Steam Digest 2001: A compendium of articles published on steam system management and resources

Table of Contents
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Introduction (PDF 13 KB)
Fred Hart, Department of Energy
Christopher Russell, Alliance to Save Energy
Anthony Wright, Oak Ridge National Laboratory

Steam Best Practice Resources and Tools: "Old" News is "New" News! (PDF 33 KB)
Anthony Wright, Oak Ridge National Laboratory
Fred Hart, 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.

Best Practices in Steam System Management (PDF 28 KB)
Fred L. Hart, U.S. Department of Energy
David Jaber, (formerly with) Alliance to Save Energy
Common areas to look for savings opportunities in steam generation, distribution, end use, and recovery are outlined in this article.

Best Practices: The Engineering Approach for Industrial Boilers (PDF 64 KB)
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.

Performing a Steam System Checkup: A Three-Step Checkup Identifies Potential Opportunities for Improvements (PDF 25 KB)
Anthony L. 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.

The Steam System Scoping Tool: Benchmarking Your Steam Operations Through Best Practices (PDF 30 KB)
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 opportunities for enhancing efficiency. This article reviews the development and use of this easy-to-use spreadsheet tool.

The Enbridge Consumers Gas "Steam Saver" Program (PDF 155 KB)
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.

A Highly Successful Holistic Approach to a Plant-Wide Energy Management System (PDF 72 KB)
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 has 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 paper discusses this program, its history, successes, and the management processes that make it successful.

Celanese Chemicals Clear Lake Plant Energy Projects Assessment and Implementation (PDF 17 KB)
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.

Savings in Steam Systems (A Case Study) (PDF 615 KB)
Rich DeBat, Armstrong Service, Inc.
This hands-on case study of a chemical manufacturing plant exemplifies the process, documentation, and recommendations involved in an industrial steam system audit.

Steam System Diagnostics (PDF 485 KB)
John Todd, Yarway/TycoProper 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.

Ultrasonic Testing Tips for Steam Traps and Valves (PDF 16 KB)
Bruce Gorelick, Enercheck Systems, Inc
This article offers some testing tips to run a cost-effective steam distribution maintenance program.

Reliable Systems and Combined Heat and Power (PDF 41 KB)
David Jaber, (formerly with) Alliance to Save Energy
Richard Vetterick, TRC Energy
This article gives a comprehensive definition of combined heat and power (CHP) systems and reviews its attributes. It also provides guidance for choosing the various types of CHP applications.

Business Benefits from Plant Energy Assessments and Energy Management (PDF 47 KB)
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 turnaround. This article provides reference information and suggests the steps needed to improve plant performance.

Use Spreadsheet-Based CHP Models to Identify and Evaluate Energy Cost Reduction Opportunities in Industrial Plants (PDF 147 KB)
Jimmy Kumana, Consulting Engineer
Cutting edge steam technology includes combined heat and power plants. Facilities managers must examine the economics of such plants before committing capital resources. This article demonstrates financial analysis techniques that use common spreadsheet applications.

Justifying Steam Efficiency Projects to Management (PDF 19 KB)
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.

Steam Champions in Manufacturing (PDF 40 KB)
Christopher Russell, Alliance to Save Energy
Anthony Wright, Oak Ridge National Labs
The responsibilities related to industrial steam management evolve with changes in corporate, regulatory, and technology environments. This suggests a new set of managerial skills and accountability. The "steam champion " concept outlines what may be involved.