STEAM CHALLENGE: DEVELOPING A NEW DOE PROGRAM TO HELP INDUSTRY BE STEAM SMART

Transcription

1 STEAM CHALLENGE: DEVELOPING A NEW DOE PROGRAM TO HELP INDUSTRY BE STEAM SMART Ted Jones Program Manager Alliance to Save Energy Washington, DC Fred Hart Program Manager U.S. Department of Energy Washington, DC ABSTRACT Last year, the Alliance to Save Energy, the Department of Energy's Office of Industrial Technologies, and a cadre of private companies and associations fonned an innovative "Steam Partnership" with the goal of developing a new, DOE technical assistance program on steam efficiency. In 1997, the Steam Partnership began to define the appropriate activities, tools, and services of a public-private program on steam. Modeled after the successful Motor Challenge program and the newly launched Compressed Air Challenge program, "Steam Challenge" wili highlight the importance of steam system efficiency and provide information and technical assistance on technologies for today's industrial steam systems. This paper will introduce Steam Challenge, describe what has been accomplished over the last year, and describe the program's future goals and activities. BACKGROUND Last year the Alliance to Save Energy (Alliance) and the Department of Energy's Office of Industrial Technologies (DOE-OIT) fonned the Steam Partnership program. The purpose of this Steam Partnership was to determine the need for an industry-led, DOE program to highlight industrial steam system efficiency opportunities in steam generation, distribution, application, and condensate return systems as well as maintenance opportunities. The Steam Partnership was also interested in determining the best way to focus management attention on industrial steam system needs and opportunities and how to promote cost-effective, energy efficiency upgrades in these systems. For a number of reasons, many industrial companies have neglected their steam systems. As a result, too many boiler operators are not aware of steam efficiency opportunities and have not been trained to recognize them. In addition, plant managers often fail to recognize the importance of the boilerhouse or appreciate the steam system's role in the production process. Finally, operators and managers are rarely aware of steam costs. Like many forms of energy, steam costs are typically not assigned to individual processes or products; instead they are treated as fixed costs of production and assumed to be uncontrollable. Achieving a more efficient steam system is not just a "pie-in-the-sky" goal for industry companies. Like other energy efficiency opportunities, steam efficiency can result in significant energy, cost, and air emissions savings. The Alliance to Save Energy has estimated that efficiency gains of 30-to-40 percent represent a reasonable target for many plants. Such efficiency gains could result in large aggregate savings - - decreasing industrial energy consumption by close to 3 quads (3,000 trillion Btus), reducing energy costs by $6.3 billion, and preventing 60 million metric tons of emissions.! A renewed focus on steam system efficiency will likely have productivity and safety benefits that are far greater in value than those related to fuel savings. More efficient steam systems with better trained operators will mean safer and more productive industrial plants that can benefit the entire country. Over the last year, the Alliance and DOE-0rr have worked closely with both industrial users of steam and suppliers of energy efficient products to understand how best to develop a program that will accelerate the adoption of energy efficient products and practices in industrial steam systems and help move U.S. indusuy toward greater steam efficiency and competitiveness. Recommendations from these activities are being used to develop DOE-0rr's newest technical assistance program called Steam Challenge. Steam Challenge is expected to be officially launched by DOE later this year. 171

2 Key findings from the Steam Partnership activities including a Steam Partnership kick-off meeting in Washington, DC, steam efficiency conference presentations and workshops, and a steam efficiency focus group are discussed below. Alliance-DOE Kick-0tf Meeting On January 16, 1997, the Alliance and DOE OIT met with representatives from several key organizations to discuss the idea of launching a public-private initiative to promote the comprehensive upgrade of industrial steam. The meeting participants strongly supported the stearn initiative and made the following recommendations: Identify Information Needs. According to the meeting participants, the Steam Partnership should determine what types of steam efficiency information and services would be most value to industrial managers and steam plant operators, and would most likely garner the support of industrial decisionmakers. Over the next six months, the Alliance and DOE-0IT worked closely with industrial stearn users through focus groups, roundtable meetings, and conferences to obtain this information and to draft a prelirninajy program development plan based on the results. The main components of this program plan are presented later in this paper. Centralize Information. Many of the meeting participants have access to excellent steam information (e.g., case studies, product descriptions, bibliographies, fact sheets, diagnostic software, product and service provider lists, and education and training materials). The Steam Partnership should help make these resources available to industry by developing a steam efficiency information kit and a webpage. Develop Steam Tools. Several software tools are now available for individual steam technologies, such as steam traps, insulation, and boiler controls. The Partnership should investigate linking these software tools together and incorporating other steam "modules" (i.e., water treatment, boiler tune-up, common steam applications) in order to estimate comprehensive steam efficiency potential. By incorporating historical data, this steam software tool could also be used as a benchmarking tool for a particular steam system's performance vis-a-vis an industry average or best practice. Over the past year, DOE and the Alliance to Save Energy have learned that it is important for a public-private steam efficiency program to highlight how everyday plant decisions can affect the performance of an entire steam system. It is equally important for a steam program to effectively present the benefits and costs of those decisions in a simple, yet highly visible, manner. Our challenge has been to demonstrate the manifold benefits of steam system efficiency and to make the strongest case possible that steam efficiency projects are a good investment. ConferencesIWorkshopsfTrade Shows After the Steam Partnership kick-off meeting, the Alliance and DOE met with a number of organizations and sponsored steam-efficiency sessions at several major conferences, including the JETC, in order to present the steam system efficiency concept and gather input (see below). As a result of these activities, the Alliance and DOE-0IT have expanded their steam partnership to include approximately 60 partners, including trade associations and technical organizations, as well as private companies. January 16: Steam Partnership Kick-0tf Meeting, Washington, DC February 24-25: DOE-0IT EXPO., Crystal City, VA March 12: Presentation to Council of Industrial Boiler Owners Meeting on Stearn Challenge, Washington, DC March 25: Presentation to ClimateWise Steam Efficiency Workshop, Princeton, NJ April 22-23: Two Sessions at IETC'97 Conference, Houston, TX (Best attended conference session) July 9-10: Presentation at ACEEE Industrial Conference, Saratoga Springs, NY August 6-7: Presentation at Association of Energy Engineers Competitive Power Congress, Somerset, NJ October 8-9: The American Pulp & Paper Isnstitute (TAPPI) Annual Meeting, Nashville, TN October 10: Presentation at Utah Steam Technology Coalition, Salt Lake City, UT October 22-23: Presentation at Industrial Interactions Boiler Efficiency Seminar, Spotsylvania, VA December 10-11: Steam Challenge Focus Group, Cleveland, Ohio 172

3 The creation of a public-private steam efficiency program was strongly supported by every group we talked to. During these presentations and subsequent discussions several areas for further development were put forward including: demonstration of stearn efficiency projects and verification of actual savings, training of operators in energy efficiency, developing tools and resources to identify costeffective energy efficiency opportunities throughout the stearn system, and developing curriculum and training materials on efficiency. Before moving forward on these recommendations, each of these areas was described to a focus group of industrial boiler operators in order to better understand the potential value of each in a DOE-Alliance Steam Challenge program. Cleveland Focus Group The Alliance and DOE-0rr held the first in a series of stearn efficiency focus groups in Cleveland, Ohio, on December 10, Approximately twenty participants were selected to participate in the focus group, which consisted of a short questionnaire and a moderated, informal discussion. While the data from the Cleveland group are not statistically significant and therefore should not be used to draw definitive conclusions about the content of a steam program, they do provide some interesting insights. First, it was clear from the responses that this particular focus group viewed a public-private program on steam efficiency as a needed information resource. When the focus group was asked to rate the usefulness of several steam efficiency information products, two clearly rated the highest: case studies on steam efficiency and a checklist of steam system performance improvement opportunities by industry. This appears to be fairly basic information, and the kind of information that a company could apply to its own needs on an independent basis. Second, the focus group identified steam efficiency technology descriptions, steam efficiency checklists, and fact sheets as the most useful fonn of information. Furthennore, there were positive responses for the concept of a periodic steam efficiency newsletter. For the remaining options product information, a webpage, a toll-free hotline, or a toll-free fax line - responses ranged from very low to very high, with no strong trend one way or another. Third, the technical assistance option that generated the most enthusiasm was for a customized report documenting steam saving opportunities in their plant. Receiving slightly less support were the suggestions for exchanging information with peers, steam efficiency workshops and training, and a list of "certified" steam consultants. The least popular idea of this group was the computer program to diagnose problems and suggest remedies. Finally, the focus group participants were asked about the particular features a stearn efficiency program should have. The following characteristics received the greatest response: There would be access to technical experts to answer questions, It would provide customized, industryspecific, as well as standardized assistance, It would require reporting back some results to DOE-0IT, and It would publicly recognize the individual/company as a leader in steam efficiency. In the moderated discussion portion of the focus group, the main topic was capital. The implication was that financing and other economic issues should be addressed if industrial managers are going to pay attention to a stearn program, and if operators are going to treat it as a useful source of infonnation. The participants also emphasized the need for financial and other incentives for companies to improve stearn system efficiency. "How do we get emission reduction credits for doing this?" said one participant. "We're competing for funds for our primary business, which is producing chemicals, not steam," said another participant, who stressed the need for financial incentives. Several participants bemoaned the difficulty in prying loose corporate funds for anything that could not be translated into direct profits for the company. "They'd rather buy five injection molding systems," 173

4 said one. "We don't have people beating down our doors to invest money in our boilers," said another. "The problem is measuring the savings," summed up one gentleman. Several members of the group talked about the difficulties faced by companies who were heavily unionized, since that tended to compartmentalize the work, and prevented them from addressing steam efficiency problems from a systems perspective. 2 STEAM CHALLENGE Based on these findings, DOE-QIT has decided to move forward with a voluntary, technical assistance program on steam. It has been proposed to transform the organizations and resources of the Steam Partnership into a new DOE-QIT Technology Access Partnership Program, called "Steam Challenge". As planned, Steam Challenge will be one of several voluntary programs offered through DOE OIT's Technology Access Office, along with Motor Challenge, Compressed Air Challenge, the Industrial Assessment Centers, Inventions and Innovations, NICE 3, and other technology development programs. Collectively, these programs aim to assist industry in adopting near-term energy-efficient technologies. The goal of Steam Challenge will be to increase the market penetration of energy efficient industrial steam systems by helping industry adopt the systems approach in designing, purchasing, installing, and managing boilers, distribution systems, and steam applications. Steam Challenge will provide a network of resources that promote energy efficiency in industrial steam systems and will supply unbiased information about steam system design, purchase, and operation from experts who have practical experience addressing steam system challenges. Participation in Steam Challenge will be open to steam system operators and managers, developers and distributors of steam systems equipment, as well as steam trade and membership organizations. As an industry led program, these participating organizations will play an active role, ensuring that Steam Challenge is a credible program and one that provides tools and resources that are of value to industrial steam operators and managers. In addition, Steam Challenge will assist steam equipment and service providers, such as utilities, distributors, manufacturers, consulting engineers, and others promoting steam efficiency by serving as a valuable source of third-party, credible information on efficient steam systems. One of the first activities of Steam Challenge will be to form an advisory committee consisting of users and suppliers of steam and steam-related products as well as relevant associations and nonprofits to provide guidance to the program on an ongoing basis. The advisory committee's role will provide guidance and direction on the development of Steam Challenge, and will help collect and recommend important steam efficiency resources. Thanks to the efforts of its "steam partners" Steam Challenge is already off to a good start in pulling together some excellent steam efficiency resources, including: working with the Council of Industrial Boiler Owners' (CrnO's) to publish its energy efficiency guidebook for boilerhouse operators, releasing a newly developed World Wide Web site on steam efficiency, benefiting from the Steam Partnership program concept paper and brochure, and assembling tools from various associations and trade groups, such as North American Insulation Manufacturers Association's (NAIMA's) 3E plus insulation software, Oak Ridge National Laboratory's Industrial Insulation Guidelines and DuPont's "Steam: Use it or Lose it" video. STEAM CHALLENGE PROGRAM PLAN Steam Challenge has developed a preliminary program plan, which will be discussed, reviewed, and implemented over the next year. The main components of the program plan are briefly discussed below. Steam Challenge Meetings and RoU-0ut. The Alliance and DOE-QIT will meet regularly with a Steam Challenge advisory committee as well as other task-specific working groups participating in the Steam Challenge to review the program's current status and make recommendations. The Advisory Committee will provide guidance and direction on Steam Challenge programs and tools, discuss new areas where attention and resources are needed within industrial steam systems, and identify 174

5 informational resources on steam system efficiency. The stearn efficiency advisory committee will also identify steam projects in industrial plants that can be highlighted as Steam Challenge case studies. In trulny instances the case studies will be based on steam system swveys. With assistance from the Advisory Committee to compile and analyze the resulting data, the Steam Challenge program will be in a position to start defining best practices for steam efficiency and establishing steam system benchmarks. The Alliance to Save Energy and DOE-GIT are planning to formally annowlce the new Steam Challenge progrnm in late spring or early swnmer of At this event, DOE and the Alliance will lawlch the progrnm, describe its activities, and release some of the preliminary infonnation tools and products of the program in a steam efficiency source book. Demonstrations. Demonstrations and case studies are a compelling way to present the benefits of energy efficiency because they provide examples of how companies have Wldertaken improvements and benefited from verified energy savings. In exchange for technical assistance and the opportunity to see the benefits of new technologies, the demonstration participants should be willing to Wldertake detailed monitoring and analysis that will help other companies Wlderstand how steam-related technologies and projects can make their facilities run better. DOE and the Alliance are currently seeking Steam Challenge Partners who are willing to participate in stearn efficiency demonstrations and case studies. The Alliance and DOE are exploring demonstration opportunities with several large industrial steam users across the COWltry. Under these demonstrations, steam use will be carefully monitored before and after specific projects are implemented in order to measure and document the savings. The results will be published into case studies and broadly disseminated to all Steam Challenge participants and the public. TrainingIWorkshops. A series of workshops on steam system efficiency are being planned in The goal of this workshop activity is twofold. The first goal is to provide boiler and steam system operators with the knowledge and tools to identify and docwnent energy-saving steam system projects. A secondary goal is to develop a training curriculum and educational materials in steam efficiency that can be used by other trainers and engineering consultants nationwide. The Steam Challenge and the National Institute for the Uniform Licensing of Power Engineers (NIULPE) are currently exploring the idea of creating a one-time examination to accredit steam energy efficiency. This approach would allow boiler and steam operators to demonstrate their knowledge of steam efficiency technologies and practices. Research The Steam Challenge plans to sponsor more focus groups and to stay in communication with several industrial steam user groups across the COWltry in order to monitor Steam Challenge's effectiveness and progress. One steam users group, the Utah Steam Technology Coalition, has already provided helpful advice on the features and offerings of a publicprivate initiative on steam. A Steam Challenge goal will be to encourage the formation of several other users groups, like the one in Utah, across the country that can help promote Steam Challenge and benefit from its technical assistance and resources. Communications. To make sure the steam system efficiency message is being clearly presented, Steam Challenge will produce a set of presentation materials and brochures on steam efficiency. A Steam Challenge website has been created that describes the program and highlights basic steam efficiency opportunities. The website will allow users to review or download stearn efficiency materials (such as the ClBO energy efficiency guidebook), ask steam-related questions, or receive regular updates on the progrnm. In addition, the website will have a calendar of conferences, workshops, and tradeshows that are relevant to steam. The website is expected to be released in the Spring of In addition, the Steam Challenge wiil sponsor and organize steam efficiency sessions at conferences, trade shows, and seminars. Similar to the Texas!ETC conference, these sessions will highlight the offerings of the Steam Challenge progrnm materials as well as present the experiences and expertise of Steam Challenge partner companies. 175

6 Products Before developing any new tools or resources on steam efficiency, Steam Challenge is collecting and reviewing existing steam efficiency materials, including handbooks, data and fact sheets, case studies, technical bulletins, research reports, source books, and schedules of events, software tools, educational and training materials, and other resources on steam efficiency opportunities. Many of these resources will be compiled into a steam system efficiency tool kit. The steam efficiency toolkit will be incorporated into a larger Steam Challenge Sourcebook. In addition to the toolkit, the Sourcebook will contain an overview of the Steam Challenge program, fact sheets and checklists of common steam system efficiency opportunities, and additional reference materials. The Sourcebook is expected to be published with the roll-out of the Steam Challenge program this summer. By collecting and reviewing the current literature on steam system efficiency, Steam Challenge will serve as a clearinghouse of reliable steam information. The goal here is to provide steam users and suppliers with up-to-date information to enhance the quality and profitability of industrial steam systems. Steam Challenge is also exploring the idea of making steam efficiency experts and resources more accessible by creating a toll-free hotline, and frequently updating its steam efficiency website. After reviewing exlstmg materials and compiling the Sourcebook, Steam Challenge will explore developing a diagnostic software tool to give industrial steam users some indication of how efficiently their plant's entire steam system is running and to suggest potential areas (and projects) for improving steam system efficiency. Even if such a tool were relatively simple, it would need to provide some indication of potential fuel savings and incorporate the interactive effects of changes in steam generation, delivery, control, application, and maintenance technologies and practices. This tool development activity would incorporate the results of nearer term Steam Challenge activities, such as steam efficiency demonstrations, case studies, industrial steam surveys, and identifying steam efficiency best practices. CONCLUSION Existing research and consensus among industry experts indicates that industrial steam systems are energy in-efficient, mainly due to a lack of awareness in the industrial community. Steam is often vital to production, but it is not unusual for experts to find cost-effective opportunities to reduce energy usage while increasing system effectiveness, reliability, and safety at the same time. Steam Challenge represents a true partnership of interests to address this situation, including government, nonprofits, trade associations, private industry, and utilities. It is a unique opportunity to increase industry awareness of steam energy efficiency, while achieving major energy and cost savings and improving productivity. With guidance and resources from a preliminary activity called the Steam Partnership program, the Steam Challenge will have value both domestically and internationally and could eventually be applied more broadly to steam systems located in schools, hospitals, large commercial buildings, and municipal district heating systems. 1 T. Jones. Alliance to Save Energy. "Steam Partnership: Improving System Efficiency Through Marketplace Partnerships." In 1997ACEEE Summer Study on Energy EffiCiency in Industry: Proceedings. American Council for an Energy Efficient Economy. Washington, DC, August L. Halverson, Macro International. Draft Report. Steam Information Needs: Report ofa Meeting with Steam Users and Related Industry Professionals. Cleveland,OH: December 10,