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Steam Conditioning – Part 1

Sunand Mohan
Director SDS & BU
Flow Controls

Emerson Confidential
Emerson Confidential
Agenda

Basics of steam conditioning

Understand Technical terms you might come
across while talking to customer
Impact of proper steam conditioning on
overall thermal efficiency of the plant
Basic Information Check List for Customer
Visit

Steam Conditioning Products

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 Steam Conditioning Loop – How it works?

TC
How it works?
• Basic Feedback Loop
• Bypass Valve is controlled such that the
Spray Water
desired outlet pressure is achieved
PC • Spray water Valve is controlled such that the
PT
TT desired outlet temperature is achieved
TE
Where do these valves find their use?
• Power Plants
• Refinery, Petrochemical, Chemical Facilities
• Pulp and Paper, Metals and Mining

Inlet: Superheated Steam Outlet: Conditioned Steam What are the applications?
• Turbine Bypass
• Steam PRDS

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 Steam Conditioning – Typical Data and our Solution

TC

Spray Water
Pressure: 1000 psig
PC Temperature: 250 ⁰F
TT
PT
TE

At DSH Inlet:
Pressure: 600 psia
Temperature: 700 ⁰F
Inlet: Superheated Steam Outlet: Conditioned Steam
Pressure: 800 Psia Pressure: 600 psia
Temperature: 720 ⁰F Temperature: 500 ⁰F

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Understanding Steam Properties
Steam Conditions
Pressure – 600 psia Dry Superheated • Suitable for
Temperature – 700 ⁰F steam, say point D mechanical work ,
running turbines
700 • 10degF reduction
yields 4.7 Btu per
D pound – inefficient
for heat transfer
A B
C Steam near • Suitable for heat
saturation point, say transfer
point C
• 10degF reduction
yields 970 Btu per
pound – efficient for
Saturation Point Two phase zone heat transfer
Point A Between Point A & B

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Saturation Temperature

Steam Conditions
Pressure – 600 psia
Temperature – 700 ⁰F

700
Saturation Temperature
The thermodynamic state of equilibrium between the
vapor and liquid phase where they both exist at the
same temperature. For each pressure there is only one
saturation temperature and vice versa.

For Steam at Pressure 600 psia, the saturation

temperature is 486 ⁰F

**Steam conditions close to Saturation is good for heat

transfer
**Recommended outlet steam temperature is 10 ⁰F
greater than the saturation temperature

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Superheat

Steam Conditions
Pressure – 600 psia
Temperature – 700 ⁰F

700
Superheat is the difference between
the Steam Temperature and Saturation
Temperature

In this case, Superheat is 214 ⁰F

700 ⁰F - 486 ⁰F = 214 ⁰F

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Enthalpy

Steam Conditions
Pressure – 600 psia
Temperature – 700 ⁰F

700
Enthalpy
A thermodynamic quantity,
equivalent to the total heat content of a
system

In this case, Enthalpy of the steam is

1350 BTU/LBM

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 Understanding Steam Conditioning Specification
msteam in*hsteam in + mwater*hwater = (msteam in + mwater)*hout
TC
100*1350.8 + 13.482*220.7 = (100+13.482)*1216.5

Spray Water
Pressure: 1000 psig
PC Temperature: 250 ⁰F
PT Mass Flow: 13.482 tph TT
Enthalpy: 220.7 Btu/lbm TE

At DSH Inlet:
Pressure: 600 psia
Temperature: 700 ⁰F
Enthapy: 1350.8 Btu/lbm
Superheat: 214 ⁰F Outlet: Conditioned Steam
Inlet: Superheated Steam Pressure: 600 psia
Pressure: 800 Psia Temperature: 500 ⁰F
Temperature: 720 ⁰F Mass Flow: 113.482 tph
Mass Flow: 100 tph Enthalpy: 1216.5 KJ/Kg
Superheat: 13.8 ⁰F
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 Straight Pipe Length - SPL

TC

Spray Water
Pressure: 1000 psig
PC Temperature: 250 ⁰F
TT
PT
TE

Straight Pipe Length

SPL

Inlet: Superheated Steam Outlet: Conditioned Steam

Pressure: 800 Psia Pressure: 600 psia
Temperature: 720 ⁰F Temperature: 500 ⁰F

Straight Pipe Length - Distance at which it is acceptable to change direction without

concerns of water impingement. Normally within first 10 to 40 feet
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 Temperature Sensor Length - TSL

TC

Spray Water
Pressure: 1000 psig
PC Temperature: 250 ⁰F
TT
PT
TE

Temperature Sensor Length

TSL
Inlet: Superheated Steam Outlet: Conditioned Steam
Pressure: 800 Psia Pressure: 600 psia
Temperature: 720 ⁰F Temperature: 500 ⁰F

Temperature Sensor Length - Distance at which complete vaporization happens.

Normally 20 to 100 feet (depends on DSH, Steam mass and velocity)
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Key Parameters
• Outlet Steam Temperature
– At least 10degF greater than the saturation temperature
• Spray Water conditions
– Pressure – at least 100 to 150 psi greater than steam
pressure – higher is better, helps in achieving complete
atomization of spray water
– Temperature – Hotter is better
• Valve Orientation
– Horizontal and Vertical Down installation are common
• Actuator Orientation
– Vertical up is recommended

Vertical Inlet & Horizontal Inlet &

Horizontal Outlet Vertical Outlet

Emerson Confidential
Importance of Steam Conditioning Valves
• Plant Efficiency
– Steam conditioning valves in Turbine Bypass application is critical to protect the steam turbine. Malfunction could
lead to turbine trip
– These valves need to provide tight shutoff to avoid steam leakage for two reasons
• Every pound of steam costs to customer and unnecessary leakage is direct loss of profits
• Steam leakage leads to increase in downstream pressure affecting condenser pressure, thereby affecting the
plant efficiency
• Protect Downstream Equipment's
– These valves should provide top performance by precisely controlling the outlet steam pressure and temperature.
• For instance, in paper industry, if the outlet steam temperature is not precisely controlled by the steam
conditioning valve, it will impact the paper quality

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 Steam Conditioning – Checklist for Customer Visit
TBX/315 – Flow Up CVX/TBX/115 – Flow Down
TC Inlet: Superheated Steam
Pressure:_____
Temperature:_____
Spray Water Steam Mass Flow:______
Pressure: _____ Line Size & Schedule:______
PC Temperature: _____
TT
PT
TE

Spray Water
SPL: ______ Pressure:_____
Temperature:_______

TSL:______ TE
SPL:______
Inlet: Superheated Steam Outlet: Conditioned Steam
Pressure: ______ Pressure:_______
Temperature: _____ Temperature: ________
Steam Mass Flow:_____ Line Size & Schedule: ______ Outlet: Conditioned Steam
Line Size & Schedule: ______ Pressure:________
TSL:______ Temperature:_______
Line Size & Schedule:______
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 THANK YOU!!!
For any questions or support,
you can reach,
Sunand Mohan
Sunand.Mohan@emerson.com
P.R. Balaji
PR.Balaji@emerson.com

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