industrial boilers planner guide

Planner Guide Industrial Boiler – Steam Systems 1

Small to medium size steam boilers

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1 System Description 7

2 Product overview 9

3 Benefit of Hoval steam boilers 9

4 System P&I Diagram 10

5 Design Basics 125.1 Steam production 125.2 Technical parameters for saturated steam boilers 12 Capacity 12 Pressure 12

6 Steam boilers control systems 136.1 Capacity control 136.2 Level control 136.3 Plant periphery 136.4 Sludge blow down device (purge) 136.5 Desalting 136.6 Condensate return 146.7 Water treatment plant 146.8 Feed water tank 136.9 Efficiency of steam boiler plants 14

7 Saturated steam tables – part 1 15

8 Saturated steam tables – part 2 16

9 Technical details for industrial boilers 17

10 Selection of burners / technical data for boilers up to ~ 5 to/h steam capacity (Part 1) 18

Selection of burners / technical data for boilers up to ~ 5 to/h steam capacity (Part 2) 18

11 Properties of some supply fuel oils (av. values – physical standard condition) 19

12 Properties of some supply gases (av. values – physical standard condition) 20

13 Excess of air – calculation 21

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14 Boiler load / output – Steam quantity 21

15 Conversion from “ Nm3 ” to “ operating m3 ” (gas, air, smoke gas) 22

16 Conversion from “operation m3 ” to “Nm3 ” (gas, air, smoke gas) 22

17 Feed water tank and feed water conditioning 2317.1 Operating temperature 2317.2 Cavitation of the boiler feed pump 2417.3 Feed tank design 2517.4 Feed tank materials 2617.5 Feedtank capacity 2617.6 Feed tank piping 2617.7 Pressurised deaerator 2917.8 Conditioning treatment 29

18 Water preparation for steam boiler plants 3018.1 Good quality steam 3118.2 External water treatment 3118.3 Ion exchange 3218.4 Base exchange softening 3218.5 Dealkalisation 3418.6 Dealkaliser 3418.7 Demineralisation 3518.8 Selection of external water treatment plant 3618.9 Shell boiler plant 3618.10 Summary 3618.11 Boiler – and Feed water specifications for Hoval steam boilers 37

19 Purge pit – part 1 38

20 Purge pit – part 2 39

21 Calculation of temperatures and quantities (Mixture of 2 water streams) 40

22 Pressure loss at steam pipes (see also point 25, 26, 28 and 32) 40

23 Pressure loss at straight water pipes 42

24 Determination of pipe size 42

25 Flow speed at pipes (liquid, gaseous) 43

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26 Steam pipes – dimensions 44

27 Condensate pipes – dimensions 45

28 Pipe expansion and support 4628.1 Allowance for expansion 4628.2 Pipework flexibility 4728.3 Expansion fittings 4828.4 Pipe support spacing 52

29 Pipe dimensions and weights 53

30 Dimensions for gaskets and connections – Part 1 54

31 Dimensions for gaskets and connections – Part 2 55

32 Steam lines and drains 5632.1 Main steam lines 5632.2 Piping layout 5632.3 Water hammer and its effects 5732.4 Branch lines 5832.5 Rising ground and drainage 6032.5 Steam separators 6032.6 How to drain steam mains 6132.7 Summary 62

33 Steam consumption of plants 6333.1 Non-flow type applications 6433.2 Flow type applications 6633.3 Warm-up and heat loss components 6833.4 An outflow heater 68

34 Steam consumption of plant items 6934.1 Heating calorifiers 6934.2 Hot water storage calorifiers 7034.3 Drying cylinders 7134.4 Presses 72

35 Safety valves – Installation 73

35.1 Seat tightness 7335.2 Safety valve installation 7335.3 Installation 7435.4 Reaction forces when discharging 76

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36 Required formulas and conversion tables 7836.1 Conversion of pressure units (quick use – rounded) 7836.2 Conversion of anglo - american units to SI units 78 Length 78 Area 78 Volume 78 Flow (volume) 78 Force 78 Energy, work or amount of heat 78 Power or heat flow rate 78 Conversion of water hardness units 7836.3 Software Conversions see (examples - freeware) 81

37 Literature references 81

38 Versions-Info

39 P + I Diagram 82

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1 System Description

The Hoval steam system “1” was developed to provide for the following applications a medium / high output of saturated steam where simple, safely and cost-efficient solutions are necessary.

• Small / medium sized soft drink manufacturers (steam for bottle washing and production)

• Brick- and building material industry (steam for production)

• Meat industries (steam for cooking process and production)

• Bakeries (steam for production)• Food industries (steam for production) • Laundries (steam for washing machines and ironing)• Hotels (steam for cooking and laundry supply)• Hospitals (steam for cooking, supply to heat

exchangers – sterilization)• Textile industries (steam for production)• Small / medium sized breweries

(steam for brewing procedures)• Small / medium sized paper and cellulose industries

(steam for production)• Small / medium sized car parts industries

(steam for production)• Pharmacy industries (steam for production)• Chemical industries (steam for production)

Principally anywhere, where steam is necessary as a heat carrier or as a power transmission force.

Steam plays an important role in many processes as energy carrier or driving force. More and more emphasis is laid on a highest possible efficiency and a lowest possible environmental harm.

Steam boilers do also represent a danger potential though. The equipment, as well as the installation and operation of steam boiler plants are therefore legally ruled in many countries, e.g. by • 97/23/EG European pressure devices – Guiding rule• EN 12953• TRD

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Benefit of steam

Steam has some outstanding characteristics:• High pressure for drive of machines• High temperature for technical processes• Flow to consumers without extern energy (pumps)• Steam transfer through small pipe dimensions

The medium temperature does not change in evaporation and condensation process

In addition to the above also our best cost of ownership philosophy has been taken in consideration which means, the best price value for the end-user.

This takes in consideration the following aspects:

1. Planner: Easy to plan (providing fast information in the required quality and quantity)

2. Installer: Easy to purchase (one order, one supplier)3. Owner: Product costs are not necessarily to be low

(high quality material and manufacturing, high efficiency, Swiss engineered products)

4. Installer: A dministration cost (responsible one stop shop)5. Installer: Installation cost (principle P&I including all

information and supply of components for a perfect functional system)

6. Installer: System integration (Hoval System technology and controls matches all building requirements, eg. BMS, lead lag, etc.)

7. Installer: Commissioning costs (since all components match from the beginning,checked by Hoval engineers and Hoval on site engineers fast commissioning is possible)

8. Owner: Running cost (high efficiency, engineered pro-ducts with focus to conservation of energy and environment lead to low running cost. Cheap pro-ducts are not always cheap in the long run time.)

9. Owner: Environmental costs (all our products comply with the latest regulations and they are even better)

10. Owner: Maintenance costs (engineered products with focus to easy maintenance lead to lower costs)

11. Owner: Service cost’s (engineered quality products usually need less Service in life)

12. Owner: Disposal cost’s (Construction in combination with the selected materials allow a cost effective disposal)

Hoval is worldwide known as technological leading supplier of innovative easy- systems for heat and ventilation technology with a high measurably economical and ecological added value for the customer.

Innovativeeasy-systems

with measurable added value

Planning costs 1. Planning Procurement costs 2. Purchase

3. Product 4. Administration

Installation costs 5. Installation 6. System integration 7. Commissioning

Operating costs 8 .Operating 9. Environmental 10. Maintenance

Service costs 11. ServiceDisposal costs 12. Disposal

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Last but not least, a Hoval steam system provides you the following advantages:• Long life time of boiler, thanks the internal construction.• Less fuel consumption since our steam systems operate

on highest efficiency• Reduced heat transmission loss of boilers due to

completely watercooled boiler walls• More safety by using 2 boilers smaller capacity instead of

one large boiler• Easy to be operated by boiler operator• Lower investment cost for a split system (small steam

system for steam demand and all the rest heated with hot water system). This gives best efficiency and load rates for both systems!

• Less pipe work, fittings (boiler could be supplied completely “preinstalled”)

• More than 35 years experience on steam and superheated hot water systems

and finally, behind all you will find the Hoval family, friendly, professional, solution oriented, enthusiastic and responsible for energy and environment.

2 Product overview

Hoval steam boiler series THD-U (size 500 – 5000 kg/h), steam pressure 10, 13, 16 bar(g)

Hoval feedwater tanks “SPW-D” (size 500 – 3000 L) – pressureless

Hoval feedwater tanks “SPW-E” (size > 3000 L / 0,5 bar(g)) – see steam system 2 for details

Hoval feedwater pumps

Hoval switchboards and SPS-controls

Hoval selected and matched control valves, safety valves, pressure gauges, sensors, etc.

3 Benefit of Hoval steam boilersCompact 3-pass boiler construction according actual EN-norms (mainly EN 12953 and PED – 97/23/EG)

Natural circulation boiler with good purge possibilities

Flame tube dimensioned according actual burner technology

Relative thin turning chamber head results in a very good connection between distance of smoke tubes comparing to turning chamber head thickness and an optimized flexibility against heat tensions.

100% water cooled turning chamber back wall made from seamless fin-tubes, no anchors necessary and extension of heat transfer area at the „hot zone“ of the boiler.

Good insulation – without metallic supports

Big water space – insensible against moving load peaks

High efficiency rate – up to higher then 90% – without eco

Easy to be equipped with economizer (on request)

Very good cleaning possibilities (easy to swivel boiler front door, no turbulators at the boiler smoke gas tubes)

Easy to maintain – except fire proof concrete at boiler front door there´s no other concrete at the boiler.

Reliable due to long year experience on boiler production and design.

Boiler could be supplied completely (mechanically and electrically) installed – so there´s a lot less work to do on site.

Efficiency coded according real boiler operation temperature

Boiler safety instrumentation with 1 safety pressure limiter, 2 safety valves and 2 independent water level insufficiency electrodes.

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4 System P & I Diagram

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5 Design Basics

5.1. Steam production

At the process of heating, the water or the steam wants to expand but this is avoided by the boiler shell. The more energy is added by the firing into the closed boiler, the higher the pressure in the boiler will rise.

After reaching the needed pressure the steam can be led to the consumers by opening the main steam valve. If the

pressure inside the boiler will decrease (due to steam consumption) the burner will switch on. The load regulation for the burner is always done according steam pressure at the boiler.

Saturated steam from the boiler includes an water content between 1 and 2 %.

5.2. Technical parameters for saturated steam boilers

This statement of capacity refers to a constant duration load!

Pressure Temperature Enthalpy Evaporation- Enthalpy Volume DensityGauge

pressureAbsolutepressure

water h´

heat r

steam h´´

steam steam

bar(g) bar °C kJ / kg kJ / kg kJ / kg m3 / kg kg / m3

0 1 99,6 417 2258 2675 1,694 0,5904

0,5 1,5 111,4 467 2226 2693 1,159 0,8628

1 2 120,2 505 2201 2706 0,885 1,129

6 6 165,0 697 2065 2762 0,2727 3,667

10 11 184,1 781 1999 2780 0,1774 5,637

13 14 195,0 830 1958 2788 0,1407 7,106

16 17 204,3 872 1921 2793 0,1166 8,575

20 21 214,9 920 1878 2798 0,0949 10,54

25 26 226,0 972 1829 2801 0,0769 13,01

30 31 235,7 1017 1785 2802 0,0645 15,51

89 90 303,3 1364 1381 2745 0,0205 48,79

Capacity Pressure

Heat capacity kW (10 bar) ~ kg/h x 0,65 Recommended operation pressure = boiler design pressure - 15%*

h ´´ 10 bar = 2780 kJ/kg * Hysteresis of safety valve

- h ´ 100 °C = 418 kJ/kg*

h = 2362 kJ/kg = 0,6561 kW/kg

* feed water temperature from feed water tank

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Saturated steam from the boiler includes an water content between 1 and 2 %.

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6 Steam boilers control systems

6.1 Capacity control

The capacity regulation of the steam boiler is done related to pressure. • two levels (smaller plants)

burner on/off and full/min. load• modulating (bigger plants)

Protection against too high pressure • Manometer (indication operation pressure) • Safety pressure limiter (switches off firing) Safety valve (leads off the inadmissible over pressure outside)

6.2. Level control

The steam boiler has to be fed with as much water as it evaporates. • two levels

(pump on/off)• continuously by pump

(frequency converter on pump)*• continuously by regulation valve • three-components regulation Protection against water shortage• water level glasses • water shortage safeties

Protection against overfilling • high water level electrode

*Attention: lower loads as approximately 20% are not possible with

frequency converters (due to min. rpm ofpump and needed flow pressure) – the pump has to beswitched on/off for this load! This could

lead to damages on plants which are equipped with economisers.

6.3 Plant periphery

There are a lot of factors and materials, which can endanger and impair the boiler operation:• too cold feed water – it leads to high heat tension

in the boiler water hardness – calcium and magnesium may create a boilerstone / scale (more fuel consumption, overheated materials)

• gases and acids – attack the boiler material • salts – impair the level regulation and supervision • dirt – lays itself as sludge and leads to material

overheating Therefore the boiler has to be suitably protected.

6.4 Sludge blow down device (purge)

Because of the starting operation and the use of dosing chemicals some boiler sludge is created, which lays itself on the bottom. This boiler sludge is removed out of the boiler discontinuously by a fast sealing valve (manually or automatically with time control).

6.5 DesaltingIn the water there are solved earth alkaline (carbonates, salts), which do not flow with the steam but will remain at the boiler water (thickening the boiler water). This is measured by use of conductivity in µS/cm. A too high thickening leads to foaming of the boiler water, which will impair the level regulation, the level safety sensors as well as the steam quality.

That is why the conductivity in the boiler water has to be supervised and regulated. Therefore a part of the “bad” boiler water is continuously led off and replaced by fresh feed water (manual measure and valve adjustment or conductivity control with desalination control) = Energy loss!

Attention: The desalting rate has to be considered at the feed water pump design too!

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6.6 Condensate return

In many processes there is some condensate created, which should be returned to the boiler.

According to the system structure this return is done• directly from the consumers to the feed water tank• back to an open system (pressure less condensate tank

– expansion steam losses)• in a closed system (direct return into the steam boiler,

efficient at a high condensate percentage and high pressures)

6.7 Water treatment plant

The required water quantity, which does not return to the boiler circuit as condensate, has to be replaced with additional water (freshwater).

By the water treatment station this additional water is conditioned. For the treatment there are different procedures available: • soften (ion exchanger) • part- or full desalting • reverse osmosis • chemicals dosing

(for oxygen binding, pH – value stabilisation, corrosion protection)

The selection of the process depends on the following parameters: • raw water total hardness • raw water carbonate hardness • returned condensate percentage• required steam quality

The higher the carbonate hardness and the demand of additional water, the more economic are desalting plants and reverse osmosis systems.

6.8 Feed water tank

At the feed water tank the feed water for the steam boiler is prepared.

By preheating the feed water:• too high temperature differences (warmth tensions) in

the boiler will be avoided• the gases O2 and CO2 which are contained in the water

are largely reduced • the dosing chemicals are brought to their full efficiency

The content of the feed water tank should correspond to the boiler capacity, in order to • secure a reserving time in the case of an external

damage• bring the dosing chemicals to their full efficiency

Layouts of feed water tanks:• Direct heating (90-95 °C) – smaller plants with open feed

water tanks , often suspect because of oxygen contact, higher operation costs because of higher consumption of chemicals

• Thermal degasifying 105 °C – good removal of the gases O2 and CO2 out from the feed water, operation pressure 0,5 bar(g) will prevent a oxygen contact.

Attention: The steam demand for the feed water tank and/or deaerator has to be considered at the layout of the boiler capacity.

6.9 Efficiency of steam boiler plants

Steam boilers have an efficiency grade of 88-91 % acc. to operation pressure, and at exhaust gas temperatures of 200° to 280°C. So there is a considerable energy loss going through the chimney which could be reduced by additional systems (example: economisers).

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7 Saturated steam tables – part 1 For details (freeware – download) see: www.x-eng.com

Absolute pressure Temperature Steam volume Steam density Water enthalpy Steam enthalpy Evaporation enthalpy

p t v‘‘ ϱ h‘ h‘‘ rbar °C m³/kg kg/m³ kJ/kg kJ/kg kJ/kg

0,010 6,98 129,200 0,008 29,34 2514,4 2485,00,015 13,04 87,980 0,011 54,71 2525,5 2470,70,020 17,51 67,010 0,015 73,46 2533,6 2460,20,025 21,10 54,260 0,018 88,45 2540,2 2451,70,030 24,10 45,670 0,022 101,00 2545,6 2444,60,035 26,69 39,480 0,025 111,85 2550,4 2438,50,040 28,98 34,800 0,029 121,41 2554,5 2433,10,045 31,04 31,140 0,032 129,99 2558,2 2428,20,050 32,90 28,190 0,035 137,77 2561,6 2423,80,055 34,61 25,770 0,039 144,91 2564,7 2419,80,060 36,18 23,740 0,042 151,50 2567,5 2416,00,065 37,65 22,020 0,045 157,64 2570,2 2412,50,070 39,03 20,530 0,049 163,38 2572,6 2409,20,075 40,32 19,240 0,052 168,77 2574,9 2406,20,080 41,53 18,100 0,052 173,86 2577,1 2403,20,085 42,69 17,100 0,055 178,69 2579,2 2400,50,090 43,79 16,200 0,058 183,28 2581,1 2397,90,095 44,83 15,400 0,062 187,65 2583,0 2395,30,10 45,83 14,670 0,065 191,83 2584,8 2392,90,15 54,00 10,020 0,100 225,97 2599,2 2373,20,20 60,09 7,650 0,131 251,45 2609,9 2358,40,25 64,99 6,204 0,161 271,99 2618,3 2346,40,30 69,12 5,229 0,191 289,30 2625,4 2336,10,40 75,89 3,993 0,250 317,65 2636,9 2319,20,45 78,74 3,576 0,280 329,64 2641,7 2312,00,50 81,35 3,240 0,309 340,56 2646,0 2305,40,55 83,74 2,964 0,337 350,61 2649,9 2299,30,60 85,95 2,732 0,366 359,93 265w3,6 2293,60,65 88,02 2,535 0,395 368,62 2656,9 2288,30,70 89,96 2,365 0,423 376,77 2660,1 2283,30,75 91,79 2,217 0,451 384,45 2663,0 2278,60,80 93,51 2,087 0,479 391,72 2665,8 2274,00,85 95,15 1,972 0,507 398,63 2668,4 2269,80,90 96,71 1,869 0,535 405,21 2670,9 2265,60,95 98,20 1,777 0,563 411,49 2673,2 2261,71,00 99,63 1,694 0,590 417,51 2675,4 2257,91,5 111,37 1,159 0,863 467,13 2693,4 2226,22,0 120,23 0,885 1,129 504,70 2706,3 2201,62,5 127,43 0,718 1,392 535,34 2716,4 2181,03,0 133,54 0,606 1,651 561,43 2724,7 2163,23,5 138,87 0,524 1,908 584,27 2731,6 2147,44,0 143,62 0,462 2,163 604,67 2737,6 2133,04,5 147,92 0,414 2,417 623,16 2742,9 2119,75,0 151,84 0,375 2,669 640,12 2747,5 2107,45,5 155,46 0,343 2,920 655,78 2751,7 2095,96,0 158,84 0,316 3,170 670,42 2755,5 2085,06,5 161,99 0,293 3,419 684,12 2758,8 2074,07,0 164,96 0,273 3,667 697,06 2762,0 2064,97,5 167,75 0,255 3,915 709,29 2764,8 2055,58,0 170,41 0,240 4,162 720,94 2767,5 2046,58,5 172,94 0,227 4,409 732,02 2769,9 2037,99,0 175,36 0,215 4,655 742,64 2772,1 2029,59,5 177,66 0,204 4,901 752,81 2774,2 2021,410 179,88 0,194 5,147 762,61 2776,2 2013,6

ϱ

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8 Saturated steam tables – part 2 For details (freeware – download) see: www.x-eng.com

Absolute pressure Temperature Steam volume Steam density Water enthalpy Steam enthalpy Evaporation enthalpy

p t v‘‘ ϱ h‘ h‘‘ r bar °C m³/kg kg/m³ kJ / kg kJ / kg kJ / kg10,5 181,98 0,185 5,39 771,87 2777,95 2006,0511 184,07 0,175 5,64 781,13 2779,70 1998,5011,5 186,02 0,169 5,88 789,78 2781,20 1991,4012 187,96 0,163 6,13 798,43 2782,70 1984,3012,5 189,79 0,157 6,37 806,57 2784,05 1977,5013 191,61 0,151 6,617 814,70 2785,4 1970,713,5 193,33 0,146 6,86 822,39 2786,60 1964,2014 195,04 0,141 7,106 830,08 2787,8 1957,714,5 196,67 0,136 7,35 837,38 2788,85 1951,4515 198,29 0,132 7,596 844,67 2789,9 1945,215,5 199,83 0,128 7,84 851,62 2790,80 1939,2016 201,37 0,124 8,085 858,56 2791,7 1933,216,5 202,84 0,120 8,33 865,20 2792,55 1927,3517 204,31 0,117 8,575 871,84 2793,4 1921,517,5 205,71 0,113 8,82 878,21 2794,10 1915,9018 207,11 0,110 9,065 884,58 2794,8 1910,318,5 208,46 0,108 9,31 890,70 2795,45 1904,8019 209,80 0,105 9,555 896,81 2796,1 1899,319,5 211,09 0,102 9,80 902,70 2796,65 1893,9520 212,37 0,100 10,05 908,59 2797,2 1888,620,5 213,61 0,097 10,30 914,28 2797,70 1883,4021 214,85 0,095 10,54 919,96 2798,2 1878,222 217,24 0,091 11,03 930,95 2799,1 1868,123 219,55 0,087 11,52 941,60 2799,8 1858,224 221,78 0,083 12,02 951,93 2800,4 1848,525 223,94 0,080 12,51 961,96 2800,9 1839,026 226,04 0,077 13,01 971,72 2801,4 1829,627 228,07 0,074 13,51 981,22 2801,7 1820,528 230,05 0,071 14,01 990,48 2802,0 1811,529 231,97 0,069 14,51 999,53 2802,2 1802,630 233,84 0,067 15,01 1008,4 2802,3 1793,931 235,65 0,065 15,52 1016,90 2802,30 1785,4032 237,45 0,062 16,02 1025,4 2802,3 1776,934 240,88 0,059 17,03 1041,8 2802,1 1760,336 244,16 0,055 18,05 1057,6 2801,7 1744,238 247,31 0,052 19,07 1072,7 2801,1 1728,440 250,33 0,050 20,10 1087,4 2800,3 1712,942 253,24 0,047 21,14 1101,6 2799,4 1697,844 256,05 0,045 22,18 1115,4 2798,3 1682,946 258,75 0,043 23,24 1128,8 2797,0 1668,348 261,37 0,041 24,29 1141,8 2795,7 1653,950 263,91 0,039 25,36 1154,5 2794,2 1639,755 269,33 0,036 28,07 1184,9 2789,9 1605,060 275,55 0,032 30,83 1213,7 2785,0 1571,365 280,82 0,030 33,65 1241,1 2779,5 1538,470 285,79 0,027 36,53 1267,4 2773,5 1506,075 290,50 0,025 39,48 1292,7 2766,9 1474,280 294,97 0,024 42,51 1317,1 2759,9 1442,885 299,23 0,022 45,61 1340,7 2752,5 1411,790 303,31 0,021 48,79 1363,7 2744,6 1380,995 307,21 0,019 52,06 1386,1 2736,4 1350,2100 310,96 0,018 55,43 1408,0 2727,7 1319,7110 318,05 0,016 62,48 1450,6 2709,3 1258,7120 324,65 0,014 70,01 1491,8 2689,2 1197,4130 330,83 0,013 78,14 1532,0 2667,0 1135,0140 336,64 0,012 86,99 1571,6 2642,4 1070,7150 342,13 0,010 96,71 1611,0 2615,0 1004,0160 347,33 0,009 107,4 1650,5 2584,9 934,3170 352,66 0,008 119,5 1691,7 2551,6 859,9180 356,96 0,007 133,4 1734,8 2513,9 779,1190 361,43 0,007 149,8 1778,7 2470,6 692,0200 365,70 0,006 170,2 1836,5 2418,4 591,9220 373,69 0,004 268,3 2011,1 2195,6 184,5221,20 374,15 0,003 315,5 2107,4 2107,4 0

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9 Technical details for industrial boilers See external catalogue

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10 Selection of burners

Technical data for boilers up to ~ 5 to/h steam capacity (part 1)To select the burner you need to know the following data:Fuel type light Oil – diesel (example)Mode of the burner two stage burner (example)Boiler load 1300 kW (example)Flame tube length 1624 mm (example)

Technical data for boilers up to ~ 5 to/h steam capacity (Part 2)

Note: Hoval industrial boilers are produced with direct burner connections to boiler front door (no adapter flange necessary) – so it´s absolutely necessary to know the exact burner type and dimensions before ordering the boiler!

Boiler typeBoiler

capacity

[kW]

Boiler flame tube

length [m]

Boiler flame tube

diameter [mm]

Smoke gas resistance

without ECO [mbar]

Smoke gas resistance with ECO

[mbar]

Turning chamber

lenght [mm]

Burner head

lenght [mm]

Burner capacity

without Eco [kW]

Burner capacity with Eco

[kW]THD-U 500 - 10 bar 326 1495 575 3,10 6,10 - 400 366 347THD-U 650 - 10 bar 424 1645 575 3,30 6,30 - 400 474 451THD-U 800 - 10 bar 522 1795 650 3,60 6,60 - 400 585 555

THD-U 1000 - 10 bar 652 2045 650 4,20 7,20 - 400 729 694THD-U 1200 - 10 bar 783 2395 700 4,70 7,70 - 400 873 832THD-U 1600 - 10 bar 1044 2495 725 5,50 8,50 - 400 1165 1111THD-U 2000 - 10 bar 1304 2540 850 5,70 8,70 - 400 1455 1387THD-U 2500 - 10 bar 1631 2640 925 6,50 9,50 - 400 1822 1735THD-U 3000 - 10 bar 1957 2640 975 6,70 9,70 - 400 2189 2082THD-U 3500 - 10 bar 2283 2890 1100 5,00 8,00 - 400 2551 2429THD-U 4000 - 10 bar 2609 3390 1100 7,30 10,30 - 400 2908 2776THD-U 4500 - 10 bar 2935 3390 1150 6,90 9,90 - 400 3272 3122THD-U 5000 - 10 bar 3261 3390 1200 6,90 9,90 - 400 3631 3469

Boiler type

Boiler capacity

max.

[kW]

Boiler capacity

norm.

[kW]

Boiler flame tube

length

[mm]

Boiler flame tube diameterinside/outside

[mm]

Smoke gas resistance

without ECO max/norm.

[mbar]

Smoke gas resistance with ECO max/norm.

[mbar]

Turning chamber

length

[mm]

Burner head

length

[mm]

Burner capacity

without ECO max/norm.

[kW]

Burner capacity with ECO max/norm.

[kW]THSD-I E 25/20 -10 bar 1630 1304

2300 650 11/8,5 14/11,5 380 3001826/1450 1726 / 1381

13 bar 1635 1308 1842/1462 1732 / 138516 bar 1639 1311 1854/1472 1736 / 1388

THSD-I E 30/25 -10 bar 1956 16302500 700 12/9 15/12 380 300

2197 / 1840 2072 / 172613 bar 1963 1635 2216 / 1834 2079 / 173216 bar 1967 1639 2225 / 1847 2083 / 1736

THSD-I E 35/30 -10 bar 2283 19562700 750 12/9,5 15/12,5 380 300

2567 / 2188 2418 / 207213 bar 2290 1963 2590 / 2194 2425 / 207916 bar 2295 1967 2607 / 2222 2431 / 2083

THSD-I E 45/40 -10 bar 2934 26083050 800 12/8 15/13 380 300

3293 / 2914 3108 / 276213 bar 2944 2617 3322 / 2941 3118 / 277216 bar 2951 2623 3346 / 2961 3126 / 2778

THSD-I E 55/50 -10 bar 3586 32603500 850 12,5/10 15,5/13 380 300

4005 / 3629 3798 / 345313 bar 3596 3271 4040 / 3661 3809 / 346516 bar 3606 3278 4068 / 3686 3820 / 3472

Flame tube diameter 606 mm (example)Boiler flue gas side resistance 4,9 mbar (example)Boiler efficiency at (full load) 92,7 % (example) or Burner capacity 1453 kW (example)

For more details about burner selection see below-mentioned list and Hoval technical catalogue.

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11 Properties of some supply fuel oils (av. values - physical standard condition)

Parameters Symbol Unit Extra-light fuel oil (diesel) Heavy fuel oil

Calorific value LCV MJ/kg 42,7 40,7

LCV kWh/kg 11,86 11,3

LCV Mcal/kg 10,2 9,72

Density at 15 °C ρ15 kg/l 0,84 0,96

Flame point ∆F °C 70 120

Viscosity

at 20 °C ν mm²/s Max. 6 -

at 50 °C ν mm²/s 2 Max. 50

at 100 °C ν mm²/s - 30

Combustion value at λ =1

Air consumption vL m³/kg 11,0 10,7

Smoke gas volume dry vA,tr m³/kg 10,3 10,0

Smoke gas volume – wet vA,f m³/kg 11,8 11,4

Water quantity at smoke gas vH2O m³/kg 1,5 1,4

Max. Carbon dioxide CO2,max Vol.-% 15,5 15,9

Contents:

Carbon C Weight-% 86 84

Hydrogen H Weight-% 13 12

Sulphur S Weight-% < 0,2 (< 0,1) < 2,8 (changes possible)

Oxygen O2 Weight-% 0,4 0,5

Nitrogen N Weight-% 0,02 0,3

Water H2O Weight-% 0,4 0,4

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12 Properties of some supply gases (av. values - physical standard condition)

Parameters Symbol Unit Natural gas “L”

Natural gas “H”

PropaneC3H8

ButaneC4H10

Calorific value LCV kWh/m³ 8,83 10,0 25,9 34,4

LCV MJ/m³ 31,8 36,0 93,2 123,8

LCV Mcal/m³ 7,59 8,6

Explosion limit (Vol % gas / air, at 20°C)

Lowest limit LFL Vol.-% 5 4 2,1 1,4

Highest limit HFL Vol.-% 15 16 9,0 9,3

Density ρ Kg/m³ 0,829 0,784 2,011 2,708

Relative Density d Kg/m³ 0,641 0,606 1,555 2,094

Combustion value at λ =1

Air consumption vL m³/m³ 8,36 9,47 24,37 32,37

Smoke gas volume dry vA,tr m³/m³ 7,64 8,53 22,81 29,74

Smoke gas volume – wet vA,f m³/m³ 9,36 10,47 26,16 34,66

Max. Carbon dioxide CO2,max Vol.-% 11,8 12,00 13,7 14,0

Water quantity at smoke gas (related to input gas quantity) vH2O m³/m³ 1,72 1,94 3,29 4,2

Dew point (dry combustion air) ∆T °C 58 58 54 53

Contents:

Nitrogen N2 Vol. 14 3,1 - -

Oxygen O2 Vol. - - - -

Carbon dioxide CO2 Vol. 0,8 1,0 - -

Hydrogen H2 Vol. - - - -

Carbon monoxide CO Vol. - - - -

Methan CH4 Vol. 81,8 92,3 - -

Ethan C2H6 Vol. 2,8 2,0 - -

Propane C3H8 Vol. 0,4 1,0 100 -

Butan C4H10 Vol. 0,2 0,6 - 100

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λ =

VL ≈ CO2,max

≈ 21 %

VL (stö) CO2,metered (21 % - O2,metered)

Guide value for Vtr,stö / VL,stö

Effective dry smoke gas quantity

Effective wet smoke gas quantity

14 Boiler load / output – Steam quantity

13 Excess of air – calculation

Natural gas Propane Fuel oil extra light (diesel)

Heavy fuel oil

Vtr,stö / VL,stö 0,91 0,93 0,93 0,94

λ = Excess air value

VL = Effective air quantity m3(i.N.)/kg (or m3)

VL,stö = stoichiometrical air quantity m3

(i.N.)/kg (or m3/m3 i.N.)

Vf = Effective smoke gas quantity (wet) m3 (i.N.)/kg (or m3/m3 i.N)

CO2,max = max. CO2-content at stoichiometrical combustion (Vol %)

CO2,metered = CO2-content (Vol.-%)

Vtr,stö = Effective smoke gas quantity (dry) m3 (i.N.)/kg (or m3/m3 i.N) at stoichiometrical combustion

O2 = O2-content – dry (Vol.-%)

14.1 Steam quantity calculation

1 t/h saturated steam ≈ 0,65 MW boiler load* * at 12 bar(g) and 102°C feed water temperature

1 kg oil or 1 m3 gas results in following saturated steam quantity (kg/h):

1 kg oil produces round 16 kg steam

To produce 1t saturated steam the following oil- or gas quantity is needed (kg or m3):

14.2 Boiler load, firing load and fuel consumption in connection with boiler efficiency

Boiler output – produced saturated steam quantity

Boiler efficiency Firing load Needed quantity of heavy fuel oil Needed quantity of extra light fuel oil

(diesel)

t/h MW % MW kg/h kg/h

1 0,65 85 0,77 67,5 64,5

1 0,65 88 0,74 65,5 62,5

1 0,65 90 0,72 64,0 61,0

1 0,65 92 0,71 62,5 59,5

CO2,max CO2,metered - 1

λ = 1 +Vtr,stö VL,stö*

Vtr,stö VL,stö*

O2, metered 21 – O2, metered

λ = 1 +

Vtr = Vtr, stö + (λ- 1) * VL, stö

Vf = Vf, stö + (λ- 1) * VL, stö

234000

Lower calorific value in * boiler efficiency in %orkJ kg

kJ m3

Lower calorific value in * boiler efficiency in %orkJ kg

kJ m3

2,34 * 108

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14.3 Exact calculation of fuel consumption at known steam capacity and steam parameters

mB bzw. VB = fuel consumption in kg/h or m³/hMD = steam quantity in kg/hh‘‘ = Enthalpy of steam in kJ/kgh‘sw = Enthalpy of feed water in kJ/kgHu = lower calorific value in kJ/kg or kJ/m3ηK = boiler efficiency in %

14.4 Determination of efficiency with smoke gas measurement*

ηK (in %) = 100% – XA%

XA = Smoke gas lossϑA = Metered smoke gas temperatureϑL = Metered combustion air temperatureCO2,tr = metered CO2-value at dry smoke gas in vol.-%f = Constant figure

MD * (h‘‘-h‘sw) * 100% Hu * nk

mB or VB =ϑA– ϑL CO2,tr

Smoke gas loss XA = f * in %

15 Conversion from “Nm³” to “operating m³” (gas, air, smoke gas)

Extra light fuel oil Heavy fuel oil Natural gas Propane/Butane

f 0,59 0,61 0,46 0,50

Example 3861 Nm³/hVoperation = Vnorm * (1013 / (1013 + p)) * ((273 + t) / 273)

Voperation = operation cubic meter (per hour) at actual gas temperature and gas pressure

Vnorm = Norm cubic meter (per hour) at 0°C and 1013 mbar

p = gas pressure in mbar

t = gas temperature in °C

For this example = 1068,10606 operation m³/hactual gas temperature 15 °C (see local indication + fill in)

actual gas pressure 2850 mbar (see local indication + fill in)

Example 360 operation m³/hVnorm = Voperation / ((1013 / (1013 + p)) * ((27 3+ t) / 273))

Voperation = operation cubic meter (per hour) at actual gas temperature and gas pressure

Vnorm = Norm cubic meter (per hour) at 0°C and 1013 mbar

p = gas pressure in mbar

t = gas temperature in °C

For this example = 1301,33144 Nm3/hactual gas temperature 15 °C (see local indication + fill in)

actual gas pressure 2850 mbar (see local indication + fill in)

16 Conversion from “operation m³” to “Nm³” (gas, air, smoke gas

* calculation base: Siegert formula

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17 Feed water tank and feed water conditioningThe importance of the boiler feed tank, where boiler feed water and make-up water are stored and into which condensate is returned, is often underestimated. Most items of plant in the boiler house are duplicated, but it is rare to have two feed tanks and this crucial item is often the last to be considered in the design process.The feed tank is the major meeting place for cold make-up water and condensate return. It is best if both of these if flow through sparge pipes installed well below the water surface in the feed water tank. The sparge pipes must be adequately supported.

17.1 Operating temperature

It is important that the water in the feed tank is kept at a high enough temperature to minimise the content of dissolved oxygen and other gases. The correlation bet-ween the water temperature and its oxygen content in a feed tank can be seen in Figure 3.11.1. If a high proportion of make-up water is used, heating the feed water can substantially reduce the amount of oxygen scavenging chemicals required.

Example 3.11.1:Cost savings associated with reducing the dissolved oxygen in feed water by heating.

Basis for calculation:• The standard dosing rate for sodium sulphite is 8 ppm per 1 ppm

of dissolved oxygen.• It is usual to add an additional 4 ppm to maintain a reserve in the boiler.• Typical liquid catalysed sodium sulphite contains only 45% sodium sulphite.

For the example: The average generation rate of the boiler = 10 000 kg/h The boiler operation per annum = 6 000 h/year The cost of sodium sulphite = £1000/1000kg=£1/kg

Calculation 1 Feedtank temperature = 60°C From Figure 3.11.1, the oxygen content of water at 60°C = 4.8 ppm Amount of sodium sulphite required = (4.8 x 8)+4 = 42.4 ppm Amount of sodium sulphite required = 42.4 ppm x 100 / 45 = 94.2 ppm (45% concentrated) Annual amount of sodium sulphite required = 10 000kg / h x 6 000 h/year x Annual amount of sodium sulphite required = 5653 kg / year Annual costs of sodium sulphite = 5653 kg / year x £1/kg Annual cost of sodium sulphite = £ 5653 / year

Calculation 2 Feedtank temperature = 85°C

From Figure 3.11.1, the oxygen content of water at 85°C = 2.3 ppm Amount of sodium sulphite required = (2.3 x 8)+4 = 22.4 ppm Amount of sodium sulphite required = 22.4 ppm x 100 / 45 = 49.8 ppm (45% concentrated) Annual amount of sodium sulphite required = 10 000kg / h x 6 000 h / year x

49.8 ppm dissolved O2 1 000000 ppm to 1 kg

Annual amount of sodium sulphite required = 2988 kg / year Annual costs of sodium sulphite = 2988 kg / year x £1 / kg Annual cost of sodium sulphite = £ 2988 / year Annual cost saving This is the difference between the two values calculated: Annual cost saving = £ 5 653 - £ 2 988 Annual cost saving = £2 665/year Percentage of annual cost saving =

£ 2665 £5653

100 1*

Percentage of annual cost saving = 47%

Obviously a cost is involved in heating the feed tank, but since the water temperature would be increased by the same amount inside the boiler, this is not additional energy, only the same energy used in a different place.

The only real loss is the extra heat lost from the feed tank itself. Provided the feed tank is properly insulated, this extra heat loss will be almost insignificant.An important additional saving is reducing the amount of sodium sulphite added to the boiler feed water. This will reduce the amount of bottom blow down needed, and this saving will more than compensate for the small additional heat loss from the boiler feed tank.

94.2ppm dissolved O2 1 000000 ppm to 1 kg

Fig. 3.11.1 Water temperature versus oxygen content

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To avoid damage to the boiler itselfThe boiler undergoes thermal shock when cold water is introduced to the hot surfaces of the boiler wall and its tubes. Hotter feed water means a lower temperature difference and less risk of thermal shock.

To maintain the designed outputThe lower the boiler feed water temperature, the more heat is required in the boiler to produce steam. It is important to maintain the feed tank temperature as high as possible, to maintain the required boiler output.

17.2 Cavitation of the boiler feed pump

Caution: very high condensate return rates (typically over 80%) or damages at temperature regulators or condensate traps may result in excessive feed water temperature, and cavitation in the feed pump.If water close to boiling point enters a pump, it is liable to

flash to steam at the low pressure area at the eye of the pump impeller. If this happens, bubbles of steam are formed as the pressure drops below the water vapour. When the pressure rises again, these bubbles will collapse and water flows into the resulting cavity at a very high velocity.This is known as ‚cavitation‘; it is noisy and can seriously damage the pump.To avoid this problem, it is essential to provide the best possible Net Positive Suction Head (NPSH) to the pump so that the static pressure is as high as possible. This is greatly aided by locating the feed tank as high as possible above the boiler, and generously sizing the suction pipe work to the feed pump (Figure 3.11.2).See capacity curves of selected feed water pump for details about “NPSH” value and respect additional figures for higher temperatures! If in doubt contact Hoval specialist! Also it´s to observe that pump cavitation danger increase if pumps are operated below the designed lifting pressure; the necessary “NPSH” value increase due to higher flow rates!

Figure 3.11.2 NPSH above feedpump

Boiler feedtank

NPSH

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17.3 Feed tank design

The feed tank (Figure 3.11.3) can influence the way in which the whole boiler house operates in several ways. By careful design of the feed tank and associated systems, substanti-al savings can be made in energy and water treatment chemicals together with increased reliability of operation.

Whilst cylindrical feed tanks, both vertical and horizontal, are not uncommon in other parts of the world, the rectan-gular shape is most regularly used for smaller capacities. This normally offers the maximum volume of water storage for the floor area that it occupies.

Fig. 3.11.3 Boiler feed tank

VentFlash condensingdeareator head

Level control system

Condensate Return

Recirculation system

Feedwater to boiler

Steam

Temperature control system

Cold make-up

Blowdown heat recovery

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17.4 Feed tank materials:

• Carbon steel: Probably the most common construction material for feed tanks: Uncoated, it is a relatively low cost material but it is extremely susceptible to corrosion. This weakness can be improved by applying suitable coatings to the surface, but the cost of this can be more than the cost of the tank, especially as the coating will also need regular mainte-nance.

• Plastic: This material is not usually suitable for feed tanks due to the high cost of materials able to withstand the relatively high temperatures involved. However, plastic is a suitable material for the cold make-up water tank.

• Austenitic stainless steel: The enhanced life of a properly made feed tank in this material will invariably justify the higher initial cost. Type 304L is generally selected as the most appropriate grade of stainless steel.

17.5 Feedtank capacity

The feed tank provides a reserve of water to cover the interruption of make-up water supply. Traditional practice is to have a feed tank with sufficient capacity to allow one hour of steaming at maximum boiler evaporation; this gives the needed reaction time for the dosing chemicals at the feed tank too. For larger plants this may be impractical and an alternative might be to have a smaller ‚hotwell‘ feed tank with additional cold treated water storage. It should also have sufficient capacity above its normal working level to accommodate any surges in the rate of condensate return. This capacity is referred to as ‚ullage‘.

A high condensate return rate can occur at start-up when condensate lying in the plant and pipe work is suddenly returned to the tank, where it may be lost to drain through the overflow. If this occurs, it may be wise to review the condensate return system, to control the return rate and avoid wastage.

17.6 Feed tank piping

Fig. 3.11.4 The feed tank in relation to the other elements within a steam system

LoadSteam

Feedpump

Boiler blowdown

Make-Up water

Feedtank

Boiler

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Fig. 3.11.5 Comparison of energy to raise steam at 10 bar(g)

Condensate returnAs steam is generated, the water within the boiler evapo-rates and is replaced by pumping feed water into the boiler.

As the steam passes around the system to the various items of steam-using plant, it changes state back to conden-sate, which is, essentially, very good quality hot water.

Unless some contamination is likely (perhaps due to the process), this condensate is ideal boiler feed water. It makes economic sense, therefore, to return as much as possible for re-use. In reality, it is almost impossible to return all the condensate; some steam may have been injected directly into the process for applications such as humidification and steam injection, and there will usually be water losses from the boiler itself, for instance, via blow

down. Make-up (chemically treated) water will therefore have to be introduced to the system to maintain the correct working levels.

The return of condensate represents huge potential for energy savings in the boiler house. Condensate has a high heat content and approximately 1% less fuel is required for every 6°C temperature rise in the feed tank.

Figure 3.11.5(a) shows the formation of steam at 10 bar g when the boiler is supplied with cold feed water at 10°C. The portion at the bottom of the diagram represents the enthalpy (42 kJ / kg) available in the feed water. A further 740 kJ / kg of heat energy has to be added to the water in the boiler before saturation temperature at 10 bar g is reached.

Formation of 1 kg of steam @ 10 bar g –

feedwater 10°C

Formation of 1 kg of steam @ 10 bar g –

feedwater 70°C Requires 9.2% less energy

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Figure 3.11.5(b) again shows the formation of steam at 10 bar g, but this time the boiler is fed with feed water heated to 70°C by returning more condensate.

The increased enthalpy contained in the feed water means that the boiler now only has to add 489 kJ / kg of heat energy to bring it up to saturation temperature at 10 bar(g). This represents a saving of 9.2% in the energy needed to raise steam at this same pressure.

The returned condensate is virtually pure water and this saves not only on water costs but also on water treatment chemicals, which reduces the losses associated with blow down.

If pressurised condensate is being returned then flash steam will be released in the feed tank. This flash steam needs to be condensed to ensure that both the heat and water content are recovered. The traditional method of doing this has been to introduce it into the feed tank through sparge pipes.

Make-up waterThis is cold water from the water treatment plant that makes up any losses in the system.

Many water treatment plants need a substantial flow through them in order to achieve optimum performance. A ‚trickle‘ flow as a result of a modulating control into the feed tank can, for example, have an adverse effect on the performance of a softener. For this reason a small plastic or galvanised steel cold make-up tank is often fitted. The flow from the softener is controlled ‚on / off‘ into the make-up tank. From there a modulating valve controls its flow into the feed tank.

This type of installation leads to ‚smoother‘ operation of the boiler plant. To avoid the relatively cold make-up water sinking directly to the bottom of the tank (where it will be drawn directly into the boiler feed water line), and to ensure uniform temperature distribution, it is common practice to sparge the make-up water into the feed tank at a higher level.

Steam injectionAs previously mentioned, there are significant advantages to maintain the feed tank contents at a high temperature. One of the most convenient ways of achieving this higher temperature is by injecting steam into the feed tank.

VentThe feed tank must be vented to prevent any build-up of pressure. The vent should be fitted with a vent head which incorporates an internal baffle to separate entrained water from the steam for discharge through a drain connection.

OverflowThis should be fitted with a ‚U‘ tube water seal to prevent flash steam loss.

Feed pump take-offIt should be generously sized so that friction losses are minimised, and the net positive suction head (NPSH) to the feed pump is maximised.

DrainA drain connection should be fitted in the bottom of the feed tank to facilitate its emptying for inspection.

InsulationThe feed tank should be adequately insulated to prevent heat losses. The advice of a reputable insulation specialist should be sought in selecting the correct material and economic thickness.

Inspection openingAn adequately sized inspection opening should be fitted to enable internal inspection and the fitting of ancillaries, as appropriate.

Water level controlTraditionally, float controls have been used for this application. Modern controls use level probes, which will give an output signal to modulate a control valve. Not only does this type of system require less maintenance but, with the use of an appropriate controller, a single probe may incorporate level alarms and remote indicating devices.

Level probes can be arranged to signal high water level, the normal working (or control) water level, and low water level. The signals from the probe can be linked to a control valve on the cold water make-up supply. The probe is fitted with a protection tube inside the feed tank to protect it from turbulence, which can result in false readings.

Water level indicatorA local level indicator or water level gauge glass on the feed tank is recommended, allowing the viewing of the

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contents for confirmation purposes, and for commissioning level probes.

Temperature gaugeThis can be a local or remote reading device.

17.7 Pressurised deaerator

On larger boiler plants, pressurised deaerators are someti-mes installed and live steam is used to bring the feed water up to approximately 105°C to drive off the oxygen. Pressu-rised deaerators are usually thermally efficient and will reduce dissolved oxygen to very low levels.

Pressurised deaerators:• Must be fitted with controls and safety devices.• Are classified as pressure vessels, and will require

periodic, formal inspection.

This means that pressurised deaerators are expensive, and are only justified in very large boiler houses. If a pressure deaerator is to be considered, its part load performance (or effective turndown) must be investigated.

17.8 Conditioning treatment

This is additional treatment which supplements external treatment, (for example, the base exchange system) and is generally carried out by adding chemicals in metered amounts, into either the feed water tank or the feed water pipeline prior to its entry into the boiler.

The chemical treatment required depends on many factors such as:• The impurities inherent in the make-up water

and its hardness.• The volume of condensate returned for re-use and its

quality in terms of pH value, TDS content, and hardness.• The design of the boiler and its operating conditions.

Deciding on the type of chemical regime and water treatment system is a matter for a skilled water treatment specialist who should always be consulted.

The purpose of the conditioning treatment is to enhance the treatment of the raw water after it has been processed as far as possible by the main water treatment plant. It ensures quality because, inevitably, there will be some

impurities that find a way through the main treatment system. The objectives of water treatment are:• To prevent scale formation from low remaining levels of

hardness which may have escaped treatment. Sodium phosphate is normally used for this, and causes the hardness to precipitate to the bottom of the boiler where it can be blown down.

• To deal with any other specific impurities present.These will be specific substances for specific applications.

• To maintain the correct chemical balance in the boiler water - to prevent corrosion it needs to be somewhat alkaline and not acidic. Typically a 1% caustic solution will be used to achieve a target pH of between 9 and 11. EN-norms recommends pH 10.5 - 12.0 for shell boilers at 10 bar, pH 9 could be used in higher pressure boilers only.

• To condition any suspended matter. This will be a flocculant or coagulant, which will cause the suspended matter to agglomerate and sink to the bottom of the boiler from where it can be blown down.

• To provide anti-foaming protection.• To remove traces of dissolved gases.

These are primarily oxygen and carbon dioxide and the presence of these dissolved gases in the boiler plant and system will cause corrosion. It is, therefore, necessary to remove and / or neutralise them if damage is to be prevented.

Carbon dioxideDissolved carbon dioxide is often present in feed water in the form of carbonic acid and this causes the pH level to fall. Proper pH control will correct this but carbon dioxide is also released in boilers due to heating of carbonates and bicarbonates. These decompose into caustic soda with the release of carbon dioxide. This may need to be dealt with by use of a condensate corrosion inhibitor, to prevent corrosive attack to the condensate system.

OxygenThe most harmful of the dissolved gases is oxygen, which can cause pitting of metal. Very small amounts of oxygen can cause severe damage. It can be removed both mechanically and chemically. The amount of dissolved oxygen present is dependent on the temperature of the feed water; the lower the feed water temperature, the larger the volume of dissolved oxygen present.

Any remaining oxygen is then dealt with by the addition of a chemical oxygen scavenger such as catalysed sodium sulphite.

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8 ppm of sodium sulphite is sufficient to deal with 1 ppm of dissolved oxygen. However, it is usual to add an extra (or ‚reserve‘) of 4 ppm of sodium sulphite because:• There is a significant danger of corrosive damage.• The chemical dosing system is usually ‚open loop‘ with

water samples taken at intervals, and adjustments made to the dosing rate.

• There is a concern about complete dispersion of the chemical, perhaps due to the method of injection, circulation currents, or stratification within the feed tank.

The total dosing rate, therefore, is 8 ppm of sodium sulphite per 1 ppm of dissolved oxygen plus 4 ppm.

Other oxygen scavengers involve organic compounds or hydrazine. The latter, however, is thought to be carcinogenic, and is not generally used in low and medium pressure plants.

Other ‚internal treatment‘ to provide protection for the boiler and the condensate system can include:• Neutralising amines – These have a neutralising effect on

the acid generated by the solution of carbon dioxide in condensate.

• Filming amines – These create an oil attractive, water repellent film on metal surfaces which is resistant to both carbon dioxide and oxygen.

Further detail on this complicated subject is available from water treatment handbooks and water treatment specia-lists; this is very much a matter for expert advice and professional analysis.

There are however, one or two areas which call for further explanation:• The main boiler water treatment programme is aimed at

changing scale-forming salts into soft or mobile sludges. The sludge conditioners used in the chemical dosing prevent these solids from depositing on metal surfaces and keep them in suspension.

• Under high pressures and temperatures, silica can present a real problem because it can combine with the metal heating surfaces to cause hot spots. Special synthetic polymers can prevent this problem.

• Alkalinity levels in the boiler are particularly important and these are controlled by the addition of sodium hydroxide.

Maintaining a pH level of between 10.5 - 12 will avoid corrosion problems by providing stable conditions for the formation of a film of magnetite (Fe3O4) in a thin, dense layer on the metal surfaces, protecting them from corrosive attack.

Chemicals added during the conditioning treatment will increase the TDS level in the boiler water and a higher rate of blow down will be required.

18 Water preparation for steam boiler plants

The operating objectives for steam boiler plant include:• Safe operation.• Maximum combustion and heat transfer efficiency.• Minimum maintenance.• Long working life.

The quality of the water used to produce the steam in the boiler will have a profound effect on meeting these objec-tives.

There is a need for the boiler to operate under the following criteria:

• Freedom from scale – If hardness is present in the feed water and not controlled chemically, then scaling of the heat transfer surfaces will occur, reducing heat transfer and efficiency – making frequent cleaning of the boiler necessary. In extreme cases, local hot spots can occur, leading to mechanical damage or even tube failure.

• Freedom from corrosion and chemical attack – If the water contains dissolved gases, particularly oxygen, corrosion of the boiler surfaces, piping and other equip-ment is likely to occur.

If the pH value of the water is too low, the acidic solution will

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attack metal surfaces. If the pH value is too high, and the water is alkaline, other problems such as foaming may occur.

Caustic embrittlement or caustic cracking must also be prevented in order to avoid metal failure. Cracking and embrittlement are caused by too high a concentration of sodium hydroxide. Older riveted boilers are more suscep-tible to this kind of attack; however, care is still necessary on modern welded boilers at the tube ends.

18.1 Good quality steam

If the impurities in the boiler feed water are not dealt with properly, carryover of boiler water into the steam system can occur. This may lead to problems elsewhere in the steam system, such as:• Contamination of the surfaces of control valves – This

will affect their operation and reduce their capacity.• Contamination of the heat transfer surfaces of process

plant – This will increase thermal resistance, and reduce the effectiveness of heat transfer.

• Restriction of steam trap orifices – This will reduce steam trap capacities, and ultimately lead to water logging of the plant, and reduced output.

Carryover can be caused by two factors:• Priming – This is the ejection of boiler water into the

steam take-off and is generally due to one or more of the following:

• Operating the boiler with too high a water level. • Operating the boiler below its design pressure; this

increases the volume and the velocity of the steam released from the water surface.

• Excessive steam demand.• Foaming – This is the formation of foam in the space

between the water surface and the steam off-take. The greater the amount of foaming, the greater the problems which will be experienced. The following are indications and consequences of foaming:

• Water will trickle down from the steam connection of the gauge glass; this makes it difficult to accurately determine the water level.

• Level probes, floats and differential pressure cells have difficulty in accurately determining water level.

• Alarms may be sounded, and the burner(s) may even "lockout". This will require manual resetting of the boiler control panel before supply can be re-established.

These problems may be completely or in part due to foaming in the boiler. However, because foaming is endemic to boiler water, a better understanding of foam itself is required:• Surface definition – Foam on a glass of beer sits on top

of the liquid, and the liquid / foam interface is clearly defined. In a boiling liquid, the liquid surface is indistinct, varying from a few small steam bubbles at the bottom of the vessel, to many large steam bubbles at the top.

• Agitation increases foaming – The trend is towards smaller boilers for a given steaming rate. Smaller boilers have less water surface area, so the rate at which steam is released per square metre of water area is increased. This means that the agitation at the surface is greater. It follows then that smaller boilers are more prone to foaming.

• Hardness – Hard water does not foam. However, boiler water is deliberately softened to prevent scale formation, and this gives it a propensity to foam.

• Colloidal substances – Contamination of boiler water with a colloid in suspension, for example milk, causes violent foaming. Note: Colloidal particles are less than 0.0001 mm in diameter, and can pass through a normal filter.

• TDS level – As the boiler water TDS increases, the steam bubbles become more stable, and are more reluctant to burst and separate.

Corrective action against carryoverThe following alternatives are open to the Engineering Manager to minimise foaming in the boiler:• Operation – Smooth boiler operation is important. With a

boiler operating under constant load and within its design parameters, the amount of entrained moisture carried over with steam may be less than 2%. If load changes are rapid and of large magnitude, the pressure in the boiler can drop considerably, initiating extremely turbulent conditions as the contents of the boiler flash to steam. To make matters worse, the reduction in pressure also means that the specific volume of the steam is increased, and the foam bubbles are proportionally larger. If the plant conditions are such that substantial changes in load are normal, it may be prudent to consider:

• Modulating boiler water level controls if on / off are currently fitted.

• "Surplussing controls" that will limit the level to which the boiler pressure is allowed to drop.

• A steam accumulator (contact your Hoval agency for details)


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• "Feed-forward" controls that will bring the boiler up to maximum operating pressure before the load is applied.

• "Slow-opening" controls that will bring plant on-line over a pre-determined period.

• Chemical control – Anti-foaming agents may be added to the boiler water. These operate by breaking down the foam bubbles. However, these agents are not effective when treating foams caused by suspended solids.

• Control of TDS – A balance has to be found between: • A high TDS level with its attendant

economy of operation. • A low TDS level which minimises foaming.• Safety – The dangers of overheating due to scale, and of

corrosion due to dissolved gases, are easy to understand. In extreme cases, foaming, scale and sludge formation can lead to the boiler water level controls sensing improper levels, creating a danger to personnel and process alike.

18.2 External water treatment

It is generally agreed that where possible on steam boilers, the principal feed water treatment should be external to the boiler.

A summary of the treated water quality that might be obtained from the various processes, based on a typical hard raw water supply, is shown in Table 3.9.2. This is the water that the external treatment plant has to deal with.

External water treatment processes can be listed as:• Reverse osmosis – A process where pure water is

forced through a semi-permeable membrane leaving a concentrated solution of impurities, which is rejected to waste.

• Lime; lime / soda softening – With lime softening, hydrated lime (calcium hydroxide) reacts with calcium and magnesium bicarbonates to form a removable sludge. This reduces the alkaline (temporary) hardness. Lime / soda (soda ash) softening reduces non-alkaline (perma-nent) hardness by chemical reaction.

• Ion exchange – Is by far the most widely used method of water treatment for shell boilers producing saturated steam. This tutorial will concentrate on the following processes by which water is treated: Base exchange, Dealkalisation and Demineralisation.

18.3 Ion exchange

An ion exchanger is an insoluble material normally made in the form of resin beads of 0.5 to 1.0 mm diameter. The resin beads are usually employed in the form of a packed bed contained in a glass reinforced plastic pressure vessel. The resin beads are porous and hydrophilic – that is, they absorb water. Within the bead structure are fixed ionic groups with which are associated mobile exchangeable ions of opposite charge. These mobile ions can be repla-ced by similarly charged ions, from the salts dissolved in the water surrounding the beads.

18.4 Base exchange softening

This is the simplest form of ion exchange and also the most widely used. The resin bed is initially activated (charged) by passing a 7-12% solution of brine (sodium chloride or common salt) through it, which leaves the resin rich in sodium ions. Thereafter, the water to be softened is pumped through the resin bed and ion exchange occurs. Calcium and magnesium ions displace sodium ions from the resin, leaving the flowing water rich in sodium salts. Sodium salts stay in solution at very high concentrations and temperatures and do not form harmful scale in the boiler.

From Figure 3.10.1 it can be seen that the total hardness ions are exchanged for sodium. With sodium base exchange softening there is no reduction in the total dissolved solids level (TDS in parts per million or ppm) and no change in the pH. All that has happened is an exchange of one group of potentially harmful scale forming salts for another type of less harmful, non-scale forming salts. As there is no change in the TDS level, resin bed exhaustion cannot be detected by a rise in conductivity (TDS and conductivity are related). Regeneration is therefore activated on a time or total flow basis.

Softeners are relatively cheap to operate and can produce treated water reliably for many years. They can be used successfully even in high alkaline (temporary) hardness areas provided that at least 50% of condensate is returned. Where there is little or no condensate return, a more sophisticated type of ion exchange is preferable.

Sometimes a lime / soda softening treatment is employed as a pre-treatment before base exchange. This reduces the load on the resins.

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Fig. 3.10.1 Base exchange softening

Softened water = 220 ppm2NaHCO3 = Sodium bicarbonate2NaCl = Sodium chlorideNa2SO4 = Sodium sulphate

SAC = Strong acid cation resinNa+ = Sodium form

Raw water TDS = 200 ppm Ca(HCO3)2 = Calcium bicarbonate MgCl2 = Magnesium chloride Na2SO4 = Sodium sulphate

Brine regeneration

SACNa+

Fig. 3.10.2 A dealkalisation plant

1 2 3 4 5Ca(HCO3)2 2H2CO3 H2O H2O H2O

MgCl2 MgCl2 MgCl2 MgCl2 2NaClNa2SO4 Na2SO4 Na2SO4 Na2SO4 Na2SO4pH 7.6 pH 4.5 - 5.0 pH 4.5 - 5.0 pH 7.5 - 8.5

18.5 Dealkalisation

The disadvantage of base exchange softening is that there is no reduction in the TDS and alkalinity. This may be overcome by the prior removal of the alkalinity and this is usually achieved through the use of a dealkaliser.

There are several types of dealkaliser but the most common variety is shown in Figure 3.10.2. It is really a set of three units, a dealkaliser, followed by a degasser and then a base exchange softener.

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Fig. 3.10.3: The dealkalisation process

18.6 Dealkaliser

The system shown in Figure 3.10.3 is sometimes called ‚split-stream‘ softening. A dealkaliser would seldom be used without a base exchange softener, as the solution produced is acidic and would cause corrosion, and any permanent

hardness would pass straight into the boiler. A dealkalisation plant will remove temporary hardness as shown in Figure 3.10.3. This system would generally be employed when a very high percentage of make-up water is to be used.

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18.7 Demineralisation

This process will remove virtually all the salts. It involves passing the raw water through both cation and anion exchange resins (Figure 3.10.4). Sometimes the resins may be contained in one vessel and this is termed ‚mixed bed‘ demineralisation.

The process removes virtually all the minerals and produces very high quality water containing almost no dissolved

solids. It is used for very high pressure boilers such as those in power stations.

If the raw water has a high amount of suspended solids this will quickly foul the ion exchange material, drastically increasing operating costs. In these cases, some pre-treat-ment of the raw water such as clarification or filtration may be necessary.

1 2 3 4Ca(HCO3)2 2H2CO3 H2O H2O

MgCl2 2HCI 2HCI H2O

Na2SO4 H2SO4 H2SO4 H2O

Na2SiO3 H2SiO4 H2SiO3 H2O

pH 7.6 pH 2.0 - 2.5 pH 2.0 - 2.5 pH 8.5 - 9.0

Fig. 3.10.4: Demineralisation

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18.8 Selection of external water treatment plant

Looking at Table 3.10.1, it is tempting to think that a demineralisation plant should always be used. However, each system has a capital cost and a running cost, as Table 3.10.2 illustrates, plus the demands of the individual plant need to be evaluated.

Table 3.10.1: Water quality versus treatment process

Table 3.10.2: Relative costs of water treatment processes

Process Hardness ppm Non-hardness salts ppm

TDSppm

AlkalineNon

alkaline

Raw water 200 50 60 310

Lime 30 50 58 138

Lime / soda 30 0 108 138

Lime / base exchange 5 0 133 138

Base exchange 5 0 255 260

Dealkalisation 5 50 60 115

Dealkalisation + base exchange 5 0 110 115

Demineralisation 1 0 2 3

Reverse osmosis 20 5 6 31

Type of system Comparative cost saleCapital cost Running cost

Base exchange 1 1

Dealkalisation + base exchange 3 3

Demineralisation 15 12

18.9 Shell boiler plant

Generally, shell boilers are able to tolerate a fairly high TDS level, and the relatively low capital and running costs of base-exchange softening plants (see Table 3.10.2) will usually make them the first choice.If the raw water supply has a high TDS value, and / or the condensate return rate is low (< 40%), there are a few options which may be considered:• Pre-treatment with lime / soda which will cause the

alkaline hardness to precipitate out of solution as calcium carbonate and magnesium hydroxide, and then drain from the reaction vessel.

• A dealkalisation plant to reduce the TDS level of the water supplied to the boiler plant.

Within the last years it´s common used to install an reverse osmosis plant to reduce TDS level – the operation is simply and the investment costs for the modules were greatly reduced during the years.

18.10 Summary

The quality of raw water is obviously an important factor when choosing a water treatment plant. Although TDS levels will affect the performance of the boiler operation, other issues, such as total alkalinity or silica content can sometimes be more important and then dominate the selection process for water treatment equipment.

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18.11 Boiler – and Feed water specifications for Hoval steam boilers:

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1.) General: Hot boiler water is not allowed to be drained directly into the city sewer network. The temperature should normally lower then 60°C (depends to local requirements). So it´s necessary to cool the boiler waste water and vent the expansion steam before running the water into the sewer system. For fast “cool-down” it´s recommended to install a cooling water supply pipe. If there´re special requests about drain temperature it may be necessary to install 2 pits in serial connection.

2.) Selection of purge pit size:The pit size depends to • boiler size • boiler operation pressure • heat carrier (low-pressure steam, high-pressure steam,

low-temperature heating water, high temperature water) Selection is done according selection table (see “Purge-pit – part 2”)

Example: Boiler with 150m² heat transfer surface, 8 bar working pressure results in pit size = > 400 L Sometimes – especially if purge and desalination rates are higher it´s recommended to calculate the purge pit volume exactly; if bigger pit volumes are necessary extend the dimensions accordingly (length * width; the depth could stay like example drawing).

Example:

V = VH + VH * F

V = (TH-TA) / (TA – TC)

V = Minimum water volume of pit below the water levelVH = Estimated volume of hot water discharged at one timeF = The estimated factorTH = Maximum Temperature of hot water discharged into the pitTC = Assumed temperature of cold water in the pit (say 15°C)TA = Temperature of waste allowed into the sewer (say 50°C)

To size a cooling pit to receive a discharge of 200 litres of hot water (with 100°C), where the maximum permissible discharge temperature to the sewer is 50°C. The temperature of the cold water in the cooling pit is 20°C.

F = (100 – 50) / (50 – 20) = 1,66

V = 200 litres + 200 litres * 1,66 = 533 litres

Therefore the capacity of the cooling pit (below min water level) should be > 533 litres.

19 Purge pit – part 13.) Construction:Pit lining made from armoured concrete (temperature resistant) Pit cladding made from clinker brick and alkaline resistant mortar Inlet- and outlet pipes made from corrosion resistant material Vent pipe made from “Eternit”-pipe or similar material (steam resistant and to be installed over the roof or to another safe area) Cooling water inlet to be ended at least 50 mm above the highest water level The inspection opening of pit has to be done with lockable cover It´s recommended to install an “expansion vessel” in front of purge pit inlet – this will separate the inlet hot stream into water and steam, the inlet pressure and turbulences at the purge pit will be reduced.

4.) Notes: • Purge pits which are installed enclosed to cellar or other

building walls are to be done with special care; leaking water will destroy the walls (due to high alkalinity). Install expansion compensation material between cladding and lining to absorb thermal expansions between cladding and lining.

• If the purge quantity is higher than 3% of maximum boiler output it´s recommended to install a continuous “TDS” regulation (conductivity regulation).

• Install a “siphon” at overflow pipe (to protect sewer system against steam entry) and don’t forget a cleaning opening for the siphon.

5.) Operation:Before using the boiler purge valve cool down the pit by opening the cooling water inlet; if pit volume is cooled down open the purge valve.For “automatic” purge systems it´s recommended to have the cooling water supply automatically regulated too.

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20 Purge pit – part 2

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There´re following possible variations: If V1 and V2 are not known:

21 Calculation of temperatures and quantities (Mixture of 2 water streams)

22 Pressure loss at steam pipes (see also point 25,26,28 and 32)

Armatures and pipe pieces: C = ξ

Pipes: C = λ l/d with λ = 0,0206 (according Eberle)

For piping elements with same dimension take the resis-tance values from above picture. With summary of all

TG * VG = V1 * T1 + V2 * T2V = Volume flow [Litre]T = Temperature [°C]

V1, T1 V2, T2

VG, TG(V1*T1+V2*T2)

VGTG =

(VG*TG-V2*T2) V1T1 =

(VG*TG+V1*T1) V2 T2 =

(TG-T2) (T1-T2) V1 = VG *

(TG-T1) (T2-T1) V2 = VG *

ϱ * w2 2Δp = C *

(V1*T1+V2*T2) TGVG =

(VG*TG-V2*T2) T1V1 =

(VG*TG-V1*T1) T2V2 =

single values (Σ C and operating values you´ll find the complete pressure loss – in bar - at following picture.

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Example:Piping elements in DN 50 Operation values:20 m straight pipe: C = 8,1 Temperature: 300°C1 piece 90° corner valve C = 3,3 Absolute steam pressure: 16 bar2 special flow valves C = 5,6 Flow speed: 40 m/sec1 piece T-piece C = 3,12 pieces elbow 90° C = 1,0

Summary of all “C” Σ C = 21,1 Result: ΔP = 1,1 bar

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Example: Result:Cast iron pipe DN 80 Pressure loss height Hv = 2,0m/100mVolume stream V = 20 m³/h Flow speed w: 1,1 m/sec

Following picture is valid for cold water and new “cast iron” pipes. The pressure loss values are to multiply with:0,8 for new milled steel pipes1,25 for older (slightly rusty) steel pipes1,7 for old encrusted pipes (observe real inner diameter too!)

23 Pressure loss at straight water pipesPressure loss: Volume stream: Hv = c *

w2 with C = λ l/d V

•= w * A=w * d 2 *

π(2 * g) 4

Pressure loss table (water)

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24.1 Flow speed values (for the orientation)

Steam vent pipes and exhaust vapors 15 – 25 m/secExpansion steam at condensate pipes 20 – 40 m/secSaturated steam headers < 15 m/secSaturated steam pipes (< 10 bar) 15 – 20 m/secSaturated steam pipes (10 – 40 bar) 20 – 40 m/secSuperheated steam pipes (small capacity) 40 – 50 m/secSuperheated steam pipes (high capacity) 50 – 65 m/secCondensate pipes (in front of traps) 1 – 2 m/secFeed water suction pipes 0,5 – 1,0 m/sec

V = volume flow m³/sec V = volume flow m³/h W = flow speed m/sec w = flow speed m/sec A = flow area m² d = pipe inside diameter mm d = pipe inside diameter

24 Determination of pipe size

25 Flow speed at pipes (liquid, gaseous)

Feed water pressure pipes 1,5 – 3,5 m/secCooling water suction pipes 0,7 – 1,5 m/secCooling water pressure pipes 1,0 – 2,0 m/secSanitary and domestic water pipes 1,0 – 2,0 m/secCompressed air pipes 15 – 25 m/secFuel oil (light) – suction pipes < 1 m/secFuel oil (light) pressure pipes 1,5 – 2 m/secFuel oil (heavy) – suction pipes 0,1 – 0,5 m/secFuel oil (heavy) – pressure pipes 0,5 – 1 m/secNatural gas (main pipes) – up to 2 bar 4 – 20 m/secNatural gas (main pipes) – up to 5 bar 11 – 35 m/sec

4

Flow speed diagram:

w * d2 354 V =

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Example: Steam temperature: 300°C Steam quantity: 30 to/h Absolute steam pressure: 16 bar Pipe dimension: DN 200

Result: Flow speed “w” = 43 m/sec

26 Steam pipes - dimensions

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The section of pipeline downstream of the trap will carry both condensate and flash steam at the same pressure and temperature. This is referred to as two-phase flow, and the mixture of liquid and vapour will have the characteristics of both steam and water in proportion to how much of each is present. Consider the following example.

An item of plant uses steam at a constant 4 bar g pressure. A mechanical steam trap is fitted, and condensate at saturation temperature is discharged into a condensate main working at 0.5 bar g.

Determine the proportions by mass, and by volume, of water and steam in the condensate main.

Part 1 - Determine the proportions by massFrom steam tables:At 4.0 bar g hf = 640.7 kJ/kg At 0.5 bar g hf = 464.1 kJ/kg hfg = 2225.6 kJ/kg

Equation 2.2.5 is used to determine the proportion of flash steam:

(hf at P1) - (hf at P1) hfg at P2

Proportion of flash steam =

Equation 2.2.5

Where:P1 = Initial pressureP2 = Final presshf = Specific liquid enthalpy (kJ/kg)hfg = Specific enthalpy of evaporation (kJ/kg)

640.7- 464.1 2225.6

100 1

xProportion of flash steam = = 7.9 %

Clearly, if 7.9% is flashing to steam, the remaining 100 - 7.9 = 92.1% of the initial mass flow will remain as water.

Part 2 - Determine the proportions by volumeBased on an initial mass of 1 kg of condensate discharged at 4 bar g saturation temperature, the mass of flash steam is 0.079 kg and the mass of condensate is 0.921 kg (established from Part 1).

27 Condensate pipes – dimensions

Water:The density of saturated water at 0.5 bar g is 950 kg/m3,

0.921kg 950 kg/m3and the volume occupied by 0.921kg: = 0.001 m3

Steam:

From steam tables, specific volume (vg) of steam at 0.5 bar g = 1.15 m/kg

The volume, occupied by the steam is 0.079 kg x 1.15 m/kg = 0.091 m

The total volume occupied by the steam and condensate mixture is: 0.001 m (water) + 0.091 m (steam) = 0.092 m

By proportion (%):

The water occupies = = 1% space0.001 0.092

100 1

x

The steam occupies = = 99% space0.091 0.092

100 1

x

From this, it follows that the two-phase fluid in the trap discharge line will have much more in common with steam than water, and it is sensible to size on reasonable steam velocities rather than use the relatively small volume of condensate as the basis for calculation. If lines are undersized, the flash steam velocity and backpressure will increase, which can cause waterhammer, reduce the trap capacity, and flood the process.Steam lines are sized with attention to maximum velocities. Dry saturated steam should travel no faster than 40 m/s. Wet steam should travel somewhat slower (15 to 20 m/s) as it carries moisture which can otherwise have an erosive and damaging effect on fittings and valves. Trap discharge lines can be regarded as steam lines carrying very wet steam, and should be sized on similarly low velocities.Condensate discharge lines from traps are notoriously more difficult to size than steam lines due to the two-phase flow characteristic. In practice, it is impossible (and often unnecessary) to determine the exact condition of the fluid inside the pipe.Although the amount of flash steam produced (see Figure 14.3.2) is related to the pressure difference across the trap, other factors will also have an effect.

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Conclusion: For designing the dimension of condensate lines always check the amount of expansion steam. For normal operation conditions of steam systems it´s always to design the condensate line according to expansion steam quantity!

28.1 Allowance for expansion

All pipes will be installed at ambient temperature. Pipes carrying hot fluids such as water or steam operate at higher temperatures.It follows that they expand, especially in length, with an

Where: L = Length of pipe between anchors (m) ΔT = Temperature difference between ambient temperature and operating temperatures (°C) α = Expansion coefficient (mm/m °C) x 10-3

Fig. 14.3.2 Quantity of flash steam graph

28 Pipe expansion and supportincrease from ambient to working temperatures. This will create stress upon certain areas within the distribution system, such as pipe joints, which, in the extreme, could fracture. The amount of the expansion is readily calculated using Equation 10.4.1, or read from an appropriate chart such as Figure 10.4.1.

Table 10.4.1 Expansion coefficients (a) (mm/m °C x 10-3)

MaterialTemperature range (°C)

< 0 0 - 100 0 - 200 0 - 300 0 - 400 0 - 500 0 - 600 0 - 700Carbon steel 0.1% - 0.2% C 12,8 13,9 14,9 15,8 16,6 17,3 17,9 -

Alloy steel 1% Cr 0.5% Mo 13,7 14,5 15,2 15,8 16,4 17,0 17,6 -

Stainless steel 18% Cr 8% Ni 9,4 20,0 20,9 21,2 21,8 22,3 22,7 23,0

Expansion (mm) = L x ΔT x α

Equation 10.4.1

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Example 10.4.1A 30 m length of carbon steel pipe is to be used to trans-port steam at 4 bar g (152°C). If the pipe is installed at 10°C, determine the expansion using Equation 10.4.1.

Expansion (mm) = L x ΔT x α Where: L = 30m ΔT = 152°C – 10°C ΔT = 142°C α in the range 0 - 200 = 14.9 x 10-3 mm/m°C for

carbon steel pipe Expansion = 30 m x 142°C x 14.9 x 10-3 mm/m°C Expansion = 63.5 mAlternatively, the chart in Figure 10.4.1 can be used for finding the approximate expansion of a variety of steel pipe lengths – see Example 10.4.2 for explanation of use.

Example 10.4.2Using Figure 10.4.1. Find the approximate expansion from 15°C, of 100 metres of carbon steel pipework used to distribute steam at 265°C.

Temperature difference is 265 - 15°C = 250°C.

Where the diagonal temperature difference line of 250°C cuts the horizontal pipe length line at 100 m, drop a vertical line down. For this example an approximate expansion of 330 mm is indicated.

28.2 Pipework flexibility

The pipework system must be sufficiently flexible to accommodate the movements of the components as they expand. In many cases the flexibility of the pipework system, due to the length of the pipe and number of bends and supports, means that no undue stresses are imposed. In other installations, however, it will be necessary to incorporate some means of achieving this required flexibility.

An example on a typical steam system is the discharge of condensate from a steam mains drain trap into the conden-sate return line that runs along the steam line (Figure 10.4.2). Here, the difference between the expansions of the two pipework systems must be taken into account. The steam main will be operating at a higher temperature than that of the condensate main, and the two connection points will move relative to each other during system warm-up.

Fig. 10.4.1 A chart showing the expansion in various steel pipe lengths at various temperature differences

Table 10.4.2 Temperature of saturated steam

bar g 1 2 3 4 5 7,5 10 15 20 25 30°C 120 134 144 152 159 173 184 201 215 226 236

Fig. 10.4.2 Flexibility in connection to condensate return line

The amount of movement to be taken up by the piping and any device incorporated in it can be reduced by ‚cold draw‘. The total amount of expansion is first calculated for each section between fixed anchor points. The pipes are left short by half of this amount, and stretched cold by pulling up bolts at a flanged joint, so that at ambient temperature, the system is stressed in one direction. When warmed through half of the total temperature rise, the piping is unstressed. At working temperature and having fully expanded, the piping is stressed in the opposite direction. The effect is that instead of being stressed from 0 F to +1 F units of force, the piping is stressed from -½ F to + ½ F units of force.

In practical terms, the pipework is assembled cold with a spacer piece, of length equal to half the expansion, between two flanges. When the pipework is fully installed

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and anchored at both ends, the spacer is removed and the joint pulled up tight (see Figure 10.4.3).

The remaining part of the expansion, if not accepted by the natural flexibility of the pipework will call for the use of an expansion fitting.In practice, pipework expansion and support can be classified into three areas as shown in Figure 10.4.4.

The fixed or ‚anchor‘ points ‚A‘ provide a datum position from which expansion takes place.The sliding support points ‚B‘ allow free movement for expansion of the pipework, while keeping the pipeline in alignment.The expansion device at point ‚C‘ is to accommodate the expansion and contraction of the pipe.

Roller supports (Figure 10.4.5 and 10.4.6) are ideal methods for supporting pipes, at the same time allowing them to move in two directions. For steel pipework, the rollers should be manufactured from ferrous material. For copper pipework, they should be manufactured from non-ferrous material. It is good practice for pipework supported on rollers to be fitted with a pipe saddle bolted to a support bracket at not more than distances of 6 metres to keep the pipework in alignment during any expansion and contraction.

Where two pipes are to be supported one below the other, it is poor practice to carry the bottom pipe from the top pipe using a pipe clip. This will cause extra stress to be added to the top pipe whose thickness has been sized to take only the stress of its working pressure.All pipe supports should be specifically designed to suit the outside diameter of the pipe concerned.

28.3 Expansion fittings

The expansion fitting (‚C‘ Figure 10.4.4) is one method of accommodating expansion. These fittings are placed within a line, and are designed to accommodate the expansion, without the total length of the line changing. They are commonly called expansion bellows, due to the bellows construction of the expansion sleeve.Other expansion fittings can be made from the pipework itself. This can be a cheaper way to solve the problem, but more space is needed to accommodate the pipe.

Horseshoe or lyre loopWhen space is available this type is sometimes used. It is best fitted horizontally so that the loop and the main are on the same plane. Pressure does not tend to blow the ends of the loop apart, but there is a very slight straightening out effect. This is due to the design but causes no misalign-ment of the flanges.If any of these arrangements are fitted with the loop vertically above the pipe then a drain point must be provided on the upstream side as depicted in Figure 10.4.8.

Fig. 10.4.3 Use of spacer for expansion when pipework is installed

Fig. 10.4.4 Diagram of pipeline with fixed point, variable anchor point and expansion fitting

Fig. 10.4.5 Chair and roller Fig. 10.4.6 Chair roller and saddle Fig. 10.4.8 Horseshoe or lyre loop

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Expansion loops

The expansion loop can be fabricated from lengths of straight pipes and elbows welded at the joints (Figure 10.4.9). An indication of the expansion of pipe that can be accommodated by these assemblies is shown in Figure 10.4.10.It can be seen from Figure 10.4.9 that the depth of the loop should be twice the width, and the width is determined from Figure 10.4.10, knowing the total amount of expansion expected from the pipes either side of the loop.

Expansion bellowsAn expansion bellows, Figures 10.4.12, has the advantage that it requires no packing (as does the sliding joint type). But it does have the same disadvantages as the sliding joint in that pressure inside tends to extend the fitting, consequently, anchors and guides must be able to with-stand this force.

Bellows may incorporate limit rods, which limit over-com-pression and over-extension of the element. These may have little function under normal operating conditions, as most simple bellows assemblies are able to withstand small

Fig. 10.4.9 Expansion loop

Fig. 10.4.10 Expansion loop capacity for carbon steel pipes

Fig. 10.4.12 Simple expansion bellows

Welded bendradius = 1.5 Ø

Welded joint

W

W

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lateral and angular movement. However, in the event of anchor failure, they behave as tie rods and contain the pressure thrust forces, preventing damage to the unit whilst reducing the possibility of further damage to piping, equipment and personnel Figure 10.4.13 (b).

Where larger forces are expected, some form of additional mechanical reinforcement should be built into the device, such as hinged stay bars Figure 10.4.13 (c).There is invariably more than one way to accommodate the relative movement between two laterally displaced pipes

Fig. 10.4.13: (a) Axial movement of bellows

depending upon the relative positions of bellows anchors and guides. In terms of preference, axial displacement is better than angular, which in turn, is better than lateral. Angular and lateral movement should be avoided wherever possible.

Figure 10.4.13 (a), (b), and (c) give a rough indication of the effects of these movements, but, under all circumstan-ces, it is highly recommended that expert advice is sought from the bellows‘ manufacturer regarding any installation of expansion bellows.

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Fig. 10.4.13 (b) Lateral and angular movement of bellows

Fig. 10.4.13: (c) Angular and axial movement of bellows

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28.4 Pipe support spacing

The frequency of pipe supports will vary according to the bore of the pipe; the actual pipe material (i.e. steel or copper); and whether the pipe is horizontal or vertical.Some practical points worthy of consideration are as follows:• Pipe supports should be provided at intervals not greater

than shown in Table 10.4.3, and run along those parts of buildings and structures where appropriate supports may be mounted.

• Where two or more pipes are supported on a common bracket, the spacing between the supports should be that for the smallest pipe.

• When an appreciable movement will occur, i.e. where straight pipes are greater than 15 metres in length, the

supports should be of the roller type as outlined previously.

• Vertical pipes should be adequately supported at the base, to withstand the total weight of the vertical pipe and the fluid within it. Branches from vertical pipes must not be used as a means of support for the pipe, because this will place undue strain upon the tee joint.

• All pipe supports should be specifically designed to suit the outside diameter of the pipe concerned. The use of oversized pipe brackets is not good practice.

Table 10.4.3 can be used as a guide when calculating the distance between pipe supports for steel and copper pipe work.

Table 10.4.3 Recommended support for pipework

The subject of pipe supports is covered comprehensively in the European standard EN 13480, Part 3.

Nominal pipe size (mm) Interval of horizontal run (metre) Interval of vertical run (metre)Steel bore Copper outside diameter Mild steel Copper Mild steel Copper

15 1,2 2,4 1,8

15 1,8 3,0

20 22 2,4 1,2 3,0 1,8

25 28 2,4 0,5 3,0 2,4

32 35 2,4 1,8 3,7 3,0

40 42 2,4 1,8 3,7 3,0

50 54 2,4 1,8 4,6 3,0

65 67 3,0 2,4 4,6 3,7

80 76 3,0 2,4 4,6 3,7

100 108 3,0 2,4 5,5 3,7

125 133 3,7 3,0 5,5 3,7

150 159 4,5 3,7 5,5

200 6,0 8,5

250 6,5 9,0

300 7,0

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101112131415161718192021222324252627282930313233343536373839* Maximum recommended support distance according to DIN 1988 2 (TRWI). The exact distances depend on the specific pipe type and manufacturer –

see separate description about “pipe supports” too!

29 Pipe dimensions and weights

Norm: DIN EN 10255 - 11/2004(ex. DIN 2440 - 06/1978)

Norm: DIN EN 10220 - 03/2003

Steel „thread“- pipe Weight L D s empty full insulated (max)*

(mm) ( “ ) (DN) (mm) (kg / m) (kg / m) (kg / m) m10,2 ⅛ 6 2,00 0,41 0,44 0,59 1,25

13,5 ¼ 8 2,35 0,65 0,71 0,88 1,50

17,2 ⅜ 10 2,35 0,85 0,97 1,17 2,25

21,3 ½ 15 2,65 1,22 1,42 1,63 2,75

26,9 ¾ 20 2,65 1,58 1,95 2,20 3,00

33,7 1 25 3,25 2,44 3,02 3,51 3,50

42,4 1 ¼ 32 3,25 3,14 4,15 4,86 3,75

48,3 1 ½ 40 3,25 3,61 4,98 5,94 4,25

60,3 2 50 3,65 5,10 7,31 8,83 4,75

76,1 2 ½ 65 3,65 6,51 10,23 12,77 5,50

88,9 3 80 4,05 8,47 13,59 17,08 6,00

114,3 4 100 4,50 12,10 20,80 26,31 6,00

139,7 5 125 4,85 16,20 29,47 35,45 6,00

165,1 6 150 4,85 19,20 38,16 44,83 6,00

Steel pipe (seamless) Weight LD s empty full insulated (max)*

(mm) (DN) (mm) (kg / m) (kg / m) (kg / m) m10,2 6 1,6 0,34 0,38 0,53 1,2513,5 8 1,8 0,52 0,60 0,77 1,5017,2 10 1,8 0,68 0,83 1,02 2,2521,3 15 2,0 0,96 1,19 1,40 2,7526,9 20 2,3 1,40 1,79 2,22 3,0033,7 25 2,6 1,99 2,63 3,12 3,5042,4 32 2,6 2,55 3,64 4,39 3,7548,3 40 2,6 2,93 4,39 5,39 4,2560,3 50 2,9 4,11 6,44 8,03 4,7576,1 65 2,9 5,24 9,12 11,70 5,5088,9 80 3,2 6,76 12,10 15,72 6,00114,3 100 3,6 9,83 18,83 24,25 6,00139,7 125 4,0 13,40 27,02 33,05 6,00168,3 150 4,5 18,20 38,37 43,66 6,00219,1 200 6,3 33,10 67,75 72,95 6,00273,0 250 6,3 41,40 96,11 104,15 6,00323,9 300 7,1 55,50 131,57 141,56 6,00355,6 350 8,0 68,60 160,95 170,74 6,00406,4 400 8,8 86,30 207,05 217,91 6,00457,0 450 10,0 110,00 262,67 274,44 6,00508,0 500 11,0 135,00 323,79 335,87 6,00610,0 600 12,5 184,00 457,26 471,16 6,00

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Dimensions and pressures used at Hoval steam systemsGaskets (for flanges with flat surface) according DIN 2690

Screws for connections:

30 Dimensions for gaskets and connections – Part 1

DN 10 15 20 25 32 40 50

PN 6 Dim - - 53/28 - - 85/49 95/61

PN 16 Dim 45/18 50/22 60/28 70/35 82/43 92/49 107/61

PN 40 Dim - 50/22 60/28 70/35 82/43 92/49 107/61

Armature / armature DN 10 15 20 25 32 40 50

PN 6dim./pieces - - M10x4 - - M12x4 M12x4

length (mm) - - 40 - - 45 45

PN 16dim./pieces M12x4 M12x4 M12x4 M12x4 M16x4 M16x4 M16x4

length (mm) 45 45 50 50 55 55 60

PN 40dim./pieces - M12x4 M12x4 M12x4 M16x4 M16x4 M16x4

length (mm) - 50 50 55 55 55 60

Armature / wafer check valve / flange DN 10 15 20 25 32 40 50


length (mm) - - - - - - -


length (mm) - - 70 70 85 85 100


length (mm) - - 70 75 85 90 100

Flange / flange DN 10 15 20 25 32 40 50


length (mm) - - 40 - - 45 45


length (mm) 45 45 50 50 55 55 55


length (mm) - 50 50 55 55 55 60

Armature / flange DN 10 15 20 25 32 40 50


length (mm) - - 40 - - 45 45


length (mm) 45 45 50 50 55 55 55

PN 40dim./pieces x M12x4 M12x4 M12x4 M16x4 M16x4 M16x4

length (mm) x 50 50 55 55 55 60

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Screws for connections:

Dimensions and pressures used at Hoval steam systemsGaskets (for flanges with flat surface) according DIN 2690

31 Dimensions for gaskets and connections – Part 2

DN 65 80 100 125 150 200 250

PN 6 Dim 115/77 132/90 152/115 182/141 207/169 262/220 353/274

PN 16 Dim 127/77 142/90 162/115 192/141 218/169 262/220 -

PN 40 Dim 127/77 142/90 168/115 195/141 225/169 292/220 -

Armature / armature DN 65 80 100 125 150 200 250


length (mm) 45 55 55 60 60 60 65

PN 16dim./pieces M16x4 M16x8 M16x8 M16x8 M20x8 M20x12 -

length (mm) 60 60 65 70 75 80 -


length (mm) 65 65 70 75 85 100 -

Flange / flange DN 65 80 100 125 150 200 250


length (mm) 45 50 50 55 55 60 60


length (mm) 55 60 60 65 65 70 -


length (mm) 65 65 70 75 80 100 -



length (mm) - - - - - - -


length (mm) 85 - - - - - -


length (mm) 85 - - - - - -

Armature / flange DN 65 80 100 125 150 200 250


length (mm) 45 55 55 55 55 60 65


length (mm) 55 60 60 65 70 75 -


length (mm) 65 65 70 75 80 100 -



length (mm) - - - - - - -


length (mm) - - 70 70 85 85 100


length (mm) - - 70 75 85 90 100

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32.1 Main steam lines

Throughout the length of a hot steam main, an amount of heat will be transferred to the environment, and this will de pend on the parameters identified in Block 2 – ‚Steam Engineering and Heat Transfer‘, and brought together in Equation 2.5.1.

Q• = k * A * X

ΔT

Equation 2.5.1

Where: Q = Heat transferred per unit time (W) k = Thermal conductivity of the material (W/m K or W/m

°C) A = Heat transfer area (m²) ΔT = Temperature difference across the

material (K or °C) Χ = Material thickness (m)

32 Steam lines and drains

32.2 Piping layout

The subject of drainage from steam lines is covered in the European Standard EN 45510, Section 4.12.EN 45510 states that, whenever possible, the main should be installed with a fall of not less than 1:100 (1 m fall for every 100 m run), in the direction of the steam flow.

This slope will ensure that gravity, as well as the flow of steam, will assist in moving the condensate towards drain points where the condensate may be safely and effectively removed (See Figure 10.3.1).

With steam systems, this loss of energy represents inefficiency, and thus pipes are insulated to limit these losses. Whatever the quality or thickness of insulation, there will always be a level of heat loss, and this will cause steam to condense along the length of the main.

This Tutorial will concentrate on disposal of the inevitable condensate, which, unless removed, will accumulate and lead to problems such as corrosion, erosion, and water hammer.

In addition, the steam will become wet as it picks up water droplets, which reduces its heat transfer potential. If water is allowed to accumulate, the overall effective cross sectional area of the pipe is reduced, and steam velocity can increase above the recommended limits.

Fig. 10.3.1: Typical steam main installation

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Drain pointsThe drain point must ensure that the condensate can reach the steam trap. Careful consideration must therefore be given to the design and location of drain points.

Consideration must also be given to condensate remaining in a steam main at shutdown, when steam flow ceases. Gravity will ensure that the water (condensate) will run along sloping pipework and collect at low points in the system. Steam traps should therefore be fitted to these low points.

The amount of condensate formed in a large steam main under start-up conditions is sufficient to require the provision of drain points at intervals of 30 m to 50 m, as well as natural low points such as at the bottom of rising pipework.

In normal operation, steam may flow along the main at speeds of up to 145 km/h, dragging condensate along with it. Figure 10.3.2 shows a 15 mm drain pipe connected directly to the bottom of a main.

Although the 15 mm pipe has sufficient capacity, it is unlikely to capture much of the condensate moving along the main at high speed. This arrangement will be ineffec-tive.A more reliable solution for the removal of condensate is shown in Figure 10.3.3. The trap line should be at least 25 to 30 mm from the bottom of the pocket for steam mains up to 100 mm, and at least 50 mm for larger mains. This allows a space below for any dirt and scale to settle.

Fig. 10.3.2: Trap pocket too small

Fig. 10.3.3: Trap pocket properly sized

The bottom of the pocket may be fitted with a removable flange or blowdown valve for cleaning purposes.Recommended drain pocket dimensions are shown in Table 10.3.1 and in Figure 10.3.4.

32.3 Water hammer and its effects

Water hammer is the noise caused by slugs of condensate colliding at high velocity into pipe work fittings, plant, and equipment. This has a number of implications:• Because the condensate velocity is higher than normal,

the dissipation of kinetic energy is higher than would normally be expected.

• Water is dense and incompressible, so the ‚cushioning‘ effect experienced when gases encounter obstructions is absent.

• The energy in the water is dissipated against the obstruc-tions in the piping system such as valves and fittings

Table 10.3.1: Recomended drain pocket dimensions

Mains diameter – D Pocket diamter – d1 Pocket depth – d2

Up to 100 mm nb d1 = D Minimum d2 = 100 mm

125 - 200 mm nb d1 = 100 mm Minimum d2 = 150 mm

250mm and above d1 ≥ D/2 Minimum d2 = D

Fig. 10.3.4

Fig. 10.3.5: Formation of a ‘solid’ slug of water

Steam

PocketSlug

Steam

Steam

Steam

Steam

Flow

Steam trap set

Steam trap set

Condensate

Condensate

Condensate

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Indications of water hammer include a banging noise, and perhaps movement of the pipe.In severe cases, water hammer may fracture pipeline equipment with almost explosive effect, with consequent loss of live steam at the fracture, leading to an extremely hazardous situation.Good engineering design, installation and maintenance will avoid water hammer; this is far better practice than attempting to contain it by choice of materials and pressure ratings of equipment

Commonly, sources of water hammer occur at the low points in the pipe work (See Figure 10.3.6). Such areas are due to:• Sagging in the line, perhaps due to failure of supports.• Incorrect use of concentric reducers (see Figure 10.3.7)

- Always use eccentric reducers with the flat at the bottom.

• Incorrect strainer installation - They should be fitted with the basket on the side.

• Inadequate drainage of steam lines.• Incorrect operation - Opening valves too quickly at

start-up when pipes are cold

To summarise, the possibility of water hammer is minimised by:• Installing steam lines with a gradual fall in the direction of

flow, and with drain points installed at regular intervals and at low points.

• Installing check valves after all steam traps which would otherwise allow condensate to run back into the steam line or plant during shutdown.

• Opening isolation valves slowly to allow any condensate which may be lying in the system to flow gently through the drain traps, before it is picked up by high velocity steam. This is especially important at start-up.

32.4 Branch lines

Branch lines are normally much shorter than steam mains. As a general rule, therefore, provided the branch line is not more than 10 metres in length, and the pressure in the main is adequate, it is possible to size the pipe on a velocity of 25 to 40 m/s, and not to worry about the pressure drop.

Fig. 10.3.6: Potential sources of waterhammer

Fig. 10.3.7: Eccentric and concentric pipe reducers

Fig. 10.3.8: Branch line

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Branch line connectionsBranch line connections taken from the top of the main carry the driest steam (Figure 10.3.8). If connections are taken from the side, or even worse from the bottom (as in Figure 10.3.9 (a)), they can accept the condensate and debris from the steam main. The result is very wet and

dirty steam reaching the equipment, which will affect performance in both the short and long term.The valve in Figure 10.3.9 (b) should be positioned as near to the off-take as possible to minimise condensate lying in the branch line, if the plant is likely to be shutdown for any extended periods.

Drop legLow points will also occur in branch lines. The most common is a drop leg close to an isolating valve or a control valve (Figure 10.3.10). Condensate can accumulate on the

upstream side of the closed valve, and then be propelled forward with the steam when the valve opens again - consequently a drain point with a steam trap set is good practice just prior to the strainer and control valve.

Fig. 10.3.10: Diagram of a drop leg supplying a unit heater

Fig. 10.3.9: Steam off-take

(a) Incorrect (b) Correct

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32.5 Steam separators

Modern packaged steam boilers have a large evaporating capacity for their size and have limited capacity to cope with rapidly changing loads. In addition other circumstan-ces, such as . . .• Incorrect chemical feed water treatment and/or TDS control.• Transient peak loads in other parts of the plant.... can cause priming and carryover of boiler water into the steam mains.

Separators, as shown by the cut section in Figure 10.3.12, may be installed to remove this water.

As a general rule, providing the velocities in the pipe work are within reasonable limits, separators will be line sized.A separator will remove both droplets of water from pipe walls and suspended mist entrained in the steam itself. The presence and effect of water hammer can be eradicated by fitting a separator in a steam main, and can often be less expensive than increasing the pipe size and fabricating drain pockets.A separator is recommended before control valves and flow meters. It is also wise to fit a separator where a steam main enters a building from outside. This will ensure that any condensate produced in the external distribution system is removed and the building always receives dry steam. This is equally important where steam usage in the building is monitored and charged for.

32.5 Rising ground and drainage

There are many occasions when a steam main must run across rising ground, or applications where the contours of the site make it impractical to lay the pipe with the 1:100 fall proposed earlier. In these situations, the condensate must be encouraged to run downhill and against the steam flow. Good practice is to size the pipe on a low steam

velocity of not more than 15 m/s, to run the line at a slope of no less than 1:40, and install the drain points at not more than 15 metre intervals (see Figure 10.3.11).The objective is to prevent the condensate film on the bottom of the pipe increasing in thickness to the point where droplets can be picked up by the steam flow.

Fig. 10.3.12: Cut section through a separator

Air and incondesable gases vented

Fig. 10.3.10: Diagram of a drop leg supplying a unit heater

Steam velocity 30 m/s

30 m/s

Increasein pipe

diameterSteam

velocity15 m/s

Fall

Wet Steam in

Moisture to trap set

Dry Steam out

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32.6 How to drain steam mains

Steam traps are the most effective and efficient method of draining condensate from a steam distribution system.The steam traps selected must suit the system in terms of:• Pressure rating• Capacity• Suitability

Pressure rating is easily dealt with; the maximum possible working pressure at the steam trap will either be known or should be established. Capacity, that is, the quantity of condensate to be dischar-ged, which needs to be divided into two categories; warm-up load and running load.Warm-up load - In the first instance, the pipe work needs to be brought up to operating temperature. This can be determi-ned by calculation, knowing the mass and specific heat of the pipe work and fittings. Alternatively, Table 10.3.2 may be used.• The table shows the amount of condensate generated

when bringing 50 m of steam main up to working tempe-rature; 50 m being the maximum recommended distance between trapping points.

• The values shown are in kilograms. To determine the

average condensing rate, the time taken for the process must be considered. For example, if the warm-up process required 50 kg of steam, and was to take 20 minutes, then the average condensing rate would be:

Average condensing rate = 20 minutes60 minutes

* 50 kg = 150 kg

Note: Use this 150kg average condensate rate for dimensioning of condensate trap with flow rate 150kg/h

• When using these capacities to size a steam trap, it is worth remembering that the initial pressure in the main will be little more than atmospheric when the warm-up process begins. However, the condensate loads will still generally be well within the capacity of a DN15 ‚low capacity‘ steam trap. Only in rare applications at very high pressures (above 70 bar g), combined with large pipe sizes, will greater trap capacity be needed.

Running load: Once the steam main is up to operating temperature, the rate of condensation is mainly a function of the pipe size and the quality and thickness of the insulation.Alternatively, for quick approximations of running load, Table 10.3.3 can be used which shows typical amounts of steam condensed each hour per 50 m of insulated steam main at various pressures.

Steam pressure bar g

Steam main size (mm) - 18 °C correction factor50 65 80 100 125 150 200 250 300 350 400 450 500 600

1 5 9 11 16 22 28 44 60 79 94 123 155 182 254 1.392 6 10 13 19 25 33 49 69 92 108 142 179 210 296 1.353 7 11 14 20 25 36 54 79 101 120 156 197 232 324 1.324 8 12 16,17 22 30 39 59 83 110 131 170 215 254 353 1.295 8 13 17 24 33 42 63 70 119 142 185 233 275 382 1.286 9 13 18 25 34 43 66 93 124 147 198 242 285 396 1.277 9 14 18 26 35 45 68 97 128 151 197 250 294 410 1.268 9 14 19 27 37 47 71 101 134 158 207 261 307 428 1.259 10 15 20 28 38 50 74 105 139 164 216 272 320 436 1.2410 10 16 20 29 40 51 77 109 144 171 224 282 332 463 1.2412 10 17 22 31 42 54 84 115 152 180 236 298 350 488 1.2314 10 17 23 32 44 57 85 120 160 189 247 311 366 510 1.2216 11 19 24 35 47 61 91 128 172 203 265 334 393 548 1.2118 12 23 31 45 62 84 127 187 355 305 393 492 596 708 1.2120 17 26 35 51 71 97 148 220 302 362 465 582 712 806 1.2025 17 29 39 56 78 108 164 243 333 400 533 642 786 978 1.1930 19,21 32 41 62 86 117 179 265 364 437 571 702 859 1150 1.1840 22 34 46 67 93 127 194 287 395 473 608 762 834 1322 1.1650 24 37 50 73 101 139 212 214 432 518 665 834 1020 1450 1.1560 27 41 54 79 135 181 305 445 626 752 960 1218 1480 2140 1.1570 29 44 59 86 156 208 346 510 717 861 1100 1396 1694 2455 1.1580 32 49 65 95 172 232 386 568 800 960 1220 1550 1890 2730 1.1490 34 51 69 100 181 245 409 598 842 1011 1288 1635 1990 2880 1.14100 35 54 72 106 190 257 427 628 884 1062 1355 1720 2690 3030 1.14120 42 64 86 126 227 305 508 748 1052 1265 1610 2050 2490 3600 1.13

Table 10.3.2: Amount of steam condensed to warm-up 50 m of schedule 40 pipe (kg) Note: Figures are based on an ambient temperature of 20°C, and an insulation efficiency of 80%

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SuitabilityA mains drain trap should consider the following constraints:• Discharge temperature - The steam trap should discharge at, or very close to saturation temperature, unless cooling legs are used between the drain point and the trap. This means that the choice is a mechanical type trap (such as a float, inverted bucket type, or thermodynamic traps).

• Frost damage - Where the steam main is located outside a building and there is a possibility of sub-zero ambient temperature, the thermodynamic steam trap is ideal, as it is not damaged by frost. Even if the installation causes water to be left in the trap at shutdown and freezing occurs, the thermodynamic trap may be thawed out without suffering damage when brought back into use.

• Water hammer - In the past, on poorly laid out installa-tions where water hammer was a common occurrence, float traps were not always ideal due to their susceptibility to float damage. Contemporary design and manufacturing techniques now produce extremely robust units for mains drainage purposes. Float traps are certainly the first choice for proprietary separators as high capacities are readily achieved, and they are able to respond quickly to rapid load increases.

32.7 Summary

Proper pipe alignment and drainage means observing a few simple rules:

• Steam lines should be arranged to fall in the direction of flow, at not less than 100 mm per 10 metres of pipe (1:100). Steam lines rising in the direction of flow should slope at not less than 250 mm per 10 metres of pipe (1:40).

• Steam lines should be drained at regular intervals of 30-50 m and at any low points in the system.

• Where drainage has to be provided in straight lengths of pipe, then a large bore pocket should be used to collect condensate.

• If strainers are to be fitted, then they should be fitted on their sides.

• Branch connections should always be taken from the top of the main from where the driest steam is taken.

• Separators should be considered before any piece of steam using equipment ensuring that dry steam is used.

• Traps selected should be robust enough to avoid water-hammer damage and frost damage.

Table 10.3.3: Condensing rate of steam in 50 m of schedule 40 pipe - at working temperature (kg/h) Note: Figures are based on an ambient temperature of 20°C, and an insulation efficiency of 80%

Steam pressure bar g

Steam main size (mm) - 18 °C correction factor50 65 80 100 125 150 200 250 300 350 400 450 500 600

1 5 5 7 9 10 13 16 19 23 25 28 31 35 41 1.542 5 6 8 10 12 14 18 22 26 28 32 35 39 46 1.503 6 7 9 11 14 16 20 25 30 32 37 40 45 54 1.484 7 9 10 12 16 18 23 28 33 37 42 46 51 61 1.455 7 9 11 13 17 20 24 30 36 40 46 49 55 66 1.436 8 10 11 14 18 21 26 33 39 43 49 53 59 71 1.427 8 10 12 15 19 23 28 39 42 46 52 56 63 76 1.418 9 11 14 16 20 24 30 37 44 49 57 61 68 82 1.409 9 11 14 17 21 25 32 39 47 52 60 64 72 88 1.3910 10 12 15 17 21 25 33 41 49 54 62 67 75 90 1.3812 11 13 16 18 23 26 36 45 53 59 67 73 81 97 1.3814 12 14 17 20 26 30 39 49 58 64 73 79 93 106 1.3716 12 15 18 23 29 34 42 52 62 68 78 85 99 114 1.3618 14 16 19 24 30 36 44 55 66 72 82 90 100 120 1.3620 15 17 21 25 31 37 46 58 69 76 86 94 105 125 1.3525 15 19 32 28 35 42 52 66 78 86 97 106 119 141 1.3430 17 21 25 31 39 47 58 73 87 96 108 118 132 157 1.3340 20 25 30 38 46 56 70 87 104 114 130 142 158 189 1.3150 24 29 34 44 54 65 82 102 121 133 151 165 184 220 1.2960 27 32 39 50 62 74 95 119 140 155 177 199 222 265 1.2870 29 35 43 56 70 82 106 133 157 173 198 222 248 296 1.2780 34 42 51 66 81 97 126 156 187 205 234 263 293 350 1.2690 38 46 56 72 89 106 134 171 204 224 265 287 320 284 1.26100 41 50 61 78 96 114 149 186 220 242 277 311 347 416 1.25120 52 63 77 99 122 145 189 236 280 308 352 395 440 527 1.22

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The optimum design for a steam system will largely depend on whether the steam consumption rate has been accura-tely established. This will enable pipe sizes to be calcula-ted, while ancillaries such as control valves and steam traps can be sized to give the best possible results. The steam demand of the plant can be determined using a number of different methods:

• Calculation – By analysing the heat output on an item of plant using heat transfer equations, it may be possible to obtain an estimate for the steam consumption. Although heat transfer is not an exact science and there may be many unknown variables, it is possible to utilise previous experimental data from similar applications. The results acquired using this method are usually accurate enough for most purposes.

• Measurement - Steam consumption may be determined by direct measurement, using flow metering equipment. This will provide relatively accurate data on the steam consumption for an existing plant. However, for a plant which is still at the design stage, or is not up and running, this method is of little use.

• Thermal rating - The thermal rating (or design rating) is often displayed on the name-plate of an individual item of plant, as provided by the manufacturers. These ratings usually express the anticipated heat output in kW, but the steam consumption required in kg/h will depend on the recommended steam pressure.

A change in any parameter which may alter the anticipated heat output, means that the thermal (design) rating and the connected load (actual steam consumption) will not be the same. The manufacturer‘s rating is an indication of the ideal capacity of an item and does not necessarily equate to the connected load.

CalculationIn most cases, the heat in steam is required to do two things:

• To produce a change in temperature in the product, that is providing a ‚heating up‘ component.

• To maintain the product temperature as heat is lost by natural causes or by design, that is providing a ‚heat loss‘ component.

In any heating process, the ‚heating up‘ component will decrease as the product temperature rises, and the differential temperature between the heating coil and the product reduces. However, the heat loss component will increase as the product temperature rises and more heat is lost to the environment from the vessel or pipework.The total heat demand at any time is the sum of these two components.

The equation used to establish the amount of heat required to raise the temperature of a substance (Equation 2.1.4), can be developed to apply to a range of heat transfer processes.

Q = m * cp * ΔT

Equation 2.1.4

Where:Q = Quantity of energy (kJ)m = Mass of the substance (kg)cp = Specific heat capacity of the substance (kJ/kg K)ΔT = Temperature rise of the substance (K)

In its original form this equation can be used to determine a total amount of heat energy over the whole process. However, in its current form, it does not take into account the rate of heat transfer. To establish the rates of heat transfer, the various types of heat exchange application can be divided into two broad categories:

• Non-flow type applications - where the product being heated is a fixed mass and a single batch within the confines of a vessel.

• Flow type applications - where a heated fluid constantly flows over the heat transfer surface.

33 Steam consumption of plants:

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33.1 Non-flow type applications

In non-flow type applications the process fluid is held as a single batch within the confines of a vessel. A steam coil situated in the vessel, or a steam jacket around the vessel, may constitute the heating surface. Typical examples include hot water storage calorifiers as shown in Figure 2.6.1 and oil storage tanks where a large circular steel tank is filled

with a viscous oil requiring heat before it can be pumped. Some processes are concerned with heating solids; typical examples are tyre presses, laundry ironers, vulcanisers and autoclaves.In some non-flow type applications, the process heat up time is unimportant and ignored. However, in others, like tanks and vulcanisers, it may not only be important but crucial to the overall process

Consider two non-flow heating processes requiring the same amount of heat energy but different lengths of time to heat up. The heat transfer rates would differ while the amounts of total heat transferred would be the same.

Fig. 2.6.1: Hot water storage - a non-flow application

The mean rate of heat transfer for such applications can be obtained by modifying Equation 2.1.4 to Equation 2.6.1:

m * cp * ΔT t

Q• =

Equation 2.6.1

Where:Q = Mean heat transfer rate kW (kW = kJ/s)m = Mass of the fluid (kg)cp = Specific heat capacity of the fluid (kJ/kg °C)ΔT = Increase in fluid temperature (°C) t = Time for the heating process (seconds)

Example 2.6.1Calculating the mean heat transfer rate in a non-flow application.A quantity of oil is heated from a temperature of 35°C to 120°C over a period of 10 minutes (600 seconds). The volume of the oil is 35 litres, its specific gravity is 0.9 and

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its specific heat capacity is 1.9 kJ/kg °C over that tempera-ture range.

Determine the rate of heat transfer required:

As the density of water at Standard Temperature and Pressure (STP) is 1 000 kg/m³The density of the oil p0 = 0.9 x 1000 p0 = 900 kg/m3

As 1000 litres = 1m3, p0 = 900 kg/1000 litres p0 = 0.9 kg/l Therfore the mass of the oil = 0.9 x 35 Q = 31.5 kg

600 seconds

31.5 kg * * (120 - 35)°C1.9 kJ kg°C

Q• =

Q• = 8.48 kJ/s (8.48 kW)

Equation 2.6.1 can be applied whether the substance being heated is a solid, a liquid or a gas. However, it does not take into account the transfer of heat involved when there is a change of phase.

The quantity of heat provided by the condensing of steam can be determined by Equation 2.6.2:

Equation 2.6.2

Where:Q = Quantity of heat (kJ)ms = Mass of steam (kg)hfg = Specific enthalpy of evaporation of steam (kJ/kg)

It therefore follows that the steam consumption can be determined from the heat transfer rate and vice-versa, from Equation 2.6.3:

Equation 2.6.3

Where:Q• = Mean heat transfer rate (kW or kJ/s)m•

s = Mean steam consumption (kg/s)hfg = Specific enthalpy of evaporation of steam (kJ/kg)

If it is assumed at this stage that the heat transfer is 100% efficient, then the heat provided by the steam must be equal to the heat requirement of the fluid to be heated. This can then be used to construct a heat balance, in which the heat energy supplied and required are equated:

Primary side = Q•

= Secondary side

Equation 2.6.4Where: ms = Mean steam consumption rate (kg/s) hfg = Mean steam consumption rate (kg/s) Q• = Mean heat transfer rate kW (kW = kJ/s)) m = Mass of the secondary fluid (kg) cp = Specific heat capacity of the secondary fluid (kJ/kg °C)ΔT = Temperature rise of the secondary fluid (°C) t = Time for the heating process

Example 2.6.2A tank containing 400 kg of kerosene is to be heated from 10°C to 40°C in 20 minutes (1200 seconds), using 4 bar g steam. The kerosene has a specific heat capacity of 2.0 kJ/kg °C over that temperature range. hfg at 4.0 bar g is 2108.1 kJ/kg. The tank is well insulated and heat losses are negligible.

Determine the steam flowrate

Therfore

m• s = 0.0095 (kg/s)

m• s = 34.2(kg/h)

In some non-flow type applications, the length of time of the batch process may not be critical, and a longer heat up time may be acceptable. This will reduce the instantaneous steam consumption and the size of the required plant equipment.

m * cp * ΔT t

ms * hfg = Q•

=

1200 seconds

Q•

=2.0 kJ kg °C400 kg * * (40 - 10) °C

kJ sQ =

kJ s20

kJ kg2108,1

m• s =

Q•

= m• s * hfg

Q = m s * hfg

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33.2 Flow type applications

Typical examples include shell and tube heat exchangers, see Figure 2.6.2 (also referred to as non-storage calori-fiers) and plate heat exchangers, providing hot water to

heating systems or industrial processes. Another example would be an air heater battery where steam gives up its heat to the air that is constantly passing through.

Figure 2.6.3 provides a typical temperature profile in a heat exchanger with a constant secondary fluid flowrate. The condensing temperature (T s) remains constant throughout the heat exchanger. The fluid is heated from T 1 at the inlet valve to T 2 at the outlet of the heat exchanger.

Fig 2.6.2: Non-storage calorifier

cp = Specific heat capacity of the fluid (kJ/kg °CFor a fixed secondary flowrate, the required heat load ( ) is proportional to the product temperature rise (ΔT). Using

Equation 2.6.1:m * cp * ΔT t

Q•

=

Equation 2.6.1

tm

= Product flowrate=constant

cp = Specific heat = constant

Therfore: Q• ~ ΔT

As flow rate is mass flow per unit time, the secondary flow rate is depicted in equation 2.6.1 as:

tm

This can be represented by m, where m is the secondary fluid flow rate in kg/s, and is shown in equation 2.6.5.Fig. 2.6.3: Typical temperature profile in a heat exchanger

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Where:

Q• = Mean heat transfer rate kW (kW = kJ/s)m = Mean secondary fluid flowrate (kg/s)cp = Specific heat capacity of the secondary fluid

(kJ/kg K) or (kJ/kg°C)ΔT = Temperature rise of the secondary fluid (K or °C)

A heat balance equation can be constructed for flow type applications where there is a continuous flow of fluid:

Primary side = Q•

= Secondary side

m• s * hfg

= Q

• = m• * cp * ΔT

Equation 2.6.6

Where:ms = Mean steam consumption rate (kg/s)hfg = Specific enthalpy of evaporation of steam (kJ/kg)Q• = Mean heat transfer rate kW (kW = kJ/s)ms = Mass flowrate of the secondary fluid (kg/s)cp = Specific heat capacity of the secondary fluid

(kJ/kg °C)ΔT = Temperature rise of the secondary fluid (°C)

Mean steam consumptionThe mean steam consumption of a flow type application like a process heat exchanger or heating calorifier can be determined from Equation 2.6.6, as shown in Equation 2.6.7.

m• * cp * ΔT hfg

m• s =

Equation 2.6.7

Where:ms = Mean steam consumption rate (kg/s)m = Mass flowrate of the secondary fluid (kg/s)cp = Specific heat capacity of the secondary fluid

(kJ/kg °C)ΔT = Temperature rise of the secondary fluid (°C) hfg = Specific enthalpy of evaporation of steam (kJ/kg)

Equally, the mean steam consumption can be determined from Equation 2.6.6 as shown in Equation 2.6.8.

Q•

= m• * cp * ΔT

Equation 2.6.5

But as the mean heat transfer is, itself, calculated from the mass flow, the specific heat, and the temperature rise, it is easier to use Equation 2.6.7.

Example 2.6.3Dry saturated steam at 3 bar g is used to heat water flowing at a constant rate of 1.5 l/s from 10°C to 60°C.

hfg at 3 bar g is 2 133.4 kJ/kg, and the specific heat of water is 4.19 kJ/kg °C

Determine the steam flowrate:As 1 litre of water has a mass of 1 kg, the mass flowrate = 1.5 kg/s

m• * cp * ΔT hfg

m• s =

Equation 2.6.7

1.5 * 4.19 * (60 – 10) 2133,4

m• s =

m• s = 0.1473 (kg/s)

m• s = 530 (kg/h)

At start-up, the inlet temperature, T 1 may be lower than the inlet temperature expected at the full running load, causing a higher heat demand. If the warm-up time is important to the process, the heat exchanger needs to be sized to provide this increased heat demand. However, warm-up loads are usually ignored in flow type design calculations, as start-ups are usually infrequent, and the time it takes to reach design conditions is not too important. The heat exchanger heating surface is therefore usually sized on the running load conditions.

In flow type applications, heat losses from the system tend to be considerably less than the heating requirement, and are usually ignored. However, if heat losses are large, the mean heat loss (mainly from distribution pipe work) should be included when calculating the heating surface area.

Q•

hfg

m• s =

Equation 2.6.8

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33.3 Warm-up and heat loss components

In any heating process, the warm-up component will decrease as the product temperature rises, and the differential temperature across the heating coil reduces. However, the heat loss component will increase as the product and vessel temperatures rise, and more heat is lost to the environment from the vessel or pipe work. The total heat demand at any time is the sum of these two com-ponents. If the heating surface is sized only with consideration of the

warm-up component, it is possible that not enough heat will be available for the process to reach its expected tempera-ture. The heating element, when sized on the sum of the mean values of both these components, should normally be able to satisfy the overall heat demand of the application.Sometimes, with very large bulk oil storage tanks for example, it can make sense to maintain the holding temperature lower than the required pumping temperature, as this will reduce the heat losses from the tank surface area. Another method of heating can be employed, such as an outflow heater, as shown in Figure 2.6.4.

33.4 An outflow heater

Heating elements are encased in a metal shroud protruding into the tank and designed such that only the oil in the immediate vicinity is drawn in and heated to the pumping temperature. Heat is therefore only demanded when oil is drawn off, and since the tank temperature is lowered, lagging can often be dispensed with. The size of outflow heater will depend on the temperature of the bulk oil, the pumping temperature and the pumping rate.Adding materials to open topped process tanks can also be

regarded as a heat loss component which will increase thermal demand. These materials will act as a heat sink when immersed, and they need to be considered when sizing the heating surface area.

Whatever the application, when the heat transfer surface needs calculating, it is first necessary to evaluate the total mean heat transfer rate. From this, the heat demand and steam load may be determined for full load and start-up. This will allow the size of the control valve to be based on either of these two conditions, subject to choice.

Fig. 2.6.4

Oil

Condensate

Condensate

Oil out

Steam

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34.1 Heating calorifiers

Fig. 2.14.2

Typical heating calorifier installation As with air heaters, most heating calorifier manufacturers will usually provide a rating for their equipment, and the steam consumption may be determined by dividing the kW rating by the enthalpy of steam at the operating pressure to produce a result in kg/s (see Equation 2.8.1). However, calorifiers are frequently too large for the systems they serve because:• The initial heat load calculations on the building they

serve will have included numerous and over-cautious safety factors.

• The calorifier itself will have been selected from a standard range, so the first size up from the calculated load will have been selected.

• The calorifier manufacturer will have included his own safety factor on the equipment.

An estimate of the actual load at any point in time may be obtained if the flow and return temperatures and the pumping rate are known. Note however that the pressure

head on the discharge side affects the throughput of the pump, and this may or may not be constant.

Example 2.14.24 l/s of low temperature hot water (flow/return = 82/71°C) is pumped around a heating system.

Determine the heat output:Heat output = Water flowrate x specific heat of water x

temperature changeHeat output = 4 l/s x 4.19 kJ/kg°C x (82 - 71) °CHeat output = 184 kW

An alternative method of estimating the load on a heating calorifier is to consider the building being heated. The calculations of heat load can be complicated by factors including:• Air changes.• Heat transfer rates through walls, windows and roofs.

34 Steam consumption of plant items

Condensate

Condensate

Steam Flow

Heating Controller

Return

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However, a reasonable estimate may be obtained by taking the volume of the building and allowing a heating capacity of 30 W/m³. This will give the running load for an inside temperature of about 20°C when the outside temperature is about -1°C.

Typical flow and return temperatures for:• Low temperature hot water (LTHW) systems are 82°C and

71°C (ΔT = 11°C).• Medium temperature hot water (MTHW) systems are

94°C and 72°C (ΔT = 22°C).

Figures for high temperature hot water (HTHW) systems vary considerably, and must be checked for each individual application.

Example 2.14.3The steam flow to a heating calorifier has been measured as 227 kg/h when the outside temperature is 7°C and the inside temperature is 18°C.

If the outside temperature falls to -1°C, and the inside temperature is 19°C, determine the approximate steam flowrate. This can be calculated by proportionality.

Temperature difference at initial condition = 18 - 7 = 11°C

Temperature difference at second condition = 19 - (-1) = 20°C

Approximate steam flowrate = 20/11 * 227

Approximate steam flowrate = 413 kg/h

34.2 Hot water storage calorifiers

Hot water storage calorifiers are designed to raise the tempe-rature of their entire contents from cold to storage temperature within a specified time period.

Fig. 2.14.3: Typical hot water storage calorifier installation

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Typical temperature values are: Cold water temperature = 10°C Hot water temperature = 60°C Heat up time = 1 hour(also referred to as ‚recovery time‘)

The mass of water to be heated may be determined from the volume of the vessel. (For water, density = 1 000 kg/m³, and specific heat (cp) = 4.19 kJ/kg°C).

Example 2.14.4A storage calorifier comprises of a cylindrical vessel, 1.5 m diameter and 2 m high. The contents of the vessel are to be heated to 60°C in 1 hour.The incoming water temperature is 10°C, and the steam pressure is 7 bar g.

Determine the steam flow rate:

Volume of vessel = π * D2 4

* height = π * 1.52 4

* 2 = 3.53 m3

Mass of water = 3.53 m3 * 1000 kg m3

= 3530 kg

Temperature rise = 60 - 10 = 50°C

Energy required =

kJ kg°C

1 hour

3530 kg * 4.19 * 50 °C = 739535

kJ h

Enthalpy of evaporation of steam at 7 bar g = 2048 KJ/kg (from steam tables)

Steam consumption rate =

kJ h

kJ kg2048

739535

Steam consumption rate = 361 kg/h

34.3 Drying cylinders

Drying cylinders vary significantly in layout and application and, consequently, in steam consumption.

Apart from wide variations in size, steam pressure, and running speed, cylinders may be drained through the frame of the machines, as in textile can dryers, or by means of a

blow-through system in the case of high speed paper machines. Conversely, film dryers and slow speed paper machines may use individual steam traps on each cylinder. Demand will vary from small standing losses from a cylinder drying sized cotton thread, to the heavy loads at the wet end of a paper machine or in a film dryer.

Fig. 2.14.4

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Drying cylinders Because of this, accurate figures can only be obtained by measurement. However, certain trusted formulae are in use, which enable steam consumption to be estimated within reasonable limits.

In the case of textile cylinder drying machines, counting the number of cylinders and measuring the circumference and width of each will lead to the total heating surface area. The two ends of each cylinder should be included and 0.75 m² per cylinder should be added to cover doll heads and frames except where individual trapping is used. The radiation loss from the machine, while standing, measured in kg of steam per hour, can be estimated by multiplying the total area by a factor of 2.44. The running load in kg per hour will be obtained by using a factor of 8.3. (In imperial units the area will be measured in square feet and the corresponding factors will be 0.5 and 1.7 respectively). This is based on a machine drying piece goods at a rate of 64 to 73 metres per minute, (70 to 80 yards per minute), but by making allowances, it can be used for machines working under different conditions.

Where the amount of moisture to be removed is known, steam consumption can be calculated using the empirical Equation 2.14.1, assuming that the wet and dry weights of the material being handled are known.

Equation 2.14.1

1.5 * ([ Ww-Wd ] * 2550 + 1.26 * Wd * [ T2 - T1 ]) hfg

m• s =

Where: m•

s = Mass flowrate of steam (kg/h) Ww = Throughput of wet material (kg/h Wd = Throughput of dry material (kg/h) T2 = Temperature of material leaving the machine (°C) T1 = Temperature of material entering the machine (°C) hfg = Enthalpy of evaporation of steam in cylinders (kJ/kg)

The factors in the equation above are empirically derived constants: 1.5 = Factor applied to cylinder dryers. 2550 = Average water enthalpy + enthalpy of evaporation

required to evaporate moisture. 1.26 = Average specific heat of material.

Drying cylinders tend to have a heavy start-up load due to the huge volume of the steam space and the mass of metal to be heated, and a factor of three times the running load

34.4 Presses

Presses, like drying cylinders, come in all shapes, sizes and working pressures, and are used for many purposes, such as moulding plastic powders, preparing laminates, producing car tyres (see Figure 2.14.4), and manufacturing plywood. They sometimes also incorporate a cooling cycle.Clearly, it would be difficult to calculate steam loads with any accuracy and the only way of getting credible results is by measurement.This type of equipment may be ‚open‘, allowing a radiation loss to atmosphere, or ‚closed‘, when the two heating surfaces are in effect insulated from each other by the product. Although some heat is absorbed by the product, the net result is that the steam consumption is much the same whether the plant is working or standing idle, although fluctuations will occur during opening and closing.

should be allowed in sizing steam traps. It must also be remembered that air can cause particular difficulties, such as prolonged warming up times and uneven surface tempe-rature. Special provision must therefore be made for venting air from the cylinders.

Fig. 2.14.5: Tyre press

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Steam consumption can sometimes be estimated using the basic heat transfer Equation 2.5.3:

Equation 2.53

O = U *A * ΔT

Where:Q = Heat transferred per unit time (W)U = Overall heat transfer coefficient (W/m² K or W/m² °C)A = Heat transfer area (m²)ΔT = Temperature difference between the steam and the product (K or °C)

35.1 Seat tightness

Seat tightness is an important consideration when selecting and installing a safety valve, as not only can it lead to a continuous loss of system fluid, but leakage can also cause deterioration of the sealing faces, which can lead to premature lifting of the valve.

The seat tightness is affected by three main factors; firstly by the characteristics of the safety valve, secondly by the installation of the safety valve and thirdly, by the operation of the safety valve.

Characteristics of the safety valveFor a metal-seated valve to provide an acceptable shut-off, the sealing surfaces need to have a high degree of flatness with a very good surface finish. The disc must articulate on the stem and the stem guide must not cause any undue frictional effects. Typical figures required for an acceptable shut-off for a metal seated valve are 0.5 mm for surface finish and two optical light bands for flatness. In addition, for a reasonable service life, the mating and sealing surfaces must have a high wear resistance.

Unlike ordinary isolation valves, the net closing force acting on the disc is relatively small, due to there being only a

The U values shown in Figure 2.9.1 may sometimes be used. They can give reasonable results in the case of large platen presses but are less accurate when small numbers of intricately shaped moulds are considered, mainly due to the difficulty of estimating the surface area.

A feature of this type of plant is the small steam space, and a relatively high steam load when warming up from cold. To account for this and the load fluctuations, steam traps should be sized with a factor of 2 times the running load. Temperature control can be very accurate using pilot operated direct acting reducing valves, giving a constant and consistent steam pressure corresponding to the required surface temperature. These are sized simply on the designed steam load.

35 Safety valves – Installation

small difference between the system pressure acting on the disc and the spring force opposing it.

Resilient or elastomer seals incorporated into the valve discs are often used to improve shut-off, where system conditions permit. It should be noted, however, that a soft seal is often more susceptible to damage than a metal seat.

35.2 Safety valve installation

Seat damage can often occur when a valve is first lifted as part of the general plant commissioning procedure, because very often, dirt and debris are present in the system. To ensure that foreign matter does not pass through the valve, the system should be flushed out before the safety valve is installed and the valve must be mounted where dirt, scale and debris cannot collect.

It is also important on steam applications to reduce the propensity for leakage by installing the valve so that condensate cannot collect on the upstream side of the disc. This can be achieved by installing the safety valve above the steam pipe as shown in Figure 9.5.1.

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Fig. 9.5.1: Correct position of a safety valve on a steam system

Fig. 9.5.2: Incorrect position of a safety valve on a steam system

Fig. 9.5.3: Correct installation of a safety valve on a steam system

Where safety valves are installed below the pipe, steam will condense, fill the pipe and wet the upstream side of the safety valve seat. This type of installation is not recommen-ded but is shown in Figure 9.5.2 for reference purposes.

Also, it is essential at all times to ensure that the down-stream pipe work is well drained so that downstream flooding (which can also encourage corrosion and leakage) cannot occur, as shown in Figure 9.5.3.

35.3 Installation

Safety valves are precision items of safety equipment; they are set to close tolerances and have accurately machined internal parts. They are susceptible to misalignment and damage if mishandled or incorrectly installed.

Valves should be transported upright if possible and they should never be carried or lifted by the easing lever. In addition, the protective plugs and flange protectors should not be removed until actual installation. Care should also be taken during movement of the valve to avoid subjecting it to excessive shock as this can result in considerable internal damage or misalignment.

Inlet pipeworkWhen designing the inlet pipe work, one of the main considerations is to ensure that the pressure drop in this pipe work is minimised. EN ISO 4126 recommends that the pressure drop be kept below 3% of the set pressure when discharging. Where safety valves are connected using short 'stub' connections, inlet pipe work must be at least the same size as the safety valve inlet connection. For larger lines or any line incorporating bends or elbows, the branch connection should be at least two pipe sizes larger than the safety valve inlet connection, at which point it is reduced in size to the safety valve inlet size (see Figure 9.5.5a). Excessive pressure loss can lead to 'chatter',

When a safety valve is installed below the

steam pipe, steam can condensate and collect on the upstream side

of the valve seat

When a safety valve is installed correctly, above the steam pipe, the safety valve inlet pipework is self-draining

Low point small bore

drain

Vent upwards

Safety valve inlet pipe

Steam pipe

Steam pipe

Steam pipe

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Fig. 9.5.5: Correct installations of safety valves

which may result in reduced capacity and damage to the seating faces and other parts of the valve. In order to reduce the pressure loss in the inlet, the following methods can be adopted:• Increase the diameter of the pipe. (see Figure 9.5.5 (a)).• Ensure that any corners are suitably rounded. The EN

ISO 4126 standard recommends that corners should have a radius of not less than one quarter of the bore (see Figure 9.5.5 (b)).

• Reduce the inlet pipe length.• I nstall the valve at least 8 to 10 pipe diameters down-

stream from any converging or diverging 'Y' fitting, or any bend (see Figure 9.5.5 (c)).

• Never install the safety valve branch directly opposite a branch on the lower side of the steam line.

• Avoid take-off branches (such as for other processes) in the inlet piping, as this will increase the pressure drop.

Safety valves should always be installed with the bonnet vertically upwards. Installing the valve in any other orienta-tion can affect the performance characteristics.

The API Recommended Practice 520 guidelines also state that the safety valve should not be installed at the end of a long horizontal pipe that does not normally have flow through it. This can lead to the accumulation of foreign material or condensate in the pipe, which may cause unnecessary damage to the valve, or interfere with its operation.

Outlet pipe workThere are two possible types of discharge system - open and closed systems. Open system discharge directly into the atmosphere whereas closed systems discharge into a manifold along with other safety valves.

It is recommended that discharge pipe work for steam and gas systems should rise, whereas for liquids, it should fall. However, it is important to drain any rising discharge pipe work.

Horizontal pipe work should have a downward gradient of at least 1 in 100 away from the valve; this gradient ensures that the discharge pipe is self-draining. However, any vertical rises will still require separate drainage. Note that any drainage systems form part of the overall discharge system and are therefore subject to the same precautions that apply to the discharge systems, notably that they must not affect the valve performance, and any fluid must be discharged to a safe location.

It is essential to ensure that fluid cannot collect on the downstream side of a safety valve, as this will impair the performance of the valve and cause corrosion of the spring and internal parts. Many safety valves are provided with a body drain connection, if this is not used or not provided, then a small bore drain should be fitted in close proximity to the valve outlet (see Figure 9.5.3).

Branch pipe (ii) at least two pipe sizes larger than the safety valve inlet connection (i)

Radius not less than one quarter of the bore

8 - 10 pipe diameters downstream of converging

'Y' fittings or bends

(ii)

(i)

(a) (c)(b)

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One of the main concerns in closed systems is the pressu-re drop or built-up backpressure in the discharge system. As mentioned before, this can drastically affect the perfor-mance of a safety valve. The EN ISO 4126 standard states that the pressure drop should be maintained below 10% of the set pressure. In order to achieve this, the discharge pipe can be sized using Equation 9.5.1.

0.008 * p

Le * m2 *

d =

vg +2 2

Equation 9.5.1

Where: d = Pipe diameter (mm) Le = Equivalent length of pipe (m) m = Discharge capacity (kg/h) P = Safety valve set pressure (bar g) x Required

percentage pressure drop vg = Specific volume of saturated steam at the pressure

(P) (m / kg)

The pressure (P) should be taken as the maximum allowable pressure drop according to the relevant standard. In the case of EN ISO 4126, this would be 10% of the set pressure and it is at this pressure vg is taken. Notes: A) There´re special programs for calculation of discharge

pipe dimensions – please contact your safety valve supplier for details and inform him about necessary pipe length and amount of elbows or other piping elements!

B) Rule of thumb” for saturated steam safety valves (up to round < 15 m of pipe and < 3 elbows): Size the discharge pipe 2 dimensions bigger then outlet dimension flange of safety valve (example: safety valve with DN 40 outlet flange results in pipe dimension DN 65)

.Safety valves that are installed outside of a building for discharge directly into the atmosphere should be covered using a hood. The hood allows the discharge of the fluid, but prevents the build up of dirt and other debris in the discharge pipe work, which could affect the backpressure. The hood should also be designed so that it too does not affect the backpressure.

Manifolds (not recommended!)Manifolds must be sized so that in the worst case (i.e. when all the manifold valves are discharging), the pipe work is large enough to cope without generating unaccep-table levels of backpressure. The volume of the manifold should ideally be increased as each valve outlet enters it, and these connections should enter the manifold at an angle of no greater than 45° to the direction of flow (see Figure 9.5.6). The manifold must also be properly secured and drained where necessary.

For steam applications, it is generally not recommended to use manifolds, but they can be utilized if proper considera-tion is given to all aspects of the design and installation.

35.4 Reaction forces when discharging

In open systems, careful consideration must be given to the effects of the reaction forces generated in the discharge system when the valve lifts. In these systems, there will be significant resultant force acting in the opposite direction to that of discharge. It is important to prevent excessive loads being imposed on the valve or the inlet connection by these reaction forces, as they can cause damage to the inlet pipe work. The magnitude of the reaction forces can be calcula-ted using the formula in Equation 9.5.2:

(k + 1) * M

k * TF = 129 * m * + 0.1 * A * P

Equation 9.5.2

Where: F = Reaction force at the point of discharge to

atmosphere (newtons) (see Figure 9.5.4) m = Discharge mass flowrate (kg/s) k = Isentropic coefficient of the fluid T = Fluid temperature (K)

Fig. 9.5.6 :A typical manifold discharge system

< 45°

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M = Molar mass of the fluid (kg / kmol) A = Area of the outlet at the point of discharge (mm²) (see

Figure 9.5.7) P = Static pressure at the outlet at the point of discharge

(bar g)

The reaction forces are typically small for safety valves with a nominal diameter of less than 75 mm, but safety valves larger than this usually have mounting flanges for a reaction bar on the body to allow the valve to be secured.These reaction forces are typically negligible in closed systems, and they can therefore be ignored.

Regardless of the magnitude of the reaction forces, the safety valve itself should never be relied upon to support the discharge pipe work itself and a support should be provided to resist the weight of the discharge pipe work. This support should be located as close as possible to the centre line of the vent pipe (see Figure 9.5.7).

Figures 9.5.8 and 9.5.9 show typical safety valve installa-tions for both open and closed systems.

Fig. 9.5.8: A typical safety valve installation with open discharge system

Long radius elbow

Low point small bore drain

Pressure relief valve

Body drain Support to resist weight and reaction forces

Nominal pipe diamter no less than valve inlet size

Non-recoverable losses along the discharge pipe not more

than 12% of the set pressure

Non-recove-rable losses

not more than 3% of the set

pressure

Note: A weather cap may be required

Pressure relief valve Long radius elbow

Support to list weight and reaction forces

Vent pipe

A (area of the outlet at the point of discharge (mm2))

F (Reaction force at the point of discharge to atmosphere)

Low point small bore drain

Fig. 9.5.9: A typical safety valve installation with closed discharge system

Bonnet vent piping for bellows type pressure relief valves, if required

Flanges spool piece, if required to elevate PRV Non-recoverable losses

not more than 3% of the set pressure

Fig. 9.5.7: Determination of the reaction forces generated in an open system


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36.1 Conversion of pressure units (quick use – rounded):

36.2 Conversion of anglo-american units to SI units

36 Required formulas and conversion tables

Einheit Unité Unit bar mbar

Pa N/m2

kPa kN/m2

MPa MN/m2

at kp/cm2 atm

mmWS mmCE

1000 kp/m2

mWS mCE

1000 kp/m2

Torr mmHg mmQS

psi lbf/in2 kgf/cm2

1 bar 1 1000 1 * 105 100 0,1 1,02 0,987 1.02 * 104 10,2 750 14,5 1,02

1 mbar 0,001 1 100 0,1 1 * 10-4 1.02 * 10-3 0.987 * 10-5 10,2 0,010 0,75 0,015 1.02 * 10-3

1 Pa 1 N/m2 1 * 10-5 0,01 1 0,001 1 * 10-6 1.02 * 10-5 0.987 * 10-5 0,102 1.02 * 10-4 0,0075 1.45 * 10-4 1.02 * 10-5

1 kPa 1 kN/m2 0,01 10 1000 1 0,001 0,010 9.87 * 10-3 102 0,102 7,5 0,145 0,010

1 MPa 1 MN/m2 10 1 * 104 1 * 105 1000 1 10,2 9,87 1.02 * 105 102 7500 145 10,2

1 at 1 kp/cm2 0,981 981 0.981 * 105 98,1 0,098 1 0,968 1 * 104 10 736 14,22 1

1 atm 1,013 1013 1.013 * 105 101,3 0,101 1,033 1 1.033 * 104 10,332 760 14,696 1,033

1 mmWS 1 mmCE 0.981 * 10-4 0,098 9,807 9.81 * 103 9.81 * 10-6 1 * 10-4 9.68 * 10-5 1 0,001 0,074 1.422 * 10-3 1 * 10-4

1 mWS 1 mCE 0,098 98,07 9807 9,81 9.81 * 10-3 0,1 0,097 1000 1 73,6 1,422 0,1

1 Torr 1 mmHg 1.333 * 10-3 1,333 133,322 0,133 0.133 * 10-3 1.36 * 10-3 1.316*10-3 13,595 1.359 * 10-2 1 1.934 * 10-2 1.36 * 10-3

1 psi 1 lbf/in2 6.895 * 10-2 68,95 6895 6,895 6.895 * 10-3 7.031 * 10-2 0,068 703,1 0,703 51,7 1 7.031*10-2

1 kgf/cm2 0,981 981 0.981 * 105 98,1 0,098 1 0,968 1 * 104 10 736 14,22 1

Name of unit Symbol Definition Relation to SI units

foot (International) ft = 1/3 yd = 0.3048 m = 12 inches = 0.3048 m

inch (International) in = 1/36 yd = 1/12 ft = 0.0254 m

metre (SI base unit) m= Distance light travels in 1 / 299792458 of a second

in vacuum.[8]≈ 1 / 10000000 of the distance from equator to pole.

= 1 m

mile (international) mi = 80 chains = 5280 ft = 1760 yd = 1609.344 m

nanometer nm = 1 × 10−9 m = 1 × 10−9m

nautical mile (international) NM; nmi = 1852 m = 1852 m

yard (International) yd = 0.9144 m = 3 ft = 36 in = 0.9144 m

Length


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Name of unit Symbol Definition Relation to SI unitsacre (international) ac = 1 ch × 10 ch = 4840 sq yd = 4 046.856 4224 m2

hectare ha = 10 000 m2 =10 000 m2

shed = 10−52 m2 = 10−52 m2

square foot sq ft = 1 ft × 1 ft = 9.290 304 × 10−2 m2

square inch sq in = 1 in × 1 in = 6.4516 × 10−4 m2

square kilometre km2 = 1 km × 1 km = 106 m2

square metre (SI unit) m2 = 1 m × 1 m = 1 m2

square mile sq mi = 1 mi × 1 mi = 2.589 988 110 336 × 106 m2

Aerea

Volume

Name of unit Symbol Definition Relation to SI unitskilogram-force; kilopond; grave-force kgf; kp; Gf = g × 1 kg = 9.806 65 N

newton (SI unit) N A force capable of giving a mass of one kg an acceleration of one metre per second = 1 N = 1 kg·m/s2

pound lb = slug·ft/s2 = 4.448 230 531 Npound-force lbf = g × 1 lb = 4.448 221 615 2605 Nton-force tnf = g × 1 sh tn = 8.896 443 230 521 × 103 N

Force

Name of unit Symbol Definition Relation to SI unitsbarrel (petroleum) bl; bbl = 42 gal (US) = 0.158 987 294 928 m3

bucket (Imperial) bkt = 4 gal (Imp) = 0.018 184 36 m3

cubic foot cu ft = 1 ft × 1 ft × 1 ft = 0.028 316 846 592 m3

cubic inch cu in = 1 in × 1 in × 1 in = 16.387 064 × 10−6 m3

cubic metre (SI unit) m3 = 1 m × 1 m × 1 m = 1 m3

cubic mile cu mi = 1 mi × 1 mi × 1 mi = 4 168 181 825.440 579 584 m3

cubic yard cu yd = 27 cu ft = 0.764 554 857 984 m3

gallon (Imperial) gal (Imp) = 4.546 09 L = 4.546 09 × 10−3 m3

litre L = 1 dm3 = 0.001 m3

ounce (fluid Imperial) fl oz (Imp) = 1/160 gal (Imp) = 28.413 0625 × 10−6 m3

pint (Imperial) pt (Imp) = ⅛ gal (Imp) = 568.261 25 × 10−6 m3

quart (Imperial) qt (Imp) = ¼ gal (Imp) = 1.136 5225 × 10−3 m3

ton (freight) = 40 cu ft = 1.132 673 863 68 m3

ton (water) = 28 bu (Imp) = 1.018 324 16 m3

Name of unit Symbol Definition Relation to SI unitscubic foot per minute CFM = 1 ft3/min = 4.719474432 × 10−4 m3/scubic foot per second ft3/s = 1 ft3/s = 0.028316846592 m3/scubic inch per minute in3/min = 1 in3/min = 2.7311773 × 10−7 m3/scubic inch per second in3/s = 1 in3/s = 1.6387064 × 10−5 m3/scubic metre per second (SI unit) m3/s = 1 m3/s = 1 m3/sgallon (U.S. fluid) per day GPD = 1 gal/d = 4.381263638 × 10−8 m3/sgallon (U.S. fluid) per hour GPH = 1 gal/h = 1.051503273 × 10−6 m3/sgallon (U.S. fluid) per minute GPM = 1 gal/min = 6.30901964 × 10−5 m3/slitre per minute LPM = 1 L/min = 1.6 × 10−5 m3/s

Flow (volume)

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Name of unit Symbol Definition Relation to SI unitsBTU (International Table) per hour BTUIT/h = 1 BTUIT/h ≈ 0.293 071 W

BTU (International Table) per minute BTUIT/min = 1 BTUIT/min ≈ 17.584 264 W

BTU (International Table) per second BTUIT/s = 1 BTUIT/s = 1.055 055 852 62 × 103 W

horsepower (boiler) bhp ≈ 34.5 lb/h × 970.3 BTUIT/lb ≈ 9.810 657 × 103 W (= 9,81 kW)

horsepower (European electrical) hp = 75 kp·m/s = 736 W

watt (SI unit) W The power which in one second of time gives rise to one joule of energy = 1 W = 1 J/s = 1 N·m/s = 1 kg·m2/s3

Name of unit Symbol Definition Relation to SI unitsBritish thermal unit (ISO) BTUISO = 1.0545 × 103 J = 1.0545 × 103 J

British thermal unit (International Table) BTUIT = 1.055 055 852 62 × 103 J

British thermal unit (39 °F) BTU39 °F ≈ 1.059 67 × 103 J

British thermal unit (59 °F) BTU59 °F = 1.054 804 × 103 J = 1.054 804 × 103 J

British thermal unit (60 °F) BTU60 °F ≈ 1.054 68 × 103 J

British thermal unit (63 °F) BTU63 °F ≈ 1.0546 × 103 J

calorie (International Table) calIT = 4.1868 J = 4.1868 J

calorie (mean) calmean1/100 of the energy required to warm one gram of

air-free water from 0 °C to 100 °C @ 1 atm ≈ 4.190 02 J

foot-pound force ft lbf = g × 1 lb × 1 ft = 1.355 817 948 331 4004 J

foot-poundal ft pdl = 1 lb·ft2/s2 = 4.214 011 009 380 48 × 10−2 J

horsepower-hour hp·h = 1 hp × 1 h = 2.684 519 537 696 172 792 × 106 J

inch-pound force in lbf = g × 1 lb × 1 in = 0.112 984 829 027 6167 J

joule (SI unit) JThe work done when a force of one newton moves the point of its application a distance of one metre

in the direction of the force.[24]= 1 J = 1 m·N = 1 kg·m2/s2 = 1 C·V = 1 W·s

therm (E.C.) = 100 000 BTUIT = 105.505 585 262 × 106 J

Conversion of water hardnes unitsTotal hardness (CaCO3 – Calciumcarbonate)

General hardness level (°dH / mmol/l calciumcabonate)

Energy, work or amount of heat

Power or heat flow rate

Symbol °dH °e °fH ppm mval / l mmol / lGerman hardness °dH 1 1,253 1,78 17,8 0,357 0,1783

English hardness °E 0,798 1 1,43 14,3 0,285 0,142

French hardness °fH 0,560 0,702 1 10 0,2 0,1

ppm CaCO3 (USA) ppm 0,056 0,07 0,1 1 0,02 0,01

mval/l earthalcali-Ions mval/l 2,8 3,51 5 50 1 0,50

mmol/l earthalcali-Ions mmol/l 5,6 7,02 10,00 100,0 2,00 1

°dH mmol/lSoft < 8,4 < 1,5

Medium 8,4 - 14 1,5 – 2,5

Hard > 14 > 2,5

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36.3 Software Conversions see (examples - freeware):

http://joshmadison.com/convert-for-windows/(easy download possible)

http://www.convertworld.com(Internet based calculations only)

http://online.unitconverterpro.com/conversion-tables/convert-group/factors.php(Internet based calculations only)

Hoval data sheets and guidelines, Hoval handbooksSpirax-Sarco steam tutorials (www.spiraxsarco.com)Gestra handbook (www.gestra.de)Saacke - rules of thumb (www.saacke.de)Wikipedia encyclopedia (www.wikipedia.org)

37 Literature references

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38 System P&I Diagram

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DisclaimerAlthough Hoval does everything possible to ensure the accuracy of all data within this document, we cannot be held responsible for the contained information

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