1

CHC
California Hydronics Corp.

Steam System Design

Presented by:
Tim Goeppner &
Hans Kaufmann
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Steam System
y Design
g Overview
1. Fundamentals of Steam
2. Steam Boiler Types and Piping
3. Heat Transfer Equipment
4. Packaged Equipment
5. Main Steam Supply Piping
6. Steam Trap Sizing and Selection
7. Condensate Return Systems
8. Pressure and Temperature Control
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1 Fundamentals of Steam
1.
• Basic Steam
• High Pressure vs. Low Pressure
• Fl h St
Flash Steam
• Condensate
• Water Hammer
• Useful Conversion Factors
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Units of Steam

• BTU: British Thermal Unit

– The amount of energy needed
to heat 1 pound of water from
39 to 40°F
– Approximately
pp y the amount of
energy released by a single
wooden match
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Sensible Heat
• Heat that is exchanged that directly changes
the temperature and not phase
• Heat that is able to be sensed with a
temperature change
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Example:
p Sensible Heat

• Heating water:

1 lb Water 1 lb Water
(100oF) Add Heat
(200oF)
(100 BTUs)
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Latent Heat
• The heat exchanged that results in a phase
change without temperature change
• The word “Latent” derived from Latin word
“Latere” meaning “to lie hidden”
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Example:
p Latent Heat of Vaporization
p

• Heating water from liquid to steam:

1 lb Water 1 lb Steam
(212oF) Add Heat (212oF)
(970 BTUs)
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Example:
p Latent Heat of Condensation
• Cooling steam from gas to water:

1 lb Steam 1 lb Water
(212oF) Remove Heat (212oF)
(970 BTUs)
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Steam Expansion
p

1 lb Steam
(212°F)
1 lb
b Water
ate ((212°F)) Volume: 26.8 ft3
Add Heat
Volume: 0.016 ft3 (970 BTUs)

Volume expanded
1675 times!!!
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Steam Explosion
8'6" dia by 108' long brick hardening autoclave had the door blown off just as
the steam pressure reached 145 psig at the start of a curing cycle. After deflecting off
the low wall of the loading bridge pit, the door of the autoclave pierced another wall
and continued piercing the plant research laboratory located over the steam kilns.
The walls and a large portion of the plant's roof collapsed from the pressure of the explosion.
The 45 ton autoclave moved 150 feet away from its foundation and destroyed a delivery truck,
curing racks, and numerous cubes of inventory block.
Fortunately and miraculously no one was seriously injured.
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Steam Advantages
g vs. Hot Water
• Steam provides its own motive force
– Pumps not required to distribute heat
• Steam carries more BTUs per pound
• Steam
S provides higher temperature differentials
ff
– Less mass flow required
– Better
B tt heat
h t transfer
t f for
f reduced
d d heat
h t exchanger
h sizing
i i
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Basic Properties of Steam

Press. Steam Sensible Latent Total Sp. Vol.
PSIG Temp. Heat Heat Heat Ft3/lb.
BTU/lb
BTU/lb. BTU/lb
BTU/lb. BTU/lb
BTU/lb.
15in. hg 179 147 990 1137 51
g
5in. hg 203 171 976 1147 32
0 212 180 970 1150 27
1 215 183 968 1151 25
5 227 195 960 1155 20
10 239 207 953 1160 16
20 259 227 939 1166 12
30 274 243 929 1172 9.5
50 298 267 912 1179 6.7
100 338 309 880 1189 3.9
150 366 339 857 1196 2.7
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T-S Diagram
• Enthalpy:
t a py The
e su
sum oof tthe
e tthermal
e a energy
e e gy o
of tthe
e fluid
u d ((latent
ate t a
and
d se
sensible)
s b e) p
plus
us
the pressure energy
• Entropy: Quantitative measure of the amount of thermal energy not available
to do work within a closed thermodynamic system
• Empathy: What you feel for someone who has to explain what Entropy is

Liquid Superheated
S perheated Steam
(Sensible Heat) (Sensible Heat)

Saturated
Li id Line
Liquid Li

T, Temperature
Saturated
Vapor Line
Phase Change
(Latent Heat)

Entropy
s, Entropy
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High
g vs. Low Pressure Steam
• Total heat per pound
• Latent heat per pound
• Pressure drop p / velocity
y
• Initial cost of materials and labor
• Operating costs,
costs heat loss

150 PSIG 15 PSIG

365oF 250oF
4” Pipe
4 8” Pipe
8
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Basic Steam
High Pressure Low Pressure
• More Total Heat • Less Total Heat
• Less Latent Heat • More Latent Heat
• Less
L V
Volume
l • More
M Volume
V l
– Smaller Pipe – Larger Pipe
• Less Installation Costs • More Installation
• More Operational Costs
Costs • Less Operational
Costs
High pressure ALWAYS moves to low pressure.
Higher pressure should ONLY be used for long distribution lines.
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Dry Steam
Steam Quality
– 94% steam quality at 200 PSIG (387oF steam)
same latent heat as:
– 98% steam quality at 0 PSIG (212oF steam)

Difference of 4% water in steam.

KEEP IT DRY!!
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Dry Steam
Keep It Dry!!
Steam Quality
– AHRI Rating
R ti (f(formerly
l IBR & GAMA)
• Require boiler manufacturer’s to produce
equivalent boilers with equivalent prices
– Based on Steam Quality
• Industry standard is to achieve 98% steam quality
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Flash Steam
Pressurized
P i d condensate
d released
l d to atmosphere
h or
to a lower pressure zone evaporates a portion of
liquid to form “Flash
Flash Steam
Steam”
Flash steam to atmosphere or
low pressure steam line

Flash
Steam

100 psig

Example: High pressure 0 psig

condensate passing
through a steam trap,
or into a flash tank.
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Flash Steam Equation
How much ‘flash steam’ will form?
 SH  SL 
Flash Steam %    100
 H 
Where:
•SH
SH = Sensible heat in condensate at higher pressure
•SL = Sensible heat in condensate at lower pressure
•H = Latent heat of the steam at lower pressure
p
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Example: Flash Steam Equation

• What ppercent flash steam is p

produced?
• Hot condensate at 100 PSIG is discharged
to atmospheric pressure (0 PSIG)
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Example: Flash Steam Equation
Basic Properties of Steam
Press. Steam Sensible Latent Total Sp.
p Vol.
PSIG Temp. Heat Heat Heat Ft3/lb.
BTU/lb. BTU/lb. BTU/lb.
SL 179 H
15in. hg 147 990 1137 51
5in. hg 203 171 976 1147 32
0 212 180 970 1150 27
1 215 183 968 1151 25
5 227 195 960 1155 20
10 239 207 953 1160 16
20 259 227 939 1166 12
SH
30 274 243 929 1172 9.5
50 298 267 912 1179 6.7
100 338 309 880 1189 3.9
150 366 339 857 1196 2.7
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Example: Flash Steam Equation

 SH  SL 
Fl h Steam
Flash St %   100 
 H 
 btu btu 
 309  180 
Flash Steam %   lb lb   100 
 btu 
 970 
 lb 
Flash Steam %  13 .3 %
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Steam Properties
Sensible Latent Total Flash
Press.
P Temp.
Temp Heat Heat Heat Sp. Vol
Sp Vol. Steam
PSIG Deg. F BTU/lb. BTU/lb BTU/lb. Ft3/lb. %
0 212 180 970 1150 27 0.0
2 219 187 966 1153 24 0.6
5 227 195 960 1155 20 1.6
10 240 208 952 1160 16 29
2.9
15 250 219 945 1164 14 3.9
30 274 243 929 1172 9.5 6.5
50 298 267 912 1179 6.7 9.0
100 338 309 880 1189 3.9 13.3
125 353 325 868 1193 32
3.2 14 8
14.8
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Percentage Flash Steam from Condensate (%)
Steam Pressure
before the
Steam Trap Condensate Pressure after the Trap (psig)
(psig) 01) 2 5 10 15 20 30 40 60 80 100
5 1.7 1
10 2.9 2.2 1.4
15 4 3.2 2.4 1.1
20 49
4.9 42
4.2 34
3.4 21
2.1 11
1.1
30 6.5 5.8 5 3.8 2.6 1.7
40 7.8 7.1 6.4 5.1 4 3.1 1.3
60 10 9.3 8.6 7.3 6.3 5.4 3.6 2.2
80 12 11 10 9 8.1 7.1 5.5 4 1.9
100 13 13 12 11 9.7 8.8 7 5.7 3.5 1.7
125 15 14 13 12 11 10 8.6 7.7 5.2 3.4 1.8
160 17 16 15 14 13 12 11 95
9.5 74
7.4 56
5.6 4
200 19 18 17 16 15 14 13 12 9.3 7.5 5.9
250 21 20 19 18 17 16 18 14 11 9.8 8.2
300 23 22 21 20 19 18 17 15 13 12 10
350 24 23 23 22 21 20 18 17 15 14 12
400 25 25 24 23 22 21 20 19 17 15 13
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Flash Steam
Set @
5 psig
i

100 p
psig
g To Low Pressure
Steam Application
(ie. Heat exchanger,
100 f coil,
fan il reheat
h t coil)
il)
psig
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Flash Steam

Example: 100 PSIG to 5 PSIG

% Flash Steam = ((309-195)  960) x 100
= 11.9%

Assume H.P. Load = 2450 lbs/hr

2450 x 11.9% = 291 lbs/hr L.P. Steam Available

Flash Steam Calculator available on line

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Steam Quality
Steam Quality
– Measurement of steam’s dryness
– Try to maintain 98% quality steam
• Steam should contain no more than 2% water as it
leaves the boiler

WHY?
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Steam Quality
Steam Quality
– 94% steam quality at 200 PSIG (387oF steam)
same latent heat as:
– 98% steam quality at 0 PSIG (212oF steam)

Difference of 4% water in steam.

KEEP IT DRY!!
“Get Rid of It!!”
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Condensate
What volume will form?

1 lb. steam
(water vapor)
at 0 PSIG &
1 lb. water - 970 BTU’s 212oF
(1 pint)
i t)
at 212oF Latent Heat of
Condensation
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Condensate Drainage

Steam Velocity of 12,000 fpm = 136 mph

Condensate forms ripples and waves
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Condensate Drainage

Steam Velocity of 12,000 fpm = 136 mph

Condensate forms ripples and waves
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Water Hammer!!

Inadequately drained condensate forms

Slugs and causes water hammer
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Water Hammer!!

Flash steam from high pressure to low pressure

Causes Steam Bubbles
Cooling and collapse of steam bubble
Causes Implosion  Water Hammer
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Water Hammer!!

Flooded Heat Exchanger:

• Steam “slams” condensate around
• Ruins valves, tubes and traps
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Conversion Factors
Flow Comparisons
• Lb/Hr. vs. GPM
– 1 lb/h
lb/hr off steam
t or condensate
d t
1 lb/hr = 0.0167 lb/min (lb/hr  60 minutes)
0.0167 lb/min
/ = .002 GPM
G (lb/min
( /  8.33))

– 1000 lb/hr. = 2 GPM

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Conversion Factors
Pressure:
• One PSI = 2.307 feet water column (cold)
• One
O PSI = 2.41
2 41 ffeett water
t column
l (hot)
(h t)
• One PSI = 2.036 inches mercury
• One inch mercury = 13.6 inches water
column
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Conversion Factors
Boiler Horse Power (BHP) =
• 33,475 BTU/HR
• 34.5
34 5 lb
lbs/hr.
/h steam
t d att 212oF
ffrom and
• 139 Sq.Ft. EDR (Equivalent Direct
Radiation)
• 0.069 GPM