STEAM EFFICIENCY GUIDE

FOR
ENERGY MANAGERS
ACKNOWLEDGMENTS

A number of people have made contributions to the preparation of this report.

EECA would like to acknowledge Meritec Limited, which prepared the majority of
this report.

In addition, Spirax Sarco Limited, John Thompson New Zealand, Ian Reid, Colgate
Palmolive and Feltex Tufted Carpets assisted with providing additional information or
reviewing the report prior to publication.

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Ta b l e o f C o n t e n t s

1 INTRODUCTION 3
1.1 WHY REVIEW YOUR STEAM SYSTEM? 3

1.2 WHAT IS STEAM? 3

1.3 WHY DO INEFFICIENCIES OCCUR? 4

2 A TYPICAL STEAM SYSTEM –

COMPONENTS AND COSTS 5
2.1 THE MAIN COMPONENTS 5

2.2 THE SIZE OF LOSSES IN A STEAM SYSTEM 6

2.3 THE COST OF STEAM 7

3 IDENTIFYING SAVINGS – THE WHOLE SYSTEM 9

3.1 DEFINITION OF THE PROCESSES 9

3.2 THE HEATING LOAD OR PROCESS 10

3.3 THE CONVERSION PROCESS 12

3.4 STEAM DISTRIBUTION 13

3.5 CONDENSATE HEAT RECOVERY 16

3.6 STEAM GENERATION 18

4 MEASURING PERFORMANCE 24
5 OTHER USEFUL GUIDES 26
6 REFERENCES 28
7 CONSULTANTS, CONTRACTORS
AND PRODUCT SUPPLIERS 30
APPENDICES 32
APPENDIX I: INTRODUCTION TO STEAM 32
APPENDIX II: UNITS 37

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1 INTRODUCTION
1.1 Why review your steam system?
1.2 What is steam?
1.3 Why do inefficiencies occur?

1.1 WHY REVIEW YOUR STEAM SYSTEM?

Many managers and accountants see energy costs involved in producing and using
steam as a fixed line item in the accounts.

However, the cost of steam energy can be three times the cost of fuel energy on a per
unit basis. Cost changes depending on how steam is produced and used, and how the
steam system is operated and maintained. Like all energy costs, steam costs should be
treated as a variable and controllable cost.

A poorly operated and maintained system can easily use twice the amount of fuel that
a well operated and maintained system will use.

This guide will help you to recognise energy cost saving opportunities in a steam
system. It provides an overview of each stage of a steam system, together with a list of
references at the end of this guide if you would like more detailed technical
information. Relevant references are listed at the end of each section.

1.2 WHAT IS STEAM?

Steam is water in a gaseous state and is generated by heating water. It has been used
in industry since the 18th Century and remains a very useful energy form.

It is used in numerous New Zealand industries, such as in the manufacture of car

tyres, processing of canned food and for sterilization in hospitals.

Although useful, system losses can be substantial unless steam systems are carefully
designed, well maintained and properly operated. Losses can result in reduced
efficiency and increased costs.

Sometimes losses are obvious, eg, a large steam leak from a pipe or other equipment is
likely to be visible and noisy. Other losses are less obvious but equally as costly.

An understanding of the properties of steam and steam systems will help you, as an

STEAM EFFICIENCY GUIDE FOR ENERGY MANAGERS page 3

Energy Manager, detect losses and take action to save energy costs. A brief discussion
on the properties and characteristics of steam, and some basic thermodynamics, is
included in Appendix I.

1.3 WHY DO INEFFICIENCIES OCCUR?

Even the best systems lose some energy, mostly in the form of heat. This is
unavoidable because perfect combustion in boilers is impossible and zero-heat loss
insulation is unavailable.

The good news is that in most systems, there are opportunities to minimise losses and
make savings. A systematic approach that considers the whole system will have a
greater impact in the reduction of energy costs than simply targeting one isolated part
of the system. Case studies published by EECA give examples where paybacks of
between ten months and three years are achieved.

Useful references: 28 – 32

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2 A TYPICAL STEAM SYSTEM –
COMPONENTS AND COSTS
2.1 The main components
2.2 The size of losses
2.3 The cost of steam

2.1 THE MAIN COMPONENTS

Figure 1 shows a typical steam system in diagrammatic form.

A steam system can be broken down into four basic components:

- steam generation plant,
- steam distribution system,
- steam using equipment, and
- condensate recovery system.

Figure 1: outline diagram of a typical steam system

The steam generation plant can take various forms and use a range of fuels. Boiler is
the general term used for this plant, although the term steam generator is often used
when referring to a specific type of plant. Boiler technology is well established and
the basic concept has not changed for many years. Efficiencies have improved using
modern technology mainly in respect to controlling the combustion process.

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The steam distribution system is primarily made up of pipes and valves that transport
the steam from the generation plant to various points of use. This can be a major
source of energy inefficiencies if poorly designed or maintained.

The steam using equipment typically uses steam to convert heat into another form,
such as hot air for drying or boiling water to cook a product. The equipment can
range in size from a large milk dryer to a small food cooker. Other applications
include space heating, where steam is used to heat air or water through heat
exchangers.

In most situations, after the steam is used it will condense back into hot water, which
contains significant energy in the form of heat. This hot water is collected and
returned to the boilerhouse through the condensate recovery system. In the boilerhouse,
condensate is stored in boiler feed-water tanks (sometimes referred to as hot wells)
and eventually pumped back into the boilers and generally mixed with some fresh
(make-up) water.

Useful references: 1 and 19

2.2 THE SIZE OF LOSSES IN A STEAM SYSTEM

Energy losses in a typical well designed and maintained system can range from about
twenty five to fifty percent. The lower figure, of about twenty five percent, would
apply to systems being run continuously at close to design ratings with short pipe
runs. The higher figure, of about fifty percent, would apply to systems with longer
pipe runs and the plant and equipment run at varying loads.

Note: These figures are typical and must be treated as guidelines only. In some cases, where
very short runs of distribution pipes serve a small number of machines, losses will be less than
twenty five percent.

Often, losses will be considerably higher, sometimes more than sixty percent, due to
the design, layout, operation and maintenance of the system. Methods to identify
and minimise losses are discussed in Section 3.

Useful references: 1, 3, 4, 7, and 19

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2.3 THE COST OF STEAM

Energy losses can occur during the generation and distribution of steam. Figure 2
below shows these losses in diagrammatic form. The losses shown below are a "poor
average" but probably not uncommon. Overall system efficiency, ie, the percentage
of the energy in the fuel that is used in the final process, is less than thirty five
percent.

Figure 2: steam system losses - "poor average"

The cost of fuel is a major factor and can range from near zero where waste product is
used, eg, wood waste, through to $15 per GJ where oil is used. The table below sets
out typical fuel cost ranges (current as at May 2001):

Fuel Cost per GJ

Natural gas $4 to $7
LPG $10 to $18
Coal $3 to $5
Oil $9 to $15

In all cases, the cost is heavily influenced by the quantity used. The lower fuel costs
would apply to larger consumers. Location and transport costs will also influence the
final cost.

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For the purposes of this guide, we have adopted $6 per GJ as an average cost.

Using this average, the cost per tonne of steam for the system shown in Figure 2 is
$42. Most of this is the cost of fuel, typically ninety seven percent. Water, chemicals
and electricity each add a further one percent to this cost. Operation and
maintenance costs vary widely and may add another $1 to $4 per tonne of steam.

If each of the three main componentsefficiencies shown above could be improved by

ten percent of their original value, the picture would change substantially, as shown in
Figure 3 below.

Figure 3: steam system losses - " average"

In this case, cost per tonne of steam reduces to $30 (or $31 to $35 when all operation
and maintenance costs are included) – a saving of more than twenty five percent.

As an example, steam boilers in a medium-sized hospital in the North Island produce

about 26,000 tonnes of steam per year. By making the savings shown above, energy
savings would be over $300,000 per year. In the case of industrial sites, steam
production can be around 180,000 tonnes per year and savings would increase
accordingly.

Even with five percent savings per component, monetary savings of nearly $150,000
per year would be achieved.

Useful references: 2, 3, and 7

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3 IDENTIFYING SAVINGS
– THE WHOLE SYSTEM
3.1 Definition of the processes
3.2 The heating load or process
3.3 Conversion process
3.4 Distribution
3.5 Heat recovery
3.6 Steam generation

3.1 DEFINITION OF THE PROCESSES

The whole process, from generation to utilisation, is made up of five stages as shown
in figure 4 and listed below.

• The heating load or process

• The conversion process
• Distribution
• Heat recovery
• Steam generation

A systematic approach which considers the whole steam system will be more effective
in reducing energy costs than targeting one isolated part of the system.

The order in which these are listed above reflects the impact of any efficiency
improvements in each process on the overall system. A reduction in energy
consumption in the heating load will be amplified in terms of fuel savings because
each further stage of the process is less than one hundred percent efficient.

For example, in the system illustrated in figure 3 above, and assuming that daily
energy required in the heating process can be reduced by 100GJ, the energy input
required by the boiler will be reduced by more than 200GJ.

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Figure 4: the steam process

3.2 THE HEATING LOAD OR PROCESS

Typical processes include:

• Heating air to dry a product, eg, milk processing, timber processing

• Cooking or processing, either in a jacketed pan or directly in a pressure-
cooker
• Evaporators
• Digesters
• Laundry and dry cleaning, eg, washers, dryers, irons and presses

Another relatively common process is to provide space heating. The steam is used to
heat air or water which is used in radiators or similar appliances.

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Common areas of saving can include:

1. Reducing the process temperature.

2. Managing a process differently, eg, changing the time of operations to
reduce peak loads.
3. Turning off equipment when not in use - often steam equipment is left
on 24 hours a day unnecessarily.
4. Using an alternative to steam. This can be particularly appropriate where
a single item of equipment is supplied through a relatively long steam
pipeline. In the case study shown below, it would not be cost effective to
convert to electricity. The electricity option could be better if a new
sterilizer was being installed.
5. Reduce steam pipe length by relocating equipment closer to the
generation process.
6. Review the process control system. This is particularly relevant in the
case of space heating systems.
7. Heat recovery from the process is sometimes an option, eg, commercial
laundry washing machines discharge large quantities of warm water from
which heat can be recovered and used to pre-heat cold water.

Case study:
Hutt Hospital achieved a six-month payback by adjusting the control of
its space heating system.

In 1995, Hutt Hospital’s Building Services team carried out an energy

audit with the assistance of a consultant.

A warm air ventilation system, providing ventilation to a ward block, ran

24 hours a day. The cost of heating the air, using hot water generated
from steam, was about $8,000 per year. A check of the air quantity
found that the system provided over twice the amount of fresh air
required by the New Zealand Building Code.

A simple speed control system was installed which reduced the fresh air
quantity by 50 percent whenever the outside temperature dropped to
below 16oC. At 16oC, heating commenced. The original level of
ventilation was used during warmer weather when it was most required.

Savings achieved were $4,000 per year at a cost of less than $2,000.

Useful references: 3, 4, 13, 25 and 27

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3.3 THE CONVERSION PROCESS

In most cases, the conversion process involves heat exchange equipment designed to
transfer heat from steam to another medium, usually air or water. Most of the heat
transferred is latent heat, given out as steam condenses to water.

In some applications, steam is used directly, eg, in sterilization. Direct injection is

sometimes used to pre-heat boiler feed-water as part of the process to remove air and
dissolved gases.

Conversion equipment can offer a number of energy cost savings opportunities but is
often overlooked. This is particularly true for older items of equipment.

Energy efficiency can be improved through:

1. Checking the general condition of equipment. Ensure there are no steam

leaks and insulation is in good condition with all hot surfaces properly insulated.
Note: this is also important for health and safety reasons.
2. Correct plant sizing. Oversized heat-exchange equipment is not energy
efficient as output is difficult to control and heat losses are increased through
greater surface area. On the other hand, undersized or incorrectly selected steam
traps can result in poor exchanger performance and inefficiencies.
3. Control system improvement. In some cases, eg, laundry tumble dryers, the
amount of heat required reduces over the process cycle. By fitting controls that
reduce steam flow, the amount of unused heat can be reduced. Note: some care
needs to be taken when retrofitting control valves in steam systems and modifications to
steam trapping may be required. Please seek specialist advice.
4. Heat exchange surfaces should be kept clean of product build-up. By
cleaning surfaces regularly, and by increasing product velocity by mechanical
stirring or careful arrangement of product flow, heat resistance is much reduced.
5. Remove air from the system. On the steam side, the most significant barrier is
air film. Air is a very effective insulator of heat. An air film which is only 0.025
mm thick will resist heat transfer as much as a wall of copper 330 mm thick.
Air is always present in the steam system on start-up, while other non-
condensable gases may be formed in the boiler during operation with similar
negative results. Air should be removed by a combination of correctly fitted air
vents and steam traps, allowing air to pass. Some steam plant, such as heater
batteries and jacketed pans, need separate air vents fitted. These will reduce
maintenance and improve batch times, heat transfer rate and product quality.
This subject is discussed further in Section 3.4.

Useful references: 1.1, 1.4, 1.6, 2, 7, and 27

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3.4 STEAM DISTRIBUTION

Figure 5 below shows in simplified form a typical steam distribution system and
illustrates where energy losses occur.

Figure 5: distribution system losses

Distribution system losses can vary from two to fifty percent and average around
fifteen percent. These losses can have a major impact on the cost of steam. Reducing
these losses presents a good opportunity for savings.

Overall System Design

When a system is being designed or remodeled, the following principles should be

followed:

1. total length of the system pipework should be kept as short as possible.

2. valves should be kept to the minimum necessary for effective
maintenance and safe operation.

If practicable, steam pipelines not in use should be turned off. This can be time
consuming and the benefits of this should be analysed. Ideally, measures should be
taken at the design stage to minimise problems associated with this.

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Case Study:
Lower Hutt company Rembrandt Suits was able to achieve gas
consumption reductions of about ten percent by replacing or
refurbishing steam traps and renewing some sections of pipe lagging.

Even relatively new, ie, less than twelve months old, traps can become
faulty and required regular checking. A regular inspection programme is
now in place.

As a second stage, the steam distribution was rationalised to reduce the

number of steam and condensate branches. By moving plant, such as
steam irons, to serve a number of machines rather than one branch
serving one machine, gas consumption dropped by a further ten
percent.

The importance of effective insulation

Heat loss through transporting steam at 10 bar through 10 metres of 100mm

diameter, well-insulated steam pipe will be about 750 watts. If the system operates 24
hours a day all year, annual losses will be 24GJ. This will cost approximately $180
per year, assuming fuel costs $6 per GJ and a boiler operates at eighty percent
efficiency.

If the same pipework is poorly insulated or the insulation is damaged, losses can
increase substantially. If the same 10-metre length is uninsulated, losses increase to
approximately 7,500W, ie, ten-fold.

Note: Special care must be taken in respect to pipework installed outside and exposed to the
weather. Obviously, the insulation thickness should be reviewed to allow for wind and low
ambient temperatures but, most importantly, the insulation must be provided with
waterproof cladding.

Valves and flanges are often left uninsulated, resulting in substantial losses. The level
of heat loss will depend on valve design, but a typical 100mm steam-valve will emit
approximately 1,500W which, at $6 per GJ for fuel, would cost about $350 per year,
depending on boiler efficiency.

Insulation blankets can easily be clipped on to valves and are readily available. These
can be expected to reduce energy loss by at least seventy five percent. See also
reference 33.

As a rule of thumb, any pipe at 50oC or above should be insulated for both economic

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and safety reasons. An exception is a drain or vent pipe, which cannot be accidentally
touched by anyone.

The Impact of Steam Leaks

Steam is an unforgiving medium and, even in the best installed and maintained
system, leaks will occur - particularly at flanges, screwed joints and valve glands. Early
attention to steam leaks is the key as leaks tend to get worse over time and are
expensive.

A conservative estimate of the cost of steam leaking from a 2 mm diameter gap is

about $1,000 per year if left unattended. Minimise the use of screwed joints as they
are more likely to leak than other type of joint.

Steam Traps

Steam traps are essential to a distribution system. These devices drain the condensate
that forms in pipework when warming up and during normal usage. As there is no
such thing as a perfectly insultated system, condensate cannot be avoided. Steam
traps are designed to drain water without losing steam.

Condensate cannot be allowed to accumulate in pipework as this will result in water

hammer. This occurs as the steam flow picks up slugs of condensate and slams them
against bends, tees or items of plant and equipment.

While steam traps are an essential part of a steam system, they have the potential for
heat losses - mainly through leakage of steam through traps themselves.

In a system with no regular trap maintenance programme, fifteen to twenty five

percent of traps may malfunction at any one time and leakage could easily cost more
than $1000 per year. An effective trap maintenance programme will reduce overall
distribution losses by ten to twenty percent.

Steam traps can be tested by conventional methods such as checking sight-glasses

downstream of traps or listening for the noise of steam passing through the trap.
Another sign will be excessive steam venting from a condensate receiver. More
sophisticated testing methods are now available which can be monitored remotely.

Detailed information on the correct location and selection of steam traps is beyond
the scope of this guide. See references 1.6 and 2 if more detailed information is
required.

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System "Hygiene"

Unwanted air, gases, oil, grease and scale in steam pipework can all reduce the
effectiveness and efficiency of steam using plant and equipment. As such, an effective
water treatment programme is vital. Advice from companies specialising in steam
boiler and distribution water treatment is always recommended.

Air, minerals and gases, such as CO2, exist in water. As well as impacting on steam
equipment operation, these gases can cause corrosion.

Oil, grease and other materials, particularly in the milk processing industry, present a
high risk of contamining feedwater. In cases where condensate is contaminated, a
heat-exchanger can be used to recover heat while avoiding contamination.

Boiler scale results from materials such as calcium, magnesium and silica reacting with
tube metal to form a hard scale on the tube. This scale reduces heat transfer and
eventually causes tubes to overheat and fail. Tube scaling can reduce boiler efficiency
by as much as ten to twelve percent.

When a newly installed system or alteration to an existing system is commissioned,

every effort should be made to ensure the pipe interior is thoroughly cleaned of dirt,
scale, welding slag and oil, and grease.

Useful references: 1.1, 1.3, 1.4, 1.6, 2, 5, 7, 8 and 12.8.

3.5 CONDENSATE HEAT RECOVERY

The condensate heat recovery process is the collection and return of condensate from
the conversion or steam using equipment and steam traps. In most cases, the
condensate is pumped into the boiler feed-water tanks, where it is mixed with any
make-up cold water required to compensate for blowdown, flash steam and that
which is lost in the conversion process.

Due to heat energy in the condensate, recovering condensate reduces the amount of
boiler fuel required by at least fifteen percent. Typically, increasing the feed-water
temperature by 6oC reduces fuel consumption by one percent.

In addition, recovering the condensate reduces the amount of make-up water required
and consequently, the amount of water treatment chemicals to be added.

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Common areas where savings may be achieved in condensate heat recovery are:

1. General condition of the return system. Check for inadequate or damaged

insulation and leaks. A damp environment and low temperatures can make
corrosion a big problem. Condensate can sometimes be high in iron which can
cause water treatment problems.

2. Flash steam heat recovery. Flash steam is released from hot condensate when
pressure is reduced, as can happen when a faulty steam trap discharges
condensate to the atmosphere. The higher the steam pressure, the higher the
temperature of the condensate and greater the quantity of flash steam.

Flash steam is typically vented from condensate collection receivers. This

vented flash steam represents a direct loss of energy.

Flash steam losses can be reduced in a number of ways, including:

1. Recovery of flash steam to use in a low-pressure steam system. The

challenge here is to have a steady demand for low-pressure steam
which matches the production of flash steam.
2. Passing hot condensate through a heat exchanger and using the
transferred heat to pre-heat cold water for use as part of a process or to
pre-heat boiler feed water.

Case Study:
Amcor Kiwi Packaging was able to save $140,000 per year at its Wiri
plant, representing eleven percent of its fuel bill.

These savings were made through the installation of a heat exchanger

which recovered heat from hot condensate (at 154oC) and used this
heat to raise the temperature of the boiler feed water.

The capital cost involved was around $14,000, including a new well-
insulated feed tank, achieving a simple payback of six months.

Useful references: 1.3, 14, 15, and 16

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3.6 STEAM GENERATION

Steam generation plant can range in size from 30MW water tube boilers at a milk
processing plant down to a 12 kW electric boiler supplying steam to a hospital
sterilizer.

A wide range of fuel is used with gas, coal, waste products, biomass and electricity
being most common.

Compared with hot-water boilers, steam boilers are expensive to manufacture and to
operate. This is due to the high temperatures and pressures involved and a need for
sound design and operating practices.

While boilers have to be well maintained for safety reasons, it is still possible to
operate a boiler safely but inefficiently.

Boiler Types

For the purposes of this guide, three boiler types are mentioned:

• Water tube - typically used in larger installations of 8MW output and

above.
• Fire tube - the most common type in installations of up to 6MW.
• Steam generators - these are found at the small end of the market.

Boiler Efficiency

Boiler efficiency is the term used when comparing the amount of heat supplied to the
boiler with energy that comes from the boiler in the form of steam. In an well-
operated and maintained boiler, efficiency is expected to be in eighty to eighty four
percent at full load. If an economiser is fitted, the efficiency can be increased by
another two to five percent.

Cautionary note:
In New Zealand, the convention is to base efficiency calculations on the gross calorific value, sometimes referred to as the higher
heating value, of the fuel. This value includes heat energy required to convert water produced during the combustion process
(from the hydrogen content of the fuel) to water vapour. The net calorific value (or lower heating value) excludes the heat of
evaporation and, in the case of gas, is about 10 percent less than the gross calorific value. To confuse matters, the convention in
some countries is to use the net calorific value and some boiler manufacturers use this figure in technical literature when quoting
efficiencies for boilers. These figures are typically 10 percent higher than figures based on gross calorific value.

As the above percentages imply, some loss is inevitable. Figure 6 below shows where
these can occur.

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Figure 6: typical boiler energy losses

Considering each element in turn:

Radiation and convection losses

Generally referred to as the standing or fixed losses, these losses comprise heat lost
from the boiler structure and typically amount to between one and four percent.
These can be minimised by good insulation which should include boiler mountings
and access openings, eg, manhole and mudhole doors. The losses from an
uninsulated manhole door will be substantial - around 2kW, which over one year
could amount to 65GJ or over $350.

It is important to remember that the one to four percent standing loss is constant and
relates to the boiler rating rather than output at any given time. Often, particularly
in institutional buildings where steam demand varies substantially depending on time
of year and occupancy, a boiler can operate at fifty percent or less of its rating,
generally referred to as the boiler maximum continuous rating, or "MCR".

For example, if a 6MW boiler has an average output of 3MW, standing losses will
increase from two to six percent when considering the true operating efficiency.

Even a small reduction in these losses can result in a worthwhile saving. However, the
best saving will result from selecting a boiler that matches the load as closely as
possible.

In some situations, periods of low demand exist. In this case, consideration should be
given to reducing boiler pressure which will, in turn, reduce standing losses.

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Combustion Losses
Combustion losses occur during the combustion process and are represented by the
energy that goes out of the chimney rather than into the steam.

In most cases, more air than is required has to be delivered to the process to ensure all
the fuel is properly burnt. This excess air means hot flue gases are increased and
losses take place. While this cannot be eliminated, it can be minimised by properly
setting or tuning a boiler and carrying regular combustion checks.

Monitoring the oxygen (O2) content of the flue gases provides a reliable indication of
the level of excess air. The O2 content should be in the range of two to four percent
for natural gas, six to eight percent for coal and three to five percent for oil.

Figures higher than these indicate too much excess air and increased losses, while
lower figures are a warning that incomplete combustion may be taking place. The
sensing of the O2 content can be used to automatically trim the air-fuel mix to
minimise excess air.

Variable speed drives (VSD) on forced and induced draught fans can be used to
control combustion air rather than using dampers. Used in combination with O2
trim, one hospital was able to save $55,000 annually in coal fuel costs by fitting
VSD’s on the boiler fans with a payback of under three years.

The use of PLC’s to control the steam generation process is now common in boiler
plant, particularly in limited and unattended plant. This, coupled with data logging,
enables the boiler manager to analyse boiler operation closely and to identify
opportunities for efficiency improvements.

Case Study:
In 1984, a factory owner complained that his boilers were not meeting
demand and that his fuel bill had skyrocketed. An energy consultant
visited the factory and identified that maintenance of the boiler had been
poor.

A gas burner specialist was employed to do some combustion checks

and it was quickly found the boiler was so out of tune that excess air
was nearly ten times what it should be. As a consequence, the boiler
efficiency was less than fifty percent.

An hour’s work saved the factory owner nearly $100,000 a year.

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Even in perfect combustion situations, flue gases contain heat. It is possible to
recover some of this heat by fitting economisers, located just after the point where flue
gases leave the boiler. In the economiser, flue gases are used to pre-heat feed water
before it enters the boiler, reducing the amount of work the boiler has to do.

Another potential saving measure is to use flue gases to heat the air delivered to the
boiler for combustion purposes. These measures will typically improve efficiency by
two to six percent.

In a larger boiler plant, this can represent worthwhile savings but may not be
economically feasible in small plants.

Blowdown
Blowdown, an essential feature of good boiler operation practice, involves draining off
water in the boiler to dispose of dissolved solids which will have accumulated.

These solids naturally occur in water supplies and are usually carbonates and sulphates
of calcium and magnesium. As water evaporates into steam, the concentration of
these solids increases with the risk of scale deposits.

While appropriate water treatment will reduce the problem, blowdown is essential if
the concentration of solids is to be kept within a desirable range. The concentration
of solids is referred to as the total dissolved solids (TDS) and is measured as parts per
million.

Blowdown involves draining off hot water from the boiler and is a loss of energy. For
example, the typical blowdown rate for a 6MW (10,000kg/hr steam output) is likely
to be in the order of 1,000kg/hr. Assuming an operating pressure of 10 bar, this
represents a loss of over 5,000GJ annually or around three percent of boiler output.

The first step is to minimise the amount of blowdown through effective water
treatment to minimise TDS. Maximising condensate recovery will also help by
minimising make-up water.

A second step is to consider automating the blowdown process through continuous

monitoring of TDS and blowing down only the amount necessary. By automating
continuous blowdown, this reduces the total blowdown rate.

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Case study:
reducing excessive blowdown
Colgate Palmolive Ltd. achieved a less than two-year payback by
improving the control of blowdown on its three boilers.

It replaced the original continuous blowdown system with intermittent

valves controlled by a microprocessor sampling water conductivity at
timed intervals.

This reduced the amount of continuous blow down from 50kg per hour,
which was set for peak operation, to less than 25kg per hour on
average. It cost $4400 to install and saved $2400 per year in water,
chemicals and gas.

The final step is to consider recovering heat from the blowdown process through one
of two commonly used methods.

The first uses blowdown water to preheat make-up water before it enters the feed
tank. The second uses flash steam by taking it back to the de-aerator or hot well for
direct contact heating of the feed water. Using either method can recover up to fifty
percent of the energy in the blowdown.

Boiler Plant Operation

Good boiler plant operating practice can result in energy savings, often with minimal
investment. Some examples include:

1. In multi-boiler installations it is much more efficient to have one boiler

operating at close to capacity rather than two boilers at fifty percent
capacity.
2. Good water treatment not only reduces the risk of corrosion, but also
reduces scale build up on boiler heat transfer surfaces which can reduce
heat transfer effectiveness. This can also occur in steam using equipment
where scale formation can inhibit the transfer of heat from steam.
3. Switching off of boilers, either manually or automatically, when not in
use.

STEAM EFFICIENCY GUIDE FOR ENERGY MANAGERS page 22

Fuels

Fuels commonly used in New Zealand for steam generation include:

• Natural gas
• LPG
• Coal
• Oil
• Wood waste
• Electricity

In the case of solid fuels, well-designed storage facilities are very important as wet fuel
does not heat effectively.

Useful references: 1.2, 1.4, 3, 10, 11, 17, 18, 19, 20 and 24.

STEAM EFFICIENCY GUIDE FOR ENERGY MANAGERS page 23

4 MEASURING PERFORMANCE
If a steam plant is to operate efficiently, it is essential to measure and analyse its
performance as a comparison with industry benchmarks. Where industry
benchmarks are unavailable, internal benchmarks can be adopted, such as fuel
consumption per unit output, and used to set improvement targets.

Metering fuel used and steam produced is a useful starting point. Data from these
meters allows easy calculation of steam generation plant efficiency as set out below:

Thermal efficiency percent = Energy in steam produced

Energy in fuel consumed

Metering of gas and oil fuels is also easily done but the metering of solid fuels, such as
coal and wood-waste, can be more difficult. An automatic weighing system could be
considered.

In such circumstances, the boiler operator should use records of O2 or CO2

measurements and flue gas temperatures to estimate combustion efficiency. This will
be useful information but be aware that this will not include standing or blowdown
losses.

Some caution is required with steam meters as many are only accurate over a certain
range. It is important to establish this range, along with any likely errors if operating
outside the range. This may be a problem if a boiler operates over a wide range of
outputs.

In medium sized (4MW) installations and larger, feed-water should be metered and
temperature recorded as this provides a useful check on steam meter calibration. It
also refines the efficiency calculation by adjusting the energy in steam to allow for
energy in the feed-water, ie:

Net energy in steam = (energy in steam - energy in feed water)

Make-up water, ie, water required to compensate for blowdown and condensate that
is lost, should be metered as this provides a good indicator of how much is lost in the
system. Any increase in make-up water could provide early warning of a new loss.

Note: The above methods of estimating thermal efficiency are appropriate for day-to-day
energy monitoring. In situations where an accurate measurement of efficiency is required,
such as in new boiler acceptance trials or as part of a boiler purchase process, a formal
efficiency test should be conducted as set out in an appropriate code such as the ASME Boiler
Code or BS 845-2:1987.

STEAM EFFICIENCY GUIDE FOR ENERGY MANAGERS page 24

The thermal efficiency of a boiler that will be achieved in day-to-day operations will
depend on a number of variables including:

• Boiler type (eg, water or fire tube)

• Fuel
• Load factor
• Size of plant

For example, large industrial boilers operating at high load factors can be expected to
have higher efficiencies than small boilers serving institutional buildings with widely
varying loads.

The efficiency of coal and oil fired boilers are likely to reduce over time as the use of
coal and oil can result in soot deposits.

Target figures below are based on data from the references given in this guide and
through discussion with boiler manufacturers and operators. As noted above, the
higher figures tend to relate to industrial users:

Gas fired boilers: 78-83 percent

Oil fired boilers: 78-84 percent
Coal fired boilers: 76-81 percent
Steam generators: 75 percent

Boiler tune-ups can be expected to improve efficiencies by two to five percent.

Metering of steam at other points in the distribution is worthwhile, particularly in

larger systems serving multiple load points. This enables the energy manager to
identify where and how the steam is being used and also to establish losses in the
distribution system. It also leads to early detection of unexpected changes in steam
flows, which can often indicate a problem with the system.

Useful references: 1.5, 5, 9 and 24

STEAM EFFICIENCY GUIDE FOR ENERGY MANAGERS page 25

5 OTHER USEFUL GUIDES

1. Spirax Sarco, ‘Technical Reference Guides’.

See www.spiraxsarco.com. (Note: to obtain copies of the guides, phone
Spirax Sarco (New Zealand) Ltd, ph: 0800 800 229)
1.1 Steam distribution, 1997
1.2 Boilers, boiler fittings and steam off-takes, 1998
1.3 Condensate and flash steam recovery, 1999
1.4 Water treatment, storage and blowdown, 1998
1.5 Steam metering, 1991
1.6 Steam trapping and air venting, 1998
1.7 Steam engineering principles, 2000

2. Armstrong, ‘Solution Source for Steam, Air and

Water Systems’, 2001. See www.armstrong-intl.com.

3. Chartered Institution of Building Services Engineers (CIBSE), ‘CIBSE

guide books a, b & c’.

4. American Society of Heating, Refrigeration and Air Conditioning

Engineers (ASHRAE) ‘ASHRAE handbooks’.

ETSU guides (www.ETSU.com)

5. Department of the Environment, UK, ‘Fuel Efficiency Booklet 2 –

steam, best practice programme’, 1996. This booklet discusses
steam generation and distribution and examines in detail the most
common causes of heat loss and suggests methods to deal with these. A
number of heat recovery methods are presented.

6. Department of the Environment, UK, ‘Energy Consumption

Guide 66 – steam generation costs, best practice
programme’, 1997. This guide provides the opportunity for steam
users to compare their steam consumption with other users together with
thermal efficiencies. The information is based on surveys of more than
100 sites involving over 300 boilers. The guide discusses the scope for
reducing energy use and provides a Steam Energy Cost Calculator to help
users calculate their steam cost. Some energy saving suggestions are
included.

STEAM EFFICIENCY GUIDE FOR ENERGY MANAGERS page 26

7. Department of the Environment, UK, ‘Energy Consumption
Guide 67 – steam distribution costs, best practice
programme’, 1996. The aim of this guide is to raise awareness of
steam distribution costs and shows, step by step, how to calculate these
costs and thereby to prioritise areas for improvement. The guide uses the
results of energy surveys of over 100 sites and its objective is to assist
energy and technical managers to improve efficiency and reduce operating
costs.

8. EECA ‘EW Practice 16: Steam leaks make a big hole in

company profits’, 1998.

STEAM EFFICIENCY GUIDE FOR ENERGY MANAGERS page 27

6 REFERENCES
Other ETSU publications:

9. Department of the Environment, UK, ‘Good Practice Guide 18 –

Reducing consumption costs by steam metering’, 2000.
10. Department of the Environment, UK, ‘Good Practice Guide 30 –
Energy efficient operation of industrial boiler plant’, 1995.
11. Department of the Environment, UK, ‘Good Practice Guide 221
– Improving boiler efficiency through water treatment’,
1998.
12. Department of the Environment, UK, ‘Fuel efficiency booklet 5 –
Steam costs and savings, best practice programme’,
1976.
13. Department of the Environment, UK, ‘Fuel efficiency booklet 3 –
Utilisation of steam for process and heating, best
practice programme’, 1979.
14. Department of the Environment, UK, ‘Fuel efficiency booklet 6 –
Flash steam and vapour recovery, best practice
programme’, 1976.
15. Department of the Environment, UK ‘Fuel efficiency booklet 9 –
How to make the best use of condensate, best practice
programme’, 1977.
16. Department of the Environment, UK ‘Fuel efficiency booklet 13 –
The recovery of waste heat from industrial processes,
best practice programme’, 1978.
17. Department of the Environment, UK ‘Fuel efficiency booklet 17 –
Economic use of coal-fired boiler plant, best practice
programme’, 1981.
18. Department of the Environment, UK ‘New Practice Report 59 –
The performance of a condensing economiser fitted to
an industrial gas fired steam boiler, best practice
programme’, 1992.
19. Department of the Environment, UK ‘Good Practice Case Study
339 – Heat recovery from boiler blowdown, best
practice programme’, 1996.
20. Department of the Environment, UK ‘Future Practice R & D
Profile 84 – Low cost intelligent control and analysis
systems for shell steam boilers, best practice
programme’, 1998.
21. Department of the Environment, UK ‘Good Practice Case Study
339 – Heat recovery from boiler blowdown, best
practice programme’, 1996.

STEAM EFFICIENCY GUIDE FOR ENERGY MANAGERS page 28

USA "Steam Challenge"

22. Power Specialities Company, ‘Steam Challenge: Improving

Efficiency through marketplace partnerships,’ March 2000.
23. Department of Energy, ‘DOE Steam Challenge: what is Steam
Challenge?’, March 2000. See
www.oit.doe.gov/bestpractices/explore_library/technical_publications.shtml;
Steam Systems Energy Efficiency Handbook: 1998

Other EECA publications

24. EECA, Energy-Wise News, ‘Big Savings With Energy Efficient

Steam Supply’, December 1999.
25. EECA, ‘Industrial Heat Recovery - technical series’, 1994.
26. EECA, ‘Energy Efficiency - A guide to current and
emerging technologies’, Vol.2, Industry and Primary Production,
CAE, 1996.
27. EECA, ‘Energy wise tips for industrial processes’, 1996.
28. EECA, ‘Energy Wise Case Study 3: innovative boiler
automation could have wide application’, 1997.
29. EECA, ‘Energy Wise Case Study 11: boiler efficiency
upgrade pays for itself in under three years’, 1997.
30. EECA, ‘Energy Wise Case Study 15: decentralising heat
supply helps reduce company’s use by 31%’, 1997.
31. EECA, ‘Energy Wise Case Study 25: heat recovery project
cuts steam costs, impresses accountants’, 2000,
32. EECA, ‘Energy Management Demonstration 12: valve
insulation blanket project summary’, 1996.

STEAM EFFICIENCY GUIDE FOR ENERGY MANAGERS page 29

7 C O N S U LT A N T S ,
CONTRACTORS AND
PRODUCT SUPPLIERS
Consultants:

(1) Boilers and combustion

Allan Estcourt Ltd. 07 347 7261 [email protected]

Aquacare NZ Ltd. 09 939 3639 [email protected]
Armadillo Engineering Ltd. 09 267 3410 [email protected]
Babbage Consultants Ltd. 09 379 9980
Beca Carter Hollings & Ferner Ltd. 04 479 6253 [email protected]
Beca Simons Ltd. 09 300 9700 [email protected]
Easteel Industries Ltd. 06 374 6089 [email protected]
Energy Management Systems 03 348 9935 [email protected]
Ian Reid 06 379 6086
Ivan A Fraser 09 410 5008 [email protected]
JWB Consultants Ltd. 04 479 5870 [email protected]
Meritec Limited 04 382 2980 [email protected]
Process Development Ltd. 04 569 3852 [email protected]
URS New Zealand Ltd. [email protected]

(2) Steam plant and equipment

Aquacare NZ Ltd. 09 939 3639 [email protected]

Armadillo Engineering Ltd. 09 267 3410 [email protected]
Babbage Consultants Ltd. 09 379 9980
Beca Carter Hollings & Ferner Ltd. 04 479 6253 [email protected]
Ian Reid 06 379 6086
Ivan A Fraser 09 410 5008 [email protected]
Meritec Limited 09 379 1283 [email protected]
PB Power 04 499 1000 [email protected]

(3) Steam distribution

Allan Estcourt Ltd. 07 347 7261 [email protected]

Beca Simons Ltd. 09 300 9700 [email protected]
Energy Management Systems 03 348 9935 [email protected]
Ian Reid 06 379 6086
Lance Hope Consulting Engineer 03 313 7433 [email protected]
Meritec Limited 04 382 2980 [email protected]

STEAM EFFICIENCY GUIDE FOR ENERGY MANAGERS page 30

Contractors:

(1) Boilers and combustion

Aquaheat Industries Limited 04.232 5179 [email protected]

Easteel Industries Limited 06 374 6089 [email protected]
John Thompson New Zealand 07 856 9039 [email protected]
Lyttelton Engineering Co Ltd. 03 328 8105 [email protected]
Scotts Engineering Co Ltd. 03 352 9015

(2) Steam distribution

Aquaheat Industries Limited 04.232 5179 [email protected]

Easteel Industries Limited 06 374 6089 [email protected]
John Thompson New Zealand 07 856 9039 [email protected]
Lyttelton Engineering Co Ltd. 03 328 8105 [email protected]
S Hardisty Limited 04 567 5060 [email protected]
ThermoSystems LBF Ltd. 09 533 7330 [email protected]

Product suppliers:

(1) Boilers and combustion

Aquaheat Industries Limited 04 232 5179 [email protected]

Easteel Industries Limited 06 374 6089 [email protected]
John Thompson New Zealand 07 856 9039 [email protected]
Lyttelton Engineering Co Ltd. 03 328 8105 [email protected]
Scotts Engineering Co Ltd. 03 352 9015

(2) Steam equipment

Custom Control Ltd. 09 634 1391 [email protected]

Easteel Industries Limited 06 374 6089 [email protected]
John Thompson New Zealand 07 856 9039 [email protected]
Lyttelton Engineering Co Ltd. 03 328 8105 [email protected]
Spirax Sarco 09 263 4205 [email protected]

STEAM EFFICIENCY GUIDE FOR ENERGY MANAGERS page 31

APPENDICES

APPENDIX I: INTRODUCTION TO STEAM

Steam has been used in industry since the 18th Century, with its heyday in the late
19th Century when it was unchallenged as the major source of energy for industry and
transport.

While those days have passed, steam still remains an extremely useful energy form and
is used in a number of industries in New Zealand.

Sixty percent of energy use in New Zealand (excluding transport) is process heating
using temperatures below 300oC. Most of this is in the form of steam. Steam is also
commonly used in hospitals as a sterilizing agent and for cooking.

Steam - a simple guide to thermodynamics

Steam is water in a gaseous state and is normally produced by heating water.

Figure 7 below shows the process of producing steam at atmospheric pressure. In the
first part of the process, water is heated from a typical ambient temperature of 20oC
to 100oC. The amount of heat energy required is 335 kilojoules (kJ) per kg. This
heat is known as sensible heat because it can be felt or sensed.

In the second part of the process, heat continues to be added. The temperature
remains at 100oC and water changes to steam. This heat is known as the latent heat
of vaporization, or more commonly, latent heat. To convert 1kg of water to 1kg of
steam, with no change in temperature, requires 2,257kJ.

The total heat required to convert the water at 20oC to steam at 100oC is therefore
2,592 kJ.

STEAM EFFICIENCY GUIDE FOR ENERGY MANAGERS page 32

Figure 7: basic properties of steam

If these processes take place in a sealed or fixed volume space and steam cannot vent
to the atmosphere (as in the case above) the process changes, as shown in Figure 8
below.

Starting with 1kg of water at 20oC and adding heat, if the steam formed cannot
escape, pressure will increase. When pressure reaches 1,000kPa, the temperature of
the water will have increased to 185oC and the sensible heat added will be 700kJ.

If, at this point, the valve on the boiler is opened then latent heat will have to be
added to the water at 185oC to convert it to steam at 185oC. At this temperature and
pressure, the latent heat required is 2,000kJ. Total heat required to generate this
steam from water at 20oC is therefore 2,700kJ, which is just over 100kJ more than
was the case with steam at atmospheric pressure, as described earlier.

STEAM EFFICIENCY GUIDE FOR ENERGY MANAGERS page 33

If steam is allowed to cool, the process is reversed - the steam condenses back to
water, releasing the latent heat and, if allowed to continue cooling back to 20oC,
releasing sensible heat.

Figure 8: basic properties of steam

There is a direct relationship between steam pressure and temperature. The higher
the pressure, the higher the temperature. For example, if pressure is increased from
1,000kPa to 2,000kPa, steam temperature will increase to 215oC. This is referred to
as saturation temperature.

The saturation temperature is boiling temperature for pressure at which water and
steam is held and, as more heat is applied, saturation temperature will increase, along
with pressure in accordance with the saturation curve. See reference 1.4 for further
explanation.

STEAM EFFICIENCY GUIDE FOR ENERGY MANAGERS page 34

This demonstrates a number of important characteristics:
• As steam pressure increases, temperature increases.
• As steam pressure increases, more energy is required to generate each
kilogram of steam, ie, the higher the pressure, the higher the energy
content.
• The energy content includes about seventy percent latent heat at
1,000kPa pressure. As pressure increases, the amount of latent heat
decreases.

Where steam is produced in direct contact with water, the temperature and pressure
relationship mentioned above is maintained.

If steam is taken out of the main body of a boiler and further heated, the temperature
will increase beyond saturation temperature. This is known as superheating and is
commonly used in power generation. It is not a common practice in typical
industrial steam installations. For this reason, superheated steam is not covered in
this guide.

Why is steam used?

Steam has several characteristics which make it useful:

- It is readily transportable from a central point of production through a

simple piping system to one or more points of use.
- It contains a lot of energy, as heat and pressure, in comparison with
competing forms of energy. For example, 1kg of steam at 10 bar contains
2,785kJ whereas 1kg of pressurized hot water at 125oC only contains 525kJ.
- Expanding on the above, to transport 2,785kW (kJ/second) in the form
of steam at 10 bar over 100 metres could be achieved with an 80mm
diameter pipe with a condensate return of 50mm diameter. To transport
the equivalent as hot water at 125oC with a temperature drop of 25oC
will typically require flow and return lines of 125mm diameter.
- The raw material – water - is cheap and does not create a major pollution
risk if released.
- It is relatively simple to produce and transport and technology is well
established.

Steam is most commonly used where heat energy is required for an industrial process
such as drying, curing or cooking. The most common applications are found in the
dairy, timber and food processing industries. In hospitals, steam is still the most
commonly used sterilizing medium and it is also used in hospital kitchens for
cooking. Laundries and dry-cleaners are also steam users.

STEAM EFFICIENCY GUIDE FOR ENERGY MANAGERS page 35

There is a demand for both steam and electricity in some industries, such as the
timber processing and dairy industries. Where demands are well matched, this
provides an opportunity to consider co-generation, where the steam is first used to
generate electricity and, after passing through a generator turbine or steam engine,
exhaust steam is used for processing.

Why is steam not used more often?

The simple answer to this question is that, for many applications, there are more cost-
effective means of transporting the same quantity of energy to a point of use.

Steam is effectively a hot, pressurised gas and it presents a potential hazard. Steam
raising plant, distribution pipework and steam using equipment has to be
constructed, operated and maintained to a high standard.

In New Zealand, the Department of Labour, in administering the Health and Safety
in Employment Act, has implemented a series of regulations and codes of practice
governing the construction and operation of steam systems.

Compliance with these regulations and codes, along with the good practice and
maintenance required to ensure a safe system, is costly. As a consequence, steam
systems are relatively expensive to install and run.

High temperatures and pressures involved in a steam system increase potential for
energy losses, either in the form of heat losses from pipes and equipment or steam
leaks. Steam is unforgiving of poor maintenance - a small leak at a joint inevitably
becomes bigger if neglected.

In comparison to other competing forms of energy, steam is definitely in the high

maintenance class.

STEAM EFFICIENCY GUIDE FOR ENERGY MANAGERS page 36

APPENDIX II: UNITS

In this guide, a number of units are used. These are as follows:

Temperature:
Degrees Celsius - ˚C

Pressure:
Bar - bar
Kilopascal - kPa

Notes:
1. In the text, "bar" is used when referring to operating pressures whereas when
discussing steam properties, "kPa" is used. This reflects customary usage in the
industry. 1 bar = 100 kPa.
2. Gauge pressure, rather than absolute pressure, is used throughout.

Energy (or heat content):

Joule - J

Notes:
1. kJ = 1,000 J, MJ = 106 J, GJ = 109J.
2. GJ is used in the context of energy cost as commercial and industrial gas
tariffs are typically priced per GJ.
3. Sometimes, kWh (kilowatthours) is used as the energy unit for gas,
particularly in the case of small commercial and domestic tariffs.
1 kWh = 3.6 MJ.

Mass:
Kilogram - kg

STEAM EFFICIENCY GUIDE FOR ENERGY MANAGERS page 37