STEAM SYSTEM SCOPING TOOL

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INTRODUCTION
AUDIENCE FOR THE TOOL The audience for this tool is steam system energy managers and steam system operations personnel for industrial plants - from industries noted by the Department of Energy (DOE) as "Industries of the Future." The Department of Energy's nine Industries of the Future are Agriculture, Forest Products, Mining, Aluminum, Glass, Petroleum, Chemicals, Metal Casting and Steel. Using this Tool will assist you to: a) Develop a greater awareness of opportunities to improve your steam system; b) Identify actions to substantially reduce your steam energy costs; c) Allow you to evaluate your steam system operations against identified best practices; and d) Compare your steam system operations to those from other facilities (by comparing responses to the various Scoping Tool questions). The Steam System Scoping Tool includes eight worksheets: 1. Introduction 2. Steam System Basic Data 3. Steam System Profiling 4. Steam System Operating Practices - Total Steam System 5. Steam System Operating Practices - Boiler Plant 6. Steam System Operating Practices - Distribution, End Use, Recovery 7. Summary Results 8. NEXT STEPS - Additional DOE BestPractices Steam Resources Access Each Worksheet by clicking on the appropriate worksheet label at the bottom of the screen. For example, click on the "Steam System Basic Data" tab to access that worksheet. Start by Choosing a File Name for your spreadsheet, and Save a copy of the spreadsheet using that name. Answer the questions in Worksheet #2 - Steam System Basic Data. Provide scores for your steam system in Worksheets #3 through #6. Each of the questions in these four worksheets has a number of possible scores. Enter your appropriate score in the correct worksheet cell. Once you have entered your scores in Worksheets #3 through #6, go to Worksheet #7 - Summary Results to see a summary of the scores that you entered. Then go to Worksheet #8 - NEXT STEPS - for information on other BestPractices resources to help you improve your steam system. Finally, Save a copy of your completed spreadsheet and Print copies of any of Worksheets #2 through #7 that you would like paper copies of. Review Results - Are there any areas where you can make rapid improvements to your steam system? Share Results - Share what you learned from using this tool with your coworkers and your management. Look for opportunities to identify improvement projects based on your results. Compare Results - DOE is collecting results from many plants and will publish summary results on the BestPractices Steam web site - so you can compare what you have found for your system with results obtained in other similar plants. Complete The Tool Again At A Later Date - Reapplying the Steam Scoping Tool can show that you have made improvements, or maintained the effectiveness of the improvements that you previously made.

PURPOSE OF THE SCOPING TOOL

WHAT IS INCLUDED IN THIS TOOL

HOW TO USE THE STEAM SCOPING TOOL

HOW YOU CAN USE YOUR RESULTS

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INTRODUCTION (page 2)
HOW DOE WILL USE YOUR RESULTS The DOE requests that you provide your results to them. DOE is creating a database of responses to the Steam Scoping Tool questions. The summary information from this database will be available on the BestPractice Steam website - www.oit.doe.gov/bestpractices/steam - and can be made available to anyone who requests it. You will then be able to compare your individual results to results from all respondents and from respondents who have similar-type industrial plants. Confidentiality Of Your Input - DOE will insure that - if you provide them with your results - they will not be disseminated in any manner identified with your company's name; the results will be held strictly confidential. DOE will also not release your contact information to any third party service providers, so you can be sure that there will be no unsolicited contacts as a result of you providing your results to them.

HOW TO SUBMIT YOUR RESULTS When you complete the Steam Tool, you can submit your results (by email attachment or by sending a paper copy) to: Dr. Anthony Wright, Oak Ridge National Laboratory phone: 865-946-1353 email: [email protected] THANK YOU!! We appreciate your interest in using the Steam System Scoping Tool to evaluate your steam system, and hope that you will provide your results to us to include in the database of summary results that we are developing. The Steam System Scoping Tool was developed by the DOE BestPractices Steam effort, a part of the programs of the DOE Office of Industrial Technologies. Thanks to all of the members of the BestPractices Steam Best Practice and Technical subcommittee for reviewing early versions of the tool and providing their useful input to its development. This updated version of the Steam System Scoping Tool includes improvements based on comments received from six university Industrial Assessment Centers (IACs). We also thank these IACs for their help.

ACKNOWLEDGEMENTS

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STEAM SYSTEM BASIC DATA

BASIC DATA ABOUT YOUR SYSTEM What To Do Document some of the basic operating information about your steam system. Why Important Documenting basic steam system data is important to help you to identify the current conditions of your steam system operations, and to establish a baseline/benchmark that you can refer to in the future. ANSWERS TO BASIC DATA QUESTIONS a Briefly describe the type of production that your plant does in the column to the right. If you know the Standard Industrial Code (SIC) for your industry, please include that in your description.

IF YOU CONSUME STEAM BUT DO NOT GENERATE ANY OF YOUR OWN, PLEASE SKIP TO QUESTION "g" ANSWERS TO BASIC DATA QUESTIONS b c d What Is Your Total Annual Steam Production? How Many Hours Per Year Is Your System In Operation? What Is Your Total Steam Generation Capacity?

What Is Your Average Steam Generation Rate?

What Is The % Distribution (On A Btu Basis) Of Your Fuel Sources For Steam Generation? Coal Fuel Oil (#6) No. 2 Fuel Oil Natural Gas Process Waste Heat Biomass Solid Wastes Other TOTAL (Should add up to 100%)

0.0

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STEAM SYSTEM BASIC DATA (page 2)

ANSWERS TO BASIC DATA QUESTIONS g Do You Have Any Heat Engines In Use On Site? Back Pressure Steam Turbines Number Total Capacity Condensing Steam Turbines Number Total Capacity Combustion Gas Turbines Without Heat Recovery Steam Generators (HRSGs) Total Capacity Combustion Gas Turbines With HRSGs Total Capacity Other (specify type) Total Capacity How Much Steam Do You Buy Annually From Others? How Many Steam Traps Do You Have In Your Steam System? What is Your Average Boiler Blowdown Rate?

h I j

e current conditions of your uture. BASIC DATA QUESTIONS

R OWN,

BASIC DATA QUESTIONS Million lbs/year hours/year 1000 lbs/hour, or Boiler Horsepower 1000 lbs/hour, or Boiler Horsepower

% % % % % % % % %

BASIC DATA QUESTIONS

kW

kW

kW kW kW Million lbs/year

% of average feedwater flow rate

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STEAM SYSTEM PROFILING

STEAM COSTS What To Do Identify what it costs at your facility to produce steam (in units of $/1000 lbs), and use this as a benchmark for evaluating opportunities for improving your steam operations. Start with determining what your fuel costs are to make steam, then add other costs associated with your operations (chemical costs, labor, etc). Why Important Understanding the cost to make steam can be an eye-opener - producing steam is not free! Any opportunity that reduces the amount of steam generated saves money, so understanding the cost to make steam is a key step to being able to quantify improvement opportunities. ACTIONS yes no at least quarterly at least yearly less than yearly SCORE 10 0 10 5 0

SC1 Do you monitor your Fuel Cost To Generate Steam - in terms of ($) / (1000 lbs. of steam produced)? SC2 How often do you calculate and trend your Fuel Cost To Generate Steam?

STEAM/PRODUCT BENCHMARKS What To Do Identify how much steam it takes to make your key products. Then track this benchmark: a) with what other facilities in your company do; b) with what other similar plants in your industry do; and c) with how this benchmark varies in your operations over time. Why Important The bottom line of your operation is how cost effectively you make your products, and steam use has an impact on your productivity. Steam/product benchmarking is an excellent way to monitor productivity and how steam improvements translate to improved productivity. ACTIONS yes no SCORE 10 0 10 5 0

BM1 Do you Measure your Steam/Product Benchmark - in terms of (lbs. of steam needed) / (unit of product produced)?

BM2 How often do you Measure and Trend your Steam/Product Benchmark - at least quarterly at least yearly in terms of (lbs. of steam needed) / (unit of product produced)? less than yearly

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STEAM SYSTEM PROFILING (page 2)

STEAM SYSTEM MEASUREMENTS What To Do Identify key steam operational parameters that you should monitor and ensure that you are adequately measuring them. Why Important You Can't Manage What You Don't Measure! Measurement of key steam system parameters assists you in monitoring your system, diagnosing potential system problems, and ensuring that system improvements continue to provide benefits to your operations. ACTIONS MS1 Do you measure and record Critical Energy Parameters for your Steam System? Steam Production Rate (to obtain total steam production) Fuel Flow Rate (to obtain total fuel consumption) Feedwater Flow Rate Makeup Water Flow Rate Blowdown Flow Rate Chemical Input Flow Rate SCORE

yes yes yes yes yes yes no to all of above by major user/equip by process unit by area or building by plant as a whole (i.e., total boiler output) not at all

10 6 6 4 2 2 0 20 10 5 2

MS2 How intensely do you meter your steam flows? - CHOOSE ONE OF FIVE ANSWERS

as a benchmark costs are to make

t free! Any ake steam is a key YOUR SCORE

: a) with what other enchmark varies

steam use has an nd how steam YOUR SCORE

re adequately

ameters assists ements continue YOUR SCORE

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STEAM SYSTEM OPERATING PRACTICES

STEAM TRAP MAINTENANCE What To Do Implement a comprehensive program to correctly select, test, and maintain your steam traps. Why Important Steam traps play three important functions: a) prevent steam from escaping from the system before the heat is utilized; b) remove condensate from the system; and c) vent noncondensable gases. Poor steam trap selection, testing, and maintenance can result in many system problems including water hammer, ineffective process heat transfer, steam leakage, and system corrosion. An effective steam trap selection and maintenance program is often an excellent investment with paybacks of less than half a year. ACTIONS ST1 Does Your System Steam Trap Maintenance Program Include The Following Activities? Proper Trap Selection For Application At Least Annual Testing Of All Traps Maintaining A Steam Trap Database Repairing/Replacing Defective Traps SCORE

yes yes yes yes none of the above

10 10 10 10 0

WATER TREATMENT PROGRAM What To Do Implement and maintain an effective Water Treatment Program in your steam system. Why Important An effective steam system Water Treatment Program: a) reduces the potential for waterside fouling problems in your boilers; b) is critical to minimizing boiler blowdown and the resulting energy losses; c) can reduce the generation of wet steam; and d) greatly reduces the potential for corrosion problems throughout your steam system. Most effective water treatment programs include both mechanical (filtration, softening, and deaeration) and chemical treatment. Problems in this area can lead to significant plant productivity issues related to equipment failure and downtime - be sure to consult with a chemical treatment specialist on an ongoing basis. ACTIONS at least daily at least weekly less than weekly every 5-10 years every 1-5 years once/year or more continuous, or at least once/shift once/day once/week or less SCORE 10 5 0 10 5 0 10 5 0

WT1 How often do you ensure that your Water Chemical Treatment System is functioning properly?

WT2 How often do you NEED to clean Fireside or Waterside deposits in your Boiler?

WT3 How often do you measure Conductivity (or Total Dissolved Solids [TDS]) in your Boiler and determine what your Steam and Mud Drum Blowdown Rate (or Top and Bottom Boiler Blowdown Rate) should be?

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STEAM SYSTEM OPERATING PRACTICES (page 2)

SYSTEM INSULATION What To Do Ensure that the appropriate major components of your steam system are well insulated. Determine the economic insulation thickness for your system components, and perform system insulation reviews to identify exposed surfaces that should be insulated and/or unrestored or damaged insulation. Why Important Effective insulation - on piping, valves, fittings, and vessels - serves many important purposes. Insulation keeps steam energy within the system to be effectively used by processes, it can reduce temperature fluctuations in the system, it can reduce space conditioning requirements, and it can reduce the potential for personnel burns. ACTIONS insulation excellent insulation good, but can be improved insulation inadequate IN2 Is your Steam Distribution, End Use, and Condensate Recovery equipment insulation (piping, valves, flanges, heat exchangers, etc.) maintained and in good condition? insulation excellent insulation good, but can be improved insulation inadequate 20 14 0 SCORE 10 7 0

IN1

Is your Boiler Plant equipment and piping system insulation (refractory, piping, valves, flanges, vessels, etc.) maintained and in good condition?

STEAM LEAKS What To Do Identify and quickly repair steam leaks in your steam system. Why Important Steam leaks can result from failures associated with such things as improper piping design, corrosion problems, and joint and valve seal failures. In high-pressure industrial steam systems, energy costs associated with steam leaks can be substantial. Identifying and repairing steam leaks is essential to properly balancing your steam system. ACTIONS none minor moderate numerous SCORE 10 8 3 0

LK1

How would you characterize Steam Leaks in your Steam System?

WATER HAMMER What To Do Detect and quickly eliminate Water Hammer in your steam system. Why Important Water Hammer is a serious concern - it can lead to failure and rupture of piping and valves, and in many cases significant personnel injury due to contact with steam and condensate. There are two main types of water hammer: one caused by accumulation of condensate in steam distribution piping and transport of this condensate by high-velocity steam; and the other caused by a pressure pulse resulting from steam collapse (rapid condensation) in condensate return lines and heat exchange equipment. Water Hammer in your steam system always says FIX ME!!

WH1 How often do you detect noticeable Water Hammer in your Steam and Condensate Recovery System?

ACTIONS less than once a month monthly or weekly daily or hourly

SCORE 10 5 0

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STEAM SYSTEM OPERATING PRACTICES (page 3)

MAINTAINING EFFECTIVE STEAM SYSTEM OPERATIONS What To Do Establish and carry out a comprehensive steam system maintenance program. Why Important Effective steam system operating practices and improvements can provide benefits to your steam operations year after year - IF you have an effective system maintenance program in place. Major areas of maintenance that will provide year-after-year benefits to your operations include: a) steam traps; b) boiler performance; c) water treatment; d) turbines, piping, heat exchangers, pumps, motors, and valves; and e) system insulation.

ACTIONS MN1 Do you periodically - at least once a year - inspect the following important Steam Plant Operational Equipment? Boiler Plant Equipment - boiler, deaerator, feedwater tank, chemical treatment equipment, blowdown equipment, economizer, combustion air preheater, insulation, etc.? Distribution System Equipment - piping (including design), steam traps (types, sizes, locations), air vents, valves, pressure reducing stations, insulation, etc.? End Use System Equipment - turbines, piping (including design), heat exchangers, coils, jacketed kettles, steam traps (types, sizes, locations), air vents, vacuum breakers, pressure reducing valves, insulation, etc.? Recovery System Equipment - piping (including design), valves, fittings, flash tanks, condensate pumps, condensate meters, insulation, etc.?

SCORE

yes

yes

yes

yes

no to all of above

aps. system before the m trap selection, ess heat transfer, often an excellent YOUR SCORE

erside fouling can reduce the eam system. Most hemical treatment. owntime - be sure YOUR SCORE

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urposes. perature al for personnel YOUR SCORE

esign, corrosion sociated with your steam YOUR SCORE

alves, and in many s of water hammer: e by high-velocity condensate return

YOUR SCORE

your steam as of maintenance ce; c) water

YOUR SCORE

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BOILER PLANT OPERATING PRACTICES

BOILER EFFICIENCY What To Do Measure, trend, and look for opportunities to improve the efficiency of your boilers. Why Important One of the key boiler plant functions is to generate steam at the highest possible efficiency. Major sources of boiler efficiency losses include: a) combustion and flue gas energy losses [typically the largest]; b) blowdown losses; and c) refractory insulation losses. It is important to measure and trend boiler efficiency, flue gas temperature, flue gas oxygen content, and flue gas carbon monoxide content on a regular basis. Measurement and control of excess oxygen is critical to minimizing boiler combustion energy losses. Trending flue gas temperature can provide indications of other potential boiler problems, such as waterside or fireside fouling problems. ACTIONS at least quarterly at least yearly less than yearly SCORE 10 5 0

BE1 How often do you measure your overall Boiler Efficiency - [(heat absorbed to create steam) / (energy input from fuel)]?

BE2 Do you measure the following parameters as a function of boiler load and ambient temperature? Flue gas temperature Flue gas Oxygen content Flue gas CO content

yes yes yes no to all of above automatically manually not at all

5 5 5 0 10 5 0

BE3 How do you control Excess Air in your Boiler to maximize Boiler Efficiency?

HEAT RECOVERY EQUIPMENT What To Do Evaluate installation of Heat Recovery Equipment on your Boiler Plant. Why Important In some boilers, high flue gas temperatures and high continuous blowdown rates can provide opportunities for installation of heat recovery equipment. Feedwater economizers and combustion air preheaters can, under appropriate conditions, be installed to extract excess flue gas energy and effectively increase the boiler efficiency. Blowdown heat recovery equipment can also, for some systems, be installed to extract otherwise lost heat from the blowdown system. For either potential opportunity, an economic analysis is needed to determine the feasibility of the opportunity, and the equipment should be designed and installed by qualified professionals. ACTIONS HR1 Do you have any of the following Heat Recovery Equipment installed on your Boilers? Feedwater Economizer and/or Combustion Air Preheater Blowdown Heat Recovery SCORE

yes yes no to all of above

10 5 0

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BOILER PLANT OPERATING PRACTICES (page 2)

GENERATING DRY STEAM What To Do Ensure that you generate high-quality dry steam in your boiler plant. Why Important Steam of 100% quality contains no liquid water; wet steam contains liquid droplets. Generating wet steam in your boiler can cause many system problems, including: a) inefficient process heat transfer; b) equipment failure by water hammer; c) equipment failure by corrosion and erosion; and d) steam trap failure by overloading. Some typical causes for creation of wet steam and boiler carryover are: a) wide swings in boiler water level; b) reduced operating pressure; c) boiler overload; and d) poor boiler total dissolved solids (TDS) control. A critical step to ensuring generation of high-quality steam is to measure the quality of steam leaving your boiler; this is typically done using steam calorimeters.

DS1 How often do you check the Quality of Steam that is output from your Boiler to the Distribution System, and ensure that you are generating Dry Steam?

ACTIONS at least quarterly at least yearly less than yearly

SCORE 10 5 0

GENERAL BOILER OPERATION What To Do Ensure that your boilers perform their functions without large fluctuations in operating conditions. Why Important How you control boiler operation can effect many elements of the steam system - including the operating life of the boiler, the quality of steam produced, and the effectiveness of steam use throughout your production operations.

GB1 Do you have an operational automatic blowdown controller on your Boiler? GB2 What is the frequency of High Level Alarms (possibly indicating boiler undersized) or Low Level Alarms (possibly indicating boiler oversized) for your Boiler? GB3 How often do you experience steam pressure fluctuations of greater than 10% of your Boiler Operating Pressure?

ACTIONS yes no less than 1/month 1-5 per month more than 5/month less than 1/month 1-5 per month more than 5/month

SCORE 5 0 10 5 0 5 3 0

ency. Major st]; b) blowdown as temperature, control of excess ovide indications of YOUR SCORE

provide reheaters can, boiler efficiency. eat from the asibility of the YOUR SCORE

enerating wet ) equipment failure ng. Some typical ed operating suring generation team calorimeters. YOUR SCORE

ditions. uding the operating duction operations. YOUR SCORE

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STEAM DISTRIBUTION, END USE, RECOVERY - OPERATING PRACTICES

OPTIONS FOR REDUCING STEAM PRESSURE - MINIMIZE STEAM FLOW THROUGH PRVs What To Do Investigate potential to use backpressure turbines in parallel with pressure reducing valves in your steam system. Why Important In many steam systems, pressure reducing valves (PRVs) are used to provide steam at pressures lower than generated from the boiler. A potential opportunity for improving a steam system is to minimize the flow of steam through PRVs. One opportunity for doing this is to install backpressure turbines in parallel with PRVs in your steam system; in this way you can provide the low-pressure steam required and generate electricity or shaft power that can be utilized. A detailed economic analysis must be performed to evaluate this type of opportunity. ACTIONS steam generated at required pressure, or PRVs appropriately applied backpressure turbines used in parallel with PRVs boiler control used to reduce pressure excess steam vented and/or used inefficiently SCORE 10

PR1 How do you reduce steam pressure in your steam system?

10

5 0

RECOVER AND UTILIZE AVAILABLE CONDENSATE What To Do Determine how much of your available condensate you recover and utilize. Why Important Returning a substantial portion of your condensate to your boiler can have both energy and chemical treatment benefits: a) condensate is hotter than makeup water, so less energy is required to convert condensate to steam; and b) condensate requires significantly less chemical treatment than makeup water, so there may be savings in chemical treatment costs associated with returning condensate. Returning as much condensate as possible also can help to reduce boiler blowdown (because fewer impurities are resident in condensate), and so minimize blowdown energy losses. ACTIONS greater than 80% 40% to 80% 20% to 40% less than 20% SCORE 10 6 3 0

CR1 How much of your available Condensate do you recover and utilize?

USE HIGH-PRESSURE CONDENSATE TO MAKE LOW-PRESSURE STEAM What To Do Investigate opportunity to utilize high-pressure condensate to produce useable low-pressure steam. Why Important An opportunity for utilizing high-pressure condensate is to allow it to pass through a flash tank and utilize the flash steam in low-pressure steam applications. The remainder of the condensate, now at lower pressure and temperature, can then be sent back to the boiler for use in producing steam. ACTIONS greater than 80%, or flash steam unavailable 40% to 80% 20% to 40% less than 20% SCORE 10

How much of your available Flash Steam do you recover and utilize? FS1

6 3 0

ACTICES

PRVs es in your steam

at pressures lower flow of steam n your steam ower that can be YOUR SCORE

y and chemical ndensate to may be savings in ssible also can blowdown energy YOUR SCORE

ure steam. ash tank and utilize essure and YOUR SCORE

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SUMMARY RESULTS
SCOPING TOOL QUESTIONS 1. STEAM SYSTEM PROFILING STEAM COSTS SC1: Measure Fuel Cost To Generate Steam SC2: Trend Fuel Cost To Generate Steam STEAM/PRODUCT BENCHMARKS BM1: Measure Steam/Product Benchmarks BM2: Trend Steam/Product Benchmarks STEAM SYSTEM MEASUREMENTS MS1: Measure/Record Steam System Critical Energy Parameters MS2: Intensity Of Measuring Steam Flows STEAM SYSTEM PROFILING SCORE 2. STEAM SYSTEM OPERATING PRACTICES STEAM TRAP MAINTENANCE ST1: Steam Trap Maintenance Practices WATER TREATMENT PROGRAM WT1: Water Treatment - Ensuring Function WT2: Cleaning Boiler Fireside/Waterside Deposits WT3: Measuring Boiler TDS, Top/Bottom Blowdown Rates SYSTEM INSULATION IN1: Insulation - Boiler Plant IN2: Insulation - Distribution/End Use/Recovery STEAM LEAKS LK1: Steam Leaks - Severity WATER HAMMER WH1: Water Hammer - How Often MAINTAINING EFFECTIVE STEAM SYSTEM OPERATIONS MN1: Inspecting Important Steam Plant Equipment STEAM SYSTEM OPERATING PRACTICES SCORE 3. BOILER PLANT OPERATING PRACTICES BOILER EFFICIENCY BE1: Measuring Boiler Efficiency - How Often BE2: Flue Gas Temperature, O2, CO Measurement BE3: Controlling Boiler Excess Air HEAT RECOVERY EQUIPMENT HR1: Boiler Heat Recovery Equipment GENERATING DRY STEAM DS1: Checking Boiler Steam Quality GENERAL BOILER OPERATION GB1: Automatic Boiler Blowdown Control GB2: Frequency Of Boiler High/Low Level Alarms GB3: Frequency Of Boiler Steam Pressure Fluctuations BOILER PLANT OPERATING PRACTICES SCORE POSSIBLE SCORE YOUR SCORE

10 10 10 10 30 20 90

0 0 0 0 0 0 0

40 10 10 10 10 20 10 10 20 140

0 0 0 0 0 0 0 0 0 0

10 15 10 15 10 5 10 5 80

0 0 0 0 0 0 0 0 0

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SUMMARY RESULTS (page 2)

4. STEAM DISTRIBUTION, END USE, RECOVERY OPERATING PRACTICES MINIMIZE STEAM FLOW THROUGH PRVs PR1: Options For Reducing Steam Pressure RECOVER AND UTILIZE AVAILABLE CONDENSATE CR1: Recovering And Utilizing Available Condensate USE HIGH-PRESSURE CONDENSATE TO MAKE LOW-PRESSURE STEAM FS1: Recovering And Utilizing Available Flash Steam DISTRIBUTION, END USE, RECOVERY OP. PRACTICES SCORE

10 10 10 30

0 0 0 0

SUMMARY OF STEAM SCOPING TOOL RESULTS

POSSIBLE SCORE 90 140 80 30 340 YOUR SCORE 0 0 0 0 0 0.0%

STEAM SYSTEM PROFILING STEAM SYSTEM OPERATING PRACTICES BOILER PLANT OPERATING PRACTICES DISTRIBUTION, END USE, RECOVERY OP. PRACTICES TOTAL SCOPING TOOL QUESTIONAIRE SCORE TOTAL SCOPING TOOL QUESTIONAIRE SCORE (%) Date That You Completed This Questionaire

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NEXT STEPS - Additional DOE BestPractices Steam Resources

WHAT'S YOUR NEXT STEP? Your steam system self-assessment using this Tool may have identified some potential steam system improvement projects. BestPractices Steam has developed additional tools and resources to help you to go the next step in improving your steam system. These tools are identified below.

START AT THE BESTPRACTICES WEB SITE! This web site includes links to all of the major tools and publications developed by BestPractices Steam. The web site address is www.oit.doe.gov/bestpractices.

STEAM SYSTEM SURVEY GUIDE: This guide is a reference document developed for plant energy managers and steam system operations personnel. It provides a technical basis for identifying and assessing many potential steam system improvement opportunities. It is complementary to the Steam System Scoping Tool, and provides quantitative descriptions of how to quantify major steam system improvement opportunities. It is available from the BestPractices web site.

STEAM TIP SHEETS. BestPractices Steam has developed 19 energy tip sheets that provide concise descriptions of common steam system improvement opportunities. The tips are available for download from the BestPractices web site. The topics for these tip sheets are listed below, by major topic groups: STEAM SYSTEM PROFILING Benchmark the Fuel Costs of Steam Generation

STEAM SYSTEM OPERATING PRACTICES Inspect and Repair Steam Traps Insulate Steam Distribution and Condensate Return Lines Install Removable Insulation on Uninsulated Valves and Fittings BOILER PLANT OPERATING PRACTICES Improve Your Boiler's Combustion Efficiency Use Feedwater Economizers for Waste Heat Recovery Clean Boiler Waterside Heat Transfer Surfaces Minimize Boiler Blowdown Recover Heat from Boiler Blowdown Minimize Boiler Short Cycling Losses Deaerators in Industrial Steam Replace Pressure-Reducing Valves with Backpressure Turbogenerators Consider Steam Turbine Drives for Rotating Equipment Return Condensate to the Boiler Flash High-Pressure Condensate to Regenerate Low-Pressure Steam Use a Vent Condenser to Recover Flash Steam Energy Use Low Grade Waste Steam to Power Absorption Chillers Use Vapor Recompression to Recover Low-Pressure Waste Steam Cover Heated, Open Vessels

DISTRIBUTION, END USE, RECOVERY OPERATING PRACTICES

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NEXT STEPS - Additional DOE BestPractices Steam Resources (cont.)

IMPROVING STEAM SYSTEM PERFORMANCE: A Sourcebook for Industry. BestPractices Steam has developed a Sourcebook that is designed to provide steam system users with a reference that describes basic industrial steam system components, outlines opportunities for energy and performance improvements, and provides a comprehensive list of steam system contacts, resources, tools, software, videos, and training courses and technical services. This Sourcebook should be available on the BestPractices web site in June 2002.

3E-PLUS INSULATION APPRAISAL SOFTWARE. 3E-Plus was developed by the North American Insulation Manufacturer's Association (NAIMA) to increase awareness among steam system operations and management personnel of the benefits of insulation, and to allow these personnel to assess insulation improvement opportunities. The present version of 3E-Plus can be downloaded from the BestPractices web site.

STEAMING AHEAD WEB SITE. The Alliance to Save Energy "Steaming Ahead" web site publicizes the activities and information products developed by the DOE BestPractices Steam effort. This web site is also the source for a "Steaming Ahead" bi-monthly e-mail newsletter. This newsletter promotes best-in-class practices and technology applications in steam system design and management. The "Steam Digest" - a yearly compilation of articles and papers on steam efficiency measures - is also available from the Steaming Ahead web site. The web site address is www.steamingahead.org.