2 Curriculum Steam User

UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION
Training Steam System Optimization (SSO) 2-Day User Workshop

Training Expert / Trainer Location Comments
Day 1 Advanced Training room
Day 2 Advanced Training room
Target Group: National energy efficiency experts, service providers, equipment vendors and industry engineers
Learning Objectives
o Understand the need of using a Systems Approach to accurately evaluate steam systems and optimization opportunities
o Develop and model simple steam system projects using the fundamental laws of physics, thermodynamics and heat transfer
o Proficiently use the US DOE Steam BestPractices software tools (SSST, SSAT and 3EPlus) and/or other resources to evaluate steam systems,
identify optimization opportunities in industrial plants and conduct an impact-level analysis
o Identify the measurements required to manage steam generation efficiency
o Measure individual boiler and overall plant generation efficiency
o Estimate the magnitude of specific steam generation losses
o Identify and prioritize areas of potential boiler and overall plant generation efficiency improvement
o Recognize the impacts of fuel selection
o Evaluate the effectiveness of system insulation
o Identify areas of end-use efficiency improvements
o Recognize the requirements of an appropriate steam trap management program
o Evaluate the primary economic impact of condensate recovery
o Characterize the operational impact of backpressure and condensing steam turbines
o Calculate the energy costs associated with steam systems operation
o Increase familiarity to undertake field work to do steam system assessments
Page 1 of 19 UNIDO 2012, All rights reserved

Title: Day One of 2-Day User SSO User Workshop
Section 1: Fundamentals
Start Time: 08:30 120 minutes
(SSO 2 Day Training Fundamentals Section1.ppt)
Content Means of Evaluation Learning Activities Duration Slide #s

Introduction of attendees and Outline
Not applicable Understand participant backgrounds 30 minutes 1-23
of course
Review of the UNIDO Industrial

Not applicable Information only 20 minutes
Energy Efficiency Project
Introduction to System Approach and Understanding of Systems Approach with

Participants questions 20 minutes 24-38
Steam System Optimization an example; Benefits of SSO
Thermodynamics of steam
Participants questions or
discussions on steam system Steam system components
thermodynamics and steam
system components Law of Conservation of Mass
Steam System Fundamentals 50 minutes 39-92
Participants are able to solve First Law of Thermodynamics
mass and energy balance
Application of these principles in steam
problems
system evaluations
Start Time: 10:30 Tea / Coffee Break 15 minutes

Section 2: Steam System Scoping Tool
(SSO 2 Day Training SSST Section2.ppt)


List of possible BestPractices
Common BestPractices Participants questions 15 minutes 1-6
(Opportunities) in steam systems
Steam System Scoping Tool Participants questions Demonstration of the SSST Excel version 15 minutes 7-20
Effective use of software Tool; Hands-on use of SSST in an industrial plant

Student exercise - Evaluation of an
Questions from students on assessment to identify potential 30 minutes 21-34
industrial plant steam system
applicable BestPractices opportunity areas
Section 3: Steam System Assessment Tool Part 1

(SSO 2 Day Training SSAT Section3.ppt)

Students start SSAT and make Overview of SSAT
Review of the Steam System
input changes to a 3-header Gaining familiarity with the different 10 minutes 1-11
Assessment Tool (SSAT)
model header model templates of SSAT
Calculation of electrical cost Understanding impact electrical cost

Understanding Electric Rate Structure 5 minutes 12-20
given demand and energy charge Calculating it from utility information
Understanding different kinds of fuels, their

Questions related to fuels that heating values (HHV & LHV) and costs
participants maybe using Understanding impact fuel cost based on
Understanding Fuels & Costs 15 minutes 21-35
Calculation of operating fuel cost multi-fuel use at a plant
for a boiler Completing an example to determine fuel
operating cost and steam cost indicator

Definition of end-use of steam in SSAT

Understanding Process steam Participants input process end-
Calculation and techniques to determine 5 minutes 36-39
demands and end use use data in the 3-header model
steam flow to end-use demand
Understanding of steam traps and their

Overview of how steam traps and Participants input steam trap impact in the SSAT model and in real steam
steam leaks are handled in the model information in the 3-header systems 5 minutes 40-45
as compared to real systems model Calculation of steam trap loss and steam
leaks in SSAT
Methodologies and definitions of steam

generation efficiency
Questions from participants on
observations from the field How to calculate direct boiler efficiency in
Steam generation (or Boiler) Efficiency
the field 10 minutes 46-57
Direct method Participants input boiler
efficiency in the 3-header model Understanding losses in a boiler and doing
an energy balance on the boiler to
determine efficiency
A general guide for shell losses based on

Understanding Shell Losses & their Questions from participants on industrial data from plants 5 minutes 58-61
magnitudes observations from the field
Sample calculation of shell loss
Questions from participants on Understand blowdown and its need

Determination of Blowdown Losses & observations from the field
Sample calculation of blowdown rate and 5 minutes 62-72
boiler versus system level implications
Participants input blowdown energy loss associated w/blowdown
information in the 3-header

model Understand impact of blowdown energy

loss on boiler and system
Questions from participants on

Understand stack loss and the main
observations from the field
Stack Losses parameters to calculate it 5 minutes 73-79
Participants estimate stack loss
Sample calculation of stack loss
from SSAT and/or chart
Calculate boiler efficiency using the indirect

method for example boiler
Participants estimate steam
Steam generation (or Boiler) Efficiency generation efficiency Defining boiler efficiency to be used in SSAT
5 minutes 80-86
Indirect method model
General discussions
Understanding Loss on Ignition
(Miscellaneous losses) for fuels
Participants execute a 1-header Defining marginal cost of steam

Marginal steam cost SSAT model and determine Demonstrating calculation of marginal 5 minutes 87-92
marginal cost of steam steam cost in SSAT
Start Time: 13:00 Lunch Break 60 minutes

Section 4: Steam System Assessment Tool Part 2

Participants input blowdown info Understanding blowdown modeling in SSAT
Blowdown & Flash Steam 10 minutes 1-4
in the 3-header model and how energy recovery is done

Understanding different modes of steam

Participants input steam generation superheated, saturated (dry)
Steam Generation Conditions generation conditions in the 3- and saturated (wet) 5 minutes 5-6
header model Modeling generation conditions
appropriately in SSAT
Understanding operations of Letdown

Participants input Letdown / PRV stations / PRVs in plants
Letdowns / PRVs 5 minutes 7-8
conditions in the 3-header model Modeling desuperheating configurations
with Letdowns / PRVs in SSAT
Explanation of deaerator, functionality and

Participants input Deaerator its impact on steam system
Deaerator 10 minutes 9-11
conditions in the 3-header model
Modeling deaerator in SSAT
Explanation of condensate tank vent heat

exchanger
Participants input Heat Recovery
Explanation of boiler blowdown heat
Heat Recovery Components Component information in the 3- 10 minutes 12-15
exchanger
header model
Modeling feedwater heat exchangers in
SSAT
Participants input Condensate Explanation of condensate & flash tanks

Condensate Recovery Recovery information in the 3- Modeling condensate return and flash 15 minutes 16-18
header model tanks in SSAT

Calculation of steam trap losses in SSAT and

methodologies
Participants input Distribution
Calculation of steam leaks in SSAT and
Distribution Losses Loss modeling information in the 20 minutes 19-24
methodologies
3-header model
Calculation of insulation losses in SSAT and
methodologies
Review the full 3-header SSAT Steam

Participants check the steam system model including all the worksheets
system model for consistency
3-Header SSAT Model of the Example and accuracy Determine marginal cost of steam at each
15 minutes 25-31
Steam System header level and compare with 1-header
Participants use the model to model
calculate marginal steam costs
Saving and storing models

Section 5: Combined Heat & Power (Cogeneration)

Understanding applications of steam
turbines in industry for power generation
Possible questions on and for driving mechanical equipment
Fundamentals of Turbines applications of different turbines 15 minutes 1-11
from Participants Understanding different kinds of steam
turbines backpressure, extraction and
condensing

Definition of a perfect turbine
Possible questions from Definition of isentropic steam turbine

Participants on obtaining field efficiency and understanding of all the
Steam Turbine Efficiency 20 minutes 7-19
information to calculate turbine terms in the equation
efficiency
Graphical explanation of turbine efficiency
and operations on a Mollier Diagram
Understanding single and multistage

turbines
Example calculation of backpressure steam

Participants follow methodology
turbine efficiency using superheated inlet
of calculations and ask
and outlet conditions (Method 2)
questions
Backpressure Turbines Example calculation of backpressure steam 25 minutes 20-36
Participants do steam turbine
turbine efficiency using power generated,
efficiency calculations for
mass flow of steam and inlet conditions
example turbines in the system
(Method 3)
Performance characteristics of
backpressure steam turbines
Participants input steam turbine Understanding of inputs required to model

modeling information in the 3- backpressure steam turbines in a 3-header
header model SSAT model
Modeling Backpressure Turbines 25 minutes 37-57
Possible questions from Understanding different modes of steam
Participants on different modes turbine operation in the field and how it
of operation can be realistically modeled in SSAT

Participants complete an impact Learn the methodology to take a 3-header

level analysis of saving 1 Tph of SSAT model of an example system and
high pressure and low pressure conduct impact level analysis of saving
steam in the example system steam at different header levels
Repeat the above analysis with different

parametric configurations as described in
the presentation
Participants input condensing

Understanding of inputs required to model
steam turbine modeling
Modeling Condensing Turbines condensing steam turbines in a 3-header 10 minutes 58-65
information in the 3-header
SSAT model
model
All Participants should have

completed all the inputs into the
Building a full model for a steam system to
3-header SSAT model
do a system-level analysis in SSAT
3-Header SSAT Model of the Example Participants should have
Understanding that the model has the full 10 minutes 66
Steam System identical answers for impact cost
ability to do accurate economic analysis
analysis of saving 1 Tph of steam
Saving the model for retrieval later
Participants should be able to
save the 3-header SSAT model
End Time: 17:30 Adjourn (End of Day 1)

Title: Day Two of 2-Day User SSO User Workshop
Section 6: Steam System Optimization - Generation

(SSO 2 Day Training Generation Section6.ppt)

Quick review of boiler losses and indirect
efficiency calculation
Participants questions on any of
Boiler Efficiency Improvement Understanding of Shell Losses 10 minutes 1-6
the losses in the boiler
Action items to monitor and minimize shell
losses
Overview of different methodologies used

in water treatment in steam systems
Participants correctly implement Principles of blowdown management and

Blowdown Management Project 4 on Blowdown control boiler blowdown control 20 minutes 7-16
in the SSAT 3-header model
Complete Project 4 in SSAT 3-header model
and evaluate economic impact of reducing
blowdown
Blowdown Energy Recovery Components

Participants correctly implement
Project 5 and 12 on Blowdown Complete Projects 5 and 12 in SSAT 3-
Blowdown Energy Recovery header model and evaluate economic 30 minutes 17-24
Energy Recovery in the SSAT 3-
header model impact of blowdown energy recovery
components

Review of energy recovery components:

Feedwater Economizers; Combustion
Participants questions on AirPreheaters; and Condensing
common applications in the field Economizers
Participants manually calculate Factors influencing higher stack energy loss

economic impact of heat (Temperature component)
Stack Losses (Temperature
recovery equipment in a boiler Complete manual calculations and evaluate 30 minutes 25-44
Component)
Participants correctly implement economic impact of improving boiler
Project 3 on Boiler Efficiency efficiency by adding (or modifying) heat
Improvement in the SSAT 3- recovery equipment
header model Complete Project 3 in SSAT 3-header model
and evaluate economic impact of boiler
efficiency improvement
Participants questions on oxygen Review of Combustion Management

(or excess air) limits and Principles & Strategy
BestPractices
Understanding positioning control and
Participants manually calculate automatic oxygen trim control their
Stack Losses (Combustion economic impact of improving operational limits available equipment
combustion control in a boiler 30 minutes 45-67
Component)
Factors influencing higher stack energy loss
Participants correctly implement (Temperature component)
Project 3 on Boiler Efficiency
Improvement in the SSAT 3- Complete manual calculations and evaluate
header model for each of the economic impact of improving boiler
cases investigated for the efficiency by tune up (modifying) and/or

example system adding combustion control equipment

and evaluate economic impact of boiler
efficiency improvement for the cases

Section 6 (Continued): Steam System Optimization - Generation
(SSO 2 Day Training Generation Section6.ppt)

Understand the concept of fuel switching
Participants questions on and how and when it can be applied to a
different fuels industrial steam system
Participants manually calculate Different configurations of optimizing a

economic impact of fuel boiler plant operation
Fuel Switching & Boiler Operation switching
Complete manual calculations of fuel 25 minutes 68-81
Optimization
Participants correctly implement switching in the example steam system and
Projects 2 and 3 on in the SSAT evaluate economic impacts
3-header model for modeling
fuel switching scenarios in the Complete Projects 2 and 3 in SSAT 3-header
example system model and evaluate economic impact of
fuel switching
BestPractices & Optimization

Information Only Summary of Generation area BestPractices 5 minutes 82
Opportunities in the Generation area

Section 7: Steam System Optimization - Distribution


Participants questions related to
how they deal with steam leaks Most common areas for steam leaks
in their industry Methods and equipment used to determine
Participants manually calculate a magnitude of steam leak
economic impact of steam leak Complete a manual calculation of
Steam Leaks Management Program 20 minutes 1-12
Participants correctly implement determining the impact of a steam leak
Projects 1 and 17 in the SSAT 3- Complete Projects 1 and 17 in SSAT 3-
header model for impact analysis header model for evaluating economic
of a steam leak management impact of steam leaks
program
Understanding the importance of steam

system insulation
Participants questions related to
Main reasons for missing or damaged
Steam System Insulation steam system insulation and 10 minutes 13-15
insulation
experiences in their industry
Data and equipment needed to determine
impact of insulation energy loss
Participants open the 3EPLus Demonstration of functionality of 3E Plus

3E Plus Insulation Evaluation Software 20 minutes 16-17
software and go to Energy tab software and its capabilities as needed
Participants manually calculate 40 minutes 18-29

Evaluation of Energy Loss due to Using 3E Plus to determine the heat energy
economic impact of missing

missing (or damaged) insulation steam system insulation in the loss from missing insulation in the system
example system
Calculation of equivalent energy cost
Participants correctly use 3E Plus savings for the addition of insulation
information with Project 1 in the
Determining equivalent steam demand
SSAT 3-header model for impact
analysis corresponding to the insulation energy loss
and using marginal cost of steam for cost
impact

for evaluating economic impact of adding
insulation to the uninsulated piping
Common insulation issues in industrial

Insulation issues and implications in steam plants
Information Only 10 minutes 30-34
cogeneration systems How to handle cost impacts of insulation
energy savings in cogeneration systems

Information Only Summary of Distribution area BestPractices 5 minutes 35
Opportunities in the Distribution area
Start Time: 13:00 Lunch Break 60 minutes

Section 8: Steam System Optimization Steam Demand (End Use)
(SSO 2 Day Training EndUse Section8.ppt)

Steam Generation Conditions Participants understanding that Understanding the impact of superheated, 5 minutes 1-5
steam can be generated at saturated and wet steam on system

different conditions operations
Using Project 6 in SSAT 3-header model for

evaluating economic impact of changing
steam generation conditions
Participants questions related to Understanding optimization opportunities

different kinds of end-uses of and methodologies to reduce steam
steam in their industry demand in end-uses
Participants manually calculate Brief overview of different types of steam

economic impact of steam end-uses in industry
Steam Demand (End-Use) savings in an end-use example Complete a manual calculation of 25 minutes 6-16
Participants correctly implement determining the impact of steam demand

Project 1 in the SSAT 3-header savings in an end-use
model for impact analysis of a Complete Project 1 in the SSAT 3-header
steam savings in an end-use model for evaluating economic impact of
example steam demand savings in example system

Information Only Summary of End-Use area BestPractices 5 minutes 17
Opportunities in the End-Use area
Section 9: Steam System Optimization Steam Demand (End Use)

(SSO 2 Day Training Recovery Section8.ppt)

Participants questions related to Understanding different kinds of steam
Steam Traps 15 minutes 1-12
different kinds of steam traps in traps and their principles of operation

their industry Observing steam traps in the field
Participants questions related to Review of all the steam trap performance

different kinds of equipment, investigation procedures that should be
methods to test performance of followed
Steam Trap performance investigation steam traps in the field Review of equipment that can be used for
10 minutes 13-20
and Management program Participants can share their steam traps performance investigation
experiences with steam trap Understanding the elements of a steam
management programs in their trap management program that should be
industry implemented in industry
Participants correctly compute Understand the 3 methods for calculating

Energy and Cost Impact evaluations of the impact of implementing a the impact of implementing a steam trap
10 minutes 21-25
Steam Traps steam trap management management program using the 3-header
program SSAT model and projects 1 or 16
Understand the importance of condensate

Condensate Recovery Information only 5 minutes 26-28
recovery and the influencing parameters
Participants manually calculate Methods of collecting field data required

economic impact of recovering for impact analysis
condensate Complete a manual calculation for impact
Condensate Recovery Example Participants correctly implement of condensate recovery on system 15 minutes 29-37
Project 13 in the SSAT 3-header Complete Project 13 in the SSAT 3-header
model for condensate recovery model for evaluating economic impact of
impact analysis condensate recovery in example system

Participants correctly implement

Projects 14 and 15 in the SSAT 3- Complete Projects 14 and 15 in the SSAT 3-
header model for flash steam header model for evaluating economic
recovery impact analysis impact of flash steam recovery
Flash Steam Recovery 10 minutes 38-40
Participants correctly implement Understanding of condensate tank vent
Project 11 in the SSAT 3-header heat exchanger and execution of Project 11
model for condensate tank vent in SSAT 3-header model for impact analysis
heat exchanger impact analysis

Information Only Summary of Recovery area BestPractices 5 minutes 42-43
Opportunities in the Recovery area

Section 10: Steam System Optimization - Combined Heat & Power (CHP) or
Start Time: 16:00 Cogeneration 60 minutes
(SSO 2 Day Training Cogeneration Section10.ppt)

Understanding benefits of industrial
Backpressure Turbine PRV Participants questions on
cogeneration and the impact parameters 10 minutes 1-5
Operations applications of turbines
required for an economic analysis
Participants manually calculate Calculating economic benefit of electrical

impact of operating a steam energy savings by operating a turbine
turbine versus letting steam
Backpressure Turbine PRV example Calculating incremental energy (fuel) cost 20 minutes 6-24
down through a PRV
required to produce additional steam for
Participants correctly implement the steam turbine
Project 7 in the SSAT 3-header

model for steam turbine PRV Complete Project 7 in the SSAT 3-header
operations impact analysis model for evaluating economic impact of
backpressure turbine PRV operations
Undertake similar analysis with Projects 8

and 9 in the SSAT 3-header model
Participants follow methodology

of calculations and ask Understanding implications of each of the
questions impact parameters on the net economic
Parametric analysis for Backpressure
impact and to answer the classic 10 minutes 25-34
Turbines PRV operations Participants correctly input cogeneration questions by using the SSAT
information in the SSAT 3-header 3-header model for the example system
to do parametric analysis
Understanding benefits of condensing

Participants questions on
turbines, their specific applications and the
Condensing Turbines applications of condensing 5 minutes 35-39
impact parameters required for an
turbines
economic analysis
Participants correctly implement Complete Project 10 in the SSAT 3-header

Project 10 in the SSAT 3-header model for evaluating economic impact of
Condensing Turbine example model for modifying condensing condensing turbine operation 10 minutes 40-49
steam turbine operations for Understand the impact of condenser
impact analysis pressure on operations and economics
BestPractices & Optimization Summary of Cogeneration area

Information Only 5 minutes 50
Opportunities in Cogeneration BestPractices
Start Time: 17:00 Section 11: Steam System Optimization - Conclusions 20 minutes

(SSO 2 Day Training Conclusions Section11.ppt)

Summary of Key Points & Action
Conclusions Information and Review only Items covered in the 2-Day SSO User 15 minutes 1-19
course
References for additional tools and

Tools & Resources Information and Review only resources for Steam System 5 minutes 20-30
Optimization in industrial plants
Start Time: 17:20 Course Evaluation & Feedback 10 minutes

End Time: 17:30 Adjourn (End of Day 2)

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UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION

Training Steam System Optimization (SSO) 2-Day User Workshop

Day 1 Advanced Training room

Day 2 Advanced Training room

Page 1 of 19 UNIDO 2012, All rights reserved

Title: Day One of 2-Day User SSO User Workshop

Content Means of Evaluation Learning Activities Duration Slide #s

Review of the UNIDO Industrial

Introduction to System Approach and Understanding of Systems Approach with

Start Time: 10:30 Tea / Coffee Break 15 minutes

Page 2 of 19 UNIDO 2012, All rights reserved

Content Means of Evaluation Learning Activities Duration Slide #s

Effective use of software Tool; Hands-on use of SSST in an industrial plant

Section 3: Steam System Assessment Tool Part 1

Content Means of Evaluation Learning Activities Duration Slide #s

Calculation of electrical cost Understanding impact electrical cost

Understanding different kinds of fuels, their

Page 3 of 19 UNIDO 2012, All rights reserved

Definition of end-use of steam in SSAT

Understanding of steam traps and their

Methodologies and definitions of steam

A general guide for shell losses based on

Questions from participants on Understand blowdown and its need

Page 4 of 19 UNIDO 2012, All rights reserved

model Understand impact of blowdown energy

Questions from participants on

Calculate boiler efficiency using the indirect

Participants execute a 1-header Defining marginal cost of steam

Start Time: 13:00 Lunch Break 60 minutes

Content Means of Evaluation Learning Activities Duration Slide #s

Page 5 of 19 UNIDO 2012, All rights reserved

Understanding different modes of steam

Understanding operations of Letdown

Explanation of deaerator, functionality and

Explanation of condensate tank vent heat

Participants input Condensate Explanation of condensate & flash tanks

Page 6 of 19 UNIDO 2012, All rights reserved

Calculation of steam trap losses in SSAT and

Review the full 3-header SSAT Steam

Start Time: 15:30 Tea / Coffee Break 15 minutes

Content Means of Evaluation Learning Activities Duration Slide #s

Page 7 of 19 UNIDO 2012, All rights reserved

Definition of a perfect turbine

Possible questions from Definition of isentropic steam turbine

Understanding single and multistage

Example calculation of backpressure steam

Participants input steam turbine Understanding of inputs required to model

Page 8 of 19 UNIDO 2012, All rights reserved

Participants complete an impact Learn the methodology to take a 3-header

Repeat the above analysis with different

Participants input condensing

All Participants should have

End Time: 17:30 Adjourn (End of Day 1)

Page 9 of 19 UNIDO 2012, All rights reserved

Title: Day Two of 2-Day User SSO User Workshop

Section 6: Steam System Optimization - Generation

Content Means of Evaluation Learning Activities Duration Slide #s

Overview of different methodologies used

Participants correctly implement Principles of blowdown management and

Blowdown Energy Recovery Components

Page 10 of 19 UNIDO 2012, All rights reserved

Review of energy recovery components:

Participants manually calculate Factors influencing higher stack energy loss

Participants questions on oxygen Review of Combustion Management