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["Instructions"]

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["PLANT NAME"]
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["City, State"]
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["Prepared On:"]
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[]
[{"$f":"TODAY()","v":"2020-02-10"}]
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[]
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["Prepared By:"]
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[]
["Name - Title"]
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[]
["Rep. Company"]

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{"sheet":"Table of Contents","index":3,"n_rows":13,"n_cols":3,"rows_kept":13}
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[null,"TABLE OF CONTENTS"]
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["1)","Introduction"]
["2)","Utilities and Steam System"]
["3)","Observations"]
["4)","Assessment Results"]
["5)","Closing"]

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["1)    Introduction"]

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["2)    Utilities, Steam, and Hot Water Systems"]
["Site Energy Information"]
[]
["Company Name",{"$nulls":8},"Date"," "]
["Address "]
["City",{"$nulls":3},"State",null,null,"ZIP",null,"Phone"]
["Name / Title",{"$nulls":7}," e-mail"]
["Name / Title",{"$nulls":7}," e-mail"]
["Utilities Cost Information",{"$nulls":6},"Facility details"]
["Utility","Cost",null,"Total Consumption",null,"Annual Cost",null,"Production",null,"Units/year"]
[null,"Unit Cost","Units","Qty","Units","$/year",null,"Total Capacity",null,"Units/year"]
["Raw Water: ",null,"$/kgal",null,"kgal",null,null,"Operation ",null,"Hours/year"]
["Treated Water",null,"$/kgal",null,"kgal",null,null,"Operation ",null,"Days/week"]
["Sewer",null,"$/gal",null,"kgal",null,null,"Operation ",null,"Hours/day"]
["Chem Treatment",{"$nulls":6},"Shutdown Date"]
["Primary Fuel",null,"$/MMBtu",null,"MMBTU",null,null,"Cogeneration and Steam Generated as By-product"]
["Back Up Fuel",null,"$/gal",null,"MMBTU",null,null,"Power Generation Capacity",null,null,"kW",null,"Manufacturer"]
["If fueloil #6, S%",null,"%",{"$nulls":4},"Heat Recovery","- Steam",null,"lb/h",null,"Psig"]
["Electricity",null,"$/MWh",null,"MWh",null,null," ","- Hot water",null,"MMBTU",null,"gpm"]
["Own/Purchased Steam",null,"$/klb",null,"klb",null,null,"Steam as by-product?",null,null,"lb/h",null,"Psig"]
["Steam Generation",{"$nulls":6},"Major Steam Users"]
["Boilers #","Units",1,2,3,4,null,"Equipment\n(fill details in next tab)",null,"Steam Pressure","Operation","Flow","Metered"]
["Manufacturer",{"$nulls":8},"Psig","Cont/Batch","lb/h","Yes or No"]
["Year"]
["Type ","WT / FT"]
["Rated Capacity","MMBTU/h"]
["Rated Pressure / Temp","Psig / ⁰F"]
["Operating Press/Temp","Psig / ⁰F"]
["Avg. Firing Rate","0 - 100%"]
["Main Fuel Used"]
["Back-up Fuel"]
["% Back-up Fuel Used","0 - 100%"]
["Flue Gas - O2 %","0 - 21%"]
["Flue Gas Temperature","⁰F"]
["Economizer ","Yes/No",{"$nulls":5},"Condensate Return System"]
["Air Preheater (Yes/No)","Yes/No",{"$nulls":5},"Condensate Returned",null,"%"]
["D/A Pressure","Psig",{"$nulls":5},"Condensate Pressure",null,"Psig"]
["Feed Water Temperature","⁰F",{"$nulls":5},"Condensate Temperature",null,"⁰F"]
["Boiler Efficiency","%",{"$nulls":5},"Where is Condensate Returned To?"]
["Boiler House Efficiency","%",{"$nulls":5},"How is Condensate Returned?"]
["Boiler Blowdown","%","BD Heat recovery",null,"Yes / No"," ",null,"Is Condensate Metered?"]
["Feed Water/Make Up Water/Condensate Quality",{"$nulls":6},"Hot Water Generation"]
[null,"Units","Condensate","MUW","FW","Boiler",null,"Hot Water System #",null,null,1,2,3]
["Oil content","mg/l",{"$nulls":5},"Method of production"]
["Conductivity","μS/cm",{"$nulls":5},"Capacity installed",null,"MMBTU/hr"]
["Ferric Oxides","μg/l",{"$nulls":5},"Temperature",null,"⁰F"]
["pH","-",{"$nulls":5},"Once Through/Closed Loop",null,"OT or CL"]
[{"$nulls":7},"Average Hot Water Production ",null,"kgal/day"]
{"$rows_empty":13}
["Steam Distribution System",{"$nulls":6},"Major Hot Water Users"]
["Distribution Header #",null,null,1,2,3,null,"Equipment",null,"Flow","Temperature","Operation","Metered"]
["Header Pressure",null,"Psig",{"$nulls":6},"gpm","⁰F","Injection/Once Through/\nClosed loop","Yes or No"]
["Header Temperature",null,"⁰F"]
["Is it Metered?",null,"Yes/No"]
["Winter Flow Rate (average)",null,"klb/h",null,"Peak:"]
["Summer Flow Rate (average)",null,"klb/h",null,"Peak:"]
["Estimated No. of Steam Traps",null," "]
["Date of Last Trap Survey"]
["Estimated % failure",null," "]
["Do you have a year to year managed Steam Trap program?"]
[]
["Projects (What Energy Projects Are Known But Not Funded - Any Additional Comments)"]
[1]
[2]
[3]

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["3)    Observations"]
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["4)    Assessment Results / Verifications Completed During the Audit"]
[]
["Potential Optimization","Comment"]
["OVERALL STEAM SYSTEM PROFILE"]
["Steam System - Measurements and Monitoring"]
["      Steam Generation"]
["      Fuel "]
["      Feedwater"]
["      Make-up Water "]
["      Steam Distribution - to plant, to areas and/or to individual users"]
["Costs Tracking - fuel, water, sewer, chemicals, steam"]
["Safety"]
["BOILER HOUSE"]
["Boiler Efficiency - is it measured or calculated?"]
["Stack temperature"]
["Oxygen in flue gas"]
["Combustion Air Supply Temperature"]
["Boiler/Burner Tune-Up"]
["Steam Pressure Setting"]
["Gauges and Instrumentation"]
["Boiler Sizing and Reliability"]
["Steam Quality"]
["Boiler Blow-Down Rate"]
["Boiler Blow-Down Recovery"]
["Deaerator Pressure "]
["Feed Water Temperature"]
["Heat Recovery - MUW Pre-Heating"]
["Vents"]
["STEAM DISTRIBUTION"]
["Proper Piping Practices"]
["Water Hammer"]
["Steam Quality"]
["External Leaks of Steam or Condensate from Pipes, Flanges, etc."]
["Steam Pressure"]
["Internal Leaks"]
["Insulation"]
["Steam Traps and Steam Trap Management"]
{"$rows_empty":10}
["STEAM USERS"]
["Steam Users / Heat Exchangers Performance - Stall, Air Locked, Vacuum"]
["Point of Use Pressure"]
["Piping Practices - Users"]
["CONDENSATE AND FLASH STEAM RECOVERY"]
["Condensate Return - Quantity and Quality"]
["Condensate Return Piping Practices and Sizing"]
["Water Hammer"]
["Flash Steam Recovery/Utilization"]
["HOT WATER "]
["Hot Water Generation (once through) -  Domestic HW, Once Through Hoses"]
["Hot Water Generation (Recirculation) -  HW for Heating, For Process"]
["Hot Water Distribution"]
["Hot Water Use"]
["HVAC"]
["HVAC - AHU, Unit Heaters, Make-up Air"]
["Humidification"]

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["5)    Closing"]

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["Comments",null,"Categories",null,"Issue","Description"," ",null,"Relevant Issues"]
["OK",null,"M & R",null,"Boiler Operation at Low Loads","At low loads, boilers operate at lower combustion efficiency.  Any boiler has a fixed amount of radiation losses. These losses, as a percent of the total boiler fuel consumption, will increase when the boiler operates at low loads.  As a result, the overall boiler efficiency is the lowest at lower loads."," ",null,"Boiler Operation at Low Loads"]
["Yes",null,"Prod",null,"Cavitation in Electric Condensate Pump","Most electric pumps are rated for 200°F max condensate temperature (pumping). When the 200°F threshold is exceeded, the condensate will flash when it takes a pressure drop in the pump housing. This flashing will cause thermal shock, which will damage impellers and lead to mechanical seal failure."," ",null,"Cavitation in Electric Condensate Pump"]
["No",null,"Safety",null,"Condensate Contamination (Poor Quality)","Condensate conductivity is above the recommended range, which indicates contamination. Common potential sources are leaking heat exchangers.  High level of conductivity results in condensate drain and/or greater boiler blowdown rates, which is a waste of hot treated water and increases annual make-up water, chemicals, sewer and fuel costs. "," ",null,"Condensate Contamination (Poor Quality)"]
["Not Applicable",null,"Energy",null,"Condensate Drain","Draining condensate results in wasted heat energy and decreased system efficiency, increasing costs for fuel, make-up water, chemicals, and sewage. Typical system issues leading to condensate drain include high back-pressure, water hammer, and stall in heat exchange equipment."," ",null,"Condensate Drain"]
["Not Available",{"$nulls":3},"Condensate Receiver Venting","There is excessive steam venting at the condensate receiver vent. Venting steam is a waste of heat (fuel), treated water and chemicals.  If recovered, the vented steam will save energy and water."," ",null,"Condensate Receiver Venting"]
["Partial",{"$nulls":3},"Condensate Return Unit Overflowing ","An overflowing condensate return unit can be a result from various issues, including undersized or failed pumps and improperly set float switches."," ",null,"Condensate Return Unit Overflowing "]
["To be Improved",{"$nulls":3},"Deaerator Venting","The deaerator removes dissolved non-condensable gases (mainly oxygen and carbon dioxide) from the boiler feedwater. A fraction of the steam is also vented out along with non-condensable gases. This vented steam contains energy, and when excessive, it can be recovered."," ",null,"Deaerator Venting"]
["Can be Improved",{"$nulls":3},"Disconnected Humidifier","The humidity levels in the hospital cannot be controlled.  All humidifiers have been disconnected. Proper installation of the humidifier and supply of good steam quality will restore the ability to control humidity levels, will improve reliability and reduce operational and maintenance issues"," ",null,"Disconnected Humidifier"]
["Needs Attention",{"$nulls":3},"Drip Trap Piped on Bottom of Drip Leg","A drip trap off the bottom of a drip leg will be exposed to dirt and scale, which could cause a plugged (cold) condition or a blow through condition wasting energy."," ",null,"Drip Trap Piped on Bottom of Drip Leg"]
[{"$nulls":4},"Gang Trapping","If a single trap connects more than one drain point, condensate and air from one or more of the units may fail to reach the trap. Any difference in condensing rates will result in a difference in the steam pressure drop. A pressure drop difference too small to register on a pressure gauge is enough to let steam from the higher pressure unit block the flow of air or condensate from the lower pressure unit. The net result is reduced heating, output, and fuel waste. "," ",null,"Gang Trapping"]
[{"$nulls":4},"Heat Exchanger Stall","Stall occurs when the steam pressure, downstream of the control valve, or at the outlet of a heat exchanger is less than the pressure needed to lift condensate into the return line. The result is no pressure differential across the process steam trap and condensate backing up into the exchanger, reducing efficiency (inconsistent product temperatures) and/or causing damaging water hammer."," ",null,"Heat Exchanger Stall"]
[{"$nulls":4},"High Flue Gas Temperatures","Hot flue gases contain a lot of wasted energy. It is beneficial to reduce the stack temperature and use this energy back into the boiler with heat recovery equipment."," ",null,"High Flue Gas Temperatures"]
[{"$nulls":4},"High O2% in The Flue Gas","The fuel /air ratio is controlled through a mechanical linkage system.  There is no oxygen trim system installed, resulting in a higher than recommended oxygen percent in the flue gas. The recommended optimum excess air level depends on the type of fuel and burner design. Any additional margin lowers the boiler efficiency."," ",null,"High O2% in The Flue Gas"]
[{"$nulls":4},"Improper Disc Trap Installation","When a disc trap is installed improperly, it fails prematurely due to uneven wear and binding. Incorrectly installed steam trap leads to premature failure and increased energy losses."," ",null,"Improper Disc Trap Installation"]
[{"$nulls":4},"Improper Trap Installation","Incorrectly installed steam traps lead to premature failure and increased energy losses."," ",null,"Improper Trap Installation"]
[{"$nulls":4},"Incorrect Orifice Plate Installation","The upstream piping of orifice plate flow meters requires a minimum straight run of ten pipe diameters. The orifice plate meters have a limited rangeability.  Their turndown ratio is 3 or 4 to 1.  The strict piping requirements and the 3 (4): 1 flow turndown affect the accuracy of orifice plate flow meters."," ",null,"Incorrect Orifice Plate Installation"]
[{"$nulls":4},"Leaking Safety Relief Valve","Steam is observed through the discharge vent of the Safety Relief Valve (SRV), indicating an SRV malfunction which presents a safety concern."," ",null,"Leaking Safety Relief Valve"]
[{"$nulls":4},"Low Domestic Hot Water Temperature","Domestic hot water generation, distribution and point of use temperatures are not within the safety recommendations for waterborn bacteria (Legionella and others) disease prevention.  Legionella can survive at temperatures below 124F.  Domestic hot water generation at 140F is common for health and human safety."," ",null,"Low Domestic Hot Water Temperature"]
[{"$nulls":4},"Misapplied Trap","A different type of steam trap is recommended for this application.  Misapplied steam traps may prevent the removal of condensate from the steam systems.  The result is poor steam quality, water hammer, damaged equipment, and safety hazards."," ",null,"Misapplied Trap"]
[{"$nulls":4},"Missing Drip Legs","The drip legs are main components of the steam distribution system, assuring the quality of the steam at the point of usage. They are provided to:  \n• Let condensate escape by gravity from the fast-moving steam  \n• Store condensate until the pressure differential can discharge through the steam trap  \nIf not correctly installed or sized, the condensate cannot be removed from the steam headers, and the quality of the steam deteriorates.  Wet steam can induce water hammer or damage valves and equipment."," ",null,"Missing Drip Legs"]
[{"$nulls":4},"Missing Drip Trap","Missing drip traps cause condensate to pool in the steam piping. As a result, corrosion of the pipe walls (due to carbonic acid formation) and water hammer typically occur."," ",null,"Missing Drip Trap"]
[{"$nulls":4},"Missing Insulation","Missing or damaged insulation results in greater heat losses through radiation and convection and respectively to increased fuel consumption.  Due to greater heat loss, steam condenses faster, which can lead to water hammer."," ",null,"Missing Insulation"]
[{"$nulls":4},"No Air Vent Installed on Shell and Tube HE","Without an air vent mounted on the high side of the shell, air and non-condensible gases accumulate on the opposite side of the steam inlet. The accumulation reduces the efficiency of the heat exchanger by insulating part of the tube bundle, effectively reducing heat transfer in that area of the bundle."," ",null,"No Air Vent Installed on Shell and Tube HE"]
[{"$nulls":4},"No Blowdown Heat Recovery","The heat from continuous blowdown is not recovered and lost to the atmosphere.  Recovering the heat of the blowdown reduces energy losses, as the water temperature is the same as the temperature of the steam generated in the boiler. "," ",null,"No Blowdown Heat Recovery"]
[null," ",null,null,"No Drip Trap Ahead of PRV/CV","A drip trap should be installed before any pressure reducing valve (PRV) and control valve (CV) to ensure proper removal of condensate from the system.  Only dry steam and no condensate should be passing through the valve seat. Without a drip trap, condensate, dirt, and scale accumulate in the system, damaging the seat, causing excess wear and premature failure of the valve."," ",null,"No Drip Trap Ahead of PRV/CV"]
[{"$nulls":4},"No Drip Trap on Boiler Header","A properly sized inverted bucket steam trap must be installed on the boiler header to remove condensate and solids from boiler water carryover, typically around 10%. Carryover (condensate) will enter the steam distribution system if not properly removed."," ",null,"No Drip Trap on Boiler Header"]
[{"$nulls":4},"No Drip Trap on Steam Filter","Dryness fraction of the steam at the outlet of a steam filter is very important. The filter housing is a vessel that will lose heat causing condensate to form. If the condensate is not effectively and immediately removed, the dryness fraction of the steam will be negatively impacted which can lead to system performance and/or quality issues downstream. "," ",null,"No Drip Trap on Steam Filter"]
[{"$nulls":4},"Open Drain Valve","Open drain valve indicates an attempt to solve a problem in the system.  Draining condensate and leaking/venting steam is a waste of energy, leads to higher fuel and make-up water costs."," ",null,"Open Drain Valve"]
[{"$nulls":4},"Poor Steam Quality (Wet Steam) ","Not removing condensate effectively and immediately from the steam pipes impacts the dryness fraction negatively, resulting in poor system performance, poor steam quality, water hammer, and damaged equipment."," ",null,"Poor Steam Quality (Wet Steam) "]
[{"$nulls":4},"PRV Overshooting Set Pressure","Overpressurization after a PRV is caused by excess steam passing through the valve.  This is typically the result of dirt holding open either the pilot or main valve.  Excess steam may also leak through if the valve has become steam cut (typically caused by wet steam).   \n\nFor information on troubleshooting a leaking PRV, please visit the Troubleshooting Guide section of Armstrong's Externally Piloted PRV IOM."," ",null,"PRV Overshooting Set Pressure"]
[{"$nulls":4},"Raising Condensate After Modulating Steam","When the steam pressure to a user is reduced (control valve modulates) due to low demand , the condensate will back up and could flood steam traps, heat exchangers, or other equipment. "," ",null,"Raising Condensate After Modulating Steam"]
[{"$nulls":4},"Sensing Line Twisted/Sloped toward PRV","The PRV's control pipe (sensing line) must be sloped away from the PRV to drain condensate away from the pilot.  Condensate flowing into the pilot valve could result in erratic control and corrosion to the internal parts. Control pipe length/connection should be a minimum of 10 outlet pipe diameters from the last tee, elbow or fitting."," ",null,"Sensing Line Twisted/Sloped toward PRV"]
[{"$nulls":4},"Steam Leaks","Steam and condensate leaks waste fuel, treated water, and chemicals and increase safety hazards."," ",null,"Steam Leaks"]
[{"$nulls":4},"Steam Traps","Traps have not been surveyed for many years.  A 5% annual failure rate is common.  Traps may fail and go unnoticed for long periods of time.  Lack of trap management leads to loss of efficiency, equipment downtime and safety concerns."," ",null,"Steam Traps"]
[{"$nulls":4},"Take-Off From Bottom or Side of Pipe","If a branch line is not taken from the top of a steam main, condensate from the bottom of the pipe will get distributed throughout the steam system.  Condensate in the steam (wet steam) has the potential to cause water hammer which can damage equipment and create a safety hazard.  The condensate could also lead to pipe walls corrosion."," ",null,"Take-Off From Bottom or Side of Pipe"]
[{"$nulls":4},"Tilted Inverted Bucket Trap","The inverted bucket trap was not installed in a vertical position.  When tilted, the free floating bucket inside may not operate properly and the valve may not make full contact with the seat.   The trap would fail leaking (no full contact) or stuck closed.  Both positions will have a negative effect on the system."," ",null,"Tilted Inverted Bucket Trap"]
[{"$nulls":4},"Undersized Condensate Return Header","Undersized condensate return headers cannot properly handle bi-phase condensate, causing high back-pressure and reduced capacity of all steam traps connected to the condensate header.  Water hammer in condensate return lines is often due to undersized lines."," ",null,"Undersized Condensate Return Header"]
[{"$nulls":4},"Undersized Drip Legs","Undersized drip leg can cause a venturi \"piccolo\" effect where pressure drop pulls condensate out of the trap and prevents removal from the steam system. Correctly sized drip leg allows condensate to flow out of the steam main/branch, into the drip leg and through the steam trap."," ",null,"Undersized Drip Legs"]
[{"$nulls":4},"Undersized Trap(s) on Boiler Header","A recommended safety factor of 1.5:1 is applied for boiler header traps assuming a 10% condensate carryover of the generated load. An undersized drip trap cannot adequately remove condensate from the header, which causes carryover to the steam distribution network."," ",null,"Undersized Trap(s) on Boiler Header"]
[{"$nulls":4},"Water Hammer (Condensate Line)","Water hammer occurs in bi-phase condensate systems, liquid (condensate) and vapor (flash steam), which are not adequately designed for the specific routing or operating conditions. Water hammer is destructive to piping, valves, steam traps, and other equipment and creates a hazardous environment."," ",null,"Water Hammer (Condensate Line)"]
[{"$nulls":4},"Water Hammer (Steam Line)","Water hammer occurs in a steam line when condensate is not adequately removed.  Water hammer is destructive to piping, valves, steam traps, and other equipment and creates a hazardous environment."," ",null,"Water Hammer (Steam Line)"]
[{"$nulls":4},"Water Hammer (Thermal Shock)","Water hammer is caused when mixing cold liquid condensate with hot bi-phase condensate in the same condensate return line.  Water hammer is destructive to piping, valves, steam traps, and other equipment and creates a hazardous environment."," ",null,"Water Hammer (Thermal Shock)"]
[{"$nulls":4},"Wet Packs","Wet pack form when sterilizers operate with a poor steam quality. Missing and undersized drip legs and drip traps typically cause poor steam quality."," ",null,"Wet Packs"]
[{"$nulls":6}," "]

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["3)    Observations"]
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