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DOEBestPracticesSteamEndUserTraining
Guide
AlternateTextNarrativesand
GraphicDescriptions
June29,2010
DOE BestPractices Steam End User Training
SteamEndUserTrainingTableofContentsii
June29,2010
TableofContents
Welcome ....................................................................................................................................................................................................... 3
NavigationalTutorial............................................................................................................................................................................... 6
Introduction ................................................................................................................................................................................................ 8
TechnicalModules
SteamGenerationEfficiency
EfficiencyDefinition......................................................................................................................................................30
ShellLosses.......................................................................................................................................................................42
BlowdownLosses ..........................................................................................................................................................45
StackLosses......................................................................................................................................................................73
ResourceUtilizationAnalysis............................................................................................................................................. 114
SteamDistributionSystemLosses ................................................................................................................................... 157
Conclusion.............................................................................................................................................................................................. 188
EndofCourseQuiz ............................................................................................................................................................................ 201
DOEs BestPractices Steam End User Training
WelcomeModule1
June28,2010
SteamEndUserTraining
SteamEndUserTrainingWelcomeModule
Slide1SteamEndUserTraining
WelcometotheDepartmentofEnergysIndustrialTechnologiesProgramBestPracticesSteamEndUserTraining.
[SlideVisualSteamEndUserCourseWelcome]Banner:USDepartmentofEnergyEnergyEfficiencyandRenewableEnergy
USDepartmentofEnergysIndustrialTechnologiesProgram
BestPracticesSteamEndUserTraining
Slide2CourseContentsTherearesevendifferentsectionsinthistraining.Thenavigationaltutorialwillprovideyouwithabriefdemonstrationonhowtonavigatethroughthetraining.TheIntroductionwillprovideyouahistoryofthecoursedevelopment,andthenfocusonthegeneralaspectsofsteamsystemmanagementandinvestigation.Inthissectionwewillintroducethefirstofthesteamsystemsoftwaretools,whichprovidessupportinidentifyingareasofpotentialimprovement.Thiswillprepareyouformoreindepthdiscussionsintheforthcomingsectionsofthetraining.TheSteamGenerationEfficiencymodulefocusesonboilerefficiency.Inthissectionthedefinitionofboilerefficiencywillbediscussedandthevariousavenuesofboilerlosseswillbeexplored.ResourceUtilizationEffectivenesswilldiscussfuelselection,steamdemands,andcogeneration.TheSteamDistributionSystemLossesmodulewillcoversteamleaks,steamtraps,insulationissues,andcondensateloss.EverythingwillbewrappedupwiththeConclusion.Lastly,therewillbeanEndofCourseQuiz,whichwillevaluateyourknowledgeandunderstandingofthetraining.Slide3SteamAssessmentsThiscourseisstructuredlikeatypicalsteamsystemassessment.Theassessmentisdesignedtoinvestigatetheperformancecharacteristicsofthesystem,pointoutbestpractices,identifyopportunitiestoimproveperformance,andevaluatetheeconomicimpactofpotentialimprovements.
DOEs BestPractices Steam End User Training
SteamEndUserTrainingWelcomeModule2
June28,2010
Thistrainingwillprovideanoverviewoftypicalsteamsystems,theircomponents,operatingprinciples,managementtechniques,andpotentialimprovementopportunities.Steamsystemmodificationsoftenaffecttheentiresystemrequiringcomplicatedcalculationstoaccuratelyevaluatemass,energy,andeconomicimpacts.Thiscoursewillpointoutthevarioustoolswehaveavailabletousintheinvestigationprocess.Manyofthetoolsarethefundamentalprinciplesofphysicsthatallowustoidentifythebeforeandafterconditionsassociatedwithaspecificmodification.Additionally,theU.S.DOEhasdevelopedasophisticatedsetoftoolsthatenhanceourabilitytoaccuratelyandeffectivelyevaluatesteamsystemmodifications.Wewilldiscussthesefreetoolsthatcompletecomplicatedcalculationsandhelpyouidentify,analyze,quantify,andprioritizeenergysavingswithinyourplantssteamsystem.Slide4SteamSystemSchematicsWewilluseanexamplesteamsystemtoserveasthefocusofourinclasssteamsystemassessment.Theexamplesteamsystemrepresentsaheavyindustrysitewithtypicalcomponentsandcommonoperatingconditions.Theevaluationsandfindingsnotedinthistrainingrepresentopportunitiescommonlyidentifiedinindustrialsteamsysteminvestigations.Thissteamsystemisnotextraordinaryinanymannerincludingfuelcost,steamproduction,andoperatingconditions.Asyouwillsee,theexamplesystemoperateswiththreeboilerseachboilerconsumesadifferentfuel(naturalgas,number6fueloil,andgreenwood).Thetotalfuelexpenditureforthesiteisnominally19MillionDollarsperYear.Typicalsteamproductionis260,000poundsperhourof400psig,700Fsuperheatedsteam.Thethreeboilersdeliverhighpressuresteamtothedistributionsystemheader.Highpressuresteamservessteamloads,aswellasseveralcogenerationcomponents.Thebackpressureturbinesareconnectedtoelectricalgenerators,thusservingtoreducesteampressureandtogenerateelectricity.Pressurereducingstationsalsoassistinmanagingtheflowofsteamthroughthesystem.Asinallsteamsystemstherearemanyauxiliarycomponentssuchascondensaterecoverytanks,makeupwatertreatmentequipment,deaerator,feedwaterpumps,andmanymorecomponentsnotshownintheschematic.
[SlideVisualSteamSystemSchematic]Thisschematicrepresentsathreeheadersteamsystemincorporatingthreeboilersandmanysystemcomponents.Thesteamdistributionsystemincludesthreebackpressureturbinesandtwopressurereducingvalves.Theturbinesandpressurereducingvalvesoperatebetweenthevarioussteampressuresofthesystem.Eachsteamheaderincludesendusesteamloadswhichdischargecondensatethroughsteamtrapstotheirrespectivecondensatecollectiontanks.Condensateisultimatelycollectedinthemaincondensatereceiver,thenpumpedtoadeaerator.Thedeaeratoralsoreceivesmakeupwaterandsteamtopreheatthecollectedcondensateandmakeupwater.Thedeaeratoroutflowbecomesthefeedwaterfortheboilers.
DOEs BestPractices Steam End User Training
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Slide6ResultsTheexamplesystem,whichisbasedonarealworldsteamsystem,wassubjectedtoasteamsystemassessmentusingfundamentalinvestigationtechniquesandtheU.S.DOESteamTools.Theassessmentidentifiedseveralprojectsthatwillresultinsignificantenergysavingsthatpresenteconomicallyattractiveprojects.Theassessmentidentifiedmorethan$1,300,000/yrofenergysavings,whichrepresentsmorethan7%ofthefuelinputcosttothesite.ThisSteamEndUserTrainingwillwalkyouthroughthisrealworldexampleofasteamsystemtohelpillustratehowyoucanidentifyareaswithpotentialforsavingenergyandforreducingcosts.Now,letsgetstartedsoyoucanlearnhowtoidentifyenergyefficiencyimprovementsatyoursite!
DOEs BestPractices Steam End User Training
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SteamEndUserTrainiNavigationalTutorial
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SteamEndUserTrainingNavigationalTutorialModule
Slide1IntroductionHello,andwelcometotheSteamEndUserTraining.Iwouldliketotakeafewminutestoshowyouhowtonavigatethroughthetraining.Slide2TableofContents1Asyoucanseeinthetableofcontents,itisseparatedinto3differentmodules,eachonedemonstratingadifferentmajortopicintheSteamEndUserTraining:SteamGenerationEfficiency,ResourceUtilizationAnalysis,andSteamDistributionSystemLosses.Attheendofthecourse,youcantakeaninteractivequiztotestyourunderstandingofsteamsystemconceptsandimprovementopportunities.Clickonamodule,individualslide,orthequiz,tonavigatetoit.Slide6StatusIfyouclickonamodule,thesidebarwilldisplayitsindividualslides,aswellastheirtitlesandduration.Youcanclickonanyslideinordertonavigatetoit.UnderStatus,youwillseeacheckmarknexttoeachmoduleorslidethatyouhavecompleted.Atthebottom,youwillseethetotaltimeofthetraining,aswellashowmuchofthattimeyouhavecompleted.ClickonCleartogetridofallofthecheckmarks.Youcanalsoutilizethebookmarkfeature.Selectthesmallbuttonontheleftsideoftheslidetitletobookmarkaslide,Slide7Bookmarktoreturntoitlatertocompletethetrainingsession,orforreferenceorquestions.Youcanclickthebuttonagaintocancelthebookmark.Slide8Rewind/Play1Atanytimeyouhavenavigatedthecoursewiththesidebarorbottomcontrolbar,andtheaudiodoesnotbegin,doubleclickonthehighlightedsidebarslidetitle.Thehighlightidentifieswhereyouare,andtheaudioshouldrestart.Noticethetoolbarbelowthemainscreen.Rewindwilltakeyoutothebeginningofthemodulethatyouareviewing.Clickplaytocontinue,Slide10Back/Forwardandpausetopausethetraining,Backandforwardwillmovebackandforwardbetweenslides.Ifyouwanttogotwiceasfast,youcanclickon2timesFastForwardSpeed.
DOEs BestPractices Steam End User Training
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Slide11FastForwardClickonitagaintoget4timesFastForwardSpeed.Youmustreturntonormalspeedtoheartheaudio,astheaudioisoffduring2timesand4timesFastforward.Slide12NormalSpeedClickonitonemoretimetogobacktothenormalspeed.Slide13SliderBar1Youcanalsonavigatetoaparticularsectionofthetrainingbydraggingthesliderbackandforward.Clickitandholddownthemousebutton.Slide15SlideNumber/Play/Pause1Itwilldisplaywhichslideyouareon,outofthetotalnumberofslidesinthemodule.Asyourepositiontheslidercursor,youwillnoticethesidebarwillhighlighttheslidecorrespondingtothecursorposition.Slide16SlideNumber/Play/Pause2Torestartthetraining,youmayclickonthecorrespondingslide(whichishighlighted),orjusthittheplaybutton,asthepausebuttonwasautomaticallyengagedwhenusingtheslider.Slide19SoundOn/Off1Also,Youcanchoosetohavethesoundonoroff.Slide21ClosedCaptioning1CCallowstheusertoturntheclosedcaptioningonoroff.ClickingtheXwillexittheprogram.ClickingIwilldisplayinformationabouttheprogram,includingtheauthorandtheauthorsemailaddress.Slide23MinimizeScreenAtthetoprightofthescreen,youcanclicktheleftbuttontominimizethewindow.Slide24MaximizeScreenClickonthemiddlebuttontomaximizeit,sothatyoucanseeitbetter.ClickontheXallthewayontherightinordertoclosethetraining.IfyouareusingInternetExplorersF11Fullscreenmode,youwontbeabletoseethebigXintheupperrightcorneruntilyouhitF11again.IfyouareusingabrowserotherthanInternetExplorer,thesebuttonswilllookdifferent.Now,letsgetstarted!
DOEs BestPractices Steam End User Training
SteamEndUserTrainingIntroductionModule1
June28,2010
SteamEndUserTrainingIntroductionModule
Slide1IntroductionTitlePageHello,andwelcometotheSteamSystemEndUsertraining.Inthistraining,wewillinvestigatehowtoassess,evaluate,andmanagesteamsystems.Wewillcovertheentiresteamsystem,fromoneendtotheother.Letsgetstarteddiscussingtheoriginofthecourse,theneedforthecourse,andthentheoverallcourseobjectives.
[SlideVisualIntroductionTitlePage]
DOEsBestPracticesSteamEndUserTraining
Introduction
CourseDevelopmentTheNeedfortheCourse
CourseObjectivesStarttheInvestigation
Slide2OriginalCourseThiswebbasedtrainingtoolhasbeendevelopedfromitsoriginal,instructorledclassroomsetting.Theoriginalcoursewasdesignedprimarilywiththeindustrialsectorinmindandwithanindustrialexperiencebasis.Theprimaryprinciplesareapplicabletoallsteamsystemsandeventhermalwatersystems;but,thefoundationprinciplesarebasedinheavyindustry.Thecourseisdesignedforplantpersonnel,suchasenergymanagers,steamsystemsupervisors,engineers,equipmentoperators,andotherswithsteamsystemresponsibilitiesinindustrialapplications.Nowasawebbasedtrainingtool,participantscanaccessthetraininganytimeandreturntorevisittopicsofinteresttohelpimprovetheefficiencyandperformanceoftheirsteamsystems.
DOEs BestPractices Steam End User Training
IntroductionModule2
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SteamEndUserTraining
[SlideVisualDescriptionoftheInstructorledClassroomCourse]Headercontains:
IndustrialTechnologiesProgramTitleincludes:
ABestPracticesTrainingPresentationUSDepartmentofEnergy
SystemSystemsAssessmentTrainingIncludingUseoftheSteamSystemsToolSuite
Threephotographsofsteamsystems.
Photo1:alargeverticalexhaustpipeonabuildingexteriorexhaustingasteamplumefromthetopofthestack. Photo2:aseriesofsmallsteampipeswithasteampressuregauge. Photo3:Fivehorizontalrunsofsteamdistributionpipingfromacommonheader.Steamdistributionpipingisinsulatedwithan
aluminumjacketing.Apersonisstandingneartheheader.
Bottomfootercontains:USDepartmentofEnergySealUSDepartmentofEnergyEnergyEfficiencyandRenewableEnergyBringyouaprosperousfuturewhereenergyisclean,abundant,reliable,andaffordable.
Slide3CourseDeveloperThiscoursewasdevelopedbyGregHarrellandisintendedtopresentarealworldviewofhowsteamsystemsoperate,practicalevaluationtechniques,andcommonimprovementopportunities.Thiscoursehasdevelopedovermanyyearsofobservingandinvestigatingsteamsystems.ItrepresentsthecompilationofBestPracticesobservedassustainablesteamsystemmanagementmeasures.
[SlideVisualGregHarrellsCredentials]CourseDeveloperGregHarrell,Ph.D.,P.E.
Ph.D.MechanicalEngineeringThermodynamics,VirginiaTech(VPI&SU)1997
1987to1993DesignEngineer,UtilitiesProcessEngineer,BASFCorp.
Oversightforengineering,technicalactivitiesofentireutilitiesdepartment(steamproduction,electricpowergeneration,compressedairsystems,industrialrefrigerationfacilities,industrialHVACsystems,waterfiltrationfacilitiesandwastewatertreatmentplant
DOEs BestPractices Steam End User Training
AtVirginiaTechMechanicalEngineeringProfessor,EnergyManagementInstitute(EMI)
SteamEndUserTrainingIntroductionModule3
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From1997to2001DirectorofTechnicalAssistanceforEMI Undergraduateandgraduatelevelthermodynamicsprofessor Directlyinvolvedinimportantaspectsofenergymanagementforindustrieslocatedworldwide Hasconductednumerousenergysurveysforindustrialclientsthroughouttheworldon6continents,in22countries,andin36of
theUnitedStates DevelopedU.S.DOEBestPracticesSteamEndUserTrainingandU.S.DOESteamSpecialistQualificationTraining PlayedmajorroleindevelopmentoftheUSDOEBestPracticesSteamToolsandauthoredSteamSystemSurveyGuide,whichhas
becomeatextforuniversitymechanicalengineeringcourses ACertifiedInstructor,CompressedAirChallenge
CurrentlyConsultantforEnergyManagementServices
Primaryrolescontinuetoincludeindustrialsystemsenergyanalysisandindividualprocessanalyses,industrialtrainingcourses,universityinstruction,energysystemmodeling,andsoftwaredevelopment
AprimaryinstructorintheNorthCarolinaStateUniversityEnergyManagementDiplomaProgram Majorsystemfocusareasboilers,steamsystems,combinedheatandpowersystems(cogeneration),gasturbines,and
compressedairsystemsSlide4QualifiedPresentersThecoursehasbeenpresentedtothousandsofparticipantsrepresentingalltypesofindustry.Thecourseinstructorsallhavemanyyearsofpracticalsteamsystemexperiencetheircareersfilledwithconductingsteamsystemassessmentthroughouttheworldinalltypesofsettings.Thiscombinationoftechnicalexpertise,realworldexperience,anddirectfeedbackfromindustrialparticipantshasresultedinthepractical,useful,andstraightforwardcourseyouseetoday.
[SlideVisualQualifiedPresentersandTheirContactInformation]
GregHarrell,Ph.D.,P.E.EnergyManagementServices341WillocksDriveJeffersonCity,Tennessee37760Phone:8657190173Email:gregharrell@emscas.com
RichardJendrucko,Ph.D.Consultant,IndustrialEnergyManagement458HillvaleTurnEastKnoxville,Tennessee37919Phone:8655237323Email:drj@utk.edu
DOEs BestPractices Steam End User Training
IntroductionModule4June28,2010
SteamEndUserTraining
RiyazPapar,P.E.,CEM
HudsonTechnologies14SplitRailFenceTheWoodlands,Texas77382Phone:2812980975Email:rpapar@houstontech.com
DebbieBloomNalcoCompany1601WestDiehlRoadNaperville,Illinois60187Phone:6303052445Email:dbloom@nalco.com
StephenTerry,Ph.D.,P.E.NorthCarolinaStateUniversityIndustrialAssessmentCenterDepartmentofMechanicalandAerospaceEngineeringRaleigh,NorthCarolina27695Phone:(919)5151878Email:sdterry@eos.ncsu.edu
BillMoirSteamEngineeringInc.204NE117thAvenueVancouver,Washington98684Phone:(800)3466152Email:BillMoir@steamengineering.com
Slide5IndustrialEnergyJustforamomentletsexaminetheimportanceofeffectivemanagementofsteamsystems.Tostartthisdiscussion,considertheamountofenergyrequiredtooperateourindustries.ItisinterestingtonotethatintheUnitedStatesenergyisusedinthreebroadcategoriesofconsumers.Theseconsumersaresegregatedintotransportation(automobiles,trucks,andairplanes),residentialcommercial(homesandbuildings),andindustry.ItisinterestingtonotethateachofthesethreesectorsconsumeapproximatelyonethirdoftheenergyusedintheU.S.Thetransportationsectorconsumesalmostonethirdoftheenergy,whileresidentialandcommercialtogetherusesomewhatmorethanonethirdoftheenergy.Remarkably,industryaloneusesathirdofthecountrysenergy.Thesethreesectorsuseenergyinverydifferentways.Thetransportationsectorusesprimarilyliquidfuelsastheenergyresource.Residentialandcommerciallocationsusealargeamountofelectricityalongwithnaturalgasandfueloils.Industryusesabroadmixofenergyresourcesincorporatingelectricity,manyfueltypes,andotherenergyresources.Managementandsupportforthesesectorsrequireverydifferentapproaches.OnethingisveryapparentmanagingtheenergyutilizationofindustryiscriticaltothecompetitivenessoftheU.S.ontheworldstage.
DOEs BestPractices Steam End User Training
SteamEndUserTrainingIntroductionModule5
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[SlideVisual2004EnergyUsePieChart]Title:2004EnergyUse*
Industry34.0%(orangeslice)Transportation28.0%(blueslice)Commercial17.0%(greenslice)Residential21.0%(yellowslice)
Footnotes:
*IncludeselectricitylossesSource:DOE/EIAMonthlyEnergyReview2004(preliminary)
Slide6EnergyConsumptionOurfocushereistheindustrialsector.Itwillbeinterestingtoustocharacterizethetypesofenergyuseintheindustrialsector.U.S.DOEisservingasanenergymanagerforindustrialsitesintheUnitedStates.FromtheperspectiveoftheU.S.DOEhelpingU.S.industrymanageenergyresourcesisadauntingchallengethereareaquarterofamillionindustrialsitesintheUnitedStates.HowcanDOEhelpaquarterofamilliondiverseusers?LikeanygoodenergymanagerDOEinvestigatedthemeasurementsthatindicatehowenergyisusedinindustrythroughoutthecountry.WhatDOEfoundisthathalfoftheenergyusedinindustrialsitesisusedbylargeindustrialsites.Thisisveryinterestingbecauselargeindustrialsitescompriseonly3percentoftheindustrialpopulation.Ifwecaninfluencetheenergyconsumptionofthissmallfractionofthetotalindustrialpopulation,thenwecaninfluenceasignificantportionofU.S.energy!Also,thetechniquesusedtoaidthelargeindustrialsitescanbereplicatedtotheremainingindustrialsites.
[SlideVisualU.S.ManufacturingPlants:BySizeBarChart}Title:U.S.ManufacturingPlants:BySize HorizontalAxis:PlantsizeandAnnualEnergyCosts
SmallPlants$2MAllU.S.Plants(nocostprovided)
VerticalAxis:NumberofU.S.Plants
Range0to250,000by50,000increments
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Chartreads:
SmallPlants$2Mhas6,802plants(orangebar)AllU.S.Plants(nocostprovided)has226,737plants(greenbar)
[SlideVisualPercentofTotalIndustri galEner yPieChart]Title:PercentofTotalIndustrialEnergy
SmallandMedium47%(yellowslice)Large53%(orangeslice)
Source:1998EIAMECS
Slide7EnergyRequirementsAsaresult,letstakealookathowenergyisusedinatypicalindustrialsite.Asyoucanseefromthechart,mostoftheenergyisgoingintoprocessheatingandsteamsystems.Bothprocessheatingandsteamsystemsconsumemorethanonethirdoftotalindustrialenergy.Itisalsoexcellenttonotethateventhoughprocessheatingandsteamsystemshavetheirdistinctdifferences,theinvestigationtechniquesandopportunitieswehaveinprocessheatingareverysimilartothoseforsteam.Ifwecanbettermanageourprocessheatingandsteamsystems,wecanhaveasignificantimpactonourenergyconsumptionandcompetitivenessintheworldmarket.Thisistheprimarydrivingforceforthiscourse;inotherwords,steamsystemsareamajorfactorintheenergyconsumptionoftheUnitedStatesandmuchoftheworld;therefore,weneedtomanagethemeffectively.
[SlideVisualTypicalEnergyRequirementsPieChart]Title:ManufacturingEnergyUsebyTypeofSystem(%)
Steam35%(blueslice)ProcessHeating38%(brightyellowslice)MotorSystems12%(peachslice)ProcessCooling1%(whiteslice)ElectroChemical2%(yellowslice)Other4%(blueslice)Facilities8%(greenslice)
Footnotes:
Note:DoesnotincludeoffsitelossesSource:DOE/EIAMonthlyEnergyReview2004(preliminary)
DOEs BestPractices Steam End User Training
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Slide8CourseDivisionsThiscourseisarrangedinasimilarmannertoatypicalsteamsystemassessment.Wewillinvestigateallareasofthesteamsystem.WewillstartwiththeboileroperationsintheSteamGenerationAssessmentsectionofthecourse.Inthissectionwewillexaminetheenergyconversionefficiencyoftheboiler.Variousboilerefficiencyinvestigationmethodswillbeidentified.Boilerefficiencyimprovementavenueswillbeexploredalongwithcontrolstrategies.IntheResourceUtilizat sectionofthecoursewewilltargetsteamendusecomponents,fuelselection,steamsystembalancing,aswellascombinedheatandpoweractivities.Thesearemajorconcernsformostfacilitiesandcanpresentsignificantopportunitiesforeconomicimprovement.
ionAnalysis
TheDistributionSystemcanprovidetremendouswasteintheformofsteamleaks,steamtrapfailures,insulationrelatedlosses,andlostcondensate.Theseareaswillserveasinvestigationtargetsforourdiscussions.Slide9U.S.DOEToolsInvestigatingandanalyzingsteamsystemsrequiresasignificantamountofcomplexcalculationstoidentifytheimpactpotentials.Throughoutthistraining,wewilldemonstratethefundamentalcalculationsandinvestigationtechniquesrequiredtoevaluateeachareaandeachimprovementopportunity.TheSteamSystemSurveyGuideisacompaniondocumenttotheSteamEndUserTrainingtodiscussmajorareasofpotentialimprovementsforsteamsystemsandhowtoquantifythoseopportunitiesandisavailableforfreedownloadfromtheBestPracticesTrainingArea.AdditionaltechnicalpublicationsareprovidedforfreedownloadfromtheBestPracticesResources.Youcanreferencethesedocumentsasyouinvestigateimprovementsforyoursteamsystemsefficiencyandperformance.TheSteamSystemToolsSuiteisasetofsoftwaretoolsconstructedtoaidintheevaluationofsteamsystemprojects.ThesesoftwaretoolsareavailableforfreedownloadfromtheU.S.DOEwebsite.TheToolsSuiteincludestheSteamSystemScopingTool,whichisdesignedtoguidetheusertopotentialimprovementopportunities.Also,includedistheSteamSystemAssessmentTool,whichallowstheusertocompleteacomprehensivemass,energy,andeconomicbalanceonthesteamsystem.Thistoolisdesignedtoevaluatethesystemwideimpactsofchangesinthesteamsystem.Finally,theToolsSuitecontainsthe3EPlusInsulationEvaluationTool.Thistoolcanbeusedtoevaluateanyinsulationrelatedproject.Slide10CourseObjectives1Wearegoingtofocusourattentiononthefundamentalandpracticalaspectsofsteamsystemoperation,maintenance,andmanagement.Whatwewouldliketoaccomplishistohelpyouidentifyopportunitiesyoumayhavetoimproveyoursteamsystem,understandhowtoevaluatethetrueimpacts,andtosetapathtoimplementtheimprovements.Thefocuswillbeonthefundamentalsofsteamsystemsifthefundamentalsaremasteredthesteamsystemwillbewellmanaged.Effectivesteamsystemmanagementrequiresanexcellenttoolboxfilledwithevaluationtoolsandtechniquesthatwillenabletheskilledassessortoidentifyandquantifyimprovementopportunities.Wewillfocusontheessentialmeasurementsthatcharacterizeoperations.Wewillfocussomeattentionontheboilerandunderstandhowboilerefficiencycanbeimpactedandimproved.
DOEs BestPractices Stea
sualCourseObjectives1]
m End User Training
IntroductionModule8
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SteamEndUserTraining
[SlideVi
BecomefamiliarwithU.S.DOEToolsSuitetoassesssteamsystems
Identifythemeasurementsrequiredtomanagesteamsystems Measureboilerefficiency Estimatethemagnitudeofspecificboilerlosses Identifyandprioritizeareasofboilerefficiencyimprovement Recognizetheimpactsoffuelselection
Slide11CourseObjectives2Wewillintroducethetopicofcogenerationandidentifythecommonaspectsofturbineoperation.Attentionwillbegiventotheenduseequipmentandpotentialopportunitiestoreducesteamdemand.Steamtrapmanagement,insulationopportunities,andcondensaterecoveryareallvitalcomponentsinsteamsystems.Theseareaswillbeinvestigated.Thereisalotofinformationtodiscuss;so,letsgetstarted.
[SlideVisualCourseObjectives2]
Characterizetheimpactofbackpressureandcondensingsteamturbines Quantifytheimportanceofmanagingsteamconsumption Identifytherequirementsofasteamtrapmanagementprogram Evaluatetheeffectivenessofthermalinsulation Evaluatetheimpactofcondensaterecovery Recognizetheeconomicimpactsofsteamsystemoperations
Slide12SteamSystem
Steamsystemscanbelargeandcomplexwithmanycomponentsandarrangementsbutmanyoftheprimarycomponentswillbecommonfromsystemtosystem.
Oneofthefirststepsincompletingasteamsystemassessmentistoidentifytheprimarycomponentsofthesteamsystem.
Boilersandtheirauxiliarycomponents,heatexchangersandotherenduseequipment,watertreatmentsystems,condensaterecoverycomponents,distributionpiping,andmanyothercomponents.Thesecomponentsmaybearrangedinasimplesystem,withasingleboiler,maybeonebackupboileroritcanbemuchmorecomplicated.
[SlideVisualSteamSystemImpactSchematic]
Thisschematicrepresentsatwoheadersteamsystemwithtwoboilersandallofthesystemcomponents.Feedwaterispreheatedbysteaminjectionfromthelowpressuresteamdistributionheader,aswellaspreheatedmakeupwaterutilizingboilerblowdownheatrecovery.
DOEs BestPractices Steam End User Training
ThetopoftheschematicshowstheBoilerFeedwaterenteringthetwoboilers.Thetwoboilersareconnectedtothehighpressuresteamdistributionheader.
SteamEndUserTrainingIntroductionModule9
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Thesteamexitstwoboilersandentersthehighpressuresteamsystemdistributionheader,indicatedbyalinebelowtheboilers.
Atthefarrightofthehighpressuresteamdistributionsystem,thehighpressureendusercomponentloadsareidentifiedthrougharectangulargraphicandarrowsenteringandleavingtherectangle,indicatingheatexchangewiththecomponents.Theendusecomponentsdischargecondensatethroughasteamtrap,representedbyarectangulargraphic.Schematically,condensatepassesthroughthebottomofthetrapandrecoveredinacondensingtank.Thecondensatetankusesapump,whichisdenotedbyacircle/squarecombination,todeliverthecondensatetothemaincondensatereceiver.Themaincondensatereceiverthenpumps(denotedbyacircle/squarecombination)thecondensatetothedeaeratortankasdenotedbytworedrectangles,withthesmalleroneonthetop.Thetoprectanglealsoshowstwotriangles,eachpointedawayfromeachother,longestendsnearlytouching.Thebottomtriangleisconnectedtoacontrolvalverepresentedbyahourglassfigurewithadomeontheside,whichprovidessteamtothedeaeratorfromsteamdistributionsystemtopreheatthecollectedcondensateandmakeupwater.Makeupwateralsoschematicallyentersatthetopofthedeaeratorwiththecollectedcondensate.Theboilerfeedwaterschematicallyexitsthedeaeratorfromthebottomandispumped(denotedasacircle/squarecombination)tothefeedwaterinletsofeachboiler,nearthetoptheschematic.
Slide13SteamSystem2PressuresThesystemmayincludemultipleboilers,severalsteampressures,differenttypesoffuel,steamturbines,andmanyprocessendusers.
[SlideVisualSteamSystemImpactSchematic]
Thisschematicrepresentsatwopressureheadersteamsystemwithmultipleboilersandallofthesystemcomponents.Feedwaterispreheatedbysteaminjectionfromthelowpressuresteamdistributionheader,aswellaspreheatedmakeupwaterutilizingboilerblowdownheatrecovery.ThetopoftheschematicshowstheBoilerFeedwaterenteringthetwoboilers.Thetwoboilersareconnectedtothehighpressuresteamdistributionheader.
Thesteamexitstwoboilersandentersthehighpressuresteamsystemdistributionheader,indicatedbyalinebelowtheboilers.
Underthehighpressuresteamdistributionline,youwillseethreeconeshapedgraphics,thatrepresentthesteamturbines.Theonenearesttotheleftisahighpressuretocondensingturbine.Thisturbinedischargestothecondenserrepresentedbythebluecirclebelowtheturbine.Therectangulargraphictotherightoftheconeshapedgraphicindicatestheelectricalgenerationcomponentofthesteamturbine.Theturbineinthemiddlereceiveshighpressuresteamandexhaustslowpressuresteamtothelowpressuresteamdistributionsystem,aswellasgenerateselectricity.Thisturbineisdenotedasredconeandrectanglecombination.Thesteamturbinetothemostrightreceiveshighpressuresteam,drivesapump(denotedasacircle/squarecombination)andisalsocalledasteamturbinedrivenpump,thendischargestothelowpressuresteamdistributionsystemheader.
DOEs BestPractices Steam End User Training
SteamEndUserTrainingIntroductionModule10
June28,2010
Betweenthecondensingturbineandthehightolowpressureturbine,alightbluetriangulargraphicthatrepresentsapressurereducingvalve,whichdischargestothelowpressuresteamdistributionheader,identifiedbyaredlinebelowtheturbines.Atthefarrightofthehighpressuresteamdistributionsystem,thehighpressureendusercomponentloadsareidentifiedthrougharectangulargraphicandarrowsenteringandleavingtherectangle,indicatingheatexchangewiththecomponents.Theendusecomponentsdischargecondensatethroughasteamtrap,representedbyarectangulargraphic.Schematically,condensatepassesthroughthebottomofthetrapandrecoveredinacondensingtankwhichisalsoconnectedtothelowpressuresteamdistributionsystem.Underthelowpressuresteamdistributionline,youwillseethelowpressureendusercomponentloadsidentifiedasarectangulargraphicandarrowsenteringandleavingtherectangle,indicatingheatexchangewiththecomponents.Theendusecomponentsdischargecondensatethroughasteamtrap,representedbyanotherrectangulargraphic.Schematically,condensatepassesthroughthebottomofthetrapandrecoveredinacondensatetank,inwhichsteamisventedrepresentedbyaverticalarrowleavingthetopofthetank.Thelowpressureendusercondensatetankusesapump,whichisdenotedbyacircle/squarecombination,todeliverthecondensatetothemaincondensatereceiver,whichisalargerectanglewiththreeinputsdenotedbythreearrowsatthetopoftherectangle.Thecondensateentersthismaincondensatereceivertank,afteritpassesthroughacontrolvalve,denotedasanhourglassshapewithadomeontop.Thethirdcondensateinputcomesfromthecondensatefromtheheatexchangerthatutilizesthehighpressuresteamturbine.Thecondensateleavesthisheatexchangerandisdeliveredviaapump(denotedasacircle/squarecombination)tothemaincondensatereceiver.Themaincondensatereceiverthenpumps(denotedbyacircle/squarecombination)thehighpressurecondensate,lowpressurecondensate,andthecondensingsteamturbinecondensatetothedeaeratortankasdenotedbytworedrectangles,withthesmalleroneonthetop.Thetoprectanglealsoshowstwotriangles,eachpointedawayfromeachother,longestendsnearlytouching.Thebottomtriangleisconnectedtoacontrolvalverepresentedbyaredhourglassfigurewithadomeontheside,whichprovideslowpressuresteamtothedeaeratorfromthelowpressuresteamdistributionsystemtopreheatthecollectedcondensateandmakeupwater.Preheatedmakeupwateralsoschematicallyentersatthetopofthedeaeratorwiththecollectedcondensate.Themakeupwaterispreheatedfromtheboilerblowdownandlowpressuresteam.Boilerblowdownfromeachboilerisnotedasreddashedlinesleadingtoablowdownreceivertankdenotedasaredrectangleontherightofthescreen.Flashsteamisdivertedfromtheblowdownflashvesseltothelowpressuresteamdistributionline,alsodenotedinreddashedlines.Liquidfromtheblowdownflashtankthenschematicallyentersthetopofaheatexchanger(representedasawhiteandgreenstripedrectangle).Makeupwaterisshownenteringtheheatexchangerfromtheright,afteritpassesthroughthewatertreatmentequipment,denotedastworedrectanglesfurtherontheright.Theliquidexitingtheheatexchangerissenttothedeaerator.Theheatedboilerfeedwaterschematicallyexitsthedeaeratorfromthebottomandispumped(denotedasacircle/squarecombination)tothefeedwaterinletsofeachboiler,nearthetoptheschematic.
DOEs BestPractices Steam End User Training
IntroductionModule11June28,2010
SteamEndUserTraining
Slide14SteamSystem3PressuresSomesystemsareevenmorecomplicatedthanthatincludingmanysteampressuresandincorporatingsteamturbinesdrivingprocesscomponentsaswellaselectricalgenerators!
[SlideVisualSteamSystemImpactSchematic]
Thisschematicrepresentsathreepressureheadersteamsystemwithmultipleboilersandallofthesystemcomponents.Feedwaterispreheatedbysteaminjectionfromthelowpressuresteamdistributionheader,aswellaspreheatedmakeupwaterutilizingboilerblowdownheatrecovery.
ThetopoftheschematicshowstheBoilerFeedwaterenteringthetwoboilers.Thetwoboilersareconnectedtothehighpressuresteamdistributionheader.
Thesteamexitstwoboilersandentersthehighpressuresteamsystemdistributionheader,indicatedbyalinebelowtheboilers.
Underthehighpressuresteamdistributionline,youwillseethreeconeshapedgraphics,thatrepresentthesteamturbines.Theonenearesttotheleftisahighpressuretocondensingturbine.Thisturbinedischargestothecondenserrepresentedbythebluecirclebelowtheturbine.Therectangulargraphictotherightoftheconeshapedgraphicindicatestheelectricalgenerationcomponentofthesteamturbine.Theturbineinthemiddlereceiveshighpressuresteamandexhaustslowpressuresteamtothelowpressuresteamdistributionsystem,aswellasgenerateselectricity.Thisturbineisdenotedasredconeandrectanglecombination.Thesteamturbinetothemostrightreceiveshighpressuresteam,drivesapump(denotedasacircle/squarecombination)andisalsocalledasteamturbinedrivenpump,thendischargestothelowpressuresteamdistributionsystemheader.Betweenthecondensingturbineandthehightolowpressureturbine,alightbluetriangulargraphicthatrepresentsapressurereducingvalve,whichdischargestothelowpressuresteamdistributionheader,identifiedbyaredlinebelowtheturbines.Atthefarrightofthehighpressuresteamdistributionsystem,thehighpressureendusercomponentloadsareidentifiedthrougharectangulargraphicandarrowsenteringandleavingtherectangle,indicatingheatexchangewiththecomponents.Theendusecomponentsdischargecondensatethroughasteamtrap,representedbyarectangulargraphic.Schematically,condensatepassesthroughthebottomofthetrapandrecoveredinacondensingtankwhichisalsoconnectedtothelowpressuresteamdistributionsystem.Underthelowpressuresteamdistributionline,youwillseethelowpressureendusercomponentloadsidentifiedasarectangulargraphicandarrowsenteringandleavingtherectangle,indicatingheatexchangewiththecomponents.Theendusecomponentsdischargecondensatethroughasteamtrap,representedbyanotherrectangulargraphic.Schematically,condensatepassesthroughthebottomofthetrapandrecoveredinacondensatetank,inwhichsteamisventedrepresentedbyaverticalarrowleavingthetopofthetank.Thelowpressureendusercondensatetankusesapump,whichisdenotedbyacircle/squarecombination,todeliverthecondensatetothemaincondensatereceiver,whichisalargerectanglewiththreeinputsdenotedbythreearrowsatthetopoftherectangle.Thecondensateentersthismaincondensatereceivertank,afteritpassesthroughacontrolvalve,denotedasanhourglassshapewithadomeontop.Thethirdcondensateinputcomesfromthecondensatefromtheheatexchangerthatutilizesthehighpressuresteamturbine.Thecondensateleavesthisheatexchangerandisdeliveredviaapump(denotedasacircle/squarecombination)tothemaincondensatereceiver.
DOEs BestPractices Steam End User Training
IntroductionModule12June28,2010
SteamEndUserTraining
Themaincondensatereceiverthenpumps(denotedbyacircle/squarecombination)thehighpressurecondensate,lowpressurecondensate,andthecondensingsteamturbinecondensatetothedeaeratortankasdenotedbytworedrectangles,withthesmalleroneonthetop.Thetoprectanglealsoshowstwotriangles,eachpointedawayfromeachother,longestendsnearlytouching.Thebottomtriangleisconnectedtoacontrolvalverepresentedbyaredhourglassfigurewithadomeontheside,whichprovideslowpressuresteamtothedeaeratorfromthelowpressuresteamdistributionsystemtopreheatthecollectedcondensateandmakeupwater.Preheatedmakeupwateralsoschematicallyentersatthetopofthedeaeratorwiththecollectedcondensate.Themakeupwaterispreheatedfromtheboilerblowdownandlowpressuresteam.Boilerblowdownfromeachboilerisnotedasreddashedlinesleadingtoablowdownreceivertankdenotedasaredrectangleontherightofthescreen.Flashsteamisdivertedfromtheblowdownflashvesseltothelowpressuresteamdistributionline,alsodenotedinreddashedlines.Liquidfromtheblowdownflashtankthenschematicallyentersthetopofaheatexchanger(representedasawhiteandgreenstripedrectangle).Makeupwaterisshownenteringtheheatexchangerfromtheright,afteritpassesthroughthewatertreatmentequipment,denotedastworedrectanglesfurtherontheright.Theliquidexitingtheheatexchangerissenttothedeaerator.
Slide15SteamSystemComplexThesteamsystemmayincludecondensingsteamturbinesandothermajorcomponents.However,nomatterhowcomplexorsimplethesteamsystemsare,themanagementandinvestigationactivitiesarebasicallythesameweneedthesametoolsandfundamentalknowledge.
[SlideVisualSteamSystemImpactSchematic]
Thisschematicrepresentsathreepressureheadersteamsystemwithmultipleboilersandallofthesystemcomponents.Feedwaterispreheatedbysteaminjectionfromthelowpressuresteamdistributionheader,aswellaspreheatedmakeupwaterutilizingboilerblowdownheatrecovery.
ThetopoftheschematicshowstheBoilerFeedwaterenteringthetwoboilers.Thetwoboilersareconnectedtothehighpressuresteamdistributionheader.
Thesteamexitstwoboilersandentersthehighpressuresteamsystemdistributionheader,indicatedbyalinebelowtheboilers.
Underthehighpressuresteamdistributionline,youwillseethreeconeshapedgraphics,thatrepresentthesteamturbines.Theonenearesttotheleftisahighpressuretocondensingturbine.Thisturbinedischargestothecondenserrepresentedbythebluecirclebelowtheturbine.Therectangulargraphictotherightoftheconeshapedgraphicindicatestheelectricalgenerationcomponentofthesteamturbine.Theturbineinthemiddlereceiveshighpressuresteamandexhaustslowpressuresteamtothelowpressuresteamdistributionsystem,aswellasgenerateselectricity.Thisturbineisdenotedasredconeandrectanglecombination.Thesteamturbinetothemostrightreceiveshighpressuresteam,drivesapump(denotedasacircle/squarecombination)andisalsocalledasteamturbinedrivenpump,thendischargestothelowpressuresteamdistributionsystemheader.Betweenthecondensingturbineandthehightolowpressureturbine,alightbluetriangulargraphicthatrepresentsapressurereducingvalve,whichdischargestothelowpressuresteamdistributionheader,identifiedbyaredlinebelowtheturbines.
DOEs BestPractices Steam End User Training
Atthefarrightofthehighpressuresteamdistributionsystem,thehighpressureendusercomponentloadsareidentifiedthrougharectangulargraphicandarrowsenteringandleavingtherectangle,indicatingheatexchangewiththecomponents.Theendusecomponentsdischargecondensatethroughasteamtrap,representedbyarectangulargraphic.Schematically,condensatepassesthroughthebottomofthetrapandrecoveredinacondensingtankwhichisalsoconnectedtothelowpressuresteamdistributionsystem.
SteamEndUserTrainingIntroductionModule13
June28,2010
Underthelowpressuresteamdistributionline,youwillseethelowpressureendusercomponentloadsidentifiedasarectangulargraphicandarrowsenteringandleavingtherectangle,indicatingheatexchangewiththecomponents.Theendusecomponentsdischargecondensatethroughasteamtrap,representedbyanotherrectangulargraphic.Schematically,condensatepassesthroughthebottomofthetrapandrecoveredinacondensatetank,inwhichsteamisventedrepresentedbyaverticalarrowleavingthetopofthetank.Thelowpressureendusercondensatetankusesapump,whichisdenotedbyacircle/squarecombination,todeliverthecondensatetothemaincondensatereceiver,whichisalargerectanglewiththreeinputsdenotedbythreearrowsatthetopoftherectangle.Thecondensateentersthismaincondensatereceivertank,afteritpassesthroughacontrolvalve,denotedasanhourglassshapewithadomeontop.Thethirdcondensateinputcomesfromthecondensatefromtheheatexchangerthatutilizesthehighpressuresteamturbine.Thecondensateleavesthisheatexchangerandisdeliveredviaapump(denotedasacircle/squarecombination)tothemaincondensatereceiver.Themaincondensatereceiverthenpumps(denotedbyacircle/squarecombination)thehighpressurecondensate,lowpressurecondensate,andthecondensingsteamturbinecondensatetothedeaeratortankasdenotedbytworedrectangles,withthesmalleroneonthetop.Thetoprectanglealsoshowstwotriangles,eachpointedawayfromeachother,longestendsnearlytouching.Thebottomtriangleisconnectedtoacontrolvalverepresentedbyaredhourglassfigurewithadomeontheside,whichprovideslowpressuresteamtothedeaeratorfromthelowpressuresteamdistributionsystemtopreheatthecollectedcondensateandmakeupwater.Preheatedmakeupwateralsoschematicallyentersatthetopofthedeaeratorwiththecollectedcondensate.Themakeupwaterispreheatedfromtheboilerblowdownandlowpressuresteam.Boilerblowdownfromeachboilerisnotedasreddashedlinesleadingtoablowdownreceivertankdenotedasaredrectangleontherightofthescreen.Flashsteamisdivertedfromtheblowdownflashvesseltothelowpressuresteamdistributionline,alsodenotedinreddashedlines.Liquidfromtheblowdownflashtankthenschematicallyentersthetopofaheatexchanger(representedasawhiteandgreenstripedrectangle).Makeupwaterisshownenteringtheheatexchangerfromtheright,afteritpassesthroughthewatertreatmentequipment,denotedastworedrectanglesfurtherontheright.Theliquidexitingtheheatexchangerissenttothedeaerator.Theheatedboilerfeedwaterschematicallyexitsthedeaeratorfromthebottomandispumped(denotedasacircle/squarecombination)tothefeedwaterinletsofeachboiler,nearthetoptheschematic.
Slide16FocusAreasWhenassessingoursteamsystem,wemustevaluatethesystemasawhole;but,wewillberequiredtoanalyzemanycomponentsindividuallythendeterminetheirimpactonthesystem.Therearemanydifferentcomponentsandsubsystemsassociatedwiththesteamsystem.Weaskquestionslike,howcanweimproveboilerefficiency?Howcanwereducesteamconsumption?Whatenergyresourcesareavailabletous?Howcanweloselessenergythroughoutthesystem?
DOEs BestPractices Steam End User Training
SteamEndUserTrainingIntroductionModule14
June28,2010
[SlideVisualSteamSystemFocusAreas]SteamSystemFocusAreas SteamGenerationEfficiency ResourceUtilizationEffectiveness DistributionSystemlosses
Slide17SteamGenerationEfficiencyForexample,wewillfocusourattentionontheboilerandaskquestionslike:
Whataretheperformancecharacteristicsofourboiler? Whatarethecriticalmeasurementsrequiredtomanageboilerperformance? Howcanweimpactboilerefficiency?
[SlideVisualSteamGenerationEfficiency]SteamGenerationEfficiency Boilerefficiencyisamajorfactordeterminingtheoperatingcostsofasteamsystem Severalmajorfactorsimpactboilerperformance Whataretheefficiencycontrolparameters? Aretheymaintainedatappropriatelevels?
Slide18ResourceUtilizationWefocusourattentionontheenduseequipmentandtheenergyresourcesweemployinoursystems.Weinvestigateopportunitiestorecoverenergyfromprocessunits.Wetargetopportunitiestoreducesteamuse.Significantfocusisplacedonimprovingtheperformanceofourendusesystems.Cogenerationinvestigationsidentifypotentialstoconvertsteamenergyintopower.Weinvestigateopportunitiesusealternativeenergysources.
[SlideVisualResourceUtilizationEffectiveness]ResourceUtilizationEffectiveness Steamisgeneratedformanypurposes Steamcanoftenbegeneratedfromdifferentprimaryenergysources Multipleenergyexportscanbedevelopedfromoneenergyresource Areresourcesbeingproperlyutilized? Isthesteamenduseappropriateorinappropriate?
DOEs BestPractices Steam End User Training
SteamEndUserTrainingIntroductionModule15
June28,2010
Slide19SteamDistributionSystemLossesSteamsystemsareoftenverylarge,extendingintomanyprocessareas.Weexaminehowenergycanbelostfromthedistributionsystem?Wetrytoidentifyopportunitiestoreducethelosses?Wefocusattentiononrecoveringenergyfromthedistributionsystem.
[SlideVisualSteamDistributionSystemLosses]SteamDistributionSystemLosses
Thedistributionsystemcanexperiencesignificantlosses Whatarethemainavenuesofloss? Whatmethodsareavailabletoreducethelosses?
Slide20DrivingForceQuestionInmoststeamsystemsthereareopportunitiesthatwillallowenergyconsumptiontobereduced.Ifatyourfacilityideasaredevelopedtoreduceenergyconsumption,whatwillbetheprimaryreasonthattheinitiativewillbeimplemented?
[SlideVisualDrivingForce]Whatisthemaindrivingforceforchange??
Slide21DrivingForceEconomicsEconomicimpactistheprimarydrivingforceforchange.Oneofourprimaryfocalpointsinthiscourseistoidentifyhowtoaccuratelyconnectarealworldsteamsystemchangetothetrueeconomicimpactitwillprovide.
[SlideVisualDrivingForce]Whatisthemaindrivingforceforchange??
Answer:$Slide22DrivingForceMoreEnergysavings,oftenfuelsavings,aredominantpointsoffocusresultingineconomicimpact.However,wedonotwanttolosesightofothereconomicfactors;suchas,maintenanceimpacts,reliabilityfactors,siteproductivity,productquality,environmentalimpact,andpotentiallyavoidingcostlysystemmodifications.Alloftheseissueshaveeconomicconnectionssometimesitisdifficulttoestablishthetrueeconomicimpactoftheseitems.Someoftheseimpactsmayresultinincreasedcost.Wemustattempttoaccuratelyandrealisticallyidentifythetrueeconomicimpactsandimplementationcostsassociatedwithanopportunity.
DOEs BestPractices Steam End User Training
SteamEndUserTrainingIntroductionModule16
June28,2010
[SlideVisualDrivingForce]
Whatisthemaindrivingforceforchange??
Answer:$ Energy Reliability Maintenance Productivity Quality Costavoidance Emissionsreductions
Slide23MeasureManagementofanyresourcerequiresmeasurements.Throughoutthiscoursewewillidentifythecriticalmeasurementsthatallowustounderstandhowoursystemsareperformingandhowmuchimprovementhasbeenorcanbeaccomplished.
[SlideVisualMeasure]Youarenotmanagingwhatyoudonotmeasure.
Slide24StarttheInvestigationEvaluatingsteamsystemsrequiresabroadrangeofknowledgeandsignificantskillsset.Itcanbeverydifficulttodeterminewherebesttostartinvestigating.Oftenobtainingabroadoverviewofthesystemandtheoperatingpracticeswillleadtoimportantinvestigationstrategies.Slide25SSST1Investigatingsteamsystemsoftenbeginswithtakingabroadviewofthesystemandidentifyingareastoinvestigatethatmayyieldfruitfulresults.TheSteamSystemScopingTool(knownasSSST)isdesignedtohelpyouidentifythesepotentiallyfruitfulareas.
[SlideVisualSteamSystemScopingTool]
SteamSystemScopingTool(SSST)OrangeBannerwithindustrialplantgraphicinbackground
OfficeofIndustrialTechnologiesBestPracticesEnergySmartTechnologyforTodaySteamSystemScopingToolVersion2.0.0December2002
DO
UnitedStatesDepartmentofEnergy
Es BestPractices Steam End User Training
SteamEndUserTrainingIntroductionModule17
June28,2010
Clickanywhereonthisframetobegintheassessment.
Slide26ScopingTool2TheSteamSystemScopingToolisavailablefreeasanExcelbasedsoftwaretool.SSSTisnotacalculationtoolorasolutionevaluationtool;rather,itisatoolusedtohelptheusertobecomemoreawareofareasofthesteamsystemthatcanbeimproved.Thetoolisbasicallyaquestionnairethatasksgeneralquestionsaboutthemanagementpracticesofthesteamsystem.Questionsareprovidedforeachareaofthesteamsystem.Theresultsofapplyingthistoolarerelativescoresfortheperceivedperformanceofeachareaofthesystem.Thesescoresprompttheusertoinvestigatecertainareasofthesteamsystemfurther.Slide27SSSTProfilingForexampletheScopingToolasksquestionsabouttheintensityoffuelandsteammeasurements.Basedontheusersinputascoreisdevelopedforeachcategory.ThescoresshownhereareaveragescoresforasectorofU.S.industry.
[SlideVisualSSSTScorecardSystemProfiling]
SUMMARYRESULTS
SCOPINGTOOLQUESTIONSPOSSIBLESCORE
TYPICALSCORE
1.STEAMSYSTEMPROFILING STEAMCOSTS SC1:MeasureFuelCostToGenerateSteam 10 7.5SC2:TrendFuelCostToGenerateSteam 10 6.9STEAM/PRODUCTBENCHMARKS BM1:MeasureSteam/ProductBenchmarks 10 5.6BM2:TrendSteam/ProductBenchmarks 10 5.7STEAMSYSTEMMEASUREMENTS MS1:Measure/RecordSteamSystemCriticalEnergyParameters
30 22.5
MS2:IntensityOfMeasuringSteamFlows 20 8.5STEAMSYSTEMPROFILINGSCORE 90 56.7STEAMSYSTEMPROFILINGSCORE 100% 63%
DOEs BestPractices Steam End User Training
SteamEndUserTrainingIntroductionModule18
June28,2010
Slide28SSSTSystemOperationsQuestionstargetingsteamtrapmanagementandinsulationconditionprompttheusertoinvestigatethesevitalareasofsteamsystemmanagement.Again,thescoresnotedherearereflectiveofaveragescoresforasectorofU.S.industry.
[SlideVisualSSSTScorecardSystemOperations]BM2:TrendSteam/ProductBenchmarks 10 5.7STEAMSYSTEMMEASUREMENTS MS1:Measure/RecordSteamSystemCriticalEnergyParameters
30 22.5
MS2:IntensityOfMeasuringSteamFlows 20 8.5STEAMSYSTEMPROFILINGSCORE 90 56.7STEAMSYSTEMPROFILINGSCORE 100% 63%
SCOPINGTOOLQUESTIONSPOSSIBLESCORE
TYPICALSCORE
2.STEAMSYSTEMOPERATINGPRACTICES STEAMTRAPMAINTENANCE ST1:SteamTrapMaintenancePractices 40 23.9WATERTREATMENTPROGRAM WT1:WaterTreatmentEnsuringFunction 10 8.6WT2:CleaningBoilerFireside/WatersideDeposits 10 7.1WT3:MeasuringBoilerTDS,Top/BottomBlowdownRates
10 7.7
SYSTEMINSULATION IN1:InsulationBoilerPlant 10 8.6IN2:InsulationDistribution/EndUse/Recovery 20 14.0STEAMLEAKS
DOEs BestPractices Steam End User Training
SteamEndUserTrainingIntroductionModule19
June28,2010
Slide29SSSTBoilerOperationsBoilerefficiencyandcontrolcomponentsareprimarypointsoffocusintheScopingTool.Boilerblowdownissuesarealsoofconcern.
[SlideVisualSSSTScorecardBoilerOperations]
SCOPINGTOOLQUESTIONSPOSSIBLESCORE
TYPICALSCORE
3.BOILERPLANTOPERATINGPRACTICES BOILEREFFICIENCY BE1:MeasuringBoilerEfficiencyHowOften 10 6.3BE2:FlueGasTemperature,O2,COMeasurement 15 9.4BE3:ControllingBoilerExcessAir 10 7.1HEATRECOVERYEQUIPMENT HR1:BoilerHeatRecoveryEquipment 15 8.5GENERATINGDRYSTEAM DS1:CheckingBoilerSteamQuality 10 4.2GENERALBOILEROPERATION GB1:AutomaticBoilerBlowdownControl 5 2.6GB2:FrequencyOfBoilerHigh/LowLevelAlarms 10 8.6GB3:FrequencyOfBoilerSteamPressureFluctuations 5 3.9
BOILERPLANTOPERATINGPRACTICESSCORE 80 50.6BOILERPLANTOPERATINGPRACTICESSCORE 100% 63%
DOEs BestPractices Steam End User Training
SteamEndUserTrainingIntroductionModule20
June28,2010
Slide30SSSTEndUseOfcoursecondensaterecoverypracticesareamajorpointofconcern.Thetoolfocusessomeattentiontothepotentialofusingbackpressuresteamturbines.
[SlideVisualSSSTScorecardEndUse]
SCOPINGTOOLQUESTIONSPOSSIBLESCORE
TYPICALSCORE
4.STEAMDISTRIBUTION,ENDUSE,RECOVERYOPERATINGPRACTICES
MINIMIZESTEAMFLOWTHROUGHPRVs PR1:OptionsForReducingSteamPressure 10 7.4RECOVERANDUTILIZEAVAILABLECONDENSATE CR1:RecoveringAndUtilizingAvailableCondensate 10 6.4USEHIGHPRESSURECONDENSATETOMAKELOWPRESSURESTEAM
FS1:RecoveringAndUtilizingAvailableFlashSteam 10 3.7DISTRIBUTION,ENDUSE,RECOVERYOP.PRACTICESSCORE 30 17.5DISTRIBUTION,ENDUSE,RECOVERYOP.PRACTICESSCORE 100% 58%
Slide31SSSTResultsTheoutputofthetoolisanoverallscoreandindividualareascores.Solutionsarenotofferedsimplyalowscorepromptstheusertoinvestigatefurtherandpotentiallyidentifyimprovementopportunities.Inmoststeamsystemsthereareinterestinginvestigationopportunitiesinseveralareas.Typicaloverallscoresforindustrialplantsareinthe60%and70%ranges.
DOEs BestPractices Steam End User Training
SteamEndUserTrainingIntroductionModule21
June28,2010
[SlideVisualSSSTScorecardResults]
SUMMARYOFRESULTS
SCOPINGTOOLAREASPOSSIBLESCORE
TYPICALSCORE
STEAMSYSTEMPROFILING 90 63%STEAMSYSTEMOPERATINGPRACTICES 140 69%BOILERPLANTOPERATINGPRACTICES 80 63%DISTRIBUTION,ENDUSE,RECOVERYOP.PRACTICES 30 58%
TOTALSCOPINGTOOLQUESTIONAIRESCORE 340 222.0TOTALSCOPINGTOOLQUESTIONAIRESCORE 100% 65%
Slide32SSSTNextStepsThetoolprovidesguidanceintowheretofindadditionalinformationforaparticulararea.TheScopingToolwillpointtheusertoadditionalU.S.DOEresources.
[SlideVisualNextStepsDirectedbySSST] Focusonareasrequiringattention Investigateresources
ConsulttheU.S.DOEBestPracticeswebsite www1.eere.energy.gov/industry/bestpractices
SteamSystemSurveyGuide U.S.DOESteamTipSheets
ImprovingSteamSystemPerformance:ASourcebookforIndustry UsetheSteamSystemAssessmentTool(SSAT) UseInsulationTool(3EPlus)\
Slide33GeneralToolsManytoolsarerequiredtoevaluatesteamsystems.TheSteamSystemScopingToolisoneofmanytoolsthatcanbeemployedtoinvestigatesteamsystems.TheothertoolsintheU.S.DOESteamToolsSuitewillbeintroducedinthiscourseaswellasthefundamentaltechniquesusedtoinvestigateandmanagesteamsystems.Themostimportanttoolsarethefundamentalprinciplesofphysicsandtherealsystemmeasurementsrequiredtoemploythem.TheU.S.DOESteamToolsareextensionsofthesevitalcomponents.
DOEs BestPractices Steam End User Training
SteamEndUserTrainingIntroductionModule22
June28,2010
Slide34InformationAdditionaltechnicalresourcesareavailablefromtheDepartmentofEnergy.
[SlideVisualAdditionalTechnicalResources]
Information
Programs IndustrialTechnologiesProgram(ITP) BestPracticesSteamProgram
Softwaretools
http://www1.eere.energy.gov/industry/bestpractices/steam.html
(877)3373463 http://www1.eere.energy.gov/industry/bestpractices/software.html
SteamPublications http://www1.eere.energy.gov/industry/bestpractices/techpubs_steam.html
Training
TechnicalAssistancehttp://www1.eere.energy.gov/industry/bestpractices/training.html
http://www1.eere.energy.gov/industry/bestpractices/info_center.htmlSlide35IntroductionSummarySteamsystemsarecomplexarrangementsofinterconnectedcomponentsthatrequiretremendousamountsofenergyandeconomicexpenditure.Propermanagementofasteamsystemisvitaltoeffectivelyutilizeenergyresources.Toolsareavailabletohelpinthisinvestigationandmanagementprocess.
DOEs BestPractices Steam End User Training
SteamEndUserTrainingSteamGenerationModule
BoilerEfficiency1June28,2010
SteamEndUserTrainingSteamGenerationEfficiencyModule
EfficiencyDefinitionSection
Slide1SteamGenerationEfficiencyModule
Thismodulewilldiscusssteamgenerationefficiencyandtheprimaryfactorsthataffectit..Thegeneralconceptsofboilerefficiencywillbediscussed.
[SlideVisualEfficiencyDefinitionTitlePage]
DOEsBestPracticesSteamEndUserTraining
Steam iencyGenerationEffic
EfficiencyDefinitionShellLosses
BlowdownLossesStackLosses
Slide2BoilerTypes
Therearemanytypesofboilers,buttheprimaryboilerdesignationsarefiretubeboilersandwatertubeboilers.Afiretubeboilerisoneinwhichthecombustiongasesareinsidethetubes.Thisschematicdepictsa3passfiretubeboiler,inwhichwehaveacombustionzone,andsmallertubesthatallowmoreheattransferfromtheexhaustgases.Firetubeboilersservedasourfirstindustrialsteamgenerators.Thelargediameterpressurevesselholdsallofthestressofthehighpressuresteam.Asindustrialrequirementsnecessitatedhigherpressuresteamandgreatersteamflowrates,thevesselhadtobecomelargerandthewallofthevesselhadtogetthickertoaccommodatethestressofgreaterpressures.Thesefactorsmadeboilermanufacturingdifficultandexpensive.Asaresult,watertubeboilersweredeveloped.Theseboilerscontainhundredsoftubesthatholdthehighpressuresteamandwater.Theserelativelysmalldiametertubescanaccommodatethestressofmuchhigherpressuresthanthelargediametervessel.
Watertubeboilersallowthecombustiongasestoprovideheattransfertothewater(andsteam)thatiscontainedinthetubesoftheboiler.Acommonwatertubeboilerarrangementwillincorporateanuppersteamdrumthatallowstheliquidwaterandsteamtoseparate.Alowerdrum,oftencalledamuddrum,willserveasthelowercollectionheaderforthetubes.Hundredsofrelativelysmalldiametertubeswillconnectthemuddrumtothesteamdrum.Asthewaterheatsandboilingoccursthefluidrisesinthetubestothesteamdrum.
DOEs BestPractices Steam End User Training
eamEndUserTrainingSteamGenerationModule
BoilerEfficiency2June28,2010
St
[SlideVisualBoilerTypes(FireTubeandWaterTube)]Thisschematicdepictsa3passfiretubeboiler,inwhichwehaveacombustionzone(atthebottom),andsmallertubesthatallowmoreheattransferfromtheexhaustgases.Thepressurevesselholdsallofthestressofthehighpressuresteam.
Watertubeboilersallowthecombustiongasestoprovideheattransfertothewater(andsteam)thatiscontainedinthetubesoftheboiler.Atypicalwatertubeboilerarrangementwillincorporateanuppersteamdrumthatallowstheliquidwaterandsteamtoseparate.Alowerdrum,oftencalledamuddrum,willserveasthelowercollectionheaderforthetubes.Hundredsofrelativelysmalldiametertubeswillconnectthemuddrumtothesteamdrum.Asthewaterheatsandboilingoccursthefluidrisesinthetubestothesteamdrum.
Slide3FireTubeBoiler
Generally,firetubeboilersaredesignedforlowerpressureandlesscapacitythanwatertubeboilersbuttheiroperatingrangesoverlap.Atypicalfiretubeboilermighthaveasteamproductionrateof5,000poundsperhour,whileatypicalwatertubeboilermighthaveasteamproductionrateof200,000poundsperhour.Firetubeboilersproducesaturatedsteaminmostallcases.
[SlideVisualaFireTubeBoiler]Thisschematicdepictsa3passfiretubeboiler,inwhichwehaveacombustionzone(atthebottom),andsmallertubesthatallowmoreheattransferfromtheexhaustgases.Thepressurevesselholdsallofthestressofthehighpressuresteam.
Slide4WaterTubeBoiler
Watertubeboilerscanproducesaturatedsteamortheycanbeequippedwithasuperheaterinternaltotheboiler.Fromthestandpointsofmanagement,investigation,andimprovement,knowingthedifferencesbetweenthetwoboilertypesisnotessentialbecausetheygenerallyworkthesame.Therearenosignificantefficiencyrelatedreasonstochooseonetypeofboilerortheother.Thereasonsforchoosingoneortheotherareusuallyrelatedtotherelativecostforthegivenpressureandsteamproductionrequirements.
[SlideVisualaWaterTubeBoiler]Watertubeboilersallowthecombustiongasestoprovideheattransfertothewater(andsteam)thatiscontainedinthetubesoftheboiler.Atypicalwatertubeboilerarrangementwillincorporateanuppersteamdrumthatallowstheliquidwaterandsteamtoseparate.Alowerdrum,oftencalledamuddrum,willserveasthelowercollectionheaderforthetubes.Hundredsofrelativelysmalldiametertubeswillconnectthemuddrumtothesteamdrum.Asthewaterheatsandboilingoccursthefluidrisesinthetubestothesteamdrum.
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Slide5CommonFuels
ThistablecontainsinformationconcerningthemostcommonfuelsusedintheUnitedStatesandthroughouttheword.Naturalgasandnumber2fueloilaregenerallyconsideredveryeasyfuelstoutilize.Theheavierfueloils,likenumber6fueloilareverycommon;but,aremoredifficulttohandle.Number6fueloilisgenerallyasolidatroomtemperatureandisheatedtomorethan200Ftobepumpedtotheboilerburner.Solidfuelslikecoalandgreenwoodaremuchmoredifficulttohandleandstore.Solidfuelsgenerallycontainaportionofnoncombustiblematerialcalledashthatmustbedisposedofafterthecombustionprocess.
Greenwoodisadominantfuelinthepulpandpaperindustrybecausetheygenerateasignificantamountofwastewoodmaterials.Itshouldbenotedthatgreenwoodistypicallybarkandtreecomponentsthatwererecentlyapartofalivetree.Thisfactisimportantbecauselivetreesareessentiallyhalfliquidwatergreenwoodasafuelisnominally50%liquidwater.
TheunitcostsidentifiedinthistablearereflectiveoftheaverageU.S.fuelcostsfor2005.Thisinformationisunderstandablynotcurrent;but,itisreflectiveofthecommondifferencesinfuelprices.Itiscommonfortheenergybasedcostofnaturalgastobefourtimesgreaterthantheenergybasedcostofcoalorevenmore.Fueloilpricescanbeevenhigher.Thisisadominantreasonwhyweusecoal.
Itshouldbenotedthatthereissignificantvolatilityinthefuelmarket.
[SlideVisualCommonFueltable]
TypicalFuelProperties Sales ExamplePrice HHV UnitPrice
Fuel Unit [$/s nit]alesu [Btu/lbm] [$/ u]10BtNaturalGas 10stdft 7.00 23,311 7.00Number2FuelOil gallon 1.80 19,400 12.92Number6Oil(LS) gallon 1.20 18,742 7.82Number6Oil(HS) gallon 1.00 18,815 6.62EasternCoal ton 45.00 13,710 1.64WesternCoal ton 30.00 10,088 1.49GreenWood ton 11.00 5,250 1.05
Slide6BoilerExample
Throughoutthistrainingwewilluseanexamplesteamsystemthatreflectsasteamsystemwithrealworldcharacteristics.Thisexamplesystemwillhelpusillustratetheimportanceandusefulnessoftoolsandinvestigationspresentedinthistraining.Throughoutthiscoursewewilldiscussalltheaspectsofthissteamsystem;but,wewillstartbylookingatoneoftheboilersservingthisexamplesite.
Forthisexampletheboilerisproducing100,000poundsperhour,of400PSIG,700degreeFahrenheitsteamfromthecombustionofnaturalgas.
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Thisboilerisequippedwithafuelflowmeterandthecostofthefuelistakenas$10/106Btu.
[SlideVisualWaterTubeBoiler]Watertubeboilersallowthecombustiongasestoprovideheattransfertothewater(andsteam)thatiscontainedinthetubesoftheboiler.Atypicalwatertubeboilerarrangementwillincorporateanuppersteamdrumthatallowstheliquidwaterandsteamtoseparate.Alowerdrum,oftencalledamuddrum,willserveasthelowercollectionheaderforthetubes.Hundredsofrelativelysmalldiametertubeswillconnectthemuddrumtothesteamdrum.Asthewaterheatsandboilingoccursthefluidrisesinthetubestothesteamdrum.
Slide7CaseStudy
Thisdatawillprovideenoughinformationtocalculatethefuelrelatedoperatingcostoftheboiler.
[SlideVisualOperatingCost]
Boilerfiredwithnaturalgaswhichhasahigherheatingvalueof23,311Btu/lbmHHVis1,000Btu/sftSteamconditions:400psig,700FOutput:100,000lbm/hr(steady)Rating:120,000lbm/hr(maximumcontinuous)Feedwater:600psig,242FFuelsupply:149,000sft/hr(2,480sft/min)Fuelcost:$10.00/10Btu($10.0/10sft)Determinetheoperatingcostoftheboiler
Slide8BoilerOperatingCost
Thefuelrelatedoperatingcostofthisexampleboileris$13,000,000/yr.Itshouldbenotedthatthisexampleboilercanbeconsideredatypicalindustrialboiler.Thefuelisnaturalgas,whichisoneofthesimplestfuelstoburn.Itisinterestingtonotethatthecharacteristicsofthisboilerarenotextreme;inotherwords,theboilerisproducingamoderateamountofsteamundertypicalconditions.Additionally,whilethefuelcostmaynotbeexactlyrepresentativeofthefuelcostsatagivenfacilitythisexamplecostisnotextraordinary.Thecharacteristicsofthisboilerareeasilyscalabletomostboilers.Itshouldalsobenotedthattheinvestigationandimprovementtechniquesrequiredtomanagethisexampleboilerarethesametechniquesavailabletoallboilers.Alongwiththisisthefactthatthisexampleboilerisarealboilerthatappropriatelyrepresentsthetypesofopportunitiespotentiallyavailabletomanyboilers.Boilersareextremelyexpensivecomponentsthisisthereasonweareinterestedinthem.
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[Slide u al ion]Vis alC culat
Kboiler=Vfuelxkfuelxoperation
Boileroperatingcostsequalsthecostoffuelperhourperhourmultipliedbythecostofthefuelpercubicfootmultipliedbythehoursofoperation
AbbreviationsK=BoilerOperatingCostsV=VolumeflowofFuelperHourk=CostofFuelperCubicFoot=Operatingperiod
Slide9OperatingCost
Thecostoffuelforatypicalboilerissolargethatevenverysmallchangesinefficiencycanrepresentsignificantcostimpact.A1%improvementinefficiencyfortheexampleboilerrepresentsapproximately$130,000/yroffuelsavings.
Thereareothercostfactorsassociatedwithboileroperationswatertreatmentcosts,auxiliaryequipmentcosts,maintenancecosts,andoperationscosts;however,thesecoststypicallycombinetobesignificantlylessthanthecostoffuelfortheboiler.Eachcostfactorshouldbeinvestigated;but,fuelcosttypicallydominates.
Inthisexampleboilerinvestigationwewillidentifyrealworldmethodsthatwillreducethefuelconsumptionofthisboilermorethan7%,whichrepresentsmorethan$1,000,000/yr.
[SlideVisualSavingsCalculation1]
0.01x$13,000,000/yr$130,000savings!
Inthisequation,KequalsBoilerOperatingCost,VequalsCostoffuelperhour,KequalsCostoffuelpercubicfoot,andTequalsHoursofOperation.
Calculationsareoftenthoughtofasacademicexercises;however,inthecaseofmanagingboilerperformanceandcost,evaluatingboilerefficiencyisoneofthemostimportantandpracticaltoolsavailabletous.Toillustratetheimportanceandusefulnessofboilerefficiency,wewillexaminetheefficiencyofanexampleboiler.Wewillalsoexplorethemajorfactorsthatimpacttheefficiencyandoperatingcostofaboiler.
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[SlideVisualOperatingCost]
Boilerfiredwithnaturalgaswhichhasahigherheatingvalueof23,311Btu/lbmHHVis1,000Btu/sftSteamconditions:400psig,700FOutput:100,000lbm/hr(steady)Rating:120,000lbm/hr(maximumcontinuous)Feedwater:600psig,242FFuelsupply:149,000sft/hr(2,480sft/min)Fuelcost:$10.00/10Btu($10.0/10sft)Operatingcost:13,000,000$/yrAsmallchangeinboilerefficiency(even1%)canrepresentasignificanteconomicimpactOtheroperatingcostsinclude:WatertreatmentBoilerfeedpumpsFluegasconditioningMaintenance(personnel,services,equipment)Typicallythesecostscombinetobemuchlessthanfuelcosts
Slide10EfficiencyDefinition
Calculationsareoftenthoughtofasacademicexercises;however,inthecaseofmanagingboilerperformanceandcost,evaluatingboilerefficiencyisoneofthemostimportantandpracticaltoolsavailabletous.Toillustratetheimportanceandusefulnessofboilerefficiency,wewillexaminetheefficiencyofanexampleboiler.Wewillalsoexplorethemajorfactorsthatimpacttheefficiencyandoperatingcostofaboiler.
[SlideVisualEfficiencyDefinitionTitlePage]
DOEsBestPracticesSteamEndUserTraining
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Effici tionencyDefiniShellLosses
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Slide11DefineBoilerEfficiency
Boilerefficiencyisawaytodeterminehowmuchfuelenergyaboilerconvertsintosteamenergy.Steamenergyisthedesiredcommodityandfuelenergyisthepurchasedcommodity.Theequationshownhereisasimplifieddescriptionoftheenergyefficiencyofaboilerexpressedintermsoffuelenergyintotheboilerandsteamenergyoutoftheboiler.
Thefuelenergysuppliedtotheboilerisdeterminedbymultiplyingthefuelflowratebythefuelenergycontent.Fuelenergycontentisdescribedintermsoftheheatingvalueofthefuel,whichisanexpressionofthethermalenergythatisreleasedwhenthefuelisburned.ThemaximumthermalenergythatcanbereleasedwhenafuelisburnedisidentifiedasthefuelHigherHeatingValueorHHVofthefuel.Thefuelheatingvalueisdeterminedbylaboratoryanalysis.
[SlideVisualEfficiencyEquation1]n =energydesiredboiler /x(100)energythatcostsTheboilerefficiencyisequaltotheenergydesireddividedbytheenergythatcosts.
Theenergydesiredistheenergyaddedtothesteamasitpassesthroughtheboiler.Steamenergyisdeterminedbymultiplyingthesteamproduction(ormassflowrate)bythespecificenergyaddedtothesteamasitpassesthroughtheboiler.Wedescribetheenergycontentofthesteamastheenthalpyofthesteam(hintheequation)enthalpyisthethermodynamicpropertydescribingtheamountofenergyresidinginthematerial.Theenergyaddedtothesteamintheboileristhedifferenceinenthalpyofthesteamleavingtheboilerversusthefeedwaterenteringtheboiler.Enthalpyvaluesareobtainedfromthermophysicalpropertydatasetsandfieldmeasurementslikesteamtemperatureandpressure.
[SlideVisualEfficiencyEquation2]n =mboiler steam(hsteamhfeedwater)/
mfuelHHVfuelBoilerefficiencyisequaltothemassflowrateofthesteammultipliedbythedifferenceintheenthalpyofthesteamandtheenthalpyofthefeedwater;,dividedbythemassflowofthefuelmultipliedbythehigherheatingvalueofthefuel.
Enthalpyenergyofasubstancethatcanbeconvertedintoheat,work,andotherformsofenergy.
Fuelenergyisdeterminedbymultiplyingthefuelconsumptionratebythefuelenergycontent,alsoknownastheheatingvalue.
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Ab ationsbr vienboiler =Efficiencyoftheboiler,alsocalledcombustionefficiency,overallefficiency(dimensionless)mste =massflowrateofsteamgeneratedintheboiler(lbm/hr)ammfuel =massflowrateoffuelburned(lbm/hr)h =Enthalpyisenergycontentofasubstance(Btu/lbm)HHV =HigherHeatingValueoffuel(Btu/lbm)
AnalternateexpressionfortheenergycontentofthefuelisidentifiedastheLowerHeatingValue(LHV).Mostcommonfuelsarecomposedprimarilyofcarbonandhydrogen.Theseelementsreactwithoxygeninthecombustionprocessandprimarilyformcarbondioxideandwater.Thewaterformedinthecombustionprocessisinitiallyvapor(steam).Ifthethiswatervaporisallowedtocoolbelowitscondensationtemperaturethevaporwillcondenseliberatingheat.Thisenergyreleasefromthewatervaporrepresentsadditionalenergyavailablefromthecombustionofthefuel.ThedifferencebetweentheHigherHeatingValueandtheLowerHeatingValueistheHigherHeatingValueaccountsforthisadditionalenergyliberationwhenthewatervaporcondenses.TheLowerHeatingValuemeasuresthefuelenergyreleasewithallthecombustionproductsremaininginthevaporphase.Slide12BoilerEfficiency1Itisinterestingtoidentifytypicalboilerefficiency.Thiswillallowustocompareourboilertotypicaloperation.Ifwecanidentifybestpracticeboilerefficiencythenwecancharacterizetheoperationofourboilerpossiblyidentifyingtheimprovementpotential.Slide13BoilerEfficiency2Ifweweretoexaminemanyboilerswewouldprobablyfindthatthetypicalboilerefficiencyisinthemid80%range.Wewouldalsoseethatmanyoftheboilerswouldhavehigherefficiencythanthisandmanywouldhavelowerefficiencythanthis.But,wewouldseeveryfewboilerswithefficienciesmuchgreaterthan90%andveryfewboilerswithefficienciesmuchlowerthan70%.Greenwoodisacommonfuelinmanyindustriesmostprominentlyinthepulpandpaperindustry.Thetermgreenwoodreferstowoodproductsthathavenotbeendried.Pulpandpaperplantsharvesttreestoprocessthemintopulpandpaperproducts.Paperisnotmadefromthebarkandlimbsofthetrees.Asthetreesareharvestedthelimbs,bark,andpoorqualitymaterialsareremovedalongwithotherpartsofthetreethatcannotbeconvertedintopaper.Thisgreenwoodisfreshfromtheforestandtypicallycontainsabout50%celluloseand50%liquidwater.Greenwoodisusedasamajorfuelsourcebecauseitisreadilyavailableandislowcost.However,afuelthatiscomposedof50%liquidwaterwillburninefficientlytheliquidwaterwillboilandcarryalargeamountofenergyoutoftheboiler.Asaresult,greenwoodfiredboilerswilloperatewithlowefficiency.Itisinterestingtonotethatatypicalindustrialcoalfiredboilerwilloperatewithrelativelyhighefficiency.Thisresultsfromthefactthathydrocarbonfuelsarecomposedprimarilyofhydrogenandcarbon.Carboncombustsandformscarbondioxide.HydrogencombustsandformsH2Owater.WaterisGodsgreatestchemicalforabsorbingandtransportingenergy.Mostofourboilersburninghydrocarbonfuelsreleasewatervapor(steam)asaproductofcombustion.Asaresult,asignificantportionoftheenergyavailableinthefueliscarriedoutoftheboilerinthewatervaporthatisformedin
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thecombustionprocess.Fuelscontaininglesshydrogenexhaustlesswatervaporinthefluegasesandgenerallyhavehigherefficiency.Coalsgenerallycontainsomeamountofliquidwater,someamountofash(rocks),butmostlycarbon.
Fueloilsusuallycontainmorehydrogenthancoalsbuttheytypicallycontainverylittleashandalmostnoliquidwater.Asaresult,fueloilfiredboilerswilloperatewithrelativelyhighefficiency.
Naturalgascontainsarelativelylargeamountofhydrogen.Therefore,naturalgasfiredboilerswilloperatewithefficiencieslowerthancomparablecoalandoilfiredboilers.
Therearemanyfactorsthatimpactboilerefficiencyfueltypeisoneofthem,thewaywecontrolthecombustionprocessisanother,andenergyrecoveryequipmentinstalledontheboileronemoremajorfactoreffectingefficiency.
Slide14SteamProperties
Letsreturntoourexampleboilerbecausewehaveenoughinformationtoevaluateboilerefficiency.Inordertodeterminetheenergyaddedtothesteampassingthroughtheboilerwemustusesteampropertydataoftenknownassteamtables.Fromthetemperatureandpressuremeasurementsofthesteamandfeedwaterwecanidentifytheirenthalpiesagain,enthalpyisanindicationofenergycontent.Hereyoucanseefor700degreesFahrenheitand400poundspersquareinchgage,theenthalpyofthesteamis1,362Btuperpoundofsteam.Thefeedwaterisat242degreesFahrenheitand600poundspersquareinchgagetheenthalpyofthefeedwateris210Btu/lbasshowninthetable.
Slide15Direct(Classic)EfficiencyCalculationThesteampropertydataalongwiththefuelconsumptiondatagivesusenoughinformationtocalculateboilerefficiency.Thisboilerisoperatingwithanefficiencyofabout77%.Weareexpectingatypicalnaturalgasfiredboilertooperatewithanefficiencyinthelow80%range.Thisboilerisoperatingwithanefficiencythatisbelowtheexpectedvalueweanticipatethattheremaybeopportunitiestoimprovetheperformanceofthisboiler.
[SlideVisualEnthalpy]hsteam =1,361.88Btu/lbm
hfeedwater=210.42Btu/lbmDirectEfficiencyCalculation1Enteringdataintothedirectefficiencyequation,weget77%boilerefficiency.
[SlideVisualEquations]n =mboiler steam(hsteamhfeedwater)/x(100)
m xHHVfuel fuel
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Theboilerefficiencyisequaltothemassflowofthesteammultipliedbythedifferenceintheenthalpyofthesteamandtheenthalpyofthefeedwater;dividedbythemassflowofthesteammultipliedbythehighheatingvalueofthefuel.
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n =(100,000lbm/hr)x(1,361.88Btu/lbm210.42Btu/lbm)x(100)boiler (149,000sft3/hr)x(1,000Btu/sft3) *basedonvolumetricflowrate(HHVunitsareBtu/sft3)Theboilerefficiencyisequalto100,000poundsperhour,multipliedby1,361.88BTUperpoundminus210.42Btuperpound;dividedbythe149,000standardcubicfeetperhourmultipliedby1,000Btuperstandardcubicfeet.Orusingfuelmassflowdata(p=0.043lbm/sft3)mfuel =(149,000sft3/hr)x(0.043lbm/sft3)=6,407lbm/hrn =(100,000lbm/hr)x(1,361.88Btu/lbm210.42Btu/lbm)x(100)boiler (6,407lbm/hr)x(23,311Btu/lbm)*basedonmassflowrate(HHVunitsareBtu/lbm)Theboilerefficiencyisequalto100,000poundsperhour,multipliedby1,361.88BTUperpoundminus210.42Btuperpound;dividedbythe6,407poundsperhourmultipliedby23,311Btuperpound.nboiler=77.1%A e ationsbbr vinboiler =Efficiencyoftheboiler,alsocalledcombustionefficiency,overallefficiency(dimensionless)mste =massflowrateofsteamgeneratedintheboiler(lbm/hr)ammfuel =massflowrateoffuelburned(lbm/hr)h =Enthalpyisenergycontentofasubstance(Btu/lbm)HHV =HigherHeatingValueoffuel(Btu/lbm)
Slide16EfficiencyCalculation
Inordertoidentifytheimprovementopportunitiesassociatedwiththisboilerweaskwhyistheefficiencynot100%?Inotherwords,ifboilerefficiencyindicatesthat77%ofthefuelenergywentintothesteam,wheredidtheother23%ofthefuelenergygo?Itwenttosupplythelossesoftheboiler.
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Slide17BoilerLosses1
Whatarethetypicalboilerlosses?Wherecanfuelgootherthanintothesteam?
[GraphicalDescriptionBoilerLosses]
Thisschematicdepictsawatertubeboiler.Fuelandairentersatthelowerleftofthecombustionzone,feedwaterentersatthetopintothesteamdrumwhichconnectstothemuddrumthroughmanytubes.Themuddrumisatthebottomoftheboiler.Steamexitstheboilerfromthesteamdrumintothesuperheatersection,whichisshownatthetopoftheboiler.Thecombustiongasesleavingtheboilerthroughtheductingattheupperright.
Slide18BoilerLosses2
Eventhoughboilersareinsulatedtheiroutersurfacesarehot,indicatingtheyarenotperfectlyinsulatedandfuelenergyisbeinglost.Thisisidentifiedasthe alsoknownas .shellloss radiationandconvectionloss
Anotherlossassociatedwithoperatingaboilerisidentifiedastheblowdownloss.Inordertomaintainproperboilerwaterchemistrysomeoftheboilerwatermustberemoved.Thisisanenergylossbecausethewaterthatisdischargedhasbeenheatedwithfuelenergy.
Theexhaustgasesfromthecombustionprocessexittheboilerwithfuelenergy.Thisenergycanbeidentifiedbytheelevatedtemperatureofthegases.Buttherealsocanbeunreactedfuelorextraairintheexhaustgases.Theseexhaustgasrelatedlossesareidentifiedasthe .stackloss
Manyotherlossescanbeidentifiedforboilers;suchas,theenergycarriedfromtheboilerwithashinacoalfiredboiler.However,thethreelossesidentifiedshell,blowdown,andstackarepresentonallfiredboilersandtheyrepresentthefundamentalpointsofconcernformanagingboilerefficiency.
Slide19IndirectEfficiency
Generallymanagingboilerperformancefocusesonidentifyingandmanagingthelosses.Infact,oneofourmostimportanttoolsistoidentify,quantify,andreducetheboilerlosses.Thisisaccomplishedthroughanindirectefficiencyevaluationtechnique,whichisthetoolmostoftenusedinthefield.
Boilerefficiencyisdeterminedinanindirectmannerbyassumingtheboilerefficiencyis100percentminusallofthelosses.Eachlossisidentifiedandquantifiedinthisanalysis.
Inthenextsectionsofourtrainingwewillfocusoneachoftheselosses.Wewillexploreeachlossindetailidentifyinghowtoevaluateeachoneforourboilers.Additionallywewillidentifythefuelimpactassociatedwitheachlossandtherealworldimprovementopportunitiesthatcanbetargetedineacharea.Therealbenefitassociatedwithevaluatingboilerperformancewiththeindirectefficiencytoolisthatasboilerefficiencyisdeterminedtheroadmapforimprovementisestablished.Evaluatingtheindividuallossesnotonlycharacterizeseachlossbutitalsoaffordsustheopportunitytoidentifytheimprovementpotentialassociatedwitheach.
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[ sualBoilerLosSlideVi sIndirectEfficiencyEquations]
nindirect =100percentElossesIndirectBoilerEfficiencyisequalto100%minusthesumofallboilerlosses.
nindirect =100percentshellblowdownstackmiscIndirectBoilerEfficiencyisequalto100%minustheshelllosses,minustheblowdownlosses,minusthestacklosses,minusthemiscellaneouslosses.
Abbreviationsnindirect=IndirectefficiencyElosses=SumofallLosses
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ShellLossesSection
Slide1ShellLossesModuleNext,wewillidentifythemethodsusedtoinvestigate,quantify,andcontroltheseindividuallosses.Wewillstartwithshelllosses.
[SlideVisualShellLossesTitlePage]
SteamGenerationEfficiency
EfficiencyDefinition
ShellLossesBlowdownLosses
StackLosses
Slide2ShellLossMagnitudeShelllossisthefuelenergythatleavestheboilerfromitsoutersurface.Inotherwords,theoutersurfaceoftheboilerishot,whichindicatesitislosingheat.Itisdifficulttoaccuratelymeasurethethermalenergylossfromtheoutershellofaboiler.Asaresult,shelllossisgenerallyestimatedfromsomelimitedfieldmeasurements.AnexcellentandrelativelyeasyestimatingtechniqueisidentifiedintheAmericanSocietyofMechanicalEngineersPerformanceTestCode4(ASMEPTC4).
[SlideVisualShellLossesEstimationTechnique]ASMEPTC4AmericanSocietyofMechanicalEngineersPerformanceTestCode4
Inthistechniquethetemperatureofeachsurfaceoftheboilerismeasured.Typicallythismeasurementisobtainedwithaninfraredsurfacethermometer.Surfacetemperaturestypicallyrangefrom120to180degreesFahrenheit,buthotspotsgreaterthanthisrangecanexist.Hotspotscandevelopfromdamagedinsulationontheboilerordamagedrefractoryinsidetheboiler.
Theshelllossestimatingtechniqueutilizesthecharacteristictemperatureofaboilersurfaceorareaandanestimatedambientsurfaceairflowvelocity.Theseestimatesareusedtocompleteaheattransferanalysisforallofthesurfacesoftheboileryieldinganestimatefortheboilershellloss.Thistechniqueissimple;however,theresultsmustbeconsideredageneralestimate.Thetotalshelllossestimateiscomparedtothetotalfuelenergyinputtodeterminethemagnitudeoftheloss.
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Slide3ShellLossItisinterestingtonotethatformostboilersthetotalenergylostfromtheshellremainsessentiallyconstantwithrespecttoboilerload.Inotherwords,theshelllossenergyflowisbasicallyconstant.Thisisnottosaythatthefractionoffuelinputenergylostfromtheboilershellremainsconstantrathertheenergyflow(Btu/hr)remainsessentiallyconstantwithrespecttoboilerload.Thisbeingthecase,theshelllossexpressedasafractionoffuelinputenergywoulddoubleastheboilertransitionsfromfullloadtohalfload.Formostwellmaintainedboilers,thefullloadshelllosswillbebetween0.1%to2%offuelinputenergy.Usually,shelllossesareminimalandthebestwaytomanageshelllossistomonitorforhotspots,damagedinsulation,andothersurfaceproblems.Typically,shelllossissuesdonottranslateintosignificantenergylossesbutsignifyinsulationorrefractoryissuesthatneedtoberepairedtoincreasethelongevityoftheboiler.Slide4ExampleBoilerSavingsForourexampleboileranASMEtypeshelllossinvestigationindicatesapproximately0.5%ofthefuelinputenergyislostthroughtheshelloftheboiler.Thisrepresentsapproximately$65,000/yroffuelenergy.Thisisarelativelysmallfractionofthefuelinputenergyandthereisverylittlethatcanbedonetosignificantlyreduceit.
OurExampleBoiler:
FromanASMEtypeinvestigationtheradiationandconvectionlossoftheexampleboilerisapproximately0.5%ofthetotalfuelenergyinputtotheboiler.
Thisrepresentsalossofapproximately$65,000/yr. Surfacetemperaturemeasurementsdidnotindicateanyhotspotsontheexampleboiler.Theinsulation,cladding,andrefractoryarein
goodcondition.Asaresult,wewilljustacceptthatthislosswilloccurandcontinueourinvestigationintootherareasofboilerefficiency.
RadiationandConvectionLoss=$13,000,000/hrx(0.5%/100)=$65,000/yr
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Slide5ShellLossSummaryInsummary,shelllossisgenerallyaminorcontributortotheoverallfuelenergyloss.Directmeasurementsofboilershelllossaredifficulttocomplete;but,simplifiedestimatingtechniquesprovideexcellentinsightintothemagnitudeofboilershellloss.Shelllossshouldnotbeignoredhotspotsintheboilershellindicateproblemsthatshouldbecorrected.
[SlideVisualShellLossSummary]
ASMEPTC4AmericanSocietyofMechanicalEngineersPerformanceTestCode4 Searchforhotspots
o Damagedinsulationo Damagedrefractoryo
MeasureboilersurfacetemperatureMonitorsurfacecladdingintegrity
o
Infrared Typicalsurfacetemperatureshouldrangebetween120oFand180oF Repairrefractory Monitorsurfacecladdingintegrity Reduceboilerloadcanpresentanopportunity
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BlowdownLossesSection
Slide1BlowdownLossesModuleThissectionwilldiscussblowdownlossanditsaffectonboilerefficiency.
[SlideVisualBlowdownLossesTitlePage]
SteamGenerationEfficiency
EfficiencyDefinitionRadiationandConvectionLossesShellLosses
Blo eswdownLossStackLosses
Slide2Blowdown
Thenexttypeoflossinvestigatedisblowdownloss.Boilerfeedwaterisverycleanwater.However,infeedwatertherearesomedissolvedchemicals.Essentiallypuresteamexitstheboilerthemajorityofthechemicalsenteringtheboilerwithfeedwaterarenotsolubleinthesteamandwillnotleavetheboilerwiththesteam.Asaresult,theconcentrationofthesechemicalsincreasesintheboiler.Elevatedconcentrationsofchemicalsresultsinmanyseriousboilerproblemsincludingfoamingresultinginliquidcarryover,scalingonthewatersideofthetubes,andloosesludgeintheboilerwater.Blowdownistheprimarymechanismthatallowsustocontrolchemicalconcentrationsintheboilerwater.Blowdownallowsustomaintainanacceptableconcentrationofdissolvedandprecipitatedchemicalsintheboiler.
Thereisanenergylossassociatedwithblowdown,becausethewaterhasbeenheatedtotheboilingpointfromfeedwaterconditions.
Slide3BoilerBlowdown
Therearetwogeneraltypesofboilerblowdown.Oneistypicallyfromthelowersectionsoftheboilercalledbottomblowdown.Theothertypeofblowdownistypicallyfromtheuppersectionsoftheboilerandiscalledsurfaceblowdown.
Bottomblowdownisactuatedbecausesomesolidswillprecipitatefromthechemicalsdissolvedinthefeedwater.Thesesolidstendtobeheavierthanwater,andthereforetendtocongregateinlowersectionsoftheboiler.Bottomblowdownisusedtoflushthesesolidsout.Bottomblowdownistypicallyasignificantflowofwaterforaveryshortperiodoftime.Theintentistosweepawayanysolidprecipitatesformedinthewater.Even
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thoughwhileitisoccurringitisalargeflowrate,itcontinuesforashortperiodoftime.Asaresult,thetotalflowofbottomblowdownisusuallymuchlessthanthetotalflowsurfaceblowdown.
SteamEndUserTrainingSteamGenerationM
Surfaceblowdownistypicallyamuchsmallerflowratethanbottomblowdown;however,itcontinuesforamuchlongerperiodoftimeoftencontinuously.Surfaceblowdownistheprimarymechanismusedtocontrolthedissolvedchemicalconcentrationsintheboiler.Surfaceblowdownendsupremovingmostoftheblowdownwater.
[SlideVisualBoilerBlowdown]
Thisschematicdepictsawatertubeboiler.Fuelandairentersatthelowerleftofthecombustionzone,feedwaterentersatthetopintothesteamdrumwhichconnectstothemuddrumthroughmanytubes.Themuddrumisatthebottomoftheboiler.Steamexitstheboilerfromthesteamdrumintothesuperheatersection,whichisshownatthetopoftheboiler.Thecombustiongasesleavingtheboilerthroughtheductingattheupperright.Thebottomblowdownisshownfromthebottommuddrum.Thesurfaceblowdownisshownatthetopfromthesteamdrum.
Slide4BlowdownControl
Generally,surfaceblowdowniscontrolledbasedonboilerwaterconductivity.Conductivityisadirectmeasurementthatcancontinuouslyprovideanindicationofboilerwaterquality.However,conductivitymustbecorrelatedtoindividualchemicalcontaminantsthroughperiodicwateranalysis.Conductivityandtheresultsofspecificboilerwatertestingaidinadjustingtheblowdownrate.
[SlideVisualConductivitySensor]
Thisschematicdepictsawatertubeboiler.Fuelandairentersatthelowerleftofthecombustionzone,feedwaterentersatthetopintothesteamdrumwhichconnectstothemuddrumthroughmanytubes.Themuddrumisatthebottomoftheboiler.Steamexitstheboilerfromthesteamdrumintothesuperheatersection,whichisshownatthetopoftheboiler.Thecombustiongasesleavingtheboilerthroughtheductingattheupperright.Thesurfaceblowdownisshownatthetopfromthesteamdrumwithaconductivitysensorcontrollingtheblowdownvalveposition.Theblowdownisdischargedtothesewer.
Slide5BlowdownLossEstimate
Fromtheviewoftheboiler,feedwaterenters,steamandblowdownexit.Theboileraddsfuelenergytothesteamandblowdownthatexittheboiler.Blowdownisanenergystreamthatisdischargedfromtheboiler.Blowdownistypicallyexpressedasafractionoffeedwatermassflowandcanrangefromlessthan1%tomuchgreaterthan10%dependingonwaterchemistry,boileroperatingpressure,andotherfactors.However,itshouldbenotedthat10%blowdownratedoesnotmean10%energylossblowdowndischargedfromtheboilerisnothighenergysteam,itismoderateenergywater.Fromtheperspectiveoftheboiler,theenergyaddedtotheblowdownstreamisblowdownflowratetimesthedifferenceintheenthalpyoftheblowdownandthefeedwater.Therefore,10%blowdownratecantranslateinto5%fuelenergyinput.Itshouldbenotedthattherelationshipbetweenblowdownmassfractionandblowdownenergyfractionisdependentonmanyfactorsincludingboileroperatingpressureandfeedwatertemperature.
DOEs BestPractices Steam End User Training
BlowdownLosses3June28,2010
SteamEndUserTrainingSteamGenerationModule
[ isua ler ow BoilerCalcSlideV lBoi Blowd nLoss ulation]
L =mblowdown blowdown(hblowdownhfeedwater)/x(100)
mfuel fuelxHHV
AbbreviationsLblowdown =Lossduetoblowdown(%)mblowdown =massflowrateofblowdown(lbm/lbm)h eed ater massflowrateoffeedwater(lbm/lbm)f w =mfuel =massflowrateofsteamgeneratedperpoundoffuelburned(lbm/lbm)h =Enthalpyisheatcontentorusefulenergyofasubstance(Btu/lbmorkJ/kg)HHV =HigherHeatingValueoffuel(Btu/lbm)
Slide6SystemLoss
Again,fromtheperspectiveoftheboiler,theenergyaddedtotheblowdownstreamisblowdownflowratetimesthedifferenceintheenthalpyoftheblowdownandthefeedwater.However,everypoundofblowdowndischargedfromthesystemismadeupwithcoldmakeupwaterasaresult;aportionofthesteamgeneratedintheboilerisusedtoheatthemakeupwatertofeedwaterconditionsinthedeaerator.Therefore,fromasystemperspective,theenergyassociatedwiththeblowdownstreamisevenlargerthanthatidentifiedfromtheboilerperspective.
[VisualDescriptionSteamSystemImpactSchematic]
Thisschematicrepresentsathreepressureheadersteamsystemwithmultipleboilersandallofthesystemcomponents.Feedwaterispreheatedbysteaminjectionfromthelowpressuresteamdistributionheader,aswellaspreheatedmakeupwaterutilizingboilerblowdownheatrecovery.ThetopoftheschematicshowstheBoilerFeedwaterenteringthetwoboilers.Thetwoboilersareconnectedtothehighpressuresteamdistributionheader.Thesteamexitstwoboilersandentersthehighpressuresteamsystemdistributionheader,indicatedbyalinebelowtheboilers.Underthehighpressuresteamdistributionline,youwillseethreeconeshapedgraphics,thatrepresentthesteamturbines.Theonenearesttotheleftisahighpressuretocondensingturbine.Thisturbinedischargestothecondenserrepresentedbythebluecirclebelowtheturbine.Therectangulargraphictotherightoftheconeshapedgraphicindicatestheelectricalgenerationcomponentofthesteamturbine.Theturbineinthemiddlere