training steam system optimization (sso) experts...

UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION

of 39 © UNIDO 2012, All rights reserved 1

Training Steam System Optimization (SSO) Experts Workshop

Training Expert / Trainer Location Comments

Day 1 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



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



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




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


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



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



A general guide for shell losses based on

industrial data from plants

Sample calculation of shell loss

5 minutes 58-61



Determination of Blowdown Losses &

boiler versus system level

implications



Participants input blowdown


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



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





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


model

Explanation of condensate tank vent heat

exchanger

Explanation of boiler blowdown heat

exchanger

Modeling feedwater heat exchangers in

SSAT

10 minutes 12-15



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: 15:45 Section 5: Combined Heat & Power (Cogeneration)





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



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


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



Participants should be able to

save the 3-header SSAT model

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



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


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


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



Stack Losses (Temperature

Component)

Participants questions on

common applications in the

field

Participants manually calculate

economic impact of heat

recovery equipment in a boiler


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



boiler efficiency improvement

30 minutes 25-44

Stack Losses (Combustion

Component)


oxygen (or excess air) limits and

BestPractices


economic impact of improving

combustion control in a boiler


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



of the cases investigated for the

example system

and/or adding combustion control

equipment



boiler efficiency improvement for the

cases


Start Time: 10:45 Section 6 (Continued): Steam System Optimization - Generation

(5_6 SSO Experts Training Generation.ppt) 30 minutes


Fuel Switching & Boiler Operation

Optimization


different fuels


economic impact of fuel

switching


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


header model and evaluate economic

impact of fuel switching

25 minutes 68-81



BestPractices & Optimization

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



Start Time: 11:15 Section 7: Steam System Optimization - Distribution

(SSO 2 Day Training SSAT Section7.ppt) 105 minutes


Steam Leaks Management Program

Participants questions related to

how they deal with steam leaks

in their industry


economic impact of steam leak


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


header model for evaluating economic

impact of steam leaks

20 minutes 1-12

Steam System Insulation


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



Evaluation of Energy Loss due to

missing (or damaged) insulation


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


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


Opportunities in the Distribution area Information Only

Summary of Distribution area

BestPractices 5 minutes 35


Start Time: 14:00 Section 8: Steam System Optimization – Steam Demand (End Use)

(5_8 SSO Experts Training EndUse.ppt) 35 minutes




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)


different kinds of end-uses of

steam in their industry


economic impact of steam

savings in an end-use example


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


steam demand savings in example system

25 minutes 6-16


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




Steam Traps


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


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


economic impact of recovering

condensate


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



condensate recovery impact

analysis



condensate recovery in example system

Flash Steam Recovery


implement Projects 14 and 15 in

the SSAT 3-header model for

flash steam recovery impact

analysis




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


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


Start Time: 16:00

Section 10: Steam System Optimization - Combined Heat & Power (CHP) or

Cogeneration

(5_10 SSO Experts Training Cogeneration.ppt)

60 minutes


Backpressure Turbine – PRV

Operations


applications of turbines

Understanding benefits of industrial

cogeneration and the impact parameters

required for an economic analysis

10 minutes 1-5



Backpressure Turbine – PRV example


impact of operating a steam

turbine versus letting steam

down through a PRV


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



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


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



Condensing Turbine example




modifying condensing steam

turbine operations for impact

analysis



condensing turbine operation

Understand the impact of condenser

pressure on operations and economics

10 minutes 40-49


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


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




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


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


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



Industrial Steam System Energy

Assessment – System Information

Participants questions on the

information provided about the


Information only 25 minutes 44-62


Assessment – Student Exercise

Questions Review

Participants questions on what

needs to be evaluated in the


Information only 15 minutes 63-73


Start Time: 10:45 Industrial Steam System Energy Assessment (Continued)





Participants questions on what

needs to be evaluated in the


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)

-




Start Time: 14:00 Industrial Steam System Energy Assessment (Continued)





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



Start Time: 15:00 Industrial Steam System Energy Assessment Report



Elements of an industrial steam

system assessment report


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



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


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


Understanding how process heat

exchangers using steam work and their

control strategy

15 minutes 140-145



Fouling in heat exchangers and their

impact on steam usage

Thermocompressors Participants questions on


Principle of thermocompressor operations

Applications of thermocompressors 10 minutes 146-149

Absorption Chillers Participants questions on


Special case of thermocompressor

Understanding principle and operations of

absorption chillers

5 minutes 150-151


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


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



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


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



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



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




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


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




Plant Walk-through


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: 13:30 HOST PLANT – GENERATION AREA (Measurements & Data Collection) 120 minutes


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



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


Distribution Area






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





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



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


End-Use Area






end-use equipment

Participants investigate end-

uses of steam, controls, etc.

Participants talk to production

personnel and understand


Visit all the major end-use areas of steam

that were identified during the preliminary

walk-through for additional investigation





instruments, as required, in the end-use

areas

Understand the production needs & steam

demands of the plant

90 minutes



Start Time: 10:30 HOST PLANT – CONDENSATE RECOVERY AREA (Measurements & Data

Collection) 60 minutes


Condensate Recovery Area


data using portable instruments

(as necessary)


condensate recovery equipment

Participants investigate areas of

condensate recovery

Participants talk to maintenance



Visit all the major condensate recovery

areas that were identified during the

preliminary walk-through for additional

investigation


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


Combined Heat and Power

(Cogeneration) Area






CHP equipment

Visit all the major CHP areas that were

identified during the preliminary walk-

through for additional investigation




60 minutes



Participants investigate control

methodologies, operations, etc.

Participants talk to plant




instruments, as required, in the CHP area

Understand the design, generation needs

& steam requirements of the plant


Start Time: 13:30 HOST PLANT Steam System Analysis – Conference Room ON SITE 150 minutes


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



and the quantified potentials

from the projects


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


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




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



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


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: 10:15 SSO Experts – Questions & Interesting Topics of Discussion for the benefit of

all the Participants 90 minutes


Based on Participants Requests Participant questions Specific Topics requested by Participants

Examples from Candidate Plants 90 minutes




Start Time: 12:45 SSO Experts Exam Introduction 15 minutes


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


SSO Experts Exam Passing score = 70 points Answering practical questions from steam

system assessments 240 minutes


training steam system optimization (sso) experts...

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