SystemsPartIII:Distribution,Control&RegulationofSteam

Transcript

Slide1
WelcometoSteamSystemsPartIII:Distribution,Control&RegulationofSteam.Thiscourseis
thethirdintheSteamSeriesofcourses.ItisrecommendedthatyoutakeSteamIandSteamII
beforetakingthiscourse.

Slide2
ThismodulewasproducedwiththesupportofSpiraxSarco.

Slide3
Forbestviewingresults,werecommendthatyoumaximizeyourbrowserwindownow.The
screencontrolsallowyoutonavigatethroughtheeLearningexperience.Usingyourbrowser
controlsmaydisruptthenormalplayofthecourse.ClicktheNotestabtoreadatranscriptof
thenarration.

Slide4
Atthecompletionofthiscourseyouwillbeableto:
Describethebasicsteamcircuit
Explainwhyadequatedrainageisimportant
Listthebenefitsofsteamandcondensatemetering
Namethemaincomponentsusedincontrollingandregulatingsteam
Explaintwotypicalapplicationsandtwotypicalmethodsoftracing
Identifythebenefitsofsteamandcondensatemanifolds

Slide5
Steamisoneoftheoldestandmostwidelyusedformsofenergyinindustry.Difficultiesinthe
energymanagementofsteamarisefromthefactthatitisoftenatotallyunmeasuredservice.
Thedistribution,controlandregulationofsteamiscrucialbecauseinefficiencytranslatesinto
additionaloperatingcosts.Thiscoursewillreviewthechiefcomponentsofsteamsystemsfor
controlofpressureandtemperature,andsystemaccessviamanifolds.Wewillalsoexaminethe
benefitsassociatedwithmeasuringsteamandapplicationsoftracing.
Slide6
Fromtheoutset,anunderstandingofthebasicsteamcircuit,steamandcondensateloopis
required.Thesteamflowinacircuitisduetothecondensationofsteamwhichcausesa
pressuredrop.Thisinducestheflowofsteamthroughthepiping.

Thesteamgeneratedintheboilermustbeconveyedthroughpipeworktothepointwhereits
heatenergyisrequired.Initially,therewillbeoneormoremainpipesorsteammainswhich
carrythesteamfromtheboilerinthedirectionofthesteamusingequipment.Smallerbranch
pipescanthencarrythesteamtotheindividualpiecesofequipment.

SystemsPartIII:Distribution,Control&RegulationofSteam
Transcript

ImagescourtesyofSpiraxSarco

Side7
Whentheboilercrownvalveisopenedadmittingthesteamintothedistributionpipingnetwork,
thereimmediatelybeginsaprocessofheatloss.Theselossesofenergyareintheheatingupof
thepipingnetworktothesteamtemperatureandnaturallossestotheambientairconditions.
Theresultingcondensatefallstothebottomofthepipingandiscarriedalongwiththesteam
flowalongthesteammain.Thiscondensatemustbedrainedfromthispipingorseveredamage
willresult.

Whenthevalvesservingtheindividualpiecesofequipmentcallforsteam,theflowintothe
heatexchangeequipmentbeginsagaincausingcondensationandtheresultantpressuredrop
whichinducesevenmoreflow.

Slide8
Sincewehavealreadyestablishedthatsteamsprincipaljobistogiveupitslatentheatenergy
andrecondensetowater,wecanassumethatitwilldosoanywhereandeverywherebecause
allheatflowisfromhottocold.Whenthesteamisadmittedintothedistributionpiping
network,thesteamimmediatelybeginstoheatthepiping.Thistransferofheatenergycreates
condensate,orifthepipingisalreadyatthesametemperatureasthesteam,therearestill
lossestotheambientairconditions,evenwheninsulated.Thisliquidcondensatewould
continuetobuilduptothepointofblockingallofthesteampipingifitisnotproperlyremoved.
Abuildupofwatercanleadtowaterhammer,capableoffracturingpipesandfittings.When
carriedintothesteamspacesofheatexchangers,itsimplyaddstothethicknessofthe
condensatefilmandreducesheattransfer.Inadequatedrainageleadstoleakingjoints,andisa
potentialcauseofwiredrawingofcontrolvalveseats.

ImagescourtesyofSpiraxSarco

Slide9
Wiredrawingcanoccurwhenavalveisoperatedforextendedperiodsclosetoitsshutoffpoint.
Waterflowerodesorscoresapathwayintheseatingmaterial.Thiserosionorgougeremains
openwhenthevalveisclosedtoitsoffposition.Smallflowsandpressurecreepcanoccur.

Periodicallyinasteamdistributionmainpipingnetwork,condensatedripstationsneedtobe
installedtoremovethiscondensatefromthesystem.Thesepocketsshouldbedesignedwithas
muchcareaspossible.Thisallowsthecondensatealowpointinwhichtodropoutofthesteam

SystemsPartIII:Distribution,Control&RegulationofSteam
Transcript

flowandberemovedbysteamtraps.WewilllearnmoreaboutthisinpartsIVandVofthis
seriesofclasses:includingtheenergyefficiencyvalueofrecoveringthecondensate!

Slide10
Aswesaidearlier,difficultiesintheenergymanagementofsteamarisefromthefactthatitis
oftenatotallyunmeasuredservice.Meteringstartingintheboilerhouse,isessentialifsavings
aretobevalidated.Althoughfuelconsumptionisfairlyeasytomonitor,measurementofsteam
isabitmoredifficult.Asteammetermustcompensateforqualityaswellaspressure,specific
volumeandtemperature.
ImagescourtesyofSpiraxSarco
Slide11
Performanceofdifferenttypesofmeterswhenusedonsteamwillvaryandthemeasurement
maynotalwaysbeaccurate.Mostmetersdependonameasurementofvolume.Sincevolume
dependsonpressure,measurementsneedtobetakenataconstantpressuretothemeteror
elsespecificcorrectionshavetobeapplied.Readingstakenunderfluctuatingpressure
conditionsareinaccurateunlessthemetercanautomaticallycompensate.

Steammeteringshouldbedonedownstreamofagoodqualityreducingvalvewhichmaintainsa
constantpressure.Readingsshouldbeinterpretedusingthemeterfactorandthemeter
calibrationshouldbecheckedfromtimetotime.

ImagescourtesyofSpiraxSarco

Slide12
Althoughsteammeteringismostoftencarriedoutintheboilerhouse,itisalsoimportantin
ordertodetermine:

1.Custodytransfer.Tomeasuresteamusageandthusdeterminesteamcost:
a)Centrallyattheboilerhouse
b)Atallmajorsteamusingareas

2.Equipmentefficiency.Identifyingmajorsteamusers,whenloadedtocapacityoridle;also
peakloadtimes,plantdeteriorationandcleaningrequirements.

3.Processcontrol.Metersindicatethatthecorrectsteamrequirementandquantityissupplied
toaprocess,whenbypasslinesareopened;andwhenvalvesandsteamtrapsneedattention.

4.Energyefficiency.Comparetheefficiencyofoneprocessareawithanother;monitorthe
resultsofplantimprovementsandsteamsavingprograms.

SystemsPartIII:Distribution,Control&RegulationofSteam
Transcript

Slide13
Steamisstillthemostwidelyusedheatcarryingmediumintheworld.Itisusedintheprocesses
thatmakemanyofthefoodweeat,theclotheswewear,componentsofthecarsthatweridein
andthefurniturethatweuse.Itisusedinhospitalsforsterilizationofinstrumentsandsurgical
packs,intherefiningprocessforcrudeoilbasedproducts,inchemicalproduction,andinthe
laundrythatcleansourclothes.

Despitethis,itiscommonlyregardedasanalmostfreeserviceeasilyavailable.Veryfew
attempttomonitoritsusageandcosts,astheywouldforotherrawmaterialsintheprocess.

Slide14
"Butasteammeterwon'tsaveenergy''.Thisstatementissometimesusedasareasonfornot
installingsteammeters.Itcannotbearguedagainstifsteammetersareevaluatedinthesame
wayasotherpiecesofenergysavingequipmentorschemes.

Astatement,suchastheonequotedhere,doeslittletoeasethefrustrationoftheEnergy
ManagerorFactoryManagertryingtoestablishwheresteamisbeingused,howmuchisbeing
usedandwhetheritisbeingusedwiselyandeffectively.

ImagescourtesyofSpiraxSarco

Slide15
Alltoooften,whentheneedforasteammeterisaccepted,onlycentralmonitoringi.e.inthe
BoilerHouseoramajorPlantRoomiscarriedout.Monitoringatbranchmainsorateachplant
room,asectionoftheprocessormajorpiecesofsteamusingequipment,arenotconsidered.

Whilecentralmonitoringwillestablishoverallsteamflowfigures(andthus,
costs),departmental'monitoringwillgivedatawhichismuchmoreuseful.Suchsteammeters
willenablecheckstobekeptonindividualplantperformance.Costscanbeanalyzedforeach
partoftheprocessandpayback'recordscanbeestablishedfollowingtheimplementationof
energysavingmeasures.

Wearededicatedtoprovidingyouwithrelevant,cuttingedgeeducationontopicspertinentto
energyefficiency.Pleasetakeourbriefsurveyandtellushowweredoing.
Howdoyoubegin?Itseasy!ClickontheHomeicon,locatedintherightcornerofyour
screen.ClickontheCourseSurveys"linkontheleftsideofthescreenunderBrowseCatalog.
Selectthecoursetitleyouhavejustcompletedandtakeourbriefsurvey.

SystemsPartIII:Distribution,Control&RegulationofSteam
Transcript

Slide16
Thesteammeteristhefirstbasictoolingoodsteamhousekeepingitprovidestheknowledge
ofsteamusageandcostwhichisvitaltoanefficientlyoperatedplantorbuilding.Themain
reasonsforusingasteammeterare:

PlantEfficiency
EnergyEfficiency
ProcessControl
CostingandCustodyTransfer

Clickeachofthesetoexplorethetopicsfurther.

Slide17
PlantEfficiency:Asteammeterwillindicateprocessefficiency.Forexample,whetheridle
machineryisswitchedoff;whethertheplantisloadedtocapacityandwhetherworking
practicesaresatisfactory.Itwillalsoshowthedeteriorationoftheplantovertime,allowing
optimalplantcleaningorevenreplacement,tobecalculated.Further,itcanestablishpeak
steamusagetimesoridentifysectionsoritemsofplantwhicharemajorsteamusers.Thismay
leadtoachangeinproductionmethodstoevenoutsteamusageandeasethepeakload
problemsontheboilerplant.

Slide18
EnergyEfficiency:Steammeterscanbeusedtomonitortheresultsofenergysavingschemes
andtocomparetheefficiencyofonepieceofplantwithanother.

Slide19
ProcessControl:Steammeterscanindicatethatthecorrectquantityofsteamisbeingsupplied
toaprocessandthatitisatthecorrecttemperatureandpressure.

Slide20
CostingandCustodyTransfer:Steammeterscanmeasuresteamusageandthussteamcost.
(a)Centrally
(b)Atmajorsteamusingcenters.
Steamcanbecostedasa'rawmaterial'atvariousstagesoftheproductionprocessthus
allowingthetruecostofindividualproductlinestobecalculated.

Slide21
Thepropercontrolandregulationofsteameitherinregardstosteampressureforequipment
orfortheflowofthisvaluableheatenergysourcetoheattransferequipmentismandatoryfor

SystemsPartIII:Distribution,Control&RegulationofSteam
Transcript

todaysindustrialandHVACsteamusersforefficientusageofthisenergysource.Thecontrolof
heatflowtoproducttemperaturesinprocessequipmentismandatory,otherwiseproduction
wastagebecomesintolerable,whichmeanslostprofits.

Thecontrolofsteampressuresandtheregulationofsteamflowtoheatexchangersis
accomplishedbyseveraldifferenttypesofvalves.

Slide22
Moststeamboilersaredesignedtoworkatrelativelyhighpressures,generallyabovethesteam
pressurerequiredinequipment,andshouldnotbeoperatedatlowerpressures.Operationat
loweredpressurescausesreducedefficienciesandincreasedpotentialforboilercarryover.For
thisreason,thehighestefficiencyismaintainedbygeneratinganddistributingthehighest
steampressuresthattheboileriscapableofproducing.Toproducelowerpressuresteamatthe
pointofuse,abuildingpressurereducingvalveshouldbeused.

Slide23
Thissystemdesignallowsformuchsmallerdistributionpiping,reducingthecostsandreducing
heatlossesfromthesepipes.Alsoeverypieceofsteamusingequipmenthasamaximumsafe
workingpressurewhichcannotbeexceededinoperation.Anotherenergyefficiencyreasonfor
reducingsteampressuresisthelatentheatcontentwhichisgreaterinlowerpressuresteam.
Moreheatcontentperpoundmeanslesspoundsofsteamtodothework.Thesearenotthe
onlyreasonsforreducingsteampressure.Sincethetemperatureofsaturatedsteamis
determinedbyitspressure,controlofpressureisasimplebuteffectivemethodofaccurate
temperaturecontrol.Thisfactisusedinapplicationssuchassterilizersandcontrolofsurface
temperaturesoncontactdryers.Reducingsteampressurewillalsocutdownonthelossesof
flashsteamfromventedcondensatereturnreceivers.

Slide24
Mostpressurereducingvalvescurrentlyavailablecanbedividedintothreegroups,organizedby
theiroperation:

DirectActingControlValves
PilotOperatedValves
PneumaticallyOperatedValves

Clickeachofthesetoexplorethetopicsfurther.

Slide25

SystemsPartIII:Distribution,Control&RegulationofSteam
Transcript

Thedirectactingvalveisthesimplestdesign.Thistypeofvalvehastwomaindrawbacksinthat
itallowsgreaterfluctuationofthedownstreampressure,underunstableloaddemands,and
thesevalveshaverelativelylowcapacityfortheirsize.Itisneverthelessperfectlyadequatefora
wholerangeofsimpleapplicationswhereaccuratecontrolisnotessentialandwherethesteam
flowisfairlysmallandreasonablyconstant.

Slide26
Whereaccuratecontrolofpressureorlargecapacityisrequired,apilotoperatedreducingvalve
shouldbeused.Thepilotoperateddesignoffersanumberofadvantagesoverthedirectacting
valve.Onlyverysmallchangesindownstreampressurearenecessarytoproducelargechanges
inflow.Theresultisavalvewhichgivesclosecontrolofdownstreampressureregardlessof
variationsontheupstreamsides.

Slide27
Pneumaticallyoperatedcontrolvalves,withactuatorsandpositionersbeingpilotedby
controllers,willprovidepressurereductionwithevenmoreaccuratecontrol.Industry
sophisticationandcontrolneedsaredemandingcloserandmoreaccuratecontrolofsystem
pressures,makingPneumaticcontrolvalvesmuchmorepopulartoday.

Slide28
Oversizing,acommonindustrypractice,shouldbeavoidedatallcostsregardlessofthetypeof
controlvalveselected.Avalvethatistoolargeincapacitycapabilitieswilltendtobeerodedand
almostalwaysallowmoreorlessflowthroughthevalvethanwasactuallyneededcausing
largerpressurefluctuationsdownstream.

Asmaller,correctlysizedreducingvalvewillbelesspronetowearandwillgivemoreaccurate
control.Whereitisnecessarytomakebiggerreductionsinpressureortocopewithwide
fluctuationsinloads,itisrecommendedtousetwoormorevalvesinseriesorparallelto
improvecontrollabilityandthelifeexpectancyofthevalves.

Slide29
Althoughreliabilityandaccuracydependoncorrectselectionandsizing,theyalsodependon
correctinstallation.
Sincethemajorityofreducingvalveproblemsarecausedbythepresenceofwetsteamand/or
dirt,asteamseparatorandstrainerwithafinemeshscreenisfittedbeforethevalve.Asapart
ofaPreventativeMaintenanceProgramallstrainersshouldbeinstalledwithblowdownvalves
forregulardirtremoval.

SystemsPartIII:Distribution,Control&RegulationofSteam
Transcript

Ifthedownstreamequipmentisnotcapableofwithstandingthefullupstreamsteampressure,
thenasafetyreliefvalvemustbefittedeitheronthedownstreampipingorthespecificpieceof
equipmenttobeprotectedfromoverpressurizationincaseofavalvefailure.Thissafetyrelief
valvemustbesizedtohandlethemaximumsteamflowofthereducingvalveatthedesiredset
reliefpressure.

ImagescourtesyofSpiraxSarco

Slide30
Mosttypesofsteamequipmentneedtoutilizesomeformoftemperaturecontrolsystem.In
processequipment,productqualityisoftendependentuponaccuratetemperaturecontrol,
whileheatingsystemsneedtobethermostaticallycontrolledinordertomaintainoptimum
comfortconditions.Fromanenergysavingsandqualitypointofview,controllingthesteam
energysupplytoaprocesspieceofequipmenttomaintainthedesiredproducttemperature,
whetherairoranyproduct,ismandatory.Ifprocesssystemsarenotcontrolledtothedesired
temperatures,thenthesystemwillrunwildeithernotprovidingtherequiredheatenergyor
overheatingtheproducttounacceptablelevels.

ImagescourtesyofSpiraxSarco

Slide31
Temperaturecontrolcanbeaccomplishedbyseveralmethodsandvalves:

ManualControlValves
SelfActingControlValves
PilotOperatedControlValves
PneumaticControlValves

Clickeachofthesetoexplorethetopicsfurther.

Slide32
Manualvalvescanbeappliedtoapieceofequipmenttocontroltheenergysuppliedtothe
processassimplyastheyareusedtoregulatetheflowofotherfluids.Themajordrawbackof
manualvalvestocontroltemperaturesisthatthesevalveswillundoubtedlyneedfrequent
adjustmentsandmonitoringtomaintainjustthecorrecttemperaturesunderconstantly
changingloadconditions,whichisthecaseofmostpiecesofprocessequipment.

Slide33

SystemsPartIII:Distribution,Control&RegulationofSteam
Transcript

SelfActingControlValvesareoperatedbyasensorsystemthatsensestheproduct
temperatures.Theycanbesettoanytemperaturebetweentheupperandlowerlimitsby
meansofanadjustmentknob.

Slide34
PilotOperatedTemperatureControlValvescontrolasmallpilotdevicewhich,inturn,operates
themainvalveforthrottlingofthesteamflow.Thesensingsystemismuchsmallerinphysical
size.Thesesystemstendtocontroltherequiredtemperaturesmuchclosertothedesiredlevels
andifandwhenaloadchangerequirementoccurs,thepilotoperatedvalvesareableto
respondtothesechangesmuchmorerapidly.

Slide35
PneumaticControlValvesrelyoncontrolsignalsfromanexternalsensingsystem,converting
thistemperaturesignalintoeitheracompressedairsignaltoactuate(throttle)thevalveorfrom
atemperaturesignaltoanelectricalsignal(4to20mA).Sensitivityandresponsetimeto
changesofloadconditionareenhancedwiththistypeofvalvesystem.Anotherbenefitofusing
thisarrangementofcontrolsystemistheabilitytoobservethevalvesopeningposition
externallybyeitheranindicatoronthevalvestemorbythecompressedairsignalappliedto
theactuator.

Slide36
Thedecidingfactorsfortheselectionofthepropercontrolvalvesystemforaspecific
applicationiscertainlythedegreeofaccuracyrequiredontheproductstemperatureandthe
responsetimetoloadchangesifthereareany.

Wehavelookedathowsteamisdistributedthroughatypicalsystem.Anotherinterestinguse
ofsteamistracing.

Therearetwotypicalapplicationsoftracing.Theyaretypicallyreferredtoaseitherprocessfluid
(critical)orfreezeprotection(noncritical)tracing.Therearedifferentrequirementsforeachas
farasheatisconcerned,sowewillseparatetheirrequirementspriortodiscussinghowto
attachtracingtotheapplication.

Tracingisasitsnameimplies,apipeortubefollowingeitherprocessfluidlinesorlineswhereit
isdesirabletopreventfreezingduringthewintermonths.Steamtracingisthedistributionof
steamthroughsmallboretubingorpipeswhichbasicallytransferheattoalargerpipetokeep
fluidsfrombecomingviscous,solidifyingorfreezing.

SystemsPartIII:Distribution,Control&RegulationofSteam
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SystemsPartIII:Distribution,Control&RegulationofSteam
Transcript

Slide37
Typically,processfluidsarealreadyatashighatemperatureasdesired.Theyhavepassed
throughheatexchangeequipmentandabsorbedasmuchheatasnecessarytokeepthe
viscositytoalevelthattheyflowsmoothlythroughthepiping.Tracingisinstalledrunningalong
thefluidlinesmainlytokeeptheproductatthespecifictemperatureitalreadyhas.Itis,
therefore,aheatmaintainer,andnotaheatexchanger.Becauseofthis,theconsumptionofthe
steamisusuallyverylow.Infact,itisoneofthesmalleststeamconsumersinagivenplant.The
factishowever,thatinsomeplants(suchasHydrocarbonProcessingfacilities),theyaccountfor
asmuchas70%ofthesteamusinglocations.Thefactthattheyconsumeverylittlesteamis
thenovershadowedbythesheernumberoflines.

Slide38
Inareaswherefreezingconditionsprevailduringthewintermonths,manydifferenttypesof
systemsrequireprotectionfromfreezeup.Obviously,theselinesarewaterlinesorperhaps
meteringequipmentthatusewaterinsensortubestodetectflowofgases,etc.Tracinglines
keepthewaterfromfreezingwhichwillinturnpossiblyrupturepiping,tubingorequipment.
Sometimes,liquidsthatwillnotnecessarilyfreezebecomeverythickifnotheatedandkept
heatedthroughouttheirprocessing.

Therearemanydifferentwaysofattachingtracingandtherearemanydifferenttypesor
methodsofusingthetracingconcept.Typically,tracingiscoppertubingattachedtoapipefilled
withsometypeoffluid.Anotherpopularmethodoftracingistheuseofjacketedpipe.This
methodoftracingisusedparticularlywhenthereisaneedtokeepafluid(suchassulphur)
fromsolidifyinginthepipes.

Slide39
Theeasiestmethodoftracingisbyattachingcoppertubingtothepipe.Itisusedmostly
becauseoftheabundanceofcoppertubingandthecostwhichisrelativelylow.Thetubingis
attachedinthelowerquadrantofthepipebeingtraced.Anotherimportantconsiderationin
tracingistoopposethetwoflows,fluidsintheprocesspipingandsteaminthetracertubes.
Thismaynotalwaysbepracticed,buttherearesomesolidreasonswhyyouwouldwantto
considerdoingthis.Thinkaboutwhatthetracerjobismaintainheatalreadyabsorbedbythe
processfluid.AsittransfersfrompointAtopointBintheplant,heatwillnaturallybelost
throughtheinsulation.Thejobofthetracerthenistoallowtransferoftheheatofthesteam
intotheflowingfluidsasitislosttotheatmosphere.
Slide40

SystemsPartIII:Distribution,Control&RegulationofSteam
Transcript

Thetracerlinethenshouldalsobeinstalledrunninginastraightlineasfartowardthebottom
ofthepipingaspossible.Thetracerishousedinsidetheinsulationwrappingonthepipe,and
wegainmuchbenefitfromattachingitinthismanner.Heat,whichyoumayrecall,rises
naturallyandsurroundsthepipingallowingforasmuchnaturalconductionofjoulesorBTUsas
possible.Thisheatbarrieralsoreducestheheatlossesfromtheprocessfluids.

Slide41
Onsomeoccasions,theamountofheatavailableandtemperatureofthesteamissuchthat
spacersareusedtopreventburningtheliquidsontheinsideoftheprocesslines.Thiscould
causecoking(burning)ofthelinesandalsorestrictflowoftheprocess.Whenspacersareused,
itisimportantthattheinsulationbesizedtoallowfortheextraspacerequired.Itmayalsobe
advisabletolabeltheoutsideoftheinsulationwithinformationsuchastracedandmaybe
eventhenumberoftracerlinesattachedalongwiththepressuresbeingused.Thismayhelpin
futuremaintenanceofthesystem.

Slide42
Theremaybetimeswhenthenumberoftracerlinesbeingusedcanbereduced.Forexample,a
processpipeduringthewintermonthsmayrequiremultipletracerlinestoensurethatthe
fluidsremainatthepropertemperature.However,duringthesummermonths,thenumbersof
tracerlinesmaybereducedbecauseoflessheatlossthroughtheinsulation.Someplantslist
thesteammanifoldheadernumberwheretheon/offvalvesmaybefoundtohelpwithreducing
theamountofsteambeingconsumedunnecessarily.

Slide43
Jacketedpipemaybeanalternativemethodoftracingusedwhentheprocessfluidsrequirea
hightemperaturetostayflowingwiththeleastamountofresistance.Theseliquidlinesare
usuallyfluidsthatsetupatveryhightemperaturessuchassulfur.Theyareveryspecialized
tracerlinesasthesteamjacketcompletelyencirclestheprocessfluidline.Thispipewithina
piperequiresspecialattentionandwillrequirespecializedtrapstoensureproperdrainage.
Jacketedpipeobviouslytransfersalotofheatincomparisontosteamtracerlinesmadeof
copperorstainlesssteel.

Slide44
Thistypeoftracerlineusuallyisusedwhenthetemperatureoftheprocessfluidisaboutthe
sametemperatureasthesteambeingused.Thelinesareusuallyflangefittedandthepassingof
steamfromonelinetothenextrequiressteamflowtoensurethepassageofsteamondown
thelines.Thischartwillhelpinsizingthesteamconnectionlineforthesizeofjacketedpipe
beingused.Eachjacketedlinehasaconnectionatthebottomonthedownstreamlinethatis
usedtodraineachsectionindividually.Thisisimportantbecausethisparticulartypeof

SystemsPartIII:Distribution,Control&RegulationofSteam
Transcript

specializedtraceristrulyactinglikeaheatexchanger.Thesteamconsumptionofthistypeof
tracingmaybemuchhigherthanthesmallertubingtypetracersusedinplants.

Slide45
Steammanifoldsaremosthelpfulinrunningthesteamtothesystem.Manifoldsareeasily
maintainedandlocatedasopposedtoindividuallyvalvingareasofaplant.Acentralizedlocation
formanifoldsensuresoperatorsofturningonandoffthecorrectvalvesfortracing.Manifolds
shouldbefittedwithatagthatidentifieswhatlinesaretracedandhowmanylinesaregoingto
thatparticularprocessline.Otherconsiderationsformanifoldingsteamlinesistheabilityto
controlautomaticvalvesonandoff.Ifthetracingonaparticularmanifoldisusedforfreeze
protection,ambientsensorsoncontrolvalveswillautomaticallyturnthesteamonwhen
needed.Thisensuresthatthesteamisturnedonandoffproperly.Theimportantwordhereis
off.

Slide46
Itisnotunusualtoseesteamlinesturnedonduringaparticulartimeofyear.Theconditions
maychangeatanygiventimeandthesteammaynotberequired.Ifthesteamisalwayson,
thenitisalwaysusedeveninsmallquantities.Thisiswastefulandshouldbeavoided.Asthis
coursehasmentioned,itisimportanttoconservethispreciousandcostlycommoditycalled
steam.Eventhoughtracingsystemsindividuallyusesmallamountsofsteam,rememberthe
sheernumbersoflinesthatmaybeinvolved.

Slide47
Condensatemanifoldsarealsoveryusefulinanytypicalplantthatusestracing.Thecondensate
manifolditselflocatestrapsandtracersinasmallgivenarea.Thecondensatefromthetracer
linesisusuallyveryhighqualitycondensateandshouldbecollectedandreturnedtotheboiler.
Thereisnormallynocrosscontaminationofproductfluidlinestotracerlines.Condensate
manifoldsalsomakeitveryeasytofindandmonitorthetracingtrapsbeingused.Eachtrap
stationonamanifoldshouldbetaggedwithanumberthatidentifiesthetrap,size,pressure,
etc.sothatamaintenanceprogramcanhelpdeterminethecorrectnessofeitherthetraps
beingselectedorsizeoftrapbeingused.Thesemanifoldscanbeeitherhorizontallyorvertically
designeddependingonthespaceavailableandthespecificationofanygivenplant.Wewill
learnmoreaboutcondensateintheotherclassesinthesteamseries.

Slide48
Letstakeamomenttoreviewwhatwehavecoveredthroughoutthiscourse.

SystemsPartIII:Distribution,Control&RegulationofSteam
Transcript

TheBasicsteamcircuitisasteamandcondensateloopwherethesteamsjobistogiveupits
latentheatenergyandrecondensetowater.

Itisimportanttometerandremoveanycondensatethattheheatfromsteampipescancreate.

Thebenefitsofmeasuringsteamincludeimprovementsinthefollowingareas:
PlantEfficiency
EnergyEfficiency
ProcessControl
CostingandCustodyTransfer

Controllingandregulatingsteamisnecessarytoavoidwaste.Thiscanbedonethrough:
PressureReducingValves
DirectActingControlValves
PilotOperatedValves
PneumaticallyOperatedValves
TemperatureControlValves
ManualControlValves
SelfActingControlValves
PilotOperatedControlValves
PneumaticControlValves

TwotypicalapplicationsofTracinginclude:
Process(Critical)Tracing
FreezeProtection(NonCritical)Tracing

TwotypicalmethodsofTracingare:
Coppertubing
JacketedPipe

SteamManifoldsaremosthelpfulinrunningthesteamtothesystem.Theyareeasily
maintainedandlocatedasopposedtoindividuallyvalvingareasofaplant.

CondensateManifoldsareveryusefulinanytypicalplantthatusestracing.Theselocatetraps
andtracersinasmallgivenarea.

Slide49
Thankyouforparticipatinginthiscourse.

SystemsPartIII:Distribution,Control&RegulationofSteam
Transcript

Slide50
Totestyourknowledgeofthecoursematerial,clicktheKnowledgeCheckpointlinkonyour
personalhomepage.
TheKnowledgeCheckpointlinkislocatedunderBROWSECATALOGontheleftsideofthepage.

Slide51
Wearededicatedtoprovidingyouwithrelevant,cuttingedgeeducationontopicspertinentto
energyefficiency.Pleasetakeourbriefsurveyandtellushowweredoing.

Howdoyoubegin?Itseasy!ClickontheHomeicon,locatedintherightcornerofyour
screen.ClickontheCourseSurveys"linkontheleftsideofthescreenunderBrowseCatalog.
Selectthecoursetitleyouhavejustcompletedandtakeourbriefsurvey.