Measurement of Steam Consumption

Methods of measuring steam consumption, from the very basic to sophisticated flow
metering, are explained in this tutorial.

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By a steam flowmeter
The use of a steam flowmeter may be used to directly measure the steam usage of an
operational item of plant. This may be used to monitor the results of energy saving
schemes and to compare the efficiency of one item of plant with another. The steam can
then be costed as a raw material at any stage of the production process, so that the cost of
individual product lines may be determined.

It is only in comparatively rare cases that a meter cannot measure steam flow. Care
should be taken, however, to ensure that the prevailing steam pressure is considered and
that no other calibration factor has been overlooked.

Steam flowmetering is discussed in detail in Block 4.

Fig. 2.7.1
Typical steam flowmeter installation
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By a condensate pump
A less accurate method of estimating the steam consumption is by incorporating a
counter into the body of a positive displacement pump used to pump condensate from the
process. Each discharge stroke is registered, and an estimate of the capacity of each
stroke is used to calculate the amount of steam condensed over a given time period.

Fig. 2.7.2
Positive displacement pump with cycle counter

A purpose built electronic pump monitor can be used which enables this to be carried out
automatically, converting the pump into a condensate meter. The electronic pump
monitor can be read locally or can return digital data to a central monitoring system. If
the pump is draining a vented receiver, a small allowance has to be made for flash steam
losses.

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By collecting the condensate

Steam consumption can also be established directly, by measuring the mass of
condensate collected in a drum over a period of time. This may provide a more accurate
method than using theoretical calculations if the flash steam losses (which are not taken
into account) are small, and can work for both non-flow and flow type applications.
However, this method cannot be used in direct steam injection applications,
humidification or sterilisation processes, where it is not possible to collect the
condensate.

Figure 2.7.3 shows a test being carried out on a jacketed pan. In this case an empty oil
drum and platform scales are shown, but smaller plant can be tested just as accurately
using a bucket and spring balance. This method is quite easy to set up and can be relied
upon to give accurate results.

Fig. 2.7.3
Equipment for measurement of steam consumption

The drum is first weighed with a sufficient quantity of cold water. Steam is then supplied
to the plant, and any condensate is discharged below the water level in the container to
condense any flash steam. By noting the increase in weight over time, the mean steam
consumption can be determined.

Although this method gives the mean rate of steam consumption, if the weight of
condensate is noted at regular intervals during the test, the corresponding steam
consumption rates can be calculated. Any obvious peaks will become apparent and can be
taken into account when deciding on the capacity of associated equipment. It is important
to note that the test is conducted with the condensate discharging into an atmospheric
system. If the test is being used to quantify steam consumption on plant that would
otherwise have a condensate back pressure, the steam trap capacity must relate to the
expected differential pressure.

Care must also be taken to ensure that only condensate produced during the test run is
measured. In the case of the boiling pan shown, it would be wise to drain the jacket
completely through the drain cock before starting the test. At the end, drain the jacket
again and add this condensate to that in the container before weighing.

The test should run for as long as possible in order to reduce the effect of errors of
measurement. It is always advisable to run three tests under similar conditions and
average the results in order to get a reliable answer. Discard any results that are widely
different from the others and, if necessary, run further tests.
If the return system includes a collecting tank and pump, it may be possible to stop the
pump for a period and measure condensate volume by carefully dipping the tank before
and after a test period. Care must be taken here, particularly if the level change is small or
if losses occur due to flash steam.

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Questions
Relative questions on this subject will be asked in Block 4, 'Flowmetering'.

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What do I do now?
• The printable version of this page has now been replaced by
The Steam and Condensate Loop Book
• Try answering the Questions for this tutorial
• View the complete collection of Steam Engineering Tutorials

Steam Engineering Principles and Heat Transfer

• Engineering Units
• What is Steam?
• Superheated Steam
• Steam Quality
• Heat Transfer
• Methods of Estimating Steam Consumption
• Measurement of Steam Consumption
• Thermal Rating
• Energy Consumption of Tanks and Vats
• Heating with Coils and Jackets
• Heating Vats and Tanks by Steam Injection
• Steam Consumption of Pipes and Air Heaters
• Steam Consumption of Heat Exchangers
• Steam Consumption of Plant Items
• Entropy - A Basic Understanding
• Entropy - Its Practical Use

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