Steam Digest 2002: A compendium of articles published on steam system management and resources

You can download the following publications as fully formatted documents with graphics in Adobe PDF. (Download Adobe Reader).

Steam Digest 2002: Full Edition (PDF 1.36 MB)

Introduction (PDF 124 KB)
Christopher Russell, Alliance to Save Energy
Fred Hart, U.S. Department of Energy
Dr. Anthony L. Wright, Oak Ridge National Laboratory

Energy Efficiency and Industrial Boiler Efficiency: An Industry Perspective (PDF 230 KB)
Robert Bessette, Council of Industrial Boiler Owners
Consideration of energy efficiency for industrial boilers, more often than not, is simplified and categorized to a one-size-fits-all approach. This article addresses the four factors most critical for assessing energy efficiency in the industrial powerhouse supplying energy to make products for the benefit of customers in a highly competitive international marketplace.

Decision Climate for Steam Efficiency: Update December 31, 2002 (PDF 85 KB)
Carlo La Porta, Future-Tec
The Performance Evaluation and Policy Subcommittee of the BestPractices Steam Steering Committee issues a periodic compilation of data that the Energy Information Administration, U.S. Department of Energy, reports in its Short-Term Energy Outlook. The author selected data relevant to industrial decision makers concerned with supply and price of energy purchased for industrial fuel. The ulterior purpose is to help frame decisions that will encourage more investment to improve efficiency of industrial steam systems.

An Analysis of Steam Process Heater Condensate Drainage Options (PDF 94 KB)
James R. Risko, TLV Corporation
The production and reliability performance of steam process heaters can be significantly affected by the condensate drainage design that is employed. The current variety of drainage options can be confusing to a system designer who is unaware of the reasons for each specific design. This paper provides us an understanding of the various types and why they may be used.

Combustion Control Strategies for Single and Dual Element Power Burners (PDF 128 KB)
David C. Farthing, Federal Corporation
Today's economic and environmental demands dictate that we get the greatest practical efficiencies from our plants. The use of more advanced automatic control systems for combustion control has proven to be an excellent example of systems and process automation success.

Insulation Improves Economic Returns in Manufacturing (PDF 87 KB)
Christopher Russell, Alliance to Save Energy
Mechanical insulation plays a role in optimizing a plant's valuable energy resources. Two tip sheets, part of a series of BestPractices Steam tip sheets that currently numbers 19, discuss the benefits of mechanical insulation and demonstrate the calculation of energy savings that it provides.

Reduce Fuel Costs — Use the Proper Air-to-Fuel Ratio in Boiler Combustion (PDF 88 KB)
Christopher Russell, Alliance to Save Energy
Tony Tubiolo, Alliance to Save Energy
Opportunities for combustion improvement projects involve any or all of the following: boiler tune-ups, combustion control repair, burner repair, and repairs to existing oxygen trim systems. With an average payback period of less than half a year, optimizing steam system combustion is a proven and effective way to reduce operating costs.

Safety Issues in Fossil Utility and Industrial Steam Systems (PDF 173 KB)
Otakar Jonas, Ph.D., P.E., Jonas, Inc.
The U.S. National Board of Boiler and Pressure Vessel Inspectors reports that 296 power plant boiler-related accidents (including 56 injuries and 7 deaths) occurred in 2001. This report presents results of recent surveys of safety issues in fossil utility and industrial steam systems.

The Human Side of Energy Efficiency: The Value of Training (PDF 81 KB)
Rachel Madan, Alliance to Save Energy
Many plant managers concentrate their efforts solely on technical improvements, ignoring the tremendous savings that can arise through low-risk, low-tech solutions such as training for proper maintenance and operation.

Preliminary Results from the Industrial Steam Market Assessment (PDF 268 KB)
Glenn P. McGrath, P.E., CEM, Resource Dynamics
Dr. Anthony L. Wright, Oak Ridge National Laboratory
This paper discusses fuel use and potential energy savings in the steam systems of three steam-intensive industries: pulp and paper, chemical manufacturing, and petroleum refining. The results indicate that to generate steam, the pulp and paper industry used 2,221 trillion Btu, the chemical manufacturing industry used 1,548 trillion Btu, and the petroleum refining industry use 1,676 trillion Btu. Preliminary results from the effort to determine potential steam system fuel savings are discussed.

Results from the Industrial Assessment Center (IAC) Steam Tool Benchmarking Support Project (PDF 238 KB)
Dr. Anthony L. Wright, Oak Ridge National Laboratory
Dr. Kurt Bassett, South Dakota State University
Dr. Herbert Eckerlin, North Carolina State University
Dr. Ahmad Ganji, San Francisco State University
Derek Hengeveld, South Dakota State University
Dr. Richard Jendrucko, University of Tennessee, Knoxville
Dr. Dragoljub Kosanovic, University of Massachusetts, Amherst
Dr. Wayne Turner, Oklahoma State University
The U.S. Department of Energy's (DOE) Industrial Technology Program (ITP) BestPractices effort is developing a number of software tools to assist industrial energy users to improve the efficiency of their operations. One of the software tools developed is the "Steam System Scoping Tool." Based on actual plant assessment experience, several DOE Industrial Assessment Center (IACs) evaluate the Steam System Scoping Tool in this paper.

ProSteam — A Structured Approach to Steam System Improvement (PDF 420 KB)
Alan Eastwood, Linnhoff March Ltd.
A spreadsheet-based steam cost model gives plant managers a clear and reliable understanding of their system and of any operational constraints. Models allow managers to identify and prioritize improvement opportunities before capital and other scarce resources are committed. ProSteam is one such analytical tool.

Steam System Improvements at Dupont Automotive Marshall Laboratory (PDF 112 KB)
Andrew Larkin, P.E., C.E.M., Trigen-Philadelphia Energy Corporation
Modifications to increase energy efficiency, reduce steam system maintenance costs, and implement small scale cogeneration are all cited in a Trigen-Philadelphia Energy Corporation recommendation for a campus composed of several buildings that are served by a district stream loop.

Closed-Loop Energy Management Control of Large Industrial Facilities (PDF 176 KB)
Ronald L. Childress, Jr., Automation Applications, Inc.
This is a case study of a closed-loop control system installed and running at a pulp and paper facility in the southeast. A fuzzy logic, rule-based control system optimally loads multiple steam turbines for maximum electrical generation, while providing steam to the process. A Sell Advisor calculates Make-Buy decisions based on real-time electrical prices, fuel prices, and boiler loads.

An Introduction to Steam Outsourcing (PDF 72 KB)
Tom Henry, Armstrong Service Inc.
One evolving trend in the boiler replacement business is the movement to outsource the equipment, installation, and operation and maintenance—called the build, own, operate, and maintain (BOOM) market. Energy service companies (ESCOs) and lending institutions are developing services that respond to this emerging need.