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SteamSystemDesignandPracticesRelatedtoKilnDrying ScottHerl
SteamSystemDesignandPracticesRelatedtoKilnDrying ScottHerl
SteamSystemDesignandPracticesRelatedtoKilnDrying ScottHerl
What is Steam?
HOT
Its Powerful
Its Easy
Its
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Environmental friendly
2. Electric heating
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Steam Generation
Steam Distribution
Steam Utilization
Condensate Recovery
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Steam Generation
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
STEAM GENERATION
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Build up of
impurities in the
boiler surface
blow down to
drain or heat
recovery
Impurities - bottom
blow down to waste
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Condensate
Returns
Vent to
Atmosphere
Condensate
Return
OR
To Boiler
To Boiler
SURGE-1
BF-1
BF-1
BF-2
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
0 LB/H
To Boiler
DEA-1
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
CR-1
DA tank is
pressurized
with steam
0 LB/H
5 PSIG
? PSIG
PRV-1
0 LB/H
SURGE-1
DEA-1
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Steam Distribution
Typical Steam Circuit
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Pipe Sizing
Greater Heat Loss
Greater Cost
Greater Volume of Condensate
Formed
Steam Volume
1 - 12 oz Can of Soda
2 - 4 Drawer Filing Cabinets 1 - 4 Drawer Filing Cabinets 1-
0.012 cu ft.
20.10 cu ft @ 0 psig [1675:1]
11.18 cu ft @ 15 psig [867:1]
2.97 cu ft @ 100 psig [243:1]
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Sizing
Steam
Lines
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Steam Main
Relaying to Higher Level
Fall 1/250
Steam
Relay
to high
level
150 - 300 ft
Drain Points
Steam Flow
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Condensate
Steam
Incorrect
Condensate
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Steam Separators
How Separators Work
Wet
Steam
Dry Steam
S3 Separator
Correct
Pocket
Steam Trap Set
Steam Flow
Cross Section
Incorrect
8
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Size of Main D
1/2 to 6
6 & larger
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Steam Traps in
a Typical Steam Circuit
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Air Venting
Balanced Pressure
Air Vent
Steam Main
Air
Thermodynamic
Steam Trap Set
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Branch Connections
Steam
Steam
Condensate
Incorrect
Correct
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Supply Leg
Main
Shut Off
Valve
Trap Set
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Strainers
Strainers should be installed ahead of pressure reducing valves,
control valves, flow meters and steam traps. All these components are
susceptible to scale, dirt and debris. Screens of 60/100 mesh for valves
and flow meters, 20 mesh for traps.
Control Valve
Strainer
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.
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Pressure Reduction
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
CON
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Steam Utilization
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Steam Utilization
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
14.7
29.7
64.7
114.7
212
250
298
338
180
218
268
309
970
946
912
881
1150
1164
1180
1190
26.8
13.9
6.68
3.9
5.4 : 1
4.4 : 1
3.4 : 1
2.9 : 1
GAUGE
PRESSURE
Vacuum
ins Hg
29.76
19.79
9.58
1.41
1
5
10
14
102
162
193
209
70
130
161
178
1033
1000
982
972
1103
1130
1143
1150
333
73
38
28
14.7 : 1
77 : 1
6.1 : 1
5.5 : 1
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Elevation Changes
Flow
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Control
Valves
Vacuum
Breakers
Kiln Typical
Steam &
Condensate System
Air Vents
Drip Traps
Coil Traps
Condensate
Pump
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
CONTROL
VALVE
VACUUM
BREAKER
AIR FLOW
VACUUM
BREAKER
AIR VENT
AIR VENT
TRAP
AIR FLOW
TRAP
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
DirtFilm
Water
Condensate Film
Air Film
Steam
Temperature
Product
Product
Product
Temperature
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Use properly sized F&T traps on coils not too small & dont go too large
Provide for 12 minimum drop to trap
Make sure traps are gravity draining without any lift in piping
Install vacuum breakers on the inlet of each coil to break vacuum lock which impedes
drainage
Trap each coil section independently, dont group coils on a single trap
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Vacuum Breakers
Simple ball check types are the best and most reliable type
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Air Vents
Out
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Steam Traps
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Mechanical Traps
Thermostatic Traps
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Out
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Out
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Out
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
B
A
In
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
In
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
In
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
In
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
D
F
IN
OUT
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
IN
OUT
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
IN
OUT
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
IN
OUT
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Balanced
Pressure
Capsule
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
380
Temp. (oF)
330
280
Response of Balanced
Pressure Trap
230
180
130
80
0
14.5
29 43.5
58 72.5
Pressure (psig)
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Bimetallic Type
Cold
Hot
Heat
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Valve
Open
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Valve Closed
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Orifice Plate
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Welded
construction
with no
gasketed joint
to ASM IX
2 bolts for
minimum
downtime
Flange
rotation to
suit pipeline
connector
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Thermodynamic Trap
UTD30, UTD30A
UTD30H, UTD30HA
UTD52L
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
UIB30, UIB30H
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
User Benefits
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Condensate Lift
Return System Pressure
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Water logging
Irregular Temperature Control
Product Spoilage
Decrease in Heat Output
Damage to Plant Equipment
Waterhammer (Carryover in Mains)
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Condensate Return
Systems
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
FLASH STEAM
FLASH 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 BTUs / lb. of heat which
can be utilized for lower pressure applications.
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
0 psig
212 F
100 psig
338 F
FLASH
STEAM
90-95%
100 PSIG
STEAM
CONDENSATE
5-10%
TRAP WITH 10' LIFT AFTER TRAP
100 psig
338 F
5 psig
227 F
FLASH
STEAM
TO
ATMOSPHERIC
RETURN SYSTEM
(O PSIG)
0 psig/212 F
TO
ATMOSPHERE
RETURN SYSTEM
(O PSIG)
10 FOOT RISE
5 psig/227 F
100 PSIG
STEAM
CONDENSATE
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Flash Steam
Mass = 100 lb
Spec. Vol. = 2680 cu-ft.
99.5% of Total Volume
60 psig
0 psig
Condensate
Mass = 900 lb
Spec. Vol. = 14.42 cu-ft.
1000 lb. /hr
0.5%
of Total
Volume
New England Kiln Drying Association Steam Design & Best Practices
HerLine
Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Inlet check
valve open
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.
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
1. 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.
Outlet check
valve open.
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Wet steam
Water hammer
Pressure in the return system
Failed traps
Failed pumps
Failed valves
Premature component failures
Premature coil and piping failures
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Water
Reduced heat content
Barrier for effective heat transfer
Water hammer - dangerous
Wire-drawing of valves
Water logging of traps and valves
Air
Barrier for effective heat transfer
Air binding of process vessels, traps, valves, pumps etc.
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Wet Steam ?
Good practices in steam distribution design, layout, pipe
sizes
Moisture separators
Steam traps sufficient number, appropriate type, correct
sizes
Water hammer
Go slow with boiler start-ups and opening isolation valves into cold systems
Make sure all low points in the piping are drained properly by trap stations
Make sure you have proper drip legs and trap stations
Pressure relief make sure you have safety valves to protect the system from over
pressure
Condensate pump overflows- install overflows on pump receivers to prevent
system flooding
Insulation minimally, insulate steam lines, if outside make sure jackets are
water tight
Fix all steam leaks
Watch your vents for blowing traps
Flash steam recovery if feasible
Boiler blowdown heat recovery
Boiler surface & bottom blow downs per mfr. recommendation & have good
chemical treatment
Blow down strainers and dirt legs periodically
Keep your control valves in good repair-inspect heads & seats periodically
Traps-track down problems and repair or replace as needed
Fix leaking and non-functional pumps
Test condensate return PH periodically acid destroys systems
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Quality Counts!!!
Ultrasonic Leak
Detector
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
The End
New England Kiln Drying Association Steam Design and Best Practices HerLine Technologies
Steam/Water in Pipe
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Waterhammer
Sagging Main
Condensate
Vibration and
noise caused by
waterhammer
New England Kiln Drying Association Steam Design & Best Practices HerLine Technologies
Waterhammer
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