steam system design and best practices related to kiln drying · locate trap stations at all...
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New England Kiln Drying Association – Steam Design and Best Practices – HerLine Technologies
Steam System Design Steam System Design and Best Practices and Best Practices
Related to Kiln DryingRelated to Kiln Drying
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
What is Steam?What is Steam?
Like other substances water can exist in the form Like other substances water can exist in the form of a solid, a liquid or a gas.of a solid, a liquid or a gas.
Gaseous form of water is called STEAMGaseous form of water is called STEAM
ItIt’’s s HOTHOTItIt’’s s PowerfulPowerfulItIt’’ss EasyEasy
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Why use Steam ?Why use Steam ?•• Made from water, which is relatively inexpensive and Made from water, which is relatively inexpensive and
plentiful commodity available through out the worldplentiful commodity available through out the world
•• Carries relatively large amounts of energy in a small massCarries relatively large amounts of energy in a small mass
•• Temperature can be adjusted accurately by controlling its Temperature can be adjusted accurately by controlling its pressure using control valvespressure using control valves
•• Environmental friendlyEnvironmental friendly
•• Relatively inexpensive to generate when firing with wood Relatively inexpensive to generate when firing with wood chipschips
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Steam Steam -- the best choicethe best choiceWhy other systems fail to measure up to steam ?Why other systems fail to measure up to steam ?
1. Gas fired direct heating1. Gas fired direct heatingHigher operating cost than wood fired boilerHigher operating cost than wood fired boilerMore difficult to controlMore difficult to controlHigher MaintenanceHigher MaintenanceRequires separate humidification systemsRequires separate humidification systems
2. Electric heating2. Electric heatingVery high cost to operateVery high cost to operateRequires separate humidification systemsRequires separate humidification systems
3. Hot water systems3. Hot water systemsCarries less than 1/5Carries less than 1/5thth (20%) the heat (Btu(20%) the heat (Btu’’s) of Steams) of SteamHigher system installation costHigher system installation costHigher operating costsHigher operating costs
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Requirements for an Effective, Requirements for an Effective, Efficient and Safe Steam SystemEfficient and Safe Steam System
Good initial system designGood initial system designHigh quality system equipment and componentsHigh quality system equipment and componentsGood knowledge of system operational safeties Good knowledge of system operational safeties and periodic testing of safety devicesand periodic testing of safety devicesGood system operational knowledge and practicesGood system operational knowledge and practicesRegular tuning and maintenanceRegular tuning and maintenanceReplacement of old or worn componentsReplacement of old or worn components
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Steam System SubSteam System Sub--SystemsSystems
Steam GenerationSteam Generation
Steam DistributionSteam Distribution
Steam UtilizationSteam Utilization
Condensate RecoveryCondensate Recovery
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Steam GenerationSteam Generation
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Steam Generation Steam Generation –– the Boiler Housethe Boiler House
Steam Boiler Steam Boiler –– high or low pressurehigh or low pressureBoiler Feed Water Tank Boiler Feed Water Tank –– minimumminimumCondensate Surge Tank & DA Tank Condensate Surge Tank & DA Tank –– idealidealWater Softeners for makeWater Softeners for make--up waterup waterChemical Treatment System for boiler waterChemical Treatment System for boiler waterSurface blow down (TDS) control system for boiler Surface blow down (TDS) control system for boiler ––recommendedrecommendedFlash steam and blow down heat recovery systems Flash steam and blow down heat recovery systems --optionaloptional
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
STEAM GENERATIONSTEAM GENERATION
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Generating Quality SteamGenerating Quality Steam
Impurities - bottom‘blow down’ to waste
Good quality steam to plant
Build up of impurities in the boiler – surface blow down to drain or heat recovery
Feed water with
impurities
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Typical Simple Boiler Feed Water Typical Simple Boiler Feed Water TanksTanks
SURGE-1 BF-1
OR
Vent toAtmosphere
CondensateReturns
CondensateReturn
Vent toAtmosphere
BF-1 BF-2
To Boiler
To Boiler
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Typical Deareator TankTypical Deareator Tank
DEA-1
0 LB/H
Direct condensate returns,pumped returns & make-up water
Low pressure steamsupply to deareator
To Boiler
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Surge and DA Tank CombinationSurge and DA Tank Combination
SURGE-1 DEA-1
0 LB/H
? PSIG5 PSIG
PRV-1
0 LB/H
CR-1
Surge tank is vented to the atmosphere
Make-up water is usually added here and pre-heated
DA tank is pressurized with steam
Typical Condensate pump
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Optional Heat Recovery SystemsOptional Heat Recovery SystemsTypical Blow down Heat RecoverySystem
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Complex Flash Recovery SystemComplex Flash Recovery System
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
The Steam Distribution The Steam Distribution SystemSystem
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Steam Distribution SystemSteam Distribution SystemProper layout design & pipe sizing of mainsProper layout design & pipe sizing of mainsPiping always pitched in the direction of flowPiping always pitched in the direction of flowUse of eccentric reducers to eliminate creation of Use of eccentric reducers to eliminate creation of condensate collection points (low spots) in pipingcondensate collection points (low spots) in pipingUse of separators to eliminate wet steamUse of separators to eliminate wet steamProper drip trap stations in all required locationsProper drip trap stations in all required locationsUse of air vents at all endUse of air vents at all end--ofof--main locationsmain locationsMake steam main branch takeMake steam main branch take--offs from top of pipeoffs from top of pipeUse of pressure reducing valves as needed or desiredUse of pressure reducing valves as needed or desiredPut strainers before control valves, traps and pumpsPut strainers before control valves, traps and pumps
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Steam DistributionSteam DistributionTypical Steam CircuitTypical Steam Circuit
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Typical Steam Distribution HeaderTypical Steam Distribution Header
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Pipe SizingPipe Sizing
Greater Heat LossGreater Heat LossGreater CostGreater CostGreater Volume of Condensate Greater Volume of Condensate FormedFormed
Greater System Pressure DropsGreater System Pressure DropsNot Enough Volume of Steam Not Enough Volume of Steam Water Hammer and ErosionWater Hammer and Erosion
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
1 - 12 oz Can of Soda 0.012 cu ft.2 - 4 Drawer Filing Cabinets - 20.10 cu ft @ 0 psig [1675:1]1 - 4 Drawer Filing Cabinets - 11.18 cu ft @ 15 psig [867:1]1 - Drawer of Filing Cabinet 2.97 cu ft @ 100 psig [243:1]
Steam VolumeSteam Volume
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Sizing Sizing Steam Steam LinesLines
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Steam Main Steam Main Relaying to Higher LevelRelaying to Higher Level
Steam Relayto highlevel
Drain Points
150 - 300 ft
Fall 1/250
Steam Flow
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Steam Line ReducersSteam Line Reducers
Condensate
Correct
Incorrect
Steam
Steam
Condensate
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
How Separators WorkHow Separators Work
S3 Separator
Condensate Outlet
Wet Steam
Dry Steam
Steam SeparatorsSteam Separators
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Proper Drip Trap StationProper Drip Trap Station
Condensate
PocketSteam Trap Set
Cross Section
Cross Section
Steam Trap Set
Steam Flow
Steam Flow
CorrectCorrect
IncorrectIncorrect
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
H
D
Size of Main ‘D’ Collection Leg Diameter
1/2” to 6”
6” & larger
Same dia. as main ‘D’
2 to 3 Pipe Sizes Smaller than Main, But Never Smaller than 6”
Length of Collection Leg ‘H’
Automatic Start up: ‘H’ to be 28” or MoreSupervised Start up: Length to be1-1/2 times steam Main Diameter, but never shorter than 18”
Typical Steam Main Drip StationTypical Steam Main Drip Station
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Steam Traps in Steam Traps in a Typical Steam Circuita Typical Steam Circuit
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Air VentingAir Venting
Steam Main
Thermodynamic Steam Trap Set
Air
Balanced Pressure Air Vent
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Branch ConnectionsBranch Connections
CorrectIncorrect
Steam Steam
Condensate
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Supply LegSupply Leg
Shut Off Valve
Trap Set
Main
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
StrainersStrainers
Strainer
Control Valve
Note: Turn steam pipe line strainers 90° so the “Y”is parallel with the floor, not pointing down at it. This will eliminate the condensate pocket shown here.
Strainers should be installed ahead of pressure reducing valves,control valves, flow meters and steam traps. All these components aresusceptible to scale, dirt and debris. Screens of 60/100 mesh for valvesand flow meters, 20 mesh for traps.
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Pressure ReductionPressure Reduction
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Why Reduce Pressure?Why Reduce Pressure?PROPRO
ItIt’’s better to run boilers at higher pressure for effective system s better to run boilers at higher pressure for effective system operation and best system responseoperation and best system responseSteam should be used at lowest pressure to meet process system Steam should be used at lowest pressure to meet process system temperature requirements for highest efficiency and ease of temperature requirements for highest efficiency and ease of controlcontrol
CONCON
Adds additional system devices such as pressure reducing valves Adds additional system devices such as pressure reducing valves and safety valves to be concerned withand safety valves to be concerned withLower pressures increase the size of piping and system Lower pressures increase the size of piping and system components which add costcomponents which add cost
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Pilot Operated PRV CutawayPilot Operated PRV Cutaway
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Pressure Reducing StationPressure Reducing Station
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Typical Pressure Reducing StationsTypical Pressure Reducing Stations
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Typical Pressure Reducing StationsTypical Pressure Reducing Stations
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Steam Main PipingSteam Main PipingUse schedule 40 carbon steel pipeUse schedule 40 carbon steel pipeSize for proper velocity at operating pressureSize for proper velocity at operating pressureSize for current and future needsSize for current and future needsPitch in the direction of flowPitch in the direction of flowUse eccentric reducers to prevent condensate collection poolsUse eccentric reducers to prevent condensate collection poolsInstall proper drainable drip legs with allowance for dirt legs Install proper drainable drip legs with allowance for dirt legs and and trap stationstrap stationsLocate trap stations at 150Locate trap stations at 150’’ min and 300min and 300’’ max on long linear runsmax on long linear runsLocate trap stations at all changes in elevation, at the bottom Locate trap stations at all changes in elevation, at the bottom of of drop lines and at the end of mainsdrop lines and at the end of mainsAll branch take offs should be from the top of the main where All branch take offs should be from the top of the main where dry steam is availabledry steam is availableAir vents are also recommended at the ends of the mainAir vents are also recommended at the ends of the mainInsulate all steam pipingInsulate all steam piping
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Steam UtilizationSteam Utilization
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Steam UtilizationSteam Utilization
Is the ultimate goal of any steam system and it Is the ultimate goal of any steam system and it includes all the heat transfer systems and includes all the heat transfer systems and functionsfunctions
In the case of Kiln Drying, it would provide the In the case of Kiln Drying, it would provide the heat for drying and the steam for humidificationheat for drying and the steam for humidification
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
GAUGE ABSOLUTE TEMP SENSIBLE LATENT TOTAL VOLUME LATENTPRESSURE Pressure oF Heat Heat Heat Steam SENSIBLE
psig psia (hf) (hfg) (hg) (vg) RatioBTU/lb ft3/lb.
0 14.7 212 180 970 1150 26.8 5.4 : 115 29.7 250 218 946 1164 13.9 4.4 : 150 64.7 298 268 912 1180 6.68 3.4 : 1100 114.7 338 309 881 1190 3.9 2.9 : 1
GAUGE PRESSURE
Vacuumins Hg29.76 1 102 70 1033 1103 333 14.7 : 119.79 5 162 130 1000 1130 73 77 : 19.58 10 193 161 982 1143 38 6.1 : 11.41 14 209 178 972 1150 28 5.5 : 1
Selection from Steam TablesSelection from Steam Tables
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
PRESSURE & FLOWPRESSURE & FLOWDifferential Pressure:
•Is the difference between the inlet pressure and the outlet pressure acting upon any steam component such as a trap, valve, etc..
Flow
Elevation Changes
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Kiln Typical Kiln Typical Steam & Steam &
Condensate SystemCondensate System
ControlValves
Vacuum Breakers
Air Vents
Drip TrapsCoil Traps
Condensate Pump
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Typical Kiln Air Coil Steam Control Layout
AIR VENT
TRAP
CONTROLVALVE
VACUUMBREAKER
AIR VENT
TRAP
VACUUMBREAKER
AIR FLOW
AIR FLOW
GRAVITY DRAIN DOWN-NO LIFT-NO CHECK VALVES
GRAVITY DRAIN DOWN-NO LIFT-NO CHECK VALVES
MODULATING STEAM TEMPERATURE CONTROL
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
PrePre--Dryer Control Layout at AMF Bowling ProductsDryer Control Layout at AMF Bowling Products
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Air Film Product
Barriers to Heat TransferBarriers to Heat Transfer
Water Film
Metal H
eating Surface
Condensate Film
When steam comes into contact with a cooler surface, it gives up its latent heat and condenses.
Dirt Product
Steam Temperature
Product Temperature
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Effective Efficient Heat TransferEffective Efficient Heat TransferGood quality dry steamGood quality dry steam
Use separators if necessaryUse separators if necessary
Remove air from steam and coilsRemove air from steam and coilsUse air vents on mains and particularly on coils before trapsUse air vents on mains and particularly on coils before traps
Remove condensate completelyRemove condensate completelyUse properly sized F&T traps on coils Use properly sized F&T traps on coils –– not too small & donnot too small & don’’t go too larget go too largeProvide for 12Provide for 12”” minimum drop to trapminimum drop to trapMake sure traps are gravity draining without any lift in pipingMake sure traps are gravity draining without any lift in pipingInstall vacuum breakers on the inlet of each coil to break vacuuInstall vacuum breakers on the inlet of each coil to break vacuum lock which impedes m lock which impedes drainagedrainageTrap each coil section independently, donTrap each coil section independently, don’’t group coils on a single trapt group coils on a single trap
Keep coil fin and tube area as clean as possibleKeep coil fin and tube area as clean as possiblePower wash occasionally as necessaryPower wash occasionally as necessary
Use only the highest quality control componentsUse only the highest quality control components
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Use High Quality Industrial Grade Use High Quality Industrial Grade ValvesValves
•Pneumatic Actuated–least expensiveand most reliable
•Use Positioners when possible–betteraccuracy and control
•Use high pressure air when possible–keeps cost of actuators down
•Hardened stainless steel trim-plug & seat
•Good live loaded packing stem seals
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Vacuum BreakersVacuum BreakersSimple ball check types are the best and most reliable type
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Air VentsAir Vents
Thermostatic Air Ventsfor
Steam Systems
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
In
Water Level Increases, the Float Rises and
the Valve Opens
Float Trap with Thermostatic Air VentFloat Trap with Thermostatic Air Vent
Out
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Proper System Design Makes a Proper System Design Makes a Difference...Difference...
Accurate reliable controlAccurate reliable controlAir VentingAir VentingCondensate RemovalCondensate Removal
= equals= equalsThermal EfficiencyThermal EfficiencyReliabilityReliability
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Steam TrapsSteam Traps
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
What is a Steam Trap?What is a Steam Trap?
Definition:Definition:A steam trap is an A steam trap is an automatic valveautomatic valve designed to designed to stop the flow of steam so that heat energy can stop the flow of steam so that heat energy can be transferred, and the condensate and air can be transferred, and the condensate and air can be discharged as required. be discharged as required.
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Why Steam Traps are required?Why Steam Traps are required?Steam traps are automatic devices Steam traps are automatic devices
for:for:Air VentingAir VentingCondensate RemovalCondensate RemovalThermal EfficiencyThermal EfficiencySystem ReliabilitySystem Reliability
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Types of Steam TrapsTypes of Steam TrapsMechanical TrapsMechanical Traps
•• Float & thermostatic trapsFloat & thermostatic traps•• Inverted bucket trapsInverted bucket traps
Kinetic Energy TrapsKinetic Energy Traps•• Thermodynamic or disk trapsThermodynamic or disk traps
Thermostatic TrapsThermostatic Traps•• Balanced pressure trapsBalanced pressure traps•• Liquid ExpansionLiquid Expansion•• Bimetallic trapsBimetallic traps
Ventures & Orifices (these are not traps)Ventures & Orifices (these are not traps)
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Steam Traps TypesSteam Traps Types
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Float Trap with Thermostatic Air VentFloat Trap with Thermostatic Air VentIn
Out
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Float Trap with Thermostatic Air VentFloat Trap with Thermostatic Air Vent
Out
In Air Vent Open
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Float Trap with Thermostatic Air VentFloat Trap with Thermostatic Air Vent
Out
In Water Level Increases, the Float Rises and
the Valve Opens
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Inverted Bucket TrapInverted Bucket Trap
A
B
Out
In
C
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Operation of Inverted Bucket TrapOperation of Inverted Bucket TrapOut
In
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Operation of Inverted Bucket TrapOperation of Inverted Bucket TrapOut
In
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Operation of Inverted Bucket TrapOperation of Inverted Bucket TrapOut
In
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Typical Thermodynamic Steam Trap Typical Thermodynamic Steam Trap
H
OUT
C
GD
F
A
BE
IN
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
OUTIN
Operation of a Thermodynamic Steam Operation of a Thermodynamic Steam Trap Trap
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
OUTIN
Operation of a Thermodynamic Steam Operation of a Thermodynamic Steam Trap Trap
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
OUTIN
Operation of a Thermodynamic Steam Operation of a Thermodynamic Steam Trap Trap
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Modern Balanced Pressure TrapModern Balanced Pressure Trap
Balanced Pressure Capsule
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Balanced Pressure CapsuleBalanced Pressure Capsule
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Balanced Pressure CapsuleBalanced Pressure Capsule
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Response of Balanced Pressure TrapResponse of Balanced Pressure Trap
Pressure (psig)
Steam Saturation Curve
Response of Balanced Pressure Trap
Tem
p. (o
F)
80
130
180
230
280
330
380
430
0 14.5 29 43.5 58 72.5 87 101.5 116 130.5 145 159.5 174 188.5 203
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Liquid Expansion Thermostatic TrapLiquid Expansion Thermostatic Trap
A B C G
E DF
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Liquid Expansion Thermostatic TrapLiquid Expansion Thermostatic Trap
A B C G
E DF
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Bimetallic TypeBimetallic Type
Cold Hot
Heat
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Bimetallic Trap With Valve On OutletBimetallic Trap With Valve On Outlet
Valve Open
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Bimetallic Trap With Valve On OutletBimetallic Trap With Valve On Outlet
Valve Closed
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Fixed Orifice DeviceFixed Orifice DeviceItIt’’s s NotNot a Steam Trap and is not an a Steam Trap and is not an
effective controller of condensate floweffective controller of condensate flow
Orifice Plate
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Swivel Connector TrapsSwivel Connector Traps
Gasket mating faces in same material to eliminate galvanic corrosion
2 bolts forminimum downtime
Screwed, socket weld,butt weld or flangedconnections
Weldedconstruction with no gasketed jointto ASM IX
Flange rotation to suit pipeline connector
High integrity, spirally wound gasket
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Thermodynamic TrapThermodynamic TrapUTD30, UTD30A
UTD30H, UTD30HA UTD52L
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Balanced Pressure TrapBalanced Pressure TrapUBP30
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Inverted Bucket TrapInverted Bucket Trap
UIB30, UIB30H
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
User BenefitsUser Benefits
Minimum maintenance costs and plant downtime Minimum maintenance costs and plant downtime Only two bolts involved in replacement or removalOnly two bolts involved in replacement or removalVariety of trap types available to suit wide range of applicatioVariety of trap types available to suit wide range of applicationsnsCommon pipeline connector suits all trap typesCommon pipeline connector suits all trap types360360°° independent trap alignment offers flexible installationindependent trap alignment offers flexible installationIdeal for unattended plant or inaccessible placesIdeal for unattended plant or inaccessible placesStainless Steel construction and gaskets minimises corrosion, Stainless Steel construction and gaskets minimises corrosion, maximises product life and eliminates blowmaximises product life and eliminates blow--outoutAvailable with the option of one or two integral isolation valveAvailable with the option of one or two integral isolation valves.s.
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Steam Traps SelectionSteam Traps Selection
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
General Trap RecommendationsGeneral Trap Recommendations
High and medium pressure main drip applicationsHigh and medium pressure main drip applications½”½” or or ¾”¾” reduced port thermodynamic traps (TD type)reduced port thermodynamic traps (TD type)
Low pressure (15 psig or less) main drip applicationsLow pressure (15 psig or less) main drip applications½”½” or or ¾”¾” float & thermostatic (F&T) trap (FTI & FT float & thermostatic (F&T) trap (FTI & FT type)type)
Steam heating coil with modulating control valveSteam heating coil with modulating control valveF&T trap that is properly sized for condensing load (FTI F&T trap that is properly sized for condensing load (FTI & FT type)& FT type)
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Steam Traps SizingSteam Traps Sizing
ConsiderationsConsiderations……1. Condensate Load 1. Condensate Load 2. Safety Factor2. Safety Factor3. Available Differential Pressure:3. Available Differential Pressure:
System Pressure System Pressure Total BackpressureTotal Backpressure
Condensate LiftCondensate LiftReturn System PressureReturn System Pressure
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Steam Trap Sizing GuidelinesSteam Trap Sizing Guidelines
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Steam Traps SizingSteam Traps Sizing
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Why do steam traps fail?Why do steam traps fail?
Normal wear and tearNormal wear and tearCarryover creates scale which can block the trapCarryover creates scale which can block the trapPoor strainer maintenance Poor strainer maintenance -- small trap orifices and small trap orifices and parts can block or jam due to scale or rust.parts can block or jam due to scale or rust.Acidic condensate can cause corrosionAcidic condensate can cause corrosionWaterhammerWaterhammerFreezingFreezingIncorrect sizing and selectionIncorrect sizing and selectionIncorrect installationIncorrect installationInadequate maintenanceInadequate maintenance
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Problems Caused by Leaking TrapsProblems Caused by Leaking Traps
If a Trap Fails Open:If a Trap Fails Open:Wasted Steam = Wasted Fuel = Wasted MoneyWasted Steam = Wasted Fuel = Wasted MoneyHigh velocity in plant equipmentHigh velocity in plant equipmentSteam in condensate line Steam in condensate line Pressurisation of condensate linePressurisation of condensate lineExcessive back pressures acting on other trapsExcessive back pressures acting on other trapsFailure to maintain constant pressure / temperatureFailure to maintain constant pressure / temperatureReduced pressure differential across good trapsReduced pressure differential across good trapsUnsightly escaping steamUnsightly escaping steam
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Problems Caused by Waterlogged TrapsProblems Caused by Waterlogged Traps
If a Trap Fails ClosedIf a Trap Fails ClosedWater loggingWater loggingIrregular Temperature ControlIrregular Temperature ControlProduct SpoilageProduct SpoilageDecrease in Heat OutputDecrease in Heat OutputDamage to Plant EquipmentDamage to Plant EquipmentWaterhammer (Carryover in Mains)Waterhammer (Carryover in Mains)
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Troubleshooting Steam TrapsTroubleshooting Steam TrapsWhat is the problem? Trap Failed Closed, Failed What is the problem? Trap Failed Closed, Failed Open, Open, ““StalledStalled””Potential Potential ““StallStall”” Situation Situation –– Is a Vacuum Breaker Is a Vacuum Breaker installed?installed?Is there enough Installation Head available?Is there enough Installation Head available?Is there enough Differential Pressure available?Is there enough Differential Pressure available?Dirt Dirt -- Is a strainer installed upstream and is it blown Is a strainer installed upstream and is it blown down regularly?down regularly?Type of the steam trap used Type of the steam trap used –– Proper Application?Proper Application?
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Troubleshooting Steam TrapsTroubleshooting Steam TrapsIs the steam trap installed correctly? Direction of Is the steam trap installed correctly? Direction of flow, Float Movement, etc.flow, Float Movement, etc.Is the steam trap large enough?Is the steam trap large enough?Air Binding of a steam Trap Air Binding of a steam Trap –– Use of a separate Air Use of a separate Air VentVentWater logging Water logging –– Number of steam traps at Number of steam traps at appropriate locationsappropriate locationsSteam Locking Steam Locking –– Steam Lock ReleaseSteam Lock Release
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Steam Trap MaintenanceSteam Trap Maintenance
Frequency of maintenance:Frequency of maintenance:Quality of Steam Quality of Steam –– wet steam, carryoverwet steam, carryoverLife of the system Life of the system –– Initial blowdown, CorrosionInitial blowdown, CorrosionCriticality of the ApplicationCriticality of the ApplicationSteam Distribution PracticesSteam Distribution PracticesGeneral Maintenance Practices General Maintenance Practices –– e.g. Blowinge.g. Blowingdown strainers regularlydown strainers regularly
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Condensate Return Condensate Return SystemsSystems
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
FLASH STEAMFLASH STEAMFLASH STEAM occurs when hot condensate at high pressure is released to a lower pressure. At the lower pressure, the heat content (SENSIBLE HEAT) of the water (hot condensate) cannot exist in that form. A portion of the water ‘boils off’ and becomes FLASH STEAM
Flash Steam contains valuable BTU’s / lb. of heat which can be utilized for lower pressure applications.
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
100 psig338 F
0 psig212 F
SURPLUS HEAT CAUSES FLASH STEAM FORMATIONDUE TO PRESSURE DROP ACROSS A STEAM TRAP
TOATMOSPHERIC
RETURN SYSTEM(O PSIG)
100 PSIGSTEAM
TOATMOSPHERE
RETURN SYSTEM(O PSIG)
100 PSIGSTEAM
100 psig338 F
5 psig227 F
10 FOOT RISE
5 psig/227 F
0 psig/212 F
FLASHSTEAM
CONDENSATE
FLASHSTEAM90-95%
CONDENSATE5-10%
TRAP WITH 10' LIFT AFTER TRAP
TRAP WITH NO LIFT AFTER TRAP
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Pressurized Condensate ReturnPressurized Condensate Return
1000 lb. /hr
60 psig 0 psig
Flash Steam
Mass = 100 lb
Spec. Vol. = 2680 cu-ft.
99.5% of Total Volume
Condensate
Mass = 900 lb
Spec. Vol. = 14.42 cu-ft.
0.5 % of Total Volume
Typical of trap discharge lines prior to draining to pumpreceivers or dedicated pressurized returns prior to surgeor DA tank.
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Typical Vertical Flash TankTypical Vertical Flash Tank
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Simple Flash Steam Recovery SystemSimple Flash Steam Recovery System
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Complex Flash Recovery SystemComplex Flash Recovery System
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Electric Condensate PumpElectric Condensate Pump
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Electric Condensate PumpElectric Condensate Pump
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Electric Condensate Pump Typical Electric Condensate Pump Typical HookHook--up for Low Pressure Condensateup for Low Pressure Condensate
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
High Pressure/Temperature Condensate with separate High Pressure/Temperature Condensate with separate Flash Steam Vent TankFlash Steam Vent Tank
Electric Condensate Pump Typical HookElectric Condensate Pump Typical Hook--up up for HP Condensatefor HP Condensate
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
PPP Filling StrokePPP Filling Stroke
1. If there is sufficient filling
head, inlet check valve opens and
pump begins to fill and exhaust.
2. Filling action causes float to
rise.Inlet check valve open
Exhaust valve open, inlet valve shut.
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
PPP Discharge Stroke1. Float rising triggers valve
mechanism; opens steam valve and closes exhaust
valve.2. Pump body
pressurizes and resistance at outlet
check valve (back pressure) is
overcome.3. Pump empties.
Steam inlet valve open exhaust valve shut.
Outlet check valve open.
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Pressure Powered Pump Typical Pressure Powered Pump Typical HookHook--up for an Open Venting up for an Open Venting
SystemSystem(multiple sources of condensate with possible varying pressures)(multiple sources of condensate with possible varying pressures)
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Summary Summary –– Best Practices Best Practices -- System System Problems & SolutionsProblems & Solutions
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Best Practices Best Practices -- Common Steam System Common Steam System ProblemsProblems
Improper system designImproper system designImproper installationsImproper installationsImproper operationImproper operationImproper chemical treatmentImproper chemical treatmentInattention to maintenanceInattention to maintenanceWorn and/or failed componentsWorn and/or failed components
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Best Practices Best Practices –– Most Common ProblemsMost Common Problems
Wet steamWet steamWater hammerWater hammerPressure in the return systemPressure in the return systemFailed trapsFailed trapsFailed pumpsFailed pumpsFailed valvesFailed valvesPremature component failuresPremature component failuresPremature coil and piping failuresPremature coil and piping failures
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Best Practices Best Practices –– Most Common Most Common ProblemsProblems
How do They Manifest ThemselvesHow do They Manifest ThemselvesCondensate tank or pump receiver vents blowing excessivelyCondensate tank or pump receiver vents blowing excessivelyConstant banging or pounding in steam mainsConstant banging or pounding in steam mainsConstant banging or pounding in condensate return linesConstant banging or pounding in condensate return linesSlow heat upsSlow heat upsOverheatingOverheatingDifficulty with temperature and humidity controlDifficulty with temperature and humidity controlElectric condensate pumps cavitating and constantly leakingElectric condensate pumps cavitating and constantly leakingPremature failure of major components such as valves, traps, Premature failure of major components such as valves, traps, pumps, coils and pipingpumps, coils and piping
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Killers of a steam systemKillers of a steam systemDirtDirt
Damage the valves and seatsDamage the valves and seats
Obstruction to tight sealing resulting in leakageObstruction to tight sealing resulting in leakage
WaterWater
Reduced heat contentReduced heat content
Barrier for effective heat transferBarrier for effective heat transfer
Water hammer Water hammer -- dangerous dangerous
WireWire--drawing of valvesdrawing of valves
Water logging of traps and valvesWater logging of traps and valves
AirAir
Barrier for effective heat transferBarrier for effective heat transfer
Air binding of process vessels, traps, valves, pumps etc.Air binding of process vessels, traps, valves, pumps etc.
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
What is the solution ?What is the solution ?Dirty Steam ?Dirty Steam ?Strainers and blow downsStrainers and blow downs
Wet Steam ?Wet Steam ?Good practices in steam distribution Good practices in steam distribution –– design, layout, pipe design, layout, pipe
sizessizesMoisture separatorsMoisture separatorsSteam traps Steam traps –– sufficient number, appropriate type, correct sufficient number, appropriate type, correct
sizessizes
Longer Heating Cycles ?Longer Heating Cycles ?Good practices in steam distribution Good practices in steam distribution –– design, layout, pipe design, layout, pipe
sizessizesVacuum breakers Vacuum breakers –– on heat transfer equipmenton heat transfer equipmentAir vents Air vents –– on steam mains & heat transfer equipmenton steam mains & heat transfer equipmentProper type & size of steam traps Proper type & size of steam traps –– in good operating in good operating
conditioncondition
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Best Practices Best Practices -- Safety, Energy & MaintenanceSafety, Energy & MaintenanceWater hammerWater hammer
•• Go slow with boiler startGo slow with boiler start--ups and opening isolation valves into cold systemsups and opening isolation valves into cold systems•• Make sure all low points in the piping are drained properly by tMake sure all low points in the piping are drained properly by trap stationsrap stations•• Make sure you have proper drip legs and trap stationsMake sure you have proper drip legs and trap stations
Pressure relief Pressure relief –– make sure you have safety valves to protect the system from ovemake sure you have safety valves to protect the system from over r pressurepressureCondensate pump overflowsCondensate pump overflows-- install overflows on pump receivers to prevent install overflows on pump receivers to prevent system floodingsystem floodingInsulation Insulation –– minimally, insulate steam lines, if outside make sure jackets aminimally, insulate steam lines, if outside make sure jackets are re water tightwater tightFix all steam leaksFix all steam leaksWatch your vents for blowing trapsWatch your vents for blowing trapsFlash steam recovery if feasibleFlash steam recovery if feasibleBoiler blowdown heat recoveryBoiler blowdown heat recoveryBoiler surface & bottom blow downs per mfr. recommendation & havBoiler surface & bottom blow downs per mfr. recommendation & have good e good chemical treatmentchemical treatmentBlow down strainers and dirt legs periodicallyBlow down strainers and dirt legs periodicallyKeep your control valves in good repairKeep your control valves in good repair--inspect heads & seats periodicallyinspect heads & seats periodicallyTrapsTraps--track down problems and repair or replace as neededtrack down problems and repair or replace as neededFix leaking and nonFix leaking and non--functional pumpsfunctional pumpsTest condensate return PH periodically Test condensate return PH periodically –– acid destroys systemsacid destroys systems
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Best Practices Best Practices -- Words to the WiseWords to the WiseQuality Counts!!!Quality Counts!!!
Not all steam components are created equalNot all steam components are created equalYou get what you pay forYou get what you pay forPay me now or pay me later (Fram)Pay me now or pay me later (Fram)
DonDon’’t hesitate to ask questions!!!t hesitate to ask questions!!!It may be appropriate to challenge It may be appropriate to challenge ““conventional conventional wisdomwisdom””, the way we, the way we’’ve always done it may not be bestve always done it may not be bestFollow the manufacturerFollow the manufacturer’’s recommendationss recommendationsUtilize your resourcesUtilize your resources
Some systems and components work better than Some systems and components work better than others!!!others!!! –– itit’’s not a generic world out theres not a generic world out there
Get the Get the bestbest advice!!!advice!!! –– from people you can trustfrom people you can trust
Avoid orifice traps!!!Avoid orifice traps!!!
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Trap Testing ToolsTrap Testing Tools
Infrared or Contact Thermometer
Ultrasonic LeakDetector
New England Kiln Drying Association – Steam Design and Best Practices – HerLine Technologies
The EndThe End
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Common Steam TermsCommon Steam Terms
Water HammerWater HammerShock caused in piping & equipment due to rapid displacement of water by expanding or flowing steam.
Latent Heat or Heat of VaporizationLatent Heat or Heat of VaporizationThe extra heat that has to be added to each pound of water to tuThe extra heat that has to be added to each pound of water to turn it rn it into steam.into steam.
Dry SteamDry SteamIt is steam that is fully evaporated, thereby containing no entrIt is steam that is fully evaporated, thereby containing no entrained ained moisture.moisture.
Flash SteamFlash SteamIt is created when high temperature condensate (water above 212 It is created when high temperature condensate (water above 212 F F @ atmospheric pressure) crosses from an area of high pressure to@ atmospheric pressure) crosses from an area of high pressure to an an area of lower pressure, as through a steam trap. The excess heaarea of lower pressure, as through a steam trap. The excess heat t that is released, will boiler a percentage of the condensate bacthat is released, will boiler a percentage of the condensate back into k into steam.steam.
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Steam/Water in PipeSteam/Water in Pipe
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
WaterhammerWaterhammer
Sagging Main
Slug of water from condensate Vibration and
noise caused by waterhammer
Condensate
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
WaterhammerWaterhammer
Result of a drip trap being removed, that was draining a 100 psig line, before a valve
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
SHOCKING FACTS REGARDING SHOCKING FACTS REGARDING THE PHYSICS OF STEAMTHE PHYSICS OF STEAM
STEAM IS STEAM IS NOTNOT COMPRESSED AIR COMPRESSED AIR –– IT DOES NOT MAINTAIN IT DOES NOT MAINTAIN PRESSURE WITHOUT TEMPERATURE !!PRESSURE WITHOUT TEMPERATURE !!STEAM EXPANDS AS IT COOLS (REDUCES IN PRESSURE)!!STEAM EXPANDS AS IT COOLS (REDUCES IN PRESSURE)!!STEAM SYSTEMS ARE DYNAMIC STEAM SYSTEMS ARE DYNAMIC –– DYNAMIC MEANS CONSTANTLY DYNAMIC MEANS CONSTANTLY CHANGING CHANGING –– NOT STATICNOT STATIC !!!!PRESSURE FLOWS FROM HIGH TO LOW PRESSURE FLOWS FROM HIGH TO LOW –– NOTNOT LOW TO HIGH !!LOW TO HIGH !!STEAM & WATER DO STEAM & WATER DO NOTNOT MIX WELL !!MIX WELL !!ON EARTH WE HAVE GRAVITY !!ON EARTH WE HAVE GRAVITY !!WATER DOES WATER DOES NOTNOT FLOW UP HILL !!FLOW UP HILL !!VACUUMS WILL FORM IN VACUUMS WILL FORM IN ““PRESSURIZEDPRESSURIZED”” STEAM SYSTEMS !!STEAM SYSTEMS !!VACUUMS CAN OVERCOME GRAVITY !!VACUUMS CAN OVERCOME GRAVITY !!NEGATIVE PRESSURE (VACUUM) WILL LOWER THE BOILING POINT NEGATIVE PRESSURE (VACUUM) WILL LOWER THE BOILING POINT OF WATER !!OF WATER !!WHEN THINKING OF A STEAM SYSTEM VISUALIZE WIND & WATER !!WHEN THINKING OF A STEAM SYSTEM VISUALIZE WIND & WATER !!DRAINAGE IS EVERYTHING !!DRAINAGE IS EVERYTHING !!
New England Kiln Drying Association – Steam Design & Best Practices – HerLine Technologies
Don’t Stress Your Boilers
•Keep your boilers in good repair and keep them tuned up forefficient operation
•Perform safe slow start-ups•If you have capacity problems, use back pressure regulators to
throttle non-critical loads•Use separators to solve wet steam problems•Insulate steam mains•Fix leaks•Repair or replace wet insulation-its worse than no insulation•Repair or replace blowing traps•Distribute steam at high pressure and reduce at point of use•Return condensate•Maximize boiler feed water temperatures•Control boiler blowndown and consider heat recovery