STEAM DIGEST For additional information A compendium of articles on BestPractices Steam, contact: on the technical and financial benefits of steam FRED HART Office of Industrial Technologies efficiency, presented U.S. Department of Energy 202 586-1496 by stakeholders in the U.S. Department of Energy’s CHRISTOPHER RUSSELL Senior Program Manager BestPractices Steam efforts. for Industry The Alliance to Save Energy 202 530-2225 Visit the OIT Steam Web site at: www.oit.doe.gov/bestpractices/steam www.steamingahead.org For information about other OIT Programs call: OIT Clearinghouse Phone: (800) 862-2086 Fax: (360) 586-8303 http://www.oit.doe.gov Office of Industrial Technologies OFFICE OF INDUSTRIAL TECHNOLOGIES Energy Efficiency and ENERGY EFFICIENCY AND RENEWABLE ENERGY • U.S. DEPARTMENT OF ENERGY Renewable Energy U.S. Department of Energy Washington, D.C. 20585 ALLIANCE TO SAVE ENERGY THIRD DECADE OF LEADERSHIP DOE/SBP001 November 2001 Rev. SteamSteam DigestDigesttt 20012001 Compiled and produced for OFFICE OF INDUSTRIAL TECHNOLOGIES ENERGY EFFICIENCY and RENEWABLE ENERGY U.S. DEPARTMENT OF ENERGY by THE ALLIANCE TO SAVE ENERGY THIRD DECADE OF LEADERSHIP TABLE OF CONTENTS INTRODUCTION Fred Hart, U.S. Department of Energy Christopher Russell, Alliance to Save Energy Anthony Wright, Oak Ridge National Laboratory, September 2001 3 BESTPRACTICES STEAM RESOURCES AND TOOLS: “OLD” NEWS IS “NEW” NEWS! Anthony Wright, Oak Ridge National Laboratory Fred Hart, U.S. Department of Energy Christopher Russell, Alliance to Save Energy David Jaber, (formerly with) Alliance to Save Energy The mission, purpose, and products of the U.S. Department of Energy’s BestPractices Steam program are reviewed here. 5 BEST PRACTICES IN STEAM SYSTEM MANAGEMENT Fred Hart, U.S. Department of Energy David Jaber, (formerly with) Alliance to Save Energy Common areas in which to look for savings opportunities in steam generation, distribution, end use, and recovery are outlined in this article. 11 BEST PRACTICES: THE ENGINEERING APPROACH FOR INDUSTRIAL BOILERS Natalie R. Blake, ONDEO Nalco Boiler best practices represent the Engineering Approach for boilers–a way to examine mechanical, operational and chemical aspects of the systems (pretreatment through condensate) to ensure reliable boiler operations with no surprises. 17 PERFORMING A STEAM SYSTEM CHECKUP: A THREE-STEP CHECKUP IDENTIFIES POTENTIAL OPPORTUNITIES FOR IMPROVEMENTS Anthony Wright, Oak Ridge National Laboratory Greg Harrell, University of Tennessee at Knoxville Glenn Hahn, Spirax Sarco To protect steam systems and ward off potential problems, operators and plant energy managers need to perform a “checkup” on their steam system. This checkup can improve the productivity and profitability of plant operations and/ or assess the status of operations. 23 THE STEAM SYSTEM SCOPING TOOL: BENCHMARKING YOUR STEAM OPERATIONS THROUGH BEST PRACTICES Anthony Wright, Oak Ridge National Laboratory Glenn Hahn, Spirax Sarco Plant managers can use the Steam Scoping Tool to assess their steam system operations while also discovering opportu- nities for enhancing efficiency. This article reviews the development and use of this easy-to-use spreadsheet tool. 27 THE ENBRIDGE CONSUMERS GAS “STEAM SAVER” PROGRAM Bob Griffin, Enbridge Consumers Gas A Canadian gas utility’s audit of 41 steam plants summarizes the frequency of common problems, solutions, and pay- back performance. 33 A HIGHLY SUCCESSFUL HOLISTIC APPROACH TO A PLANT-WIDE ENERGY MANAGEMENT SYSTEM Frederick P. Fendt, Rohm and Haas Company Rohm and Haas’ Deer Park, Texas, plant implemented a unique energy management program that has proven to be highly successful. This program resulted in a 17 percent reduction in energy use on a per pound of product basis, saving 3.25 trillion Btus and $15 million annually. This article discusses this program, its history, and the management processes that make it successful. 43 CELANESE CHEMICALS CLEAR LAKE PLANT ENERGY PROJECTS ASSESSMENT AND IMPLEMENTATION Joel Weber, (formerly with) Celanese Chemicals The Clear Lake Plant of Celanese Chemicals has implemented a strategy to reduce energy consumption during its production processes. This case study discusses practical reductions in steam, fuel, and electricity use. 49 SAVINGS IN STEAM SYSTEMS (A CASE STUDY) Rich DeBat, Armstrong Service, Inc. This hands-on case study of a chemical manufacturing plant exemplifies the process, documentation, and recommenda- tions involved in an industrial steam system audit. 51 STEAM SYSTEM DIAGNOSTICS John Todd, Yarway/Tyco Proper diagnosis of steam trap operations and maintenance requires a thorough understanding of other steam system components beyond the trap itself. This article provides a comprehensive overview of related elements. 63 ULTRASONIC TESTING TIPS FOR STEAM TRAPS AND VALVES Bruce Gorelick, Enercheck Systems, Inc. This article offers some testing tips to run a cost-effective steam distribution maintenance program. 69 RELIABLE SYSTEMS AND COMBINED HEAT AND POWER David Jaber, (formerly with) Alliance to Save Energy Richard Vetterick, TRC Energy This article gives a comprehensive definition of combined heat & power (CHP) systems and reviews its attributes. It also provides guidance for choosing various types of CHP applications. 71 BUSINESS BENEFITS FROM PLANT ENERGY ASSESSMENTS AND ENERGY MANAGEMENT David Jaber, (formerly with) Alliance to Save Energy The benefits of energy management are not limited to utility and fuel cost savings. There are also positive implications for improved productivity, increased equipment life, decreased risk of financial penalties, and increased order turn- around. This article provides reference information and suggests the steps needed to improve plant performance. 77 USE SPREAD-SHEET BASED CHP MODELS TO IDENTIFY AND EVALUATE ENERGY COST REDUCTION OPPORTUNITIES IN INDUSTRIAL PLANTS Jimmy Kumana, Consultant Cutting edge steam technology includes combined heat and power plants. Facilities managers must examine the eco- nomics of such plants before committing capital resources. This article demonstrates financial analysis techniques that use common spreadsheet applications. 81 JUSTIFYING STEAM EFFICIENCY PROJECTS TO MANAGEMENT Christopher Russell, Alliance to Save Energy Plant managers need to convince top management that steam efficiency is an effort that creates value. This article suggests ways to demonstrate steam efficiency’s impact on corporate and financial goals. 89 STEAM CHAMPIONS IN MANUFACTURING Christopher Russell, Alliance to Save Energy Anthony Wright, Oak Ridge National Laboratory The responsibilities related to industrial steam management evolve with changes in corporate, regulatory, and technol- ogy environments. This suggests a new set of managerial skills and accountability. The “steam champion” concept outlines what may be involved. 93 Acknowledgements The Steam Digest 2001 owes its existence to the U.S. Department of Energy’s Office of Industrial Technologies (OIT), led by Deputy Assistant Secretary Denise Swink. Special Assistant Marsha Quinn enables us to interact effectively throughout OIT. Mr. Fred Hart of DOE provides dedicated pro- gram management for the steam effort, while Mr. Christopher Russell of the Alliance to Save Energy leads program marketing and outreach. Dr. Anthony Wright of Oak Ridge National Laboratory leads our technical agenda. Ms. Rachel Madan of the Alliance provides additional program support. A steering committee consisting of steam experts from industry, business, government, trade associa- tions, and national labs provides guidance to our effort. Mr. Bill Pitkin of the National Insulation Association is the Chair of this Steering Committee. His rapport with government and business leaders greatly facilitates all of our accomplishments. Ms. Debbie Bloom of ONDEO Nalco is Vice Chair and a peerless referee of our technical content. Mr. Fred Fendt of Rohm & Haas is the committee’s Executive-at-Large, giving voice to the energy end-user’s perspective. Mr. Glenn Hahn of Spirax Sarco provides multifaceted leadership within the Steam and the overall BestPractices steering com- mittee structures. Each of these individuals provided a unique and valuable contribution to the BestPractices Steam Steering Committee throughout 2001: Bob Bessette Walter Johnson Council of Industrial Boiler Owners Association of Energy Engineers Charles Cottrell Mike Makofsky North American Insulation Manufacturers Shannon Enterprises Association Anthony Martocci Lee Doran Bethlehem Steel National Board of Boiler and Pressure Vessel Jim McDermott Inspectors Yarway Corp. Beverly France Kelly Paffel Industrial Interactions Plant Evaluations & Support Elodie Geoffroy-Michaels Miriam Pye Turbo Steam New York State Energy Research & Robert Griffin Development Authority Enbridge Consumers Gas Doug Riley Bill Haman Millennium Chemicals Iowa Energy Center Mike Sanders Tom Henry Sunoco Armstrong Services, Inc. Thomas Scheetz Ron Holt BASF Swagelok John Todd Yarway Corp. All of our steering committee members volunteer their time to BestPractices Steam, and our apprecia- tion is underscored here. A previously unheralded contributor to the program is Mr. Carlo LaPorta of Future Tech, who is the “utility in-fielder” on our management team. We thank each author for his or her contribution to this compendium. Mr. David Jaber provided several articles; he has since left the employ of the Alliance to Save Energy and we wish him well in his new endeavors. As was the case last year, a note of thanks goes