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Steam Utilization PDF
Steam Utilization PDF
DESIGN
OF FLUID
SYSTEMS
Published by
PREFACE
Recognizing the on-going need for education as it relates to the
fundamentals of steam including the most efficient use of its heat
content, Spirax Sarco has developed the Steam Utilization Course.
This handbook represents over 80 years of steam experience in the
proper selection, sizing and application of steam traps, pressure
and temperature controls, and condensate recovery systems
in major industrial plants throughout the world.
The Steam Utilization Course can be used in conjunction with
Design of Fluid SystemsHook Ups for a complete and
concise knowledge of the use of steam for heat.
Spirax Sarco
Spirax Sarco is the recognized industry standard for
knowledge and products and for over 85 years has
been committed to servicing the steam users worldwide. The existing and potential applications for steam,
water and air are virtually unlimited. Beginning with
steam generation, through distribution and utilization
and ultimately returning condensate to the boiler,
Spirax Sarco has the solutions to optimize steam system performance and increase productivity to save
valuable time and money.
In todays economy, corporations are looking for reliable products and services to expedite processes and
alleviate workers of problems which may arise with
their steam systems. As support to industries around
the globe, Spirax Sarco offers decades of experience,
knowledge, and expert advice to steam users worldwide on the proper control and conditioning of steam
systems.
Spirax Sarco draws upon its worldwide resources of
over 3500 people to bring complete and thorough service to steam users. This service is built into our
products as a performance guarantee. From initial consultation to effective solutions, our goal is to
manufacture safe, reliable products that improve productivity. With a quick, responsive team of sales
engineers and a dedicated network of local authorized
distributors Spirax Sarco provides quality service and
support with fast, efficient delivery.
Reliable steam system components are at the heart of
Spirax Sarcos commitment. Controls and regulators
for ideal temperature, pressure and flow control; steam
traps for efficient drainage of condensate for maximum
heat transfer; flowmeters for precise measurement of
liquids; liquid drain traps for automatic and continuous
drain trap operation to boost system efficiency; rotary
filters for increased productivity through proper filtering
of fluids; condensate recovery pumps for effective condensate management to save water and sewage
costs; stainless steel specialty products for maintaining
quality and purity of steam; and a full range of pipeline
auxiliaries, all work together to produce a productive
steam system. Spirax Sarcos new line of engineered
equipment reduces installation costs with prefabricated
assemblies and fabricated modules for system integrity and turnkey advantages.
From large oil refineries and chemical plants to local
laundries, from horticulture to shipping, for hospitals,
universities, offices and hotels, in business and government, wherever steam, hot water and compressed
air is generated and handled effectively and efficiently,
Spirax Sarco is there with knowledge and experience.
For assistance with the installation or operation of any
Spirax Sarco product or application, call toll free:
1-800-883-4411
3
Contents
BASIC STEAM ENGINEERING PRINCIPLES
INTRODUCTION
WHAT IS STEAM
DEFINITIONS
STEAM GENERATION
8
10
10
11
Steam Velocity
12
13
14
15
17
18
Plant Efficiency
18
Energy Efficiency
18
Process Control
18
18
19
19
19
20
21
22
Manual Controls
22
Self-Acting Controls
22
23
Pneumatic Controls
24
24
26
CONDENSATE REMOVAL
26
Air Venting
27
Thermal Efficiency
27
Reliability
27
Contents
STEAM TRAPS
Mechanical Steam Traps
Thermostatically or Temperature Controlled Traps
Thermodynamic Steam Traps
Variations on Steam Traps
STEAM TRAP TESTING METHODS
Visual Testing
Ultrasonic Trap Testing
Temperature Testing
Conductivity Testing
BY-PASSES AROUND STEAM TRAPS
PREVENTIVE MAINTENANCE PROGRAMS
Steam Trap Fault Finding
Steam Trap Discharge Characteristics
STEAM TRAP SELECTION
Waterlogging
Lifting of Condensate
REQUIREMENTS FOR STEAM TRAP/APPLICATIONS
Application Requirements
Steam Trap Selection Chart
Steam Trap Sizing
STEAM TRACING
CRITICAL TRACING
NON-CRITICAL TRACING
Attaching Tracer Lines
JACKETED PIPE TRACERS
STEAM TRACING MANIFOLDS
CONDENSATE MANIFOLDS
CONDENSATE MANAGEMENT
FLASH STEAM RECOVERY
CONDENSATE RECOVERY SYSTEMS
Electrically Driven Pumps
Non Electric Pressure Powered Pumps
WATERHAMMER IN CONDENSATE RETURN LINES
27
28
30
32
33
37
37
37
37
38
39
39
39
41
41
41
42
42
42
43
44
45
45
45
46
47
48
48
50
51
55
57
58
60
62
What Is Steam
Like many other substances,
water can exist in the form of
either a solid, liquid, or gas. We
will focus largely on liquid and
gas phases and the changes that
occur during the transition
between these two phases.
Steam is the vaporized state of
water which contains heat energy
intended for transfer into a variety
of processes from air heating to
vaporizing liquids in the refining
process.
Perhaps the first thing that
we should do is define some of
the basic terminology that will be
used in this course.
Definitions
BTU
The basic unit of measurement for all types of heat energy
is the British Thermal Unit or
BTU. Specifically, it is the amount
of heat energy necessary to raise
one pound of water one degree
Fahrenheit.
Temperature
A degree of hot or cold measured on a definite scale. For all
practical purposes a measurement from a known starting point
to a known ending point.
Heat
Energy
Saturation
The point where a substance
can hold no more energy without
changing phase (physical state).
Enthalpy
The term given for the total energy, due to both pressure and
temperature of a fluid or vapor,
at any given time or condition.
Gauge Pressure (PSIG)
Pressure shown on a standard
gauge and reflects the pressure
above atmospheric pressure.
Absolute Pressure (PSIA)
The pressure from and above
perfect vacuum
Sensible Heat (hf)
The enthalpy of saturated water.
The heat energy that raises the
water temperature.
Latent Heat(hfg)
The enthalpy of evaporation. The
heat input which produces a
change of water from liquid to
gas.
Figure 1
Steam Saturation Curve Graph at a Specific Boiler Pressure
Temperature/Pressure
Latent Heat
Sensible
Heat
Total Heat
Figure 2
25
20
Flash
Steam
Steam
(Coal)
Steam
(No. 6 Fuel Oil)
(0.5% Sulfur)
Steam
(No. 2 Fuel Oil)
(Refinery)
Steam
(No. 2 Fuel Oil)
(Industrial)
0
Electricity
(Industrial)
Absolute
Pressure
psia
Temperature
Degrees F
Sensible
(hf)
BTU/LB
Latent
(hfg)
BTU/lb
Total
(hg)
BTU/lb
Spec. Volume
Steam (Vg)
ft3/lb
1
2
3
4
5
6
7
8
9
10
11
12
13
14
101.7
126.1
141.5
153.0
162.3
170.1
176.9
182.9
188.3
193.2
197.8
202.0
205.9
209.6
69.5
93.9
109.3
120.8
130.1
137.8
144.6
150.7
156.2
161.1
165.7
169.9
173.9
177.6
1032.9
1019.7
1011.3
1004.9
999.7
995.4
991.5
987.9
984.7
981.9
979.2
976.7
974.3
972.2
1102.4
1113.6
1120.6
1125.7
1129.8
1133.2
1136.1
1138.6
1140.9
1143.0
1144.9
1146.6
1148.2
1149.8
333.0
173.5
118.6
90.52
73.42
61.89
53.57
47.26
42.32
38.37
35.09
32.35
30.01
28.0
14.7
15.7
16.7
17.7
18.7
19.7
20.7
21.7
22.7
23.7
24.7
25.7
26.7
27.7
28.7
29.7
30.7
31.7
32.7
33.7
34.7
36.7
38.7
40.7
42.7
44.7
46.7
48.7
50.7
52.7
54.7
56.7
58.7
60.7
62.7
64.7
66.7
68.7
70.7
72.7
74.7
76.7
78.7
80.7
82.7
212.0
215.4
218.5
221.5
224.5
227.4
230.0
232.4
234.8
237.1
239.4
241.6
243.7
245.8
247.9
249.8
251.7
253.6
255.4
257.2
258.8
262.3
265.3
268.3
271.4
274.0
276.7
279.4
281.9
284.4
286.7
289.0
291.3
293.5
205.6
297.7
299.7
301.7
303.6
305.5
307.4
309.2
310.9
312.7
314.3
180.2
183.6
186.8
189.8
192.7
195.5
198.1
200.6
203.1
205.5
207.9
210.1
212.3
214.4
216.4
218.4
220.3
222.2
224.0
225.8
227.5
230.9
234.2
237.3
240.2
243.0
245.9
248.5
251.1
253.7
256.1
258.5
260.8
263.0
265.2
267.4
269.4
271.5
273.5
275.3
277.1
279.0
280.9
282.8
284.5
970.6
968.4
966.4
964.5
962.6
960.8
959.2
957.6
956.0
954.5
952.9
951.5
950.1
948.6
947.3
946.0
944.8
943.5
942.4
941.2
940.1
937.8
935.8
933.5
931.6
929.7
927.6
925.8
924.0
922.1
920.4
918.6
917.0
915.4
913.8
912.2
901.7
909.2
907.8
906.5
905.3
904.0
902.6
901.2
900.0
1150.8
1152.0
1153.2
1154.3
1155.3
1156.3
1157.3
1158.2
1159.1
1160.0
1160.8
1161.6
1162.3
1163.0
1163.7
1164.4
1165.1
1165.7
1166.4
1167.0
1167.6
1168.7
1170.0
1170.8
1171.8
1172.7
1173.5
1174.3
1175.1
1175.8
1176.5
1177.1
1177.8
1178.4
1179.0
1179.6
1180.1
1180.7
1181.3
1181.8
1182.4
1183.0
1183.5
1184.0
1184.5
26.8
25.2
23.8
22.5
21.4
20.4
19.4
18.6
17.9
17.2
16.5
15.9
15.3
14.8
14.3
13.9
13.4
13
12.7
12.3
12
11.4
10.8
10.3
9.87
9.46
9.08
8.73
8.40
8.11
7.83
7.57
7.33
7.10
6.89
6.68
6.50
6.32
6.16
6.00
5.84
5.70
5.56
5.43
5.31
Absolute
Pressure
psia
84.7
86.7
88.7
90.7
92.7
94.7
96.7
98.7
100.7
102.7
104.7
106.7
108.7
110.7
112.7
114.7
116.7
118.7
120.7
122.7
124.7
126.7
128.7
130.7
132.7
134.7
139.7
144.7
149.7
154.7
159.7
164.7
169.7
174.7
179.7
184.7
189.7
194.7
199.7
204.7
209.7
214.7
224.7
234.7
244.7
254.7
264.7
274.7
284.7
294.7
304.7
314.7
324.7
334.7
344.7
354.7
364.7
374.7
384.7
394.7
404.7
414.7
434.7
454.7
Temperature
Degrees F
316.0
317.7
319.3
320.9
322.4
323.9
325.5
326.9
328.4
329.9
331.2
332.6
333.9
335.3
336.6
337.9
339.2
340.5
341.7
343.0
344.2
345.4
346.5
347.7
348.9
350.1
352.8
355.6
358.3
360.9
363.5
365.9
368.3
370.7
372.9
375.2
377.5
379.6
381.6
383.7
385.7
387.7
391.7
395.5
399.1
402.7
406.1
409.3
412.5
415.8
418.8
421.7
424.7
427.5
430.3
433.0
435.7
438.3
440.8
443.3
445.7
448.1
452.8
457.3
Sensible
(hf)
BTU/LB
286.2
288.0
289.4
291.2
292.9
294.5
296.1
297.6
299.1
300.6
302.1
303.5
304.9
306.3
307.7
309.0
310.3
311.6
313.0
314.3
315.5
316.8
318.0
319.3
320.5
321.8
324.7
327.6
330.6
333.2
335.9
338.6
341.1
343.6
346.1
348.5
350.9
353.2
355.4
357.6
359.9
362.0
366.2
370.3
374.2
378.0
381.7
385.3
388.8
392.3
395.7
398.9
402.1
405.2
408.3
411.3
414.3
417.2
420.0
422.8
425.6
428.2
433.4
438.5
Latent
(hfg)
BTU/lb
898.8
897.5
896.5
895.1
893.9
892.7
891.5
890.3
889.2
888.1
887.0
885.8
884.8
883.7
882.6
881.6
880.6
879.6
878.5
877.5
876.5
875.5
874.5
873.5
872.5
871.5
869.3
866.9
864.5
862.5
860.3
858.0
856.0
853.9
851.8
849.8
847.9
845.9
844.1
842.2
840.2
838.4
834.8
831.2
827.8
824.5
821.2
817.9
814.8
811.6
808.5
805.5
802.6
799.7
796.7
793.8
791.0
788.2
785.4
782.7
779.9
777.4
772.2
767.1
Total (hg)
BTU/lb
ft3/lb
1185.0
1185.5
1185.9
1185.9
1186.8
1187.2
1187.6
1187.9
1188.3
1188.7
1189.1
1189.3
1189.7
1190.0
1190.3
1190.6
1190.9
1191.2
1191.5
1191.8
1192.0
1192.3
1192.5
1192.8
1193.0
1193.3
1194.0
1194.5
1195.1
1195.7
1196.2
1196.6
1197.1
1197.5
1197.9
1198.3
1198.8
1199.1
1195.5
1199.8
1200.1
1200.4
1201.0
1201.5
1202.0
1202.5
1202.9
1203.2
1203.6
1203.9
1204.2
1204.4
1204.7
1204.9
1205.0
1205.1
1205.3
1205.4
1205.4
1205.5
1205.5
1205.6
1205.6
1205.6
Specific
Volume
Steam (Vg)
5.19
5.08
4.97
4.87
1.77
1.37
1.25
1.19
1.10
4.33
4.25
4.17
4.10
4.03
3.96
3.90
3.83
3.77
3.71
3.65
3.60
3.54
3.49
3.44
3.39
3.34
3.23
3.12
3.02
5.93
2.84
2.76
2.68
2.61
2.54
2.48
2.41
2.35
2.30
2.24
2.18
2.14
2.04
1.96
1.88
1.81
1.74
1.68
1.62
1.57
1.52
1.47
1.43
1.39
1.35
1.31
1.27
1.24
1.21
1.18
1.15
1.12
1.07
1.02
Steam Generation
Figure 3 (Cont.): Steam Saturation Table
Gauge
Pressure
psig
Absolute
Pressure
psia
Temperature
Degrees F
Sensible
(hf)
BTU/LB
Latent
(hfg)
BTU/lb
Total (hg)
BTU/lb
ft3/lb
Specific
Volume
Steam (Vg)
460
480
500
520
540
560
580
600
620
640
660
680
700
720
740
760
780
800
474.7
494.7
514.7
534.7
554.7
574.7
594.7
614.7
634.7
654.7
674.7
694.7
714.7
734.7
754.7
774.7
794.7
814.7
461.7
465.9
470.0
474.0
477.8
481.6
485.2
488.8
492.3
495.7
499.0
502.2
505.4
508.5
51.5
514.5
517.5
520.3
443.4
448.3
453.0
457.6
462.0
466.4
470.7
474.8
479.0
483.0
486.9
490.7
494.4
498.2
501.9
505.5
509.0
512.5
762.1
757.1
752.3
747.5
742.8
738.1
733.5
729.1
724.5
720.1
715.8
711.5
707.4
703.1
698.9
694.7
690.7
686.6
1205.5
1205.4
1205.3
1205.1
1204.8
1205.5
1204.2
1203.9
1203.5
1203.1
1202.7
1202.2
1201.8
1201.3
1200.8
1200.2
0099.7
1199.1
.98
.94
.902
.868
.835
.805
.776
.750
.726
.703
.681
.660
.641
.623
.605
.588
.572
.557
Steam Generation
Selection of Working
Pressure
The steam distribution system is an important link between
the steam source and the steam
user. It must supply good quality
steam at the required rate and at
the right pressure. It must do this
with a minimum of heat loss, and
be economical in capital cost.
The pressure at which the
steam is to be distributed is determined by the point of usage in the
plant needing the highest pressure.
We must remember
however that as the steam passes through the distribution
pipework, it will lose some of its
pressure due to resistance to
flow, and the fact that some of it
will condense due to loss of heat
from the piping.
Therefore,
allowance should be made for
this pressure loss when deciding
upon the initial distribution pressure.
Summarizing, we need to
consider when selecting our
working pressure:
Pressure required at point of
usage
Pressure drop along pipe due
to resistance of flow (friction)
Pipe heat losses
It is a recommended practice
to select a boiler operating pressure greater than what is actually
required.
This is an acceptable practice as long as it is understood
that selecting a boiler with a
much greater operating pressure
than is required, then operating it
at the lower pressure will cause a
loss in efficiency of the boiler.
This efficiency loss comes from
the increased radiation and convection losses. Another area of
efficiency loss comes from the
lower quality (dryness) of the
steam produced due to increased
Figure 4
Boiler Operating at Design
Pressure
Design Pressure
Smaller Specific Volume
Greater Separation Area
Dry Steam
Proper Steam Velocities
(4 to 6,000 fpm)
Lower Pressure
Greater Specific Volume
Decreased Separation Area
Lower Quality of Steam
Increased Steam Velocities
11
Steam Generation
Steam Velocity
Pipe Size
(Schedule 40 pipe)
Process Steam
8000 to 12000 ft/min
3"
Heating Systems
4000 to 6000 ft/min
11-1 1/4"
/2"
2
2-1 "
/2"
20000
1"
1/2
"
12000
10000
8000
3/4
"
4"
6"
5"
3000
8"
2000
10
1 "
14 2"
"
16
"
1000
50000
40000
30000
20000
10000
8000
0
25 0
20 0
15 25
1 00
1 5
7
50
6000
5000
4000
25
3000
2000
Capacity lb/h
6000
5000
4000
Velocity ft/min
Reasonable
Steam Velocities
in Pipes
1000
800
B
0
25 00
2 0
15 25
1 00
1 5
7
600
500
400
50
300
25
200
10
5
12
10
100
Product/Ambient
Insulation
Thickness
5"
6"
8"
10"
12"
14"
2"
4"
2"
4"
2"
4"
2"
4"
2"
4"
2"
4"
2"
4"
80
66
41
77
47
89
53
109
63
132
75
153
166
92
150
123
77
14
87
166
99
205
120
247
140
286
161
311
173
200
164
10
19
117
221
131
274
159
329
187
382
214
415
231
250
205
12
240
146
276
164
342
199
412
235
477
268
519
288
300
246
153
288
175
331
198
411
238
495
281
573
321
622
346
350
288
178
336
205
386
230
478
278
576
328
668
375
726
404
Figure 7
The Practical Effect of Air & Water Films
Metal
Heating
Surface
250F
210F
Steam
at 15
psi
Air
Film
Condensate
Film
Water
Film
Water
Being
Heated
13
Figure 8
Air Venting and Steam Trap
at End of Main
Balanced
Pressure
Thermostatic
Air Vent
Steam Main
Drip Leg
Thermo-dynamic
Steam Trap Set
with Trap Tester
14
Figure 9
Process
Vessels
Space
Heating
System
Pans
Condensate
Vats
Steam
Make-up Water
Condensate
Feed Tank
Boiler
Feed Pump
Figure 10
Terms
Steam Header
Steam Separator
Steam Strainer
15
Main Size
2"
6.2
6.9
7.5
8.4
9.9
11.0
12.0
12.8
13.7
14.5
15.3
16.0
17.2
25.0
27.8
30.2
32.7
38.0
45
52
62
71
78
80
2-1/2"
9.7
11.0
11.8
13.4
15.8
17.5
19.0
20.3
21.7
23.0
24.2
25.3
27.3
38.3
43
46
50
58
64
72
79
87
94
97
3"
12.8
14.4
15.5
17.5
20.6
22.9
24.9
26.6
28.4
30
31.7
33.1
35.8
51
57
62
67
77
86
96
106
117
126
129
4"
18.2
20.4
22.0
24.9
90.3
32.6
35.3
37.8
40
43
45
47
51
75
83
91
98
113
126
140
155
171
184
189
5"
24.6
27.7
29.9
33.8
39.7
44
48
51
55
58
61
64
69
104
116
126
136
203
227
253
280
309
333
341
6"
31.9
35.9
38.8
44
52
57
62
67
71
75
79
83
89
143
159
173
187
274
305
340
376
415
448
459
8"
48
48
58
66
78
86
93
100
107
113
119
125
134
217
241
262
284
455
508
566
626
692
746
764
10"
68
77
83
93
110
122
132
142
152
160
169
177
191
322
358
389
421
670
748
833
922
1018
1098
1125
12"
90
101
109
124
145
162
175
188
200
212
224
234
252
443
493
535
579
943
1052
1172
1297
1432
1544
1584
14"
107
120
130
146
172
192
208
222
238
251
265
277
299
531
590
642
694
1132
1263
1407
1558
1720
1855
1902
16"
140
157
169
191
225
250
271
290
310
328
347
362
390
682
759
825
893
1445
1612
1796
1988
2194
2367
2427
18"
176
198
213
241
284
316
342
366
391
414
437
456
492
854
971
1033
1118
1835
2047
2280
2524
2786
3006
3082
20"
207
233
251
284
334
372
403
431
461
487
514
537
579
1045
1163
1263
1367
2227
2485
2767
3064
3382
3648
3741
24"
308
324
350
396
465
518
561
600
642
679
716
748
807
1182
1650
1793
1939
3227
3601
4010
4440
4901
5285
5420
0F
Correction
Factor *
1.50
1.44
1.41
1.37
1.32
1.29
1.27
1.26
1.25
1.24
1.23
1.22
1.21
1.20
1.18
1.17
1.16
1.156
1.147
1.140
1.135
1.130
1.128
1.127
* For outdoor temperature of 0F, multiply load value in table for each main size by correction factor shown
Figure 12: Running Load in Pounds per Hour per 100 Ft. of Insulated Steam Main
Ambient Temperature 70F. Insulation 80% efficient.
Load due to radiation and convection for saturated steam.
Steam
Pressure
psi
10
30
60
100
125
175
250
300
400
500
600
800
1000
1200
1400
1600
1750
1800
Main Size
2"
6
8
10
12
13
16
18
20
23
27
30
36
43
51
60
69
76
79
2-1/2"
7
9
12
15
16
19
22
25
28
33
37
44
52
62
73
85
93
96
3"
9
11
14
18
20
23
27
30
34
39
44
53
63
75
89
103
113
117
4"
11
14
18
22
24
26
34
37
43
49
55
69
82
97
114
132
145
150
5"
13
17
24
28
30
33
42
46
53
61
68
85
101
119
141
163
179
185
6"
16
20
27
33
36
38
50
54
63
73
82
101
120
142
168
195
213
221
8"
20
26
33
41
45
53
62
68
80
91
103
131
156
185
219
253
278
288
10"
24
32
41
51
56
66
77
85
99
114
128
164
195
230
273
315
346
358
12"
29
38
49
61
66
78
92
101
118
135
152
194
231
274
324
375
411
425
14"
32
42
54
67
73
86
101
111
130
148
167
214
254
301
356
412
452
467
16"
36
48
62
77
84
98
116
126
148
170
191
244
290
343
407
470
516
534
18"
39
51
67
83
90
107
126
138
162
185
208
274
326
386
457
528
580
600
* For outdoor temperature of 0F, multiply load value in table for each main size by correction factor shown.
16
20"
44
57
74
93
101
119
140
154
180
206
232
305
363
430
509
588
645
667
24"
53
68
89
111
121
142
168
184
216
246
277
365
435
515
610
704
773
800
0F
Correction
Factor *
1.58
1.50
1.45
1.41
1.39
1.38
1.36
1.35
1.33
1.32
1.31
1.30
1.27
1.26
1.25
1.22
1.22
1.21
Figure 13
A Typical Steam Metering Station
Pipeline
Strainer
Steam
Separator
Separator
&Trap Set
Steam
Meter
6 Pipe
Diameters
Eccentric
Reducers
3 Pipe
Diameters
Plant Efficiency
Energy Efficiency
Steam meters can be used to
monitor the results of energy saving schemes and to compare the
efficiency of one piece of plant
with another.
Process Control
Steam meters can indicate
that the correct quantity of steam
is being supplied to a process
and that it is at the correct temperature and pressure.
Figure 14a
Direct Acting Pressure Reducing Valve
Inlet
Outlet
19
Figure 14b
Pilot Operated Reducing Valve
A
C
F
A
E
H
Inlet
K
L
Pneumatically Operated
Valves
Pneumatically operated control valves with actuators and
positioners (Fig. 15) being piloted
Figure 15
OUT
Air Supply
Figure 16
Pressure Reducing Station Installation
High Pressure
Decrease Piping Size
OUT
IN
Strainer
(On Side)
Low Pressure
Increase Piping Size
Steam
Separator
21
22
Valve Plug
Movement
Actuator to Valve
Connection
Sensor
Movement
caused by
Adding Temp
to Sensor
Add 1C to
Sensor
Overload Bellows
Thrust Pin
Capillary
Figure 18
Pilot Operated Temperature Control Valve
Temperature
Adjustment
Temperature
Pilot
Bulb
Orifice
Inlet
Main Valve
Control Pressure
Main Diaphragm
23
Figure 19
Pneumatic Pilot Operated Temperature Control
Air Regulator
Actuator
IN
24
Steam
Separator
Positioner
Figure 20a
Selected Proportional Band
Selected
Proportional Band
or Offset at Full
Load
100% Load
for Specific
Application
Load
0% Load
F P-Band
Application
Hot Water Service Storage Calorifier
7 - 14F
4 - 7F
2 - 5F
Bulk Storage
4 - 18F
Plating Tanks
4 - 11F
Figure 20b
Acceptable P-bands
25
26
CALCULATION:
3300 lbs./hour
x 8760 hrs/ year
28,908,000 lbs/year
or 3,412,897 gal./year
Another factor to calculate is
the monetary value of the condensate. Condensate contains
heat, chemicals and water. It is
usually as much as one third of
the cost of generating steam. If
our example were to assume a
steam generation cost of $3.00
for each 1,000 lbs., our example
of lost condensate and energy
calculates as follows:
CALCULATION:
28,908,000 lbs/year
= 28,980
1,000
28,980 x $1.00 = $ 28,980/year
Another small user in a
steam system, where condensate
is being created and discharged,
is that of the tracer lines. Tracers
are those lines that follow the flow
of process liquids to prevent them
from freezing or solidifying.
Tracer lines, however, are not
usually meant to be a type of heat
exchanger. They merely follow
the path of the process fluids to
keep them hot and less viscous.
One of the extreme costs which
are hidden in everyday plant production is the cost of pumping
liquids from one point to another.
Heavy, viscous liquids are obviously more difficult to pump so
amperage at the electrical pumps
rises. As amperage rises, electrical use rises and so does the
amount of money spent on pumping liquids.
If the tracer lines do their job,
they allow heat to transfer into the
product liquids as heat is lost
through the insulation. If the efficiency of insulation is relatively
good, the steam usage would be
reasonably low. It would not be
unusual for this type of tracing to
generate only about 25 lbs/hour.
Air Venting
At start up the trap must be
capable of discharging air. Unless
air is displaced, steam cannot
enter the steam space and warming up becomes a lengthy
business.
Standing
losses
increase and plant efficiency falls.
Separate air vents may be
required on larger or more awkward steam spaces, but in most
cases air in a system is discharged through the steam traps.
Here thermostatic traps have a
clear advantage over other types
since they are fully open at start
up.
Float traps with inbuilt thermostatic air vents are especially
useful, while many thermodynamic traps are quite capable of
handling moderate amounts of
air. The small bleed hole in the
inverted bucket trap or the orifice
plate generally leads to poor air
venting capacity.
Thermal Efficiency
Once the requirements of air
and condensate removal have
been considered we can turn our
attention to thermal efficiency.
This is often simplified into a consideration of how much heat is
profitably used in a given weight
of steam.
On this basis the thermostatic trap may appear to be the best
choice. These traps hold back
condensate until it has cooled to
something below saturation temperature. Provided that the heat
is given up in the plant itself, to
the space being heated or to the
process, then there is a real saving in steam consumption.
Indeed, there is every inducement to discharge condensate at
the lowest possible temperature.
Reliability
It has been said that good
steam trapping, means the
avoidance
of
trouble.
Undoubtedly, reliability is a major
consideration. Reliability means
the ability to perform under the
prevailing conditions with the
minimum of attention.
Given thought, the prevailing
conditions can usually be predicted.
Corrosion due to the condition
of the condensate or of the surrounding atmosphere may be
known, and can be countered by
using particular materials of construction.
Waterhammer, often due to a lift
after the trap, may be overlooked
at the design stage and can
mean unnecessary damage to
otherwise reliable steam traps.
Steam Traps
First, a definition of a steam
trap may be in order to fully
understand the function of this
piece of equipment. A steam trap
is an automatic valve designed to
stop the flow of steam so that
heat energy can be transferred,
and the condensate and air can
be discharged as required. If we
break this definition down into
sections, it is first of all an automatic valve.
This infers that there is some
form of automatic motion that
must take place. It is designed
to stop the flow of steam so that
heat energy can be transferred.
This portion of the description is
such that it would imply the transmission of energy whether by
flowing down a distribution pipe
or giving up energy to a product
in a heat exchanger. The definition also continues to say
discharge condensate and air as
required. This portion of the definition implies that some types
may handle differing amounts of
either condensate or air, or even
a combination of the two.
In the beginning, steam traps
were manually operated valves.
27
Figure 21
Float and Thermostatic Steam Trap
Figure 22
Inverted Bucket Trap
29
Thermostatically or
Temperature Controlled Traps
The balanced pressure or
bellows type of steam trap was
first manufactured with a bellows
of copper design. This bellows
(Fig. 23) had a liquid fill which, in
the beginning, was distilled water.
Modern thermostatic type traps
still have a liquid fill but it is made
up of a distilled water and alcohol
mixture and they are contained
within an enclosed capsule rather
than a bellows. Alcohol was
added to the fill to lower its boiling
point.
The capsules work by
exploiting the difference in the
boiling point between the alcohol
mixture and the surrounding condensate. As the temperature of
the condensate gets closer to
steam temperature, the mixture
contained within the capsule gets
closer to its boiling point at a set
temperature below that of steam
(before steam reaches the trap),
the mixture evaporates. This
results in an increase in internal
Figure 23
Stainless Steel Bellows for Thermostatic Trap
Valve Open
Figure 24
Bimetallic Trap
31
Figure 25
Liquid Expansion Thermostatic Trap
32
Vent
Figure 27
Float Trap
33
34
Figure 28
Free Float Trap
Figure 29
Open Top Bucket Trap
Figure 30
Balanced Pressure Capsule
for Thermostatic Trap
pressed when filled and sealed.
The problem with having a
liquid fill on the inside of a bellows
still exists. That problem being
the fill over expanding and rupturing the bellows when a small
amount of superheat may be
allowed to reach the trap internals. There have been two
attempts to try to correct for this.
As mentioned earlier, thermostatic type traps usually (but not
always) reach a point where the
inside pressure balances to the
outside pressure of the bellows.
This causes them to basically
average the pressure temperature and constantly dribble. One
attempt to solve the over expansion problem and dribble
discharge was to create a single
wafer type of capsule where the
center portion containing the
valve was forced in during the filling procedure of manufacturing.
This created a bowing type of
appearance and caused the capsule to operate more like the
bottom of an oil can. As the fill
vaporized it popped the portion
of the capsule outward and
forced the valve head on to the
seat. As the fill cooled and con-
Figure 31
Simple Bimetallic Trap
tracted it popped again to the
original position and opened the
valve to allow discharge. This
popping action meant that it
would insure the trapping of some
condensate around the capsule
at all times and prevent over
expansion. Superheat has no
condensate, as you know, and
also has a tendency of vaporizing
any condensate in a system once
it is up to full temperature. This
still created over expansion, but
the trap now had a more distinct
on and off type of operation when
used on saturated steam lines.
The problem with this type of
trap was the design and location
of the liquid fill that causes the
trap to operate. Later design of
the capsule put the liquid fill on
the outside of the moving part of
the wafer. The result of the fill
vaporizing and forcing the valve
to the seat in part then doubles
the thickness of the wafer at its
weakest point. It is also apparent
that the fill then be encased in a
thicker shell to prevent water
hammer damage to the element.
As you can see, the operation of
this type of design improvement
for the thermostatic trap is much
36
Figure 32
Impulse Trap
design. The piston design (Fig.
32) as you can see, incorporates
a constant bleed hole through the
piston stem and seating disk.
This relieves the pressure above
and allows the disk to open to discharge. This hole is very small
and easily plugged rendering it
ineffective. Other design differences in TD traps is location and
sizes of outlet orifices. Some
types use two different sized orifices located on opposite sides of
the trap and in line with the piping. This causes the disk to
operate in a tilting fashion rather
than straight up and down as with
the three symmetrically spaced
and same sized orifices. The tilting action causes the disk to spin
during the closing sequence and
cause wear on the outside edge
of the seating surface and disk
itself. Wear on this type of trap
should be kept as even as possible to prolong the life expectancy.
Another variation to disk traps is
the inlet flow directions. Some
Visual Testing
The first point that has to be
understood when visually testing
a steam trap is that it will be a
very rare occasion where the only
matter coming out of a steam trap
will be water!! Almost always,
there will be varying mixtures of
flash steam and water and in
some cases the visual discharge
will be all flash steam. So the first
thing to remember is that we do
not want to look for water only,
nor do we want to attempt to
decide if we are seeing the
Temperature Testing
Temperature testing of traps
involves measuring the temperature at, or close to, the inlet and
outlet of the steam trap.
Pyrometers, temperature sensitive crayons, paint, band-aids and
thermocouples all have their
advocates. Unfortunately, these
methods are of limited use since
the temperatures of condensate
and flash steam on the downstream side of a correctly working
steam trap are controlled by the
pressure in the condensate return
system. A very large percentage
of steam traps in the USA are
thought to discharge into 0
PSIG,
atmospheric
gravity
returns, which means that the
maximum temperature that could
be expected is 212F, regardless
of the traps operating condition.
37
Hole
Conductivity Testing
A more recent development
in trap testing uses the electrical
conductivity of condensate. This
involves the installation of a
chamber (Fig. 33) containing an
inverted weir upstream of the
steam trap shown as follows.
With the trap working normally, condensate flows under this
weir and out through the trap.
There is a small hole at the top of
the weir that equalizes the pressure on each side. A sensor is
inserted in the chamber on the
upstream side which detects the
presence of condensate by completing an electrical circuit with
the condensate. A portable indicator is plugged into the sensor
and the indicator provides the
ability to read a completed circuit
on the sensor.
If the trap
becomes defective and begins
blowing steam, equilibrium on
Steam Trap
Sensor
Chamber
Live Steam
Weir
Condensate
Green Light:
Trap Working Correctly
Red Light:
Trap Passing Live Steam
Type 30 Indicator
Figure 33
Conductivity Trap Testing System
38
Preventive Maintenance
Programs
In order to ensure that pressure reducing valves, temperature controls, steam traps, etc.
give long life and trouble-free service, it is essential to carry out a
program of planned preventive
maintenance. In general, this will
mean regular cleaning of strainer
screens and replacement of any
internals which are beginning to
show signs of wear. It is always
advisable to hold a stock of
spares recommended by the relevant manufacturer and a number
of standby valves and traps which
are on hand for use in an emergency.
Most steam system maintenance will have to be carried out
during an annual shutdown, but it
is usually easier to spread the
work evenly over the course of an
entire year. Most items will only
need attention once every twelve
months,
although
strainer
screens may need more frequent
cleaning, especially in the case of
newly installed systems. In conclusion, it may be useful to list
some of the causes of problems
commonly experienced with the
various patterns of steam traps
which are available.
Balanced Pressure
Thermostatic Trap
Symptom-Trap blows steam
Isolate the trap and allow it to
cool before inspecting for dirt. If
the seat is wire-drawn, replace all
the internals including the thermostatic element. The original
has probably been strained by
the continuous steam blow. If the
valve and seat seem to be in
good order, then check the element. To check the element
remove the complete element
and holder assembly from the
trap. Place the complete assembly in a pan of boiling water below
the water level in the pan with the
discharge end pointing up. Leave
the assembly submerged in the
boiling water for 5 minutes then
carefully lift the assembly out of
the water, as the element is
removed from the water there
should be a water accumulation
in the discharge of the element.
Set the element assembly on a
table, still with the discharge end
up and observe the water in the
discharge side of the element. If
the element is working correctly,
the water will remain in the discharge until the element cools
then the water will drain out onto
the table. If the element has
failed, the water will leak out of
the immediately.
39
40
Conclusion
It is important to know the
type of trap discharge (Fig. 34)
which should be expected when
making maintenance checks or
trap testing. The table on the following page sets out the usual
discharge characteristics of the
most commonly used traps.
Thermodynamic Disc
Bimetallic Thermostatic
Inverted Bucket
Waterlogging
With most steam heated
equipment it is desirable, and
very frequently essential, to discharge condensate as soon as it
forms in the steam space.
Although sensible heat in the
condensate is usable heat, a
much greater rate of heat transfer
will be obtained if only the steam
is in contact with the heat transfer
surface.
Steam traps of the mechanical type should always be chosen
for applications which require
rapid
condensate
removal.
Thermostatic type traps cannot
release condensate until it has
cooled a set number of degrees
below steam temperature, resulting in waterlogging the steam
space. There are, however, a
number of occasions when such
waterlogging may be perfectly
acceptable and even desirable.
41
ticularly concerned with the problems which may arise from lifting
condensate by the steam pressure at the trap inlet.
For every 1 psi of steam
pressure at the trap, condensate
can be lifted to a height of
approximately 2.3 feet. In order
to lift condensate, the trap must
have positive steam pressure at
all times. There are disadvantages to lifting condensate in this
manner. In the first place, the
necessary steam pressure may
not always be available at the
trap inlet. If, for example, the normal operating pressure is 25 psi,
it is theoretically possible to lift
the condensate 57.5 feet.
However, on a cold start up, the
steam pressure may for a time
drop to, or even below, zero.
Until this pressure builds up, condensate cannot be removed from
the equipment and will collect in
the steam space. This will result
in a greatly extended heat up
Figure 35
Requirements for Steam Trap/Applications
DISCHARGE
DISCHARGE TEMPERATURE
AIR HANDLING
Balanced Pressure
Continuous (Dribble)
20 - 40 deg. F Subcool
Excellent
Bi-metallic
Continuous (Dribble)
Excellent
(but may close
too quickly due to
subcooling)
Inverted Bucket
Intermittent
Limited
Continuous
Excellent
Disk (TD)
Intermittent
2 to 10 deg. F Subcool
Limited
APPLICATION REQUIREMENTS
42
APPLICATION
DISCHARGE
SUB-COOL
AIR HANDLING
Drip
Continuous or Intermittent
Little
Little
Tracer/Critical
Continuous or Intermittent
Little
Little
Tracer/Non-Critical
Continuous
Some
None
Process
Continuous
None
Much
1st Choice
2nd Choice
Float &
Thermo- Balanced
Liquid
Inverted
Float &
Thermo- Balanced
Liquid
Inverted
Thermostatic Dynamic Pressure Bimetallic Expansion Bucket Thermostatic Dynamic Pressure Bimetallic Expansion Bucket
Application
Steam Mains
to 30 psig
30-400 psig
to 600 psig
to 900 psig
to 2000 psig
with Superheat
Separators
Steam Tracers
Critical
Non-Critical
Heating Equipment
Shell & Tube Heat Exchangers
Heating Coils
Unit Heaters
Plate & Frame Heat Exchangers
*
*
*
*
Radiators
General Process Equipment
to 30 psig
to 200 psig
to 465 psig
*
*
*
to 600 psig
to 900 psig
to 2000 psig
Hospital Equipment
Autoclaves
Sterilizers
Evaporators
Reboilers
Rotating Cylinders
Freeze Protection
Vulcanizers
43
Steam Tracing
steam is generated. This flash
steam tends to choke the discharge orifice, reducing its
effective area. As the condensate temperature rises, the
amount of flash steam generated
will increase and the discharge
capacity of the trap will decrease.
The extent of which condensate
temperature affects the traps discharge capacity is relative to its
temperature below saturation
temperature -- lower temperatures, lower flashing rates.
Steam Tracing
There are two typical applications of tracing.
They are
typically referred to as either
process fluid (critical) or freeze
protection (non-critical) tracing.
There are different requirements
for each as far as heat is concerned, so we will separate their
requirements prior to discussing
how to attach tracing to the application.
Tracing is as its name
implies, a pipe or tube following
either process fluid lines or lines
where it is desirable to prevent
freezing during the winter
months. Steam tracing is the distribution of steam through small
bore tubing or pipes which basically transfer heat to a larger pipe
to keep fluids from becoming viscous, solidifying or freezing.
Figure 37
Tracer Line Attachments
18" Max.
Process Fluid
Tracer Tubing
Stainless Wire (Wrapped)
Process Fluid
Tracer Tubing
Insulation
Process Fluid
Steam Tracer
45
Steam Tracing
Figure 38
Figure 39
Insulation
Process Fluid
Insulation
Process Fluid
Heat Transfer Paste
Tracer Tube
Attaching Tracers
The easiest method of tracing is by attaching copper tubing
to the pipe. It is used mostly
because of the abundance of
copper tubing and the cost which
is relatively low. The tubing is
attached in the lower quadrant of
the pipe being traced (Fig. 41).
Another important consideration
in tracing is to oppose the two
flows, fluids in the process piping
and steam in the tracer tubes.
This may not always be practiced, however, but there are
some solid reasons why one
would want to consider this.
Think about what the tracer job is
- maintain heat already absorbed
by the process fluid. As it transfers from point A to point B in
the plant, heat will naturally be
lost through the insulation. The
46
Steam Tracing
Figure 40
Jacketed Pipe
Steam In
Steam Out
Process
Flow In
Condensate Out
Figure 41
Pipe Support
Multiple tracer lines attached to lower half
of process fluid lines. Insulation not shown
Process Pipe
Tracers
Pipe
Support
Figure 42
Horizontal Tracing
Tracing lines that must pass over flanges should pass in the
horizontal. If it is required to place a connection fitting along
side of flanges, they should also be placed horizontally.
47
Steam Tracing
Figure 43
Jacketed Tracing System
Stop
Valve
Air Vent
Steam
25P Valve
Process Pipe
Jacket
TD 42
NOTE: Each section of jacketed pipe
should be trapped. Steam jumper lines
should continue over the top of the flanges.
Condensate to grade
Figure 44
Steam Connection Line Sizing for Jacketed Pipe
STEAM CONNECTION LINE SIZING FOR JACKETED PIPE
Product Line
2-1/2"
3"
4"
6"
8"
10"
Jacket Diameter
4"
6"
6"
8"
10"
12"
Steam Manifolds
Steam manifolds are most
helpful in running the steam to
the system. Manifolds are easily
maintained and located as
opposed to individually valving
areas of a plant. A centralized
location for manifolds (Fig. 45a)
ensure operators of turning on
and off the correct valves for tracing. Manifolds should be fitted
with a tag that identifies what
lines are traced and how many
lines are going to that particular
process line. Other considera48
Steam Connection
1/2"
3/4"
3/4"
3/4"
1"
1"
Condensate Manifolds
Condensate manifolds (Fig.
45b) are also very useful in any
typical plant that uses tracing.
The condensate manifold itself
locates traps and tracers in a
small given area. The condensate from the tracer lines is
usually very high quality condensate and should be collected and
returned to the boiler. There is
normally no cross contamination
of product fluids to tracer lines.
Condensate manifolds also make
it very easy to find and monitor
the tracing traps being used.
Each trap station on a manifold
Steam Tracing
Air
Vent
Steam Out
Vertical Manifold
Horizontal Manifold
Steam Out
Steam
Trap
Figure 45a
Steam Manifolds
Steam
Trap
Figure 45b
Condensate Manifolds
Figure 46
NUMBER OF 1/2 TRACERS USED WITH DIFFERENT SIZES OF PRODUCT LINES
Type A
Type B
Type C
General Frost
protection or
where solidification
may occur at
temps below 75F
Where solidification
may occur at temps
between
75-150F
Where solidification
may occur at temps
between
150-300F
Condensate Management
Figure 47
Switch Back Tracing Line
End View
Note:
Condensate
pipe is
always
sloped in a
downward
direction.
In some
cases, using
switch back
tracing adds
more surface
contact area.
Steam Trap
Tracing Valves
Steam In
Figure 48
Approximate amount of flash
steam in Condensate
Flash
Steam
15%
Steam In
Condensate Management
When steam condenses,
energy is transferred to the cooler material to be heated. This
accounts for only around 75% of
the energy supplied in the boiler
to produce the steam. The
remainder, about 25%, is still held
by the condensed water.
As well as having heat content, the condensate is distilled
water: ideal for use as boiler feed
water. An efficient installation will
collect every drop of condensate
it economically can, and either
return it to the deaerator or boiler
feed tank, or use it in the process.
Condensate is discharged
through steam traps from a higher to a lower pressure. As a result
of this drop in pressure, some of
the condensate will then re-evaporate, and is referred to as flash
steam. The proportion that will
flash off differs according to the
level of pressure reduction
between the steam and condensate sides of the system, but a
50
Figure 49
Approximate amount of energy in
Condensate
Flash
Steam
50%
Water
50%
Condensate Management
charge condensate into lower
pressure systems. A chart is provided to assist in quickly
estimating the amount of flash
that can be produced. The volumetric change of condensate
flashing into steam may cause
substantial increasing velocities
that may damage existing con-
Velocity
(ft/min)
100
6000
4000
66
50
33
30 28" 26 24
" "
"
20 18 16 14 12
" " " " "
10
"
6"
8"
5"
4"
3"
2-1
/2"
3000
2"
1-1 1-1
/2" /4"
3/4
"
1"
1/2
"
Recommended
Service
Condensate Return
Line Sizing
Vent Pipe Sizing
2000
1000
17
10
600
Flash Tank
Diameter Sizing
50,000
Multiply chart velocity
by factor below
to get velocity
in schedule 80 pipe
0
10 0
8
60 0
4 0
3 0
2
30,000
20,000
10
Pipe Size
1/2"
3/4" & 1"
1-1/4" & 1-1/2"
2" & 3"
4" to 24"
26" to 30"
5
0
5000
0
10 0
8
60 0
4 0
3 0
2
3000
2000
10
5
0
10,000
8000
Factor
1.30
1.23
1.15
1.12
1.1
1.0
1000
800
500
300
200
0
10 0
8
60 0
4 0
3 0
2
100
80
10
5
0
60
50
40
30
20
10
P
c re
fla ond ssu
sh en re
ta sa in
nk te
(p lin
si e
g) or
51
Condensate Management
Percentage Quantity of Flash
Steam
= Sensible Heat at
the Higher Pressure
- Sensible Heat at
the Lower Pressure
Latent Heat of
the Lower Pressure
To simplify this procedure we
can use the chart (Fig. 51) to read
off the percentage of flash steam
produced by this pressure drop.
An example would be if we had
100 PSIG saturated steam/condensate being discharged from a
steam trap to an atmospheric,
gravity flow condensate return
system (0 PSIG), the flash percentage of the condensate would
be 13.3% of the volume discharged.
Conversely, if we had 15
PSIG saturated steam discharging to the same (0 PSIG)
atmospheric gravity flow return
system, the percentage of flash
steam would be only 4% by volume. These examples clearly
show that the amount of flash
released depends upon the differ-
52
Condensate Management
The specific volume of water
at 0 PSIG is .016 cubic feet per
pound, compared to 26.8 cubic
feet per pound for flash steam at
the same pressure. Sizing of
condensate return lines from trap
discharges based totally on water
is a gross error and causes lines
to be drastically undersized for
the flash steam. This causes
condensate lines to become
pressurized, not atmospheric,
which in turn causes a backpressure to be applied to the traps
discharge which can cause
equipment failure and flooding.
This undersizing explains
why the majority of 0 PSI atmospheric
condensate
return
systems in the United States do
not operate at 0 PSIG. To take
this thought one step further for
those people who perform temperature tests on steam traps to
determine if the trap has failed,
the instant we cause a positive
pressure to develop in the condensate return system by flash
steam, the condensate return line
now
must
follow
the
pressure/temperature relationship of saturated steam. So, trap
testing by temperature identifies
only that we have a return system
at a certain temperature above
212F (0 PSIG) and we can then
determine by that temperature
the system pressure at which it is
operating. Elevated condensate
return temperatures do not necessarily mean a trap has failed.
If the flash steam is to be recovered and utilized, it obviously has
to be separated from the condensate. This is best achieved by
passing the mixture of flash
steam and condensate through
what is known as a flash tank or
flash vessel (Fig. 52). A typical
arrangement is shown.
Figure 52
Operation of a flash
steam vessel
Pressure
Gauge
Connection
Condensate and
Flash Steam Inlet
Condensate Outlet
Condensate Management
which either equals or
exceeds the available flash
steam supply. The deficit can
then be made up through a
pressure reducing valve set.
If the supply of flash steam
exceeds the demand for it,
the surplus may have to be
vented to waste through a
backpressure relief valve.
Thus it is possible to utilize
the flash steam from process
condensate on a space heating
installation, but the savings will
only be achieved during the heating season. When heating is not
required, the recovery system
becomes ineffective.
Wherever possible, the better
arrangement is to use flash
steam from process condensate
to supply process loads, and that
from heating condensate to supply heating loads. Supply and
demand are then more likely to
remain in step.
Safety Valve
Figure 53
Boiler Blowdown Heat
Recovery System
Cold Water
Hot Water
Flash Vessel
Boiler
Blowdown
Source
a
54
Condensate Management
Control Valve
Steam
Pressure
Reducing
Valve
Flash Steam
Air
Flow
Steam Trap
Flash
Vessel
Figure 54
Control of Flash
Steam Pressure
Condensate
Condensate Recovery
Systems
The importance of effective
condensate removal from steam
spaces has been stressed
throughout this course. If maximum steam system efficiency is
to be achieved, the best type of
steam trap must be fitted in the
most suitable position for the
application in question. Having
considered how to best utilize any
flash steam which may be available, we must now decide what to
do with the condensate which
remains.
There are a number of reasons why condensate should not
be allowed to discharge to drain.
The most important consideration
is the valuable heat which it contains even after flash steam has
been recovered. It is possible to
use condensate as hot process
55
Condensate Management
Heat Exchanger
Condensate
Return System
Figure 55
Flash Steam Condensor or Heater
water but the best arrangement is
to return it to the boiler house,
where it can be re-used as boiler
feed water without further treatment, saving preheating fuel, raw
water and the chemicals needed
for boiler feed treatment. These
savings will be even greater in
cases where effluent charges
have to be paid for the discharge
of valuable hot condensate down
the drain.
Condensate recovery savings can add up to 25 to 30% of
the plants steam generating
56
Condensate Management
Electrically Driven Pumps
Figure 56
pressure gauge.
If cavitation problems still
exist due to elevated temperatures, the only recourse is to cool
the condensate down to a
pumpable temperature.
This
sounds like a simple cure, but if
we look at the oxygen solubility
chart (Fig. 57 on the following
page), we see that as condensate
cools down, the ability of that
water to contain oxygen goes up.
The more oxygen contained in
condensate when it reaches the
boiler house, the more chemicals
that have to be added to remove
that oxygen.
Sodium Sulfite is the chemical added to condensate to
remove this dissolved, contained
oxygen and it takes 8 PPM of
Sodium Sulfite to remove 1 PPM
of oxygen. So cooling down the
condensate is certainly an
answer to pumping problems, but
it causes the usage of more
chemicals, increased heat energy
to preheat this condensate back
up and certainly will cause
decreased life of the condensate
return piping system due to the
increased corrosion attack.
57
Condensate Management
Figure 57
10
8
6
4
2
0
30
50
70
90
110
130
150
170
190
210
Figure 58
PPF/PPC Features
Valve
Changeover
Mechanism
Ductile Iron or
Fabricated
ASME Steel
Body
Float and
Mechanism
Check Valve
Inlet Port
58
Check Valve
Outlet Port
Non
Electric
Pressure
Powered Pumps have become
the state of art method of condensate pumping in industry
today. This type of pump does not
require any electrical connections, has no high speed rotating
impellers, no temperature sensitive mechanical seals or large
oversized receivers for storage of
condensate (Fig. 58). The nonelectric pressure powered pump
can operate on steam, compressed air or any inert gas with
pressures up to 300 PSIG.
In open atmospheric systems (Fig. 59), there are several
benefits to using this pumping
system. Receivers are not as
large, condensate does not have
to cool down before pumping, the
pump can be installed directly
below heat exchange equipment
and will handle the condensate at
212F without any cavitation or
mechanical problems. There is
still a need for a small receiver to
allow steam traps that are discharging into it to sense a
common pressure of 0 PSIG so
as not to apply any backpressure
to any of the steam traps. The
condensate is then pumped back
to the boiler house for re-use.
Industry requirements for
more efficient usage of steam
energy is demanding that condensate not only be returned at
the highest possible temperatures, but that there are less and
less atmospheric vents allowing
flash steam to be lost. To accommodate this need for efficient
usage and the need for increasing equipment life expectancy of
all heat exchange equipment, the
closed system (Fig. 60) of
removal and recovery of condensate is becoming the design
criteria. In closed systems
aa
Condensate Management
Vent to Atmosphere
Figure 59
OPEN Atmospheric
System
Pump Exhaust
Operating Steam
or Gas Supply
Condensate to Pump
Receiver
Filling Head
Inlet Strainer
Steam Trap
When Steam
Supply is
Used
Height (H)
Pressure
Powered
Pump
Temperature
Control
Figure 60
Closed System
Steam Supply
Heat
Exchanger
Air Vent
Condensate
Return Line
Float
Type
Steam
Trap
Pressure
Powered
Pump
a
59
Condensate Management
All temperature controlled
equipment, as discussed earlier,
has fluctuating steam pressures
inside the equipment based upon
equipment
load
demands.
Historically, we have depended
upon steam pressure to lift condensate out of a piece of
equipment via the steam trap into
the condensate return system.
Because of the operation of the
temperature control valves, there
would be times that there would
be sufficient steam pressure at
the trap inlet to overcome the
condensate return line pressure
or the required lift.
At other times during operation, there would not be enough
steam pressure supplied to the
equipment to lift condensate. At
those times we would begin to
flood the heat exchange equipment, causing either product
temperature fluctuations or even
worse, freezing of the air coils,
because we were unable to effectively remove the condensate.
Installing a pumping device
between the equipment and the
trap (Fig. 61) allows for condensate to be recovered and
removed from the steam equipment at all times during
operation, whenever the steam
pressure is sensed in the equipment.
When the steam pressure is
greater than the condensate
return pressure or lift, steam
pressure alone lifts the condensate out through the steam trap.
However, when steam pressure
in the equipment is equal to or
lower than that of the condensate
return system or lift, condensate
completely fills the pump body,
steam pressure is supplied to the
pump and the condensate is
pumped out through the steam
trap into the condensate return
system.
60
Waterhammer In Condensate
Return Lines
Waterhammer in condensate
return lines is an indication of two
possible problems. In open systems, atmospheric returns, the
causes of waterhammer are air
pockets and/or steam traps discharging into a flooded section of
piping. Air pockets in the line are
easily remedied by adding an air
venting device for water systems,
a float actuated device that will
remain open until it is full of water
and air eliminated.
These
devices are mounted on the high
points of the return line and vent
to atmosphere. Steam traps discharging into a water line should
be avoided at all costs.
As we mentioned earlier in
the flash steam recovery section,
Condensate Management
Figure 61
Temperature
Control Valve
Closed System
Condensate Return
Air Vent
Reservoir Piping
Float &
Thermostatic
Trap
Pressure
Powered
Pump
Figure 62
Discharging Into Condensate Return Line
Sparge Pipe
61
2.
3.
4.
5.
6.
How much condensate is created in a steam main of 8 diameter at 125 psig for
every 100 feet?____________________________________________________
7.
8.
9.
10.
When lifting condensate, how much pressure is exerted for every 2.3 feet of lift?
________________________________________________________________
62
12.
How many tracer lines are recommended for an 8 product pipe to keep
temperatures at or above 150*F?
_____________________________________________________________________
13.
14.
15.
The term used when condensate is discharged to a lower pressure and partially
vaporizes is __________________________________________________________.
16.
Calculate the percent of flash steam created when 100 psig condensate is
discharged to atmosphere (Sh L.P. - SH H.P.) ) Lh L.P.)
17.
18.
List 3 considerations that must be met before flash steam recovery is viable and
economical.
1. ___________________________________________________________________
2. ___________________________________________________________________
3. ___________________________________________________________________
19.
20.
63
64
Argentina
Spirax Sarco S.A.
Ruta Panamericana Km. 24,900
1611 Don Torcuato
Buenos Aires, Argentina
Australia
Spirax Sarco Pty. Limited
P.O. Box 6308
Delivery Centre
Blacktown
N.S.W. 2148, Australia
Austria
Spirax Sarco Ges.m.b.H.
Eisgrubengasse 2/PF 41
A-2334 Vosendorf-Sud.
Austria
Belgium
Spirax Sarco N. V.
Industriepark Zwijnaarde 5
9052 Gent - Zwijnaarde
Belgium
Brazil
Spirax Sarco Ind. E Com Ltda
Rodovia Raposo Tavares Km. 31
Caixa Postal 143
06700-000. Cotia S.P.
Brazil
Canada
Spirax Sarco Canada Limited
383 Applewood Crescent
Concord
Ontario L4K 4J3, Canada
China
Spirax Sarco Engineering Co. Ltd.
2nd Floor, Block 20, No:481
Gui Ping Road
Caohejing Hi Tech Park
Shanghai, China, Postcode 200233
Colombia
Spirax Sarco Internacional Ltda
Apartado Aereo 32484
Cali (Valle)
Colombia, South America
Czech Republic
Spirax Sarco Spol. s. r. o.
V korytech (areal nakladoveho nadrazi CD)
100 00 Praha 10 Strasnice
Czech Republic
Denmark
Spirax Sarco Limited
Birkedommervej - 31
2400-Copenhagen N.V., Denmark
East Africa
Spirax Sarco Sales Representative
P.O. Box 38919
Nairobi
Kenya, East Africa
Finland
Spirax Oy
Sorvaajankatu 9
00810 Helsinki, Finland
France
Spirax Sarco S.A.
B P 61
F 78193 Trappes
Cedex, France
Germany
Spirax Sarco GmbH
Postfach 10 20 42
D-78420 Konstanz, Germany
Hygromatik Lufttechnischer
Apparatebau GmbH
Lise-Meitner-StraBe 3
D-24558 Henstedt-Ulzburg
Germany
Great Britain
Spirax Sarco Limited
Head Office
Charlton House, Cheltenham
Gloucestershire, GL53 8ER
Great Britain
Hong Kong
See Singapore
Hungary
Spirax Sarco Ltd.
11-1143 Budapest
Zszls u. 18.
Hungary
India
Spirax Marshall Limited
P.B. No. 29
Bombay Poona Road
Kasarwadi
Pune 411 034, India
Indonesia
See Singapore
Italy
Spirax-Jucker S.r.l.
Via Donat Cattin, 5
20063 Cernusco Sul Naviglio (MI)
Milano, Italy
Japan
Spirax Sarco Limited
3rd Floor, Koyo Building
1-10-17 Hamamatsu-cho
Minato-ku
Tokyo, Japan
Korea
Spirax Sarco Korea Limited
3rd-5th Floor, Jungwoo Building
1552-8 Seocho-dong
Seocho-ku
Seoul 137-070, Korea
Lebanon
Spirax Sarco Resident Engineer
P.O. Box 11-3052
Beirut, Lebanon
Malaysia
Spirax Sarco Sdn Bhd
25, Jalan PJS 11/1
Bandar Sunway
46150 Petaling Jaya
Selangor Darul Ehsan
West Malaysia
Mexico
Spirax Sarco Mexicana S.A. de CV
Apartado Postal 5287-K
Monterrey NL
64000 - Mexico
New Zealand
Spirax Sarco Limited
P.O. Box 76-160
Manukau City
Auckland, New Zealand
Nigeria
Spirax Sarco Sales Representative
Cakasa Company Ltd.
96 Palm Ave.
P.O. Box 871
Mushin
Lagos
Nigeria
Norway
Spirax Sarco Limited (Norge)
P.O. Box 47
1483 Skytta, Norway
Pakistan
Spirax Sarco Sales Representative
2-C Gulistan-E-Zafar P.R.E.C.H.S.
Near SMCHS Block B
Postal Code 74400
Karachi, Pakistan
Poland
Spirax Sarco Sp. z o.o.
Fosa 25
02-768 Warszawa, Poland
Portugal
Spirax Sarco-Equipamentos
Industrias Lda.
Rua Da Quinta Do Pinheiro, Lote 3
Portela de Carnaxide
2795 Carnaxide, Portugal
Russia
Spirax Sarco Ltd.
(Room 1401)
4 Vozrozhdenija Str.
198188 St. Petersburg, Russia
Singapore
Spirax Sarco Pvt. Limited
464 Tagore Avenue
Upper Thomson Road
Singapore 787833
South Africa
Spirax Sarco (Pty) Ltd.
P.O. Box 925
Kempton Park 1620
Transvaal, South Africa
Spain
Spirax Sarco S.A.
Sant Josep, 130
Poligon El Pla
08980 Sant Feliu de Llobregat
Spain
Sweden
Spirax Sarco AB
Vstberga All 60
S-126 30 Haegersten, Sweden
Switzerland
Spirax Sarco A. G.
Gustav-Maurer-Str.9
8702 Zollikon, Switzerland
Taiwan
Spirax Longbridge Limited
6th Floor
No. 8, Lane 94, Tsao Ti Wei
Shen Keng Hsiang
Taipei County
Taiwan, Republic of China
Thailand
Spirax Boonyium Limited
9th Floor, Benjaporn Building
222 Krungtep-kreetha Road
Bangkapi
Bangkok 10240, Thailand
U.S.A.
Spirax Sarco, Inc.
Northpoint Park
1150 Northpoint Blvd.
Blythewood, SC 29016
Watson-Marlow Bredel Inc.
220 Balladvale Street
Wilmington, MA 01887
Venezuela
Spirax Sarco S.A.
Apartado 81088
Caracas 1080A, Venezuela
65
NORTHEAST
209 W. Central Street
Suite 228
Natick, MA 01760
Phone: (508) 651-3200
Fax: (508) 655-9434
MID-ATLANTIC
1125 S. Cedar Crest Blvd.
Suite 101
Allentown, PA 18103
Phone: (800) 251-7676
Fax: (800) 996-3232
SOUTHEAST
1304 Rockbridge Road
Suite 2
Stone Mountain, GA 30087
Phone: (770) 209-0999
Fax: (770) 209-0777
MIDSOUTH
(temporary address)
1304 Rockbridge Road
Suite 2
Stone Mountain, GA 30087
Phone: (770) 209-0999
Fax: (770) 209-0777
MIDEAST
7760 Olentangy River Road
Suite 120
Columbus, OH 43235
Phone: (614) 436-8055
Fax: (614) 436-8479
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2806 Centre Circle Drive
Downers Grove, IL 60515
Phone: (630) 268-0330
Fax: (630) 268-0336
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Deer Park, TX 77536
Phone: (281) 478-4002
Fax: (281) 478-4615
WEST
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San Ramon, CA 94583
Phone: (925) 829-0193
Fax: (925) 829-1712
66