Steam Systems

Related System Areas

Consider improving the performance of the pumps or process heating equipment installed on steam systems.

• Pump Systems
• Process Heating

Also review a range of projects, analyses, protocols, and strategies to reduce industrial energy intensity and carbon emissions in specific industries and technology areas.

• Industries and Technologies

Technical Publications

Sourcebook

• Improving Steam System Performance: A Sourcebook for Industry, Second Edition, October 2012

• Achieve Steam System Excellence: Industrial Technologies Program BestPractices Steam Overview
• Steam System Opportunity Assessment for the Pulp and Paper, Chemical Manufacturing, and Petroleum Refining Industries, October 2002
  • Main Report
  • Appendices
• Guide to Combined Heat and Power Systems for Boiler Owners and Operators, July 2004
• Guide to Low-Emission Boiler and Combustion Equipment Selection, April 2002
• Steam System Survey Guide, May 2002
• Review of Orifice Plate Steam Traps, January 2001
• BestPractices Steam Technical Brief: Steam Pressure Reduction-Opportunities and Issues, November 2005
• BestPractices Steam Technical Brief: How to Calculate the True Cost of Steam, September 2003
• BestPractices Steam Technical Brief: Industrial Heat Pumps for Steam and Fuel Savings, June 2003
• BestPractices Steam Technical Brief: Industrial Steam System Heat-Transfer Solutions, June 2003
• BestPractices Steam Technical Brief: Industrial Steam System Process-Control Schemes, July 2003
• Save Energy Now in Your Steam Systems, January 2006
• Steam Systems Energy Efficiency Handbook, November 1997

Tip Sheets

• Benchmark the Fuel Cost of Steam Generation, January 2012
• Clean Boiler Water-side Heat Transfer Surfaces, January 2012
• Consider Installing a Condensing Economizer, January 2012
• Consider Installing High-Pressure Boilers with Backpressure Turbine-Generators, January 2012
• Consider Installing Turbulators on Two- and Three-Pass Firetube Boilers, January 2012
• Consider Steam Turbine Drives for Rotating Equipment, January 2012
• Considerations When Selecting a Condensing Economizer, January 2012
• Cover Heated, Open Vessels, January 2012
• Deaerators in Industrial Steam Systems, January 2012
• Flash High-Pressure Condensate to Regenerate Low-Pressure Steam, January 2012
• Inspect and Repair Steam Traps, January 2012
• Install an Automatic Blowdown Control System, January 2012
• Install Removable Insulation on Valves and Fittings, January 2012
• Insulate Steam Distribution and Condensate Return Lines, January 2012
• Improve Your Boiler's Combustion Efficiency, January 2012
• Minimize Boiler Blowdown, January 2012
• Minimize Boiler Short Cycling Losses, January 2012
• Recover Heat from Boiler Blowdown, January 2012
• Replace Pressure-Reducing Valves with Backpressure Turbogenerators, January 2012
• Return Condensate to the Boiler, January 2012
• Upgrade Boilers with Energy-Efficient Burners, January 2012
• Use Feedwater Economizers for Waste Heat Recovery, January 2012
• Use Low Grade Waste Steam to Power Absorption Chillers, January 2012
• Use Steam Jet Ejectors or Thermocompressors to Reduce Venting of Low-Pressure Steam, January 2012
• Use Vapor Recompression to Recover Low-Pressure Waste Steam, January 2012
• Use a Vent Condenser to Recover Flash Steam Energy, January 2012

Case Studies

• Boise Inc. St. Helens Paper Mill Achieves Significant Fuel Savings, May 2008
• Chrysler: Energy Assessment Enables a Vehicle Assembly Complex to Achieve Significant Natural Gas Savings, February 2008
• Dow Chemical Company: Assessment Leads to Steam System Energy Savings, November 2007 – Repairing leaks and failed steam traps and making those activities permanent can yield substantial energy savings.
• Goodyear Tire Plant Gains Traction on Energy Savings After Completing Energy Assessment, May 2008 – By optimizing boiler operation and improving insulation, Goodyear significantly reduced fossil fuel consumption.
• J.R. Simplot: Burner Upgrade Project Improves Performance and Saves Energy at a Large Food Processing Plant, September 2005
• Longest-Serving Active Paper Mill in the Western United States Uncovers New Ways to Save Energy, Mar. 2008
• Save Energy Now Assessment Helps Expand Energy Management Program at Shaw Industries, July 2008
• Steam System Efficiency Optimized After J.R. Simplot Fertilizer Plant Receives Energy Assessment, July 2008
• Terra Nitrogen Company, L.P.: Ammonia Plant Greatly Reduces Natural Gas Consumption After Energy Assessment, Oct. 2007

Assessments

• Qualified Specialists and Energy Experts
• Energy Assessments
• Recommendations from Completed Assessments – Steam Plant Assessments

Training

• DOE's Boiler MACT Technical Assistance Program
• Steam Systems Training
  • Steam Tool Suite Training – 2-hour workshop (online)
  • Steam End User – 1-day workshop (onsite and online)
  • Qualified Steam Tool Specialist – 2½ day workshop (onsite)
• Training Calendar
• Events Calendar

Tools

Tools to Assess Your Energy System

• Steam System Scoping Tool (SSST)
• Steam System Assessment Tool (SSAT)
• 3E Plus© Insulation Program

Scorecards and Simple Calculators

• Boiler Tune-Up
• Steam System Calculators and Modeler
• Steam Generation Equipment Scorecard
• Mechanical Insulation Assessment and Design Calculators