe
wouldliketoaccomplishistohelpyouidentifyopportunitiesyoumayhavetoimproveyoursteamsystem,understandhowtoevaluatethetrue
impacts,andtosetapathtoimplementtheimprovements.Thefocuswillbeonthefundamentalsofsteamsystemsifthefundamentalsaremastered
thesteamsystemwillbewellmanaged.
Effectivesteamsystemmanagementrequiresanexcellenttoolboxfilledwithevaluationtoolsandtechniquesthatwillenabletheskilledassessorto
identifyandquantifyimprovementopportunities.Wewillfocusontheessentialmeasurementsthatcharacterizeoperations.Wewillfocussome
attentionontheboilerandunderstandhowboilerefficiencycanbeimpactedandimproved.
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[SlideVisualCourseObjectives1]
BecomefamiliarwithU.S.DOEToolsSuitetoassesssteamsystems
Identifythemeasurementsrequiredtomanagesteamsystems
Measureboilerefficiency
Estimatethemagnitudeofspecificboilerlosses
Identifyandprioritizeareasofboilerefficiencyimprovement
Recognizetheimpactsoffuelselection
Slide11CourseObjectives2
Wewillintroducethetopicofcogenerationandidentifythecommonaspectsofturbineoperation.Attentionwillbegiventotheenduseequipmentand
potentialopportunitiestoreducesteamdemand.Steamtrapmanagement,insulationopportunities,andcondensaterecoveryareallvitalcomponents
insteamsystems.Theseareaswillbeinvestigated.
Thereisalotofinformationtodiscuss;so,letsgetstarted.
[SlideVisualCourseObjectives2]
Characterizetheimpactofbackpressureandcondensingsteamturbines
Quantifytheimportanceofmanagingsteamconsumption
Identifytherequirementsofasteamtrapmanagementprogram
Evaluatetheeffectivenessofthermalinsulation
Evaluatetheimpactofcondensaterecovery
Recognizetheeconomicimpactsofsteamsystemoperations
Slide12SteamSystem
Oneofthefirststepsincompletingasteamsystemassessmentistoidentifytheprimarycomponentsofthesteamsystem.
Steamsystemscanbelargeandcomplexwithmanycomponentsandarrangementsbutmanyoftheprimarycomponentswillbecommonfromsystem
tosystem.
Boilersandtheirauxiliarycomponents,heatexchangersandotherenduseequipment,watertreatmentsystems,condensaterecoverycomponents,
distributionpiping,andmanyothercomponents.
Thesecomponentsmaybearrangedinasimplesystem,withasingleboiler,maybeonebackupboileroritcanbemuchmorecomplicated.
[SlideVisualSteamSystemImpactSchematic]
Thisschematicrepresentsatwoheadersteamsystemwithtwoboilersandallofthesystemcomponents.Feedwaterispreheatedbysteam
injectionfromthelowpressuresteamdistributionheader,aswellaspreheatedmakeupwaterutilizingboilerblowdownheatrecovery.
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ThetopoftheschematicshowstheBoilerFeedwaterenteringthetwoboilers.Thetwoboilersareconnectedtothehighpressuresteam
distributionheader.
Thesteamexitstwoboilersandentersthehighpressuresteamsystemdistributionheader,indicatedbyalinebelowtheboilers.
Atthefarrightofthehighpressuresteamdistributionsystem,thehighpressureendusercomponentloadsareidentifiedthrougharectangular
graphicandarrowsenteringandleavingtherectangle,indicatingheatexchangewiththecomponents.Theendusecomponentsdischarge
condensatethroughasteamtrap,representedbyarectangulargraphic.Schematically,condensatepassesthroughthebottomofthetrapand
recoveredinacondensingtank.
Thecondensatetankusesapump,whichisdenotedbyacircle/squarecombination,todeliverthecondensatetothemaincondensatereceiver.
Themaincondensatereceiverthenpumps(denotedbyacircle/squarecombination)thecondensatetothedeaeratortankasdenotedbytwored
rectangles,withthesmalleroneonthetop.Thetoprectanglealsoshowstwotriangles,eachpointedawayfromeachother,longestendsnearly
touching.Thebottomtriangleisconnectedtoacontrolvalverepresentedbyahourglassfigurewithadomeontheside,whichprovidessteamto
thedeaeratorfromsteamdistributionsystemtopreheatthecollectedcondensateandmakeupwater.Makeupwateralsoschematicallyenters
atthetopofthedeaeratorwiththecollectedcondensate.
Theboilerfeedwaterschematicallyexitsthedeaeratorfromthebottomandispumped(denotedasacircle/squarecombination)tothefeedwater
inletsofeachboiler,nearthetoptheschematic.
Slide13SteamSystem2Pressures
Thesystemmayincludemultipleboilers,severalsteampressures,differenttypesoffuel,steamturbines,andmanyprocessendusers.
Thisschematicrepresentsatwopressureheadersteamsystemwithmultipleboilersandallofthesystemcomponents.Feedwaterispreheated
bysteaminjectionfromthelowpressuresteamdistributionheader,aswellaspreheatedmakeupwaterutilizingboilerblowdownheatrecovery.
distributionheader.
Underthehighpressuresteamdistributionline,youwillseethreeconeshapedgraphics,thatrepresentthesteamturbines.Theonenearestto
theleftisahighpressuretocondensingturbine.Thisturbinedischargestothecondenserrepresentedbythebluecirclebelowtheturbine.The
rectangulargraphictotherightoftheconeshapedgraphicindicatestheelectricalgenerationcomponentofthesteamturbine.Theturbineinthe
middlereceiveshighpressuresteamandexhaustslowpressuresteamtothelowpressuresteamdistributionsystem,aswellasgenerates
electricity.Thisturbineisdenotedasredconeandrectanglecombination.Thesteamturbinetothemostrightreceiveshighpressuresteam,
drivesapump(denotedasacircle/squarecombination)andisalsocalledasteamturbinedrivenpump,thendischargestothelowpressure
steamdistributionsystemheader.
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Betweenthecondensingturbineandthehightolowpressureturbine,alightbluetriangulargraphicthatrepresentsapressurereducingvalve,
whichdischargestothelowpressuresteamdistributionheader,identifiedbyaredlinebelowtheturbines.
recoveredinacondensingtankwhichisalsoconnectedtothelowpressuresteamdistributionsystem.
Underthelowpressuresteamdistributionline,youwillseethelowpressureendusercomponentloadsidentifiedasarectangulargraphicand
arrowsenteringandleavingtherectangle,indicatingheatexchangewiththecomponents.Theendusecomponentsdischargecondensate
throughasteamtrap,representedbyanotherrectangulargraphic.Schematically,condensatepassesthroughthebottomofthetrapandrecovered
inacondensatetank,inwhichsteamisventedrepresentedbyaverticalarrowleavingthetopofthetank.
Thelowpressureendusercondensatetankusesapump,whichisdenotedbyacircle/squarecombination,todeliverthecondensatetothemain
condensatereceiver,whichisalargerectanglewiththreeinputsdenotedbythreearrowsatthetopoftherectangle.Thecondensateentersthis
maincondensatereceivertank,afteritpassesthroughacontrolvalve,denotedasanhourglassshapewithadomeontop.Thethirdcondensate
inputcomesfromthecondensatefromtheheatexchangerthatutilizesthehighpressuresteamturbine.Thecondensateleavesthisheat
exchangerandisdeliveredviaapump(denotedasacircle/squarecombination)tothemaincondensatereceiver.
Themaincondensatereceiverthenpumps(denotedbyacircle/squarecombination)thehighpressurecondensate,lowpressurecondensate,and
thecondensingsteamturbinecondensatetothedeaeratortankasdenotedbytworedrectangles,withthesmalleroneonthetop.Thetop
rectanglealsoshowstwotriangles,eachpointedawayfromeachother,longestendsnearlytouching.Thebottomtriangleisconnectedtoa
controlvalverepresentedbyaredhourglassfigurewithadomeontheside,whichprovideslowpressuresteamtothedeaeratorfromthelow
pressuresteamdistributionsystemtopreheatthecollectedcondensateandmakeupwater.Preheatedmakeupwateralsoschematicallyenters
Themakeupwaterispreheatedfromtheboilerblowdownandlowpressuresteam.Boilerblowdownfromeachboilerisnotedasreddashed
linesleadingtoablowdownreceivertankdenotedasaredrectangleontherightofthescreen.Flashsteamisdivertedfromtheblowdownflash
vesseltothelowpressuresteamdistributionline,alsodenotedinreddashedlines.Liquidfromtheblowdownflashtankthenschematically
entersthetopofaheatexchanger(representedasawhiteandgreenstripedrectangle).Makeupwaterisshownenteringtheheatexchangerfrom
theright,afteritpassesthroughthewatertreatmentequipment,denotedastworedrectanglesfurtherontheright.Theliquidexitingtheheat
exchangerissenttothedeaerator.
Theheatedboilerfeedwaterschematicallyexitsthedeaeratorfromthebottomandispumped(denotedasacircle/squarecombination)tothe
feedwaterinletsofeachboiler,nearthetoptheschematic.
IntroductionModule10
June28,2010
Slide14SteamSystem3Pressures
Somesystemsareevenmorecomplicatedthanthatincludingmanysteampressuresandincorporatingsteamturbinesdrivingprocesscomponentsas
wellaselectricalgenerators!
Thisschematicrepresentsathreepressureheadersteamsystemwithmultipleboilersandallofthesystemcomponents.Feedwaterispreheated
distributionheader.
June28,2010
Slide15SteamSystemComplex
Thesteamsystemmayincludecondensingsteamturbinesandothermajorcomponents.However,nomatterhowcomplexorsimplethesteamsystems
are,themanagementandinvestigationactivitiesarebasicallythesameweneedthesametoolsandfundamentalknowledge.
Thisschematicrepresentsathreepressureheadersteamsystemwithmultipleboilersandallofthesystemcomponents.Feedwaterispreheated
distributionheader.
June28,2010

Slide16FocusAreas
Whenassessingoursteamsystem,wemustevaluatethesystemasawhole;but,wewillberequiredtoanalyzemanycomponentsindividuallythen
determinetheirimpactonthesystem.Therearemanydifferentcomponentsandsubsystemsassociatedwiththesteamsystem.
Weaskquestionslike,howcanweimproveboilerefficiency?Howcanwereducesteamconsumption?Whatenergyresourcesareavailabletous?How
canweloselessenergythroughoutthesystem?
June28,2010
[SlideVisualSteamSystemFocusAreas]
SteamSystemFocusAreas
ResourceUtilizationEffectiveness
DistributionSystemlosses
Slide17SteamGenerationEfficiency
Forexample,wewillfocusourattentionontheboilerandaskquestionslike:
Whataretheperformancecharacteristicsofourboiler?
Whatarethecriticalmeasurementsrequiredtomanageboilerperformance?
Howcanweimpactboilerefficiency?
[SlideVisualSteamGenerationEfficiency]
Boilerefficiencyisamajorfactordeterminingtheoperatingcostsofasteamsystem
Severalmajorfactorsimpactboilerperformance
Whataretheefficiencycontrolparameters?
Aretheymaintainedatappropriatelevels?
Slide18ResourceUtilization
Wefocusourattentionontheenduseequipmentandtheenergyresourcesweemployinoursystems.Weinvestigateopportunitiestorecoverenergy
fromprocessunits.Wetargetopportunitiestoreducesteamuse.Significantfocusisplacedonimprovingtheperformanceofourendusesystems.
Cogenerationinvestigationsidentifypotentialstoconvertsteamenergyintopower.Weinvestigateopportunitiesusealternativeenergysources.
[SlideVisualResourceUtilizationEffectiveness]
ResourceUtilizationEffectiveness
Steamisgeneratedformanypurposes
Steamcanoftenbegeneratedfromdifferentprimaryenergysources
Multipleenergyexportscanbedevelopedfromoneenergyresource
Areresourcesbeingproperlyutilized?
Isthesteamenduseappropriateorinappropriate?
June28,2010
Slide19SteamDistributionSystemLosses
Steamsystemsareoftenverylarge,extendingintomanyprocessareas.Weexaminehowenergycanbelostfromthedistributionsystem?Wetryto
identifyopportunitiestoreducethelosses?Wefocusattentiononrecoveringenergyfromthedistributionsystem.
[SlideVisualSteamDistributionSystemLosses]
SteamDistributionSystemLosses
Thedistributionsystemcanexperiencesignificantlosses
Whatarethemainavenuesofloss?
Whatmethodsareavailabletoreducethelosses?
Slide20DrivingForceQuestion
Inmoststeamsystemsthereareopportunitiesthatwillallowenergyconsumptiontobereduced.Ifatyourfacilityideasaredevelopedtoreduce
energyconsumption,whatwillbetheprimaryreasonthattheinitiativewillbeimplemented?
[SlideVisualDrivingForce]
Whatisthemaindrivingforceforchange??
Slide21DrivingForceEconomics
Economicimpactistheprimarydrivingforceforchange.Oneofourprimaryfocalpointsinthiscourseistoidentifyhowtoaccuratelyconnectareal
worldsteamsystemchangetothetrueeconomicimpactitwillprovide.
Answer:$
Slide22DrivingForceMore
Energysavings,oftenfuelsavings,aredominantpointsoffocusresultingineconomicimpact.However,wedonotwanttolosesightofothereconomic
factors;suchas,maintenanceimpacts,reliabilityfactors,siteproductivity,productquality,environmentalimpact,andpotentiallyavoidingcostly
systemmodifications.Alloftheseissueshaveeconomicconnectionssometimesitisdifficulttoestablishthetrueeconomicimpactoftheseitems.
Someoftheseimpactsmayresultinincreasedcost.Wemustattempttoaccuratelyandrealisticallyidentifythetrueeconomicimpactsand
implementationcostsassociatedwithanopportunity.
June28,2010

Answer:$
Energy
Reliability
Maintenance
Productivity
Quality
Costavoidance
Emissionsreductions
Slide23Measure
Managementofanyresourcerequiresmeasurements.Throughoutthiscoursewewillidentifythecriticalmeasurementsthatallowustounderstand
howoursystemsareperformingandhowmuchimprovementhasbeenorcanbeaccomplished.
[SlideVisualMeasure]
Youarenotmanagingwhatyoudonotmeasure.
Slide24StarttheInvestigation
Evaluatingsteamsystemsrequiresabroadrangeofknowledgeandsignificantskillsset.Itcanbeverydifficulttodeterminewherebesttostart
investigating.Oftenobtainingabroadoverviewofthesystemandtheoperatingpracticeswillleadtoimportantinvestigationstrategies.
Slide25SSST1
Investigatingsteamsystemsoftenbeginswithtakingabroadviewofthesystemandidentifyingareastoinvestigatethatmayyieldfruitfulresults.The
SteamSystemScopingTool(knownasSSST)isdesignedtohelpyouidentifythesepotentiallyfruitfulareas.
[SlideVisualSteamSystemScopingTool]
SteamSystemScopingTool(SSST)
OrangeBannerwithindustrialplantgraphicinbackground
OfficeofIndustrialTechnologies
BestPractices
EnergySmartTechnologyforToday
SteamSystemScopingTool
Version2.0.0
December2002
June28,2010

UnitedStatesDepartmentofEnergy
Clickanywhereonthisframetobegintheassessment.
Slide26ScopingTool2
TheSteamSystemScopingToolisavailablefreeasanExcelbasedsoftwaretool.
SSSTisnotacalculationtoolorasolutionevaluationtool;rather,itisatoolusedtohelptheusertobecomemoreawareofareasofthesteamsystem
thatcanbeimproved.
Thetoolisbasicallyaquestionnairethatasksgeneralquestionsaboutthemanagementpracticesofthesteamsystem.
Questionsareprovidedforeachareaofthesteamsystem.Theresultsofapplyingthistoolarerelativescoresfortheperceivedperformanceofeach
areaofthesystem.
Thesescoresprompttheusertoinvestigatecertainareasofthesteamsystemfurther.
Slide27SSSTProfiling
ForexampletheScopingToolasksquestionsabouttheintensityoffuelandsteammeasurements.Basedontheusersinputascoreisdevelopedfor
eachcategory.ThescoresshownhereareaveragescoresforasectorofU.S.industry.
[SlideVisualSSSTScorecardSystemProfiling]
SUMMARYRESULTS
POSSIBLE
TYPICAL
SCOPINGTOOLQUESTIONS
SCORE
SCORE
1.STEAMSYSTEMPROFILING
STEAMCOSTS
SC1:MeasureFuelCostToGenerateSteam
10
7.5
SC2:TrendFuelCostToGenerateSteam
10
6.9
STEAM/PRODUCTBENCHMARKS
BM1:MeasureSteam/ProductBenchmarks
10
5.6
BM2:TrendSteam/ProductBenchmarks
10
5.7
STEAMSYSTEMMEASUREMENTS
MS1:Measure/RecordSteamSystemCriticalEnergy
30
22.5
Parameters
MS2:IntensityOfMeasuringSteamFlows
20
8.5
STEAMSYSTEMPROFILINGSCORE
90
56.7
100%
63%
June28,2010
Slide28SSSTSystemOperations
Questionstargetingsteamtrapmanagementandinsulationconditionprompttheusertoinvestigatethesevitalareasofsteamsystemmanagement.
Again,thescoresnotedherearereflectiveofaveragescoresforasectorofU.S.industry.
[SlideVisualSSSTScorecardSystemOperations]
BM2:TrendSteam/ProductBenchmarks
10
5.7
STEAMSYSTEMMEASUREMENTS
MS1:Measure/RecordSteamSystemCriticalEnergy
30
22.5
Parameters
MS2:IntensityOfMeasuringSteamFlows
20
8.5
90
56.7
100%
63%
POSSIBLE
TYPICAL
SCORE
SCORE
2.STEAMSYSTEMOPERATINGPRACTICES
STEAMTRAPMAINTENANCE
ST1:SteamTrapMaintenancePractices
40
23.9
WATERTREATMENTPROGRAM
WT1:WaterTreatmentEnsuringFunction
10
8.6
WT2:CleaningBoilerFireside/WatersideDeposits
10
7.1
WT3:MeasuringBoilerTDS,Top/BottomBlowdown
10
7.7
Rates
SYSTEMINSULATION
IN1:InsulationBoilerPlant
10
8.6
IN2:InsulationDistribution/EndUse/Recovery
20
14.0
STEAMLEAKS
June28,2010
Slide29SSSTBoilerOperations
BoilerefficiencyandcontrolcomponentsareprimarypointsoffocusintheScopingTool.Boilerblowdownissuesarealsoofconcern.
[SlideVisualSSSTScorecardBoilerOperations]
POSSIBLE
TYPICAL
SCORE
SCORE
3.BOILERPLANTOPERATINGPRACTICES
BOILEREFFICIENCY
BE1:MeasuringBoilerEfficiencyHowOften
10
6.3
BE2:FlueGasTemperature,O2,COMeasurement
15
9.4
BE3:ControllingBoilerExcessAir
10
7.1
HEATRECOVERYEQUIPMENT
HR1:BoilerHeatRecoveryEquipment
15
8.5
GENERATINGDRYSTEAM
DS1:CheckingBoilerSteamQuality
10
4.2
GENERALBOILEROPERATION
GB1:AutomaticBoilerBlowdownControl
5
2.6
GB2:FrequencyOfBoilerHigh/LowLevelAlarms
10
8.6
GB3:FrequencyOfBoilerSteamPressureFluctuations
5
3.9
BOILERPLANTOPERATINGPRACTICESSCORE
80
50.6
BOILERPLANTOPERATINGPRACTICESSCORE
100%
63%
June28,2010
Slide30SSSTEndUse
Ofcoursecondensaterecoverypracticesareamajorpointofconcern.Thetoolfocusessomeattentiontothepotentialofusingbackpressuresteam
turbines.
[SlideVisualSSSTScorecardEndUse]
POSSIBLE
TYPICAL
SCORE
SCORE
4.STEAMDISTRIBUTION,ENDUSE,RECOVERYOPERATING
PRACTICES
MINIMIZESTEAMFLOWTHROUGHPRVs
PR1:OptionsForReducingSteamPressure
10
7.4
RECOVERANDUTILIZEAVAILABLECONDENSATE
CR1:RecoveringAndUtilizingAvailableCondensate
10
6.4
USEHIGHPRESSURECONDENSATETOMAKELOWPRESSURE
STEAM
FS1:RecoveringAndUtilizingAvailableFlashSteam
10
3.7
DISTRIBUTION,ENDUSE,RECOVERYOP.PRACTICESSCORE
30
17.5
DISTRIBUTION,ENDUSE,RECOVERYOP.PRACTICESSCORE
100%
58%
Slide31SSSTResults
Theoutputofthetoolisanoverallscoreandindividualareascores.Solutionsarenotofferedsimplyalowscorepromptstheusertoinvestigate
furtherandpotentiallyidentifyimprovementopportunities.Inmoststeamsystemsthereareinterestinginvestigationopportunitiesinseveralareas.
Typicaloverallscoresforindustrialplantsareinthe60%and70%ranges.
June28,2010

[SlideVisualSSSTScorecardResults]
SUMMARYOFRESULTS
SCOPINGTOOLAREAS
STEAMSYSTEMPROFILING
STEAMSYSTEMOPERATINGPRACTICES
BOILERPLANTOPERATINGPRACTICES
DISTRIBUTION,ENDUSE,RECOVERYOP.PRACTICES
TOTALSCOPINGTOOLQUESTIONAIRESCORE
TOTALSCOPINGTOOLQUESTIONAIRESCORE
POSSIBLE
SCORE
90
140
80
30
340
100%
TYPICAL
SCORE
63%
69%
63%
58%
222.0
65%
Slide32SSSTNextSteps
Thetoolprovidesguidanceintowheretofindadditionalinformationforaparticulararea.TheScopingToolwillpointtheusertoadditionalU.S.DOE
resources.
[SlideVisualNextStepsDirectedbySSST]
Focusonareasrequiringattention
Investigateresources
ConsulttheU.S.DOEBestPracticeswebsite
www1.eere.energy.gov/industry/bestpractices
SteamSystemSurveyGuide
U.S.DOESteamTipSheets
ImprovingSteamSystemPerformance:ASourcebookforIndustry
UsetheSteamSystemAssessmentTool(SSAT)
UseInsulationTool(3EPlus)\
Slide33GeneralTools
Manytoolsarerequiredtoevaluatesteamsystems.TheSteamSystemScopingToolisoneofmanytoolsthatcanbeemployedtoinvestigatesteam
systems.TheothertoolsintheU.S.DOESteamToolsSuitewillbeintroducedinthiscourseaswellasthefundamentaltechniquesusedtoinvestigate
andmanagesteamsystems.Themostimportanttoolsarethefundamentalprinciplesofphysicsandtherealsystemmeasurementsrequiredtoemploy
them.TheU.S.DOESteamToolsareextensionsofthesevitalcomponents.
June28,2010
Slide34Information
AdditionaltechnicalresourcesareavailablefromtheDepartmentofEnergy.
[SlideVisualAdditionalTechnicalResources]
Information
Programs
IndustrialTechnologiesProgram(ITP)
BestPracticesSteamProgram
http://www1.eere.energy.gov/industry/bestpractices/steam.html
Softwaretools
(877)3373463
http://www1.eere.energy.gov/industry/bestpractices/software.html
SteamPublications
http://www1.eere.energy.gov/industry/bestpractices/techpubs_steam.html
Training
http://www1.eere.energy.gov/industry/bestpractices/training.html
TechnicalAssistance
http://www1.eere.energy.gov/industry/bestpractices/info_center.html
Slide35IntroductionSummary
Steamsystemsarecomplexarrangementsofinterconnectedcomponentsthatrequiretremendousamountsofenergyandeconomicexpenditure.
Propermanagementofasteamsystemisvitaltoeffectivelyutilizeenergyresources.Toolsareavailabletohelpinthisinvestigationandmanagement
process.
June28,2010
SteamGenerationEfficiencyModule
EfficiencyDefinitionSection
Slide1SteamGenerationEfficiencyModule
Thismodulewilldiscusssteamgenerationefficiencyandtheprimaryfactorsthataffectit..Thegeneralconceptsofboilerefficiencywillbediscussed.
[SlideVisualEfficiencyDefinitionTitlePage]
DOEsBestPractices
EfficiencyDefinition
ShellLosses
BlowdownLosses
StackLosses
Slide2BoilerTypes
Therearemanytypesofboilers,buttheprimaryboilerdesignationsarefiretubeboilersandwatertubeboilers.Afiretubeboilerisoneinwhichthe
combustiongasesareinsidethetubes.Thisschematicdepictsa3passfiretubeboiler,inwhichwehaveacombustionzone,andsmallertubesthat
allowmoreheattransferfromtheexhaustgases.Firetubeboilersservedasourfirstindustrialsteamgenerators.Thelargediameterpressurevessel
holdsallofthestressofthehighpressuresteam.Asindustrialrequirementsnecessitatedhigherpressuresteamandgreatersteamflowrates,the
vesselhadtobecomelargerandthewallofthevesselhadtogetthickertoaccommodatethestressofgreaterpressures.Thesefactorsmadeboiler
manufacturingdifficultandexpensive.Asaresult,watertubeboilersweredeveloped.Theseboilerscontainhundredsoftubesthatholdthehigh
pressuresteamandwater.Theserelativelysmalldiametertubescanaccommodatethestressofmuchhigherpressuresthanthelargediametervessel.
Watertubeboilersallowthecombustiongasestoprovideheattransfertothewater(andsteam)thatiscontainedinthetubesoftheboiler.Acommon
watertubeboilerarrangementwillincorporateanuppersteamdrumthatallowstheliquidwaterandsteamtoseparate.Alowerdrum,oftencalleda
muddrum,willserveasthelowercollectionheaderforthetubes.Hundredsofrelativelysmalldiametertubeswillconnectthemuddrumtothesteam
drum.Asthewaterheatsandboilingoccursthefluidrisesinthetubestothesteamdrum.
June28,2010
SteamGenerationModule
BoilerEfficiency1
[SlideVisualBoilerTypes(FireTubeandWaterTube)]
Thisschematicdepictsa3passfiretubeboiler,inwhichwehaveacombustionzone(atthebottom),andsmallertubesthatallowmoreheat
transferfromtheexhaustgases.Thepressurevesselholdsallofthestressofthehighpressuresteam.
Watertubeboilersallowthecombustiongasestoprovideheattransfertothewater(andsteam)thatiscontainedinthetubesoftheboiler.A
typicalwatertubeboilerarrangementwillincorporateanuppersteamdrumthatallowstheliquidwaterandsteamtoseparate.Alowerdrum,
oftencalledamuddrum,willserveasthelowercollectionheaderforthetubes.Hundredsofrelativelysmalldiametertubeswillconnectthe
muddrumtothesteamdrum.Asthewaterheatsandboilingoccursthefluidrisesinthetubestothesteamdrum.
Slide3FireTubeBoiler
Generally,firetubeboilersaredesignedforlowerpressureandlesscapacitythanwatertubeboilersbuttheiroperatingrangesoverlap.Atypical
firetubeboilermighthaveasteamproductionrateof5,000poundsperhour,whileatypicalwatertubeboilermighthaveasteamproductionrateof
200,000poundsperhour.Firetubeboilersproducesaturatedsteaminmostallcases.
[SlideVisualaFireTubeBoiler]
Thisschematicdepictsa3passfiretubeboiler,inwhichwehaveacombustionzone(atthebottom),andsmallertubesthatallowmoreheat
transferfromtheexhaustgases.Thepressurevesselholdsallofthestressofthehighpressuresteam.
Slide4WaterTubeBoiler
Watertubeboilerscanproducesaturatedsteamortheycanbeequippedwithasuperheaterinternaltotheboiler.Fromthestandpointsof
management,investigation,andimprovement,knowingthedifferencesbetweenthetwoboilertypesisnotessentialbecausetheygenerallyworkthe
same.Therearenosignificantefficiencyrelatedreasonstochooseonetypeofboilerortheother.Thereasonsforchoosingoneortheotherareusually
relatedtotherelativecostforthegivenpressureandsteamproductionrequirements.
[SlideVisualaWaterTubeBoiler]
June28,2010
BoilerEfficiency2
Slide5CommonFuels
ThistablecontainsinformationconcerningthemostcommonfuelsusedintheUnitedStatesandthroughouttheword.Naturalgasandnumber2fuel
oilaregenerallyconsideredveryeasyfuelstoutilize.Theheavierfueloils,likenumber6fueloilareverycommon;but,aremoredifficulttohandle.
Number6fueloilisgenerallyasolidatroomtemperatureandisheatedtomorethan200Ftobepumpedtotheboilerburner.Solidfuelslikecoaland
greenwoodaremuchmoredifficulttohandleandstore.Solidfuelsgenerallycontainaportionofnoncombustiblematerialcalledashthatmustbe
disposedofafterthecombustionprocess.
Greenwoodisadominantfuelinthepulpandpaperindustrybecausetheygenerateasignificantamountofwastewoodmaterials.Itshouldbenoted
thatgreenwoodistypicallybarkandtreecomponentsthatwererecentlyapartofalivetree.Thisfactisimportantbecauselivetreesareessentially
halfliquidwatergreenwoodasafuelisnominally50%liquidwater.
TheunitcostsidentifiedinthistablearereflectiveoftheaverageU.S.fuelcostsfor2005.Thisinformationisunderstandablynotcurrent;but,itis
reflectiveofthecommondifferencesinfuelprices.Itiscommonfortheenergybasedcostofnaturalgastobefourtimesgreaterthantheenergybased
costofcoalorevenmore.Fueloilpricescanbeevenhigher.Thisisadominantreasonwhyweusecoal.
Itshouldbenotedthatthereissignificantvolatilityinthefuelmarket.
[SlideVisualCommonFueltable]
TypicalFuel
Properties
Fuel
NaturalGas
Number2FuelOil
Number6Oil(LS)
Number6Oil(HS)
EasternCoal
WesternCoal
GreenWood
Sales
Unit
10stdft
gallon
gallon
gallon
ton
ton
ton
ExamplePrice
[$/salesunit]
7.00
1.80
1.20
1.00
45.00
30.00
11.00
HHV
[Btu/lbm]
23,311
19,400
18,742
18,815
13,710
10,088
5,250
UnitPrice
[$/10Btu]
7.00
12.92
7.82
6.62
1.64
1.49
1.05
Slide6BoilerExample
Throughoutthistrainingwewilluseanexamplesteamsystemthatreflectsasteamsystemwithrealworldcharacteristics.Thisexamplesystemwill
helpusillustratetheimportanceandusefulnessoftoolsandinvestigationspresentedinthistraining.Throughoutthiscoursewewilldiscussallthe
aspectsofthissteamsystem;but,wewillstartbylookingatoneoftheboilersservingthisexamplesite.
Forthisexampletheboilerisproducing100,000poundsperhour,of400PSIG,700degreeFahrenheitsteamfromthecombustionofnaturalgas.
BoilerEfficiency3
June28,2010
Thisboilerisequippedwithafuelflowmeterandthecostofthefuelistakenas$10/106Btu.
[SlideVisualWaterTubeBoiler]
Slide7CaseStudy
Thisdatawillprovideenoughinformationtocalculatethefuelrelatedoperatingcostoftheboiler.
[SlideVisualOperatingCost]
Boilerfiredwithnaturalgaswhichhasahigherheatingvalueof23,311Btu/lbm
HHVis1,000Btu/sft
Steamconditions:400psig,700F
Output:100,000lbm/hr(steady)
Rating:120,000lbm/hr(maximumcontinuous)
Feedwater:600psig,242F
Fuelsupply:149,000sft/hr(2,480sft/min)
Fuelcost:$10.00/10Btu($10.0/10sft)
Determinetheoperatingcostoftheboiler
Slide8BoilerOperatingCost
Thefuelrelatedoperatingcostofthisexampleboileris$13,000,000/yr.Itshouldbenotedthatthisexampleboilercanbeconsideredatypical
industrialboiler.Thefuelisnaturalgas,whichisoneofthesimplestfuelstoburn.Itisinterestingtonotethatthecharacteristicsofthisboilerarenot
extreme;inotherwords,theboilerisproducingamoderateamountofsteamundertypicalconditions.Additionally,whilethefuelcostmaynotbe
exactlyrepresentativeofthefuelcostsatagivenfacilitythisexamplecostisnotextraordinary.Thecharacteristicsofthisboilerareeasilyscalableto
mostboilers.Itshouldalsobenotedthattheinvestigationandimprovementtechniquesrequiredtomanagethisexampleboilerarethesame
techniquesavailabletoallboilers.Alongwiththisisthefactthatthisexampleboilerisarealboilerthatappropriatelyrepresentsthetypesof
opportunitiespotentiallyavailabletomanyboilers.Boilersareextremelyexpensivecomponentsthisisthereasonweareinterestedinthem.
June28,2010
BoilerEfficiency4
[SlideVisualCalculation]
K boiler =V fuel xk fuel x operation
Boileroperatingcostsequalsthecostoffuelperhourperhourmultipliedbythecostofthefuelpercubicfootmultipliedbythehoursof
operation
Abbreviations
K=BoilerOperatingCosts
V=VolumeflowofFuelperHour
k=CostofFuelperCubicFoot
=Operatingperiod
Slide9OperatingCost
Thecostoffuelforatypicalboilerissolargethatevenverysmallchangesinefficiencycanrepresentsignificantcostimpact.A1%improvementin
efficiencyfortheexampleboilerrepresentsapproximately$130,000/yroffuelsavings.
Thereareothercostfactorsassociatedwithboileroperationswatertreatmentcosts,auxiliaryequipmentcosts,maintenancecosts,andoperations
costs;however,thesecoststypicallycombinetobesignificantlylessthanthecostoffuelfortheboiler.Eachcostfactorshouldbeinvestigated;but,fuel
costtypicallydominates.
Inthisexampleboilerinvestigationwewillidentifyrealworldmethodsthatwillreducethefuelconsumptionofthisboilermorethan7%,which
representsmorethan$1,000,000/yr.
[SlideVisualSavingsCalculation1]
0.01x$13,000,000/yr$130,000savings!
Inthisequation,KequalsBoilerOperatingCost,VequalsCostoffuelperhour,KequalsCostoffuelpercubicfoot,andTequalsHoursofOperation.
Calculationsareoftenthoughtofasacademicexercises;however,inthecaseofmanagingboilerperformanceandcost,evaluatingboilerefficiencyis
oneofthemostimportantandpracticaltoolsavailabletous.Toillustratetheimportanceandusefulnessofboilerefficiency,wewillexaminethe
efficiencyofanexampleboiler.Wewillalsoexplorethemajorfactorsthatimpacttheefficiencyandoperatingcostofaboiler.
June28,2010
BoilerEfficiency5
[SlideVisualOperatingCost]
Boilerfiredwithnaturalgaswhichhasahigherheatingvalueof23,311Btu/lbm
HHVis1,000Btu/sft
Steamconditions:400psig,700F
Output:100,000lbm/hr(steady)
Rating:120,000lbm/hr(maximumcontinuous)
Feedwater:600psig,242F
Fuelsupply:149,000sft/hr(2,480sft/min)
Fuelcost:$10.00/10Btu($10.0/10sft)
Operatingcost:13,000,000$/yr
Asmallchangeinboilerefficiency(even1%)canrepresentasignificanteconomicimpact
Otheroperatingcostsinclude:
Watertreatment
Boilerfeedpumps
Fluegasconditioning
Maintenance(personnel,services,equipment)
Typicallythesecostscombinetobemuchlessthanfuelcosts
Slide10EfficiencyDefinition
Calculationsareoftenthoughtofasacademicexercises;however,inthecaseofmanagingboilerperformanceandcost,evaluatingboilerefficiencyis
oneofthemostimportantandpracticaltoolsavailabletous.Toillustratetheimportanceandusefulnessofboilerefficiency,wewillexaminethe
efficiencyofanexampleboiler.Wewillalsoexplorethemajorfactorsthatimpacttheefficiencyandoperatingcostofaboiler.
[SlideVisualEfficiencyDefinitionTitlePage]
DOEsBestPractices
June28,2010
ShellLosses
BlowdownLosses
StackLosses
BoilerEfficiency6
Slide11DefineBoilerEfficiency
Boilerefficiencyisawaytodeterminehowmuchfuelenergyaboilerconvertsintosteamenergy.Steamenergyisthedesiredcommodityandfuel
energyisthepurchasedcommodity.Theequationshownhereisasimplifieddescriptionoftheenergyefficiencyofaboilerexpressedintermsoffuel
energyintotheboilerandsteamenergyoutoftheboiler.
Thefuelenergysuppliedtotheboilerisdeterminedbymultiplyingthefuelflowratebythefuelenergycontent.Fuelenergycontentisdescribedin
termsoftheheatingvalueofthefuel,whichisanexpressionofthethermalenergythatisreleasedwhenthefuelisburned.Themaximumthermal
energythatcanbereleasedwhenafuelisburnedisidentifiedasthefuelHigherHeatingValueorHHVofthefuel.Thefuelheatingvalueisdetermined
bylaboratoryanalysis.
[SlideVisualEfficiencyEquation1]
n boiler =energydesired/x(100)
energythatcosts
Theboilerefficiencyisequaltotheenergydesireddividedbytheenergythatcosts.
Theenergydesiredistheenergyaddedtothesteamasitpassesthroughtheboiler.Steamenergyisdeterminedbymultiplyingthesteamproduction
(ormassflowrate)bythespecificenergyaddedtothesteamasitpassesthroughtheboiler.Wedescribetheenergycontentofthesteamasthe
enthalpyofthesteam(hintheequation)enthalpyisthethermodynamicpropertydescribingtheamountofenergyresidinginthematerial.The
energyaddedtothesteamintheboileristhedifferenceinenthalpyofthesteamleavingtheboilerversusthefeedwaterenteringtheboiler.Enthalpy
valuesareobtainedfromthermophysicalpropertydatasetsandfieldmeasurementslikesteamtemperatureandpressure.
[SlideVisualEfficiencyEquation2]
n boiler =m steam (h steam h feedwater )/

m fuel HHV fuel
Boilerefficiencyisequaltothemassflowrateofthesteammultipliedbythedifferenceintheenthalpyofthesteamandtheenthalpyofthe
feedwater;,dividedbythemassflowofthefuelmultipliedbythehigherheatingvalueofthefuel.
Enthalpyenergyofasubstancethatcanbeconvertedintoheat,work,andotherformsofenergy.
Fuelenergyisdeterminedbymultiplyingthefuelconsumptionratebythefuelenergycontent,alsoknownastheheatingvalue.
June28,2010
BoilerEfficiency7
Abbreviations
n boiler =Efficiencyoftheboiler,alsocalledcombustionefficiency,overallefficiency(dimensionless)
m steam =massflowrateofsteamgeneratedintheboiler(lbm/hr)
m fuel =massflowrateoffuelburned(lbm/hr)
h
=Enthalpyisenergycontentofasubstance(Btu/lbm)
HHV =HigherHeatingValueoffuel(Btu/lbm)
AnalternateexpressionfortheenergycontentofthefuelisidentifiedastheLowerHeatingValue(LHV).Mostcommonfuelsarecomposedprimarilyof
carbonandhydrogen.Theseelementsreactwithoxygeninthecombustionprocessandprimarilyformcarbondioxideandwater.Thewaterformedin
thecombustionprocessisinitiallyvapor(steam).Ifthethiswatervaporisallowedtocoolbelowitscondensationtemperaturethevaporwillcondense
liberatingheat.Thisenergyreleasefromthewatervaporrepresentsadditionalenergyavailablefromthecombustionofthefuel.Thedifference
betweentheHigherHeatingValueandtheLowerHeatingValueistheHigherHeatingValueaccountsforthisadditionalenergyliberationwhenthe
watervaporcondenses.TheLowerHeatingValuemeasuresthefuelenergyreleasewithallthecombustionproductsremaininginthevaporphase.
Slide12BoilerEfficiency1
Itisinterestingtoidentifytypicalboilerefficiency.Thiswillallowustocompareourboilertotypicaloperation.Ifwecanidentifybestpracticeboiler
efficiencythenwecancharacterizetheoperationofourboilerpossiblyidentifyingtheimprovementpotential.
Slide13BoilerEfficiency2
Ifweweretoexaminemanyboilerswewouldprobablyfindthatthetypicalboilerefficiencyisinthemid80%range.Wewouldalsoseethatmanyof
theboilerswouldhavehigherefficiencythanthisandmanywouldhavelowerefficiencythanthis.But,wewouldseeveryfewboilerswithefficiencies
muchgreaterthan90%andveryfewboilerswithefficienciesmuchlowerthan70%.
Greenwoodisacommonfuelinmanyindustriesmostprominentlyinthepulpandpaperindustry.Thetermgreenwoodreferstowoodproductsthat
havenotbeendried.Pulpandpaperplantsharvesttreestoprocessthemintopulpandpaperproducts.Paperisnotmadefromthebarkandlimbsof
thetrees.Asthetreesareharvestedthelimbs,bark,andpoorqualitymaterialsareremovedalongwithotherpartsofthetreethatcannotbeconverted
intopaper.Thisgreenwoodisfreshfromtheforestandtypicallycontainsabout50%celluloseand50%liquidwater.Greenwoodisusedasamajor
fuelsourcebecauseitisreadilyavailableandislowcost.However,afuelthatiscomposedof50%liquidwaterwillburninefficientlytheliquidwater
willboilandcarryalargeamountofenergyoutoftheboiler.Asaresult,greenwoodfiredboilerswilloperatewithlowefficiency.
Itisinterestingtonotethatatypicalindustrialcoalfiredboilerwilloperatewithrelativelyhighefficiency.Thisresultsfromthefactthathydrocarbon
fuelsarecomposedprimarilyofhydrogenandcarbon.Carboncombustsandformscarbondioxide.HydrogencombustsandformsH 2 Owater.Water
isGodsgreatestchemicalforabsorbingandtransportingenergy.Mostofourboilersburninghydrocarbonfuelsreleasewatervapor(steam)asa
productofcombustion.Asaresult,asignificantportionoftheenergyavailableinthefueliscarriedoutoftheboilerinthewatervaporthatisformedin
June28,2010
BoilerEfficiency8
thecombustionprocess.Fuelscontaininglesshydrogenexhaustlesswatervaporinthefluegasesandgenerallyhavehigherefficiency.Coalsgenerally
containsomeamountofliquidwater,someamountofash(rocks),butmostlycarbon.
Fueloilsusuallycontainmorehydrogenthancoalsbuttheytypicallycontainverylittleashandalmostnoliquidwater.Asaresult,fueloilfiredboilers
willoperatewithrelativelyhighefficiency.
Naturalgascontainsarelativelylargeamountofhydrogen.Therefore,naturalgasfiredboilerswilloperatewithefficiencieslowerthancomparable
coalandoilfiredboilers.
Therearemanyfactorsthatimpactboilerefficiencyfueltypeisoneofthem,thewaywecontrolthecombustionprocessisanother,andenergy
recoveryequipmentinstalledontheboileronemoremajorfactoreffectingefficiency.
Slide14SteamProperties
Letsreturntoourexampleboilerbecausewehaveenoughinformationtoevaluateboilerefficiency.Inordertodeterminetheenergyaddedtothe
steampassingthroughtheboilerwemustusesteampropertydataoftenknownassteamtables.Fromthetemperatureandpressuremeasurements
ofthesteamandfeedwaterwecanidentifytheirenthalpiesagain,enthalpyisanindicationofenergycontent.Hereyoucanseefor700degrees
Fahrenheitand400poundspersquareinchgage,theenthalpyofthesteamis1,362Btuperpoundofsteam.Thefeedwaterisat242degrees
Fahrenheitand600poundspersquareinchgagetheenthalpyofthefeedwateris210Btu/lbasshowninthetable.
Slide15Direct(Classic)EfficiencyCalculation
Thesteampropertydataalongwiththefuelconsumptiondatagivesusenoughinformationtocalculateboilerefficiency.Thisboilerisoperatingwith
anefficiencyofabout77%.Weareexpectingatypicalnaturalgasfiredboilertooperatewithanefficiencyinthelow80%range.Thisboileris
operatingwithanefficiencythatisbelowtheexpectedvalueweanticipatethattheremaybeopportunitiestoimprovetheperformanceofthisboiler.
[SlideVisualEnthalpy]
h steam =1,361.88Btu/lbm
h feedwater =210.42Btu/lbm
DirectEfficiencyCalculation1Enteringdataintothedirectefficiencyequation,weget77%boilerefficiency.
[SlideVisualEquations]
n boiler =m steam (h steam h feedwater )/x(100)

m fuel xHHV fuel
June28,2010
BoilerEfficiency9
Theboilerefficiencyisequaltothemassflowofthesteammultipliedbythedifferenceintheenthalpyofthesteamandtheenthalpyofthe
feedwater;dividedbythemassflowofthesteammultipliedbythehighheatingvalueofthefuel.
n boiler =(100,000lbm/hr)x(1,361.88Btu/lbm210.42Btu/lbm)x(100)
(149,000sft3/hr)x(1,000Btu/sft3)
*basedonvolumetricflowrate(HHVunitsareBtu/sft3)
Theboilerefficiencyisequalto100,000poundsperhour,multipliedby1,361.88BTUperpoundminus210.42Btuperpound;dividedbythe
149,000standardcubicfeetperhourmultipliedby1,000Btuperstandardcubicfeet.
Orusingfuelmassflowdata(p=0.043lbm/sft3)
m fuel =(149,000sft3/hr)x(0.043lbm/sft3)=6,407lbm/hr
n boiler =(100,000lbm/hr)x(1,361.88Btu/lbm210.42Btu/lbm)x(100)
(6,407lbm/hr)x(23,311Btu/lbm)
*basedonmassflowrate(HHVunitsareBtu/lbm)
Theboilerefficiencyisequalto100,000poundsperhour,multipliedby1,361.88BTUperpoundminus210.42Btuperpound;dividedbythe
6,407poundsperhourmultipliedby23,311Btuperpound.
n boiler =77.1%
Abbreviations
h
Slide16EfficiencyCalculation
Inordertoidentifytheimprovementopportunitiesassociatedwiththisboilerweaskwhyistheefficiencynot100%?Inotherwords,ifboiler
efficiencyindicatesthat77%ofthefuelenergywentintothesteam,wheredidtheother23%ofthefuelenergygo?Itwenttosupplythelossesofthe
boiler.
June28,2010
BoilerEfficiency10
Slide17BoilerLosses1
Whatarethetypicalboilerlosses?Wherecanfuelgootherthanintothesteam?
[GraphicalDescriptionBoilerLosses]
Thisschematicdepictsawatertubeboiler.Fuelandairentersatthelowerleftofthecombustionzone,feedwaterentersatthetopintothe
steamdrumwhichconnectstothemuddrumthroughmanytubes.Themuddrumisatthebottomoftheboiler.Steamexitstheboilerfromthe
steamdrumintothesuperheatersection,whichisshownatthetopoftheboiler.Thecombustiongasesleavingtheboilerthroughtheducting
attheupperright.
Slide18BoilerLosses2
Eventhoughboilersareinsulatedtheiroutersurfacesarehot,indicatingtheyarenotperfectlyinsulatedandfuelenergyisbeinglost.Thisisidentified
astheshelllossalsoknownasradiationandconvectionloss.
Anotherlossassociatedwithoperatingaboilerisidentifiedastheblowdownloss.Inordertomaintainproperboilerwaterchemistrysomeoftheboiler
watermustberemoved.Thisisanenergylossbecausethewaterthatisdischargedhasbeenheatedwithfuelenergy.
Theexhaustgasesfromthecombustionprocessexittheboilerwithfuelenergy.Thisenergycanbeidentifiedbytheelevatedtemperatureofthegases.
Buttherealsocanbeunreactedfuelorextraairintheexhaustgases.Theseexhaustgasrelatedlossesareidentifiedasthestackloss.
Manyotherlossescanbeidentifiedforboilers;suchas,theenergycarriedfromtheboilerwithashinacoalfiredboiler.However,thethreelosses
identifiedshell,blowdown,andstackarepresentonallfiredboilersandtheyrepresentthefundamentalpointsofconcernformanagingboiler
efficiency.
Slide19IndirectEfficiency
Generallymanagingboilerperformancefocusesonidentifyingandmanagingthelosses.Infact,oneofourmostimportanttoolsistoidentify,quantify,
andreducetheboilerlosses.Thisisaccomplishedthroughanindirectefficiencyevaluationtechnique,whichisthetoolmostoftenusedinthefield.
Boilerefficiencyisdeterminedinanindirectmannerbyassumingtheboilerefficiencyis100percentminusallofthelosses.Eachlossisidentifiedand
quantifiedinthisanalysis.
Inthenextsectionsofourtrainingwewillfocusoneachoftheselosses.Wewillexploreeachlossindetailidentifyinghowtoevaluateeachoneforour
boilers.Additionallywewillidentifythefuelimpactassociatedwitheachlossandtherealworldimprovementopportunitiesthatcanbetargetedin
eacharea.Therealbenefitassociatedwithevaluatingboilerperformancewiththeindirectefficiencytoolisthatasboilerefficiencyisdeterminedthe
roadmapforimprovementisestablished.Evaluatingtheindividuallossesnotonlycharacterizeseachlossbutitalsoaffordsustheopportunityto
identifytheimprovementpotentialassociatedwitheach.
June28,2010
BoilerEfficiency11
[SlideVisualBoilerLossIndirectEfficiencyEquations]
n indirect =100percentE losses
IndirectBoilerEfficiencyisequalto100%minusthesumofallboilerlosses.
n indirect =100percentshellblowdownstackmisc
IndirectBoilerEfficiencyisequalto100%minustheshelllosses,minustheblowdownlosses,minusthestacklosses,minusthemiscellaneous
losses.
Abbreviations
n indirect =Indirectefficiency
E losses =SumofallLosses
June28,2010
BoilerEfficiency12
ShellLossesSection
Slide1ShellLossesModule
Next,wewillidentifythemethodsusedtoinvestigate,quantify,andcontroltheseindividuallosses.Wewillstartwithshelllosses.
[SlideVisualShellLossesTitlePage]
ShellLosses
BlowdownLosses
StackLosses
Slide2ShellLossMagnitude
Shelllossisthefuelenergythatleavestheboilerfromitsoutersurface.Inotherwords,theoutersurfaceoftheboilerishot,whichindicatesitislosing
heat.Itisdifficulttoaccuratelymeasurethethermalenergylossfromtheoutershellofaboiler.Asaresult,shelllossisgenerallyestimatedfromsome
limitedfieldmeasurements.AnexcellentandrelativelyeasyestimatingtechniqueisidentifiedintheAmericanSocietyofMechanicalEngineers
PerformanceTestCode4(ASMEPTC4).
[SlideVisualShellLossesEstimationTechnique]
ASMEPTC4AmericanSocietyofMechanicalEngineersPerformanceTestCode4
Inthistechniquethetemperatureofeachsurfaceoftheboilerismeasured.Typicallythismeasurementisobtainedwithaninfraredsurface
thermometer.Surfacetemperaturestypicallyrangefrom120to180degreesFahrenheit,buthotspotsgreaterthanthisrangecanexist.Hotspotscan
developfromdamagedinsulationontheboilerordamagedrefractoryinsidetheboiler.
Theshelllossestimatingtechniqueutilizesthecharacteristictemperatureofaboilersurfaceorareaandanestimatedambientsurfaceairflowvelocity.
Theseestimatesareusedtocompleteaheattransferanalysisforallofthesurfacesoftheboileryieldinganestimatefortheboilershellloss.This
techniqueissimple;however,theresultsmustbeconsideredageneralestimate.
Thetotalshelllossestimateiscomparedtothetotalfuelenergyinputtodeterminethemagnitudeoftheloss.
ShellLosses1
June28,2010

Slide3ShellLoss
Itisinterestingtonotethatformostboilersthetotalenergylostfromtheshellremainsessentiallyconstantwithrespecttoboilerload.Inotherwords,
theshelllossenergyflowisbasicallyconstant.Thisisnottosaythatthefractionoffuelinputenergylostfromtheboilershellremainsconstantrather
theenergyflow(Btu/hr)remainsessentiallyconstantwithrespecttoboilerload.Thisbeingthecase,theshelllossexpressedasafractionoffuelinput
energywoulddoubleastheboilertransitionsfromfullloadtohalfload.
Formostwellmaintainedboilers,thefullloadshelllosswillbebetween0.1%to2%offuelinputenergy.
Usually,shelllossesareminimalandthebestwaytomanageshelllossistomonitorforhotspots,damagedinsulation,andothersurfaceproblems.
Typically,shelllossissuesdonottranslateintosignificantenergylossesbutsignifyinsulationorrefractoryissuesthatneedtoberepairedtoincrease
thelongevityoftheboiler.
Slide4ExampleBoilerSavings
ForourexampleboileranASMEtypeshelllossinvestigationindicatesapproximately0.5%ofthefuelinputenergyislostthroughtheshelloftheboiler.
Thisrepresentsapproximately$65,000/yroffuelenergy.Thisisarelativelysmallfractionofthefuelinputenergyandthereisverylittlethatcanbe
donetosignificantlyreduceit.
OurExampleBoiler:
FromanASMEtypeinvestigationtheradiationandconvectionlossoftheexampleboilerisapproximately0.5%ofthetotalfuelenergyinputto
theboiler.
Thisrepresentsalossofapproximately$65,000/yr.
Surfacetemperaturemeasurementsdidnotindicateanyhotspotsontheexampleboiler.Theinsulation,cladding,andrefractoryarein
goodcondition.Asaresult,wewilljustacceptthatthislosswilloccurandcontinueourinvestigationintootherareasofboilerefficiency.
RadiationandConvectionLoss=$13,000,000/hrx(0.5%/100)=$65,000/yr
ShellLosses2
June28,2010

Slide5ShellLossSummary
Insummary,shelllossisgenerallyaminorcontributortotheoverallfuelenergyloss.Directmeasurementsofboilershelllossaredifficulttocomplete;
but,simplifiedestimatingtechniquesprovideexcellentinsightintothemagnitudeofboilershellloss.Shelllossshouldnotbeignoredhotspotsinthe
boilershellindicateproblemsthatshouldbecorrected.
[SlideVisualShellLossSummary]
ASMEPTC4AmericanSocietyofMechanicalEngineersPerformanceTestCode4
Searchforhotspots
o Damagedinsulation
o Damagedrefractory
o Monitorsurfacecladdingintegrity
Measureboilersurfacetemperature
o Infrared
Typicalsurfacetemperatureshouldrangebetween120oFand180oF
Repairrefractory
Monitorsurfacecladdingintegrity
Reduceboilerloadcanpresentanopportunity
ShellLosses3
June28,2010
BlowdownLossesSection
Slide1BlowdownLossesModule
Thissectionwilldiscussblowdownlossanditsaffectonboilerefficiency.
[SlideVisualBlowdownLossesTitlePage]
RadiationandConvectionLossesShellLosses
BlowdownLosses
StackLosses
Slide2Blowdown
Thenexttypeoflossinvestigatedisblowdownloss.Boilerfeedwaterisverycleanwater.However,infeedwatertherearesomedissolved
chemicals.Essentiallypuresteamexitstheboilerthemajorityofthechemicalsenteringtheboilerwithfeedwaterarenotsolubleinthesteamand
willnotleavetheboilerwiththesteam.Asaresult,theconcentrationofthesechemicalsincreasesintheboiler.Elevatedconcentrationsof
chemicalsresultsinmanyseriousboilerproblemsincludingfoamingresultinginliquidcarryover,scalingonthewatersideofthetubes,and
loosesludgeintheboilerwater.Blowdownistheprimarymechanismthatallowsustocontrolchemicalconcentrationsintheboilerwater.
Blowdownallowsustomaintainanacceptableconcentrationofdissolvedandprecipitatedchemicalsintheboiler.
Thereisanenergylossassociatedwithblowdown,becausethewaterhasbeenheatedtotheboilingpointfromfeedwaterconditions.
Slide3BoilerBlowdown
Therearetwogeneraltypesofboilerblowdown.Oneistypicallyfromthelowersectionsoftheboilercalledbottomblowdown.Theothertypeof
blowdownistypicallyfromtheuppersectionsoftheboilerandiscalledsurfaceblowdown.
Bottomblowdownisactuatedbecausesomesolidswillprecipitatefromthechemicalsdissolvedinthefeedwater.Thesesolidstendtobeheavier
thanwater,andthereforetendtocongregateinlowersectionsoftheboiler.Bottomblowdownisusedtoflushthesesolidsout.Bottomblowdown
istypicallyasignificantflowofwaterforaveryshortperiodoftime.Theintentistosweepawayanysolidprecipitatesformedinthewater.Even
June28,2010
BlowdownLosses1
thoughwhileitisoccurringitisalargeflowrate,itcontinuesforashortperiodoftime.Asaresult,thetotalflowofbottomblowdownisusually
muchlessthanthetotalflowsurfaceblowdown.
Surfaceblowdownistypicallyamuchsmallerflowratethanbottomblowdown;however,itcontinuesforamuchlongerperiodoftimeoften
continuously.Surfaceblowdownistheprimarymechanismusedtocontrolthedissolvedchemicalconcentrationsintheboiler.Surfaceblowdown
endsupremovingmostoftheblowdownwater.
[SlideVisualBoilerBlowdown]
attheupperright.Thebottomblowdownisshownfromthebottommuddrum.Thesurfaceblowdownisshownatthetopfromthesteam
drum.
Slide4BlowdownControl
Generally,surfaceblowdowniscontrolledbasedonboilerwaterconductivity.Conductivityisadirectmeasurementthatcancontinuouslyprovide
anindicationofboilerwaterquality.However,conductivitymustbecorrelatedtoindividualchemicalcontaminantsthroughperiodicwater
analysis.Conductivityandtheresultsofspecificboilerwatertestingaidinadjustingtheblowdownrate.
[SlideVisualConductivitySensor]
attheupperright.Thesurfaceblowdownisshownatthetopfromthesteamdrumwithaconductivitysensorcontrollingtheblowdownvalve
position.Theblowdownisdischargedtothesewer.
Slide5BlowdownLossEstimate
Fromtheviewoftheboiler,feedwaterenters,steamandblowdownexit.Theboileraddsfuelenergytothesteamandblowdownthatexitthe
boiler.Blowdownisanenergystreamthatisdischargedfromtheboiler.Blowdownistypicallyexpressedasafractionoffeedwatermassflowand
canrangefromlessthan1%tomuchgreaterthan10%dependingonwaterchemistry,boileroperatingpressure,andotherfactors.However,it
shouldbenotedthat10%blowdownratedoesnotmean10%energylossblowdowndischargedfromtheboilerisnothighenergysteam,itis
moderateenergywater.Fromtheperspectiveoftheboiler,theenergyaddedtotheblowdownstreamisblowdownflowratetimesthedifference
intheenthalpyoftheblowdownandthefeedwater.Therefore,10%blowdownratecantranslateinto5%fuelenergyinput.Itshouldbenotedthat
therelationshipbetweenblowdownmassfractionandblowdownenergyfractionisdependentonmanyfactorsincludingboileroperating
pressureandfeedwatertemperature.
June28,2010
BlowdownLosses2
[SlideVisualBoilerBlowdownLossBoilerCalculation]
L blowdown =m blowdown (h blowdown h feedwater )/x(100)
m fuel xHHV fuel
Abbreviations
L blowdown
m blowdown
h feedwater
m fuel
h
HHV
=Lossduetoblowdown(%)
= massflowrateofblowdown(lbm/lbm)
= massflowrateoffeedwater(lbm/lbm)
=massflowrateofsteamgeneratedperpoundoffuelburned(lbm/lbm)
=Enthalpyisheatcontentorusefulenergyofasubstance(Btu/lbmorkJ/kg)
=HigherHeatingValueoffuel(Btu/lbm)
Slide6SystemLoss
Again,fromtheperspectiveoftheboiler,theenergyaddedtotheblowdownstreamisblowdownflowratetimesthedifferenceintheenthalpyof
theblowdownandthefeedwater.However,everypoundofblowdowndischargedfromthesystemismadeupwithcoldmakeupwaterasa
result;aportionofthesteamgeneratedintheboilerisusedtoheatthemakeupwatertofeedwaterconditionsinthedeaerator.Therefore,froma
systemperspective,theenergyassociatedwiththeblowdownstreamisevenlargerthanthatidentifiedfromtheboilerperspective.
[VisualDescriptionSteamSystemImpactSchematic]
Thisschematicrepresentsathreepressureheadersteamsystemwithmultipleboilersandallofthesystemcomponents.Feedwateris
preheatedbysteaminjectionfromthelowpressuresteamdistributionheader,aswellaspreheatedmakeupwaterutilizingboilerblowdown
heatrecovery.
distributionheader.
rectangulargraphictotherightoftheconeshapedgraphicindicatestheelectricalgenerationcomponentofthesteamturbine.Theturbinein
themiddlereceiveshighpressuresteamandexhaustslowpressuresteamtothelowpressuresteamdistributionsystem,aswellasgenerates
June28,2010
BlowdownLosses3
Betweenthecondensingturbineandthehightolowpressureturbine,alightbluetriangulargraphicthatrepresentsapressurereducing
valve,whichdischargestothelowpressuresteamdistributionheader,identifiedbyaredlinebelowtheturbines.
Atthefarrightofthehighpressuresteamdistributionsystem,thehighpressureendusercomponentloadsareidentifiedthrougha
rectangulargraphicandarrowsenteringandleavingtherectangle,indicatingheatexchangewiththecomponents.Theendusecomponents
dischargecondensatethroughasteamtrap,representedbyarectangulargraphic.Schematically,condensatepassesthroughthebottomofthe
trapandrecoveredinacondensingtankwhichisalsoconnectedtothelowpressuresteamdistributionsystem.
Underthelowpressuresteamdistributionline,youwillseethelowpressureendusercomponentloadsidentifiedasarectangulargraphic
andarrowsenteringandleavingtherectangle,indicatingheatexchangewiththecomponents.Theendusecomponentsdischargecondensate
throughasteamtrap,representedbyanotherrectangulargraphic.Schematically,condensatepassesthroughthebottomofthetrapand
recoveredinacondensatetank,inwhichsteamisventedrepresentedbyaverticalarrowleavingthetopofthetank.
Thelowpressureendusercondensatetankusesapump,whichisdenotedbyacircle/squarecombination,todeliverthecondensatetothe
maincondensatereceiver,whichisalargerectanglewiththreeinputsdenotedbythreearrowsatthetopoftherectangle.Thecondensate
entersthismaincondensatereceivertank,afteritpassesthroughacontrolvalve,denotedasanhourglassshapewithadomeontop.The
thirdcondensateinputcomesfromthecondensatefromtheheatexchangerthatutilizesthehighpressuresteamturbine.Thecondensate
leavesthisheatexchangerandisdeliveredviaapump(denotedasacircle/squarecombination)tothemaincondensatereceiver.
Themaincondensatereceiverthenpumps(denotedbyacircle/squarecombination)thehighpressurecondensate,lowpressurecondensate,
andthecondensingsteamturbinecondensatetothedeaeratortankasdenotedbytworedrectangles,withthesmalleroneonthetop.Thetop
controlvalverepresentedbyaredhourglassfigurewithadomeontheside,whichprovideslowpressuresteamtothedeaeratorfromthe
lowpressuresteamdistributionsystemtopreheatthecollectedcondensateandmakeupwater.Preheatedmakeupwateralsoschematically
entersatthetopofthedeaeratorwiththecollectedcondensate.
linesleadingtoablowdownreceivertankdenotedasaredrectangleontherightofthescreen.Flashsteamisdivertedfromtheblowdown
flashvesseltothelowpressuresteamdistributionline,alsodenotedinreddashedlines.Liquidfromtheblowdownflashtankthen
schematicallyentersthetopofaheatexchanger(representedasawhiteandgreenstripedrectangle).Makeupwaterisshownenteringthe
heatexchangerfromtheright,afteritpassesthroughthewatertreatmentequipment,denotedastworedrectanglesfurtherontheright.The
liquidexitingtheheatexchangerissenttothedeaerator.
June28,2010
BlowdownLosses4
Slide7SystemLossEstimate
Theactualtotalsystemimpactassociatedwithblowdowncanbemorethantwicetheimpactidentifiedfromtheboilerperspective.Anestimateof
thetotalsystemwideimpactofblowdownbeinglostfromthesystemcanbedeterminedbyevaluatingtheenergyaddedtotheblowdownstream
byheatingmakeupwatertotheblowdownconditions.Thelossequationnotedhereestimatesthatimpact.
L blowdown =m blowdown (h blowdown h feedwater )/
m fuel xHHV fuel
Abbreviations
L blowdown
m blowdown
h feedwater
m fuel
h
HHV
Slide8BlowdownManagement
Blowdownlossismanagedthroughtwoprimaryavenues.First,theamountofblowdownrequiredcanbereducedifthefeedwaterqualityis
improved.Second,thermalenergycanberecoveredfromtheblowdownstream.Toalesserdegree,theblowdowncontrolstrategycanbe
improvedtoreducetheamountofblowdown.
Generally,feedwaterqualityisimpactedmostbythemakeupwater.Condensateiscommonlythecleanestwaterinthesteamsystem.Makeup
watermustbeconditionedbeforeitisaddedtothesystem.Themakeupwatertreatmentsystemcanbeimprovedresultinginimprovedmakeup
waterquality.Commonimprovementsincludechangingfromsodiumcyclesofteningtodemineralizationortoreverseosmosisconditioning.
Ofcoursefeedwaterqualitycanbeimprovedthroughincreasedcondensaterecovery.
Blowdownthermalenergyrecoverywillbediscussedinmoredetailinthissection.But,itshouldbenotedthatthermalenergyrecoveryhas
provenaverysuccessfulmanagementactivity.
Inanyevent,thefirststepinmanagingblowdownistomeasuretheenergylossassociatedwithit.Wewilluseourexampleboilertofurther
examinetheblowdownissues.
Slide9BlowdownEstimate
Utilizingconventionalflowmetersfortheblowdownstreamisproblematicbecausetheblowdownisreadytoboil.Mostflowmeterswillimposea
sufficientpressuredroptoresultintwophaseflow,whichisverydifficulttomeasure.Therefore,inordertomeasureblowdownrate,weusually
measurechemicalcompositioninthefeedwaterandintheboilerwater.Thechemicalcomponentmeasuredintheanalysismustbeofsufficient
June28,2010
BlowdownLosses5
concentrationtoallowaccuratemeasurementwithourinstruments.Wetaketheratioofthechemicalconcentrationinthefeedwatertothe
chemicalconcentrationintheboilerwatertoestablishtheblowdownrate.
Ourexampleboilerisoperatingwithanominalblowdownrateof6%.
[SlideVisualBlowdownRateFractionEquation]
%Blowdown=C feedwater (100)=15ppm(100)

C blowdown 250ppm
%Blowdown=6.0% mass offeedwaterflow
Abbreviations
C=conductivityofwater(partspermillion)
B=blowdownratefraction(percentoffeedwater)
BlowdownPercentisequaltotheConductivityofthefeedwaterdividedbytheConductivityoftheblowdown;allmultipliedby100.
BlowdownPercentisequaltothe15partspermilliondividedby250partspermillion;allmultipliedby100.
BlowdownPercentisapproximatelyequalto6%massofthefeedwaterflow.
Slide10BlowdownFlowRate
equalsMassFlowRateandequals
Theseblowdownequationsarebasedonasimplemassbalanceontheboilerwaterandsteamflows. m
BlowdownFraction.Itmustbenotedthatsteadyflowandsteadyoperatingconditionsareassumedintheanalysis.Additionalanalysisisrequired
forsystemsoperatingwithintermittentblowdown.Theblowdownflowrateforourexampleboilerisabout6,400lbm/hr.
[SlideVisualBlowdownFlowRateCalculation]
m blowdown= (B)m steam

(1B)
m blowdown= (0.06)100,000lbm/hr6,400lbm/hr
(10.06)
June28,2010
BlowdownLosses6
ThemassflowrateoftheblowdownisequaltotheBlowdownFraction;dividedby1minustheBlowdownFraction;allmultipliedbythemass
flowrateofthesteam.
Themassflowrateoftheblowdownisequalto0.06;dividedby1minus0.06;allmultipliedbythe100,000poundsperhourequals6,400
poundsperhour.
Abbreviations
m blowdown= massflowrateofblowdown(lbm/lbm)
m steam =massflowrateofsteamgeneratedperpoundoffuelburned
B=blowdownratefraction(percentoffeedwater)
Slide11BoilerLossEstimate
Theexampleboileroperateswithapproximately6%ofthefeedwaterleavingtheboilerasblowdown.Thisrepresentsapproximately1percentof
equalsmassflowrate,hequalsenthalpy,isblowdownfraction,HHVequalsHigherHeatingValue
thetotalfuelinputenergy.Inthisformula, m
ofthefuel.
[SlideVisualBoilerBlowdownLossBoilerCalculation]
L blowdown =m blowdown (h blowdown h feedwater )/x(100)
m fuel xHHV fuel
Theblowdownlossisequalthemassflowrateoftheblowdown;multipliedbythedifferenceoftheenthalpyoftheblowdown{minus}the
enthalpyofthefeedwater);dividedbythemassflowrateofthefuelmultipliedbytheHighHeatingValueofthefuel;allmultipliedby100.
h feedwater at242oFis210.42Btu/lbm
Theenthalpyofthefeedwaterat242degreesFahrenheitis210.42Btu/lbm.
L blowdown =(6,400lbm/hr)x(428.04Btu/lbm210.42Btu/lbm)x(100)
Theblowdownlossisequalthe6,400lbm/hr;multipliedbythedifferenceofthe428.04Btu/lbm{minus}210.42Btu/lbm);dividedbythe
6,407lbm/hrmultipliedby23,311Btu/lbm;allmultipliedby100.
L blowdown =0.9% energy
June28,2010
BlowdownLosses7
Theblowdownlossisequalto0.9%energy.
Abbreviations
L blowdown
m blowdown
m feedwater
m fuel
h
HHV
Slide12BlowdownLossEstimate
However,aspointedoutpreviouslytheimpactonthesteamsystemisevengreaterthanthisboilerfocusblowdownenergyanalysis.Thisis
becauseblowdowndischargedfromthesystemhastobereplacedwithcoldmakeupwater.Thesystembasedblowdownenergyimpactisabout
1.7percentofthefuelinputenergy.Thismaybearelativelysmallfractionoffuelinputenergy;however,ittranslatesintomorethan$200,000/yr
offuelcost.Additionally,andmoreimportantly,therearecosteffectivemeasureswecanemploytovirtuallyeliminatethisloss.
Twoprimaryavenuesareusedtoreducethelossassociatedwithblowdown.First,providingcleanerfeedwatercandramaticallyreducethe
requiredblowdown.Theprimarymethodsusedtoimprovefeedwaterqualityaretoutilizetechnologiestoprovidecleanermakeupwater
demineralization,dealkalization,reverseosmosis.Increasingcondensaterecoveryisanexcellentstrategytoimprovefeedwaterquality;because,
condensateistypicallythecleanestwateravailableanditcontainsvaluablethermalenergy.
Second,thethermalenergyintheblowdownstreamcanberecovered.Infact,almostallofthethermalenergyoftheblowdownstreamcanbe
recoveredwithtimeprovencosteffectivemeasures.
[SlideVisualBoilerBlowdownLossSystemCalculation]
L blowdown =m blowdown (h blowdown h makeup )/x(100)
m fuel xHHV fuel
Theblowdownlossisequalthemassflowrateoftheblowdown;multipliedbythedifferenceoftheenthalpyoftheblowdown{minus}the
enthalpyofthemakeupwater);dividedbythemassflowrateofthefuelmultipliedbytheHighHeatingValueofthefuel;allmultipliedby100.
h makeup at75oFis43.04Btu/lbm
Theenthalpyofthemakeupwaterat75degreesFahrenheitis43.04Btu/lbm.
June28,2010
BlowdownLosses8
L blowdown =(6,400lbm/hr)x(428.04Btu/lbm43.04Btu/lbm)x(100)
Theblowdownlossisequalthe6,400lbm/hr;multipliedbythedifferenceofthe428.04Btu/lbm{minus}43.04Btu/lbm);dividedbythe6,407
lbm/hrmultipliedby23,311Btu/lbm;allmultipliedby100.
L blowdown =1.7% energy
Theblowdownlossisequalto1%energy.
Abbreviations
L blowdown
m blowdown
m makeup
m fuel
h
HHV
= massflowrateofmakeupwater(lbm/lbm)
Slide13BoilerBlowdown
Blowdownthermalenergyrecoverytypicallyfocusesonsurfaceblowdown,becauseitisthelargestportionoftheblowdownflowandcanbea
relativelyconstantstream.Themostcommon(andsuccessful)blowdownthermalenergyrecoverysystemsincludetwostagesofrecovery.
[SlideVisualBlowdownTypes]
attheupperright.Thebottomblowdown(intermittent)isshownatthebottommuddrumoftheboilerschematic.Thesurfaceblowdown
(continuous)isshownatthetopsteamdrum.
Slide14BlowdownEnergyRecovery
First,webringthehighpressureblowdownstreamintoapressurevessel(flashtank)operatingatlowpressure.Thisallowsthesaturatedhigh
pressureliquidtogenerateflashsteamasitcomestoequilibriumintheflashtank.Partoftheblowdownliquidflashestosteamandtherest
remainsliquid.Theflashsteamisclean,sowecandirectitrightintothelowpressuresteamsystem.Theliquidthatremainsintheflashvesselis
June28,2010
BlowdownLosses9
hot,sowecanstillusethiswaterinaheatexchangertopreheatmakeupwaterTheblowdownwaterwilleventuallybedischargedfromthesystem
becauseitcontainstheboilerwatercontaminants.Wecancapturealmostalloftheblowdownthermalenergywiththeinstallationofasimple
flashtankandaheatexchanger.Theblowdownlosscanbevirtuallyeliminatedwithverysimple,robustequipment!
[SlideVisualBlowdownEnergyRecovery]
attheupperright.Thesurfaceblowdownisshownleavingthetopsteamdrumandpassingthroughaconductivitysensorwhichoperatesa
controlvalve.Blowdownisdischargedthroughthecontrolvalveintothelowpressureflashvessel,orflashtank.Thesaturatedhighpressure
liquidgeneratesflashsteamintheflashtank.Theflashtanknowcontainslowpressureflashsteamandsaturatedliquid.Thelowpressure
flashsteamcanbeconnectedtothelowpressuresteamdistributionsystemoroftendirectlytothedeaerator.Theremaininghotliquidcanbe
utilizedinaheatexchangertopreheatmakeupwater,butisultimatelydischargedfromthesystemforwaterqualitycontrol.
Slide15BoilerBlowdownRecovery
Intheexamplesteamsystemablowdownthermalenergyrecoverysystemwasinstalledandthefuelconsumptiondecreasedby$215,000/yr.The
equipmentrequiredfortheexamplesystemcostlessthan50,000dollars!
However,youneedtobecarefulwhenselectingaheatexchangerforthisservice.Theheatexchangerappliedinthisservicemustbecapableof
beingcleanedbecausetheblowdownstreamcanfowltheheatexchangesurface.
Temperaturesensorsineachofthestreamsenteringandleavingtheheatexchangerallowtheheatexchangereffectivenesstobedeterminedand
thefrequencyofcleaningevaluated.
Twotypesofheatexchangersoffergoodresultsinthisapplication.Ashellandtubestraighttubeheatexchangercanbespecifiedwiththe
blowdownstreamonthetubeside.Inthisarrangementtheheatexchangerendsmustberemovabletoallowthetubeinternalstobecleaned
periodically.Alternately,aplateandframeheatexchangercanbeused,whichallowsboththeblowdownsideandthemakeupwatersidetobe
cleaned.
[SlideVisualBlowdownEnergyRecoveryEquipment]
Boilerblowdownhasexitedtheboilerathighpressure,passedthroughtheblowdowncontrolvalve,andentersflashvesselat20psig.Low
Pressureflashsteamdischargesfromthetopoftheflashvesseltothelowpressuresteamsystem.
Liquidisdischargedfromthebottomoftheflashvesseltoaheatexchangerthatexchangedenergywithmakeupwater.Thetemperatureofthe
blowdownliquidenteringtheheatexchangerismeasuredbyatemperaturesensor,T1;theleavingtemperaturebysensorT2.Makeupwater
enterstheheatexchangerfromthetopanditstemperatureismeasuredbysensorT3.Makeupwatertemperatureleavestheheatexchanger
andismeasuredbysensorT4.
June28,2010
BlowdownLosses10
Aliquidlevelcontrolsensorisattachedtothesideoftheflashvesselwhichcontrolstheflowthroughtheexitoftheheatexchangerthrougha
controlvalve.
Slide16SteamSystemImpact
Theinstallationofablowdownthermalenergyrecoverysystemwillhavemultipleimpactsonacogenerationsystem.Flashsteamwillbedirected
tothelowpressureheader,whichwillreducetheamountofsteamthatcanpassthroughthebackpressureturbines.Additionally,themakeup
waterwillbehighertemperature,whichwillreducethedeaeratorsteamdemandfurtherreducingtheturbinesteamflow.Finally,becausethe
flashsteamgeneratedfromtheblowdownisdirectedbackintothesteamsystemtheamountofmakeupwaterrequireddiminishes.Asaresult,the
analysisofblowdownenergyrecoverybecomesmuchmorecomplicatedwhencogenerationsystemsareconsidered.ThisiswheretheSteam
SystemAssessmentToolcomesinhandy!
[SteamSystemImpactSchematicVisualDescription]
Thisschematicrepresentsatwoheadersteamsystemwithtwoboilersandallofthesystemcomponents.Feedwaterispreheatedbysteam
injectionfromthelowpressuresteamdistributionheader,aswellaspreheatedmakeupwaterutilizingboilerblowdownheatrecovery.
distributionheader.
rectangulargraphictotherightoftheconeshapedgraphicindicatestheelectricalgenerationcomponentofthesteamturbine.Theturbinein
themiddlereceiveshighpressuresteamandexhaustslowpressuresteamtothelowpressuresteamdistributionsystem,aswellasgenerates
drivesapump(denotedasacircle/squarecombination)andisalsocalledasteamdrivenpump,thendischargestothelowpressuresteam
distributionsystemheader.
Betweenthecondensingturbineandthehightolowpressureturbine,alightbluetriangulargraphicthatrepresentsapressurereducing
station,whichdischargestothelowpressuresteamdistributionheader,identifiedbyaredlinebelowtheturbines.
Atthefarrightofthehighpressuresteamdistributionsystem,thehighpressureendusercomponentloadsareidentifiedthrougha
rectangulargraphicandarrowsenteringandleavingtherectangle,indicatingheatexchangewiththecomponents.Theendusecomponents
dischargecondensatethroughasteamtrap,representedbyarectangulargraphic.Schematically,condensatepassesthroughthebottomofthe
trapandrecoveredinacondensingtankwhichisalsoconnectedtothelowpressuresteamdistributionsystem.
June28,2010
BlowdownLosses11
Underthelowpressuresteamdistributionline,youwillseethelowpressureendusercomponentloadsidentifiedasarectangulargraphic
andarrowsenteringandleavingtherectangle,indicatingheatexchangewiththecomponents.Theendusecomponentsdischargecondensate
throughasteamtrap,representedbyanotherrectangulargraphic.Schematically,condensatepassesthroughthebottomofthetrapand
recoveredinacondensatetank,inwhichsteamisventedrepresentedbyaverticalarrowleavingthetopofthetank.
Thelowpressureendusercondensatetankusesapump,whichisdenotedbyacircle/squarecombination,todeliverthecondensatetothe
maincondensatereceiver,whichisalargerectanglewiththreeinputsdenotedbythreearrowsatthetopoftherectangle.Thecondensate
entersthismaincondensatereceivertank,afteritpassesthroughacontrolvalve,denotedasanhourglassshapewithadomeontop.The
thirdcondensateinputcomesfromthecondensatefromtheheatexchangerthatutilizesthehighpressuresteamturbine.Thecondensate
leavesthisheatexchangerandisdeliveredviaapump(denotedasacircle/squarecombination)tothemaincondensatereceiver.
Themaincondensatereceiverthenpumps(denotedbyacircle/squarecombination)thehighpressurecondensate,lowpressurecondensate,
andthecondensingsteamturbinecondensatetothedeaeratortankasdenotedbytworedrectangles,withthesmalleroneonthetop.Thetop
controlvalverepresentedbyaredhourglassfigurewithadomeontheside,whichprovideslowpressuresteamtothedeaeratorfromthe
lowpressuresteamdistributionsystemtopreheatthecollectedcondensateandmakeupwater.Preheatedmakeupwateralsoschematically
entersatthetopofthedeaeratorwiththecollectedcondensate.
linesleadingtoablowdownreceivertankdenotedasaredrectangleontherightofthescreen.Flashsteamisdivertedfromtheblowdown
flashvesseltothelowpressuresteamdistributionline,alsodenotedinreddashedlines.Liquidfromtheblowdownflashtankthen
schematicallyentersthetopofaheatexchanger(representedasawhiteandgreenstripedrectangle).Makeupwaterisshownenteringthe
heatexchangerfromtheright,afteritpassesthroughthewatertreatmentequipment,denotedastworedrectanglesfurtherontheright.The
liquidexitingtheheatexchangerissenttothedeaerator.
Slide17SteamSystemAssessmentTool
TheSteamSystemAssessmentTool,alsoknownasSSAT,wasdevelopedbytheUnitedStatesDepartmentofEnergytoaidinevaluatingthe
complexinteractionsofsteamsystemmodifications.SSATisasoftwaretoolbasedinExcel.KBCLinnhoffMarchsProsteamsoftwareservesasthe
foundationofthetool.Thistoolallowstheusertobuildamodeloftheirsteamsystem.Thismodelcanbeusedtoevaluatetheimpactsofsystem
changes.
June28,2010
BlowdownLosses12
[SlideVisualSteamSystemAssessmentTool(SSAT)]
ThefirstscreenoftheSSATisshown.ItsaysIndustrialTechnologiesProgramToolsSuiteSteamSystemAssessmentTool,andhasapictureof
asteamsiteinthebackground.
Slide18SSATModel
TheSSATmodelcontainsthecommonsteamsystemcomponentsincludingtheboiler,steamturbines,enduseequipment,condensaterecovery,
feedwaterconditioningcomponents,andtheinterconnectionsofthesystem.Thisschematicdemonstratesthegeneralconnectivityofthemodel.
Highpressuresteamisgeneratedintheboiler.Thissteamcanpasstoenduseequipment,throughsteamturbines,orthroughpressurereducing
valves.Themediumandlowpressuresteamsystemsaresimilarlyarranged.Usershaveflexibilityinarrangingthemodeltoreflecttheirsteam
systems.
[SlideVisualModelTabSchematic]
Thetopcenterwillcontainthedescriptivetitleprovidedbytheuser,theinitialtemplatereadsSSATDefault3HeaderModelorasimilartitle
forwhatevermodelyouchose.Belowit,youwillseetheModelStatus,whichshouldreadOK.Themodelstatusprovidesanindicationofthe
calculationconditionofthemodel.
TotheleftoftheModelStatus,youwillseeachartinlightblue,whichindicatestheemissionsperyearforcarbondioxide,sulfuroxide,and
nitrogenoxide.
Atthetopright,itwillsayCurrentOperationifyouareontheModeltab,orOperationAfterProjectsifyouareontheProjectsModeltab.
Theredgraphicnearthetopleftrepresentstheboiler.Fromtheleft,thereisadottedlineenteringit,whichrepresentstheamountof
feedwaterenteringtheboilerfromthedeaerator.
Alsototheleftoftheboiler,weseethefollowinginformationhighlightedinorange:thetypeoffuelbeingusedintheboiler,thefuelinput
energy,thefuelflowrate,andtheboilerefficiency.
Totherightoftheboiler,weseeadottedlinepointingtotherightandthendown,withanumbernexttoit,indicatingtheamountofboiler
blowdown.
Belowtheboiler,weseetheamountofsteamthatisenteringthehighpressureheader,thetemperatureofit,andthethermodynamicquality
ofthesteam.
Thesteamexitstheboilerandentersthehighpressureheader,representedbyadarkblueline.Undertheline,tothefarleft,youwillseea
lightbluetriangulargraphicthatrepresentsapressurereducingstation.Thepressurereducingstationisalsoequippedwithadesuperheating
station.Thenumberatthetopindicatestheamountofsteamenteringthepressurereducingvalve.Thenumberatthecenterleftofthevalve
June28,2010
BlowdownLosses13
indicatestheamountofdesuperheatingwaterenteringtheunit.Thenumberbelowindicatestheamountofdesuperheatedsteamenteringthe
mediumpressureheader;aswellasthetemperatureofthesteam.
Totherightofthepressurereducingstation,youwillseelightblue,coneshapedgraphics,thatrepresentthesteamturbines.Theonenearest
totheleftisahighpressuretocondensingturbine.Thisturbinedischargestothecondenserrepresentedbythebluecirclebelowtheturbine.
Theturbineexhaustpressureisnotedasthecondenserpressure.Theturbineinthemiddlereceiveshighpressuresteamandexhaustslow
pressuresteam.Theonetotherightreceiveshighpressuresteamandexhaustsmediumpressuresteam.Aboveeachturbineisanindication
oftheamountofsteamcomingintotheturbinefromtheheader.Totheright,indarkblue,youseethepowergenerationoftheturbine.
Inthecenterofthemediumpressureandlowpressureheaders,weseeanarrowpointingdownward,whichindicatestheamountofflash
enteringtheheaderfromthecondensatecollectionflashvesselsthatarelocatedatthefarrightoftheschematic.
Abovetheheader,totheright,theamountofheatlossisexpressedinorange.Below,thereisayellowboxthatindicatesthepressure,
temperature,andthermodynamicqualityofthesteam.
Thearrowtotherightoftheheaderpointstoadarkbluecirclewithalinethroughit,indicatingthesteamendusecomponents.Belowthis
symbolisanindicationofthethermalenergysuppliedtotheendusecomponentsfromthesteam.Theendusecomponentsdischarge
condensatethroughasteamtrap,representedbyabluecirclewithaTinit.Schematically,condensatepassestotherightthroughthetrap.
Failedsteamtrapsthatareblowingsteamtotheatmospherearerepresentedwiththeredarrowexitingthetopofthetrapsymbol.The
condensateappropriatelypassingthroughtraps,againrepresentedasexitingtotherightofthetrap,canberecoveredorlost.Lostcondensate
isrepresentedastheunrecoveredcondensatedischargingdownfromthetrapsandrecoveredcondensateentersthecondensatecollection
systemfurthertotheright.
Thegreenfigurestothefarrightoftheschematicrepresentcondensateflashvessels.Thetopflashvesselreceivescondensatefromthehigh
pressureendusers.Flashsteamisformedbecausetheflashvesseloperatesatmediumpressurebutitreceivessaturatedliquidcondensateat
highpressure.Asequilibriumisreachedflashsteamisformed.Thisflashsteamexitsthevesselthroughthetopandisdirectedtothemedium
pressuresteamheader,whichisshowninthecenterofthediagram.Condensateexitstheflashvesselandentersthemediumpressure
condensatecollectionsystem.Themediumpressurecondensatesystemisequippedwithsimilarequipmentasthehighpressuresystem.
Allofthecollectedcondensateentersthemaincondensatereceiverlocatedinthelowercenteroftheschematic.Processcondensateismixed
withturbinecondensateandmakeupwaterpriortoenteringthedeaerator.
Thesteamsystemdeaeratorisrepresentedatthelowerleftoftheschematic.Thedeaeratorreceiveslowpressuresteamtopreheatthe
collectedcondensateandmakeupwaterrepresentedasenteringfromthebottomofthevessel.Boilerfeedwaterdischargesfromthedeaerator
totheleftanduptotheboiler.Thelinepointingoutfromthetopofthedeaeratorandleadingtotherightshowstheamountofsteamescaping
fromthevent.
June28,2010
BlowdownLosses14
Slide19BasicModelData
ThepowerofSSATisinthefactthatitcompletesmass,energy,andeconomicbalancesonthesteamsystemthatisbuiltbytheuser.Theusercan
makemodificationstothesteamsystemandobserveasidebysidecomparisonofthesystembeforeandafterthechanges.Thisallowstheimpact
tomass,energy,andeconomicstobeidentified.
Inthemodel,economicimpactsareonlyassociatedwithfuel,electricity,andwaterpurchases.Ofcourse,theboilerconsumesfuelinthegeneration
ofsteam.Theturbinescanimpacttheamountofelectricitypurchasedfromtheelectricalsupplier.Andmakeupwaterissuppliedtothesystemas
required.
Themodelisthermodynamicallyrigorousandallowstheverycomplexinteractionsinsteamsystemstobeaccuratelyidentifiedandevaluated.
Thetoolhasgreatflexibilityallowingvariousfueltypesandcosttobecoupledwithelectricalimpactcostsaswellassteamconditions.Thisslide
showsasmallportionoftheinputdatathatcanbearrangedbytheuser.
[SlideVisualBasicModelData]
GeneralSiteData
InputData
SitePowerImport(+forimport,forexport)
15000
kW
SitePowerCost
0.0700
$/kWh
Operatinghoursperyear
8760
SiteMakeUpWaterCost
0.0025
MakeUpWaterTemperature
70
hrs
$/gallon
Notes/Warnings
Powerimport+sitegeneratedpower=site
electricaldemand
Typical2003value:$0.05/kWh
Typical2003value:$0.0025/gallon
NaturalGas
Typical2003value:$5.78/(1,000scu.ft)
Note:Enteraveragevaluesfortheoperatingperiodbeingmodeled
BoilerfuelChoosefromthisdropdownlist
SiteFuelCostper1000s.cu.ft
June28,2010
10.00
BlowdownLosses15
SteamDistribution
InputData
Warnings
HighPressure(HP)
400
psig
MediumPressure(MP)
150
psig
20
psig
LowPressure(LP)
HPSteamUsebyProcesses
5.00
klb/h
MPSteamUsebyProcesses
15
klb/h
LPSteamUsebyProcesses
63
klb/h
June28,2010
BlowdownLosses16
Slide20BoilerCharacteristics
Thecharacteristicsoftheboilersaremodeledbythetool.Thisallowsaccuratesystemimpactstobeidentified.
[SlideVisualOperatingCharacteristics]
Boiler
Methodforspecifyingboilerefficiency
Option2EnterUserDefinedValue
Note:ModeldefaultefficienciesrepresentBestPracticevaluesassuminggoodoperationandtheinstallationofaneconomizer
Option2Enterefficiency(%)
78.73
Note:Boilerefficiencyisdefinedas100%StackLoss(%)ShellLoss(%).The"StackLoss"sheetgivesmoreinformationonheat
losses
Note:EfficiencyisbasedonHigherHeatingValue.Economizersareincludedintheboilerefficiency.Boilerblowdownlossesare
excluded
BlowdownRate(%offeedwaterflow)
DoyouhaveblowdownflashsteamrecoverytotheLPsystem?
No
PleaseselecthowyouwishtodefineyourHPgenerationconditionandthenprovidesupplementaryinformationbelowifrequired:
MethodforspecifyingHPgenerationcondition
Option2Userdefinedsuperheated
Conditions
Note:Asadefault,themodelwilluseHPsteamwith100Fofsuperheat.AtHPpressure(600psig),thiscorrespondstoa
temperatureof589F
Option2Entertemperature
Option3Enterthermodynamicquality
700
99
%dry
June28,2010
BlowdownLosses17
Slide21SteamTurbines
Thecomplexityofanalyzingcogenerationsystemsissignificant.Theinteractionbetweencomponentscanmakeevaluationstediousandtime
consuming.SSATallowsthecharacteristicsofsteamturbinestobeincorporatedinthemodel.Thetoolaccuratelyevaluatestheinteractions
betweenthesecomplexcomponents.
[SlideVisualOperatingCharacteristics]
HPtoLPSteamTurbine(s)
InputData
Isentropicefficiency
65
Notes/Warnings
Note:Ifmultipleturbinesareinstalled,theoperationoftheimpactturbine(theturbineaffectedbychangestothesystem)should
bemodeled
Note:Ageneratorelectricalefficiencyof100%isassumedbythemodel
Selecttheappropriateturbineoperatingmode
Option1BalancesLPheader(Model
defaultoption)
June28,2010
BlowdownLosses18
Slide22SSATInvestigations
BuiltintoSSATaremanyprojects(orsystemmodifications)thatarecommontorealworldssteamsystems.Forexample,thetoolissetuptomodel
theimpactassociatedwithreducingsteamdemand,changingthefuelsuppliedtotheboiler,orimprovingboilerefficiency.
Again,thesoftwareprovidesasidebysidecomparisonofthebeforeandafteroperatingcharacteristics.Thetoolidentifiesthechangeinfuel
consumption,electricalconsumption,andwaterconsumptionresultingfromthechangeinsystemoperation.
[SlideVisualProject1]
Project1SteamDemandSavings(Changingtheprocesssteamrequirements)
CurrentuseHP:5klb/h(4.66MMBtu/h)MP:8klb/h(8.16MMBtu/h)LP:58.4klb/h(65.99MMBtu/h)
Doyouwishtospecifysteamdemandsavings?
Yes
Ifyes,enterHPsteamsaving
klb/h
Ifyes,enterMPsteamsaving
klb/h
Ifyes,enterLPsteamsaving
klb/h
June28,2010
BlowdownLosses19
Slide23Projects
Therearemanyprojectsthatarebuiltintothetool.Projectsareincludedthatallowtheusertomodifyblowdowncharacteristicsorcondensate
recovery.Onlyasmallsamplingofprojectsisshownhere.
[SlideVisualProjects4and13]
Project4ChangeBoilerBlowdownRate
ExistingBlowdownRate:6%
Doyouwishtospecifyanewboilerblowdownrate?

Ifyes,enternewrate(%offeedwaterflow)
Yes

Project13CondensateRecovery
Currentlyrecover50%ofHP,50%ofMPand50%ofLPat180F

Doyouwishtospecifynewcondensaterecoveryrates?

Yes
Ifyes,enternewHPcondensaterecovery
50
Ifyes,enternewMPcondensaterecovery
60
Ifyes,enternewLPcondensaterecovery
50
June28,2010
BlowdownLosses20
Slide24SteamTurbineProjects
Turbineoperationscanalsobemodified.
[SlideVisualProject7]
Project7HPtoLPSteamTurbine(s)
NotInstalled
DoyouwishtomodifytheHPtoLPturbineoperation?
Ifyes,selecttheappropriateturbineoperatingmode
Yes,installanewturbine
Option1BalancesLPheader
Note:IfOption1ischosen,themodelwillpreferentiallyusetheHPtoLPturbinetobalancetheLPdemand

Specifyanewisentropicefficiency(%)
70
Note:Isentropicefficiencyofexistingturbineis65%
Option2Notselected
Option2Howdowishtodefinethefixedturbineoperation?
Option2Fixedsteamflow
100
Option2Fixedpowergeneration
June28,2010
2000

klb/h
kW
BlowdownLosses21
Option3Howdowishtodefinetheoperatingrange?
Option3notselected
Option3Minimumsteamflow
50 klb/h
Option3Maximumsteamflow
150 klb/h
Option3Minimumpowergeneration
1500 kW
Option3Maximumpowergeneration
2500 kW
Slide25BlowdownThermalEnergyRecovery
AsanintroductiontothetoolwewilluseSSATtoevaluatetheboilerblowdownthermalenergyrecoveryopportunity.Ihavedevelopedamodel
thatreflectsthecharacteristicsofthesteamsystemwehavebeendealingwith.Initiallywewillassumethesteamsystemisnotequippedwith
cogenerationcomponents.Inotherwords,therearenosteamturbinesinthissystemweinitiallyinvestigate.
Wewillusethebuiltinprojectsassociatedwithboilerblowdownthermalenergyrecoverytoidentifytheeconomicimpactassociatedwiththe
realworldproject.
[SlideVisualProjects5and12]
Project5BlowdownFlashtoLP
Notcurrentlyinstalled
Doyouwishtomodifytheblowdownflashsystem?
Option1Installblowdownflash
Project12FeedwaterHeatRecoveryExchangerusingBoilerBlowdown
Notcurrentlyinstalled
June28,2010
BlowdownLosses22
Modifytheboilerblowdownheatrecoverysystem?
Yes,installanewheatexchanger
Note:Anapproachtemperatureof20Fwillbeassumedforanewexchanger
Slide26BeforeandAfterComparison
Theresultsindicatethatforasteamsystemthatisgeneratingapproximately100,000lb/hrof400psigsteamfrom10dollarspermillionBTU
naturalgasimplementingblowdownthermalenergyrecoverycanreduceoperatingcostmorethan$260,000/yr.
Themajorityofthesavingsisdevelopedfromthereductionoffuelconsumptionintheboilerapproximately$262,000/yr.Minimalsavingsis
developedfromareductioninmakeupwaterconsumption$3,000/yr.
[SlideVisualResultsSummary]
SteamSystemAssessmentTool
3HeaderModel
ResultsSummary
SSATDefault3HeaderModel
ModelStatus:OK
CostSummary
($'000s/yr)
PowerCost
FuelCost
MakeUpWaterCost
TotalCost(in$'000s/yr)
CurrentOperation
9,198
12,930
177
22,306
AfterProjects
9,198
12,669
174
22,041
Reduction
0
262
3
265
0.0%
2.0%
2.0%
1.2%
Slide27ProjectImplementation
Itisinterestingtonotethatimplementingtheprojectinthissteamsystemwouldmostprobablyrequirelessthan$100,000.Asaresult,theproject
isveryattractivefromaneconomicstandpoint.
June28,2010
BlowdownLosses23
Itisalsointerestingtonotethattheeconomicimpactisevengreaterthanthelossestimateidentifiedpreviously.Thisisbecausethemodel
accuratelyidentifiestheboilerefficiencyimpactsandotherenergyrelatedinteractions.
[SlideVisualProjectImplementation]
Fortheexampleboilerimplementingblowdownenergyrecovery:
Reducesfuelconsumptionmorethan$260,000/yr
o
Thesavingsisgreaterthanthesystemlossestimateprovidedpreviouslyof$215,000/yr
Theenergyrecoveredtothemakeupwaterisnotsubjectedtotheboilerinefficiency
Steamgenerationandmakeupwaterrequirementsarereducedbecauseofflashsteam
o
Theprojectimplementationcostshouldbemuchlessthan$100,000
Slide28BlowdownEnergyRecovery
Effectiveblowdownthermalenergyrecoverycanallowwaterqualitytobecontrolledtohigherlevelswithminimaleconomicimpactbecausethe
blowdownenergyisbeingrecovered.
Makeupwaterrequirementsarereducedprimarilybecausetheflashsteamgeneratedintheflashrecoveryvesselisreturnedtothesteamsystem.
Oftentheblowdownstreammustbecooledbeforeitisintroducedtothesewersystem.Thiscanresultinalargeamountofpurchasedcooling
watertobelosttothesewersystem.Effectiveboilerblowdownthermalenergyrecoverycanresultinlowtemperatureblowdownbeing
dischargedtothesewerwithnocoolingwaterrequirements.
Slide29SteamTurbineInfluences
Nowwewillexaminethesystemimpactswhenblowdownthermalenergyrecoveryisaddedtoasteamsystemthatisequippedwithcogeneration
components.Ihaveconstructedamodelthatincludessteamturbinesthatareconnectedtoelectricalpowergenerators.Atthispointwewillnot
discusstheturbinecharacteristicsotherthantoindicatetheturbinesaretypicalofwhatwouldbefoundinanindustrialcomplex.
June28,2010
BlowdownLosses24
nitrogenoxide.
blowdown.
ofthesteam.
enteringtheheaderfromthecondensatecollectionflashvesselsthatarelocatedatthefarrightoftheschematic.Thereisaredcirclearound
themediumandlowpressureheaders.
June28,2010
BlowdownLosses25
fromthevent.
Slide30SSATEvaluation
Theresultsarenotdramaticallydifferentthatwhatwasobservedinthesystemwithoutcogenerationcomponents.Thecombinedeconomicimpact
is$241,000/yr.Blowdownthermalenergyrecoveryisnotexpectedtodramaticallyimpactsteamturbineoperation;but,theimpactsonthe
turbinesareaccuratelyreflectedinthemodelresults.Itisinterestingthatthefuelimpactissignificantlygreater.Themodelindicatesfuel
consumptionwillreducemorethan$300,000/yr.Electricalpurchaseswillincreasemorethan$70,000/yr.Thesearenotinsignificantimpacts.
ThepointisthatSSATisapowerfulandusefultoolthatcanbereliedupontoaccuratelyreflectthesysteminteractionsofcomplexsteamsystems.
June28,2010
BlowdownLosses26
[SlideVisualResultsSummary]
CostSummary
($'000s/yr)
CurrentOperation
AfterProjects
PowerCost
9,198
9,268
70
0.8%
FuelCost
12,861
12,554
307
2.4%
174
170
2.2%
22,234
21,993
241
1.1%
CurrentOperation
AfterProjects
PowerGeneration
3245kW
3131kW
PowerImport
15000kW
15115kW
115kW
0.8%
TotalSiteElectrical
Demand
18245kW
18245kW
143kW
NaturalGas
4kW
143313.3 scu.ft/h
3507scu.ft/h
96.6klb/h
2.4klb/h
MakeUpWaterCost
TotalCost(in$
'000s/yr)
Reduction
UtilityBalance
BoilerDuty
FuelType
FuelConsumption
147kW
NaturalGas
146820.3
BoilerSteamFlow
scu.ft/h
99.0klb/h
Reduction
2.4%
2.4%
2.4%
FuelCost(in$/MMBtu)
10.00
10.00
PowerCost(as$/MMBtu)
20.51
20.51
176m3/h
MakeUpWaterFlow
7961m3/h
7785m3/h
2.2%
June28,2010
BlowdownLosses27
Slide31BlowdownLossReduction
Insummary,withrespecttoboilerblowdown;wemustmeasureboilerwaterchemistryandtheblowdownratetoappropriatelymanageour
resourcesinthisarea.Weshouldworktoimproveourboilerfeedwaterquality.Incorporatingthermalenergyrecoverycomponentscanalmost
eliminatethelossassociatedwithblowdown.
[SlideVisualBlowdownLossReductionSummary]
Measureblowdownflow(chemicalanalysis)
Controlblowdownflow(conductivityandchemistry)
Controlwaterchemistry
Improvefeedwaterquality
Recoverflashsteamtolowpressuresystems
June28,2010
BlowdownLosses28
DOEs BestPractices Steam End-User Training
StackLossesSection
Slide1
StackLossesModule
Whileblowdownandshelllossesarerelativelysmall,stacklossisalmostalwaysthelargestboilerloss.
[SlideVisualStackLossTitlePage]
BlowdownLosses
StackLosses
Slide2
StackLosses
Stacklossisgenerallycharacterizedintotwointerrelatedcategoriestemperature,andcombustion(orexcessair).Managingthestacklossisacritical
factorinmanagingboilerperformance.Wewilldiscussbothoftheseaspectsofstacklosswewillstartourdiscussionsbyfocusingonfluegas
temperature.
Slide3
StackLossesTemp.Component
[SlideVisualStackLossTemperatureComponentTitlePage]
BlowdownLosses
StackLossesTemperatureComponent
June28,2010
StackLosses1

Slide4
FlueGasLoss
Asignificantamountoffuelenergyresidesintheboilerexhaustgas.Thetemperatureoftheexhaustgasisanindicatoroftheamountofenergylost
fromtheboiler.Fluegastemperatureisameasurementthatisrequiredtoreflectboilerperformance.Boilerfluegastemperatureshouldbemonitored
withrespecttoambienttemperature
Higherfluegastemperaturesindicategreaterloss.Itisgoodtoknowwhatcantypicallycausefluegastemperaturetoincrease.
Slide5
BoilerDesign
Boilerdesignisaprimaryfactorinestablishingthefluegastemperature.Aboilerwithmoreheattransferareawillbeabletoextractmoreenergyfrom
thefluegas.Forexample,theonepassfiretubeboilerhasmuchlessheattransferareathanthethreepassfiretubeboiler.Iftheboilerswere
operatingundersimilarcircumstancestheonepassboilerwilloperatewithahigherfluegastemperaturethanthethreepassboiler.Ofcourse,higher
temperatureindicateslowerefficiency.
[SlideVisualBoilerSchematic]
Boilerschematicsareshownforaonepassandathreepassboilerconfigurations.
Thesinglepass,oronepassboilerisshownontheleft.Fuelentersthecombustionzone,representedbyarectangle,whichissurroundedby
boilerwater.Steamisreleasedthroughthetopoftheboiler.Exhaustgasesarereleasedfromtheboilerviathecombustionchamber.Afront
viewoftheonepassboilerisindicatedbyasmallcircle(representingthefiretubeorcombustionzone)insidealargercirclerepresentingthe
boiler.
Thethreepassboilerormultiplepassboilerisshownontheright.Fuelentersthecombustionzone,representedbyarectangle,whichis
surroundedbyboilerwater,howeverthereareseveralsmallrectangleofcombustionzonesinthelargeboilingwaterchamber,which
representsthemultipletubesinsidetheboilerforheatexchange.Steamisreleasedthroughthetopoftheboiler.Exhaustgasesarereleased
fromtheboilerviathemultiplefluegaspasses.Afrontviewofthethreepassboilerisindicatedbyasmallcircle(representingthefiretubeor
combustionzone),manysmallercirclesrepresentingthemultiplefiretubepassesinsidethecombustionchamber,allinsidealargercircle
representingthesteamliquidchamber.
Slide6
EnergyRecoveryComponents
Afeedwatereconomizerisaheatexchangerinstalledtotransferthermalenergyfromthefluegasintotheboilerfeedwater.Thisisacommonenergy
recoverycomponentinstalledonboilers.Asimilardeviceisacombustionairheatertheseheatexchangersrecoverthermalenergyfromthefluegas
bypreheatingcombustionairpriortoenteringthecombustionzone.Aboilerequippedwithoneoftheseenergyrecoverydeviceswilloperatewith
lowerfluegastemperaturethanasimilarboilernotequippedwithone.
June28,2010
StackLosses2

[SlideVisualBoilerConfigurations]
Boilerschematicsareshownforwatertubeboilerconfigurations,onewithafeedwatereconomizerheatrecoverydeviceontheexhaustgases,
andthesecond,mostrightconfiguration,without.
Bothschematicsdepictwatertubeboilers.Fuelandairenteratthelowerleftofthecombustionzone,feedwaterentersatthetopofthesteam
generationsectionatthesteamdrumwhichincludesmultipletubesforwatertomovethroughtheheatexchangearea.Thesteamoutletis
shownatthetopoftheboiler,aswellastheexhaustgasesleavingtheboiler.
Themostleftschematicincorporatesaheatexchangerontheexhaustgasoutlet,whichappearsasaredserpentinelinethroughoutthe
exhaustgasexitfromtheboilerthisisafeedwatereconomizer.
Themostrightschematicdoesnothaveafeedwatereconomizershown.
Slide7
FlueGasTemp.Limitations
Caremustbetakentoavoidreachingtoolowofanexhaustgastemperature,asthiscouldcausecorrosivecondensatetoformintheexhaustgases.If
thereissulfurinthefuel,sulfuricacidcouldform.Evenifthefueldoesnotcontainsulfur(liketypicalnaturalgas),wecontinuetobeconcernedabout
corrosivecondensatebecausetheproductsofcombustionarecarbondioxideandwater,whichtendtocombinetoformcarbonicacid.
[SlideVisualFlueGasTemperatureLimitationsGraph]
Agraphicdepictsfuelsulfurcontentalongthexaxisasapercentofmass,beginningwith0%andincreasingto5%inincrementsof1.The
verticaloryaxisdepictstheFlueGasExitTemperatureindegreesFahrenheit,beginningat100andincreasingto450degreesFahrenheitin
incrementsof50degrees.
Theaciddewpointlinebeginsat0%fuelsulfurcontentand250degreesFahrenheitandincreaseslinearlyuntil5%content,inwhichthetrend
Lineincreasesabitsteeperwiththeresultof5%boilerloadand300degreesFahrenheit.
Theminimumrecommendedfeedwatertemperaturelinebeginsat0%fuelsulfurcontentand225degreesFahrenheitandincreaseslinearly
until5%content,inwhichthetrendLineincreasesabitsteeperwiththeresultof5%boilerloadand250degreesFahrenheit.
Slide8
CondensingEconomizers
Itisinterestingtopointoutherethatthewatervapor(steam)formedinthecombustionprocesscontainsasignificantamountofenergy.Ifthiswater
vaporisallowedtocondensethencorrosionissuesresult.However,heatrecoveryheatexchangeequipmenthasbeendevelopedthatcanhandlethe
corrosiveissuesandallowthewatervaportocondenseandreleaseitsenergy.Thesecomponentsareidentifiedascondensingeconomizers.
June28,2010
StackLosses3

Condensingeconomizerscanimproveboilerefficiencymorethan10percentagepointswhichisexceptional.Condensingeconomizersareappliedin
cleanfuelapplications(naturalgasandpossiblynumber2fueloil).Itisveryimportanttonotethatthefluegasmustbecooledtolessthan120Fto
condensethemajorityofthewatervaporandrecovertheenergy.Asaresult,thestreamthatisheatedbythefluegasmustberelativelycoldlessthan
100Fandtheremustbealargeamountofmaterialtobeheated.Applicationslikefoodprocessingplantsareoftenthetargetlocationsforthis
technology.Foodprocessingplantscommonlyhavelargeamountsofprocesswaterthatrequiresheating.
Slide9
BoilerLoad
Anotherfactorthatimpactsfluegasexhausttemperatureisboilerload.Typically,fluegastemperatureincreasesasboilerloadincreases.Thisissimply
aresultofpassingmorematerialthroughaheatexchanger(theboiler).Thegraphoffluegastemperatureversusboilerloadisforaspecificboilerand
isintendedtoindicateatypicaltrendthevaluesonthisgrapharereflectiveofaspecificboiler;thevalueswillbedifferentforyourboiler;but,the
trendwillbesimilar.
[SlideVisualBoilerLoadGraph]
Agraphicdepictsboilerloadalongthexaxisasapercentofboilerfullload,beginningwith50%andincreasingto110%inincrementsof10.
TheverticaloryaxisdepictstheFlueGasExitTemperatureindegreesFahrenheit,beginningat400andincreasingto600degreesFahrenheit
inincrementsof50degrees.
Thetrendlinebeginsat50%boilerloadand425degreesFahrenheitandincreaseslinearlyuntil100%load,inwhichthetrendLineincreasesa
bitstepperwiththeresultof110%boilerloadand560degreesFahrenheit.
Slide10
FailedFlueGasComponent
Inalmostallboilers,thecombustiongasesareforcedtotakeaspecificpaththroughtheheatexchangesections.Bafflesorspecialductingisinplaceto
ensurethegasestravelthroughtheboilerproperly.Ifabafflefails,thenthegascanbypassheattransfersectionsoftheboiler.Thefluegas
temperaturewillincreaseasaresult.Thiscanberemediedbyrepairingthebaffle.
[SlideVisualBoilerBaffleOperationandFailure]
Boilerschematicsareshownfortwoboilerconfigurations,onewithbafflesoperatingproperlyandthesecondwithafailedbaffle.
Thefirstconfiguration(ontheleft)depictsbafflesoperatingproperly.Theschematicdepictsawatertubeboiler,inwhichtwobafflesare
shownasredverticallinesinsidetheboilerscombustionzone.Thecombustiongaspathisdepictedbygreenarrows,beginningwherethefuel
andairentersatthelowerleftofthecombustionzone,throughthebaffleswhichinazigzagpaththroughthecombustionzone,thenoutthe
combustionzonetoptotheboilerexhaust.Feedwaterentersatthetopofthesteamgenerationsectionatthesteamdrum.Thesteamoutletis
shownatthetopoftheboiler,aswellastheexhaustgasesleavingtheboiler.
June28,2010
StackLosses4

Thesecondconfiguration(ontheright)depictsaboilerwithafailedbaffle.Theschematicdepictsthesamewatertubeboiler,inwhichtwo
bafflesareshownasredverticallinesinsidetheboilerscombustionzone.However,thesecondbafflehasasectionmissingatthetop,thus
allowingthehotgas(depictedbyredarrows)topassstraighttotheboilerexhauststack,bypassingmostofthecombustionzone.Feedwater
entersatthetopofthesteamgenerationsectionatthesteamdrum.Thesteamoutletisshownatthetopoftheboiler,aswellastheexhaust
gasesleavingtheboiler.
Slide11
Fouling
Ifwehavewatersidescalingorfiresidefoulingoftheheattransfersurfaces,thesurfacesbecomeinsulated,andmoreenergyremainsintheexhaust
gas.So,wewanttomakesurewemaintainwaterqualitytomakesuresolidsdonotprecipitateontheheattransfersurfaces.Also,wewanttokeepthe
firesideofthetubesascleanaspossible.Firesidefoulingisusuallyaproblemwithsolidfuelsandheavyfueloils.Onlinesootblowingisthemethod
usedforchronicfoulingconditions.Sootblowingistheactofinsertingalanceintothecombustionsideoftheboilertoallowahighvelocityjetofsteam
orcompressedairtopassacrossthefouledsurfacestodislodgethefoulingmaterial.
Watersidefoulingispreventedthroughboilerwaterchemistrycontrol.However,whenfoulingissignificant,treatmentmeasuresmayinclude
chemicalstodescaletheboilerheatexchangesurfaces,orhydroblasting,bothofwhichrequireaboileroutage.Often,watersidefoulingresultsintube
failures.
[SlideVisualBoilerFouling]
Theboilerconfigurationindicatesfuelandairenterontheleftsideoftheboilerscombustionzone.Internalbafflesaredepictedinwhite.The
steamflowisdepictedasaredloopinsidethecombustionzone,betweenthebaffles.Feedwaterentersatthetopofthesteamgeneration
sectionatthesteamdrum.Thesteamoutletisshownatthetopoftheboiler,aswellastheexhaustgasesleavingtheboiler.
June28,2010
StackLosses5

[SlideVisualInsertofPotentialEnergyLossResultingfromScaleDeposits]
PotentialEnergyLossResultingfromScaleDeposits
FractionofTotalFuelInputEnergyLoss[%]
ScaleType
ScaleThickness[Inches]
Normal
HighIron
Iron+Silica
1/64
1.0
1.6
3.5
1/32
2.0
3.1
7.0
3/64
3.0
4.7
1/16
3.9
6.2
NationalInstituteofStandardsandTechnology,Handbook115,Supplement1
Slide12
FlueGasTemp.Loss
Thesearethecommonfactorsthatimpactfluegasexittemperaturetherearemanymore.
Onefinalnote,excessair(extraairpassingthroughthecombustionzone)hasthepotentialofimpactingfluegasexhausttemperature.Typically,
increasingtheamountofexcessairinthecombustionzonewillincreasethefinalfluegasexhausttemperature.Wewilldiscusstheprimaryissues
associatedwithexcessairinthefollowingsection.
Slide13
TemperatureLossManagementSummary
Thefirststepinmanagingfluegasenergyistomeasureandmonitorfluegasexittemperature.Alongwiththiscriticalmeasurementambient
temperatureshouldbenoted,because,ambienttemperaturewillhaveanimpactonthefinalfluegastemperatureoftheboiler.Additionally,because
fluegastemperatureisafunctionofboilerloadthesteamproductionorfiringrateshouldbenotedalongwiththeseothermeasurements.These
measurementswillallowperformancetrendsofyouboilertobenoted.
June28,2010
StackLosses6
Slide14
CombustionComponent
Now,wewillturnoutattentiontothecombustionsideofthestackloss.Thecombustionlosscentersonunburnedfuel,excessair,andotheritemsof
thisnature.
[SlideVisualStackLossCombustionComponentTitlePage]
RadiationandConvectionlosses
Shelllosses
Blowdownlosses
StacklossesCombustionComponent
Slide15
PerfectCombustion
Asanexample,wewillexaminethecombustionofasimplefuel,methane.Inaperfectworld,methanewillreactwithoxygentoreleaseenergyandform
carbondioxideandwater.Inthisperfectarrangement,eachmoleculeoffuelwouldfindtwomoleculesofoxygeninordertocausecomplete
combustion.
[SlideVisualBasicCombustionEquation]
Methane(CH 4 )+2moleculesofOxygen(O 2 )combustsandyieldsCarbonDioxide(CO 2 )and2moleculesofWater(H 2 O)+EnergyRelease
Inthisinitialcombustiondiscussionmethaneandoxygenareusedastheonlycomponentsforsimplicity.Additionally,inertchemicals
(nitrogen)arenotconsideredatthistime.
Slide16
ActualCombustion
Intherealworld,thecombustionprocessdoesnotproceedinaperfectmanner.Infact,thecombustionreactionmayyieldmorechemicalsthancarbon
dioxideandwaterthecommonadditionalchemicalsformedarecarbonmonoxideandhydrogen.Additionally,oxygencanpassthroughthe
combustionzoneandnotreactwithanyfuelexitingasoxygenmolecules.Similarly,methanecanpassthroughthecombustionzoneandnotreact
withanyoxygenexitingasfuel.
StackLosses7
June28,2010

Aswelookatthesepossiblechemicalsthatcanformandbereleasedfromthecombustionzonesomegetourattentionmorethanothers.Forexample,
carbonmonoxideisatoxicgasthatcancausedefinitehealthconcerns.Carbonmonoxideformswhenfuelfindsaninsufficientamountofoxygento
completelyreact.Thefuelwillpartiallyreactandreleaseonlyaportionofthefuelenergyavailable.Thecarbonmonoxidecontainstheremainderofthe
originallyresidentfuelenergy.Asaresult,carbonmonoxiderepresentsmorethansafetyandhealthissues,italsorepresentsaneconomicissue
becausefuelenergywasexhaustedfromtheboiler.Infact,hydrogenandmethanepresentexactlythesameissuesnoneofthemaregoodtobreath,all
arecombustibleandexplosive,andallrepresenteconomicexpenditureintheformofpurchasedfuel.Therefore,fromacombustionmanagement
standpointitisessentialforallthefueltoreact.
Conversely,ifoxygenpassesthroughthecombustionzoneitisnothazardous,itdoesnotpresentasafetyissue,anditrequiresverylittleeconomic
investmenttoacquire.
[SlideVisualActualCombustionEquation]
Methane(CH 4 )+2moleculesofOxygen(O 2 )combustsandyieldsandenergyreleaseofalphamoleculesCarbonDioxide(CO 2 )andbeta
moleculesofWater(H 2 O)+gammamoleculesofCarbonMonoxide(CO)+deltamoleculesofHydrogen(H 2 ),+epsilonmoleculesofMethane
(CH 4 )+zetamoleculesofOxygen(O 2 )
RedcirclesencapsulatethegammamoleculesofCarbonMonoxide(CO),thedeltamoleculesofHydrogen(H 2 ),andtheepsilonmoleculesof
Methane(CH 4 )
AgreencircleencapsulatesthezetamoleculesofOxygen(O 2 )
UnreactedCH4,CO,andH2arefuelsresultingfromincompletecombustion
Wastingfuel
Safetyhazard
Healthandenvironmentalhazards
Slide17
CombustionManagement1
Thefirstprincipleofcombustionmanagementisbasedonthefactthataddingextraoxygentothecombustionzoneessentiallyensuresthatallthefuel
iscombusted.Inotherwords,inaperfectcombustionsituationonemoleculeoffuelmustencountertwomoleculesofoxygentoreactcompletely.Inthe
realworldifmorethanenoughoxygenisaddedtothecombustionzone,theneachmoleculeoffuelwillfindenoughoxygentoreact.Theextraoxygen
thatpassesthroughthecombustionzonewasacquiredwithminimalcost.Inotherwords,ifmorethanenoughoxygenispassedthroughthe
combustionzoneitalmostensuresthatallthefuelburnsup.Thisisthefirstruleofcombustioncontroladdmoreoxygentothecombustionzonethan
isnecessarytoensureallthefuelreactscompletely.
June28,2010
StackLosses8

RedcirclesencapsulatethegammamoleculesofCarbonMonoxide(CO),thedeltamoleculesofHydrogen(H 2 ),andtheepsilonmoleculesof
Methane(CH 4 )
AgreencircleencapsulatesthezetamoleculesofOxygen(O 2 )
Slide18
CombustionManagement2
However,theextraoxygenaddedtothecombustionzoneenterstheboileratambienttemperatureandexitstheboileratfluegastemperature(450
degreesFahrenheitforexample).Theextraoxygengainedthistemperaturebyreceivingfuelenergyfuelwaspurchasedtoheattheextraoxygen.The
energylossisactuallymuchmorethanjustheatingtheextraoxygen;because,ambientaircontainsalmost4moleculesofnitrogenforevery1molecule
ofoxygen(3.76fortypicalair).Asaresult,alargeamountofnitrogenentersthecombustionzonewithanyexcessoxygen.Thisnitrogenentersat
ambienttemperatureandreceivesfuelenergytoexittheboileratfluegastemperature.Themajorityofthecombustiongasisnitrogenahugeamount
ofnitrogenisheatedbyfuelenergy.ThisbringsustoCombustionManagementPrincipleNumber2donotputtoomuchairintothecombustionzone.
Stateddifferently,thetwoprinciplesofcombustionmanagementaretofirstprovideextraoxygentothecombustionzonetoensureallthefuelis
consumed;andsecond,reducetheamountofextraairtolimittheenergyloss.
RedcirclesencapsulatethemoleculesofCarbonMonoxide(CO),themoleculesofHydrogen(H 2 ),andthemoleculesofMethane(CH 4 )
AgreencircleencapsulatesthemoleculesofOxygen(O 2 )
Combustionmanagementstrivestoeliminateunreactedfuelbyaddingextraoxygentothecombustionzone
ExcessO 2 providedtothecombustionzoneessentiallyeliminatesunreactedfuel
Oxygenentersboilerasambientairatsay,70oF(ambient)
O 2 Enterswith4timestheamountofnitrogentoo!
OxygenandNitrogenexitwithfluegasat500oFbygainingheatfromthefuel
June28,2010
StackLosses9
Methane(CH 4 )+2moleculesofOxygen(O 2 )plus2moleculesofNitrogen(N 2 )(at3.76moleculeseach)combustsandyieldsandenergy
releaseofalphamoleculesCarbonDioxide(CO 2 )andbetamoleculesofWater(H 2 O)+gammamoleculesofCarbonMonoxide(CO)+delta
moleculesofHydrogen(H 2 ),+epsilonmoleculesofMethane(CH 4 )+zetamoleculesofOxygen(O 2 )plus2moleculesofNitrogen(N 2 )(at3.76
moleculeseach)
Redcirclesencapsulatethe2moleculesofOxygen(O 2 )plus2moleculesofNitrogen(N 2 )(at3.76moleculeseach)ontheinputsideofthe
equationandthezetamoleculesofOxygen(O 2 )plus2moleculesofNitrogen(N 2 )(at3.76moleculeseach)ontheresultssideoftheequation.
Slide19
MinimumOxygenEvaluation1
Theprimarymeasurementrequiredforcombustionmanagementisfluegasoxygencontent.Inordertodetermineiftheamountofextraoxygenis
appropriatelylowasecondmeasurementisrequiredthesecondmeasurementiscombustiblesconcentrationinthefluegas.Remember,combustion
managementdesirestoaddenoughoxygentoburnupallthefuelbutnottoomuchsuchthatweexperienceasignificantenergyloss.
Thisisagraphofatypicalburneroperatingwithnaturalgas.Mostburnerswilloperatewithminimalcombustiblesconcentrationforawiderangeof
oxygencontent.Foragivenfuelloadasfluegasoxygencontentisreducedapointisreachedwherecombustiblesconcentrationincreasesdramatically.
Thismarkstheminimumfluegasoxygencontentfortheburnerfuelload.Thisindicatestheconditionwheretheburnerperformanceisnotsufficientto
mixairwithfuel.Combustioncontrolthenstrivestooperatethecombustionprocessasnearaspracticaltothisloweroxygenlimit.Itisimportantto
establishbaselinecombustiblesconcentrationforeachboileroverawiderangeoffuelloading.
[SlideVisualMinimumOxygenGraph]
AgraphicdepictsFlueGasOxygencontentalongthexaxisasapercentoffluegasoxygencontent,beginningat0%andincreasingto9%in
incrementsof1%.TheverticaloryaxisdepictstheCombustiblesinpartspermillion(ppm),beginningat0andincreasingtoover160ppmin
incrementsof20ppm.
Thegeneraltrendindicatescombustiblesconcentrationtoberelativelylowandconstantoverabroadrangeoffluegasoxygencontent.The
concentrationincreasesdramaticallyasthefluegasoxygencontentdecreasesbelow2%.Combustiblesconcentrationalsoincreasesastheflue
gasoxygencontentincreasesabove8%.
Slide20
MinimumOxygenEvaluation2
Itmustbementionedthatseveralfactorsimpactthecombustiblesconcentrationinadditiontotheamountofexcessoxygeninthecombustionzone.In
additiontoextraoxygeninthecombustionzone,theburnermustalsobeingoodcondition.Thepurposeoftheburneristothoroughlymixand
June28,2010
StackLosses10

distributethefuelandtheair.Inorderforgoodcombustiontotakeplace,theairandfuelmustremaininthecombustionzoneasufficientamountof
timetoallowcombustiontotakeplace,thecombustionzonemustbeatthepropertemperature,andthefuelandairmustmixthoroughly.The
conditionoftheburnerimpactsallofthesefactors.BabcockandWilcoxidentifiytheseprimaryfactorsastheThreeTsofCombustion.TheReaction
TIMEallowsthecombustiontobecomplete.TheReactionTEMPERATUREdrivesthechemicalreactiontocompletion.TheTURBULENCE(mixing)of
thefuelandoxygenisneededtoreactcompletely.AdeficiencyinanyoneoftheseTswillresultinunreactedfuel.
Slide21
OxygenLimits
Manyfactorsimpactcombustionzoneoxygenlimits.Thetypeoffuelsignificantlyinfluencestheallowablecombustionzoneoxygenlimits.Allfuelsburn
inthegasstate;therefore,naturalgasismorereadilycombustiblethanoilorcoal.Oilmustevaporateintothevaporstatethenburn.Coalmustdiffuse
fromthesolidphasetothevaporstagebeforecombustioncantakeplace.
Combustioncontrolmethodologyalsoinfluencesthecombustionlosses.Astheoxygencontentismaintainedtothepracticalminimumandcontrolled
morepreciselythecombustionlossdecreases.
Thetypeofburnerandtheconditionoftheburneralsoinfluenceoxygencontrolparameters.
Thelocationoftheoxygenmeasurementcanbeasignificantfactorwhenoperatingboilerswithfluegaspressureslessthanatmosphericpressure.In
thesesituationsanyopeningintheboilerwillleakairintothefluegasresultinginelevatedfluegasoxygencontentmeasurements.
Generally,combustionparameterswillbesetsuchthatexcessoxygenincreasesasboilerloaddecreases.Theprimaryreasonforthisisthediminished
turbulence(mixing)astheflowsthroughtheburnerdecrease.Elevatedburnerloadingresultsinexcellentmixing,whichallowsreducedoxygen
operation.
Slide22
TrimControl
Typicallyinboilers,fuelflowiscontrolledbymeasuringsteampressureandadjustingfuelflowtomeetthepressuresetpoint.Ifsteampressure
decreasesthefuelflowcontrollerwillincreasefuelflowfortheboilertogeneratemoresteamrestoringthesteampressuretothesetpoint.
Converselyassteampressureincreases,fuelflowwillbedecreasedtoreducesteamproduction.
Asthefuelflowintotheboilerchangescombustion,airflowmustalsochangetomaintainpropercombustionparameters.Combustioncontroltakes
twoprimaryforms.Thefirsttypewewilldiscussisidentifiedascontinuousautomaticcontrol(alsoknownastrimcontrol).Inthiscontrolmethod
combustionairflowiscontrolledbycontinuallymonitoringfluegasoxygencontentandadjustingtheairflowtomatchasetpoint.Thiscontrolcanbe
veryeffectiveandefficient.
June28,2010
StackLosses11

[SlideVisualAutomatic(Trim)Control]
Theboilerconfigurationshowsafeedwatersupplyfromadeaeratordepictedbyabluerectanglewithadomeontopwhichutilizesapumpto
sendfeedwatertothesteamdrumoftheboiler.Feedwaterentersthetopoftheboileratthesteamdrum,passesthroughtheboilertubes,then
exitsassteamatthetopoftheboiler.Asteampressureindicatororgageisdepictedasasmallredcircleinthesteamoutlet.
Justbelowtheboilerfeedwatersupply,acombustionairfanprovidesairtotheboilerscombustionzone.Theairflowiscontrolledbya
damper,depictedasaslashintherectangularductworkleadingtotheboilerinlet.Thedamperiscontrolledbyacombustioncontroller
device,asmallbluerectangle,whichcommunicateswithafluegasoxygensensor,asmallbluerectanglelocatedintheboilerexhaust.The
signalsfromthefluegasoxygensensorandthesteampressureindicatorarerepresentedbyabluedottedline.
Thecombustioncontrolisaccomplishedbyadjustingairflowintothecombustionzonetomakethefluegasoxygencontentmatchthesetpoint.
Slide23
PositioningControl
Theothercommontypeofcombustioncontrolinboilersissimpleandverycommon.Thissecondtypeofcontrolmanagesfuelflowthesamewayitis
managedwithcontinuousautomaticcombustioncontrol.Ifsteampressuredecreases,fuelflowincreases,andviceversa.Combustionairflowcontrol
isaccomplishedbymechanicallylinkingtheairflowcontroldevicetothefuelflowcontroldevice.Thisiscommonlycalledpositioningcontrolbecause
theairflowcontroldevicewillhaveapositionthatisbasedsolelyonthepositionofthefuelflowcontroldevice.Itshouldbenotedthatthiscontrol
doesnotincorporateanyactiveoxygenorcombustiblesmeasurements.Oxygenandcombustiblesmeasurementsareonlytakentoestablishthe
positionrelationshipbetweenthefuelcontrollerandtheaircontroller.Afterthepositionrelationshipisestablishedoxygenandcombustibles
measurementscease.
Itshouldbenotedthatwhenpositioningcontrolisusedtheoxygencontentcannotbeminimizedbecauseofmanyfactors.Onefactorinfluencingthe
airflowcontrollerpositionisambienttemperature.Ambienttemperatureisaconcernbecausethecombustionairfanisbasicallyaconstantvolume
flowdevice(foragivencontrollersetpoint).Ifthepositionrelationshipisestablishedforarelativelycoolinletairtemperature,themassflowofair
intothecombustionzonecouldbecomedangerouslylowastheinletairtemperatureincreases.Asaresult,positioningcontrolcanonlyattainmoderate
efficiency.
Tuningtheboileristheactofreestablishingthepositionrelationshipbetweentheairandfuel.Thistuningactivityiscompletedinthesamemannerthe
originalairfuelcontrolpointpositionswereestablished.Theboilerisoperatedsteadilyatdiscretefuelinputpositionsandtheairflowcontroldevice
positionisredefined.Theboilerwillbeoperatedatdiscreteloadsthroughouttheoperatingrangeoftheunit.Whilethefuelflowcontrolleris100
percentopen,forexample,thepositionoftheairflowcontrollerisadjusteduntilanappropriatefluegasoxygencontentisattained.Combustibles
concentrationsshouldalsobemeasuredtoensureproperburneroperation.Thepositionrelationshipexerciseisrepeatedovertheoperatingrangeof
theboiler(95percentload,90percentload,downtominimumload).Thisretuningactivityshouldbecompletedfrequentlytoensuresafeandefficient
boileroperation.
Pleasenotetherearemanyformsofcombustioncontrolbuttheconceptspresentedinthesetwocontroltechniquesarethefoundationsofall
combustioncontrolmethods.
June28,2010
StackLosses12

Positioningcontrolisalsoknownasjackshaftcontrol.
[SlideVisualAutomatic(Trim)Control]
Theboilerconfigurationshowsafeedwatersupplyfromadeaeratordepictedbyabluerectanglewithadomeontopwhichutilizesapumpto
sendfeedwatertothesteamdrumoftheboiler.Feedwaterentersthetopoftheboileratthesteamdrum,passesthroughtheboilertubes,then
exitsassteamatthetopoftheboiler.Asteampressureindicatororgageisdepictedasasmallredcircleinthesteamoutlet.
Justbelowtheboilerfeedwatersupply,acombustionairfanprovidesairtotheboilerscombustionzone.Theairflowiscontrolledbya
damper,depictedasaslashintherectangularductworkleadingtotheboilerinlet.Thedamperiscontrolledbyacombustioncontroller
device,asmallbluerectangle,whichcommunicateswithafluegasoxygensensor,asmallbluerectanglelocatedintheboilerexhaust.The
signalsfromthefluegasoxygensensorandthesteampressureindicatorarerepresentedbyabluedottedline.
Thecombustioncontrolisaccomplishedbyadjustingairflowintothecombustionzonetomakethefluegasoxygencontentmatchthesetpoint.
Slide24
OxygenContentControlParameters
Thistableisagoodindicatorofwhatyoushouldexpectfrommostboilersintermsofoxygenconcentrations.Itmustbenotedthatmanyfactorscan
influencetheactualfluegasoxygencontentthesearesimplycommonlyobservedoperatingconditions.Thetwotypesofcontrolmethodology
discussedareidentifiedinthetable,automaticcontrolandpositioningcontrol.Generally,thehigherfluegasoxygencontentvaluescorrespondwith
lowburnerloadandthelowfluegasoxygencontentscorrespondwithhighburnerload.Lessexcessairisrequiredathigherburnerloadsbecausehigh
velocitiesintheburnerenhancesmixingandthecombustionreactions.
Excessairisnotedinthetableforreferencepurposes.Fluegasoxygencontentisthemeasuredvalue.Excessairiscalculatedfromthefuelcomposition
andthemeasuredoxygenvalue.
June28,2010
StackLosses13

[SlideVisualTypicalFlueGasContentControlParametersTable]
Fuel
Natural
Gas
Number2
FuelOil
Number6
FuelOil
Pulverized
Coal
Stoker
Coal
AutomaticControl
FlueGasO 2 Content
Min.
Max.
[%]
[%]
1.5
3.0
PositioningControl
FlueGasO 2 Content
Min.
Max.
[%]
[%]
3.0
7.0
AutomaticControl
ExcessAir
Min.
Max.
[%]
[%]
9
18
PositioningControl
ExcessAir
Min.
Max.
[%]
[%]
18
55
2.0
3.0
3.0
7.0
11
18
18
55
2.5
3.5
3.5
8.0
14
21
21
65
2.5
4.0
4.0
7.0
14
25
25
50
3.5
5.0
5.0
8.0
20
32
32
65
Higheroxygenlimitsarepairedtolowburnerloads.
Loweroxygenlimitsarepairedwithhigherburnerloads.
Slide25
StackLossEvaluation
Insummary,stacklossisthelargestlossassociatedwithmostboilers.Managingstacklossiscriticaltocontrollingsteamsystemoperatingcosts.The
measurementsrequiredtomanagestacklossarefluegasexittemperature,fluegasoxygencontent,ambienttemperature,boilerload,andfluegas
combustiblesconcentration.Inordertoquantifythestackloss,thecriticalmeasurementsmustbeusedinconjunctionwithcombustioncalculations.
Combustioncalculationscanbearrangedinmanyforms.Onestraightforwardformisastacklosstable.
Slide26
StackLossNaturalGas
Thestacklosstablespresentedherearejustoneformofcombustiondatausedtoquantifystackloss.Otherformsofstacklossinformationinclude
computermodels,calculations,graphs,andnomographs.Allstacklossanalysesusethesameinitialinformationfluegastemperature,fluegasoxygen
content,combustiblesconcentration,andfuelcomposition.Stacklosstablesareastraightforwardcommunicationvehicle.Stacklosscalculationsare
basedonthedifferenceinfluegastemperatureandambienttemperaturethisisknownasthenetstacktemperature.Ambienttemperaturedoeshave
June28,2010
StackLosses14

animpactonfluegastemperaturebecausesuchalargeamountofairpassesthroughtheboiler.Whenambientairtemperaturedecreasesfluegas
temperaturewilldecrease.
Theotherprimaryinputinformationrequiredtousestacklosscalculatorsistheamountofoxygeninthefluegas.Athirdmeasurementisalsorequired
tocompletethestacklossanalysiscombustiblesconcentrationinthefluegas.Combustiblesconcentrationisofcourseameasureoftheunburnedfuel
exitinginthefluegas.Combustiblesconcentrationslessthan100ppmgenerallyyieldnegligibleimpactonstackloss.Thestacklosstablesthatfollow
areforvariouscommonfuels,thefluegascontainsnegligiblecombustibles,andwaterexitsasavapor(nocondensate).
[SlideVisualStackLossTableforNaturalGas]
FlueGas
Oxygen
Content
WetBasis[%]
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
ActualExhaustT
[F]
AmbientT[F]
June28,2010
StackLoss[%offuelhigherheatingvalueinput]
NetStackTemperature[F]
{Differencebetweenfluegasexhausttemperatureandambienttemperature}
155
13.1
13.2
13.4
13.6
13.8
14.1
14.4
14.7
15.1
15.5
225
180
13.6
13.8
14.0
14.2
14.5
14.8
15.1
15.5
16.0
16.5
250
205
14.1
14.3
14.6
14.8
15.1
15.5
15.9
16.3
16.8
17.4
275
230
14.7
14.9
15.2
15.5
15.8
16.2
16.6
17.1
17.7
18.4
300
255
15.2
15.5
15.8
16.1
16.5
16.9
17.4
17.9
18.6
19.4
325
280
15.8
16.1
16.4
16.7
17.2
17.6
18.1
18.8
19.5
20.3
350
305
16.3
16.6
17.0
17.4
17.8
18.3
18.9
19.6
20.4
21.3
375
330
16.9
17.2
17.6
18.0
18.5
19.1
19.7
20.4
21.2
22.2
400
355
17.4
17.8
18.2
18.7
19.2
19.8
20.5
21.2
22.1
23.2
425
380
18.0
18.4
18.8
19.3
19.9
20.5
21.2
22.1
23.0
24.2
450
405
18.5
18.9
19.4
20.0
20.5
21.2
22.0
22.9
23.9
25.2
475
430
19.1
19.5
20.0
20.6
21.2
22.0
22.8
23.7
24.8
26.1
500
70
70
70
70
70
70
70
70
70
70
70
70
StackLosses15
Slide27
Number2FuelOil
Thisstacklosstableiscompiledfornumber2fueloil.Number2fueloiliscommonhouseholdheatingfuelandisessentiallydieselfuel.
[SlideVisualStackLossTableforNumber2FuelOil]
FlueGas
Oxygen
Content
WetBasis[%]
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
ActualExhaustT
[F]
AmbientT[F]
180
205
230
255
280
305
330
355
380
405
430
455
9.5
9.6
9.8
10.1
10.3
10.6
10.9
11.3
11.7
12.2
250
10.0
10.2
10.4
10.7
10.9
11.3
11.6
12.1
12.6
13.1
275
10.5
10.7
11.0
11.3
11.6
12.0
12.4
12.8
13.4
14.1
300
11.0
11.3
11.6
11.9
12.2
12.6
13.1
13.6
14.3
15.0
325
11.5
11.8
12.1
12.5
12.9
13.3
13.8
14.4
15.1
15.9
350
12.1
12.4
12.7
13.1
13.5
14.0
14.6
15.2
16.0
16.8
375
12.6
12.9
13.3
13.7
14.2
14.7
15.3
16.0
16.8
17.8
400
13.1
13.5
13.9
14.3
14.8
15.4
16.1
16.8
17.7
18.7
425
13.7
14.1
14.5
15.0
15.5
16.1
16.8
17.6
18.5
19.6
450
14.2
14.6
15.1
15.6
16.2
16.8
17.5
18.4
19.4
20.6
475
14.7
15.2
15.7
16.2
16.8
17.5
18.3
19.2
20.3
21.5
500
15.3
15.7
16.3
16.8
17.5
18.2
19.0
20.0
21.1
22.5
525
70
70
70
70
70
70
70
70
70
70
70
70
June28,2010
StackLosses16

Slide28
Number6FuelOil(LowSulfur)
Number6fueloilisheavyfueloilitiscommonlysolidatroomtemperature.Oftennumber6fueloilisclassifiedintohighsulfurcontentandlow
sulfurcontent.
[SlideVisualStackLossTableforNumber6FuelOil(LowSulfur)]
FlueGas
Oxygen
Content
WetBasis[%]
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
ActualExhaustT
[F]
AmbientT[F]
205
9.5
9.7
9.9
10.1
10.4
10.8
11.1
11.6
12.1
12.7
275
230
10.0
10.2
10.5
10.8
11.1
11.4
11.9
12.3
12.9
13.6
300
255
10.5
10.8
11.1
11.4
11.7
12.1
12.6
13.1
13.8
14.5
325
280
11.0
11.3
11.6
12.0
12.4
12.8
13.3
13.9
14.6
15.4
350
305
11.6
11.9
12.2
12.6
13.0
13.5
14.1
14.7
15.5
16.4
375
330
12.1
12.4
12.8
13.2
13.7
14.2
14.8
15.5
16.3
17.3
400
355
12.6
13.0
13.4
13.9
14.4
14.9
15.6
16.3
17.2
18.2
425
380
13.2
13.6
14.0
14.5
15.0
15.6
16.3
17.1
18.1
19.2
450
405
13.7
14.1
14.6
15.1
15.7
16.3
17.1
17.9
18.9
20.1
475
430
14.3
14.7
15.2
15.7
16.3
17.0
17.8
18.8
19.8
21.1
500
455
14.8
15.3
15.8
16.4
17.0
17.7
18.6
19.6
20.7
22.0
525
480
15.3
15.8
16.4
17.0
17.7
18.5
19.4
20.4
21.6
23.0
550
70
70
70
70
70
70
70
70
70
70
70
70
June28,2010
StackLosses17

Slide30
TypicalEasternCoal
Allcommonfuelshavearangeincomposition.Therangeincompositionofcommerciallyavailablenaturalgasisverysmallwhencomparedtothe
variabilityofheavyfueloil.However,whenconsideringcoalstherangeinvariabilityisevengreater.Thesecoalandwoodstacklosstablesshouldbe
consideredestimatesonly.
[SlideVisualStackLossTableforTypicalEasternCoal]
FlueGas
Oxygen
Content
WetBasis[%]
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
ActualExhaustT
[F]
AmbientT[F]
June28,2010
230
8.5
8.7
9.0
9.3
9.6
10.0
10.4
10.9
11.4
12.1
300
255
9.0
9.3
9.6
9.9
10.3
10.7
11.1
11.7
12.3
13.0
325
280
9.6
9.9
10.2
10.5
10.9
11.4
11.9
12.5
13.2
14.0
350
305
10.1
10.4
10.8
11.2
11.6
12.1
12.6
13.3
14.0
14.9
375
330
10.7
11.0
11.4
11.8
12.3
12.8
13.4
14.1
14.9
15.9
400
355
11.2
11.6
12.0
12.4
12.9
13.5
14.2
14.9
15.8
16.8
425
380
11.8
12.1
12.6
13.1
13.6
14.2
14.9
15.7
16.7
17.8
450
405
12.3
12.7
13.2
13.7
14.3
14.9
15.7
16.5
17.6
18.7
475
430
12.8
13.3
13.8
14.3
14.9
15.6
16.4
17.4
18.4
19.7
500
455
13.4
13.9
14.4
15.0
15.6
16.4
17.2
18.2
19.3
20.7
525
480
14.0
14.4
15.0
15.6
16.3
17.1
18.0
19.0
20.2
21.6
550
505
14.5
15.0
15.6
16.3
17.0
17.8
18.7
19.8
21.1
22.6
575
70
70
70
70
70
70
70
70
70
70
70
70
StackLosses18

Slide32
TypicalGreenWood
Greenwoodisaverycommonfuelinmanyindustries.Greenwoodrefersprimarilytotheportionsoftreesthatarenotusedinthepapermakingand
lumbermakingprocesses.Barkandotherwoodchipsthathavebeenremovedfromfreshlycuttreesaretheprimarysourcesofgreenwood.Itis
interestingtonotethatgreenwoodisgenerally50%liquidwater.Asaresult,thestacklossassociatedwithgreenwoodisveryhigh.
[SlideVisualStackLossTableforTypicalGreenWood]
FlueGas
Oxygen
Content
WetBasis[%]
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
ActualExhaustT
[F]
AmbientT[F]
230
35.7
36.0
36.3
36.7
37.1
37.5
38.0
38.6
39.3
40.2
300
255
36.7
37.1
37.5
37.9
38.4
39.0
39.6
40.4
41.3
42.4
325
280
37.1
37.4
37.8
38.2
38.7
39.3
39.9
40.7
41.5
42.5
350
305
38.1
38.6
39.0
39.6
40.2
40.9
41.7
42.6
43.7
45.0
375
330
38.4
38.9
39.3
39.8
40.4
41.1
41.8
42.7
43.7
44.9
400
355
39.6
40.1
40.6
41.3
42.0
42.8
43.7
44.8
46.1
47.6
425
380
39.8
40.3
40.8
41.4
42.1
42.9
43.7
44.7
45.9
47.3
450
405
41.0
41.6
42.2
42.9
43.8
44.7
45.8
47.0
48.5
50.2
475
430
41.2
41.8
42.4
43.0
43.8
44.7
45.6
46.8
48.1
49.7
500
455
42.5
43.1
43.9
44.7
45.6
46.6
47.8
49.2
50.9
52.9
525
480
42.6
43.2
43.9
44.7
45.5
46.5
47.6
48.9
50.3
52.1
550
505
44.0
44.7
45.5
46.4
47.4
48.6
49.9
51.5
53.3
55.5
575
70
70
70
70
70
70
70
70
70
70
70
70
June28,2010
StackLosses19

Slide33
CombustionManagement
Insummary,propercombustionmanagementrequiresaddingenoughoxygentothecombustionzonetoburnallofthefuelbutnotaddingtoomuchair
tomakesurethethermallossisminimized.Combustionmanagementstrategyinitiateswithmeasuringtheconditionofthecombustionprocess,
utilizestheexistingequipmenttomanagethecombustionprocesstothebestextentpractical,andtoexaminetheopportunitiestomodifyoperations
andequipmenttofurtherimprovecombustionperformance.
[SlideVisualCombustionManagementSummary]
Combustionmanagementprinciples:
Addenoughoxygentoreactallofthefuel.
Minimizetheamountofextraairtolimittheenergyloss.
Monitorcombustiblestoidentifyproblems.
1. Measuretheoxygencontentofboilerexhaustgas.
Continuously.
Periodically.
2. Controloxygencontentwithinaminimumandmaximumrange.
Continuousautomaticcontrol.
Positioningcontrol.
3. Challengethecontrolrange.
Combustiblesmeasurement.
Burnerrepair.
Controlupgrade.
Combustiontuning.
Slide34
StackLossExample
Letsreturntoourexampleboiler,takesomemeasurements,andestimatetheboilerefficiency.Forourexampleboilerwehavemeasuredthefluegas
temperaturetobe450F,ambienttemperaturetobe70F,andthefluegasoxygencontenttobe7.0%.Combustiblesconcentrationwasmeasuredtobe
lessthan10ppm,whichisnegligiblysmall.
June28,2010
StackLosses20

[SlideVisualStackLossExample]
DeterminetheStackLoss(NaturalGas)
Combustionanalyzerdata:
FluegasO2content7%byvolume
FluegasCO2content6%byvolume
FluegasCOcontent~0ppm
Fluegasunburnedfuel~0%
Fluegastemperature450F
Intakeairtemperature70F
Fueltemperature70F
380Fnetfluegastemperature
June28,2010
StackLosses21

Slide35
StackLossNaturalGas1
Wetakethesemeasurementstothestacklosstablefornaturalgas.
FlueGas
Oxygen
Content
WetBasis[%]
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
ActualExhaustT
[F]
AmbientT[F]
June28,2010
155
13.1
13.2
13.4
13.6
13.8
14.1
14.4
14.7
15.1
15.5
225
180
13.6
13.8
14.0
14.2
14.5
14.8
15.1
15.5
16.0
16.5
250
205
14.1
14.3
14.6
14.8
15.1
15.5
15.9
16.3
16.8
17.4
275
230
14.7
14.9
15.2
15.5
15.8
16.2
16.6
17.1
17.7
18.4
300
255
15.2
15.5
15.8
16.1
16.5
16.9
17.4
17.9
18.6
19.4
325
280
15.8
16.1
16.4
16.7
17.2
17.6
18.1
18.8
19.5
20.3
350
305
16.3
16.6
17.0
17.4
17.8
18.3
18.9
19.6
20.4
21.3
375
330
16.9
17.2
17.6
18.0
18.5
19.1
19.7
20.4
21.2
22.2
400
355
17.4
17.8
18.2
18.7
19.2
19.8
20.5
21.2
22.1
23.2
425
380
18.0
18.4
18.8
19.3
19.9
20.5
21.2
22.1
23.0
24.2
450
405
18.5
18.9
19.4
20.0
20.5
21.2
22.0
22.9
23.9
25.2
475
430
19.1
19.5
20.0
20.6
21.2
22.0
22.8
23.7
24.8
26.1
500
70
70
70
70
70
70
70
70
70
70
70
70
StackLosses22

Slide36
StackLossNaturalGas2
Thisdataidentifiesthestacklosstobe21.2%.
FlueGas
Oxygen
Content
WetBasis[%]
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
ActualExhaustT
[F]
AmbientT[F]
June28,2010
155
13.1
13.2
13.4
13.6
13.8
14.1
14.4
14.7
15.1
15.5
225
180
13.6
13.8
14.0
14.2
14.5
14.8
15.1
15.5
16.0
16.5
250
205
14.1
14.3
14.6
14.8
15.1
15.5
15.9
16.3
16.8
17.4
275
230
14.7
14.9
15.2
15.5
15.8
16.2
16.6
17.1
17.7
18.4
300
255
15.2
15.5
15.8
16.1
16.5
16.9
17.4
17.9
18.6
19.4
325
280
15.8
16.1
16.4
16.7
17.2
17.6
18.1
18.8
19.5
20.3
350
305
16.3
16.6
17.0
17.4
17.8
18.3
18.9
19.6
20.4
21.3
375
330
16.9
17.2
17.6
18.0
18.5
19.1
19.7
20.4
21.2
22.2
400
355
17.4
17.8
18.2
18.7
19.2
19.8
20.5
21.2
22.1
23.2
425
380
18.0
18.4
18.8
19.3
19.9
20.5
21.2
22.1
23.0
24.2
450
405
18.5
18.9
19.4
20.0
20.5
21.2
22.0
22.9
23.9
25.2
475
430
19.1
19.5
20.0
20.6
21.2
22.0
22.8
23.7
24.8
26.1
500
70
70
70
70
70
70
70
70
70
70
70
70
StackLosses23

Slide37
StackLossExample
Thisinformationallowsagrossestimateofboilerefficiencytobeestablishedas78.8%,whichis100%minusthestacklossof21.2%.
[SlideVisualStackLossExample]
Thisinformationallowsagrossestimateofboilerefficiencytobeestablishedas78.8%(10021.2).
DeterminetheStackLoss(NaturalGas)
Combustionanalyzerdata:
FluegasO2content7%byvolume
FluegasCO2content6%byvolume
FluegasCOcontent~0%
Fluegasunburnedfuel~0%
Fluegastemperature450F(380Fnet)
Intakeairtemperature70F
Fueltemperature70F
StackLoss
21.2%
Combustionefficiency78.8%
Slide38
StackLossCalculator
TheSteamSystemAssessmentToolcontainsanotherformofstacklosscalculator.Thiscalculatorallowsfluegastemperature,ambienttemperature,
andfluegasoxygencontenttobeinputwithstacklossforvariousfuelsastheoutput.
June28,2010
StackLosses24

[SlideVisualStackLossCalculator]
SteamSystemAssessmentTool
StackLossCalculator
BasedonuserinputsofStackTemperature,AmbientTemperatureandStackOxygenContent,anestimatewillbeprovided
oftheheatlossfromtheboilerstack.
Lossesareexpressedasapercentageoftheheatfired.
StacklossesarerelatedtoSSATBoilerEfficiencyasfollows:
SSATBoilerEfficiency=100%StackLoss(%)ShellLoss(%)
ShellLossreferstotheradiantheatlossfromtheboiler.Typically<1%atfullload,12%atreducedload.
InputData
StackGasTemperature(F)
450
StackTemperatureAmbientTemperature=380F
AmbientTemperature(F)
70
StackGasOxygenContent(%)
7 %
Note:Stackgasoxygencontentisexpressedonamolarorvolumetricbasis
June28,2010
StackLosses25
Results
EstimatedStackLossesforeachofthedefaultfuelsareasfollows:
NaturalGas
21.3 %
Number2FuelOil
16.8 %
Number6FuelOil(LowSulfur)
16.4 %
Number6FuelOil(HighSulfur)
16.6 %
TypicalEasternCoal(Bituminous)
15.0 %
TypicalWesternCoal(Subbituminous)
16.5 %
27.4 %
TypicalGreenWood
Slide39
IndirectEfficiencySummary
Otherinvestigationshaveyieldedestimatesoftheshelllossandtheblowdownloss.Otherlossesareconsiderednegligibleforthisboiler.Asaresult,
boilerefficiencycanbedeterminedinanindirectmannerbysubtractingtheselossesfromaperfectlyefficientboiler.Thismethodestimatestheboiler
efficiencytobe77.4%.
Onceagain,wegetindirectefficiencybysubtractingthepercentageofeachlossfrom100percent.
Thisindirectefficiencyevaluationisinexcellentagreementwiththepreviouslydetermineddirectboilerefficiencyof77.1%.
[SlideVisualBoilerLossIndirectEfficiencyEquations]
June28,2010
StackLosses26
losses.
n indirect =100%21.2%0.9%0.5%0%
n indirect =77.4%
n direct =77.1%
Abbreviations
n indirect =indirectefficiency
n direct =directefficiency(classic)
E losses =sumofalllosses
Slide40
StackLossesExample
[SlideVisualStackLossExampleTitlePage]
RadiationandConvectionlosses
Shelllosses
Blowdownlosses
StacklossesExample
Slide41
BoilerLossExample1
Ourexampleboilerisoperatingwithanefficiencyofabout77%.Typicalnaturalgasfiredboilerefficiencyis83%andhigherefficienciesareattainable.
Asaresult,weareexpectingthisboilerwillhaveimprovementopportunities.
June28,2010
StackLosses27

[SlideVisualBoilerLossExample]
Thisschematicdepictsawatertubeboiler.Fuelandairenteratthelowerleftofthecombustionzone,feedwaterentersatthetopofthesteam
generationsectionatthesteamdrumwhichincludesmultiplepassesforheatexchangewithamuddrumatthebottomofthesection.The
steamoutletisshownatthetopoftheboileras700degreesFahrenheit.Exhaustgasesareshownleavingtheboilerat450degreesFahrenheit.
Thefluegasoxygencontentisidentifiedat7%nearthefluegasoutlet.TheFuelCostfortheboilerisreportedat$13milliondollarsperyear.
Thecurrentsteamoperatingloadis100,000poundsperhourwithacapacityof120,000poundsperhour,or83%load.
Slide42
BoilerLossExample2
Arethereareasofinterest?Aretheremeasurementsthatindicateimprovementsmaybepossible?
Slide43
BoilerLossExample3
Thefluegasexhausttemperatureisnotextremelyhigh;however,450Fiswellabovethepracticallimitoffluegastemperatureforanaturalgasfired
boiler.Itiscommontodesignnaturalgasfiredboilerstooperatewithfluegastemperatureslessthan300F.
Additionally,thefluegasoxygencontentappearstobeelevated7%fluegasoxygencontentistheupperendoftypicalfornaturalgasboilers.
Atthispointwedonotknowifthereareproblemswiththeboiler,iftheboilerhasalwaysoperatedwiththeseconditions,orifrecentchangeshave
resultedintheseconditionsbutwedoknowthattheprimaryboilermeasurementsindicateinvestigationshouldbegin.
June28,2010
StackLosses28

Aquestionatthetopoftheslideasks:
Arethereanyinterestingareasofinvestigation?
Slide44
BoilerLossExample4
Letsstartourinvestigationbytargetingthefluegasoxygencontenttheremaybeadjustmentswecanmaketotheboileroperationsimmediatelyand
beginsavingfuelnow.
Slide45
BoilerLossExample5
Ourinvestigationoftheboileridentifiesthatpositioningcontrolisusedtomanagethecombustionoperations.
Slide46
FlueGasContentControlParameters1
Recall,mostnaturalgasfiredboilersoperatingwithpositioningcontrolwilloperatewithfluegasoxygencontentrangingfrom3%to7%.Ourexample
boilerisoperatingattheupperendofthisrange;however,wealsorememberthatthehigheroxygencontentisrequiredforlowerboilerloads.This
boilerisoperatingatafairlyheavyloadgreaterthan80%.
June28,2010
StackLosses29

Fuel
NaturalGas
Number2
FuelOil
Number6
FuelOil
Pulverized
Coal
StokerCoal
AutomaticControl
FlueGasO 2
Content
Min.
Max.
[%]
[%]
1.5
3.0
2.0
3.0
PositioningControl
FlueGasO 2 Content
AutomaticControl
ExcessAir
PositioningControl
ExcessAir
Min.
[%]
3.0
3.0
Max.
[%]
7.0
7.0
Min.
[%]
9
11
Max.
[%]
18
18
Min.
[%]
18
18
Max.
[%]
55
55
2.5
3.5
3.5
8.0
14
21
21
65
2.5
4.0
4.0
7.0
14
25
25
50
3.5
5.0
5.0
8.0
20
32
32
65
Slide47
FlueGasContentControlParameters2
Asaresult,wewouldexpectthisboilertooperatewithfluegasoxygencontentcloserto3%.
Now,beforewespendalotoftimeandenergyattemptingtoreducethecombustionzoneoxygencontentletsgetanunderstandingofthesavings
potential.Rememberthefluegasanalysisdataindicatedtherewerenegligiblecombustiblesintheexhaustgas.Thisleadsustoexpectthattheburner
canoperatewithlessexcessair.Atthispointwearenotsurewhattheminimumfluegasoxygencontentisforthisburnertooperatewithgood
performance.However,wefullyexpectthisburnertobeabletooperatewithlessthan5%oxygen.Letsestimatethesavingsopportunityassociated
withreducingthefluegasoxygencontentto5%.Thiswillhelpusunderstandhowinterestedweshouldbeintuningtheboiler.
June28,2010
StackLosses30

Fuel
NaturalGas
Number2
FuelOil
Number6
FuelOil
Pulverized
Coal
StokerCoal
AutomaticControl
FlueGasO 2
Content
Min.
Max.
[%]
[%]
1.5
3.0
2.0
3.0
PositioningControl
FlueGasO 2 Content
AutomaticControl
ExcessAir
PositioningControl
ExcessAir
Min.
[%]
3.0
3.0
Max.
[%]
7.0
7.0
Min.
[%]
9
11
Max.
[%]
18
18
Min.
[%]
18
18
Max.
[%]
55
55
2.5
3.5
3.5
8.0
14
21
21
65
2.5
4.0
4.0
7.0
14
25
25
50
3.5
5.0
5.0
8.0
20
32
32
65
Slide48
StackLossNaturalGas
Thestacklosstableisanexcellentvehicletohelpidentifythetuningopportunity.Wewilltakeaconservativeapproachandassumewecantunethe
boilerto5%oxygenwearefairlyconfidentwecanusetheexistingcombustioncontrolsandachieveevenloweroxygencontent;but,rightnowwe
areinterestedtocharacterizetheopportunity.
Ifthecombustionzoneoxygencontentisreducedfrom7%to5%andthefluegastemperatureremainsconstant,thestacklosswillreducefrom21.2%
to19.9%.Thesevaluescanbeusedtoestimateoverallboilerefficiencybysubtractingthemfrom100%.
June28,2010
StackLosses31

StackLossTablefor
NaturalGas
FlueGas
Oxygen
Content
WetBasis[%]
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
ActualExhaustT
[F]
AmbientT[F]
155
13.1
13.2
13.4
13.6
13.8
14.1
14.4
14.7
15.1
15.5
225
180
13.6
13.8
14.0
14.2
14.5
14.8
15.1
15.5
16.0
16.5
250
205
14.1
14.3
14.6
14.8
15.1
15.5
15.9
16.3
16.8
17.4
275
230
14.7
14.9
15.2
15.5
15.8
16.2
16.6
17.1
17.7
18.4
300
255
15.2
15.5
15.8
16.1
16.5
16.9
17.4
17.9
18.6
19.4
325
280
15.8
16.1
16.4
16.7
17.2
17.6
18.1
18.8
19.5
20.3
350
305
16.3
16.6
17.0
17.4
17.8
18.3
18.9
19.6
20.4
21.3
375
330
16.9
17.2
17.6
18.0
18.5
19.1
19.7
20.4
21.2
22.2
400
355
17.4
17.8
18.2
18.7
19.2
19.8
20.5
21.2
22.1
23.2
425
380
18.0
18.4
18.8
19.3
19.9
20.5
21.2
22.1
23.0
24.2
450
405
18.5
18.9
19.4
20.0
20.5
21.2
22.0
22.9
23.9
25.2
475
430
19.1
19.5
20.0
20.6
21.2
22.0
22.8
23.7
24.8
26.1
500
70
70
70
70
70
70
70
70
70
70
70
70
Slide49
BoilerTuningPotentialAnalysis
Theseefficiencyestimatescanbeusedtoestimatethefuelcostimpactassociatedwithtuningtheboiler.Theequationpresentedhereisverysimple;
however,itisarigorousrepresentationoftheeconomicimpactofboilerefficiencychanges.
June28,2010
StackLosses32

Thiscalculationindicatestuningtheboilerhasapotentialofreducingfuelconsumptionmorethan200,000dollarsayear.Tuningthepositioning
controlsofanaturalgasfiredboilerwilltypicallyrequireatechnicianlessthanadaytocomplete.Thetuningactivityisrelativelylowcost.Inother
words,weareveryinterestedintuningthisboiler.
Infact,wedidtunethisboilerandweachievednominally5%oxygeninthecombustionzone.Thecombustiblesconcentrationremainednegligible
throughoutthetuningactivity.Actuallyduringthetuningactivitythecombustionzoneoxygencontentwasreducedtolessthan2%withminimal
increaseincombustiblesconcentration.Anoxygencontentlessthan3%isconsideredoutsidethetypicalrangeforpositioningcontrol.Operatorsatthe
sitewerereluctanttotunetheboilertolessthan5%oxygenbecauseofhistoricallyoperatingathighervalues.
Therefore,wewanttoexaminetheimpactoftransitioningfrompositioningcontroltocontinuousautomaticcontrol.
[SlideVisualImprovedEfficiencySavingsfor5%O 2 inExample]
O savings ={1(n existing /n adjusted )}(K boiler )
Thesavingsisequalto1minustheexistingboilerefficiencydividedbytheadjustedboilerefficiencyadjusted;multipliedbycostsoftheboiler.
O savings ={1(78.8%/80.1%)}13,000,000dollars/year=220,000dollars/year
Thesavings(Sigmasubscriptsavings)isequalto1minusthe78.8%dividedby80.1%;multipliedby13,000,000dollarsperyearequals
220,000dollarsperyear.
June28,2010
StackLosses33

Slide50
FlueGasContentControlParameters
Continuousautomaticcontrolisexpectedtobeabletooperatewithcombustionzoneoxygencontentrangingfrom1.5%to3.0%.Fieldtrialsindicate
theburnerperformswellwithreducedcombustionzoneoxygencontent.Wecancompleteanotheranalysistodeterminetheimpactoftransitioningto
continuousautomaticcontrol.
Fuel
NaturalGas
Number2
FuelOil
Number6
FuelOil
Pulverized
Coal
StokerCoal
AutomaticControl
FlueGasO 2
Content
Min.
Max.
[%]
[%]
1.5
3.0
2.0
3.0
PositioningControl
FlueGasO 2 Content
AutomaticControl
ExcessAir
PositioningControl
ExcessAir
Min.
[%]
3.0
3.0
Max.
[%]
7.0
7.0
Min.
[%]
9
11
Max.
[%]
18
18
Min.
[%]
18
18
Max.
[%]
55
55
2.5
3.5
3.5
8.0
14
21
21
65
2.5
4.0
4.0
7.0
14
25
25
50
3.5
5.0
5.0
8.0
20
32
32
65
June28,2010
StackLosses34

Slide51
StackLossNaturalGas
Theanalysisproceedsexactlylikethetuningcalculations.Thecurrentstacklossis19.9%andtheconservativeestimateoffutureoperationsis18.8%.
StackLossTablefor
NaturalGas
FlueGas
Oxygen
Content
WetBasis[%]
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
ActualExhaustT
[F]
AmbientT[F]
155
13.1
13.2
13.4
13.6
13.8
14.1
14.4
14.7
15.1
15.5
225
180
13.6
13.8
14.0
14.2
14.5
14.8
15.1
15.5
16.0
16.5
250
205
14.1
14.3
14.6
14.8
15.1
15.5
15.9
16.3
16.8
17.4
275
230
14.7
14.9
15.2
15.5
15.8
16.2
16.6
17.1
17.7
18.4
300
255
15.2
15.5
15.8
16.1
16.5
16.9
17.4
17.9
18.6
19.4
325
280
15.8
16.1
16.4
16.7
17.2
17.6
18.1
18.8
19.5
20.3
350
305
16.3
16.6
17.0
17.4
17.8
18.3
18.9
19.6
20.4
21.3
375
330
16.9
17.2
17.6
18.0
18.5
19.1
19.7
20.4
21.2
22.2
400
355
17.4
17.8
18.2
18.7
19.2
19.8
20.5
21.2
22.1
23.2
425
380
18.0
18.4
18.8
19.3
19.9
20.5
21.2
22.1
23.0
24.2
450
405
18.5
18.9
19.4
20.0
20.5
21.2
22.0
22.9
23.9
25.2
475
430
19.1
19.5
20.0
20.6
21.2
22.0
22.8
23.7
24.8
26.1
500
70
70
70
70
70
70
70
70
70
70
70
70
June28,2010
StackLosses35

Slide52
AutomaticCombustionControl
Basedontheoperatingcostofthetunedboilerthesavingsestimateexceeds150,000dollarsayear.
Thissimplifiedanalysisindicatesattractivesavingsopportunitiesassociatedwithtuningtheboilerandwithinstallingacontinuousautomatic
combustioncontroller.Atthistimethecostofinstallingacombustioncontrollerisnotknownbutitisexpectedtorequirelessthan$150,000
warrantingfurtherinvestigation.
450oF70oF=380oFNetStackTemperature
CurrentEfficiency
At7%O 2 ,n=100%21.2%=78.8%
ImprovedEfficiency
At5%O 2 ,n=100%19.9%=80.1%
At3%O 2 ,n=100%18.8%=81.2%
[SlideVisualAdditionalEfficiencySavingsfor3%O 2 inExample]
Slide53
BoilerLossExample
Wehavesetthestrategyforcombustionmanagementforthisboilertunetheexistingboilercombustioncontrols,exploreinstallingcontinuous
automaticcombustioncontrol,andcontinuallychallengethecontrolparameters.
Nowwearereadytoexaminethefluegastemperatureimpacts.Thefluegastemperatureisnominally450F,whichisnotexcessivelyhighbutitis
muchgreaterthantheminimumallowable.
June28,2010
StackLosses36

Slide54
ElevatedFlueGas1
Asweexaminethepossiblereasonsforthecurrentfluegastemperaturewefindthattheboilerwaterqualityismaintainedwellwithinacceptable
ranges,thefuelusedhasminimalpotentialforfouling,andtheboilerisoperatingwithindesignsteamproductionlimits.Theseissuesdonotidentify
anyopportunitiestoallowthefluegastemperaturetobecorrected.
[SlideVisualWatertubeBoiler]
Slide55
ElevatedFlueGas2
Anexaminationoftheoriginaldesigninformationoftheboilerrevealstheboilerwasoriginallydesignedwithafeedwatereconomizer.Inthepastthe
feedwatereconomizerexperiencedsometubefailuresandwasdecommissioned.
[SlideVisualWatertubeBoiler]
June28,2010
StackLosses37

Slide56
FeedwaterEconomizerEvaluation
Installinganewfeedwatereconomizerwillallowustorecoverfluegasthermalenergybypreheatingboilerfeedwater.Anewfeedwatereconomizer
couldbedesignedtoreducethefluegastemperatureto300Forevenless.Thestacklosstablecanbeusedtoestablishanestimateofthefuelsavings
potential.
[GraphicalDescriptionWatertubeBoiler]
June28,2010
StackLosses38

Slide57
StackLossNaturalGas
Thecurrentstacklossis19.9%(wehaveonlytunedtheboiler.Wehavenotinstalledcontinuousautomaticcombustioncontrol).Theeconomizerwill
reducethestacklossto15.8%.
StackLossTablefor
NaturalGas
FlueGas
Oxygen
Content
WetBasis[%]
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
ActualExhaustT
[F]
AmbientT[F]
155
13.1
13.2
13.4
13.6
13.8
14.1
14.4
14.7
15.1
15.5
225
180
13.6
13.8
14.0
14.2
14.5
14.8
15.1
15.5
16.0
16.5
250
205
14.1
14.3
14.6
14.8
15.1
15.5
15.9
16.3
16.8
17.4
275
230
14.7
14.9
15.2
15.5
15.8
16.2
16.6
17.1
17.7
18.4
300
255
15.2
15.5
15.8
16.1
16.5
16.9
17.4
17.9
18.6
19.4
325
280
15.8
16.1
16.4
16.7
17.2
17.6
18.1
18.8
19.5
20.3
350
305
16.3
16.6
17.0
17.4
17.8
18.3
18.9
19.6
20.4
21.3
375
330
16.9
17.2
17.6
18.0
18.5
19.1
19.7
20.4
21.2
22.2
400
355
17.4
17.8
18.2
18.7
19.2
19.8
20.5
21.2
22.1
23.2
425
380
18.0
18.4
18.8
19.3
19.9
20.5
21.2
22.1
23.0
24.2
450
405
18.5
18.9
19.4
20.0
20.5
21.2
22.0
22.9
23.9
25.2
475
430
19.1
19.5
20.0
20.6
21.2
22.0
22.8
23.7
24.8
26.1
500
70
70
70
70
70
70
70
70
70
70
70
70
June28,2010
StackLosses39

ImprovedEfficiencywith5%BoilerTuning
At5%O 2 and380oF,n=100%19.9%=80.1%
FurtherImprovedEfficiencybyAddingFeedwaterEconomizer
300oF70oF=230oFNetStackTemperature
At5%O 2 and230oF,n=100%15.8%=84.2%
Slide58
EconomizerPotentialAnalysis
Theefficiencyimprovementcalculationindicatesthefuelsavingsismorethan600,000dollarsayear.Afeedwatereconomizerisexpectedtorequire
lessthan500,000dollarstopurchaseandinstall.Asaresult,thisprojectisrecommendedtoexplorefurther.
[SlideVisualSavingsCalculation]
Slide59
StackLossReductionSummary
Managingstacklossisacriticalfactorinimprovingboilerefficiency.Significantemphasisshouldbeplacedonmeasuringthecriticalparametersthat
identifyboileroperatingcharacteristics.Challengingfluegastemperature,oxygenvalues,andcombustiblesconcentrationsareallaspectsofboiler
management.
June28,2010
StackLosses40

[SlideVisualStackLossReduction]
Measure,record,andcompare
o Fluegasexittemperature
Andintermediatetemperatures
o Fluegasoxygencontent
o Boilerload
o Ambienttemperature
o Fluegascombustibles
Reducefluegasexittemperature
o Repairfailedcomponents
o Cleanfireside
o Maintainwaterside
o Installheatrecoverycomponents
Feedwatereconomizer
Combustionairpreheater
Reduceexcessair
o Tuneboilercombustionprocess
o Installautomaticcombustioncontrol
o Challengecontrolparameters
June28,2010
StackLosses41
ResourceUtilizationAnalysisModule
Slide1
ResourceUtilizationModule
Intheresourceutilizationsectionofthiscourseweexaminethemanagementactivitiesassociatedwiththevariousenergyresourcesavailabletoasite.
Theseincludefuelselection,steamenduseordemandmanagement,andcombinedheatandpoweractivities.Inthisbroadsectionwewillexaminethe
mainfactorsinfluencingfuelselection.Wewillidentifythevitalimportanceofinvestigatingsteamendusecomponentsandreducingsteam
consumptionorimprovingtheenergyresourceutilizationofthesteamdemands.Wewillintroducetheconceptsrelatedtocombinedheatandpower
operations(alsoknownascogeneration).
[SlideVisualContentsofModuleSections]
ResourceUtilizationAnalysis
FuelSelection
SteamDemands
CombinedHeatandPower
Slide2
FuelSelectionIntro
Wewillbeginourdiscussionsinthefuelselectionarena.
[SlideVisualFuelSelectionTitlePage]
FuelSelection
SteamDemands
ResourceUtilizationAnalysisModule1
June28,2010
Slide3
FuelSelection1
Fuelpurchasestypicallydominatetheoperatingcostofasteamsystem.Ithasbeenpointedoutthatawidevarietyoffuelsareprovidedtoindustrial
facilitiesthroughouttheworld.Fuelselectionrangesfromnaturalgasthroughfueloilstocoalandwoodandmanymorefuels.Theprimarydriving
factorassociatedwithselectingafuelistypicallyenergybasedcost.However,environmentalcosts,maintenancecosts,andequipmentcostsalsoplay
majorrolesinfuelselection.Fuelselectionisnotasimplematter.Itisourintenttointroducethetopicandraiseawarenessitisnotourintentto
exploreallofthemajoraspectsoffuelselection.Itisveryapparentthatinmostcasesaparticularfacilitycannotsimplyswitchfuelstherewillbe
majorequipment,infrastructure,environmental,andmaterialhandlingimpacts.
Onecommonaspectoffuelswitchingistheopportunitytoattainfavorablepricingofaprimaryfuel.Forexample,afacilitymayconsumenaturalgasas
theonlyfuelsuppliedtothesite.Inordertosecurefuelsuppliesthesitemaypurchasenaturalgasatanelevatedcostbecauseinterruptionofservice
wouldbedetrimentaltositeoperations.Ifanalternatefuelcouldbestoredonsiteandcouldservetoprovidebackupserviceifnaturalgaswere
curtailedthenthenaturalgascouldpotentiallybepurchasedatareducedcost.Thisiscommonlyreferredtoasfirmversusinterruptiblepricing.
Wewouldexpectthatswitchingtocoalfromnaturalgaswoulddramaticallyincreasethemaintenanceandoperationsrequirementsofthesteam
generationequipment.Additionally,environmentalequipmentwillmostprobablybesignificantlymoreforcoalcombustion.Regulatoryrequirements
canbeinsurmountableaswell.However,ifafacilityalreadyhasmultifuelcapability;suchas,naturalgasandcoaloroilandwoodtheopportunitiesfor
flexibilityandeffectivemanagementcanbedramatic.Ofteninthesecasesiftheequipmentisalreadyinplacethedifferenceinoperatingand
maintenancecostsmaybeminimalwithrespecttothedifferenceinfuelpurchasecost.
Slide4
FuelSelection2
Thesteamsystemwehavebeeninvestigatingisanexcellentexampleofthemainissuesassociatedwithfuelselection.Asyourecalltheboilerwehave
focusedourattentiononisanaturalgasfiredboiler.Thesiteisequippedwithtwoadditionalboilersonethatburnsgreenwoodandanotherthat
burnsheavyfueloil.Atthispointinourinvestigationtheexampleboilerhasbeenequippedwithafeedwatereconomizer(automaticcombustion
controlhasnotbeeninstalledatthistime).Allthreeboilersareinoperationtoreliablysatisfythesteamdemandsofthesite.Thefueloilfiredboiler
andthegreenwoodfiredboileroperateasabaseloadcomponentsatapproximately2/3load.Operationslikesthisconditionbecausethesefuelsare
moredifficulttohandlethannaturalgas.Thenaturalgasfiredboileriseasiesttooperate;therefore,thesitereliesmostlyonitforloadcontrolandit
carriesalargerportionofthesteamload.
Thefuelsarepurchasedwithsignificantlydifferentcosts$10/106Btunaturalgas,$5/106Btunumber6fueloil,and$2/106Btugreenwood.The
exampleisdesignedtodemonstratetheeconomicincentiveassociatedwithshiftingsteamproductionfromahighcostproducertoalowercost
producer.Aninitialinvestigationisundertakentoidentifytheeconomicincentiveassociatedwithproducingmoresteamfromthefueloilboilerand
lesssteamfromthenaturalgasfiredboiler.
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Inthisexamplewearenotintendingtoeliminateallnaturalgasconsumption.Wearesimplyidentifyingthepotentialimpactassociatedwithimproved
managementoffuelresources.Asaresult,wewillexaminetheimpactassociatedwithshiftingasmallamountofsteamproductionfromthenaturalgas
boilertotheoilboiler.Thiscaneasilybeaccomplishedbysimplyincreasingthefuelsupplytotheoilfiredboiler.Asaninitialinvestigationofthesize
oftheopportunitywewillassumeaverysmallamountofsteamproductionwillbeshiftedfromthenaturalgasboilertotheoilboiler1,000lb/hr.
[SlideVisualThreeBoilers]
Fuel:GreenWood
Fuelcost:$2.00/106Btu
Boilercapacity:120,000lbm/hr
Steamproduction:80,000lbm/hr
FluegasexitT:400F
Fluegasoxygen:5.0%
Efficiency:~71.3%
Fuel:Naturalgas
FluegasexitT:300F
Fluegasoxygen:5.0%
Efficiency:~84.2%
Fuel:Number6oilHS
FluegasexitT:350F
Fluegasoxygen:5.0%
Efficiency:~87.4%
June28,2010
Slide5
FuelSelectionCalculation
Thesavingscalculationsaresimple.Theanalysisdeterminesthefuelcostassociatedwithgenerating1,000lb/hrofsteamfromthenaturalgasfired
boilerandcomparesthistothecostofgeneratingthesameamountofsteamfromtheoilfiredboiler.Thedifferencebetweentheseoperatingcostsis
thesavingsopportunity.Intheanalysis1,000lb/hrofsteamisthetargetamountbecausethisisaneasilyscaleablevalue.Itshouldalsobenotedthat
thesteamenergyisthesameforanyoftheboilersinthisexample(samefeedwater,sameblowdownrate,samesteamdischargepressure,samesteam
dischargetemperature).Asaresult,thesavingscalculationisrelativelysimple.
Thecalculationsindicatethatforevery1,000lb/hrofsteamproductionthatcanbetransferredfromthenaturalgasboilertotheoilboilersavingsof
$62,000/yrwillresult.If10,000lbm/hrcouldbetransferredthesavingswouldbe10timestheamountandbasedontheoperatingconditions,it
appearsthisamountofsteamproductioncouldbeshifted.
[SlideVisualFuelSelectionCalculation]
Savingsfromfuelswitching=O=InitialoperatingcostFinaloperatingcost
O=(K 1 K 2 )={(E steam /N 1 )(K fuel1 )} {(E steam /N 2 )(K fuel2 )}t=E steam {(K fuel1 /N 1 )(K fuel2 /N 2 )}t
O=m steam (h steam h fw ){(K fuel1 /N 1 )(K fuel2 /N 2 )}t
O=1,000lbm/hr(1,361.88Btu/lbm210.42Btu/lbm){{(10.0)($/106Btu)}/(0.842){(5.00)($/106Btu)}/(0.874)}}(8,760hrs/yr)
O=62,000$/yr
Abbreviations
O=InitialOperatingCosts
E=VolumeflowofFuelperHour
N=Efficiency
Slide6
FuelSelection
Ofcourse,themosteconomicallyattractiveoperatingconditionistomaximizesteamproductionfromthelowestcostproducerandsteamproduction
fromthehighestcostproducershouldbeminimized.Theoretically,thelowestcostoperationwouldhavethenaturalgasfiredboileroperatingasthe
June28,2010
variableloadboilerandtheotherboilersatmaximumload.However,everyboiler(everyburner)hasaminimumstableload.Also,operatingaboilerat
fullloadcanshortenthelifeofinternalcomponents.Asaresult,therearerealworldlimitationsontheallowableoperatingconditionsfortheboilers.
Basedonthis,themostpracticaloperatingconditioncouldbetohavethenaturalgasboilerproducingminimumsteamproduction(40,000lbm/hrfor
example),operatethegreenwoodboileratthemaximumpracticalload(105,000lbm/hrforexample),andallowtheoilboilertorespondtomoderate
changesinsteamdemand.Theexamplecontinueswiththisconcept(transferringsteamproductiontothewoodfiredboiler.
Fuel:GreenWood
Efficiency:~71.3%
Fuel:Naturalgas
Efficiency:~84.2%
Fuel:Number6oilHS
Efficiency:~87.4%
Slide7
FuelSelectionCalculation
Increasingsteamproductionfromthewoodfiredboilermayhavesomemaintenanceconsequencesthatshouldbeincludedintheanalysis.Minimal
changesinsteamproductionarenotexpectedtoinfluencemaintenancerequirements.
June28,2010
[SlideVisualFuelSwitchingEquationsIncreaseinSteamProduction]
Savingsfromfuelswitching=O=InitialoperatingcostFinaloperatingcost
O=(K 1 K 2 )={(E steam /N 1 )(K fuel1 )} {(E steam /N 2 )(K fuel2 )}t=E steam {(K fuel1 /N 1 )(K fuel2 /N 2 )}t
O=m steam (h steam h fw ){(K fuel1 /N 1 )(K fuel2 /N 2 )}t
O=1,000lbm/hr(1,361.88Btu/lbm210.42Btu/lbm){{(10.0)($/106Btu)}/(0.824){(2.00)($/106Btu)}/(0.713)}}(8,760hrs/yr)
O=91,000$/yr
Abbreviations
O=InitialOperatingCosts
E=VolumeflowofFuelperHour
N=Efficiency
Ifthegreenwoodboilerloadisincreasedby25,000lb/hrbyreducingthesteamproductionofthenaturalgasfiredboilerthesavingswillbenominally
$2,275,000/yr.
Slide8
FuelSelection
Itshouldbenotedthatoftenwhenexaminingmultifuelsitesacombinedfuelcostisdevelopedbasedontheaverageorblendedfuelcost.Thisisoftena
poorrepresentationofthetrueeconomicimpacttoasite.Considerourexample,theblendedfuelcostwouldbenear$5.5/106Btu.Oftenthisfuelcost
wouldbeusedtodeterminetheeconomicimpactassociatedwithvarioussteamsystemmodifications.However,iftypicalsteamdemandchangeswere
controlledbytheoutputofthenaturalgasboilerthentheactualimpactfuelcostwouldbe$10/106Btuafargreatertrueimpact.Alternately,ifthe
naturalgasboilerisroutinelyoperatedatminimumfireandtheoilboilerrespondstochangesinsteamdemandthentheappropriateimpactfuelcost
wouldbe$5.0/106Btu.
June28,2010
[SlideVisualFuelSwitchingIssues]
Manyissueslimitfuelswitchingcapabilities.
Environmentalregulations.
Fuelstorageandhandlingissues.
Boilercapabilities.
Howshouldmultifuelsitesbeoperatedandmodeled?
Impactfuelcostshouldbeutilized.
Theimpactfuelisthefuelthatwillchangeconsumptionifsteamdemandchanges.
Typicallythehighestcostfuelinuseisdesiredtobetheimpactfuel.
Blendedcostsgenerallydonotreflectactualsystemchanges
Slide9
SteamDemandsIntro
[SlideVisualSteamDemandsTitlePage]
FuelSelection
SteamDemands
Slide10
SteamDemand
Thetypesofsteamconsumersareverydiverseandthemethodsappliedtoimproveperformancevarysignificantly.Asaresult,wewillexaminea
simpleandverycommonsteamdemand.Wewilltargetcommonavenuesusedtoreducesteamconsumptionanddemonstratethemethodsusedto
identifytheeconomicimpactofthechanges.
Slide11
ExampleSteamDemand1
Thesteamendusesystemselectedforinvestigationisasimpleairhandlingunitwithasteamcoilusedtoheattheairfrom40Fto120F.Theairis
heatedbylowpressure(20psig)saturatedsteam.Outside,ambienttemperature,airisdrawnintotheheatexchanger,isheatedto120F,andisthen
deliveredintotheprocessunit.
June28,2010
[SlideVisualSteamDemand]
Afanrepresentedbyacircle/squarecombinationsuppliesairflowat10,000standardcubicfeetperminairat40degreesFahrenheit(notedas
T i )andthreegreenarrowsleadingfromaconeshapedducttransitiontoalengthofhorizontalrectangularduct.Insidetherectangularduct
section,threeverticalwhitelineswithacircleatthetopandbottomofeachlinerepresentasteamcoilwhichisjoinedataheaderatthetopof
thesteamcoil,outsidetherectangularduct.Awhitearrowleadstotheheaderindicating20psigsaturatedsteamsupplyatthesteamcoilinlet.
Thebottomofthesteamcoilhasasteamtrap(representedasarectanglewithaTandcircleinside)foreachofthethreecoilpasses.
Thesteamtrapsschematicallydelivercondensatefromthebottomtoaheaderleadingawayfromtheductworkwithawhitearrow.Itisnoted
that20psigsaturatedliquidcondensateentersthesteamtraps.
Theairflowthatisheatedfromthesteamcoilisrepresentedbythreeredhorizontalarrowsandisat120degreesFahrenheit(notedasT c ).
Slide12
ExampleSteamDemand2
Veryoftenflowmetersarenotinplacetoallowdirectevaluationoftheendusecomponents.Inordertodeterminetheamountofenergycurrently
usedbytheairhandlingunitsomefieldmeasurementsarerequired.Asteamflowmetercouldbeinstalledtomeasurethesteamdemand.Alternatelya
condensateflowmetercouldbeinstalledorthecondensatecouldbecollectedinaknownvolumeoverameasuredtimeperiodtodeterminethepoint
intimecondensateflow.OftenitisrelativelyeasytouseaflowmeasuringdevicelikeaPitottubeorinsertionanemometertypeofdevicetomeasure
theairflowratethroughthesystem.Iftheairflowisknownalongwiththetemperatureriseoftheairthroughtheheatexchangerthenthefirstlawof
thermodynamicscanbeappliedtotheairflowtocalculatetheenergyrequiredtobesuppliedfromthesteam.Inthiscaseapproximately850,000
Btu/hrofthermalenergymustbesuppliedfromthesteamtotheair.Thistranslatesintomorethan900lb/hrofsteamdemand,whichisarelatively
smallsteamdemand;however,theimpactcostofsteamsuppliedtoenduseequipmentatthissiteisapproximately$15/103lb.Asaresult,thissteam
demandrequiresalmost$120,000/yroffuelpurchases.
June28,2010
[SlideVisualBoilerEquations]
Q air =M air (C p ) air (T e T i ) air
Q air =10,000(stdft3/min)(0.074(lbm/stdft3)(0.24(Btu/lbmR)(120F40F)(60min/1hour)
Q air =854,200Btu/hr
Abbreviations
Q
=Quantityofenergy,BTUperhour
mdot
=Massflowofthesubstance,standardcubicfeetperminute
c p
=Specificheatcapacityofthesubstance,lbm/hr
(TeTi) =Temperaturedifferenceinthesubstanceexitingandentering(Fahrenheit)
Slide13
ExampleSteamDemand3
Aninvestigationoftheendusesystemindicatedthatwarmairfromtheprocesswasbeingexhausteddirectlytotheatmosphereatmorethan65F.
Thisaircanbereintroducedtothefanratherthanintroducingambientairat40F.Supplying65Fairtotheheatexchangerwillreducethesteam
demandbyapproximately250lb/hr,whichtranslatesintomorethan$34,000/yroffuelsavings.Thisisaverysimpleexamplebutitdemonstratesthe
significantimpactsteamendusemanagementcanpresent.
Inthisformula,QequalsquantityofenergyinBTU'sperhour,mequalsMassofthesubstance,CPequalsSpecificheatcapacityofthesubstance,and(TE
TI)equalsTemperaturedifferenceinthesubstance(Fahrenheit).Ourresultis587,300BTUsperhour.
June28,2010
[SlideVisualBoilerEquations]
Q air =M air (C p ) air (T e T i ) air
Q air =10,000(stdft3/min)(0.074(lbm/stdft3)(0.24(Btu/lbmR)(120F65F)(60min/1hour)
Q air =587,300Btu/hr
Abbreviations
Q
=Quantityofenergy,BTUperhour
mdot
=Massflowofthesubstance,standardcubicfeetperminute
c p
=Specificheatcapacityofthesubstance,lbm/hr
(TeTi) =Temperaturedifferenceinthesubstanceexitingandentering(Fahrenheit)
Slide14
CombinedHeatandPowerIntro
[SlideVisualCombinedHeatandPowerTitlePage]
FuelSelection
SteamDemands
Combinedheatandpower,orcogeneration,isanextremelycommonaspectofindustrialfacilities.Therearealargenumberofcogenerationfacilitiesin
thecountry.Theavenueofcogenerationthatwewillbrieflyinvestigateisthemostcommonformofcogenerationintheindustrialarena.Typically,in
theindustrialarena,cogenerationtakestheformofconvertingfuelenergyintosteaminaboiler,thenutilizingasteamturbinetoconvertsteamenergy
intoelectricalpowerorsimplyshaftpower.
June28,2010
Slide15
Cogeneration
Thisstrategyplacestheindustrialcogenerationcomplexincompetitionwithutilitycompanies(theelectricalgenerators).So,itisusefultoexplorethe
methodsutilitiesusetogenerateelectricalpowertoidentifyanyadvantagesordisadvantagesthatmayexist.
Itisinterestingtonotethatmanypeopleassociatecogenerationwithgasturbines.Whilegasturbinescanserveincogenerationsystemstheyareonly
onepotentialcogenerationarrangement.Infact,themajorityofcogenerationsystemsconsistofconventionalboilersandsteamturbines.
Overwhelmingly,utilitiesproduceelectricitythroughthegenerationofsteam.Almost80percentoftheelectricitygeneratedintheU.S.isgeneratedby
steam.Almost60percentoftheelectricalpowerisproducedbyburningaconventionalfuelinaboilertogeneratesteamthatispassedthrougha
steamturbineconnectedtoanelectricalgenerator.
[SlideVisualCombinedHeatandPowerCogeneration]
AredarrowdepictsthefuelinputtotheHighPressureandHighTemperatureBoiler.Steamproducedfromtheboilerisdeliveredtoasteam
turbine/generator,withthesteamsectiondepictedasaconeshapefigure.Steamschematicallyleavesthesteamsectionoftheturbineatthe
bottom.Athickwhitelinetotherightofthesteamturbineleadingtotherectangleshapeofthegenerator,istheshaft.Aredarrowleavesthe
generatorsection,indicatingElectricalPowerExport.
Thesteamschematicallyleavingthebottomofthesteamturbineentersaheatexchangerdepictedasacirclewitharedzigzagarrowthroughit.
Condensateleavestheheatexchangeratthebottomandapump,depictedasacircle/squarecombination,returnsthecondensatetothetopof
theboiler.
Slide16
SimplifiedUtilityPowerStation1
Morethan50percentoftheelectricalpowerisproducedbycoalfiredboilersgeneratingsteamthatispassedthroughturbines.Therefore,lets
examineatypicalcoalfiredpowerplant.
June28,2010
theboiler.
Slide17
Wehavealreadyidentifiedthefactthatcoalwillburninaboilerwithexcellentefficiencyespeciallyiftheboileriswellequippedwithenergyrecovery
components.Atypicalcoalfiredutilityboilerwilloperatewithanefficiencynearandevengreaterthan90percent.Thesteamturbineusedtoconvert
thermalenergyinthesteamintoshaftpowerwillconvertmorethan85percentofthemaximumtheoreticalvalue.Inotherwords,thepowerplant
turbinewillbe85percentofperfect.Thegeneratorthatconvertsshaftpowertoelectricalpowerwillonlylose1percentintheconversionprocessan
efficiencyof99percent.
theboiler.
Slide18
Thefundamentalquestiontoposetoatypicalpowergenerationstationishowmuchfuelenergyisconvertedintoelectricalenergy?
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theboiler.
Slide19
Evenwithallofthesesuperbefficiencies,welldesignedcomponents,andinherentadvantages,thefueltopowerconversionefficiencyislessthan40
percent.Theprimaryreasonforthispoorperformanceisthefactthateventhoughtheturbineisnearlyperfectinconvertingthermalenergyintoshaft
energy,alargeamountofthermalenergyisleftinthesteamthatexitstheturbine.
theboiler.
Slide20
Steamturbinescanbethoughtofasremovingaportionofthethermalenergyfromthesteamandconvertingthatthermalenergyintoshaftenergy.For
almostallrealturbinesnearlyallofthethermalenergyremovedfromthesteamisconvertedintoshaftenergythelossesarealmostzero.The
problemdevelopsfromthefactthattheturbineisnotabletoremoveallofthethermalenergyinthesteamfortheconversiontoshaftpower.
Restatingessentially100percentofthethermalenergyextractedfromthesteamisconvertedtoshaftpower;however,notallofthethermalenergy
inthesteamisextracted.Infact,forallturbinesthemajorityofthethermalenergyintheinletsteamremainsintheexhauststeam.
Thesteamleavingmostutilitysteamturbineswillhaveatemperaturethatislessthan100Fahrenheitandapressurethatisnearaperfectvacuum.
Eventhoughthesteamtemperatureisverylowthereremainsatremendousamountofenergyinthesteam.Thepowerplantdoesnothaveaneedfor
thislowtemperaturethermalenergy.Asaresult,thethermalenergyisrejectedtotheambient,servingnousefulpurposeotherthantocondensethe
steamtheexhauststeamenergyisrejectedtotheenvironmentunused.Asaresult,atypicalpowerplantmayconvertonly38percentofthefuel
energyintoelectricalpower.
June28,2010
theboiler.
Slide21
Thesteamdischargedfromtheturbineisrelativelylowtemperatureandverylowpressurebutitcontainsahugeamountofthermalenergy
approximately50percentofthefuelinputenergy.Wedonothaveanymechanismthatcanconvertthislowgradethermalenergyintoshaftpower;asa
result,wecondensethesteamtoallowcondensatetobepumpedtohighpressureasreturnwaterfortheboiler.Atypicalutilitypowerplantwill
discharge50percentofthefuelenergytothecondenser.Theboilerstacklosswillbenominally10percentofthefuelenergy,leaving40percentofthe
fuelenergytobeconvertedintoelectricity.
Thecondenserisalargeheatexchangeroftencooledwithriverwater,whichisoneoftheprimaryreasonspowerplantsaretypicallylocatedonrivers.
Inthisformula,NequalsEfficiency,WequalsFuelOutputEnergy,andEequalsFuelCost.Ourresultisanoverallefficiencyof35percent.Whyisthisso
low?
[SlideVisualSimpleUtilityPowerStation]
AredarrowdepictsthefuelinputtotheHighPressureandHighTemperatureBoiler.Anoteindicatestheboileris90%efficient.Steam
producedfromtheboilerisdeliveredtoasteamturbine/generator,withthesteamsectiondepictedasaconeshapefigure.Steam
schematicallyleavesthesteamsectionoftheturbineatthebottom.Athickwhitelinetotherightofthesteamturbineleadingtotherectangle
shapeofthegenerator,istheshaft.Aredarrowleavesthegeneratorsection,indicatingElectricalPowerExport.Notesindicatetheturbineis
85%efficientandthegeneratoris99%efficient.
theboiler.
June28,2010
AnoteindicatestheOverallSystemEfficiencyis35%;modifiedcyclescanattain42%efficiency.
Whyistheefficiencythislow?
n=W electrical /E fuel
n=Efficiency
W=FuelOutputEnergy
E=FuelCost
Slide22
IndustrialPowerStation1
Inorderforanindustrialfacilitytoparticipateincombinedheatandpoweractivitiestheremustbesomeadvantagethatcanbeexploited.Arethe
performancecharacteristicsoftheindividualpowerplantcomponentsdramaticallybetterthanatypicalutilitiespowerplant?
theboiler.
Slide23
Mostindustrialplantswillnothaveequipmentthatisasefficientastheutilitypowerstations.Inmanycasesindustrialboilerswillnotbeequipped
withsomeoftheenergyrecoveryandcombustionmanagementcomponentstheutilitiesboilerwillbeequippedwith.Veryoftenindustrialsiteswillbe
burningfuelsresultinginlowerefficiencythancoalandusuallythefuelcostismuchhigherthancoal.Theturbinesandgeneratorsoftheindustrial
sitewillgenerallynotbeasefficientasthepowerplantcomponents.Asaresult,industrialplantcogenerationappearstobeapoorproposition.
June28,2010
However,thegreatadvantageindustrialfacilitieshaveoverutilitypowerstationsisthattheindustrialplanthasaneedforthermalenergyaswellas
shaftpower.Theindustrialplantcanmakeuseofthethermalenergyinthesteamdischargedfromtheturbine.
theboiler.
Slide24
Infact,industrialplantswilloperateturbineswithelevateddischargepressurethatallowsasignificantamountofthermalenergytobeexportedtothe
processunits.Thisprovidesindustrialplantswithadistinctadvantagethatallowscogenerationsystemstobeverycompetitive.Industrialplantscan
enjoyenergyconversionefficienciesapproaching70%whichisadramaticimprovementoverutilitypowerstationsoperatingat40%efficiency.
theboiler.
Slide25
DistrictHeatingUtilityPowerStation
Itisgoodtonotethatutilitypowerstationslocatedwithincitiescantakesignificantadvantageofthissameconceptbyexhaustingsteamfromtheir
powergenerationturbinestoprovidebuildingheat.Theseareidentifiedasdistrictheatingsystems.
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theboiler.
Slide26
SteamTurbines1
Ageneralunderstandingofsteamturbineoperationisrequiredtoexamineboilersteamturbinecogenerationsystems.Steamturbinestakethermal
energyfromthesteamandconvertitintomechanicalenergy.
[SlideVisualSteamTurbines]
Theschematicshowsasinglestagebackpressuresteamturbine.
Itreceiveshighpressuresteamandexhaustslowpressuresteamthroughthepoweroftheshaft.
Typically,steamturbinesoperatewithhighpressuresteampassingthroughanozzlethatincreasesthevelocityofthesteamandfocusestheflowpath
intoajetofsteam.Thishighvelocityjetofsteamisdirectedtostrikeablade.Thebladeisarrangedsuchthatthesteamjetwilltransferitsenergyintoa
forceontheblade.Thebladeismountedonashaftthatisfreetorotate.Asaresulttheforceonthebladeisconvertedintoshafttorqueandshaft
rotation.
June28,2010
Slide27
SteamTurbines2
Steamturbinesareequippedwithastationaryoutershellandarotatinginnershaft.Theoutershellconfinesthesteamandservesastheanchorforthe
nozzlesandallofthestationaryparts.Therotatingshaftisequippedwiththeturbinebladesandservestocollectandtransferthemechanicalpower
fromtheturbine.
Steamturbinesreceivehighpressuresteamanddischargelowpressuresteam.Theinletsteamispassedthroughaflowcontrolvalveandontothe
stationarynozzles.Thenozzlesincreasethevelocityofthesteamandchannelitintheproperdirectiontostriketherotatingturbineblades.Thesteam
presentsaforceonthebladeasthebladecatchesandturnsthesteam.Becausethebladeismountedtoashaftthatisfreetorotate,theforceresultsin
therotationoftheshaft.Manybladesaremountedonasinglewheelthatisinturnmountedtotheshaft.Thenozzle,blade,andshaftarrangementis
suchthatasablademovesoutofthejetofsteamleavinganozzle,anotherblademovesintothejet.
Aturbinecanbedesignedwithasinglewheelofbladesormultiplewheelsonthesameshaft.Asinglenozzlecandirectsteamtoawheelorseveral
nozzlescandirectsteamtosegmentsofasinglewheel.Ifaturbinehasmultiplerowsofbladesitwillalsobeequippedwithmultiplerowsofnozzles.
Thenozzleswillservetocollectthesteamfromtheupstreamblades,increasethevelocityofthesteam,channelthesteamintoafocusedjet,anddirect
thesteamtotheblades.Thisnozzleblade,nozzlebladearrangementcontinuesuntilthesteamexitstheturbinecasing.
Slide28
SteamTurbineTypes
Allsteamturbinesreceivehighpressuresteamanddischargelowpressuresteam.Steamturbinesusestationarynozzlesandrotatingbladestoconvert
thermalenergyintomechanicalenergy.Thereareseveraldescriptorsthatidentifysomeofthemaincharacteristicsofturbines.
Slide29
BackpressureSteamTurbines
Atoppingturbineexhaustssteamwithapressurethatisaboveatmosphericpressure.Toppingturbinesarealsoknownasbackpressureturbinesand
noncondensingturbines.
June28,2010
[SlideVisualBackpressureSteamTurbines]
Theschematicshowsasinglestagebackpressuresteamturbineandamultistageturbine.
Thesinglestagehasastopvalve,overspeedtripvalve,andahandvalve.Steamentersthroughthestopvalve,andthepoweroftheshaft
causesittooutputsteamthroughonestage.
Themultistagehasthesamecomponents,exceptthesteamtravelsthroughseveralstagesbeforeitisoutput.
Slide30
ExtractionSteamTurbines
Anextractionturbineissimplyaturbinewithmorethanoneoutlet.Thinkofamultistageturbinewiththelowpressuresteamoutletafterthelastset
ofnozzlesandblades.Thenconsiderplacinganotheroutletintheturbinecasingthatisbetweentwosetsofnozzlesandblades.Recall,assteampasses
throughasetofnozzlesandbladespressuredrops.Asaresult,thisoutletthatisbetweenthenozzlesandbladeswillbeabletodischargesteamwith
anintermediatepressure.Steamcanbepulledout(extracted)fromtheturbinebeforethefinalturbineoutlet.
Extractionturbinescanalsobethoughtofastwoturbinesonthesameshaft.
Ifaturbinehasmorethanoneintermediateoutletitisknownasamultipleextractionturbine.
Slide31
CondensingSteamTurbines
Acondensingturbinealsoexhaustssteam,butitdoessowithapressurebelowatmosphericpressure.Becausethesteampressureisbelowatmospheric
pressure,itmustbecondensedtobepumpedoutoftheturbine.Asyouknow,steamflowsfromhighpressuretolowpressurewhenthesteam
pressureisbelowatmosphericpressurethereisnomotiveforcetocausethesteamtoflowoutoftheturbine.Asaresult,thesteamiscondensedand
pumped.Veryoftenthethermalenergyinthesteamexitingacondensingturbineisrejectedtotheenvironmentandnousefulbenefitisgained.The
thermodynamicqualityofthesteamexitingacondensingsteamturbineistypicallygreaterthan90percentandissometimessuperheated.An
June28,2010
extractioncondensingturbineisaturbinewithonedischargeatanintermediatesteampressureandanotherdischargebelowatmosphericpressure.
Thistypeofturbineisdesignedtobalancesteamdemandswithpowerdemands.
[SlideVisualCondensingSteamTurbines]
Theschematicshowsasteamturbine,condensingsteambeforeitisexhaustedoutoftheboiler.
Slide32
FirstLawofThermodynamics
Whenthefirstlawofthermodynamicsisappliedtosteamturbines,asimplerelationshipdevelopsthethermalenergyextractedfromthesteamis
convertedintoshaftpower.Thedevelopmentpresentedhereisforsteadystate,steadyflowconditions.Thethermalenergyextractedfromthesteamis
identifiedasthechangeinenthalpyofthesteamasitpassesthroughtheturbine.
[SlideVisualFirstLawofThermodynamicsforTurbines]
W shaft =m steam (h i h e ) steam
Inthisformula,WequalsSteamOutputfromtheShaft,mequalsMassflowrateofthesteam,and(hihe)equalsthechangeinenthalpyofthe
steamasitpassesthroughtheturbine.
Abbreviations
W=SteamOutputfromtheShaft
m=Massflowrateofthesteam
(hihe)=enthalpydifference
Steamturbinesareexcellentatconvertingthermalenergyintoshaftenergy.Moststeamturbinesonlyexperienceminorlosses,whichincludesteam
leakagethroughtheshaftseals,heattransferlossfromtheturbinesurface,andbearingfriction.Theselossestypicallyamounttolessthan5percentof
thethermalenergythatisremovedfromtheinletsteamveryoften,thislossislessthan2percentofthethermalenergy.
Slide33
TurbineFirstLawEfficiency
Recall,oneofthemostimportantinvestigationtoolsusedinboilerinvestigationsisboilerefficiency.Boilerefficiencyinvestigationsarebasedonan
energybalancefocusedontheboiler.Typically,asignificantamountofusefulinformationisnotobtainedwhenanenergybalanceinvestigationis
focusedonasteamturbine.Thisistheresultbecausesteamturbineenergylossesaremostcommonlyminimal.
June28,2010
[SlideVisualTurbineFirstLawEfficiency]
n firstlaw =W shaft /{m steam (h i h e )}=100%
Abbreviations
n=efficiency
(hihe)=enthalpydifference
Eventhoughtheselossesareminor,acomparisonoftheperformancecharacteristicsofsteamturbinesindicatesawiderangeofconditions.For
example,twoturbinesoperatinginthesamesteamsystem,betweenthesamesteampressures,andwiththesamesteamflowrate,candemonstrate
thatoneunitwillproducethreetimesthepoweroftheotherunit.Asaresult,adifferentbasismustbeusedtoevaluateturbines.
Slide34
PerfectTurbine
Forturbines,amoreusefulcomparisonistocomparetherealturbinetoaperfectturbine.Asyouknow,thefirstandsecondlawsof
thermodynamicsarethefoundationalprinciplesofallphysics.Thefirstlawofthermodynamicsstatedsimplyismassandenergyisneithercreated
nordestroyeditcanonlychangeforms.Thesecondlawofthermodynamicsisoftenthoughttobemoredifficulttounderstandbutitcanbethought
ofasanenergyconversionlimit.Thesecondlawofthermodynamicsindicatesthatprocesses(realortheoretical)canconvertpowerfullyandtotally
intoheat;however,heatcannotbeconvertedtotallyintopower.
Considerastandardautomobile.Powerisgeneratedintheengineandisconvertedintomotionthevelocityofthecar.Thepoweroftheengineisfully
andtotallyconvertedintoheatwhenthecarstopsatastoplightasthebrakesareappliedandthebrakerotorsheat.However,noprocess,realor
theoretical,couldconverttheheatinthebrakerotorsbackintothesameamountofpoweroriginallyproducedbytheengine.But,thesecondlawof
thermodynamicscanidentifythemaximumamountofpowerthatcanbeproducedfromaheatsource.
Inotherwords,wecanusethesecondlawofthermodynamicstoidentifythetheoreticalmaximumamountofpowerthatcouldbeproducedbya
perfectturbinefromaknownamountofsteamenergy.Ourrealturbinecanthenbecomparedtothistheoreticalperfectturbine.
Whenthefirstandsecondlawsofthermodynamicsarecombinedintheevaluationofasteamturbine,theconceptofaperfectturbineisdefined.The
lawsofphysicsdictatethataperfectturbinewillconvertthemaximumamountofthermalenergyintoshaftenergy.Asaresult,wecanmeasurethe
poweroutputofourrealturbineandcomparethatmeasuredamounttothetheoreticalmaximumamountofoutputpowerpossible.Thisevaluation
techniquewillidentifyhowclosetoperfectourrealturbineis.
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Whenthesecondlawofthermodynamicsisappliedtoaturbine,itidentifiesthatthesteampassingthroughaperfectturbinewouldexperienceno
changeinentropy.Entropyisathermodynamicpropertyofsteamsimilartoenthalpy.Entropyandenthalpypropertiesareobtainedfrom
measurementsandthermophysicalpropertydatasets(likesteamtables).Constantentropyisidentifiedwiththetermisentropic.Weusetheconceptof
theperfectturbineandthefactthataperfectturbinewouldoperateisentropically,toestablishtheefficiencyevaluationmethodologyforaturbine.
Turbineefficiencyisalsocalledisentropicefficiency.
Slide35
IsentropicEfficiency
Isentropicefficiencyistheactualpowerproducedfromarealturbinecomparedtothepowerthatwouldbeproducedfromaperfectturbine.Thefirst
lawofthermodynamicsindicatesthepowerproducedfromaturbineisthesteamflowratemultipliedbythechangeinenthalpyofthesteampassing
throughtheturbine.
Foralargenumberofturbines,onlyfourmeasurementsareneededtoestablishisentropicefficiency:thepressureandtemperatureofthesteam
enteringtherealturbine,andthepressureandtemperatureofthesteamexitingtherealturbine.Thesefourmeasurementsareofteneasilyobtained
andtheinstrumentationisneitherexpensivenorelaborate.Steampropertydataisobtainedbasedontheinletandexitsteammeasurements.Inthis
formula,etaequalsEfficiency,mdotequalsMassflowrateofthesteam,and(hInlethExit)=Inletsteamminusexitsteam.
[SlideVisualIsentropicEfficiency]
n isentropic =ActualWork/IsentropicWork=W actual /W isentropic
n isentropic ={m steam (h inlet h exit )} actual /{m steam (h inlet h exit )} isentropic =(h i h e ) actual /(h i h e ) isentropic
Abbreviations
n=efficiency
(h inlet h exit )=enthalpydifference,actualorisentropic
June28,2010
Slide36
SteamTurbineEfficiency
Itshouldbeunderstoodthatasteamturbinewithlowefficiencyisnotthesameasaboilerwithlowefficiency.Aboilerwithlowefficiencyindicatesa
largeamountoffuelenergyislost(unrecoverable).Asteamturbinewithlowisentropicefficiencymerelyindicatesthatmostofthethermalenergy
originallyinthesteamhasremainedinthesteamthatisexhaustedfromtheturbine.Ifthesteamthermalenergyisusedthenthefuelenergyisnotlost.
Slide37
TypicalSteamTurbineEfficiency
Theisentropicefficiencyofatypicalsteamturbinecanbelowerthan15%andhigherthan85%.Thisisaverybroadrange.Theefficiencycanbea
resultofthebasedesigncharacteristicsofthesteamturbine,thecontrolmechanismandloading,orfailedcomponents.Isentropicefficiencyisacritical
toolusedtoevaluatecogenerationsteamsystems.
[SlideVisualTypicalSteamTurbineEfficiency]
n isentropic =(h in h out ) actual /(h in h out ) isentropic =15%to85%
Theisentropicefficiencyisequaltothedifferenceintheenthalpyoftheinletandoutletconditionsoftheactualturbinedividedbythe
differenceintheenthalpyoftheinletandoutletconditionsoftheisentropicturbine.
Abbreviations
n=efficiency
h in =Steaminputenthalpy
h out =Steamoutputenthalpy
June28,2010
Slide38
SteamTurbines
Typically,asinglestagesteamturbinewillhavelowerefficiencythanacomparablemultistageturbine;however,thereareexceptionstothis.
Generally,singlestageturbinesareusedforsituationswithlowerpoweroutputgenerallylessthan1,000kW.Usually,theirisentropicefficiencywill
notexceed45percent.Isentropicefficiencyofmultistageturbinescanapproach90percent.
Themultistagehasthesamecomponents,exceptthesteamtravelsthroughseveralstagesbeforeitisoutput.
Slide39
BackpressureTurbinePerformance
Steamturbinesoperatewithminimallosses.Asaresult,aslongasthesteamthermalenergyexitingthebackpressureturbineisbeingusedforagood
purpose,thenshaftpowerisgeneratedbasicallyatthecostoffueldividedbyboilerefficiency.Thisisaveryimportantfactindicatingthereason
turbinesaresowidelyusedturbinescanbeverycosteffective.
Thetableindicatesthegeneraleconomicimpactassociatedwithoperatingabackpressureturbinewithvariousfuelcosts.Forexample,iffuelcostis2
dollarspermillionBTU,abackpressureturbinewillgeneratepowerwithanimpactcostof8dollarsand50centspermegawatthour.Ifourpurchased
electricityis50dollarspermegawatthour,thenconsiderablesavingsisachievedbyoperatingtheturbine.Asthetableindicates,backpressuresteam
turbinescanprovideeconomicallyattractiveoperationoverawiderangeofsiteconditions.
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[SlideVisualBackpressureTurbinePerformance]
FuelCost
[$/10Btu]
BoilerEfficiency
[%]
2.00
4.00
6.00
8.00
10.00
12.00
14.00
16.00
18.00
80.00
80.00
80.00
80.00
80.00
80.00
80.00
80.00
80.00
BackpressureTurbine
PowerImpact
($/MWH)
8.5
17.1
25.6
34.1
42.7
51.2
59.7
68.3
76.8
Slide40
BackpressureTurbineEconomics
Aclassicquestionconcerningsteamturbinesis,Whatistheeconomicbenefitofpassingsteamthroughaturbinetoalowpressuredemand,as
comparedtopassingsteamthroughapressurereducingvalve?
[SlideVisualBackpressureTurbineEconomics]
theboiler.
Wewillbrieflyexploretheprimarypointsofthefocusofthisquestion.
June28,2010
Slide41
PrimaryFactors
The2dominantparametersindecidingtheanswertothisquestionareimpactelectricalcostandimpactfuelcost.Steamturbineisentropicefficiency,
boilerefficiency,andsteamdemandarefactorsofconcernbutenergycostsarethedominantfactors.
[SlideVisualPrimaryFactors]
Theprimaryfactorsimpactingtheanalysisare:
Impactelectricalcost
Impactfuelcost
Boilerefficiency
Steamturbineefficiency
Steamdemand
Slide42
ImpactCosts
Itiscriticaltoproperlyestablishthefuelandelectricalimpactcostsbecauseallotherfactorsaresecondary.Weareusingthetermimpactcostsbecause
inevaluatingtheoperationofasteamturbine,itisgenerallynotimportanttobasetheanalysisonaveragefuelandelectriccosts.Itismuchmore
importanttoestablishwhatfuelwillbeimpactedandwhatcostswillbeincurrediffuelconsumptionincreasesordecreases.Similarly,aclear
understandingoftheelectricalcostimpactsmustbedeveloped.
Forexample,considerourexamplesite.Theaverageorblendedfuelcostisapproximately$5.5/106Btu.Thetablepresentedpreviouslyindicatesa
backpressureturbineoperatingwiththisfuelcostcancompetewithelectricitypurchasedwithacostofabout$25/MWh.However,turningonthe
turbinewillrequireadditionalfueltobeconsumedintheboiler.Oursystemwillprobablyincreasesteamproductionfromthenaturalgasfiredboiler.
Asaresult,thebackpressureturbinewillonlybecompetitiveiftheimpactelectricalcostisgreaterthan$43/MWh.
Slide43
ExampleTurbinePRVEvaluation
Wearegoingtoexplorethequestionoftheeconomicsassociatedwithabackpressuresteamturbineinourexamplesystem.Wewillassumewehavea
backpressureturbineinstalledonanelectricgeneratorandapressurereducingvalvethatoperatesinparallelwiththeturbinesteampath.Theturbine
isarelativelysmallcapacitysinglestageunitwithanisentropicefficiencyof32percent.Thisisentropicefficiencyisrelativelylow,butitisreflectiveof
manysteamturbinesinoperation.
June28,2010
Slide44
TurbinePRVEconomics
Ourboilerisproducing400PSIGsuperheatedsteam.Naturalgasistheimpactfuelwithacostof$10/106Btu.Thesteamloadrequiresthermalenergy
fromthe20PSIGsteamsystem.Theelectricalimpactcosthasbeenidentifiedas$70/MWh.Anexcellentwaytoinvestigatethisquestionistocomplete
asidebysidecomparisonofthetwooperatingconditions.Inotherwords,developarepresentationoftheoperatingcharacteristicsofthesystemwith
thesteamloadsuppliedthroughthepressurereducingvalveandthendeveloparepresentationoftheoperatingcharacteristicswiththesteamload
suppliedthroughtheturbine.Thesetworepresentationscanthenbecomparedandthechangeinfuelpurchasesandelectricalpurchasescanbe
identified.
[SlideVisualTurbinePRVEconomics]
Aredarrowdepictsthefuelinputat$10permillionBtutotheboilerwithanefficiencyof84%.Steamproducedat400psigand700degrees
Fahrenheitleavestheboilerandisdeliveredtoasteamheader.
Thesteamheaderincludeabranchtoacontrolvalve,depictedasanhourglassfigurewithadometotheleftwithacontrolsignalfromthe
dometotheexitofthevalveandtoasteamturbine,asdepictedbyaconeshapeandrectanglecombination.
Steampassesthroughthesteamvalveandjoinsthedischargefromthesteamturbine.
Steamleavestheboilerheaderandentersasteamturbine/generator,withthesteamsectiondepictedasaconeshapefigure.Steam
schematicallyleavesthesteamsectionoftheturbineatthebottom.Athickwhitelinetotherightofthesteamturbineleadingtotherectangle
shapeofthegenerator,istheshaft.Aredarrowleavesthegeneratorsection,indicatingpurchasedelectricityat$70/MWH.
TheThermaldemandisnominally30,000lbm/hrof20psigsteam(35.5millionBtu/hr)ofload.
Condensateschematicallyleavestheheatexchangeratthebottomandapump,depictedasacircle/squarecombination,returnsthe
condensatetothetopoftheboiler.Saturatedliquidcondensateisdischargedfromtheload(heatexchanger)at0psig.
Theboilersoperatingperiodis8,760hr/yr.
Slide45
SidebySideComparison1
Initially,wewillpasssteamthroughthepressurereducingvalvetothesteamdemandthatrequires35.5millionBTUperhourofthermalenergy.This
translatesinto30,000poundsperhourofsteamloadontheboiler.Itisinterestingtonotethat400PSIGsteamentersthepressurereducingvalvewith
June28,2010
atemperatureof700degreesFahrenheit.Thissteamexitsthepressurereducingvalvewithapressureof20PSIGandatemperatureof659degrees
Fahrenheit.Thischangeintemperatureresultsfromthepressurechangealonenoenergyhasbeenlost.
[SlideVisualSidebySidecomparison]
AredarrowdepictsthefuelinputtotheHighPressureandHighTemperatureBoiler.Steamproducedfromtheboilerisdeliveredtoa
pressurereducingvalve,andisdischargedat659degreesFahrenheit.Steamschematicallyleavesthesteamsectionoftheturbineatthe
theboiler.
Slide46
SidebySideComparison2
Next,weturnontheturbineandallowthesteamtopassthroughittothesteamload.Theturbinetakessomethermalenergyoutofthesteamand
convertsitintoshaftenergy.Asaresult,thesteamexitstheturbineapproximately160degreescolderthanwhenitpassedthroughthepressure
reducingstation.Inordertosatisfythethermaldemand,wemustsendalargermassflowofsteamtotheenduserthesteamdemandrequiresthe
samethermalenergynomatterhowthesteamgetstoit.
[SlideVisualSidebySidecomparison2]
theboiler.
June28,2010
Slide47
SSATProjectData
Youcanimaginethatthecalculationsrequiredtocompletetheseinvestigationscanbecumbersomeandlengthy.SSAT,thesteamsystemmodeling
software,issetuptocompleteexactlythesecalculations.
[SlideVisualSSATProject7]
Project7HPtoLPSteamTurbine(s)
Efficiency:65%Operation:BalancesLPHeader
DoyouwishtomodifytheHPtoLPturbineoperation?
Ifyes,selecttheappropriateturbineoperatingmode
Yesinstallanewturbine
Option2Fixedoperation
Note:IfOption1ischosen,themodelwillpreferentiallyusetheHPtoLPturbinetobalancetheLPdemand

Specifyanewisentropicefficiency(%)
32
Option2Howdowishtodefinethefixedturbineoperation?
Option2Fixedsteamflow
32
Klb/h
Specifyfixedsteamflow
June28,2010
Slide48
InitialConditions(PRVControl)
SSATiseasilymodifiedtoincorporatethecomponentsofthisexample.SSATallowsustobuildamodelofasteamsystemthatincludesthehigh
pressureimpactboiler,thelowpressuresteamdemand,thepressurereducingvalve,andthesteamturbine.
SSATcompletesasidebysidecomparisonofthesteamsystemoperatingwiththepressurereducingvalveinservice,asispresentedhere,andwiththe
steamturbineinoperation
nitrogenoxide.
blowdown.
ofthesteam.
June28,2010
fromthevent.
June28,2010
Slide49
AdjustedConditionsTurbineOperation
asispresentedhere.
nitrogenoxide.
blowdown.
ofthesteam.
June28,2010
fromthevent.
Slide50
SystemImpact
Thisisasummaryofthetwooperatingconditionswiththepressurereducingvalveoperationindicatedasthecurrentoperationandthesteamturbine
operationindicatedasafterprojects.Thereductioncolumnindicatesthechangeinoperatingcostassociatedwithturningontheturbine.Fortheimpact
componentsandcoststhatwehavebuiltintothemodel,theeconomicopportunityassociatedwithoperatingtheturbineratherthanthepressure
June28,2010
reducingvalveis132,000dollarsayear.Asyoucansee,thesavingsdevelopsfromthereducedelectricalpurchases.However,inordertosatisfythe
thermaldemand,asignificantamountofadditionalfuelispurchased.Evenwithahighfuelcost,thereisaneconomicsincentivetooperatethe
turbines.Theyareanattractiveinvestment.,althoughitmaynotalwaysbecosteffectivetopurchaseandinstallanewone.
[SlideVisualCostSummary]
CostSummary($000s/yr)
PowerCost
FuelCost
MakeUpWaterCost
TotalCost(in$000s/yr)
CurrentOperation
9,198
31,650
461
41,310
AfterProjects
8,805
31,909
465
41,178
Reduction
393
258
3
132
4.3%
0.8%
0.7%
0.3%
Slide51
BackpressureTurbineEconomics
Itshouldbenotedthatoperatingasteamturbinewillalmostalwaysrequireadditionalfuelconsumption.Steamturbinesconvertthermalenergyinto
shaftenergy.Asaresultthesteamleavingtheturbinewillhavelessthermalenergythantheenteringsteam.Almostallindustrialsteamdemands
requirethermalenergy,notnecessarilysteammassflow.
Slide52
ImprovedTurbineEfficiency
Nowthatwehaveadetailedmodelofoursteamsystemanditissetuptoanalyzetheeconomicimpactassociatedwithoperatingasteamturbine
ratherthanpassingsteamthroughapressurereducingvalve,letsusethemodeltoexploretheinfluenceofsomekeyparameters.Recallthatthe
originalexampleincorporatedfuelwithanimpactcostof10dollarspermillionBTU,anelectricimpactcostof70dollarspermegawatthour,anda
turbinewithanisentropicefficiencyof32percent.
First,wewillonlychangetheturbineefficiency.Inotherwords,theturbineweareturningonisnotalowefficiencyturbinebutamoreefficient
turbine.Wearenowassumingtheturbineisamultistageunitwithgoodefficiency(70percent).
June28,2010
nitrogenoxide.
blowdown.
ofthesteam.
June28,2010
fromthevent.
Slide53
ImprovedTurbineEfficiencyImpact
Noticetheresultsareverydifferent.Theelectricalpowerimpactismorethantwicewhatitwasbefore1,479kilowattsversus642kilowatts.The
economicbenefitassociatedwithoperatingthismoreefficientturbineismorethan300,000dollarsperyear.
[SlideVisualResults]
PowerCost
FuelCost
MakeUpWaterCost
CurrentOperation
9,198
31,650
461
41,310
AfterProjects
8,291
32,241
469
41,001
Reduction
907
591
8
309
9.9%
1.9%
1.6%
0.7%
June28,2010
Slide54
FuelPriceImpact
Nowletsreturntotheoriginalturbine,wheretheturbineisasimplesinglestageturbinewithalowefficiency.Now,wewillchangeonlythefuelprice.
Wewillassumewehaveaspikeinfuelpricingthatdrivesthepriceto15dollarspermillionBTU.Noticeontheresultspage,theeconomicbenefit
associatedwithoperatingtheturbineiserased.
PowerCost
FuelCost
MakeUpWaterCost
CurrentOperation
9,198
47,476
461
57,135
AfterProjects
8,805
47,863
465
57,133
Reduction
393
388
3
2
4.3%
0.8%
0.7%
0.0%
Slide55
ElectricalPriceImpact1
Onceagainwereturntotheoriginalconditionsoftheexample(fuelpurchasedat10dollarspermillionBTU),andchangeonlytheelectricalimpactcost
from70dollarspermegawatthourto100dollarspermegawatthour.Theeconomicbenefitassociatedwithoperatingtheturbineincreases
significantly.
PowerCost
FuelCost
MakeUpWaterCost
CurrentOperation
13,140
31,650
461
45,252
AfterProjects
12,578
31,909
465
44,952
Reduction
562
258
3
300
4.3%
0.8%
0.7%
0.7%
June28,2010
Slide56
ElectricalPriceImpact2
Iftheelectricityimpactcostdropsto40dollarspermegawatthour,theeconomicimpactbecomesaloss.
PowerCost
FuelCost
MakeUpWaterCost
CurrentOperation
5,256
31,650
461
37,368
AfterProjects
5,031
31,909
465
37,405
Reduction
225
258
3
37
4.3%
0.8%
0.7%
0.1%
Slide57
TurbinePRVExamples
ThistableisasummaryoftheturbinePRVanalyses.Itisobviousfromthisinformationthatimpactfuelcostandimpactelectricalcostsarecritical
parametersinestablishingarepresentativeresult.
[SlideVisualTurbinePRVExamplesSummaryInformation]
ElectricityCost
FuelCost
TurbineIsentropic
Efficiency
TurbinePower
Production
TurbineOperation
Savings
$70/MWh
$10.00/10Btu
32%
642kW
$132,000/yr
$70/MWh
$10.00/10Btu
70%
1,479kW
$309,000/yr
$70/MWh
$15.00/10Btu
32%
642kW
$2,000/yr
$100/MWh
$10.00/10Btu
32%
642kW
$300,000/yr
$40/MWh
$10.00/10Btu
32%
642kW
$37,000/yr
June28,2010
Slide58
CondensingSteamTurbines1
Condensingsteamturbinesarephysicallythesamepieceofequipmentasbackpressureturbines;however,theeconomicandenergyimpactsare
dramaticallydifferent.Condensingsteamturbinesgenerallydischargesteamwithapressurethatislessthanatmosphericpressure.Theenergy
rejectedinthecondenserisnotdistributedtousefulpurposes.
[SlideVisualCondensingSteamTurbine]
Condensingturbinedischargesteampressureislessthanatmosphericpressure
o Thesteammustbecondensedtopumpitbackintotheboiler
o Exitingsteamqualityistypicallymuchgreaterthan90%
Slide59
MuchliketheturbinePRVexample,thereisashortlistofprimaryinfluencingfactors.
Slide60
Impactpowercostandimpactfuelcostarethedominantfactors,butturbineefficiencyisalsoquitesignificantmuchmoresignificantthaninthe
backpressureturbineexamples.Boilerefficiencyisalsoafactorbutitisminimalincomparisontotheotherparameters.Turbinedischargepressureis
anotherinfluencingfactorthatisasignificantdaytodayperformancemanagementissue.
June28,2010
[SlideVisualCondensingSteamTurbines]
Theprimaryfactorsinfluencingcondensingturbineoperationsare:
o Purchasedpowercost
o Purchasedfuelcost
o Boilerefficiency
o Turbineefficiency
o Turbinedischargepressure
Slide61
Itisinterestingtonotethegeneralenergyflowthroughatypicalcondensingsteamturbine.Forevery100Unitsofthermalenergysuppliedtothe
turbineapproximately120unitsoffuelenergyhadtobeinputtotheboiler.Forthecondensingturbineinthisexample,only27unitsofshaftenergy
areproducedfromthe100unitsofsteamthermalenergysuppliedtotheturbine.Approximately73unitsofthermalenergyarerejectedintothe
condenser.Onlyaboutonefifthofthepurchasedfuelisturnedintousefulenergy.Theturbineinthisexampleisrepresentativeofanexcellentturbine
withanisentropicefficiencyof80percent.Theturbinereceivessuperheatedsteamat400PSIGand700degreesFahrenheitanddischargestothe
condenseratapressureof1.4PSIA.Thatisquiteinefficient.So,withacondensingturbine,wemusttakegreatcaretomakesureeverythingoperatesat
topperformanceandthecorrectimpactparametersareconsidered.
Slide62
CondensingTurbinePerformance
Thistableidentifiestheeconomicimpactassociatedwithoperatingtheexamplecondensingsteamturbinewithvariousfuelcosts.Itshouldbenoted
thatthismustbeamuchmorespecificsetofinformationthanthebackpressureturbineinformationpresentedpreviously,becausemanyadditional
factorsinfluencetheresults.Asaresult,turbineinletsteamconditionsandisentropicefficiencymustbespecified.Thetablehighlightsthecontrastin
June28,2010
electricalpowerimpactcostagainstturbineefficiencyandfuelcost.Asanexample,afuelcostof10dollarspermillionBTU,andahighefficiency
turbine,thepowercostisabout150dollarspermegawatthour.
[SlideVisualCondensingTurbinePerformance]
FuelCost
[$/10Btu]
2.00
4.00
6.00
8.00
10.00
12.00
Steaminlet
Steaminlet
Steamexit
CondensingTurbineImpactPowerCost
ImpactCondensingPowerCost[$/MWh]
TurbineIsentropicEfficiency[%]
40
60
80
56
39
30
111
78
60
167
116
89
223
155
119
278
194
149
334
233
179
400 psig
700 F
1.4 psia
Itisalsointerestingtonotethedramaticimpactturbineefficiencyhasontheeconomicsofcondensingturbineoperations.Aprimarypointofconcern
forgeneraloperationsofcondensingturbinesmustbemaintainingturbineefficiency.Thereareseveralcommonfactorsthatinfluenceturbine
isentropicefficiency.
Slide63
Turbineisentropicefficiencyisimpactedsignificantlybythesteamflowthroughtheturbine.Thisprimarilyresultsfromthethrottlingeffectsofthe
steamflowcontroldevice.Butthereareseveraladditionalfactorsthatinfluenceturbineperformance.Thefluiddynamiccharacteristicsoftheblades
andnozzlesarefinelydesignedtoproducethemaximumperformancecharacteristics.Iftheshapeofthebladesandnozzlesarealteredthrougherosion
ordepositstheperformanceoftheturbinewilldiminish.Gapsmustexistbetweenthemovingandstationaryparts.Sealsaredesignedintotheturbine
tominimizesteamleakingthroughthegaps.Ifthesealsfailorarewornsignificantamountsofsteamcanbypassthroughthegaps.Wetsteam,steam
withwaterdroplets,canresultinwearofturbineblades.Butwaterdropletscanalsodiminishperformancebecausetheycanpresentaresultantforce
oppositeofthedesireddirectionontheturbineblades.Thisoccursbecausethenozzleseffectivelyacceleratethevaporbuttheinertiaofthedroplets
keepstheirvelocityrelativelylow.Asaresult,thedropletsoftenstrikethebackoftheblades.
June28,2010
Theseblade,nozzle,andsealissuesaretypicallyrepairedduringmajoroverhaulsoftheturbine.
[SlideVisualCondensingTurbineEfficiencyFactors]
o
Efficiencyreductionscanresultfrom:
Bladedeposits
Bladeerosion
Sealwear
Wetsteam
Efficiencyimprovementscanresultfrom
Replacedblades
Improvedseals
Turbinereplacement
Increasedload
Slide64
Thedaytodayturbinemanagementactivitythatismostcommonismanagingdischargepressure.Itisimportanttonotethattheenergyextracted
fromthesteamthatisconvertedintoshaftpower,isproportionaltothepressureratioofthesteampassingthroughtheturbine.Thepressureratiois
theinletabsolutepressuredividedbytheoutletabsolutepressure.Becausethepressureratioisarelativelylargenumberdividedbyarelativelysmall
number;aslightchangeinthedenominator(ordischargepressure)willhaveasignificantimpactonthepressureratioandthepoweroutputofthe
turbine.Forexample,500dividedby1isverydifferentfrom500dividedby2.Asaresult,managingcondensingturbinedischargepressureisacritical
point.Therefore,themostcommondaytodayoperationmanagementactivitiesfocusonmaintainingthedischargepressureaslowaspossible.Thisis
accomplishedbyensuringthecoolingmediumisascoldaspractical,maximizingtheflowofthecoolingmedium,ensuringnoncondensablegasesare
removedfromthecondenser,andbycleaningtheheattransfersurfaces.
Itshouldbenotedthatmostcondensingturbineshaveaminimumpracticaldischargepressure.Thisminimumpressurehasaneffect,sothatfurther
reductionsinpressurewillonlyminimallyincreasepoweroutputbecauseofsteamvelocityanddensityeffects.
June28,2010
Slide65
Conclusions
Insummary,investigatingandmanagingtheenergyresourcesthatareencounteredthroughoutthecomplexisacriticalfactorinmanagingoperating
costs.Primaryenergyresourcesshouldbeevaluatedtodetermineifthereareanyadvantagesthatcanbeexploitedtoimprovesiteoperations.Every
endusecomponentinthesteamsystemshouldbeevaluatedtodetermineifthereareopportunitiestoreducesteamconsumptionandtoutilizethe
mostappropriateenergyresources.Combinedheatandpoweractivitiescandramaticallyinfluencetheeconomicsofsiteoperations.Alloftheseareas
shouldbecentralpointsoffocusofsiteoperations.
June28,2010
SteamDistributionSystemLossesModule
Slide1
SteamDistributionSystemLossesModule
Thesteamdistributionsystemtypicallyconsistsofmainsteamheaders,secondaryorbranchheaders,condensatereturnpiping,condensatecollection
equipment,aswellaspipeandequipmentcondensatedrainingcomponents.Oftenthedistributionsystemisverylarge,extendingtoallareasofa
facility.Asaresult,thedistributionsystemcanbeasourceofsignificantloss.
[SlideVisualTitlePage]
SteamLeaks
HeatTransferLossThroughInsulation
CondensateLoss
Overallsystem
Slide2
PipeFailures
Wewillstartourinvestigationinmanagingthedistributionsystemlossesbyfirstfocusingonleaks.
[SlideVisualSteamLeaksTitlePage]
SteamLeaksPipeFailuresandTrapFailures
CondensateLoss
Overallsystem
Slide3
SteamLeaks1
Thistableindicatesthemaximumsteamflowthroughanorificeorshortsectionofpipe.Itshouldbenotedthatthedischargepressurenotedisthe
maximumbackpressureattheorificeoutletforthecalculationtobevalid.Many(ormost)leaksdischargetotheatmosphereat0psig.However,this
chartcanbeusedforfailedsteamtrapsdischargingtoaclosedcondensatecollectionsystemthatcanbeoperatingatanelevatedpressure.
SteamDistributionLossesModule1
June29,2010
Thetableindicatesasignificantsteamflowcanpassthrougharelativelysmallopening.Theamountof100psigsteamthatcanpassthroughanorifice
ofonesixteenthinchdiameterisabout10poundsanhour.
[SlideVisualSteamLeakRatelbm/hr]
ThischartshowstheSteamLeakRate(poundsperhour)byOrificeDiameter
SteamSupplyPressure.ThenumbersontheleftgoingupanddownfromonesixteenthtoonehalfrepresenttheOrificeDiameterinInches.
Thenumbersatthetopgoinglefttorightfrom20to500indicatetheSteamSupplyPressureinPSIG.
TheDischargeCoefficientis0.6dimensionless..
OrificeDiameter(inch)
20
1/16
1/8
3/16
1/4
5/16
3/8
7/16
1/2
Dischargecoefficient
3
13
30
53
82
118
161
210
3
0.6
LeakRate[lbm/hr]
SteamSupplyPressure[psig]
50
100
150
300
400
6
11
16
30
39
25
43
62
119
157
55
98
140
268
353
98
174
249
477
628
153
271
390
745
981
221
391
561
1,073 1,413
300
532
764
1,460 1,924
392
695
998
1,907 2,513
18
43
68
143
193
DischargePressure[psig]
500
49
195
439
780
1,218
1,754
2,388
3,118
243
dimensionless
Slide4
SteamLeaks2
Ifyouconsiderthatasteamcostof$10/thousandpoundsisamoderatecostthenevenasmallsteamleakof10lb/hrcanresultinalossofmorethan
$1,000/yr.Theexamplesteamsystemoperateswithamediumpressuresteamcostinthe$15/thousandpoundsrangeasaresult,thissmallsteam
leakwouldbemorethan$1,500/yr.Steamleaksareveryexpensiveandbecomeenormous.
June29,2010
[SlideVisualSteamLeakRateCostperYear]
ThischartshowstheSteamLeakRate(indollarsperyear)byOrificeDiameter.
SteamSupplyPressure.ThenumbersontheleftgoingupanddownfromonesixteenthtoonehalfrepresenttheOrificeDiameterinInches.
Thenumbersatthetopgoinglefttorightfrom20to500indicatetheSteamSupplyPressureinPSIG.
TheDischargeCoefficientis0.6dimensionless.Thesteamcostis10dollarsperthousandpoundsperhour.
Orifice
LeakRate[$/yr]
Diameter
SteamSupplyPressure[psig]
[inch]
20
50
100
150
300
400
500
1/16
300
500
1,000
2,600
3,400
4,300
1,400
1/8
1,200
2,100
3,800
10,400
13,800
17,100
5,500
3/16
2,600
4,800
8,600
23,500
31,000
38,400
12,300
1/4
4,600
8,600 15,200
41,800
55,000
68,300
21,900
5/16
7,200
13,400 23,800
65,200
86,000
106,700
34,100
3/8
10,400
19,300 34,200
94,000 123,800
153,700
49,200
7/16
14,100
26,300 46,600
127,900 168,500
209,200
66,900
1/2
18,400
34,300 60,900
167,000 220,100
273,200
87,400
193
243
18
68
143
DischargePressure[psig]
Dischargecoefficient
Steamcost
43
0.6
dimensionless
10.00
$/103lbm
June29,2010
Slide5
PipeFailures
Typically,evensmallsteamleakspresentsignificantsavingsopportunities.Oftenweareonlyinterestedinageneralestimateofthecostofasteamleak
inordertodeterminetherepairstrategy.Tables,liketheonesshownherecanbehelpfulinobtaininganorderofmagnitudeopportunityassociated
withsteamleaks.However,leakscanoftenbeverydifficulttoestimatebecauseoftheirirregularfeatures.But,muchofthetimeonlyaroughestimate
ofsteamlossisnecessary.Tables,liketheonespresentedherecanaidinprovidingagrossestimateofsteamloss.
Slide6
SteamTrapManagement
Oftenthelargeststeamleaksinourindustrialplantsaredifficulttodetect.Thisisbecausemostoftheleaksresultfromfailedsteamtrapsandthesteam
trapsdischargeintoclosedcondensatesystems.Condensatecollectionsystemsareessentialcomponentsinefficientsteamsystemsbuttheycanmask
thesteamlossfromfailedtrapsandmakeevaluatingsteamtrapperformancedifficult.
Asteamtrapthatisfailedopencanpassalargeamountofsteambecausemoststeamtrapshavearestrictingopeningthatisatleastonesixteenthinch
diameter.Manysteamtrapshaveopeningsthatareoneeighthinchdiameterandevengreaterthanonehalfinchdiameter.Aoneeighthinchdiameter
orificewillpassfourtimesmoresteamthanaonesixteenthinchdiameterorifice.Aswecanseefromthesteamleaktablethecostofasinglefailed
steamtrapcanbeenormous.
Itiscommonforindustrialfacilitiestohavemorethan10%andevengreaterthan30%oftheirsteamtrapsfailed.Thereareseveralfailuremodesand
allofthefailedtrapswillnotbelosingsteam,butsignificantsteamlossescanoccurwhenyouconsiderthatanindustrialplantmayhaveseveral
thousandtraps.
Itisvitaltoproperlymanagethesteamtrappopulationbyinvestigatingthetrapstodetermineiftheyareoperatingproperly.Itisnecessarytoinspect
everysteamtrapinthefacilityanddeterminehowitisperforming.Therearemanydifferenttypesoftrapsthatfunctionbasedondifferentprinciples.
Inordertoinvestigatethesteamtrapsitisvitaltounderstandhoweachtypeworks.
Slide7
SteamTraps
Thereareseveralcommontypesofsteamtrapsalongwithvariationsandcombinationsoftypes.Wewillnowdiscussthebasicoperatingprinciples
associatedwiththemostcommonsteamtraptypes.
June29,2010
[SlideVisualSteamTraps]
SteamTraps
Thermostatic
ClosedFloat
FloatandThermostatic
OpenFloat
Thermodynamic
Orifice
Slide8
ThermostaticSteamTraps1
Athermostaticsteamtrapoperatesbasedontemperature.Generally,theactuationresultsfromaninternalcomponentexpandingwhentemperature
increasesandcontractingwhentemperaturedecreases.Whenthetrapinternalsarehotthetrapvalveisclosedwhenthetrapinternalsarecoldthe
trapvalveisopen.Manufacturersusevariousmethodstoactuatetheopeningandclosingactivitywiththecommonmethodsincludingbimetallicstrips
orafluidfilledbellows.
[SlideVisualSteamTraps]
Steamdescendsthroughahottrapintoarectangularbox,throughwhichitexits.
Slide9
Animportantoperationalpointassociatedwithathermostaticsteamtrapisthatthetrapinternalsmustcooltoatemperaturethatislessthan
saturatedsteamtemperaturebeforethetrapwillopen.Saturatedsteamandsaturatedcondensateexistinthetrapwithexactlythesametemperature.
Thetrapwillonlyopenaftersteamhascooledandcondensedandthecondensatehasfurthercooledtoasufficientlylowtemperature.
[SlideVisualSteamTrap]
Steamdescendsthroughacooltrapintoarectangularbox,throughwhichitexits.
Slide10
Thistrapwillnotdischargecondensateimmediatelywhenitforms.Thecondensatemustsubcoolbeforethetrapopens5Fto30Fsubcoolingis
typical.Thistypeoftrapisoftenconsideredtheclassicselectionforheattracingapplications.
June29,2010
Steamdescendsthroughacooltrapintoarectangularbox,throughwhichitexits.
Slide11
ClosedfloatTrap1
Intheindustrialarenaafloattypesteamtrapwillalwaysbecoupledwithanothertypeoftrapasacompoundarrangement.Thefloattypearrangement
allowscondensatetodisplacesteaminthetrapbodyortoenterassteamcondensesinthetrap.
Steamentersthetrapandcondenses.Thiscausesthefloat(representedbyacircle)toraise,causingacantilevertoopentheoutletvalve.
Slide12
ClosedfloatTrap2
Asthecondensatelevelincreasesthefloatinsidethetrapraises,whichopenstheoutletvalve.Saturatedliquidcondensatepassesthroughtheoutlet
valve.
Slide13
ClosedfloatTrap3
Onlyliquidcanexitthefloattypetrap;therefore,thefloattypearrangementwillnotallowairornoncondensablegasestoexit.Thisiswhythefloat
typetrapiscommonlycoupledwithathermostatictypetrapthatprovidesairremovalcapabilities.Thiscombinedarrangementisidentifiedasafloat
andthermostatictrap.
June29,2010
Slide14
FloatandThermostatic1
Again,thefloatandthermostatictrapisacombinationoftwotypesoftraps.Whenthetrapfillswithair,theaircoolsdowntriggeringthethermostatic
elementtoopen.
Muchliketheclosedfloatsteamtrap,afloatcausesacantilevertoraise.Inthistrap,thereisaheatexchangerabove,representedbyasquare.
Slide15
Thethermostaticelementcanalsoopenduringstartupconditionswhenthecondensateloadisheavyandsubcoolinghasoccurred.
Slide16
Thistypeoftrapallowscondensatetoexitthesystemimmediatelyafteritformsmakingitanexcellentselectionforheatexchangerserviceandother
applicationswherebackingupcondensateshouldbeavoided.
Slide17
OpenfloatTrap1
Aninvertedbuckettrapisanothertypeoffloatactivatedtrap.Anupsidedownbucketservesasthefloat.
Whenthetrapbodyandbucketarefilledwithcondensatethebucketsinks.
Steamentersacoldtrapandflowsupwardthroughaseriesofvalves,enteringintothe(flashsteam?),representedbyarectangularbox.
June29,2010
Slide18
OpenfloatTrap2
Steamentersthetrapunderthebucket,thiscausesthebuckettofloat,andclosestheoutletvalve.Noncondensablegasesenteringthebucketwillpass
throughaweepholeatthetopofthebucketandthenoutthroughthevalveasthebucketbeginstosink.
Steamentersatrapunderneathabucket,causingthebuckettofloat,andclosingtheoutletvalve.Noncondensablegasesexitthroughaweep
holeatthetopofthebucketandoutthroughthevalve.
Slide19
OpenfloatTrap3
Thistrapisveryeffectiveinmanyapplications.
Steamentersatrapunderneathabucket,causingthebuckettofloat,andclosingtheoutletvalve.Noncondensablegasesexitthroughaweep
holeatthetopofthebucketandoutthroughthevalve.
Slide20
ThermodynamicTraps1
Thermodynamicsteamtrapsaredesignedwithasolidmetaldiskinacontrolchamber.Condensateentersthecontrolchamberunderthemetaldisk
pushingthediskupandoutoftheway.Condensatepassesthroughthegapmadebetweenthediskandthetrapbodytotheoutlet,whichisanannular
channelinthetrapbody.
Condensateentersupwardthroughthetrap,pushingasolidmetaldesk(representedbyagreenrectangle)outoftheway.Itleavesanareaof
lowpressureasitexits.
Slide21
ThermodynamicTraps2
Whensteamcomesin,thevelocitythroughthegapismuchgreaterthanthatofthecondensate,thisresultsinanareaoflowpressure.Thecontrol
chamberwillfillwithrelativelylowvelocitysteam,whichresultsinahighpressureareaonthetopofthemetaldisk.Therefore,thereisapressure
June29,2010
differenceactingonthediskhighpressureontheuppersurfaceofthediskandlowpressureonthelowersurfaceatthegap.Thisresultsinthedisk
slammingthetrapclosed.
Itremainscloseduntilthesteaminthecontrolchamberturnsintocondensatereducingthepressureabovethediskopeningthetrap.Ifsteamis
presentthetrapwillquicklycloseagain.
Slide22
ThermodynamicTraps3
Thistrapisveryeffectiveinmanyapplications.
Slide23
OrificeSteamTraps1
Anorificesteamtrapmakesuseofthedrasticallydifferentpropertiesofcondensateandsteamtoregulatethethroughputofthetrappingdevice.Orifice
trapsdonothaveanymovingpartsbutrelyonarestrictingorifice,smalldiametershorttube,orVenturitypenozzleastheprimaryworking
component.Thedensityofcondensateisanywherefromoneorderofmagnitudetothreeordersofmagnitudegreaterthanthedensityofsteam.This
factallowsasignificantamountofcondensatetopassthroughasmallopeningandaminimalamountofsteamtopassthroughthesameopening.
Condensatepassesthrougharestriction(representedbyanarrowgap)andleavesasflashsteam.
Slide24
OrificeSteamTraps2
Infact,whencondensateispresenttherestrictionactsasaregulatingmechanism.Thisoccursbecauseascondensatepassesthroughtherestriction
pressuredropwillcauseflashsteamtoforminthecondensateflow.Thisflashsteamformationwillrestricttheflowthatcanpassthroughthedevice.
June29,2010
Slide25
OrificeSteamTraps3
Thistypeoftraphasnomovingpartsandisexcellentforconstantloadapplications.
Slide26
SteamTrapFailures
Inordertoinvestigatesteamtraps,wemustunderstandhowtheyoperateandhowtheyfail.Therecanbemanydifferentfailuremodesforsteamtraps
thatcanmakemanagingthetrappopulationdifficult.However,itisgoodtonotethattwofailuremodes,inparticular,typicallyprovidethegreatest
impacttoanindustrialsite.Thefirstfailuremodethatimpactssitesmostsignificantlyiswhenatrapfailsclosed.Afailedclosedsteamtraptypically
doesnotwasteenergy;however,theeconomicimpactcanfarexceedenergycosts.Thisisbecausethedevicethatisservedbythefailedsteamtrapwill
notbefunctioningproperly.Thiscancausereducedproductionrates,poorquality,andwaterhammerrelatedfailures.
Theotherfailuremodethatimpactssitesmostsignificantlyiswhenatrapfailsopen,blowingasignificantamountofsteam.Thisfailuremode
obviouslywastessteamandresultsinenergyloss.
Again,thereareotherfailuremodesincludingleakingandintermittentoperationbutthesetwofailuremodesimpactsiteoperationsmostsignificantly.
Thisisactuallygoodnewsbecausethesetwotypesoffailurearetheeasiesttoidentify.Asteamtrapfailedopenandblowingwillexhibithigh
temperatureandhighnoise.Iftheoutletofthetrapcanbeseenthesteamplumewillbeadirectindicatorofthefailure.Evenifthetrapdischargestoa
closedcondensatecollectionsystemthecondensatereceiversteamplumeisanexcellentindicator.Oftenthistypeoffailurepresentselevatedpressure
inthecondensatereturnpipingandcanevenresultinpresentingenoughbackpressureonothersteamtrapsinthesystemsotheyarenotcapableof
functioningproperly.Waterhammerinthecondensatesystemisalsoasymptomofopenandblowingsteamtraps.
Ontheotherhand,steamtrapsthatarefailedclosedwillexhibitlowtemperatureandnosoundsofoperation.Itisnotrecommendedtolookonlyfor
openblowingsteamtrapsandclosedsteamtraps;however,theidentificationandrepairofthesetypesoffailedtrapshasthepotentialofsignificantly
improvingsteamsystemoperations.
June29,2010
Slide27
TrapInvestigation
Thecommontoolsusedtoinvestigatesteamtrapoperationaretemperature,sound,andsight.
[SlideVisualSteamTrapInvestigation]
SteamTrapInvestigation
Visual
Acoustic
Thermal
Combinedmethods
Inlinemonitoring
Slide28
VisualTrapInstallation
Steamtrapsthathavevisibleoutletscanoftenbeeasilyidentifiedasproperlyoperatingorfailed.However,mostofthesteamtrapsintheindustrial
sectorareconnectedtoclosedcondensatesystemsbecausewewanttorecoverthecondensateandflashsteam.
[SlideVisualVisualSteamTrapInvestigation]
Limitedinapplicability
Mostcondensatesystemsareclosed
Safetyandpracticalitylimituseofthismethod
Individualtrapoperationmustbeunderstood
Slide29
AcousticTrapInstallation
Asaresult,wemustuselisteningdevicesandthermometersasourprimaryinvestigationtools.Ultrasonicinstrumentscanprovideexcellentdiagnostic
capabilities.
[SlideVisualAcousticSteamTrapInvestigation]
Manyinstrumentsareavailable
Ultrasonicsensingistypicallythemostpractical
June29,2010
Slide30
ThermalTrapInstallation
Contactthermometersandthermalimaginginstrumentscanprovideexcellentsupport.
[SlideVisualAcousticSteamTrapInvestigation]
Manyinstrumentsareavailable
Datacanbeinconclusive
Slide31
CombinedTrapInstallation
Combininginvestigationmethodsisthebestanalysismethodology.
Inordertoimplementaworldclasssteamtrapmanagementprogrameachtrapmustbeinvestigatedfrequentlyatleastannually.Theinvestigation
mustdetermineifthetrapisfunctioningproperlyorifitisinaformoffailure.Ifthetrapisfailedthefailuremodemustbeidentified.
Fortrapsthatarefailedopenandblowinganestimateofthesteamlossshouldbedeveloped.Thiswillallowarepairprioritytobeestablished.
Accuratelyevaluatingsteamlossthroughfailedtrapsandleakscanbeverydifficult.However,keepinmindthatwearereallyinterestedintheorder
ofmagnitudeoftheloss.Asaresult,asimpleestimatingtechniquecanbeuseful.Steamtrapsaredesignedwitharestrictivevalve,opening,or
channelalimitingflowarea.
Usingthislimitingorificeandthesteampressureinthetrapthemaximumsteamlosspossiblecanbecalculated.Therearemanyfactorsthatcanimpact
theactualflowthroughthetrap;but,theyshoulddecreasetheactualflowratherthanincreaseit.Adominantfactorisifsomeoftheinternaltrap
componentspartiallyblocktheopening.Alternatelyifasignificantportionoftheflowiscondensatethesteamlosswillbereduced;however,ittakesa
verylargecondensateflowtoreducethesteamflowsignificantly.Asimpleorificecalculationoratableliketheonepresentedpreviouslyinthistraining
canprovideafoundationforanorderofmagnitudesteamlossestimate.
Slide32
TrapInstallation
Additionalinvestigationpointsshouldalsobetargetedwhendeterminingifeachtrapisfunctioningproperlyornot.Identifyingifthetrapisthecorrect
typefortheapplicationisanimportantinvestigation.Evaluatingifthetrapisinstalledproperlyisveryimportant.
Eachtrapwillexperiencetwophaseflownotonlyexitingthetrapasflashsteamformsbutalsoenteringthetrapassteampushescondensatethrough
thetrap.Infact,inmanyapplicationsthetrapinletpipingwillexperiencetwodirectionflowasthesteaminthetrapbodyisdisplacedbycondensate
enteringthetrap.Anddonotforgetthatnoncondensablegaseswillalsobepresentinthesteamsystem.Asaresult,wedliketohavethetrapinlet
June29,2010
pipesasshort,asbig,andasstraightaspossible.Gravityshouldbetheprimaryforceallowingcondensatetoflowintothetrapandthepipe
arrangementshouldallowsteamtoflowout.
Slide33
TrapSurveyInvestigation
Anothergoodquestiontoaskofeachtrapisifcondensateiscollectedfromthetrap.Itisimportanttoinvestigateifthecondensateisactuallybeing
collectedorifsomeproblemispreventingthecondensatefrombeingreturnedtotheboilerwiththehighestpracticaltemperature.Recallthatthere
aremanyexcellentreasonstorecovercondensatebuttheprimaryworthofcondensateresidesinitstemperature.Condensateneedstoreachtheboiler
withthehighestpracticaltemperature.
Veryofteneffectivecondensaterecoveryishamperedfrompoordesignofthereturnpiping.Manytimesthereturnpipingistaskedwithtransporting
bothliquidcondensateandflashsteam.Oftenthemassflowofflashsteamisarelativelysmallportionofthetotalflowbutbecausethedensityofthe
flashsteamisverylowthevolumeflowoftheflashsteamcanbealargeportionofthetotalvolumeflow.Thiscanresultinwaterhammerproblems
andbackpressureissues.Theproblemcanbeexacerbatedifasteamtrapfailsopendischarginglivesteamintothecondensatesystem.Therecanbea
significantamountofenergyintheflashsteam;but,ifitisresultinginthelossofallthecondensatethenitmaybebesttoventtheflashsteamfromthe
systemandpumptheliquidcondensatebacktotheboiler.
Slide34
MaintenanceProgram1
Aworldclasssteamtrapmanagementprogramwillincorporatealloftheseaspectstoensurethesteamtrapsandcollectionsystemsareoperatingat
peakperformance.
[SlideVisualWorldClassSteamTrapMaintenanceProgram]
Investigateeachtrapatleastonetimeeachyear(problemareasandhighpressureshouldbemorefrequent)
o Performance
Testingequipmentisrequired
Anorderofmagnitudeleakrateshouldbedeterminedforfailedtraps
Orificecalculationssetthemaximumsteamflow
o Traptype
Trapselectionshouldmatchtheapplication
Universalmountscanbeagoodoption
o Installation
o Establishaninvestigationroute
o Condensatereturn
o Outsourcingcanbeagoodoption
June29,2010
Slide35
MaintenanceProgram2
Duringthesteamtrapevaluationprocesseachtrapinthefacilityisidentifiedthisisagoodtimetodevelopadatabasethatincludeseachtrapinthe
facility.Thisallowsahistoryofeachapplicationtobedeveloped.
Asinglesteamtrapfailedopencanresultinsignificanteconomiclossforthesite;makingsteamtrapmanagementessentialformostfacilities.An
excellentdiagnostictoolthatcanbeemployedatmanyfacilitiesistovisuallyobservetheatmosphericventsofthecondensatereceivers.Moststeam
trapswillappropriatelyformflashsteamthatwillpassthroughthecondensatereceivervents;but,excessiveventsteamflowindicatesfailedsteam
traps.
[SlideVisualWorldClassSteamTrapMaintenanceProgram]
Maintainasteamtrapdatabase
Prioritizerepairsbasedonlossestimates
Dailymonitorreceivervents
Trainingisessential
Slide36
TrapSelection1
Thisisanexampleoftheimportanceofsteamtrapselection.Inthisexampleasteamcoilisservinganairhandlingunitonadrumoven.Adrumovenis
basicallyaroomthatcanbefilledwith55gallondrums.Theroom(oroven)issealedandairiscirculatedfromtheoven,throughasteamcoil,andback
totheoventoheatthecontentsofthedrums.Inthisparticularcasethedrumscontainedvariouspetroleumproductsthatwerebeingsuppliedtoa
productionplant.
Thefacilitywasdevelopingaprojecttoreplacethedrumovenwithoneoflargercapacitybecausethedrumovenwasthebottleneckoftheprocess.The
productionrateoftheentireplantwaslimitedbecausethedrumscouldnotbeheatedfastenough.Wewererequestedtoinvestigatetheovenand
determinethecapacitythenewunitshouldhavetoallowproductiontobeincreased.
Thedesiredsupplyairtemperatureinthedrumovenwas310F.However,wemeasuredasupplyairtemperatureofapproximately280F.Thesteam
coilwassuppliedwithsteamthroughafullyopencontrolvalveandthesteampressureinthesteamcoilwasessentiallythesameasthemainsupply
pressureof135psig.Thesaturationtemperatureofthesteamsupplywas358F.
Duringourinvestigationweobservedthatthesteamcoilwasservedwithathermostaticsteamtrap.Thistrapwasopeningwhenthecondensate
temperaturewas285Fmorethan30Fofsubcooling.Asaresult,thesteamcoilwasmostlyfilledwithcondensate.Thisdramaticallyreducedthe
amountofenergytransfer.
June29,2010
Theschematicshowsafloatthermostatictypetrap.Thesteamcoilissuppliedwithsteamthroughafullyopencontrolvalve,andthesteam
pressureinthesteamcoilisessentiallythesameasthemainsupplypressureof135PSIG.Thesaturationtemperatureofthesteamsupplyis
358Fahrenheit.Duringourinvestigation,weobservedthatthesteamcoilwasservedwithathermostaticsteamtrap.Thistrapwasopening
whenthecondensatewasmorethan30Fahrenheitsubcooled.Asaresult,thesteamcoilwasmostlyfilledwithcondensate.Thisdramatically
reducestheamountofenergytransfer.
Slide37
TrapSelection2
Ratherthanreplacingthedrumovenwereplacedthethermostaticsteamtrapwithafloatandthermostaticsteamtrap.Immediatelythesupplyair
temperatureincreasedtothepointthatthesteamcontrolvalveregainedcontroloftheoven.Thedrumovenreplacementprojectwascanceled.
Theschematicshowsafloatthermostatictypetrap.Thesteamcoilissuppliedwithsteamthroughafullyopencontrolvalve,andthesteam
pressureinthesteamcoilisessentiallythesameasthemainsupplypressureof135PSIG.Thesaturationtemperatureofthesteamsupplyis
358Fahrenheit.Duringourinvestigation,weobservedthatthesteamcoilwasservedwithathermostaticsteamtrap.Thistrapwasopening
whenthecondensatewasmorethan30Fahrenheitsubcooled.Asaresult,thesteamcoilwasmostlyfilledwithcondensate.Thisdramatically
reducestheamountofenergytransfer.
Slide38
Insulation
Insulationisaveryimportantaspectofallsteamsystems.Moststeamsystemshavealargeamountofsteamandcondensatepipinglocatedthroughout
theplant.Hugeenergylossescanresultifthedistributionsystemisnotproperlyinsulated.
[SlideVisualHeatLossThroughInsulationTitlePage]
SteamLeaks
CondensateLoss
Overallsystem
June29,2010
Slide39
InsulationIssues
Thefundamentalaspectofinsulationcanbethoughtofasisitthereornot.Wearenottryingtomakelightoftheveryimportantfactors;suchas,
insulationtype,insulationthickness,andinstallationmethods.However,ashortlengthofuninsulatedsteampipecanexperiencethesamelossasa
verylonglengthofpoorlyselectedinsulation.Inotherwords,wearenotadvocatingignoringinsulatedpipebutthelargestlossesandmostimportant
opportunitiestypicallyresideinrepairingareaswithmissinginsulation,badlydamagedinsulation,orwaterrelatedissues.Opportunitiesrelatedto
missingorbadlydamagedinsulationtypicallyhavesimplepaybacksinthefractionofayearrange.
Slide40
MissingInsulation
Inordertoemphasizetheprimarypointsassociatedwithinsulationwewillexamineanexample.Duringourinvestigationofthesteamsystemwe
observedasectionofthemainsteamdistributionpipingtobeuninsulated.Thissteamheaderisinsulatedformostofitslength;butasshowninthe
picture,asittransitionsfromonesideofthepipebridgetotheotheritisuninsulated.
Thereisabout20linearfeetofuninsulatedpipe.Mostofthispipeishorizontalbuttwoshortsectionsareverticallyoriented.Thenominaldiameterof
theheaderis10inches.Thepipecontainsmediumpressuresteamandaninfraredthermometerindicatesthepipesurfacetemperatureis550F.
Thecalculationsrequiredtoestimatetheheattransferreductionfrominstallingthermalinsulationarelengthyandcomplicated.U.S.DOEoffersa
specializedsoftwaretoolthatsimplifiestheanalysistremendouslythesoftwaretoolis3EPlus.
Thereisapictureofasystemofpipesinanindustrialplant.
Slide41
3EPlusInsulationTool
3EPlusisdesignedtocompleteanalysesonallcommoninsulationprojects.Thesoftwareisveryuserfriendlyandverypowerful.Letsusethistoolto
determinetheeconomicimpactofinsulatingthesteamheaderwesawwiththemissinginsulation.
Thefirstscreenofthe3EPlusInsulationtoolisshown.Itsays3EPlusInsulationThicknessComputerProgram.
June29,2010
Slide42
3EPlus1
Thesoftwareopenstoapagethatallowstheusertoinputspecificdataconcerningtheinsulationopportunity.Inthisexampleweassumeallofthepipe
ishorizontal;eventhoughweknowthereareverticalsectionsofthepipeaswell.Wehaveselectedthisforsimplicitywecanattainamoredetailed
resultiftheanalysisisbrokenintohorizontalandverticalsections.
Itisgoodtonoteatthispointthatthe3EPlussoftwareisbasedintheprinciplesofheattransferandphysicsanditrigorouslysolvesthegoverning
equationsforeachscenario.However,itshouldbenotedthatthevariabilityoftherealworldparametersgoverningthesituationsissignificant.Asa
result,theanalysismustbeconsideredanestimate.Forexample,wewillinputawindspeedintotheanalysisas3miles/hr.Thereissignificantreal
worldvariabilityinwindspeedandwindspeedhasamajorimpactontheenergylossfromthepipingsystem.
Theremaininginputdataisstraightforward.Weareworkingwithtypicalpiping;asaresult,wewillselectASTMC585,whichisthedesignationfor
commonpiping.Ifyouareworkingwithtubinganotherselectioncanbemade.
Therearemanycalculationtypesthatcanbeselectedfrom.InthisexamplewewillchooseHeatLossperYear.Thiswillsetthecalculationresultstoan
annualbasis.
Wehavemeasuredthepipesurfacetemperaturetobe550F,whichcanbetakenastheProcessTemperature.AmbientTemperatureistakenas70F,
whichisconservativelyhighfortheannualaverageambienttemperature.
Thepipeisa10inchNominalPipeSizeorNPS.Thewindspeedhasbeenselectedas3miles/hr.
Thesteamsystemservingthissiteisinoperation24hoursadayand365daysayear;inotherwords,8,760hoursperyear.
Allofthisinformationintheupperportionofthepageisbasictotheanalysis.Nowinthelowersectionofthepageweselectthespecificinsulation
properties.
Thepipematerialissteel.Theinsulationthatisinplaceontheremainderofthepipeiscalciumsilicate.Becauseweareaddressingashortsectionof
existingpipingandinsulationwewillmostprobablyinstallthesameinsulationandjacketmaterialtherestofthesystemhas.However,itisgoodto
notethatthesoftwarehasthepropertiesofthecommoninsulationmaterialsbuiltin.Theinsulationontheremainderofthepipeis3inchesthickand
coveredwithanaluminumjacket.Thisjacketwillbeoxidizedinservicefairlyquickly.
[SlideVisual3EPlusEnergyTab]
EnergyTab
InsulationThickness(DataEntryScreen)
ItemDescription:missinginsulation
SystemApplication:PipeHorizontal
June29,2010
SystemUnits:ASTMC585
FuelType:NaturalGas
HeatContent:1000BTU/cubicfoot
FuelCost:10.00$/Mcf
Efficiency:80percent
ProcessTemperature:550.0F
AmbientTemperature:70.0F
NPSPipeSize:10
WindSpeed:3mph
AnnualOperation:8760hoursperyear
InsulationLayers
AddButton
DeleteButton
#
Type
BaseMetal
Insulation
Jacket
Material
Lock
Thickness
Name
Steel
BLK+PIPE,TypeI,C53307
0.1Aluminum,oxidized,inservice07
Thickness,
Inches
Fix
Slide43
InsulationEvaluation
WhentheCostofEnergyselectionismadetheuserisallowedtoinputfuelcostwhichisusedtoevaluatetheeconomicimpactassociatedwithinstalling
theselectedinsulation.
Fueltypealongwithfuelhigherheatingvaluealsobecomeinputparameters.
AnotherinputparameterisEfficiency.ThisEfficiencyisinreferencetothefactthatforeveryunitofthermalenergylosseliminatedevenmorefuel
energyconsumptioniseliminated.Themaincontributortothisadditionallossisboilerefficiency.Asaresult,inputtingboilerefficiencywillmore
accuratelyidentifythefuelcostimpactassociatedwithinstallinginsulation.
June29,2010
[SlideVisual3EPlusEnergyTab]
EnergyTab
SystemApplication:PipeHorizontal
FuelType:NaturalGas
FuelCost:10.00$/Mcf
NPSPipeSize:10
WindSpeed:3mph
AnnualOperation:8760hoursperyear
InsulationLayers
AddButton
DeleteButton
#
Type
BaseMetal
Insulation
Jacket
Material
Lock
Thickness
Name
Steel
BLK+PIPE,TypeI,C53307
0.1Aluminum,oxidized,inservice07
Thickness,
Inches
Fix
June29,2010
Slide44
InsulationSavings
Thesoftwarecalculatestheenergylossfromtheuninsulatedpipeandfortheinsulatedpipe.Thedifferenceinthesetwoenergylossesisthesavings
opportunityassociatedwithinstallinginsulation.Theboilerfuelimpactiscalculatedasmorethan$600/yrforeveryfootofuninsulatedpipe.Inother
words,insulating20feetofuninsulatedpipewillreducefuelpurchasesapproximately$12,000/yr.
[SlideVisual3EPlus]
EnergyTabandCostofEnergy
GeometryDescription:PipeHorizontal
BareSurfaceEmittance:0.8
NPSPipeSize:10in,
WindSpeed:3mph
FuelType:NaturalGas
FuelCost:10.00$/Mcf
Hours/Year:8760hoursperyear
OuterJacketMaterial:Aluminum,oxidized,inservice
OuterSurfaceEmittance:0.1
InsulationLayer1:CalciumsilicateBLK+PIPE,TypeI
Thickness:3.08in
Variable
Insulation
Thickness
Bare
Layer1
Cost
($/ft/yr)
HeatLoss
(Btu/ft/yr)
636.90
28.74
50950000
2300000
Savings($/ft/yr)
608.200
Savings=608$/ftyr(20ft)12,000$/hr
June29,2010
Slide45
3EPlus2
Thisinformationcanbeusedtoestimatethecostofinstallingtheinsulation,underEconomics.Thisprojectwouldrequireapproximately700dollars
tocomplete.
[SlideVisualSteamTrap]EconomicsTab]
Surfacenumber:17
PipeSize:10
SingleLayer
Thick Cost
1
0.00
1.5
18.05
2
22.20
2.5
25.61
3
28.76
4
35.82
DoubleLayer
Thick Cost
3
32.26
4
41.82
5
51.54
6
61.29
0
0.00
0
0.00
TripleLayer
Thick Cost
6
69.17
7
81.04
8
92.83
9
99.73
10
115.57
0
0.00
June29,2010
Slide46
SteamLoss1
Whenevaluatinginsulationprojectsincogenerationsystemssignificantcaremustbeexercisedbecauselowpressuresteamwillhaveadifferentworth
thanhighpressuresteam.Highpressuresteamisworthfuelcostdividedbyboilerefficiency.Thisisthemethod3EPlususesintheCostofEnergy
calculation.
Incogenerationsystemstheimpactcostoflowpressuresteamcanbelessthanonehalftheimpactcostofhighpressuresteam.Wearereferringtothe
trueeconomicimpactthesitewillexperiencebyreducingthethermallossatlowpressure.
Ininstanceswheretheinsulationprojectimpactssteamthatisnotthesamecostashighpressuresteamcostaslightlymorecomplicatedanalysisis
required.3EPluswillbeusedinthesamemannertodeterminetheenergysavingsfromtheinsulationproject.
[SlideVisualEnergyLossConvertedtoSteamLossCalculation1]
Qtotal =qperlengthLtotal
HeatLossisthesumoftheheatlossperlengthmultipliedbythelengthoftheitem.
Qtotal =(50,950,000Btu/yrft2,300,000Btu/yrft)(20feet)(1yr/8,760hrs)
Qtotal =111,000Btu/hr
Abbreviations
Qtotal=HeatLoss
qperlength=HeatLossperunitlength
Ltotal=Length
Slide47
SteamLoss2
Thisenergysavingsisconvertedintoanequivalentsteamimpact.Thinkofaheatexchangerreceivingthesteamthathaspassedthroughtheun
insulatedsectionofpipe.Theenergylossfromthepipecoolsthesteam.Inorderfortheheatexchangertosupplythesameamountofthermalenergyto
thedemandmoresteammustbepassedtotheheatexchanger.Thisincreaseinsteamflowisdeterminedthroughafirstlawofthermodynamics
analysisoftheuninsulatedpipeandtheheatexchanger.Thisiscomparedtothesameheatexchangerandloadwiththepipeinsulated.
Thisadditionalsteamdemandwillbeeliminatedwhenthepipeisinsulated.
June29,2010
Properties
Location
Medium
Pressure
Saturated
vapor
Saturated
liquid
Temp
[F]
P
[psia]
Specific
Volume
[ft/lbm]
Enthalpy
[Btu/lbm]
Entropy
[Btu/lbmR]
Quality
[%]
P
[psig]
550
164.7
3.54075
1,298.86
1.67502
****
150
366
164.7
2.75693
1,195.57
1.56726
100.0
150
366
164.7
0.01818
338.36
0.52323
0.0
150
msteam=Qtotal.
(hsteamhcondensate)
MassflowrateofthesteamisequaltotheTotalHeatLossConvertedtoSteamdividedbythedifferenceintheenthalpyofthesteamandthe
enthalpyofthecondensate.
msteam=111,000Btu/hrl.
(1,298.86Btu/lbm338.36Btu/lbm)
msteam=115lbm/hr
Abbreviations
msteam =massflowrateofsteamgeneratedintheboiler(lbm/hr)
h
Qtotal=HeatLoss
Slide48
SteamLoss3
Theimpactsteamcostcanbeappliedtothissteamdemand.Impactsteamcostscanbedevelopedfromsteamsystemanalysesliketheonescompleted
withtheSSATsoftwaretool.
June29,2010
KSteam =msteamksteam
KSteam =(115lbm/hr)(14.53$/103lbm)
KSteam =1.68$/hr(8760hrs/1yr)=14,000$/yr
Abbreviations
KSteam=ImpactHeatLoss
msteam =massflowrateofsteamgeneratedintheboiler(lbm/hr)
ksteam=Costperpoundofsteam(known)
Slide49
CondensateLoss
Condensaterecoveryisavitalpartofeffectivesteamsystemmanagement.
[SlideVisualCondensateLossTitlePage]
SteamLeaks
CondensateLoss
Overallsystem
Slide50
CondensateRecovery
Condensateisgenerallythecleanestwaterontheplantsiterecoveryofitcanreduceboilerblowdownratesandreduceboilerchemicalrequirements.
However,almostalwaysthedominantworthofcondensateisthethermalenergyresidentinit.Everypoundofcondensatethatcanbereturnedat
180F,forexamplewilleliminatetheneedtopurchaseapoundofmakeupwateratpossibly70F.Thesteamsystemwouldberequiredtoheatthe
makeupwaterfrom70Fto180Fthecondensatewouldnotrequirethisenergyexpenditure.
June29,2010
[SlideVisualCondensateRecovery]
Condensatetypicallyhasanenergyvalue
Makeupwatertypicallyhasavalue
Condensaterecoverycostsgenerallycenterontherecoverysystempiping
Increasedcondensatereturnreducesmakeupwaterrequirements,whichgenerallyimprovesfeedwaterquality
Slide51
ReturnExample1
Wewillexploreasimpleexamplethatwillidentifytheimpactsassociatedwithcondensaterecovery.Inthisexample,aheatexchangerdischarges
212Fcondensatestraighttothesewer.Weuseda5gallonbucketandastopwatchtomeasurethecondensateflowtothedrain.Ittookabout30
secondsfora5gallonbuckettofillup,whichmeansthecondensateflowisabout10gallonsperminute.Thistranslatesintoabout5,000poundsper
hourofcondensatethatcanberecovered.Howbeneficialisittogetthiscondensatebacktotheboilerandwhatwouldberequiredtorecoverthe
condensate?
[SlideVisualCondensateReturnExample]
Theschematicdepictscondensatereturninaheatexchanger.Heatedmaterialandhighpressuresteamenterintotheheatexchangerthrough
severalpasses.Steamexitstheheatexchangerandgoesbackintotheboiler,alongwithsteamfromadditionalsteamtraps.Fromtheboiler,
steameithergoestothecondensatesystemoritgoestotheLowPressureSteamSystem.
Slide52
ReturnExample2
Theclassiccondensaterecoverymethodistoroutethesteamtrapdischargetoaventedcondensatereceiver.Thereceiverwillbeequippedwitha
pumpandalevelcontroldevice.Thepumpwilltransfercondensatefromthereceivertothecondensatereturnpipeandultimatelytotheboiler.The
condensatereturnpipingandequipmentshouldbeinsulatedtoensurethethermalenergyofthecondensateisrecovered.
[SlideVisualCondensateReturnExample2]
Thedischargeisthenroutedtoaventedcondensatereceiver.Itistransferredtothecondensatereturnpipeandultimatelytotheboiler.
June29,2010
Slide53
ReturnExample3
Itisassumedthatthecondensatewillreturntotheboilerareawithatemperatureof180F.WecanuseSSATtoquicklyandaccuratelydeterminethe
systemimpactassociatedwithreturningthiscondensate;however,wewillusethesimpleenergyequationshereasafirstorderestimate.
[SlideVisualCondensateReturnExample3]
steameithergoestothecondensatesystemoritgoestotheLowPressureSteamSystem.Thedischargeisthenroutedtoaventedcondensate
receiver.Itistransferredtothecondensatereturnpipeandultimatelytotheboiler.
Slide54
ReturnExample4
Thecalculationidentifiestheadditionalfuelthesteamsystemwillrequiretoheatthemakeupwaterfrom70Fto180Fwhichisthetemperatureof
thecondensateasitreturnstotheboiler.Theworthofthecondensatefromthisoneheatexchangeris60,000$/yroffuelpurchases.
ocondensate=mcondensate(hcondensatehmakeup)Kfuel
nboiler
ocondensate=5,000lbm/hr(147.91Btu/lbm38.05Btu/lbm)(8,760hours/year)(10.0$/106Btu)(1/0.80)
ocondensate=60,000$/year
Abbreviations
O
=Condensate
Mcondensate=massflowrateofcondensategeneratedintheboiler(lbm/hr)
Kfuel=massflowrateoffuelburned(lbm/hr)
h
June29,2010
Slide55
CondensateRecovery
Oftencondensatesystemsfunctionpoorlybecausetheyattempttotransportcondensateandsteamtogether.Itmustbeunderstoodthatasignificant
amountofenergyresidesintheflashsteamcollectedinthecondensatesystem.However,ifthereisnoeffectiveuseoftheflashsteamthenitmaybe
beneficialtosimplyventtheflashsteamthroughalocalcondensatereceivertoalloweffectiverecoveryoftheremainingcondensate.Thiswillallowus
topumpwaterbackintotheboilerwithouttheproblemsassociatedwithtransportingliquidandvaportogether.
Acommonfailuremodeofcondensatereceiversispumpfailure.Oftenthepumpreceivercombinationisimproperlydesignedandthecondensate
actuallyboilsasitentersthepump.Thisconditionisidentifiedascavitationandisverydetrimentaltothelifeofthepump.Oftencondensatereceiver
pumparrangementsaredesignedforlessthan180Fcondensate.Thecavitationproblemsdevelopfromthefactthatmanysteamtrapsdischarge
saturatedliquidcondensate,whichwillbe212Fasitentersthereceiver(assumingstandardatmosphericpressure).
Mostcondensaterecoverysystemsmustbedesignedwithanelevatedreceiverandthepumpswellbelowthereceivertoensuresufficientstatic
pressuretoeliminatethepossibilityofboilinginthepump.
Slide56
CascadeCondensateSystems
Ifwehaveanopportunitytoutilizetheflashsteamcollectedinthecondensatesystemthenthiscangreatlyimprovetheenergyefficiencyofthesteam
system.Cascadecondensatecollectionsystemscanmakeexcellentuseofthethermalenergyresidentintheflashsteam.Additionally,cascade
condensatecollectionsystemsminimizetheimpactoffailedsteamtrapsbecauselivesteamisdirectedtothelowerpressuresteamsystems.
[SlideVisualCascadeCondensateSystems]
Thedischargeisthenroutedtoaventedcondensatereceiver.Itistransferredtothecondensatereturnpipeandultimatelytotheboiler.
June29,2010
Slide57
OverallSystem
Atthispointwewanttodrawourattentiontoanenergyefficiencyimprovementstrategythatisoftenrecommendedforsteamsystemmanagement.
[SlideVisualOverallSystemTitlePage]
SteamLeaks
CondensateLoss
Overallsystem
Slide58
PressureReduction1
Thisstrategyistoreducethesteamsystemoperatingpressure.Thisisonlyattractiveinsystemsthatdonotcogeneratereducingthesteam
generationpressureofcogeneratingsystemsisalmostalwayscounterproductive.However,whenconsideringsteamsystemsthatdonothave
cogenerationcomponents,reducingtheoperatingpressurecanreduceenergyrequirements.
Slide59
PressureReduction2
Someoftheprimaryenergyreductionsresultinthedistributionsystemandarisefromreducedleaksandreducedheattransferlosses.Forexample,if
steamisdistributedthroughoutthesystemat150psigratherthan200psigthenanyleakwillpasslesssteam.Similarly,afailedsteamtrapwill
dischargelesssteam.Asthesteampressureisreduced,thesaturationtemperatureofthesteamisreduced.Steamsystemsthatdistributesaturated
steamthroughoutthesystemwillexperiencelessheattransferloss.Evensystemsthatdistributesuperheatedsteamcanexperiencereducedheat
transferloss.
Additionally,ascondensateisformedandcollecteditistypicallypassedthroughasteamtraptoacondensatecollectionsystem.Asthecondensate
entersthelowpressurecondensatecollectionsystemsomeflashsteamforms.Oftenthisflashsteamisexhaustedfromthesystem.Whensteam
pressureisreducedtheamountofflashsteamgeneratedinthecondensatesystemisreduced.
Mostoftenthelargestpotentialimpactassociatedwithreducingsteampressureisanimprovementinboilerefficiency.Boilerefficiencyimproves
becausetheboilingtemperatureofthewaterreducesassteampressureisreduced.Inotherwords,thereisalargertemperaturedifferencebetween
theboilingwaterandthefluegases,whichallowsmoreheattransfer.Thiswillresultinareducedfluegasexittemperatureandimprovedboiler
efficiency.
June29,2010
Itisnotknownexactlyhowtheboilerwillrespondtoreducingsteamgenerationpressurebutanestimateofthemaximumexpecteddecreaseinflue
gastemperatureisthedecreaseinboilingtemperatureofthewaterintheboiler.Asanexample,considerasteamgenerationpressurethatisoriginally
200psig.Theboilingtemperatureoftheboilerwaterisnominally388Fforthiscondition.Theboilingtemperatureofthewateroperatingat150psig
is366F.Asaresult,themaximumfluegastemperaturereductionisestimatedtobe22F.Generally,theactualimpactwillbelessthanthisvalue.
Therefore,caremustbeexercisedinusingthisestimate.Thepresenceoffluegasenergyrecoverycomponentswilldecreasetheimpactonboiler
efficiency.
Itisinterestingtonotethatformosttypicaloperatingconditions,ifthefluegasexperiencedatemperaturedropinthe20Frangetheboilerefficiency
improvementcouldapproach0.5percentagepoints.
Itshouldbenotedthatthesteamendusecomponentswillcontinuetorequirethesamethermalenergywhensuppliedhighpressuresteamorlow
pressuresteam.Asaresult,themassflowrateofsteamsuppliedtotheenduseequipmentmaychange.
Slide60
PressureReductionStudy1
Letsexaminetheimpactsexperiencedonarealsteamsystem.Thesteamsysteminquestionisalreadyoperatingatrelativelylowpressurebutitisthe
designconditionofthesystem.Measurementsindicatedthesystempressureaveraged54psiginitially.Thepressurewasreducedto30psig.The
saturationtemperatureofthesteamdecreasedfrom301Fto274Fa27Freductioninsteamtemperature.Thefluegastemperaturedecreased25F.
Theboilerwasburningnumber2fueloilandtheefficiencyimproved1percentagepoint.
Slide61
PressureReductionStudy2
Theheattransferlossfromthepipingsystemdecreased10%.Allsteamleaksdecreased30%.
Eventhoughtheboilerefficiencyimpactisonlyonepercentinthisexampleitisverysignificant.Thisisbecauseallofthefuelenergyisexposedtothis
onepercentchange;asaresult,thetotalfuelcostwillbeimpactedbythischange.Typicallytheboilerefficiencyimpactisthemostsignificantfroman
economicstandpoint.
Thesavingspotentialsfromleaks,insulationlosses,andcondensateflashsteamlosssoundsignificantandtheycanbesignificant;however,several
factorsshouldbeconsidered.First,leaksshouldbemanagedtoasmallfractionofthetotalsteamsupply.Leaksthatdoexistwilldecreasebutleaksare
typicallyasmallportionofthesystemdemands.
Second,heattransferlossesfromthedistributionsystemwilldecreaseasthesteamtemperaturedecreases.However,thedistributionsystemshouldbe
insulatedresultinginminimalsystemheattransferlosseveninsystemswithmilesofsteampiping.
Third,thecondensateflashsteamlossreductiononlyoccursonunregulatedsteamloads.Inotherwords,ifasteamtrapisservingaheatexchangerthat
iscontrolledwithasteamcontrolvalvethenthepressureofthecondensateasitpassesthroughthetrapwillnotbeinfluencedbythesteam
June29,2010
distributionpressure.Oftenitisonlythetrapsservingthemaindistributionpipingthatreducetheirflashsteamloadingwhensteampressureis
decreased.
Slide62
PressureReduction1
Thereareseveralpointsofconcernwhenconsideringreducingsteampressure.
Slide63
PressureReduction2
Thesavingspotentialcanbesignificantlydiminishedifthelowerboilerpressureresultsinliquidcarryoverfromtheboiler.Astheboilerpressureis
reducedtherelativesteamvelocityintheboilerincreasesforagivenboilerload.Thisincreasesthepotentialforliquidcarryover,whichcanresultin
lossofboilerchemicalsandpresentamasslossfromthesystemastheliquidflashesthroughthecondensatecollectionsystem.Carryovercanalso
harmdownstreamcomponents.
[SlideVisualSteamPressureReduction]
Whatarethemajorproblemsassociatedwithreducingsystempressure?
Boilercarryoverpotentialincreases
o Waterhammer
o Increasedwatertreatmentcosts
o Poorboilerwaterchemistrycontrol
o Equipmentfouling
Equipmentcorrosion
o Equipmenterosion
o Energyloss
Slide64
PressureReduction3
Thereduceddensityofthelowerpressuresteamwillresultinincreasedvelocitiesinthedistributionsystem.Thiscandecreasesteampressures
throughoutthesystemandlimitsteamsupplytocriticalcomponents.
Manysteamtrapandcondensatecollectionsystemsrelyonsteampressuretomovethecondensatethroughthecollectioncomponents.Thecapacityof
allsteamtrapsisdirectlyrelatedtosteampressure.Reducingthesteamsupplypressurecanresultinamalfunctioningcondensatecollectionsystem.
June29,2010
Whatarethemajorproblemsassociatedwithreducingsystempressure?
Steamsupplyproblemsresultingfromincreasedfrictionalloss
o Pipediametermaynotbesufficienttosupplythesteamdemand
o Valvesize
Condensaterecoveryandreturnissuesresultingfromreduceddrivingpressure
Heatexchangertemperaturedifferencereduceslimitingheattransfer
Slide65
PressureReduction4
Therearemanyissuestoconsiderwhenexaminingsteampressurereduction.Therearemanypotentialbenefitsandjustasmanypotentialpitfalls.
Boilercarryovercanbecomeaveryseriousproblemresultingfromreducingsystempressure
o Equipmentfouling
o Equipmenterosion
o Energyloss
o Waterhammer
o Watertreatmentcosts
Pressurereductioncanbeaccomplishedaftertheboiler
o Boilerefficiencyimprovementwillnotbeattained
Boilerefficiencyimprovementistypicallythelargestimpact
Slide66
PressureReduction5
Asaresult,thedecisiontoreducesteamsystemoperatingpressureshouldbethoroughlyinvestigated.
Exercisecautionwhenimplementingthisactivity
o Therearemanypotentialproblems
o Systempressurereductionisacommonrecommendation
Thisrecommendationmaynotreceiveasmuchevaluationasnecessary
June29,2010
ConclusionModule
Slide1Conclusions
Letsbrieflyexaminethemajoritemswehavecoveredinthistraining.
[SlideVisualContentsofModuleSections]
Conclusion
ObjectivesReview
AdditionalResources
Contacts
Homework
Slide2CourseObjectives
Wehadalonglistofitemstoaddressinthistraining.
[SlideVisualCourseObjectives]
BecomefamiliarwithU.S.DOEToolsSuitetoassesssteamsystems
Identifythemeasurementsrequiredtomanagesteamsystems
Measureboilerefficiency
Estimatethemagnitudeofspecificboilerlosses
Identifyandprioritizeareasofboilerefficiencyimprovement
Recognizetheimpactsoffuelselection
Characterizetheimpactofbackpressureandcondensingsteamturbines
Quantifytheimportanceofmanagingsteamconsumption
Identifytherequirementsofasteamtrapmanagementprogram
Evaluatetheeffectivenessofthermalinsulation
Evaluatetheimpactofcondensaterecovery
Recognizetheeconomicimpactsofsteamsystemoperations
ConclusionModule1
June28,2010

Slide3Tools
YouwereintroducedtotheU.S.DOESteamTools,theScopingTool,theAssessmentTool,andtheInsulationTool.
[SlideVisualTools]
Inordertoproperlyevaluatesteamsystemsthephysicsofeachprocessmustbeunderstood
o Thermodynamics
o Heattransfer
o Fluidflow
U.S.DOEToolsSuite
o SteamSystemSurveyGuide
o SteamSystemScopingTool(SSST)
o SteamSystemAssessmentTool(SSAT)
o Insulationevaluationsoftware3EPlus
Processmeasurements
Slide4Measure
Weemphasizedtheimportanceofmeasurementsandthemanagementconsequencesdevelopedfromeachmeasurement.
Slide5PrimaryMeasurements
Wepointedoutmanyoftheessentialmeasurementsrequiredtomanagethesteamsystem.
[SlideVisualPrimaryMeasurements]
Boiler
o
o
o
o
o
o
o
o
Fluegastemperature
Fluegasoxygencontent
Boilerfuelflow
Boilersteamflow
Waterchemistry
Blowdownrate
Boilerefficiency
Combustibles
ConclusionModule2
June28,2010

Systembalancing
o PRVsteamflows
o Turbineefficiencies
o Electricalunitcost
Steamconsumers
o Steamconsumption
o Controlsetpoints
Condensatereturn
o Makeupwaterflow
o Condensaterecovery
Steamtrapperformance
System
o Fuelunitcost
o Totalfuelconsumption
o Steamproduction
Slide6BoilerEfficiency
Weexploredtheclassicdefinitionofboilerefficiencyandtheimplicationsitholds.
[SlideVisualClassicBoilerEfficiency]
n boiler =energydesired/x(100)
energythatcosts
Theboilerefficiencyisequaltotheenergydesireddividedbytheenergythatcosts.
n boiler =m steam (h steam h feedwater )/x(100)

m fuel HHV fuel
Boilerefficiencyisequaltothemassflowrateofthesteammultipliedbythedifferenceintheenthalpyofthesteamandtheenthalpyofthe
feedwater;dividedbythemassflowofthefuelmultipliedbythehigherheatingvalueofthefuel
Abbreviations
h
ConclusionModule3
June28,2010
Slide7IndirectEfficiency
Weexaminedtheindirectboilerefficiencymethod.
[SlideVisualIndirectBoilerEfficiency]
losses.
Abbreviations
n indirect =Indirectefficiency
E losses =SumofallLosses
ConclusionModule4
June28,2010

Slide8StackLossNaturalGas
Weidentifiedthetechniquesavailabletoallowtheindividualboilerlossestobequantified.
StackLossTableforNaturalGas
FlueGas
Oxygen
Content
WetBasis
[%]
155
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
Actual
ExhaustT
[F]
AmbientT
[F]
13.1
13.2
13.4
13.6
13.8
14.1
14.4
14.7
15.1
15.5
180
13.6
13.8
14.0
14.2
14.5
14.8
15.1
15.5
16.0
16.5
205
14.1
14.3
14.6
14.8
15.1
15.5
15.9
16.3
16.8
17.4
225
250
275
70
70
70
230 255 280 305 330 355 380 405
430
14.7
14.9
15.2
15.5
15.8
16.2
16.6
17.1
17.7
18.4
18.5
18.9
19.4
20.0
20.5
21.2
22.0
22.9
23.9
25.2
19.1
19.5
20.0
20.6
21.2
22.0
22.8
23.7
24.8
26.1
300 325 350 375 400 425 450 475
500
70
15.2
15.5
15.8
16.1
16.5
16.9
17.4
17.9
18.6
19.4
70
15.8
16.1
16.4
16.7
17.2
17.6
18.1
18.8
19.5
20.3
70
16.3
16.6
17.0
17.4
17.8
18.3
18.9
19.6
20.4
21.3
70
16.9
17.2
17.6
18.0
18.5
19.1
19.7
20.4
21.2
22.2
70
17.4
17.8
18.2
18.7
19.2
19.8
20.5
21.2
22.1
23.2
70
18.0
18.4
18.8
19.3
19.9
20.5
21.2
22.1
23.0
24.2
70
70
70
ConclusionModule5
June28,2010

Slide9FuelSelection
Weaddressedsomeofthemainfuelselectionissues.
Fuel:GreenWood
FluegasexitT:400F
Fluegasoxygen:5.0%
Efficiency:~71.3%
Fuel:Naturalgas
FluegasexitT:300F
Fluegasoxygen:5.0%
Efficiency:~84.2%
Fuel:Number6oilHS
FluegasexitT:350F
Fluegasoxygen:5.0%
Efficiency:~87.4%
ConclusionModule6
June28,2010
Slide10BackPressureTurbines
Thefundamentalsofbackpressuresteamturbineswerepresented.
[SlideVisualBackpressureTurbineEconomics]
theboiler.
Slide11CondensingTurbines
Theoperatingcharacteristicsofcondensingsteamturbineswereidentified.
[SlideVisualCondensingTurbinePerformance]
CondensingTurbineImpactPowerCost
Fuel
ImpactCondensingPowerCost[$/MWh]
Cost
TurbineIsentropicEfficiency[%]
[$/10Btu]
40
60
80
2.00
56
39
30
4.00
111
78
60
6.00
167
116
89
8.00
223
155
119
10.00
278
194
149
12.00
334
233
179
Steaminlet
400
psig
Steaminlet
700
F
Steamexit
1.4
psia
ConclusionModule7
June28,2010

Slide12SteamDemandCosts
Wediscussedsteamendusecomponents.
Slide13MaintenanceProgram
Thefoundationalcomponentsforaworldclasssteamtrapmanagementprogramwerediscussed.
Trainingisessential
Investigateeachtrapatleastonetimeeachyear(problemareasandhighpressureshouldbemorefrequent)
o Performance
Testingequipmentisrequired
Anorderofmagnitudeleakrateshouldbedeterminedforfailedtraps
Orificecalculationssetthemaximumsteamflow
o Traptype
Trapselectionshouldmatchtheapplication
Universalmountscanbeagoodoption
o Installation
o Establishaninvestigationroute
o Condensatereturn
o Outsourcingcanbeagoodoption
Maintainasteamtrapdatabase
Prioritizerepairsbasedonlossestimates
ConclusionModule8
June28,2010
Dailymonitorreceivervents
Slide14InsulationSavings
Insulationissuesandevaluationswereaddressed.
[SlideVisual3EPlus]
EnergyTabandCostofEnergy
GeometryDescription:PipeHorizontal
BareSurfaceEmittance:0.8
NPSPipeSize:10in,
WindSpeed:3mph
FuelType:NaturalGas
FuelCost:10.00$/Mcf
Hours/Year:8760hoursperyear
OuterJacketMaterial:Aluminum,oxidized,inservice
OuterSurfaceEmittance:0.1
InsulationLayer1:CalciumsilicateBLK+PIPE,TypeI
Thickness:3.08in
Variable
Insulation
Thickness
Bare
Layer1
Cost
($/ft/yr)
HeatLoss
(Btu/ft/yr)
636.90
28.74
50950000
2300000
Savings($/ft/yr)
608.200
Savings=608$/ftyr(20ft)12,000$/hr
ConclusionModule9
June28,2010
Slide15CondensateReturnExample
Theimportantaspectsofcondensaterecoverywereidentified.
[SlideVisualCondensateRecovery]
Slide16DrivingForce
Inalloftheseareasweconnectedtherealworldequipmenttotheenergyanalysisandwetranslatedourfindingsintothelanguageofbusiness
economics.
[SlideVisualDrivingForceforChange]
Energy
Reliability
Maintenance
Productivity
Quality
Costavoidance
Emissionsreductions
ConclusionModule10
June28,2010

Slide17ContactInformation
Hereissomecontactinformationforthistraining,includingwebsites,emailaddresses,andphonenumbers.
[SlideVisualContactInformation]
BestPracticesSteam
http://www1.eere.energy.gov/industry/bestpractices/
o Tools
o Books
o Factsheets
o Tipsheets
SaveEnergyNowAssessments
IndustrialAssessmentCenters
EEREInformationCenter
o (800)8622086
o eereic@ee.doe.gov
TonyWright
o USDOEBestPracticesTechnicalManager
o (865)5746878
o wrightal@ornl.gov
BillOrthwein
o USDOEBestPracticesProgramManager
o (202)5863807
o william.orthwein@ee.doe.gov
ConclusionModule11
June28,2010

Slide18U.S.DOETipSheets
TheDepartmentofEnergyhasdevelopedreferencematerialstohelpidentifysteamsystemimprovementopportunities.Thisisalistoftipsheetsthat
canhelpyoueffectivelymanageyoursteamsystem.Theycanallbefoundatthewebaddressatthebottomofthescreen.
[SlideVisualTipSheets]
o BenchmarktheFuelCostofSteamGeneration
o CleanBoilerWatersideHeatTransferSurfaces
o ConsiderInstallingaCondensingEconomizer
o ConsiderInstallingHighPressureBoilerswithBackpressureTurbineGenerators
o ConsiderInstallingTurbulatorsonTwoandThreePassFiretubeBoilers
o ConsiderSteamTurbineDrivesforRotatingEquipment
o ConsiderationsWhenSelectingaCondensingEconomizer
o CoverHeated,OpenVessels
o DeaeratorsinIndustrialSteamSystems
o FlashHighPressureCondensatetoRegenerateLowPressureSteam
o InspectandRepairSteamTraps
o InstallanAutomaticBlowdownControlSystem
o InstallRemovableInsulationonValvesandFittings
o InsulateSteamDistributionandCondensateReturnLines
o ImproveYourBoiler'sCombustionEfficiency
o MinimizeBoilerBlowdown
o MinimizeBoilerShortCyclingLosses
o RecoverHeatfromBoilerBlowdown
o ReplacePressureReducingValveswithBackpressureTurbogenerators
o ReturnCondensatetotheBoiler
o UpgradeBoilerswithEnergyEfficientBurners
o UseFeedwaterEconomizersforWasteHeatRecovery
o UseLowGradeWasteSteamtoPowerAbsorptionChillers
o UseSteamJetEjectorsorThermocompressorstoReduceVentingofLowPressureSteam
o UseVaporRecompressiontoRecoverLowPressureWasteSteam
o UseaVentCondensertoRecoverFlashSteamEnergy
http://www1.eere.energy.gov/industry/bestpractices/tip_sheets_steam.html
ConclusionModule12
June28,2010

Slide19U.S.DOETechnicalDocuments
FormoredetailedandindepthinformationtheDepartmentofEnergyhasdevelopedTechnicalDocuments.Hereisalistoftechnicaldocumentsthat
canhelpyoueffectivelymanageyoursteamsystem.Theycanallbefoundatthewebaddressatthebottomofthescreen.
[SlideVisualTechnicalPublications]]
o ImprovingSteamSystemPerformance:ASourcebookforIndustry
o AchieveSteamSystemExcellence:IndustrialTechnologiesProgramBestPracticesSteamOverviewFactSheet
o BestPracticesSteamTechnicalBrief:SteamPressureReductionOpportunitiesandIssues
o BestPracticesSteamTechnicalBrief:HowtoCalculatetheTrueCostofSteam
o BestPracticesSteamTechnicalBrief:IndustrialHeatPumpsforSteamandFuelSavings
o BestPracticesSteamTechnicalBrief:IndustrialSteamSystemHeatTransferSolutions
o BestPracticesSteamTechnicalBrief:IndustrialSteamSystemProcessControlSchemes
o GuidetoCombinedHeatandPowerSystemsforBoilerOwnersandOperators
o GuidetoLowEmissionBoilerandCombustionEquipmentSelection
o ReviewofOrificePlateSteamTraps
o SaveEnergyNowinYourSteamSystems
o SteamDigest:VolumeIV(2003)
o SteamDigest2002
o SteamDigest2001
o SteamSystemsEnergyEfficiencyHandbook
o SteamSystemsSurveyGuide
http://www1.eere.energy.gov/industry/bestpractices/techpubs_steam.html
Slide20Homework
Foryourhomework,taketheSteamSystemToolSuiteIntroductionwebbasedtraining,ifyouhavenotalready.Then,trytoapplyittoyourownsteam
systemtoidentifyatleastoneenergyefficientimprovement.
Slide21ThankYou!
YouhavecompletedthetechnicalcomponentoftheSteamSystemEndUserTraining.Inordertocompletethetraining,testyourknowledgewiththe
EndofCourseQuiz.Youcanalsorevisitthetrainingcourseinitsentiretyorreviewaparticularindividualmoduleofinterest.Thankyouforyourtime
andeffort!
ConclusionModule13
June28,2010
EndofCourseQuiz
SteamEndUserQuiz
Thefollowing20questionquizwillhelptestyourunderstandingoftheSteamSystemBasics.
Pleaseselectthebestanswerbyclickingonthemultiplechoiceanswers.Ifyouanswerincorrectly,youwillbepromptedtotryagain.
Popupscreenswillbeprovidedforselectedquestionstoreinforceatopicorprovideaclue
Name_________________
Email_________________
Question1
BoilerEfficiencyisanattempttoidentifytheamountoffuelenergyconvertedintosteamenergy.
1. True
a. Trueisthecorrectresponse.
b. Thesimple,classicequationforboilerefficiencyisasfollows.
2. False
a. Thisisanincorrectresponse.
b. Boilerefficiencyisdefinedtodescribetheratioofdesiredenergycomparedtotheenergypurchased.
boiler
boiler
energy desired
energy that costs
steam
steam
h feedwater
m HHV
fuel
fuel
Question2
Boilerefficiencyislessthan100%becauseoflosses.Formostboilersthemostsignificantlossisknownaswhat?
1. Shellloss
b. Shelllosses(alsoknownasRadiationandConvectionLosses)aretypicallyaminorlosscomponent,oftenlessthan1%offuelinputenergy.
June29,2010
EndofCourseQuizModule1

2.
3.
4.
5.
6.
7.
Blowdownloss
b. Blowdownlossesaretypicallylessthan2%offuelinputenergy.Itisgoodtonotethatblowdownlossescanalmostbeeliminatedwith
simpleenergyrecoverymeasures.
Sootblowingloss
b. Sootblowingisusedtodislodgeashandothersolidmaterialsfromheattransfersurfacesofboilers.Sootblowersaretypicallyonlyused
whenburningsolidfuelsandheavyfueloils.Thislossiscommonlylessthan1%offuelinputenergy.
Oilheatingloss
b. Heavyheatingoilsmustbeheatedtoallowproperflowthroughtheburnersystem.Fueloilheatingistypicallylessthan1%offuelinput
energyandtheenergyisnottotallylostbecausetheheatingenergyisinputtotheflame.
Stackloss
a. Thisisthecorrectresponse.
b. Stacklosscharacterizesthetemperatureandcombustionaspectsofthefluegas.Stacklossrangesbetween8%and25%offuelinput
energy.Thisrangeisprimarilydependentonthefueltype,combustioncontrolcharacteristics,andheatrecoverycomponentsofthe
boiler.
Unburnedcarbonloss,alsoknownasLossOnIgnition(LOI)
b. Unburnedcarbonlossistypicallyafactorwhenburningfuelswithsignificantamountsofash.Mostcommonlythislossislessthan1%of
fuelinputenergy.
Ashloss
b. Fuelscontainingash(noncombustiblematerial)presentalossassociatedwiththeashremovingheatfromtheboilerasthefuelentersthe
boileratarelativelylowtemperatureandtheashexitstheboilerwithahightemperature.Theashlossistypicallylessthan1%offuel
inputenergy.
Question3
Indirectboilerefficiencyevaluatesboilerperformancebymeasuringandestimatingtheindividualenergylossesoftheboiler.Identificationoftheamount
ofenergyexitingtheboilerwitheachlosshelpstoidentifywhichareasofboileroperationtotargetforimprovement.
1. True
b. Measurementandevaluationtechniqueshavebeendevelopedtoidentifythemagnitudeofeachboilerloss.
c. Establishingthemagnitudeofeachboilerloss,understandingtheirpracticallimits,andknowingtherealworldmethodsavailableto
reduceorrecapturethelossallowsanimprovementpathtobeestablishedfortheboiler.
d. Indirectboilerefficiencyisexpressedinthefollowingequation.
2. False
b. Measurementandevaluationtechniqueshavebeendevelopedtoidentifythemagnitudeofeachboilerloss.
c. Establishingthemagnitudeofeachboilerloss,understandingtheirpracticallimits,andknowingtherealworldmethodsavailableto
reduceorrecapturethelossallowsanimprovementpathtobeestablishedfortheboiler.
June29,2010

d.
Indirectboilerefficiencyisexpressedinthefollowingequation.
indirect
indirect
100%
losses
100% stack blowdown shell misc
Question4
Identifyameasurementthatcanhelpyoumanageboilerresources.
1. Fluegasexittemperature
b. Thismeasurementisrequiredtoestablishboilerstacklossandtodevelopanimprovementstrategy.
2. Fluegasoxygencontent
b. Thismeasurementisrequiredtoestablishboilerstacklossandtodevelopanimprovementstrategy.
3. Fluegascombustiblescontent
b. Thismeasurementisrequiredtoensurethecombustionzoneoxygencontentissufficienttosustaingoodcombustionandtoevaluatethe
burnerperformance.
4. AshLossOnIgnition(LOI)
b. Thismeasurementisrequiredtoestablishunburnedcarbonlossandtodevelopanimprovementstrategy.
5. Ambienttemperature
b. Thismeasurementisrequiredtoestablishboilerstacklossbecausefluegastemperatureisdependentonambienttemperature.
6. Boilershellsurfacetemperatures
b. Thismeasurementisrequiredtoidentifytheeffectivenessofboilerrefractory,insulation,andcladding.
c. Shelltemperaturesshouldbelessthan180Fformostboileroperatingconditions.
d. Hotspotscanbeidentifiedandtargetedforrepair.
7. Blowdownfraction
b. Thismeasurementisrequiredtoestablishtheblowdownlossandtodevelopanimprovementstrategy.
8. Alloftheabove
a. Thisiscorrectresponse.
b.Thesemeasurementsareallrequiredtohelpyoumanageboilerresources.
June29,2010
Question5
Whichoftheseaspectsisnotassociatedwithboilerblowdown?
1. Canbefullyreinjectedtothefeedwatersystem.
b. Liquidblowdownmustbediscardedfromthesystembecauseitcontainsimpuritiesthathavenootherwayoutofthesystemexcept
throughtheliquidblowdownstream.
c. Flashsteamformedfromtheliquidblowdownstreamcanbedirectlyreinjectedinthesteamsystem;aslongas,thesteamisfreeof
droplets.
2. Willoftenbereducedifadditionalcondensateisreturnedtotheboiler.
b. Condensateiscommonlythecleanestwateravailabletoasteamsystem.Recoveringadditionalcondensatewillreducethesupplyof
makeupwatertotheboiler.Thiswillgenerallyimprovethequalityoffeedwaterreducingtheneedforblowdown.
3. Isoftenreducedbysupplyingthesystemhigherquality(cleaner)makeupwater.
b. Improvingmakeupwatertreatmentwillreducetheamountofdissolvedmineralsenteringtheboiler.
c. Typicalsystemsusedtoimprovemakeupwaterqualityincludethefollowing.
i. Sodiumcyclesoftening(thisiscommoninmoststeamsystems).
ii. Demineralization.
iii. Reverseosmosis.
4. Iscommonlycontrolledwithsimpleconductivitycontrolthatisverifiedthroughadditionalwaterchemistrymeasurements.
b. Commonblowdowncontrolisbasedonboilerwaterconductivity.Theconductivitycontrolsetpointsareestablishedandverifiedthrough
accurateanalysisofboilerwaterimpurities.
5. Theenergylossofblowdowncanessentiallybeeliminatedthroughtheinstallationofablowdownthermalenergyrecoverysystem.
b. Blowdownthermalenergyrecoverysystemsaresimple,effective,andlowcostcomponentsthatcandramaticallyreducetheloss
associatedwithboilerblowdown.
Question6
Identifythebasicprincipleefficientcombustioncontrolisbasedupon.
1. Supplythecombustionzonemoreoxygenthantheoreticallynecessarytoensureallthefuelcombusts.
b. CombustionManagementPrincipleNumber1istosupplythecombustionzonewithmoreoxygenthanistheoreticallyrequiredtoensure
allfuelcomponentshaveachancetoreactandreleaseenergy.
2. Limittheamountofairsuppliedtotheboilertoreducethermallosses.
b. CombustionManagementPrincipleNumber2istolimittheamountofexcessairpassingthroughtheboilerbecausetheextraairentersthe
boileratambienttemperatureandisheatedtofluegastemperaturethroughthepurchaseofadditionalfuel.
June29,2010

3.
Measurefluegasoxygencontentandmodifythecombustioncontrolsystemtoensuretheproperamountofexcessairissuppliedtothe
combustionzone.
b. Positioningcontrolshouldbereadjustedfrequentlytotunetheperformancecharacteristicsofthecombustionprocess.
c. Automaticcombustioncontrolcontinuouslymonitorsandmaintainstheoxygencontenttoasetpoint.
4. Measurefluegascombustiblesconcentrationtoensureexcessairisminimizedandtoensurethefuelisbeingfullyutilized.
b. Minimumcombustionzoneoxygenconcentrationsareestablishedbymeasuringcombustiblesconcentrations.
5. Identifythestacklossfortheboileroperatingconditionsandestablishthepathforwardfortheboileroperations.
b. Identifyingthepracticalstacklossreductionandtheeconomicimpactassociatedwithitarevitalfactorsinestablishingthepathforward
foraboiler.
6. Alloftheabove
a. Thisiscorrectresponse.
b.Thesemeasurementsareallrequiredtohelpyoumanageboilerresources.
Question7
UtilizinganAutomaticCombustionControlsystemgenerallyimprovesboilerperformancewhencomparedtoaPositioningCombustionControlsystem.
1. True
b. ThetablebelowidentifiestheexpectedfluegasoxygencontentforAutomaticControlandPositioningControl.
2. False
b. ThetablebelowidentifiestheexpectedfluegasoxygencontentforAutomaticControlandPositioningControl.
FlueGasOxygenContentControlParameters
Fuel
NaturalGas
Numb.2FuelOil
Numb.6FuelOil
PulverizedCoal
StokerCoal
June29,2010
Automatic
Control
FlueGasO2
Content
Min.
Max.
Positioning
Control
FlueGasO2
Content
Min.
Max.
Automatic
Control
ExcessAir
Positioning
Control
ExcessAir
Min.
Max.
Min.
Max.
[%]
1.5
2.0
2.5
2.5
[%]
3.0
3.0
3.5
4.0
[%]
3.0
3.0
3.5
4.0
[%]
7.0
7.0
8.0
7.0
[%]
9
11
14
14
[%]
18
18
21
25
[%]
18
18
21
25
[%]
55
55
65
50
3.5
5.0
5.0
8.0
20
32
32
65

Question8
Determinethestacklossforaboilerburningnaturalgasandoperatingwiththefollowingconditions.
Fluegastemperatureof400F
Fluegasoxygencontentof5.0% wet
Ambienttemperatureof70F
Combustiblesconcentrationof10ppm
Blowdownrateof6%offeedwaterflow
Shelltemperatureofapproximately140F
FlueGas
Oxygen
Content
WetBasis[%]
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
{Differencebetweenfluegasexhausttemperatureand
ambienttemperature}
155 180 205
13.113.6 14.1
13.213.8 14.3
13.414.0 14.6
13.614.2 14.8
13.814.5 15.1
14.114.8 15.5
14.415.1 15.9
14.715.5 16.3
15.116.0 16.8
230 255 280

14.7 15.2 15.8
14.9 15.5 16.1
15.2 15.8 16.4
15.5 16.1 16.7
15.8 16.5 17.2
16.2 16.9 17.6
16.6 17.4 18.1
17.1 17.9 18.8
17.7 18.6 19.5
305
16.3
16.6
17.0
17.4
17.8
18.3
18.9
19.6
20.4
330
16.9
17.2
17.6
18.0
18.5
19.1
19.7
20.4
21.2
355
17.4
17.8
18.2
18.7
19.2
19.8
20.5
21.2
22.1
380
18.0
18.4
18.8
19.3
19.9
20.5
21.2
22.1
23.0
405
18.5
18.9
19.4
20.0
20.5
21.2
22.0
22.9
23.9
430
19.1
19.5
20.0
20.6
21.2
22.0
22.8
23.7
24.8
15.516.5 17.4 18.4 19.4 20.3 21.3 22.2 23.2 24.2 25.2 26.1
ActualExhaustT[F] 225 250 275 300 325 350 375 400 425 450 475 500
AmbientT[F]
1.
2.
3.
4.
5.
74.5%
a.
80.0%
a.
81.5%
a.
83.0%
a.
87.2%
a.
June29,2010
70 70 70 70 70 70 70 70 70 70 70 70
Thisisanincorrectresponse.
Thisisthecorrectresponse.
FlueGas
Oxygen
Content
WetBasis[%]
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
ambienttemperature}
155 180
13.1 13.6
13.2 13.8
13.4 14.0
13.6 14.2
13.8 14.5
14.1 14.8
14.4 15.1
14.7 15.5
15.1 16.0
205
14.1
14.3
14.6
14.8
15.1
15.5
15.9
16.3
16.8
230
14.7
14.9
15.2
15.5
15.8
16.2
16.6
17.1
17.7
255
15.2
15.5
15.8
16.1
16.5
16.9
17.4
17.9
18.6
280
15.8
16.1
16.4
16.7
17.2
17.6
18.1
18.8
19.5
305
16.3
16.6
17.0
17.4
17.8
18.3
18.9
19.6
20.4
330
16.9
17.2
17.6
18.0
18.5
19.1
19.7
20.4
21.2
355
17.4
17.8
18.2
18.7
19.2
19.8
20.5
21.2
22.1
380
18.0
18.4
18.8
19.3
19.9
20.5
21.2
22.1
23.0
405
18.5
18.9
19.4
20.0
20.5
21.2
22.0
22.9
23.9
430
19.1
19.5
20.0
20.6
21.2
22.0
22.8
23.7
24.8
15.5 16.5 17.4 18.4 19.4 20.3 21.3 22.2 23.2 24.2 25.2 26.1
AmbientT[F]
70 70
70
70 70
70
70
70
70
70
70
70
stack 100% stack

stack 100% 18.5%
stack 81.5%
June29,2010
Question9
Anolderboilerisoperatingwithanaturalgasfuelconsumptionof$5,000,000/yr.Thecombustioncontrolmaintainsafluegasoxygencontentof
approximately4.0% wet overthetypicaloperatingrangeoftheboiler.Theboilerwasnotoriginallyequippedwithafeedwatereconomizer.Thecurrentflue
gastemperatureischaracterizedas450F,withanambienttemperatureof70F,andforthegeneraloperatingconditionsoftheboiler.Afeedwater
economizermanufacturercansupplyaneconomizerforthisboilerthatwillrecoverthermalenergyfromthefluegas.Theresultingfluegastemperatureis
predictedtobe300Fforthetypicaloperatingconditionsoftheboiler.Estimatethefuelcostsavingspotential.
FlueGas
Oxygen
Content
WetBasis[%]
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
ambienttemperature}
155 180 205
13.113.6 14.1
13.213.8 14.3
13.414.0 14.6
13.614.2 14.8
13.814.5 15.1
14.114.8 15.5
14.415.1 15.9
14.715.5 16.3
15.116.0 16.8
230 255 280

14.7 15.2 15.8
14.9 15.5 16.1
15.2 15.8 16.4
15.5 16.1 16.7
15.8 16.5 17.2
16.2 16.9 17.6
16.6 17.4 18.1
17.1 17.9 18.8
17.7 18.6 19.5
305
16.3
16.6
17.0
17.4
17.8
18.3
18.9
19.6
20.4
330
16.9
17.2
17.6
18.0
18.5
19.1
19.7
20.4
21.2
355
17.4
17.8
18.2
18.7
19.2
19.8
20.5
21.2
22.1
380
18.0
18.4
18.8
19.3
19.9
20.5
21.2
22.1
23.0
405
18.5
18.9
19.4
20.0
20.5
21.2
22.0
22.9
23.9
430
19.1
19.5
20.0
20.6
21.2
22.0
22.8
23.7
24.8
15.516.5 17.4 18.4 19.4 20.3 21.3 22.2 23.2 24.2 25.2 26.1
AmbientT[F]
70 70 70 70 70 70 70 70 70 70 70 70
1. $40,000/yr
2. $100,000/yr
3. $160,000/yr
4. $220,000/yr
5. $280,000/yr
6. $340,000/yr
June29,2010

FlueGas
{Differencebetweenfluegasexhausttemperatureandambient
Oxygen
temperature}
Content
WetBasis[%]
155 180 205 230 255 280 305 330 355 380 405 430
1.0
13.1 13.6 14.1 14.7 15.2 15.8 16.3 16.9 17.4 18.0 18.5 19.1
2.0
13.2 13.8 14.3 14.9 15.5 16.1 16.6 17.2 17.8 18.4 18.9 19.5
3.0
13.4 14.0 14.6 15.2 15.8 16.4 17.0 17.6 18.2 18.8 19.4 20.0
4.0
13.6 14.2 14.8 15.5 16.1 16.7 17.4 18.0 18.7 19.3 20.0 20.6
5.0
13.8 14.5 15.1 15.8 16.5 17.2 17.8 18.5 19.2 19.9 20.5 21.2
6.0
14.1 14.8 15.5 16.2 16.9 17.6 18.3 19.1 19.8 20.5 21.2 22.0
7.0
14.4 15.1 15.9 16.6 17.4 18.1 18.9 19.7 20.5 21.2 22.0 22.8
8.0
14.7 15.5 16.3 17.1 17.9 18.8 19.6 20.4 21.2 22.1 22.9 23.7
9.0
15.1 16.0 16.8 17.7 18.6 19.5 20.4 21.2 22.1 23.0 23.9 24.8
10.0
15.5 16.5 17.4 18.4 19.4 20.3 21.3 22.2 23.2 24.2 25.2 26.1
AmbientT[F]
70 70 70 70 70 70 70 70 70 70 70
70

economizer 1 old fuel
new
100% 19.3%
econ 1
100% 15.5%
econ
June29,2010
163,000 yr$
5,000,000 yr$
Question10
Reducingsteamconsumptionatthepointofusewillresultinevenmoresavingsattheboiler.
1. True
b. Theenergythatwassaved(steamsavings)atthepointofusewasprovidedtothesystemthroughtheboiler,whichexperienceslosses.
Forexample,ifboilerefficiencyis80%thensaving100unitsofsteamenergyatthepointofusewillreducefuelconsumption100/0.8
unitsoffuelenergyor125fuelunits.Thisdoesnotconsidercondensatelossesandothersystemeffects.
c. Additionalsavingscanresultfrom:
i. Chemicals,
ii. Maintenanceactivities,
iii. Waterpurchases,
iv. Environmentalimpacts.
2. False
b. Theenergythatwassaved(steamsavings)atthepointofusewasprovidedtothesystemthroughtheboiler,whichexperienceslosses.
Forexample,ifboilerefficiencyis80%thensaving100unitsofsteamenergyatthepointofusewillreducefuelconsumption100/0.8
unitsoffuelenergyor125fuelunits.Thisdoesnotconsidercondensatelossesandothersystemeffects.
c. Additionalsavingscanresultfrom:
i. Chemicals,
ii. Maintenanceactivities,
iii. Waterpurchases,
iv. Environmentalimpacts.
Question11
Backpressuresteamturbinesgeneratepoweratnocost.
1. True
b. Backpressureturbinesconvertsteamthermalenergyintoshaftpower.Thethermalenergyinthesteamwasprovidedfromfuelenergyin
theboiler.Asaresult,backpressureturbinesgenerateshaftpoweratthecostofsteamenergy.Thecostofsteamenergyisbasicallythe
costoffueldividedbyboilerefficiency.
c. Thetablebelowidentifiesthegeneralcostofbackpressureturbineoperation.
2. False
b. Backpressureturbinesconvertsteamthermalenergyintoshaftpower.Thethermalenergyinthesteamwasprovidedfromfuelenergyin
theboiler.Asaresult,backpressureturbinesgenerateshaftpoweratthecostofsteamenergy.Thecostofsteamenergyisbasicallythe
costoffueldividedbyboilerefficiency.
c. Thetablebelowidentifiesthegeneralcostofbackpressureturbineoperation.
June29,2010

Fuel
Cost
[$/10Btu]
2.00
4.00
6.00
8.00
10.00
12.00
14.00
16.00
18.00
Boiler
Backpressure
Efficiency
Turbine
Power
Impact
[%]
[$/MWh]
85.00
8.0
85.00
16.1
85.00
24.1
85.00
32.1
85.00
40.2
85.00
48.2
85.00
56.2
85.00
64.2
85.00
72.3
Question12
Condensingturbinescommonlyconvertlessthan30%oftheboilerfuelenergyintopower.
1. True
b. Condensingsteamturbinescommonlygeneratelessthan30unitsofshaftpowerforevery100unitsofthermalenergysuppliedinthe
steam.Thesteamthermalenergyissuppliedintheboiler,whichoperateswithlossesoftenresultinginlessthan25%ofthefuelinput
energyconvertedintopower.
2. False
b. Condensingsteamturbinescommonlygeneratelessthan30unitsofshaftpowerforevery100unitsofthermalenergysuppliedinthe
steam.Thesteamthermalenergyissuppliedintheboiler,whichoperateswithlossesoftenresultinginlessthan25%ofthefuelinput
energyconvertedintopower.
Question13
Evaluatingthecomplicatedinteractionsofsteamsystemcomponentsrequiresskill,knowledge,andrealworldexperience.
1. True
b. Managementofsteamsystemsrequiresunderstandingofphysicsandtherealworldsystemcomponents.
c. TheSteamSystemAssessmentTool(SSAT)enhancestheabilityofinvestigatorstoaccurateevaluatetheimpactsofsteamsystemchanges.
2. False
b. Managementofsteamsystemsrequiresunderstandingofphysicsandtherealworldsystemcomponents.
c. TheSteamSystemAssessmentTool(SSAT)enhancestheabilityofinvestigatorstoaccurateevaluatetheimpactsofsteamsystemchanges.
June29,2010

Question14
Steamtrapsarenotcapableofsignificantwaste.
1. True
b. Asinglesteamtrapcanpassatremendousamountofsteamifitfailsopen.
c. Afailedopensteamtrapcanpressurizethecondensatecollectionsystemcausingothertrapstonotfunctionproperly.
d. Afailedclosedsteamtrapcanresultinproductionequipmentnotperforming.
e. Asteamtrapdrainingasteamheadercanleadtodamagingwaterhammeriffailedclosed.
2. False
b. Asinglesteamtrapcanpassatremendousamountofsteamifitfailsopen.
c. Afailedopensteamtrapcanpressurizethecondensatecollectionsystemcausingothertrapstonotfunctionproperly.
d. Afailedclosedsteamtrapcanresultinproductionequipmentnotperforming.
e. Asteamtrapdrainingasteamheadercanleadtodamagingwaterhammeriffailedclosed.
Question15
Steamtrapselectionshouldbebasedonpurchasecostandeaseofinstallation.
1. True
b. Thevarioustypesofsteamtraps(floatandthermostatic,thermodynamic,thermostatic,invertedbucket,andothers)weredevelopedfor
specificprimaryapplication.
2. False
b. Thevarioustypesofsteamtraps(floatandthermostatic,thermodynamic,thermostatic,invertedbucket,andothers)weredevelopedfor
specificprimaryapplication.
Question16
Evaluatingtheenergylossassociatedwithmissingordamagedinsulationisextremelycomplicatedrequiringhighlytrainedexpertswithyearsoffield
experience.
1. True
b. Theinsulationevaluationtool,3EPlus,allowsaccurateevaluationstobecompletedbypersonnelwithminimaltraining.
2. False
b. Theinsulationevaluationtool,3EPlus,allowsaccurateevaluationstobecompletedbypersonnelwithminimaltraining.
June29,2010
Question17
Increasingtheamountofcondensaterecoverywillgenerallynothavewhichofthefollowingeffects?
1. Reducefuelconsumption.
b. Relativelyhightemperaturecondensatereturnedtotheboilerwillreducetheamountofrelativelylowtemperaturemakeupwater
broughtintothesystem.Lowtemperaturemakeupwatermustbeheated(usuallywithsteam)tocondensatetemperaturebeforeitis
equivalenttotheworthofcondensate.
c. Condensateshouldbereturnedwiththehighesttemperaturepracticalbecausethethermalenergyinthecondensateistypicallythe
greatestworthofthecondensate.
2. Reducemakeupwaterconsumption.
b. Condensatereturnedtotheboilerwillreducetheamountofmakeupwaterbroughtintothesystem.Makeupwaterisoftenpurchasedor
processedatsomecost.
3. Improveboilerfeedwaterquality.
makeupwatertotheboiler.Thiswillgenerallyimprovethequalityoffeedwaterreducingtheneedforblowdown.
4. Reducewatertreatmentchemicalconsumption.
makeupwatertotheboiler.Makeupwatergenerallyrequiressofteningandoftenadditionaltreatment.Thecleanerfeedwateristheless
boilerandwatertreatmentchemicalsarerequired.
5. Requireexoticpipingmaterials.
b. Steamandcondensatepipingspecificationsdonotrequireexoticmaterialsorconstructionpractices.Themostcommonissues
experiencedincondensatepipingrelatedtomaterialsofconstructionaremetalattackfromacidiccondensateandoxygenpitting.These
issuesaretypicallycombatedthroughtheadditionofdistributionandrecoverypipingprotectivechemicals.
Question18
Flashsteaminacondensatesystemisanegligibleandnecessarypartoftheoperations.
1. True
b. Flashsteamoftencontainsatremendousamountofenergythatpotentiallycanberecoveredthroughcascadecondensatecollection
systemorthermocompressorreintroduction.
c. Flashsteamincondensatepipingcommonlyresultsinwaterhammerleadingtopipingandequipmentfailures.Designsolutionsare
availabletoalleviatethissituation.
d. Whatisthoughttobeflashsteammayactuallybelivesteampassingthroughafailedsteamtrap.
June29,2010

2.
False
a. Thisisacorrectresponse.
b. Flashsteamoftencontainsatremendousamountofenergythatpotentiallycanberecoveredthroughcascadecondensatecollection
systemorthermocompressorreintroduction.
c. Flashsteamincondensatepipingcommonlyresultsinwaterhammerleadingtopipingandequipmentfailures.Designsolutionsare
availabletoalleviatethissituation.
d. Whatisthoughttobeflashsteammayactuallybelivesteampassingthroughafailedsteamtrap.
Question19
Steamsystemsthatdonothavecogenerationcomponentsshouldbeoperatedatapressurethatisjustslightlyhigherthanthepressurerequiredbythe
endusecomponents.
1. True
a. Thisisanincorrectresponsebecausecarefulevaluationmustbecompletedbeforesignificantlydecreasingoperatingpressure.
b. Reducingsteampressurecanhaveenergysavingimpacts.
i. Increasedboilerefficiencycanresultfromthereducedsaturationtemperatureoftheboilingwater.
ii. Decreasedsteamdistributiontemperatureresultinginlowerinsulationlosses.
iii. Decreasedflashsteamlossinthecondensatesystem.
iv. Decreasedleakloss.
c. Reducingsteampressurecanhavedetrimentalsystemimpacts.
i. Operatingboilersatsignificantlyreducedpressurecanresultincarryoverpotentiallycausing:
1. Waterhammer,
2. Equipmenterosion,
3. Increasedchemicalconsumption,
ii. Sufficientpressuremaynotexisttopushcondensatethroughthetrappingandcollectionsystem.
iii. Frictionalpressuredropmaydisruptthedistributionofsteam.
2. False
a. Thisisacorrectresponsebecausecarefulevaluationmustbecompletedbeforesignificantlydecreasingoperatingpressure.
b. Reducingsteampressurecanhaveenergysavingimpacts.
i. Increasedboilerefficiencycanresultfromthereducedsaturationtemperatureoftheboilingwater.
ii. Decreasedsteamdistributiontemperatureresultinginlowerinsulationlosses.
iii. Decreasedflashsteamlossinthecondensatesystem.
iv. Decreasedleakloss.
c. Reducingsteampressurecanhavedetrimentalsystemimpacts.
i. Operatingboilersatsignificantlyreducedpressurecanresultincarryoverpotentiallycausing:
1. Waterhammer,
2. Equipmenterosion,
3. Increasedchemicalconsumption,
ii. Sufficientpressuremaynotexisttopushcondensatethroughthetrappingandcollectionsystem.
iii. Frictionalpressuredropmaydisruptthedistributionofsteam.
June29,2010

Question20
Selectthemeasurementthatcanhelpmanagesteamsystems.
1. Boilerfluegastemperature
b. Fluegastemperatureisindicativeoffuelenergyintheexhaustgas.
c. Monitoringfluegastemperaturecanidentifyoperationalproblems.
2. Boilerfluegasoxygencontent
b. Fluegasoxygencontentistheprimarymeasurementrequiredforcombustioncontrol.
3. Boilerfluegascombustiblesconcentration
b. Minimumcombustionzoneoxygenconcentrationsareestablishedbymeasuringcombustiblesconcentrations.
4. Boilersteamload
b. Manyfactorsaredependentonboilersteamloadfluegasexittemperatureandfluegasoxygencontent,forexample.
5. Ambienttemperature
b. Finalfluegastemperatureisdependentoninletcombustionairtemperature.
6. Condensatereturn
b. Measuringtheamountofcondensatereturnidentifiestheimprovementpotentialandallowsreductionsinreturntobeexplored.
7. Makeupwaterflow
b. Measuringtheamountofmakeupwaterconsumedcanbeusedalongwithsteamflowtoidentifytheamountofcondensatereturn.
8. Steamflow
b. Trendingsteamproductionfromtheboilersidentifiesthetotalsitedemandsandisabasicstepindeterminingclassicboilerefficiency.
9. Fuelconsumption
b. Fuelconsumptionistheprimarycostfactorinboileroperations.
10. Boilerwaterchemistry
b. Waterchemistryanalysisrequiresmanymeasurementsofvariousstreams.Waterchemistrymeasurementsarecriticaltothelongevityof
thesteamsystem.
11. Blowdownrate
b. Blowdownrateisanindicatoroftheeffectivenessofthewatertreatmentsystemandprovidesanavenueofthermalenergyrecovery.
12. Steamenduseflowrates
b. Identificationofthemainconsumersofsteamallowstheresourcestobemanagedmorereadily.
June29,2010

13. Steamendusecontrolparameters
b. Reducingsteamconsumptionatthepointofusewillresultinevenmoresavingsattheboiler.
14. Condensaterecoverytemperature
b. Theprimaryworthofcondensateresidesinthermalenergy.Maintainingthetemperatureofrecoveredcondensatetotheboilerisa
significantpointofconcern.
15. Distributionpipingtemperatures
b. Damagedinsulation,missinginsulation,andimproperinsulationresultinsignificantenergylossandusuallylowcostrepairs.
16. Steamtrapfunction
b. Steamtrapscanfailwastingsignificantamountsofsteam,disruptingproductionequipment,causingwaterhammer,causingothertraps
tonotfunctionproperly.
17. AlloftheAbove
b. Allofthesemeasurementscanhelpmanagesteamsystems.
June29,2010

Thankyou!
YourQuiziscomplete!
WeAppreciateyourParticipationintheDepartmentofEnergys
IndustrialTechnologiesProgramBestPractices
SteamEndUserWebBasedTrainingCourse
BestPracticesTechnologyDeliveryWebsite
http://www1.eere.energy.gov/industry/bestpractices/
GoodLuck!
ForadditionaldiscussionontheQuizAnswers,pleasevisittheAlternateTextVersionoftheEndofCourseQuiz
http://www.ornl.gov/sci/ees/etsd/btric/SteamToolTestSite/Steam%20End%20ELearning/Quiz.pdf
ReturntotheSteamEndUserWebbasedTrainingortoprovideFeedback.
http://www.ornl.gov/sci/ees/etsd/btric/itp_bestpractices_steam_training.shtml
madgettmg@ornl.gov
June29,2010

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n boiler =m steam (h steam h feedwater )/

DOEs BestPractices Steam End User Training

DOEs BestPractices Steam End User Training

n boiler =m steam (h steam h feedwater )/x(100)

DOEs BestPractices Steam End User Training

DOEs BestPractices Steam End User Training

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DOEs BestPractices Steam End User Training

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%Blowdown=C feedwater (100)=15ppm(100)

%Blowdown=6.0% mass offeedwaterflow

m blowdown= (B)m steam

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DOEs BestPractices Steam End User Training

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L blowdown =1.7% energy

DOEs BestPractices Steam End User Training

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