training steam system optimization (sso) experts...
TRANSCRIPT
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION
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Training Steam System Optimization (SSO) Experts Workshop
Training Expert / Trainer Location Comments
Day 1 Advanced Training room
Day 2 Advanced Training room
Day 3 Advanced Training room
Day 4 Advanced Onsite (Industrial Plant)
Day 5 Advanced Onsite (Industrial Plant)
6 Months Advanced Virtual (Emails, Webinar,
Skype, Phone, etc.)
This is one-on-one SSO training which is very
detailed and will involve candidate plant
assessment by each participant. It will
require the Participant to work closely with
the Instructor via emails, webinar, skype,
etc. to undergo a continuous learning
process as the Participant develops all the
onsite assessment skills and evaluates the
energy savings opportunities for the steam
system.
Final Day Advanced Training room ½ day overview + ½ day Exam
Target Group: National energy efficiency experts and industry engineers
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION
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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 o Immediate and strategic benefits of undertaking industrial steam system assessments o Ability to apply a SSO methodology in an industrial facility o Working understanding of all elements of an SSO methodology including: Planning; Implementation; Checking Performance; and Review o Working understanding of resource requirements and costs involved in the SSO implementation in industry o Experience in the practical implementation of SSO including use of BestPractices tools and resources o Working and hands-on knowledge of field data, measurement and verification of potential benefits, project complexities, technological barriers
and operational risks that may exist in industry o Benefits of doing detailed due-diligence on projects to be implemented from the results of the industrial steam system assessments o Working with a vendor and/or service provider (such as an engineering company) to design, specify and procure state-of-the-art equipment that
may be required for the SSO project implementation o Create a case-study level report that summarizes the success of the SSO project and which can be disseminated industry-wide as a testimonial
or success story for replication in similar or other applications o Ability to and experience in reviewing an existing SSO system, verifying and reporting on its energy performance
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Title: Day One of SSO Experts Training Workshop
o
Start Time: 08:30 Section 1: Fundamentals
(5_1 SSO Experts Training Fundamentals.ppt) 120 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
Introduction of attendees and
Outline of course Not applicable Understand participant backgrounds 30 minutes 1-31
Review of the UNIDO Industrial
Energy Efficiency Project Not applicable Information only 20 minutes
Introduction to System Approach and
Steam System Optimization Participants questions
Understanding of Systems Approach with
an example; Benefits of SSO 20 minutes 32-46
Steam System Fundamentals
Participants questions or
discussions on steam system
thermodynamics and steam
system components
Participants are able to solve
mass and energy balance
problems
Thermodynamics of steam
Steam system components
Law of Conservation of Mass
First Law of Thermodynamics
Application of these principles in steam
system evaluations
50 minutes 47-100
Start Time: 10:30 Tea / Coffee Break 15 minutes
Start Time: 10:45 Section 2: Steam System Scoping Tool
(5_2 SSO Experts Training SSST.ppt) 60 minutes
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Content Means of Evaluation Learning Activities Duration Slide #’s
Common BestPractices Participants questions List of possible BestPractices
(Opportunities) in steam systems 15 minutes 1-6
Steam System Scoping Tool Participants questions Demonstration of the SSST Excel version 15 minutes 7-20
Student exercise - Evaluation of an
industrial plant steam system
Effective use of software Tool;
Questions from students on
applicable BestPractices
Hands-on use of SSST in an industrial plant
assessment to identify potential
opportunity areas
30 minutes 21-34
Start Time: 11:45 Section 3: Steam System Assessment Tool – Part 1
(5_3 SSO Experts Training SSAT.ppt) 75 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
Review of the Steam System
Assessment Tool (SSAT)
Students start SSAT and make
input changes to a 3-header
model
Overview of SSAT
Gaining familiarity with the different
header model templates of SSAT
10 minutes 1-11
Understanding Electric Rate Structure
Calculation of electrical cost
given demand and energy
charge
Understanding impact electrical cost
Calculating it from utility information 5 minutes 12-20
Understanding Fuels & Costs
Questions related to fuels that
participants maybe using
Calculation of operating fuel
cost for a boiler
Understanding different kinds of fuels,
their heating values (HHV & LHV) and costs
Understanding impact fuel cost based on
multi-fuel use at a plant
15 minutes 21-35
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Completing an example to determine fuel
operating cost and steam cost indicator
Understanding Process steam
demands and end use
Participants input process end-
use data in the 3-header model
Definition of end-use of steam in SSAT
Calculation and techniques to determine
steam flow to end-use demand
5 minutes 36-39
Overview of how steam traps and
steam leaks are handled in the model
as compared to real systems
Participants input steam trap
information in the 3-header
model
Understanding of steam traps and their
impact in the SSAT model and in real
steam systems
Calculation of steam trap loss and steam
leaks in SSAT
5 minutes 40-45
Steam generation (or Boiler)
Efficiency – Direct method
Questions from participants on
observations from the field
Participants input boiler
efficiency in the 3-header model
Methodologies and definitions of steam
generation efficiency
How to calculate direct boiler efficiency in
the field
Understanding losses in a boiler and doing
an energy balance on the boiler to
determine efficiency
10 minutes 46-57
Understanding Shell Losses & their
magnitudes
Questions from participants on
observations from the field
A general guide for shell losses based on
industrial data from plants
Sample calculation of shell loss
5 minutes 58-61
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Determination of Blowdown Losses &
boiler versus system level
implications
Questions from participants on
observations from the field
Participants input blowdown
information in the 3-header
model
Understand blowdown and its need
Sample calculation of blowdown rate and
energy loss associated w/blowdown
Understand impact of blowdown energy
loss on boiler and system
5 minutes 62-72
Stack Losses
Questions from participants on
observations from the field
Participants estimate stack loss
from SSAT and/or chart
Understand stack loss and the main
parameters to calculate it
Sample calculation of stack loss
5 minutes 73-79
Steam generation (or Boiler)
Efficiency – Indirect method
Participants estimate steam
generation efficiency
General discussions
Calculate boiler efficiency using the
indirect method for example boiler
Defining boiler efficiency to be used in
SSAT model
Understanding Loss on Ignition
(Miscellaneous losses) for fuels
5 minutes 80-86
Marginal steam cost
Participants execute a 1-header
SSAT model and determine
marginal cost of steam
Defining marginal cost of steam
Demonstrating calculation of marginal
steam cost in SSAT
5 minutes 87-92
Start Time: 13:00 Lunch Break 60 minutes
Start Time: 14:00 Section 4: Steam System Assessment Tool – Part 2
(5_4 SSO Experts Training SSAT.ppt) 90 minutes
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Content Means of Evaluation Learning Activities Duration Slide #’s
Blowdown & Flash Steam Participants input blowdown
info in the 3-header model
Understanding blowdown modeling in
SSAT and how energy recovery is done 10 minutes 1-4
Steam Generation Conditions
Participants input steam
generation conditions in the 3-
header model
Understanding different modes of steam
generation – superheated, saturated (dry)
and saturated (wet)
Modeling generation conditions
appropriately in SSAT
5 minutes 5-6
Letdowns / PRVs
Participants input Letdown /
PRV conditions in the 3-header
model
Understanding operations of Letdown
stations / PRVs in plants
Modeling desuperheating configurations
with Letdowns / PRVs in SSAT
5 minutes 7-8
Deaerator
Participants input Deaerator
conditions in the 3-header
model
Explanation of deaerator, functionality and
its impact on steam system
Modeling deaerator in SSAT
10 minutes 9-11
Heat Recovery Components
Participants input Heat
Recovery Component
information in the 3-header
model
Explanation of condensate tank vent heat
exchanger
Explanation of boiler blowdown heat
exchanger
Modeling feedwater heat exchangers in
SSAT
10 minutes 12-15
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Condensate Recovery
Participants input Condensate
Recovery information in the 3-
header model
Explanation of condensate & flash tanks
Modeling condensate return and flash
tanks in SSAT
15 minutes 16-18
Distribution Losses
Participants input Distribution
Loss modeling information in
the 3-header model
Calculation of steam trap losses in SSAT
and methodologies
Calculation of steam leaks in SSAT and
methodologies
Calculation of insulation losses in SSAT and
methodologies
20 minutes 19-24
3-Header SSAT Model of the Example
Steam System
Participants check the steam
system model for consistency
and accuracy
Participants use the model to
calculate marginal steam costs
Review the full 3-header SSAT Steam
system model including all the worksheets
Determine marginal cost of steam at each
header level and compare with 1-header
model
Saving and storing models
15 minutes 25-31
Start Time: 15:30 Tea / Coffee Break 15 minutes
Start Time: 15:45 Section 5: Combined Heat & Power (Cogeneration)
(5_5 SSO Experts Training SSAT.ppt) 105 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
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Fundamentals of Turbines
Possible questions on
applications of different
turbines from Participants
Understanding applications of steam
turbines in industry for power generation
and for driving mechanical equipment
Understanding different kinds of steam
turbines – backpressure, extraction and
condensing
15 minutes 1-11
Steam Turbine Efficiency
Possible questions from
Participants on obtaining field
information to calculate turbine
efficiency
Definition of a perfect turbine
Definition of isentropic steam turbine
efficiency and understanding of all the
terms in the equation
Graphical explanation of turbine efficiency
and operations on a Mollier Diagram
20 minutes 7-19
Backpressure Turbines
Participants follow methodology
of calculations and ask
questions
Participants do steam turbine
efficiency calculations for
example turbines in the system
Understanding single and multistage
turbines
Example calculation of backpressure steam
turbine efficiency using superheated inlet
and outlet conditions (Method 2)
Example calculation of backpressure steam
turbine efficiency using power generated,
mass flow of steam and inlet conditions
(Method 3)
Performance characteristics of
backpressure steam turbines
25 minutes 20-36
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Modeling Backpressure Turbines
Participants input steam turbine
modeling information in the 3-
header model
Possible questions from
Participants on different modes
of operation
Participants complete an impact
level analysis of saving 1 Tph of
high pressure and low pressure
steam in the example system
Understanding of inputs required to model
backpressure steam turbines in a 3-header
SSAT model
Understanding different modes of steam
turbine operation in the field and how it
can be realistically modeled in SSAT
Learn the methodology to take a 3-header
SSAT model of an example system and
conduct impact level analysis of saving
steam at different header levels
Repeat the above analysis with different
parametric configurations as described in
the presentation
25 minutes 37-57
Modeling Condensing Turbines
Participants input condensing
steam turbine modeling
information in the 3-header
model
Understanding of inputs required to model
condensing steam turbines in a 3-header
SSAT model
10 minutes 58-65
3-Header SSAT Model of the Example
Steam System
All Participants should have
completed all the inputs into
the 3-header SSAT model
Participants should have
identical answers for impact
cost analysis of saving 1 Tph of
steam
Building a full model for a steam system to
do a system-level analysis in SSAT
Understanding that the model has the full
ability to do accurate economic analysis
Saving the model for retrieval later
10 minutes 66
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Participants should be able to
save the 3-header SSAT model
End Time: 17:30 Adjourn (End of Day 1)
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Title: Day Two of SSO Experts Training Workshop
Start Time: 08:30 Section 6: Steam System Optimization - Generation
(5_6 SSO Experts Training Generation.ppt) 120 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
Boiler Efficiency Improvement Participants questions on any of
the losses in the boiler
Quick review of boiler losses and indirect
efficiency calculation
Understanding of Shell Losses
Action items to monitor and minimize shell
losses
10 minutes 1-6
Blowdown Management
Participants correctly
implement Project 4 on
Blowdown control in the SSAT 3-
header model
Overview of different methodologies used
in water treatment in steam systems
Principles of blowdown management and
boiler blowdown control
Complete Project 4 in SSAT 3-header
model and evaluate economic impact of
reducing blowdown
20 minutes 7-16
Blowdown Energy Recovery
Participants correctly
implement Project 5 and 12 on
Blowdown Energy Recovery in
the SSAT 3-header model
Blowdown Energy Recovery Components
Complete Projects 5 and 12 in SSAT 3-
header model and evaluate economic
impact of blowdown energy recovery
components
30 minutes 17-24
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Stack Losses (Temperature
Component)
Participants questions on
common applications in the
field
Participants manually calculate
economic impact of heat
recovery equipment in a boiler
Participants correctly
implement Project 3 on Boiler
Efficiency Improvement in the
SSAT 3-header model
Review of energy recovery components:
Feedwater Economizers; Combustion
AirPreheaters; and Condensing
Economizers
Factors influencing higher stack energy
loss (Temperature component)
Complete manual calculations and
evaluate economic impact of improving
boiler efficiency by adding (or modifying)
heat recovery equipment
Complete Project 3 in SSAT 3-header
model and evaluate economic impact of
boiler efficiency improvement
30 minutes 25-44
Stack Losses (Combustion
Component)
Participants questions on
oxygen (or excess air) limits and
BestPractices
Participants manually calculate
economic impact of improving
combustion control in a boiler
Participants correctly
implement Project 3 on Boiler
Efficiency Improvement in the
SSAT 3-header model for each
Review of Combustion Management
Principles & Strategy
Understanding positioning control and
automatic oxygen trim control – their
operational limits available equipment
Factors influencing higher stack energy
loss (Temperature component)
Complete manual calculations and
evaluate economic impact of improving
boiler efficiency by tune up (modifying)
30 minutes 45-67
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of the cases investigated for the
example system
and/or adding combustion control
equipment
Complete Project 3 in SSAT 3-header
model and evaluate economic impact of
boiler efficiency improvement for the
cases
Start Time: 10:30 Tea / Coffee Break 15 minutes
Start Time: 10:45 Section 6 (Continued): Steam System Optimization - Generation
(5_6 SSO Experts Training Generation.ppt) 30 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
Fuel Switching & Boiler Operation
Optimization
Participants questions on
different fuels
Participants manually calculate
economic impact of fuel
switching
Participants correctly
implement Projects 2 and 3 on
in the SSAT 3-header model for
modeling fuel switching
scenarios in the example system
Understand the concept of fuel switching
and how and when it can be applied to a
industrial steam system
Different configurations of optimizing a
boiler plant operation
Complete manual calculations of fuel
switching in the example steam system
and evaluate economic impacts
Complete Projects 2 and 3 in SSAT 3-
header model and evaluate economic
impact of fuel switching
25 minutes 68-81
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BestPractices & Optimization
Opportunities in the Generation area Information Only Summary of Generation area BestPractices 5 minutes 82
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Start Time: 11:15 Section 7: Steam System Optimization - Distribution
(SSO 2 Day Training SSAT Section7.ppt) 105 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
Steam Leaks Management Program
Participants questions related to
how they deal with steam leaks
in their industry
Participants manually calculate
economic impact of steam leak
Participants correctly
implement Projects 1 and 17 in
the SSAT 3-header model for
impact analysis of a steam leak
management program
Most common areas for steam leaks
Methods and equipment used to
determine a magnitude of steam leak
Complete a manual calculation of
determining the impact of a steam leak
Complete Projects 1 and 17 in SSAT 3-
header model for evaluating economic
impact of steam leaks
20 minutes 1-12
Steam System Insulation
Participants questions related to
steam system insulation and
experiences in their industry
Understanding the importance of steam
system insulation
Main reasons for missing or damaged
insulation
Data and equipment needed to determine
impact of insulation energy loss
10 minutes 13-15
3E Plus Insulation Evaluation
Software
Participants open the 3EPLus
software and go to Energy tab
Demonstration of functionality of 3E Plus
software and its capabilities as needed 20 minutes 16-17
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Evaluation of Energy Loss due to
missing (or damaged) insulation
Participants manually calculate
economic impact of missing
steam system insulation in the
example system
Participants correctly use 3E
Plus information with Project 1
in the SSAT 3-header model for
impact analysis
Using 3E Plus to determine the heat
energy loss from missing insulation in the
system
Calculation of equivalent energy cost
savings for the addition of insulation
Determining equivalent steam demand
corresponding to the insulation energy
loss and using marginal cost of steam for
cost impact
Complete Project 1 in SSAT 3-header
model for evaluating economic impact of
adding insulation to the uninsulated piping
40 minutes 18-29
Insulation issues and implications in
cogeneration systems Information Only
Common insulation issues in industrial
steam plants
How to handle cost impacts of insulation
energy savings in cogeneration systems
10 minutes 30-34
BestPractices & Optimization
Opportunities in the Distribution area Information Only
Summary of Distribution area
BestPractices 5 minutes 35
Start Time: 13:00 Lunch Break 60 minutes
Start Time: 14:00 Section 8: Steam System Optimization – Steam Demand (End Use)
(5_8 SSO Experts Training EndUse.ppt) 35 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
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Steam Generation Conditions
Participants understanding that
steam can be generated at
different conditions
Understanding the impact of superheated,
saturated and wet steam on system
operations
Using Project 6 in SSAT 3-header model for
evaluating economic impact of changing
steam generation conditions
5 minutes 1-5
Steam Demand (End-Use)
Participants questions related to
different kinds of end-uses of
steam in their industry
Participants manually calculate
economic impact of steam
savings in an end-use example
Participants correctly
implement Project 1 in the SSAT
3-header model for impact
analysis of a steam savings in an
end-use example
Understanding optimization opportunities
and methodologies to reduce steam
demand in end-uses
Brief overview of different types of steam
end-uses in industry
Complete a manual calculation of
determining the impact of steam demand
savings in an end-use
Complete Project 1 in the SSAT 3-header
model for evaluating economic impact of
steam demand savings in example system
25 minutes 6-16
BestPractices & Optimization
Opportunities in the End-Use area Information Only Summary of End-Use area BestPractices 5 minutes 17
Start Time: 14:35 Section 9: Steam System Optimization – Steam Demand (End Use)
(5_9 SSO Experts Training Recovery.ppt) 70 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
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Steam Traps
Participants questions related to
different kinds of steam traps in
their industry
Understanding different kinds of steam
traps and their principles of operation
Observing steam traps in the field
15 minutes 1-12
Steam Trap performance
investigation and Management
program
Participants questions related to
different kinds of equipment,
methods to test performance of
steam traps in the field
Participants can share their
experiences with steam trap
management programs in their
industry
Review of all the steam trap performance
investigation procedures that should be
followed
Review of equipment that can be used for
steam traps performance investigation
Understanding the elements of a steam
trap management program that should be
implemented in industry
10 minutes 13-20
Energy and Cost Impact evaluations
of Steam Traps
Participants correctly compute
the impact of implementing a
steam trap management
program
Understand the 3 methods for calculating
the impact of implementing a steam trap
management program using the 3-header
SSAT model and projects 1 or 16
10 minutes 21-25
Condensate Recovery Information only Understand the importance of condensate
recovery and the influencing parameters 5 minutes 26-28
Condensate Recovery Example
Participants manually calculate
economic impact of recovering
condensate
Participants correctly
implement Project 13 in the
SSAT 3-header model for
Methods of collecting field data required
for impact analysis
Complete a manual calculation for impact
of condensate recovery on system
15 minutes 29-37
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condensate recovery impact
analysis
Complete Project 13 in the SSAT 3-header
model for evaluating economic impact of
condensate recovery in example system
Flash Steam Recovery
Participants correctly
implement Projects 14 and 15 in
the SSAT 3-header model for
flash steam recovery impact
analysis
Participants correctly
implement Project 11 in the
SSAT 3-header model for
condensate tank vent heat
exchanger impact analysis
Complete Projects 14 and 15 in the SSAT 3-
header model for evaluating economic
impact of flash steam recovery
Understanding of condensate tank vent
heat exchanger and execution of Project
11 in SSAT 3-header model for impact
analysis
10 minutes 38-40
BestPractices & Optimization
Opportunities in the Recovery area Information Only Summary of Recovery area BestPractices 5 minutes 42-43
Start Time: 15:45 Tea / Coffee Break 15 minutes
Start Time: 16:00
Section 10: Steam System Optimization - Combined Heat & Power (CHP) or
Cogeneration
(5_10 SSO Experts Training Cogeneration.ppt)
60 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
Backpressure Turbine – PRV
Operations
Participants questions on
applications of turbines
Understanding benefits of industrial
cogeneration and the impact parameters
required for an economic analysis
10 minutes 1-5
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Backpressure Turbine – PRV example
Participants manually calculate
impact of operating a steam
turbine versus letting steam
down through a PRV
Participants correctly
implement Project 7 in the SSAT
3-header model for steam
turbine – PRV operations impact
analysis
Calculating economic benefit of electrical
energy savings by operating a turbine
Calculating incremental energy (fuel) cost
required to produce additional steam for
the steam turbine
Complete Project 7 in the SSAT 3-header
model for evaluating economic impact of
backpressure turbine – PRV operations
Undertake similar analysis with Projects 8
and 9 in the SSAT 3-header model
20 minutes 6-24
Parametric analysis for Backpressure
Turbines – PRV operations
Participants follow methodology
of calculations and ask
questions
Participants correctly input
information in the SSAT 3-
header to do parametric
analysis
Understanding implications of each of the
impact parameters on the net economic
impact and to answer the classic
cogeneration questions by using the SSAT
3-header model for the example system
10 minutes 25-34
Condensing Turbines
Participants questions on
applications of condensing
turbines
Understanding benefits of condensing
turbines, their specific applications and the
impact parameters required for an
economic analysis
5 minutes 35-39
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Condensing Turbine example
Participants correctly
implement Project 10 in the
SSAT 3-header model for
modifying condensing steam
turbine operations for impact
analysis
Complete Project 10 in the SSAT 3-header
model for evaluating economic impact of
condensing turbine operation
Understand the impact of condenser
pressure on operations and economics
10 minutes 40-49
BestPractices & Optimization
Opportunities in Cogeneration Information Only
Summary of Cogeneration area
BestPractices 5 minutes 50
Start Time: 17:00 Section 11: Steam System Optimization - Conclusions
(5_11 SSO Experts Training Conclusions.ppt) 20 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
Conclusions Information and Review only
Summary of “Key Points & Action
Items” covered in the 2-Day SSO User
course
15 minutes 1-19
Tools & Resources Information and Review only
References for additional tools and
resources for Steam System
Optimization in industrial plants
5 minutes 20-30
Start Time: 17:20 Course Evaluation & Feedback 10 minutes
End Time: 17:30 Adjourn (End of Day 2)
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Title: Day Three of SSO Experts Training Workshop
Start Time: 08:30 Training Objectives & Review
(5_12 SSO Experts Training Day 3.ppt) 60 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
Training Objectives Information only
Provide information on the Experts
Training Objectives, Time line and
Deliverables
15 minutes 1-9
Review of 2-Day User Training
Participants questions on key
points, action items and
BestPractices
Overview of key points and action items of
each area in the steam system
Overview of the BestPractices in
Generation, Distribution, End-Use,
Recovery & Combined Heat and Power
45 minutes 10-35
Start Time: 09:30 Industrial Steam System Energy Assessment
(SSO Experts Training Day 3.ppt) 60 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
Steam System Energy Assessment
Standard Participants questions
Understanding the basic principles and
elements of an industrial steam system
assessment
Overview of the elements of the ASME
Steam System Energy Assessment
Standard ASME– EA-3-2009
20 minutes 36-43
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Industrial Steam System Energy
Assessment – System Information
Participants questions on the
information provided about the
industrial steam system
Information only 25 minutes 44-62
Industrial Steam System Energy
Assessment – Student Exercise
Questions Review
Participants questions on what
needs to be evaluated in the
industrial steam system
Information only 15 minutes 63-73
Start Time: 10:30 Tea / Coffee Break 15 minutes
Start Time: 10:45 Industrial Steam System Energy Assessment (Continued)
(5_12 SSO Experts Training Day 3.ppt) 135 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
Industrial Steam System Energy
Assessment – Student Exercise
Participants questions on what
needs to be evaluated in the
industrial steam system
Ability of Participants to
manually calculate economic
impact of different projects in
the student exercise
Participants correctly build the
3-header steam system model
in SSAT and implement Projects
for modeling scenarios and
determining economic impacts
in the example system
This is a hands-on exercise and
Participants will do several fundamental
hand manual calculations to understand
basic thermodynamic concepts related to
steam systems
Participants will be building a complete
steam system model and do projects as
requested of them in the student exercise
Participants will be provided one-on-one
help with problems as they work through
the questions in the hands-on exercises
135 minutes
(This time is
for students
to work on
the hands-on
exercises)
-
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION
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Start Time: 13:00 Lunch Break 60 minutes
Start Time: 14:00 Industrial Steam System Energy Assessment (Continued)
(5_12 SSO Experts Training Day 3.ppt) 50 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
Industrial Steam System Energy
Assessment – Student Exercise
Review with final answers and
models
Participants have done all the
manual calculations correctly
and understood basic principles
Participants have built the 3-
header model in SSAT correctly
Participants have used SSST to
identify potential improvement
opportunities in the system
Participants have used the SSAT
model and the applicable
projects as required to
accurately calculate the
economic impact of projects
Participants have used 3EPlus
correctly to determine
insulation losses in the example
steam system
Complete fundamental analysis using
manual calculations that would be typical
in every steam system assessment
Complete exercise of a SSST section that
provides information on possible steam
system optimization opportunities
Build a 3-header SSAT model of the
example industrial steam system that can
accurately reflect impact analysis and
overall steam system balance
Complete projects in a 3-header SSAT
model to calculate the economic impact of
several typical projects for optimizing
steam system operations such as
blowdown heat recovery, steam end-use
opportunities, condensate recovery, steam
turbine opportunities, etc.
Use 3EPLus to model impact of insulation
energy savings in the steam system
50 minutes 74-124
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION
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Start Time: 15:00 Industrial Steam System Energy Assessment Report
(5_12 SSO Experts Training Day 3.ppt) 15 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
Elements of an industrial steam
system assessment report
Participants questions on
completing a report on an
industrial steam system energy
assessment
Overview of a typical steam system energy
assessment report
Understanding what information needs to
be presented to the customer (industry) in
a steam system energy assessment report
15 minutes 125-132
Start Time: 15:00 Common “Specific” Applications in Industry
(5_12 SSO Experts Training Day 3.ppt) 45 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
Extraction Turbines Participants questions on
possible field applications
Understanding extraction turbines and
how to model them accurately in SSAT
Understanding extraction condensing
turbines and how to model them
accurately in SSAT
10 minutes 133-137
Waste Heat Recovery Boilers Participants questions on
possible field applications
Understanding applications and forms of
waste heat boilers in industry and how to
model them accurately in SSAT
5 minutes 138-139
Heat Exchanger Applications Participants questions on
possible field applications
Understanding how process heat
exchangers using steam work and their
control strategy
15 minutes 140-145
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION
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Fouling in heat exchangers and their
impact on steam usage
Thermocompressors Participants questions on
possible field applications
Principle of thermocompressor operations
Applications of thermocompressors 10 minutes 146-149
Absorption Chillers Participants questions on
possible field applications
Special case of thermocompressor
Understanding principle and operations of
absorption chillers
5 minutes 150-151
Start Time: 15:45 Tea / Coffee Break 15 minutes
Start Time: 16:00
Case Studies (Select any 2 case studies based on possible HOST Plant
application and/or Participants interest)
(5_12 SSO Experts Training Day 3.ppt)
30 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
Case Study 1 Participants questions
Understanding background of the plant
where the SSO project was implemented
Understanding project done and the
economic impacts
15 minutes 153-211
Case Study 2 Participants questions
Understanding background of the plant
where the SSO project was implemented
Understanding project done and the
economic impacts
15 minutes 153-211
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION
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Start Time: 16:30
HOST Plant Information & Planning for Day 4 & 5 (To be prepared by
Instructor after having done preliminary host plant visit)
(5_12 SSO Experts Training Day 3.ppt)
20 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
Overview of steam system Information and Review only
Understand the steam system at the
HOST plant which will be visited on
Day 4 and 5
5 minutes
Steam System Scoping Tool Information and Review only
Information about possible
BestPractices already in place at the
HOST Plant
5 minutes
Potential Opportunities & Areas of
Interest Information and Review only
Information about possible areas of
investigation and potential
improvement opportunities to be
evaluated at the HOST Plant
5 minutes
Plan for Day 4 and 5 Information and Review only Logistics and Arrangements for the
HOST plant visit 5 minutes
Start Time: 16:50 Portable Instrumentation & Tools
(5_12 SSO Experts Training Day 3.ppt) 30 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
Portable Instrumentation Participants questions after handling
instrumentation
Demonstration of use and
functionality of portable instruments
to be used in a SSO energy
25 minutes 244
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Participants using instrumentation to
test simple things such as
temperatures, oxygen levels in the
room, etc.
assessment and at the HOST plant
and candidate plants (in the future)
Hands-on experience with portable
instruments such as: infra-red
camera, combustion analyzer,
thermometers, pitot tubes, etc.
Other Tools Information and Review only
References for additional tools and
resources for Steam System
Optimization in industrial plants
5 minutes 245-253
Start Time: 17:20 Course Evaluation & Feedback 10 minutes
End Time: 17:30 Adjourn (End of Day 3)
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION
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Title: Day Four of SSO Experts Training Workshop
It has to be noted that the information provided below is only a recommendation. It needs to be modified and adapted to appropriately fit the
HOST plant’s arrangements, schedules, etc. An effort is made here to account for all the activities that need to be conducted on Day 4 and 5
onsite at the Host plant but they may not necessarily happen in the same order and/or may require more or less time than indicated.
Start Time: 09:00 HOST PLANT - ONSITE 90 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
Welcome, Introductions & Safety
Training Information only
Understand the plant’s layout, production
information
Meet with the HOST plant team and
determine their objectives, issues, etc.
Complete safety training and PPE needs
60 minutes
Steam System Scoping Tool
Participants complete the SSST
by asking specific information
from the tool to plant personnel
Overview of the BestPractices in
Generation, Distribution, End-Use,
Recovery & Combined Heat and Power at
the HOST plant
Identification of possible target areas for
measurements and information
30 minutes
Start Time: 10:30 HOST PLANT – WALK THROUGH 120 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION
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Plant Walk-through
Participants questions on
different processes, equipment,
etc.
Participants observing critical
control parameters and taking
notes on the system
Understanding the basic operations of the
HOST plant
Walking the steam system beginning with
Generation (Boiler plant), Distribution,
Major end-uses, condensate recovery and
CHP (if any)
Capturing operating information and
understanding critical control paarmeters
for steam system operations
120 minutes
Start Time: 12:30 Lunch Break 60 minutes
Start Time: 13:30 HOST PLANT – GENERATION AREA (Measurements & Data Collection) 120 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
Generation Area
Participants correctly collect
data from field in-situ
instruments and using portable
instruments (as necessary)
Participant questions on the
equipment in the generation
area
Participants walk the generation
area and investigate fuel usage,
steam generation, metering
equipment, etc.
Understand and see all the generation
area equipment including boilers,
feedwater pumps, deaerators, condensate
tanks, fuel storage equipment, water
treatment, blowdown, etc.
Take measurements (instantaneous /
periodic) of all critical as well as “good-to-
have” from existing in-situ instrumentation
Take measurements with portable
instruments, as required
120 minutes
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Participants talk to boiler plant
operators and understand
operations and controls
Understand the control logic of operations
of one or multiple boilers
Start Time: 15:00 HOST PLANT – DISTRIBUTION AREA (Measurements & Data Collection) 90 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
Distribution Area
Participants correctly collect
data from field in-situ
instruments and using portable
instruments (as necessary)
Participant questions on the
equipment in the distribution
area
Participants walk the main
steam headers from the boiler
plant to major end-users
Participants talk to plant and
maintenance personnel to
understand distribution system
Walk and visit all the distribution areas
that were identified during the preliminary
walk-through for additional investigation
Take measurements (instantaneous /
periodic) of all critical as well as “good-to-
have” from existing in-situ instrumentation
Take measurements with portable
instruments, as required, in the
distribution area for insulation energy
savings, steam leaks, etc.
Understand the maintenance practices
followed by plant personnel
90 minutes
Start Time: 16:30 End of Day Wrap-Up Meeting at HOST Plant 30 minutes
End of Day Wrap-Up Meeting Information and Review only Summarize the activities and findings of
the day to Plant Lead 30 minutes
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION
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Develop a list of agenda items for the next
day and plant personnel required
End Time: 17:00 Adjourn
Title: Day Five of SSO Experts Training Workshop
It has to be noted that the information provided below is only a recommendation. It needs to be modified and adapted to appropriately fit the
HOST plant’s arrangements, schedules, etc. An effort is made here to account for all the activities that need to be conducted on Day 4 and 5
onsite at the Host plant but they may not necessarily happen in the same order and/or may require more or less time than indicated.
Start Time: 09:00 HOST PLANT – END-USE AREA (Measurements & Data Collection) 90 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
End-Use Area
Participants correctly collect
data from field in-situ
instruments and using portable
instruments (as necessary)
Participant questions on the
end-use equipment
Participants investigate end-
uses of steam, controls, etc.
Participants talk to production
personnel and understand
operations and controls
Visit all the major end-use areas of steam
that were identified during the preliminary
walk-through for additional investigation
Take measurements (instantaneous /
periodic) of all critical as well as “good-to-
have” from existing in-situ instrumentation
Take measurements with portable
instruments, as required, in the end-use
areas
Understand the production needs & steam
demands of the plant
90 minutes
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION
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Start Time: 10:30 HOST PLANT – CONDENSATE RECOVERY AREA (Measurements & Data
Collection) 60 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
Condensate Recovery Area
Participants correctly collect
data using portable instruments
(as necessary)
Participant questions on the
condensate recovery equipment
Participants investigate areas of
condensate recovery
Participants talk to maintenance
personnel and understand
operations and controls
Visit all the major condensate recovery
areas that were identified during the
preliminary walk-through for additional
investigation
Take measurements with portable
instruments, as required, to determine
condensate loss from the sub-systems or
process areas
Understand the limitations and issues of
not returning condensate from certain
areas of the plant
60 minutes
Start Time: 11:30 HOST PLANT – COMBINED HEAT & POWER AREA (Measurements & Data
Collection) – This is optional and may not exist in several plants 60 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
Combined Heat and Power
(Cogeneration) Area
Participants correctly collect
data from field in-situ
instruments and using portable
instruments (as necessary)
Participant questions on the
CHP equipment
Visit all the major CHP areas that were
identified during the preliminary walk-
through for additional investigation
Take measurements (instantaneous /
periodic) of all critical as well as “good-to-
have” from existing in-situ instrumentation
60 minutes
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Participants investigate control
methodologies, operations, etc.
Participants talk to plant
personnel and understand
operations and controls
Take measurements with portable
instruments, as required, in the CHP area
Understand the design, generation needs
& steam requirements of the plant
Start Time: 12:30 Lunch Break 60 minutes
Start Time: 13:30 HOST PLANT Steam System Analysis – Conference Room ON SITE 150 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
Steam System Analysis
Participants correctly identify
critical and important data that
is collected from the field
Participants complete a simple
economic balance that closely
resembles plant’s usage
Participants accurately develop
a SSAT model that represents
the overall steam system
balance and impact costs
Participants correctly identify
projects that need to be
implemented and execute them
in the SSAT model of the plant
Participants help to summarize
all the identified opportunities
Consolidation and agreement of data
collected from in-situ as well as portable
instrumentation
Complete a basic economic balance on the
utilities – specifically fuel used for steam
generation
Complete a detailed SSAT 3-header (or
appropriate) model to accurately reflect
the overall steam balance and provide an
impact analysis (marginal cost of steam)
Consolidate a final list of potential
improvement opportunities that need to
be evaluated using the steam system
model
Complete preliminary analysis for each of
those identified opportunities using the
150 minutes
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION
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and the quantified potentials
from the projects
Participants questions on
opportunities and their
experiences in the field
SSAT model and quantify the economic
impact
Summarize all the above findings into a
simple report for presentation to plant
personnel in wrap-up meeting
Start Time: 16:00 HOST PLANT Wrap Up Meeting and Summary of Findings 60 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
Wrap Up Meeting Information only
Thanking the management and plant
personnel of the HOST plant
Provide information on the activities done
during the 2-days at the HOST plant
15 minutes
Summary of Findings to Management
& Plant personnel
Participants present potential
opportunities that they feel
comfortable with
Present a summary of potential
improvement opportunities (powerpoint
presentation format or a verbal discussion
with information on flipchart)
Respond to plant personnel’s questions on
the opportunities as regards feasibility,
reliability of operations, etc.
Identify next steps (final report)
45 minutes
End Time: 17:00 Adjourn
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION
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Title: Six Months of SSO Experts Training
This part of the training is the most difficult to define but it does need to meet certain goals outlined below. The Expert Candidate has to do the
following deliverables in the slated six months.
Identify a candidate plant that meets the criteria of an UNIDO SSO Project Candidate Plant
Connect with the Plant Lead and determine a schedule of completing all the steps necessary for a SSO energy assessment
Complete preliminary site visit or data collection using the Steam System Scoping Tool (SSST)
Connect with international expert to confirm preliminary findings and possibly generating a list of potential improvement opportunities that
need to be investigated during the SSO energy assessment
Connect with the organizing in-country agency (NCPC for South Africa) to check-out the SSO portable instruments and tools required for the
onsite SSO energy assessment
Complete the steam system energy assessment at the Candidate plant – 2 or 3 days based on plant size, complexity, etc.
Complete Steam System Assessment Tool (SSAT) for the Candidate plant and model the steam system for overall steam balance and impact
analysis
Connect with international expert to confirm that the steam system is accurately modeled in SSAT and confirm the potential improvement
opportunities that will be quantified for the final report
Complete individual project analysis using the SSAT model for the Candidate plant
Develop a final report / presentation for the SSO energy assessment at the Candidate plant
Connect with international expert to review the final report and quantified opportunities identified during the SSO energy assessment
Submit final report to plant for review and comments
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION
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Title: Final Day of SSO Experts Training Workshop
Start Time: 08:30 SSO Experts Training Overview
(Using slides from the Experts SSO Training – Instructor to pick and choose) 90 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
Key Points & Action Items Information Only
Review all the key points and action items
for each of the steam system areas
Identify BestPractices and potential
improvement opportunities in each of the
steam system areas
30 minutes
SSO energy assessment tools and
resources Information Only
Review SSST
Review SSAT
Review 3EPlus
Review list of other resources and tools
60 minutes
Start Time: 10:00 Tea / Coffee Break 15 minutes
Start Time: 10:15 SSO Experts – Questions & Interesting Topics of Discussion for the benefit of
all the Participants 90 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
Based on Participants Requests Participant questions Specific Topics requested by Participants
Examples from Candidate Plants 90 minutes
Start Time: 11:45 Lunch Break 60 minutes
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION
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Start Time: 12:45 SSO Experts Exam Introduction 15 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
SSO Experts Exam Introduction Information only
Participants see the full examination
booklet and Instructor walks them through
it and answers any high-level questions
15 minutes
Start Time: 13:00 SSO Experts Exam 240 minutes
Content Means of Evaluation Learning Activities Duration Slide #’s
SSO Experts Exam Passing score = 70 points Answering practical questions from steam
system assessments 240 minutes
End Time: 17:00 Adjourn