Summer 2002

ISSUE FOCUS: 

Reaching Emerging 

Managers

By Rachel Madan

Industrial Program Associate

Alliance to Save Energy

When pursuing energy efficiency projects,

what is the best way to proceed? On the

one hand, it is fairly easy to demonstrate

payback times for technical solutions,

such as installing heat economizers, backpressure turbines, or efficient motors. 

On the other hand, many plant managers concentrate their efforts largely on

technical improvements. This sometimes

may leave untapped a part of the savings

that can be gained through the low-risk,

low-tech solution of training for proper

maintenance and operation. 

Plant managers have often focused on

technical innovations. These generally have

led to greatly improved energy efficiency

since the 1973 oil embargo. In fact, energy

intensity (energy use per unit of production)

in the manufacturing sector fell steadily

from 1973 to 1985, when it stabilized.

Reductions in energy intensity increased

again in 1993.

The Human Side of Energy Efficiency: The Value of Training

IN THIS ISSUE

The Human Side of Energy Efficiency:

The Value of Training . . . . . . . . . . . . . . . . 1

IACs Benefit Industry and 

Young Engineers . . . . . . . . . . . . . . . . . . 3

New Steam Sourcebook . . . . . . . . . . . . . 4

Steam System Awareness Tool 

in Development . . . . . . . . . . . . . . . . . . . 5

We Asked and You Responded That

Energy Matters Matters . . . . . . . . . . . . . 5

Low-Emission Boiler and 

Combustion Equipment Guide . . . . . . . 6

DOE Announces Technology

Deployment Solicitation . . . . . . . . . . . . 6

Ask the Clearinghouse . . . . . . . . . . . . . . 7

Letters to the Editor . . . . . . . . . . . . . . . . 7

EM Extra Highlights . . . . . . . . . . . . . . . . 8

Coming Events . . . . . . . . . . . . . . . . . . . . 8

“TURNING INFORMATION INTO ENERGY SOLUTIONS FOR INDUSTRY”

OFFICE OF INDUSTRIAL TECHNOLOGIES

T OF ENERGY

DEPARTMEN

U

E

NITED STAT S OFA

ERICA

M

U.S. DEPARTMENT OF ENERGY 

www.oit.doe.gov 

www.oit.doe.gov/bestpractices

To make training successful, managers must be committed, proactive, and supportive,

with both their attitudes and their funding.

Steam Sourcebook now available,

see page 5.

(continued on page 2) David Parsons, NREL/PIX 07267
2 Energy Matters, Summer 2002

ENERGY MATTERS

is published quarterly by the 

U.S. Department of Energy’s

(DOE) Office of Industrial 

Technologies (OIT). 

Information contained in the

newsletter can be reproduced

without permission provided due

acknowledgement is given (the

U.S. Department of Energy’s 

Energy Matters newsletter) and 

a copy of the publication is 

supplied to the editor.

■

EDITORIAL BOARD

Rob Boteler, representing

National Electrical Manufacturers

Association

Lynda Butek, representing 

Electrical Apparatus Service 

Association

Bill Clark, University City 

Science Center

Eric T. Fletty, Business 

Development Manager, TAPPI

Gary L. Goehring, Alcoa 

North American Extrusions

Glenn Hahn, Spirax Sarco

J. Bruce Medaris, Facilities 

Consulting Services and 

Executive Director, Compressed

Air Challenge®

Arvind Thekdi, E3M, Inc.

Chuck Whelan, DuPont 

■

DOE STAFF

Chris Cockrill, BestPractices,

Motors

Fred Hart, BestPractices, Steam 

Peter Salmon-Cox, BestPractices

Program Manager

■

COMMENTS? 

Contact: 

David Wagman, Energy Matters

Editor, at 303-275-3602, 

e-mail david_wagman@nrel.gov

or Karen Atkison, Associate 

Editor at 303-275-3730, e-mail 

karen_atkison@nrel.gov

1617 Cole Blvd., MS 1609

Golden, CO 80401

For new subscriptions, go to

www.oit.doe.gov/

bestpractices/explore_library/

energy_matters.shtml

For address/subscription changes,

please contact the editor.

Even with this remarkable track record,

facility managers can rely on technical

solutions to solve only some energy use

problems. Many problems stem from a lack

of training related to system optimization

or from ineffective training programs.

Establishing an effective, low-cost, lowtech training and maintenance program

within a plant can have a fast payback and

lasting results.

The true value of training (not only for

improving energy efficiency but also for

improving the bottom line) can sometimes

be underestimated if it is

perceived as a cost, rather

than an investment. However, investing in a training program may improve

energy efficiency, minimize costs, increase

profit, and improve productivity and reliability,

not to mention enhance

operational safety.

A study conducted by

the American Society for

Training and Development found that training

investments across all

sectors could yield favorable financial

returns for firms and their investors. This

study found that an increase of $680 in a

firm’s training expenditure per employee

generated, on average, a six-percentagepoint improvement in total shareholder

return the following year, even after controlling for other factors.

To help managers break through barriers when trying to implement training programs, it is important to extrapolate the

benefits of any energy-efficiency improvements to other areas of the company. For

instance, training staff to implement a

steam trap maintenance program will

increase the efficiency of a steam system—

but more importantly, it will save the company money through increased reliability

and productivity of the system. 

Perhaps the most obvious and important

benefit of training is improving a plant’s

safety record. For example, beginning 

in 1998, Weirton Steel Corp. undertook a

series of training initiatives, including safetyawareness training, hands-on workstation

training, and certifying all plant supervisors

in the Occupational Safety and Health

Administration’s (OSHA’s) General Industry

Standards. As a result, recorded incidents

fell 63% from 1997 to 2000. Other intangible factors, such as attitude, improved. In

1997, 15% of Weirton Steel Corp. employees surveyed believed that their own actions

could protect their co-workers. In 2000,

60% believed this to be true.

A properly trained staff is also key to

maintaining reliable equipment, which

also increases productivity. For example, in 1990,

U.S. Steel began 

a comprehensive predictive maintenance program to improve maintenance practices and

lower maintenance costs.

The program focused 

on employee involvement, training, and team

activity. Misalignments 

of rotating equipment

dropped from 15% in

1990 to 1% in 1996. Success such as this led to

the company receiving the 1993 and 1995

National Maintenance Excellence Award

for maintenance and equipment reliability.

In essence, while energy efficiency may

be a key goal of a training program, the

value of safety, reliability, productivity, and

cost savings need to be emphasized to

those who have the power to implement

such a program. To execute a successful

training program, managers must be committed, proactive, and supportive, with both

their attitudes and their funding. Training

must be treated as a fundamental requirement of comprehensive management. The

rewards are great for such support. ●

The Value of Training

continued from page 1

INVESTING IN A TRAINING

PROGRAM MAY IMPROVE

ENERGY EFFICIENCY, 

MINIMIZE COSTS, 

INCREASE PROFIT, AND

IMPROVE PRODUCTIVITY

AND RELIABILITY.

For more energy-efficiency information,

visit Energy Matters Extra at www.oit.doe.

gov/bestpractices/energymatters/emextra
Energy Matters, Summer 2002 3

By Bill Clark

Executive Director

University City Science Center

The Industrial Assessment Center (IAC) program, funded by the U.S. Department of

Energy, provides small- and medium-sized

manufacturers with no-cost individual

assessments of their plant’s energy, waste,

and productivity efficiency, followed by

recommendations for specific cost savings.

These assessments are conducted by

engineering faculty and students of IACs

hosted by 26 universities across the United

States. OIT sponsors the program as part of

its efforts to transfer energy-efficient and

environmentally sound practices and technologies to U.S. industry.

Assessments are provided at no direct

cost to participating manufacturers, who

are under no obligation to act on any recommendations. On average, recommended

actions from an assessment result in annual

cost savings of about $55,000. The university-based IAC team typically conducts the

assessment during a 1- or 2-day site visit.

Within 60 days they will send a report to

the client detailing their analyses, findings,

and recommendations. In 6 to 9 months,

follow-up calls are made to the plant manager to obtain implementation results.

The program benefits many parties.

■ Manufacturers receive unbiased technical assistance at no direct cost that

helps them become more competitive

in the global marketplace as a result of

implementing cost-saving measures recommended by the IAC teams.

■ Universities interact with

local industry to maintain

a practical orientation in

their engineering curriculum and develop productive relationships.

■ Faculty benefit by receiving hands-on experience

in the application of technical education in a working industrial environment,

and often incorporate

lessons learned into the

curriculum to benefit additional students. Faculty

have also developed ideas

for research from their

studies of manufacturing processes by

– implementing IAC team recommendations, the program also generates

opportunities for energy service companies, equipment manufacturers,

vendors, and suppliers

– implementing energy efficient technologies, reducing green house gases,

and reducing waste achieve environmental benefits.

A Vital Role

But perhaps the greatest

long-term benefit is the effect

on engineering students who

will utilize the skills learned

from IAC experience throughout their careers.

Many IAC graduates credit

their experience with the IAC

program as having shaped their

career paths. Greg Kelleher, a

recent graduate from the IAC

at Oregon State University,

wrote to his former Director

in a letter of appreciation: “I

went to work for the Industrial

Assessment Center to get practical engineering experience. I got much more out

of the IAC than what I had expected....

The IAC played vital roles both in funding

my education and in helping me land an

excellent career position in the energy

management field. In short, nothing from

my graduate study at Oregon State has

influenced my life more positively or profoundly than my experience as a student

worker at the IAC.”

Other follow-up contacts also indicate

that the education offered through the IAC

program is invaluable. Interviews performed with IAC alumni show that a disproportionately large segment pursue

careers in energy fields and continue to

make significant contributions in the

energy, waste, and productivity areas.

High Retention Rate

A recent survey completed by Oak

Ridge National Laboratory shows that one

out of every four graduates of the IAC program stays in the field and continues to

help manufacturers save energy and

reduce costs. Recently, program management has begun to track the accomplishments of IAC alumni. In 2000 it was

estimated that all program graduates combined saved more than 15 trillion Btu during that year. The alumni have also made

significant contributions by identifying

clients who can benefit from an IAC

assessment, providing valuable feedback to

program management on how the program

and educational value can be improved,

and by acting as mentors for the current

class of IAC students.

The program provides engineering students valuable hands-on training and

experience in energy, waste, and productivity management. Students are involved

in almost all components of center operations with primary focus on conducting

IACs Benefit Industry and Young Engineers

An IAC student helps perform a plant energy efficiency

assessment.

Since its inception, in 1976, more than 2,000 students have

participated in the IAC program.

(continued on page 4) 

David Parsons, NREL/PIX 05562
4 Energy Matters, Summer 2002

assessments (under the supervision of

engineering faculty) and preparing engineering reports for the clients served. Students who participate in the program

receive practical experience in a variety of

manufacturing settings. They develop

improved communication and teamwork

skills and also a heightened awareness of

energy efficiency, pollution prevention,

and productivity enhancement. Finally, the

students employed by the IACs are able to

earn income to help defray their educational expenses.

Since its inception in 1976, more than

2,000 students have participated in the IAC

program. Currently, about 250 students are

trained each year. The training each student receives augments his or her traditional engineering education. Prior to their

first industrial assessment, students are

trained in assessment methodologies,

instrument use, safety, and common industrial energy uses, such as air compressor

systems, motors, boilers and steam systems, pumping systems, and lighting.

Potential energy-conserving and costsaving recommendations are highlighted

and methods to estimate the potential conservation and cost savings are presented.

New Training

Throughout their employment with the

IAC, students acquire training in a variety of

energy efficiency topics and learn how to

apply that training to solve problems

encountered in a variety of manufacturing

settings. Students are provided the opportunity to hone the skills employers seek, such

as working independently as well as in

groups, communicating in both written and

oral forms, and applying knowledge and

available technology to solve real world

problems. In addition, this summer, the

majority of IAC students will receive formal

BestPractices training. The IAC students

regularly utilize OIT’s BestPractices Software Tools in completing their assessment

work. This training will make the students

even more proficient in using these tools.

To find out if your company is eligible

to benefit from the IAC program, check the

IAC Web site at www.oit.doe.gov/iac/. ●

IACs’ Benefits

continued from page 3

If you would like to improve your industrial

steam system’s performance and access

some practical guidelines and helpful

resources, check out a new OIT publication—Improving Steam System Performance, a Sourcebook for Industry. It offers

valuable performance-enhancing information to both the novice and experienced

steam system manager.

Often, operators are so focused on the

immediate demands of the equipment,

they overlook the broader question of how

system parameters affect the equipment.

This sourcebook shifts the focus from individual components to total system performance. In this systems approach, steam

managers analyze the supply and demand

sides of the system and how they interact. 

The sourcebook has three sections, covering the following topics.

Steam System Basics

To help users become more familiar

with the basics of steam systems, or for

users seeking a refresher, a brief discussion

of the terms, relationships, and important

system design considerations is provided. It

describes four basic components of steam

systems: generation, distribution, end use,

and recovery.

Performance Improvement Opportunities

This section discusses specific opportunities to improve steam system performance and to lower operating costs. It also

provides an overview of the finance considerations related to steam system

improvements. Topics include understanding corporate priorities, measuring the dollar impact of steam efficiency, financing

steam efficiency improvements, and relating steam efficiency to corporate priorities.

Additionally, this section discusses several resources and tools developed by the

U.S. Department of Energy’s BestPractices

Steam Program to identify and assess steam

system improvement opportunities. These

include:

■ Steam System Scoping Tool—a spreadsheet program that helps assess steam

systems

■ Steam System Survey Guide—a reference document that gives technical

guidance on identifying and assessing

many potential steam improvement

opportunities

■ 3E Plus Insulation Appraisal Software—

a program that teaches the benefits of

insulation and assists in assessing insulation opportunities

■ Steam Tip Sheets—documents that provide concise descriptions of common

steam system improvement opportunities.

In addition, the sourcebook covers the

National Insulation Association’s (NIA) Insulation Appraisal Program. It offers certification to professionals who conduct insulation

appraisals or specify insulation requirements.

Programs, Contacts, and Resources

In this section, OIT has listed associations and other organizations involved in

the steam system marketplace. Plus, it provides a description of the BestPractices

Steam Program, a directory of contacts,

and a listing of available resources and

tools, such as publications, software, training courses, and videos.

So don’t delay! The sooner you learn

about the available steam system improvement opportunities, the sooner your company could begin improving the bottom

line. Improving Steam System Performance,

a Sourcebook for Industry can be ordered

by calling the OIT Clearinghouse at 1-800-

862-2086. A PDF version of the sourcebook

is also available on the BestPractices web

site at www.oit.doe.gov. 

New Steam Sourcebook Guides Users to Improved

Performance, Lower Costs

IN THIS SYSTEMS APPROACH,

STEAM MANAGERS ANALYZE

THE SUPPLY AND DEMAND

SIDES OF THE SYSTEM AND

HOW THEY INTERACT.

IN THIS SYSTEMS APPROACH,

STEAM MANAGERS ANALYZE

THE SUPPLY AND DEMAND

SIDES OF THE SYSTEM AND

HOW THEY INTERACT.
Energy Matters, Summer 2002 5

BestPractices Steam is developing a new

tool that will assist those responsible for

steam system improvements to demonstrate key steam system improvement

opportunities in terms of energy savings

and emission reductions.

In many companies, the benefits of

improved steam system efficiency are calculated using an established in-house price

for steam. This value is often an average

price for steam so that over the course of a

fiscal year the books can be balanced and

the cost of steam generation recovered.

Such a charging structure, however,

may not be the most appropriate for system

improvement project evaluation. When

evaluating potential improvements to the

steam system, it is essential that the true

incremental cost of steam be used. The

most accurate way to analyze potential 

steam system savings is to build a model

that accurately represents what takes place

when changes are made to the system.

With such a model, any number of what-if

steam system improvement scenarios can

be evaluated.

The Steam System Awareness Tool (SSAT)

model will be a graphic representation of a

generic steam system containing key features

and variables to be analyzed. The model

will contain a number of potential steam system improvement projects including:

■ Real cost of steam

■ Steam quality

■ Boiler efficiency

■ Alternative fuels

■ Cogeneration opportunities

■ Steam turbine vs. PRV

■ Boiler blow down

■ Condensate recovery

■ Steam trap operating efficiency

■ Heat recovery

■ Vent steam

■ Steam leaks

■ Insulation efficiency

■ Actual emission calculations

■ Next step action list.

BestPractices Steam is developing the

Steam System Awareness Tool through a

cost-sharing partnership with Spirax Sarco

and Linnhoff March. An initial version of

the tool, suitable for technical review, was

to be completed in July. The final release

version of the SSAT model, including a

detailed users instruction manual, is anticipated for early in the fourth quarter of

2002. For more information, contact the

Information Technologies Clearinghouse at

1-800-862-2086, or Fred Hart, BestPractices

Steam Systems, at fred.hart@ee.doe.gov. ●

Steam System Awareness Tool in Development

Earlier this year, Energy Matters invited

readers to fill out a questionnaire to help

the editors ensure that the publication

remains an informative and relevant part of

readers’ energy efficiency strategy.

More than 900 of you took part,

answering questions designed to tell us

how relevant Energy Matters articles and

features are to your work. 

Here are some highlights:

■ Readers told us that the Top 5 Energy

Matters articles and features that were

most relevant to their work related to

energy efficiency case studies (505

responses), products/tools (485 responses),

technical issues (483 responses), emerging

technology (473 responses), and technology implementation (458 responses). 

■ A separate question asked readers to tell

us if the information in the newsletter’s

articles was “too technical”, “not technical enough” or “about right.” Of those

who responded, 90% said that Energy

Matters’ article content was “about right.”

■ Readers also told us they consider

Energy Matters to be an information

resource worth keeping and even sharing with colleagues. One third of the

readers who answered this question said

they typically pass along issues to one or

more colleagues. Another 48% said they

keep issues for future reference. 

Just over half of the readers who said

they visited the Energy Matters Extra web

site on a regular basis said they stopped by

to find links to other energy efficiency topics and links; 33% said they visited to

research topics from previous issues; and

11% said they visited to download the

most current issue’s PDF.

When asked whether or not they had

achieved energy savings as a result of articles in Energy Matters, 63% of those 

responding said they had achieved some

energy savings.

The editors wish to thank everyone who

filled out the Energy Matters questionnaire.

Your participation helps us deliver to you a

newsletter that meets your information

needs.

To view an electronic version of the

questionnaire results, visit the Energy Matters Extra web site at www.oit.doe.gov/

bestpractices/energymatters/emextra/

energy_matters.shtml. ●

We Asked, You Responded That Energy Matters Matters

0 50 100 150

 Number of responses

200 250 300

How Have You Applied What You Have Read In Energy Matters?

(Total responses = 1380)

Used ideas in

strategies

Visited

Web sites

Alerted management

 to articles

Purchased energyefficient equipment

Implemented

technology

Inquired about

OIT software

Developed energy

management plan

Attended an

OIT event

Proposed energy

assessment

284

240

167

164

162

132

87

74

70
6 Energy Matters, Summer 2002

Boiler owners and operators who need

additional generating capacity face a number of legal, political, environmental, economic, and technical challenges. Their key

to success requires them to select an adequately sized, energy-efficient, low-emission boiler and combustion equipment that

can be operated in compliance with emission standards established by state and federal regulatory agencies. 

Recognizing that many issues are

involved in making informed selection

decisions, the U.S. Department of Energy

(DOE) OIT program sponsored efforts at

the Oak Ridge National Laboratory (ORNL)

to develop a guide for choosing low-emission boilers and combustion equipment. To

ensure that it covers a broad range of technical and regulatory issues of particular

interest to the commercial boiler industry,

the guide was developed in cooperation

with the American Boiler Manufacturers

Association (ABMA) and the Council of

Industrial Boiler Owners (CIBO).

The guide presents topics pertaining to

industrial, commercial, and institutional

(ICI) boilers. Background information

about various types of commercially available boilers is provided along with discussions about the fuels they burn and the

emissions they produce. Also included are 

discussions about emissions standards and 

compliance issues, technical details related

to emissions control techniques, and other

selection considerations. Although information in the guide is primarily applicable

to new ICI boilers, it may also apply to

existing boiler installations. 

Use of the guide is primarily intended

for those involved in either expanding current steam or hot water generating capacity, or in developing new capacity.

Potential users include owners, operators,

plant managers, and design engineers who

are involved in selecting low-emission

boilers and combustion equipment that

comply with established emissions

requirements. Regulatory authorities who

deal with emission issues and boiler permit applications may also find the guide to

be useful.

The guide addresses many fundamental

concerns encountered in planning a new

steam or hot water boiler system. An

overview of boilers, fuel feed systems,

fuels, and emissions, which are fundamental considerations in the planning process,

is presented. Discussions about firetube,

watertube, cast iron, and tubeless boilers

that burn fossil or nonfossil fuels are

included along with issues pertaining to

solid, liquid, and gaseous fuels commonly

fired in these boilers. 

Following the fuel discussions, the

guide takes up the topics of solid and

gaseous emissions that are regulated under

the Clean Air Act. The four principal emissions from combustion boilers that are regulated under this act are nitrogen oxides

(NOx), sulfur dioxide (SO2), particulate

matter (PM), and carbon monoxide (CO).

Mechanisms by which these emissions are

formed are briefly described as an aid to

understanding various control techniques

for reducing emissions. 

Techniques that are effective in reducing

NOx, SO2, and PM emissions are divided

into three general categories, depending on

which stage during the combustion process

they are applied. The categories include

precombustion, combustion, and postcombustion emission control techniques.

Descriptions of each technique are presented and emission control options for 14

of the most popular boiler and fuel combinations are identified. Information presented in this guide is also intended to help

owners and operators prepare permit

applications that address the principal 

concerns and legal requirements of the

regulatory authority. 

The guide was prepared by C. B. Oland

from the Oak Ridge National Laboratory

(published as ORNL report ORNL/TM2002/19). To obtain a copy, contact the

OIT Clearinghouse at 1-800-862-2086. ●

Guide Now Available to Selecting Low-Emission Boiler and Combustion Equipment 

Energy efficiency leaders in the petroleum

refining and chemicals industries will be

interested to learn that the DOE Idaho

Operations Office (ID) is currently soliciting proposals to install and field-test technologies to reduce energy consumption,

enhance economic competitiveness, 

and reduce environmental impacts. The 

solicitation is targeted specifically toward

the petroleum refining and chemicals

industries. The objective is to find ways to

mitigate the risk of accepting and using

emerging technologies. 

Almost any U.S. company that owns

and operates a petroleum refinery or chemical plant where the technology will be

installed and field-tested is eligible to apply. 

For more information, visit the BestPractices solicitation web site at www.oit.

doe.gov/bestpractices/solicitations.shtml.

Hurry, because solicitation applications are

due October 11, 2002.

DOE Announces Technology Deployment Solicitation
Energy Matters, Summer 2002 7

Letters to the Editor 

Energy Matters welcomes

your typewritten letters and

e-mails. Please include your

full name, address, organization, and

phone number, and limit comments to 200

words. Address correspondence to:

David Wagman, Letters to the Editor

NREL, MS 1609

1617 Cole Blvd.

Golden, CO 80401

E-mail: David_Wagman@nrel.gov

We publish letters of interest to readers

on related topics, comments, or criticisms/

corrections of a technical nature. Preference is given to articles that appeared in

the previous two issues. Letters may be

edited for length, clarity, and style. ●

Read more about the benefits energy efficiency training can bring to your organization in Energy Matters Extra. Learn about

the multiple benefits a steam champion

can provide by serving as a link between

senior management and plant operations.

Read Don Casada’s thoughts on how

appropriate energy efficiency training can

help nurture the next generation of engineers. Find out how your company could

be eligible for matching funds for a plantwide assessment that could save your company energy and money, and possibly

reduce environmental impacts. Check out

the latest industrial energy efficiency publications released by OIT. And, read the full

results of the recent Energy Matters reader

questionnaire.

Log on to Energy Matters Extra at www.

oit.doe.gov/bestpractices/energymatters/

emextra. ●

EXTRA 

Ask the

Clearinghouse

“Plant Air” and 

“Instrument Air”

This column highlights key questions from

industrial customers to the OIT Clearinghouse—your source for the full portfolio of

OIT resources and technical advice about

motor, steam, compressed air, combined

heat and power, and process heating 

systems. 

Clearinghouse engineers and technical

staff expertly answer industrial efficiency

questions, 11 hours a day, Monday through

Friday. The Clearinghouse also has access

to industry experts around the country. Call

the OIT Clearinghouse at 800-862-2086,

or go to www.oit.doe.gov/clearinghouse/.

Q: For a compressed air system, what

are the definitions of “plant air” and

“instrument air”?

A: The Instrument Society of America

has published its Quality Standard for

Instrument Air (ANSI/ISA-S7.0.01-1996).

The purpose of the standard is to provide a

definition for instrument-quality air. The

scope of the standard includes:

■ Limits for moisture content

■ Limits for entrained particle size and oil

content

■ Establishing an awareness of possible

sources of corrosive or toxic contamination entering the air system through the

compressor suction

■ Establishing standard air supply pressures, limit values, and operating ranges

for pneumatic devices.

The standard establishes a set of specifications for instrument-quality air. First, the

pressure dew point measured at the dryer

outlet shall be at least 18°F below the minimum temperature to which any part of the

instrument air system is exposed. Second,

the pressure dew point shall never exceed

39°F at line pressure. Third, a maximum

particle diameter of 40 micrometers is 

designated as generally acceptable. Pneumatic control devices that require instrument air with less than 40 micrometer

particle sizes shall be equipped with additional filtration to meet the particle size

limits for the device.

Lubricant content in instrument-quality

air should be as close to zero as possible, 

and under no circumstances exceed 1 part

per million by weight or volume. Instrument air shall also be free of corrosive contaminants that may be drawn into the air

system intake due to painting, chemical

cleaning, or engine exhaust.

Plant Air 

The International Organization for Standardization has established a standard (ISO

8573-1) that designates air quality classes

(shown in Table 1). Classes are based upon

the maximum particle size and concentration of solid contaminates, maximum pressure dew point, and maximum oil content. 

The ISO standard contains a set of typical air quality class recommendations.

Recommendations for plant and instrument

air are shown in Table 2. ●

TABLE 1. ISO 8573-1 AIR QUALITY CLASS STANDARDS

Air Quality Solid Solid Max. Pressure Max. Oil 

Class Contaminants Contaminants Dew Point °F Content oz/ft3

Max. Particle Max. ConcenSize Microns tration oz/ft3

1 0.1 0.1 -94.0 0.01

2 1.0 1.0 -40.0 0.1

3 5.0 5.0 -4.0 1.0

4 15.0 8.0 37.4 5.0

5 40.0 10.0 44.6 25.0

6 — — 50.0 —

TABLE 2. TYPICAL AIR QUALITY CLASSES

Application Solid Contaminants Water Oil

Plant Air Class 4 Class 4 Class 5

Instrument Air Class 2 Class 2 Class 3 
INFORMATION

CLEARINGHOUSE

Do you have questions about 

using energy-efficient process

and utility systems in your industrial 

facility? Call the OIT Information Clearinghouse for answers, Monday through

Friday 9:00 a.m. to 8:00 p.m. (EST).

Fax: 360-586-8303, or access our 

homepage at www.oit.doe.gov/

clearinghouse.

HOTLINE: 800-862-2086

DOE Regional Office Representatives

■ David Godfrey, Atlanta, GA, 

404-562-0568

■ Scott Hutchins, Boston, MA, 

617-565-9765

■ Brian Olsen, Chicago, IL, 

312-886-8579

■ Jack Jenkins, Denver, CO, 

303-275-4824

■ Chris Cockrill, Seattle, WA, 

816-873-3299

■ Joseph Barrett, Philadelphia, PA, 

215-656-6957

This document was produced for the Office 

of Energy Efficiency and Renewable Energy at

the U.S. Department of Energy (DOE) by the 

National Renewable Energy Laboratory, a DOE

national laboratory.

DOE/GO-102002-1605 • Summer 2002

T OF ENERGY

DEPARTMEN

U

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NITED STAT S OFA ERICA

M

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OHIO TECHNOLOGY SHOWCASE AND ENERGY FAIR

■ September 24–26, 2002

For more information, call Sara Dillich at 202-586-7925

GLASS PROBLEMS CONFERENCE

■ October 22–23, 2002, Columbus, OH

For more information, contact Elliott Levine at Elliott.Levine@ee.doe.gov

ENERGY EFFICIENCY WORKSHOPS IN PARTNERSHIP WITH AICHE

■ November 6–8, 2002, Indianapolis, IN

For more information, contact AIChE customer service at 800-242-4363

National Renewable Energy Laboratory

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BestPractices

The Office of Industrial Technologies (OIT)

BestPractices initiative and its Energy Matters newsletter introduce industrial end

users to emerging technologies and wellproven, cost-saving opportunities in motor,

steam, compressed air, and other plantwide systems. For overview information

and to keep current on what is happening

office wide, check out the newsletter—The

OIT Times—at www.oit.doe.gov/oit-times.

Coming Events

To keep up-to-date on OIT training and other events, check the calendar regularly on

Energy Matters Extra at www.oit.doe.gov/bestpractices/energymatters/emextra.