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.

Why we use steam

Steam produced by evaporation of water which is relatively cheap and plentiful commodity. Its temperature can be adjusted very accurately by controlling its pressure using a simple valve. Its carries relatively large amount of heat in a small mass.

Steam Formation
1atm 1kg of water @ O0c

Zeroenthalpy datum point Total energy (enthalpy) held in 1kg of water (mass) is called specific enthalpy of saturated water (hf)

Basic Principles in Thermodynamics

O0c Water
1000c Water

1000c water @ 1atm

1000c steam

Sensible heat (hf)

Extra energy to be added is called specific enthalpy of evaporation (hfg) = hf + hfg

1000c Steam

Total energy (hg)

Basic Principles in Thermodynamics

Volume of 1000c water @ 1atm
Load (Compress)

100 times Volume

Volume of 1000c steam @ 1atm

Water molecules not easy to break, hence boiling point of water (tB.P.) moreases.

Basic Principles in Thermodynamics

Enthalpy Total energy due to pressure and temperature of a fluid / vapour @ any given time & condition. Unit: Joule (J) KJ

Specific heat capacity A measure of the ability of a substance to absorb heat. It is the amount of heat required to raise 1kg of substance by 10c.
Unit: KJ/Kg0c (eg. Water 4.186kj/kg0c)

Basic Principles in Thermodynamics

Absolute Pressure :
Pressure above the absolute zero. Absolute zero is the theoritical pressureless state of a perfect vacuum. Pressure excorted by the atmosphere at sea level is 1.013 bar abs ( 1 bar)

Gauge Pressure
Gauge pressure is the pressure above atmosphereic pressure.

Pressure gauge shows Gauge Pressure in bar g or kgf/cm2

Basic Principles in Thermodynamics

P tB.P hfg

Basic Principles in Thermodynamics

Steam Table
Relationship exists between steam pressure, saturated temperature, evaporation of staturation ethalpy.

Basic Principles in Thermodynamics

Steam Table
Enthalpy in kj/kg Gauge Pressure Temp. Water Specific Enthalpy of Evoporation Steam Volume Dry Sat.

Bar
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14

kPa
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400

0C

Hf
419 506 562 605 671 641 697 721 743 763 782 799 815 830 845

Hfg
2257 2201 2163 2133 2108 2086 2066 2048 2031 2015 2000 1986 1973 1960 1947

hg
2676 2707 2725 2738 2749 2757 2763 2769 2774 2778 2782 2785 2788 2790 2792

M3/kg
1.673 0.881 0.603 0.461 0.374 0.315 0.272 0.24 0.215 0.194 0.177 0.163 0.151 0.141 0.132

100 120 134 144 152 159 165 170 175 180 184 188 192 195 198

Steam Generation
Steam Generator is called Boiler

Two Types of Boilers

Water Tube Boilers

Fire Tube Boilers

Boiler Tubes

WaterTube Boilers
Generate high pressure steam even 50 bar Generate super steam 2000 3000c
Application
Steam turbine to produce electricity (Combine cycle plant) High temperature steam requirement

Fire Tube Boilers

Generate low pressure max. up to 17.5 bar Most common boiler generate saturated steam

Fire Tube Boiler

Design Types :
Two Pass Boiler Two Pass reverse flame

Three Pass Boiler

Three pass - wet back Three pass dry back

Two Pass Boiler

Two Pass reverse flame

Three Pass Boiler

Three pass - wet back

Three pass dry back

Selection of Boiler
Steam load

Pressure operating / maximum

Future expansion

Efficiency %
Maintenance

Types of Fuel Use

Diesel
Furnace Oil Natural Gas Low / Medium / Heavy 800 RS 1000RS 1500 RS

Bio Mass (Wood, Saw dust, Paddy husk, etc.,)

Steam Distribution and Condensate Recovery System

Steam Cycle

Feed Water Tank Management System

Feed Water Tank Management System

Steam ejector

Water
It might be good enough to drink,
but is it good enough for the Boiler?

Steam Distribution

Steam Line Pipe Sizing

On the basis of :
Fluid Velocity Pressure Drop

Pipe Sizing
Greater Cost Greater Heat Loss Greater Volume of Condensate Formed

Lower Pressure to Steam Users, or Not Enough Volume of Steam Water Hammer and Erosion

Pipeline Capacities at Specific Velocities

Kg/h Pressur e bar 0.4 Velocit y m/s 15 25 40 15 25 40 15 25 40 15 25 40 15 25 40 15mm 7 10 17 7 12 18 8 12 19 12 19 30 16 26 41 20mm 14 25 35 16 25 37 17 26 39 25 43 64 37 56 87 25mm 24 40 64 25 45 68 29 48 71 45 70 115 60 100 157 32mm 37 62 102 40 72 106 43 72 112 70 112 178 93 152 250 40mm 52 92 142 59 100 167 65 100 172 100 162 275 127 225 375 50mm 99 162 265 109 182 298 112 193 311 182 295 475 245 425 595 65mm 145 265 403 166 287 428 182 300 465 280 428 745 385 632 1025 80mm 213 384 576 250 430 630 260 445 640 410 656 1010 535 910 1460 100mm 394 675 1037 431 716 1108 470 730 1150 715 1215 1895 925 1580 2540 125mm 648 972 1670 680 1145 1712 694 1160 1800 1125 1755 2925 1505 2480 4050 150mm 917 1457 2303 1006 1575 2417 1020 1660 2500 1580 2520 4175 2040 3440 5940

0.7

1.0

2.0

3.0

Steam Metering
Measurement in mass flow rate kg/hr Density compensation
Measure the velocity Q = Av m2 Measure temp Spe. volume =

Density

=
=

Mass flow rate m = Q

Efficiency of the boler or the process equipment

Pressure Reduction
Process temperature required (0C) Equvalent steam pressure (bar) Steam consumption (kg/hr) Available steam pressure (bar)
Pressure
up stream Source

Pressure
down stream

Process

Size ?

Kg/hr consumption

Pressure Reduction
Safety of the equipments
Increase the enthalpy of evaporation Condense water convert into flash steam

Distribute at High Pressure

This will have the following advantages: Smaller bore steam mains needed and therefore less heat (energy) loss due to the smaller surface area. Lower capital cost of steam mains, both materials such as pipes, flanges and support work and labour. Lower capital cost of insulation (lagging) Dryer steam at the point of usage because of the drying effect of pressure reduction taking place. The boiler can be operated at the higher pressure corresponding to its optimum operating condition, thereby operating more efficiently. The thermal storage capacity of the boiler is increased, helping it to cope more efficiency with flcuating loads, and a reduced risk of priming and carryover.

Selection of Working Pressure

Enthalpy in kj/kg Gauge Pressure Temp. Water Specific Enthalpy of Evoporation Hfg 2257 2201 2163 2133 2108 2086 2066 2048 2031 2015 2000 1986 1973 1960 1947 Steam Volume Dry Sat. M3/kg 1.673 0.881 0.603 0.461 0.374 0.315 0.272 0.24 0.215 0.194 0.177 0.163 0.151 0.141 0.132 Bar 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 kPa 0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400
0C

Hf 419 506 562 605 671 641 697 721 743 763 782 799 815 830 845

hg 2676 2707 2725 2738 2749 2757 2763 2769 2774 2778 2782 2785 2788 2790 2792

100 120 134 144 152 159 165 170 175 180 184 188 192 195 198

Types of PRVs

Direct acting

Pilot operated

Pressure Reducing Station

Best practices in steam distribution

Pipe alignment and drainage

This will eleminate water hammer

Best practices in steam distribution

Eleminate water hammer

Best practices in steam distribution

Strainer - Remove pipe scale & dirts

Best practices in steam distribution

Eleminate air in the pipe lines

Best practices in steam distribution

Pipe laying with slope

Branch Connections

Best practices in steam distribution

Drainage in steam lines

Best practices in steam distribution

Steam Line Reducers

Best practices in steam distribution

Expansions

Best practices in steam distribution

Types of steam expansions

Best practices in steam distribution

Close / plug the steam leaks
Cost of steam Rs. 7.50/kg 5mm hole @ 10 bar press 80 kg/hr Steam leak per day (12 hrs) - 960 kg Loss in 5mm hole per day Rs. 7.50 x 960 kg = Rs. 7,200.00 Loss in 5mm x 5nos holes per day Rs. 7,200.00 x 5 = Rs. 36,000.00 Loss Per month (26 days) Rs. 36,000.00 x 26 = Rs. 936,000.00 Loss Per Annum Rs. 936,000.00 x 12 = Rs.

11,232,000.00

Best practices in steam distribution

Lagging the steam pipe lines
Q = UA (T)

Insulation Material Properties Glass wool of 64 kg/m3 density

Thumb rule : Steam lines 50mm thick glass wool pipe covers Condensate lines 25mm thick glass wool pipe covers

Steam Traps
Why traps required? What is the function of the steam trap? What are the types of traps? How to select the trap?

Steam Traps
Why traps required?

Utilise maximum energy from the steam

Trap steam & release condensate

Types of Steam Traps

Thermodynamic Traps Thermostatic Traps Balanced Pressure Traps Liquid Expansion Traps Bimetallic Expansion Traps Mechanical Traps Ball Float Traps Inverted Bucket Traps

Thermodynamic Steam Trap

Application

Ball Float Trap

Application

How to select the trap?

Refer the catalogues

Trap Module

Trap Monitoring System Steam Leak Water clogg

Condensate Management
1. Why Return Condensate? 2. Sizing Condensate Return Lines 3. Condensate Pumping 4. Long Delivery Lines 5. Lifting Condensate 6. Flash Steam

Approximate Amount of Flash Steam in Condensate

Flash Steam, 15%

Water Flash Steam

Water, 85%

Water and Chemical Savings by Returning Condensate

Total Savings by Condensate Recovery
Fuel + Water + Blowdown

Condensate Pipe Sizing

Kg/h
Pressure downstream of trap, bar g 15mm 20mm 25mm 32mm 40mm 50mm 65mm 80mm 100mm 125mm 150mm

0.0

6.2

11.0

17.8

30.3

41.9

69.0

98.4

152.0

261.8

411.4

594.1

0.1

6.8

12.0

19.4

33.2

45.8

75.5

107.6

166.2

286.3

449.9

649.7

0.2

7.4

13.0

21.1

36.0

49.7

81.8

116.7

180.3

310.5

488.1

704.7

0.3

8.0

14.0

22.7

38.8

53.5

88.2

125.8

194.3

334.7

526.0

759.5

Methods of Condensate Return

Two types of recovery systems
Without pump

With pump

Condensate lifting without Pump

Back Pressure on Traps

Pressure at end of return line Hydrostatic head Frictional resistance to flow

BACK PRESSURE

Condensate lifting with Pump

Condensate lifting with Pump

Where to go recovered condensate

Complete system of steam distribution & condensate Recovery system

Srilal Midellawala
Joint Managing Director / Director Marketing Tritech Group of Companies No. 87, Makola South, Makola, Kiribathgoda. Email : srilal@tritech.lk Web : www.tritech.lk