Steam System

Why Steam is so popular as heat

conveying media in industry?

 Highest specific heat and latent heat

 Highest heat transfer coefficient

 Easy to control and distribute

 Cheap and inert

 Properties of Steam

Liquid Enthalpy
 Liquid enthalpy is the "Enthalpy" (heat energy) in the water when it
has been raised to its boiling point is measured in kcal/kg, its symbol
is hf
 Also known as "Sensible Heat”
Enthalpy of Evaporation
 It is the heat energy to be added to the water in order to change it
into steam.
 There is no change in temperature, the steam produced is at the same
temperature as the water from which it is produced.
 Also known as latent heat and its symbol is h
The temperature at which water boils, also called as
boiling point or saturation temperature (It increases
as the pressure increases. )
As the steam pressure increases, the usable heat energy
in the steam (enthalpy of evaporation), which is given
up when the steam condenses, actually decreases.
The total heat of dry saturated steam or enthalpy of
saturated steam is given by sum of the two enthalpies
hf +hfg
When the steam contains moisture the total heat of
steam will be hg = hf +q hfg where q is the dryness
fraction.
Superheated Steam
 Superheat is the addition of heat to dry saturated steam
without increase in pressure.
Degree of Superheat
 The temperature of superheated steam, expressed as
degrees above saturation corresponding to that
pressure.
Steam Piping : Features

while laying new pipes ,it is a compromise between

aesthetic design and architect’s plans.
Steam pipes should be laid by the shortest possible
distance.
Provision for proper draining of condensate.
For example, a 100mm well lagged pipe of 30-meter
length carrying steam at 7 Kg/cm2 pressure can condense
nearly 10 Kg. of water in the pipe in one hour unless it is
removed from the pipe through traps.
The pipes should run with a fall (slope)of not less than
12.5 mm in 3 meter in the direction of flow.
Large pockets in the pipes to enable water to collect
Drain pockets should be provided at every 30 to 50
meters and at any low point in the pipe network.
Expansion loops are required to take care of the
expansion of pipes when they get heated up.
Automatic air vents should be fixed at the dead end of
steam mains, which will allow removal of air, which
will tend to accumulate.
 Steam Pipe Sizing and Design

1. Pipe Sizing
 Proper sizing of steam pipelines help in minimizing pressure drop.

 The velocities for various types of steam are:

 Superheated 50-70 m/sec
 Saturated 30-40 m/sec
 Wet or Exhaust 20-30 m/sec

 The steam piping should be sized, based on permissible velocity and the
available pressure drop in the line.
 A higher pipe size will reduce the pressure drop and thus the energy
cost. However, higher pipe size will increase the initial installation cost.
 By use of smaller pipe size, even though the installation cost can
be reduced, the energy cost will increase due to higher-pressure
drop.
Pressure drop change is inversely proportional to the 5th power of
diameter change.
Hence, care should be taken in selecting the optimum pipe size.
2) Pipe Redundancy
3) Drain Points
 These points help in removing water in the pipes due to condensation of
steam.
 The presence of water causes water hammering.
 A steam trap must be provided at the drain points to avoid leakage of
steam.
 What is the Function of Steam Traps?

A steam trap is a valve device that discharges condensate and air from
the line or piece of equipment without discharging the steam.
The purpose of installing the steam traps is to obtain fast heating of
the product and equipment by keeping the steam lines and equipment
free of condensate, air and non-condensable gases.
Functions
 To discharge condensate as soon as it is formed
 Not to allow steam to escape.
 To be capable of discharging air and other incondensable gases
 Types of Steam Traps

Group Principle Sub-group

Mechanical trap Difference in density Bucket type
between steam and - Open bucket
condensate. - Inverted bucket,
with lever,
without lever
- Float type
- Float with lever
- Free float
Thermodynamic Difference in Disc type
trap thermodynamic properties Orifice type
between steam and
condensate
Thermostatic Difference in temperature Bimetallic type metal
trap between steam and expansion type.
condensate
 To discharge condensate as soon as it is formed
 Not to allow steam to escape.
 To be capable of discharging air and other incondensable gases
Float & Thermostatic Traps
Primary Applications:
• Heating main drip traps
• Shell & tube heat exchangers
• Tank heaters with modulating
temperature regulators
• Unit heaters requiring fast venting
• Steam humidifiers
• Air blast heating coils
• Air pre-heat coils
• Modulating loads

Applications that require fast heating at

start-up
 Bucket traps

Primary Applications:
• Process main drip traps
 Where condensate is lifted or drains into wet return line
 Drum type roller dryers
 Steam separators
 Syphon type or tilting kettles
Disc steam trap (Thermodynamic)
Thermostatic Bellows Type
Trap

Applications:
• Radiators,
convectors, unit
heaters
• Cooking kettles
• Sterilizers
• Heating coils
• Tracer lines
• Evaporaters
Figure 3.5:Thermostatic Trap
Basic methods for testing a steam trap
Ultrasonic test Kit
Infrared temperature gun

Sight glass evaluation

Efficient Steam Utilisation

Avoid steam leakages

Provide dry steam for process
Utilising steam at the lowest possible pressure
Insulation of steam pipelines and hot process equipment
Minimising barriers to heat transfer
Condensate recovery
Flash steam recovery
Proper selection and maintenance of steam traps
Proper sizing of steam and condensate piping
Reducing the work to be done by steam
Avoiding Steam Leakages
 Leaking Steam Pipe / Valve
Audible Leak Visible Leak

Weak whistling Weak hissing

Almost invisible steam jet Visible steam jet

800
800 litre
litre oil
oil per
per year
year 2,000
2,000 to
to 4,000
4,000 litre
litre oil
oil per
per year
year
Provide dry steam for the process

Disadvantages of wet steam

 Less heat content, Extended process time, Irregular
heating, Barrier to heat transfer, Overloading of steam
traps
Disadvantages of superheated steam
 Poor heat transfer coefficient, takes time to give up
superheat by conduction
Benefits of dry steam
 Heat transfer is rapid and regular
 Providing Dry Steam for Process

 Use Dry Saturated

steam for
processes
 Steam Separators
to be fitted at point
of steam use

Provide a little superheat to ensure dry saturated steam

at the process end
 Utilising steam at the lowest possible
pressure
2730.7 KJ/kg 2770.8 KJ/kg Total Heat

Steam should always be generated

2151.3 KJ/kg
Latent Heat and distributed at the highest possible
2054 KJ/kg
pressure but utilised at the lowest
practicable pressure

579.4 KJ/kg 716.8 KJ/kg Sensible Heat

2.4 bar, 121.5oC 6.8 bar, 164.3oC

 Optimal Insulation
Heat loss, 89 mm black steel pipe, 90
o
C

Uninsulated 50 mm insulation 100 mm insulation

320 W/m 29 W/m 19 W/m

50 mm insulation compared with an uninsulated pipe: 320 - 29 = 291 W per m

263 litre oil per year
50 mm insulation compared with 100 mm insulation: 29 - 19 = 10 W per m
9 litre oil per y
...But don’t Over-Insulate:
There is always an optimum insulation level (1-3 years payback)
Insulation of Steam Pipelines and
Equipment

An uncovered flange is equivalent to leaving 0.6 metre of

pipe line unlagged.

if a 0.15 m steam pipe diameter has 5 uncovered flanges,

there would be a loss of heat equivalent to wasting 5 tons of
coal or 3000 litres of oil a year
 Direct Utilization of Steam

 Direct Steam use

involves both Latent
Heat and Sensible
Heat
 Use temperature
controller in Direct Use
to avoid steam
wastage
 Minimising barriers to heat transfer

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pro nant
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Resistance to heat transfer of

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i lm

du c
am

nde

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le

t al

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pro
St a
f

Sca

Sca
Air

Me
St e

water is 60 – 70 times more than

Co

steel and 500 – 600 times than

copper

Resistance to heat transfer of Air

is 1500 times more than steel and
19,000 times than copper
 Effect of air and water film
Steam at 0.75 kg/.cm2:Air and water film reduced by
Steam at 1 kg/cm2 50 % ; Quicker process time

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pro nant

pro nant
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t al

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St a

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Air

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St e

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250OC

240OC

210OC 210OC
 Air Venting

 0.25 mm thick air film

offers same resistance
to heat transfer as 330
mm thick copper wall
 Install Air vents where
air is likely to be
stagnant
 Boiler Fuel Saving by Condensate Return
Saving in percent if condensate is returned to the boiler instead of drain

14
12
10
Percentage 8
100% returned
saved 6 50 % returned
4
2
0
0 20 40 60 80 100
Condensate return temp. oC

For every 6OC rise in boiler feed water temperature,

there is a 1 % raise in boiler efficiency
 Flash Steam

Flash steam available in % - S1 - S2

L2
S1 - Sensible heat of high pressure condensate
S2 - Sensible heat of steam at lower pressure
(at which it is flashed)
L2 - Latent heat of flash steam at lower
pressure
Steam Distribution System
Ensures that adequate quantity of steam that is
dry and free of air, reaches the plant at correct
pressure

Diameter of piping should be optimum to

minimise pressure drops, investment and
operating costs
Reducing the work to be done by steam

Have shortest route of piping

Remove moisture mechanically to the fullest before steam
drying / avoid bone drying
Optimise humidity of drier exhaust
Explore process integration
Use thermostatic controls
Remove / blank redundant lines
Productive use of machinery (Maximise equipment loading)
Look for cheaper alternatives of doing the job (waste heat
boilers, thermic fluid heater etc)
End