STEAM AND

CONDENSATE SYSTEM
PRESENTED TO: ENGR. NASIR RAFIQUE
PRESENTED BY : SYED IHTASHAM JAVAID SHAH
(2017-UET-GSPCT-MECH-21)
7TH SEMESTER (2017-2021)
 STEAM SYTEM
• A steam system consists of a steam-supply/generating facility, a steam and
condensate return/water piping system.
• The steam-generating facility, located in the boiler room, consists of boilers,
feedwater systems, heat exchangers (e.g., economizers), boiler and system
controls.
• Fuel and gas handling equipment (e.g., fuel trains, stacks), and steam/water
treatment equipment and piping
 1.FEEDWATER

• The feed water is put into the steam drum from a feed pump.
• In the steam drum the feed water is then turned into steam from the heat. The
boiler receives the feed water, which consists of varying proportion of
recovered condensed water (return water) and fresh water, which has been
purified in varying degrees (make up water).
• The make-up water is usually natural water either in its raw state, or treated
by some process before use.
2. FEED WATER TREATMENT
• As steam is produced, dissolved solids become concentrated and form
deposits inside the boiler. This leads to poor heat transfer and reduces
the efficiency of the boiler.
• Dissolved gasses such as oxygen and Carbon dioxide will react with
the metals in the boiler system and lead to boiler corrosion.
INTERNAL WATER TREATMENT

• Internal treatment is carried out by adding chemicals to boiler to

prevent the formation of scale by converting the scale-forming
compounds to free-flowing sludges, which can be removed by
blowdown.
• Its purpose is to properly react with feed water hardness,
condition sludge, scavenge oxygen and prevent boiler
water foaming.
EXTERNAL WATER TREATMENT

• External treatment is used to remove suspended solids, dissolved

solids (particularly the calcium and magnesium ions which are a
major cause of scale formation) and dissolved gases (oxygen and
carbon dioxide).
• Some external treatment processes are:demineralization,reverse
osmosis and de-aeration.
CONT……

• The first stage of treatment is to remove hardness salt and

possibly non-hardness salts.
• Removal of only hardness salts is called SOFTENING,
while total removal of salts from solution is called
DEMINERALIZATION.
 3.ECONOMIZER

• Economizers are heat exchange devices

that heat fluids, usually water, up to but
not normally beyond the boiling point of
that fluid.
• Economizer fitted to a boiler which saves
energy by using the exhaust gases from
the boiler to preheat the cold water used to
fill it (the feed water).
 4.BLOW DOWN

• Boiler blowdown is the removal of water from a

boiler. Its purpose is to control boiler water
parameters within prescribed limits to minimize
scale and corrosion.
• It is necessary to control the level of concentration
of the solids and this is achieved by the process of
‘blowing down’, where a certain volume of water is
blown off and is automatically replaced by feed
water
5. STEAM TRAP

• Steam traps are a type of automatic valve

that filters out condensate (i.e. condensed
steam) and non-condensable gases such as
air without letting steam escape
6.STEAM SEPARATORS

• The steam separator is a device which

separates water particle from steam.
• It used to increase the dryness fraction
(quality) of steam before it enters into
turbine or engine.
7.CONDENSATE SYSTEM
• Condensate is a part of regenerative feed heating system-
• It also called as condensate recovery system,
• After condensing steam into water collected in the bottom of the condenser
(Hot Well).
• Steam after condensing into water in the condenser is known as condensate.
• Condensate extracted out from the Condenser Hotwell with the help of CEP
& deliever to the Deaerator through a series of GSC, Ejector, DC, LPH.
CONT….
• Condense Steam from the main turbine and steam drains/drips
collected in to the main condenser.
• Remove non-condensible gases from the main condenser.
• Provide a head to CEP from hotwell where condensate water is
reserved stored.
CONT…

• It also called Low Pressure Feed Water System because of it working

pressure is low.
• The condensate is again recirculated back to the boiler.
• The power plant cycle loses water through boiler blow down and different
vents and drains.
FLOW OF CONDENSATE THROUGH MAJOR
EQUIPMENTS
• HOT WELL
• CEP
• GSC
• EJECTORS (SJAE)
• CPU
• LP HEATERS
• DEAERATOR
ENERGY MANAGEMENT

Energy leaves a steam system as:

• Heat to the process
• Exhaust air
• Blowdown
• Condensate loss
• Flash vapor
• Heat loss from the boiler, steam pipes, condensate pipes and deaerator tank.
1.INSULATION

• Insulation helps ensure proper steam pressure

for production and can reduce radiative heat
loss from surfaces by 90 percent.
• steam pipes
• condensate return pipes
• condensate return tanks
• deaerator tank
• valves
2.FIX STEAM TRAPS

• If the trap fails open, steam escapes into the

condensate return pipe without being
utilized in the process.
• If trap fails closed, condensate fills the heat
exchanger and chokes-off heat to process.
• Fixing failed steam traps is highly cost-
effective.
3.PREHEAT BOILER FEED-WATER USING
EXHAUST AIR

• Economizer fitted to a boiler which saves

energy by using the exhaust gases from
the boiler to preheat the cold water used
to fill it (the feed water).
4.INSTALL AUTOMATIC BLOW DOWN CONTROLS

• Typical blowdown rates range from 4% to 8% of boiler feed-water.

• Manual Blow Down results in excess blow down that wastes energy or
insufficient blow down that creates excess scale on heat transfer
surfaces and reduces efficiency.
• Automatic blow down reduces energy, water and water treatment costs.
5. ADJUST FUEL/AIR RATIO

• Most boilers use linkages that connect natural gas supply valves
with combustion air inlet dampers.
• Unfortunately, the linkages do not function perfectly, and the
air/fuel ratio remain constant over the firing range.
• The linkages should be adjusted to maintain 10% excess air high
fire.
6.MINIMIZE STEAM PRESSURE

Generating steam at excess pressure:

• decreases boiler efficiency
• increases heat loss
• increases flash loss.
CONT…

• Reducing boiler pressure to match the highest required process

temperature decreases these losses.
• Reducing steam pressure to match local required process temperature
reduces flash loss.
• Thus, always produce and supply steam at the minimum pressure required
to meet the process temperature requirement.
Thanks For your
Attention