Steam Systems

Basics, Challenges and

Troubleshooting
John Cilyo
Senior Account Executive
Spirax Sarco Inc.
For
Steve Jalowiec, PE, CHFM
Steam Systems & Chaos Theory
In mathematics, chaos theory describes the
behavior of certain dynamic systems – that is, systems
whose states evolve with time – that may exhibit
dynamics that are highly sensitive to initial conditions
(popularly referred to as the butterfly effect). As a result
of this sensitivity, which manifests itself as an
exponential growth of perturbations in the initial
conditions, the behavior of chaotic systems appears to
be random. This happens even though these systems
are deterministic, meaning that their future dynamics
are fully defined by their initial conditions with no
random elements involved. This behavior is known as
deterministic chaos, or simply chaos.
 Steam Systems & the 2nd Law
Second Law of Thermodynamics
• The entropy of an isolated system not in equilibrium will
tend to increase over time, approaching a maximum value at
equilibrium.
• In a simple manner, the second law states "energy systems have a
tendency to increase their entropy rather than decrease it." This can
also be stated as "heat can spontaneously flow from a higher-
temperature region to a lower-temperature region, but not the
other way around." (Heat can flow from cold to hot, but not
spontaneously—- for example, when a refrigerator expends
electrical power.)
• A way of thinking about the second law for non-scientists is
to consider entropy as a measure of disorder. So, for
example, a broken cup has less order (more entropy) than an intact
one, and it is more difficult to repair a broken cup (reducing its
entropy) than to break an intact one (increasing its entropy).
Likewise, solid crystals, the most organized form of matter, have
very low entropy values; and gases, which are very disorganized,
have high entropy values.
Basic Steam System
Another view of a Steam System
Loads
Radiators, Sterilizers
Heat Exchangers, etc

Steam
Header Steam
Traps

BOILER
Condensate
Return
Piping
(Treated)
Make up water

Deaerator
Condensate
Return Tank
 Steam System Basics
• Boiler Design
• Water Tube, smaller steam space, need to be run closer to
design pressure
• Fire Tube, large steam chest, can be run a lower than design
pressure.
• Definitions
• "Carryover" means that you have a problem with the TDS (total
dissolved solids). You need to properly define the PPM values
needed. Fire tube boilers have a normal TDS of 3000 ppm, while
water tube designs need 2000 ppm. Everyone uses the 3000
ppm value regardless of boiler type and that is their first mistake.
• "Priming" is a mechanical condition caused by too great of a
takeoff velocity (50 to 100fpm).This is corrected mechanically.
• Testing
• With the boiler running, take a condensate sample from a drip pocket on
the main header. If you see a high TDS value (say 2000 PPM), you
have a carryover issue. If your value is 5 ppm or is immeasurable, you
have priming. Remember, steam has no TDS!
 Steam systems have many end uses in
hospitals; radiators, heat exchangers,
humidification but probably none as critical
as Steam Sterilizers
 Your Objectives
(Challenges)
• Deliver good quality steam to heating,
humidification and process equipment.
• Operate the system safely.
• Get maximum efficiency from heating
equipment - energy $$$
• Maintain the system at a reasonable cost.
Steam Has Another Objective In Mind!
(Challenges)
• Condenses anywhere and everywhere it
can.
• Happily fills the system with air, in the
worst possible locations.
• Carries entrained water, gases, chemicals
and dirt into every nook and cranny.
• Will slow down and stop flowing as soon
as differential pressure is lost.
 Your Mission Is To Stay Ahead of
Potential Problems
(Challenges)
• Test/maintain steam traps routinely.
• Clean strainers!
• Clean and maintain regulators/control valves
• Routine maintenance of condensate pumps.
• Keep an ear open for excess pipe-line water-
hammer & correct the root-cause.
• Watch for repeat instances of valve wire-draw &
correct root-cause (wet steam, valve sizing)
• Recognize that water hammer in heat
exchangers and heating coils is correctable.
 Challenges
No problem – right?
All it takes is money and manpower!
Anyone here have enough of both?

But there is help:

• Boiler Water Treatment Company
• Steam Specialty Companies
• Steam Consultants
• Some of these can help for free, some will
cost.
 Steam System Challenges
• Remember Steam Systems are dynamic systems
• Never Steady State
• Loads coming on and off
• Sterilizers
• Heating coils
• Steam Absorption Chillers
• Manual Building Heat (Old fashion radiators)
• System Sizing
• Sized for steady state or instantaneous loads (sterilizers)
Steam System Troubleshooting
Myths
• My boilers never carry over, prime, etc.
• The water level is always steady in the gauge
glass.
• I don’t need trap maintenance, failed traps will
become apparent on their own. (The water
hammer will tell me about a bad trap.)
• Boiler water treatment is a scam.
• Boiler blow-down wastes energy and water.
Steam System Troubleshooting
Steam System Chemistry
• Feed Water Quality
• Softener
• Deaerator
– Dissolved O2 and non-condensable gases
• Chemical Treatment
• Totaled Dissolved Solids (TDS)
• Blow down
• Continuous Surface
• Bottom Blow Down
 Typical Steam System Chemistry
(May vary with chemical supplier and boiler manufacturer)

Test Typical Softener Feedwater Boiler Condensate Deaerator

Limits Return
Low/Hi
pH See chart > 8.5 8.3 – 9.4
Sulfite % So2 30/60 XX XX
(Higher in lay-up)
Alkalinity P 200/400 XX
Alkalinity M 250/500
Silica Monitor XX XX
trends
< 150 mg/L
Conductivity 3000/3500 XX XX XX
Calcium < 0.3/FW XX XX XX
Iron < 0.1/FW XX XX
Copper < 0.05/FW XX XX
Primary Per XX
Treatment Chem. mfg
Dissolved O2 7 ppb XX
 Typical Boiler Water Treatment Test Report
(partial)
Status Polytreat Sulfite Alkalinity Silica Conductivity Calcium Iron Copper
TL-200 as SO3 P M pH

Boiler 2 Lead 18.5 110 370 510 - 77.6 2886(N) -

Boiler 3 Open - - - - - - - -

Softener 2 6.0 129 0.17

Pwr. Plnt. cond. 8.60 45 0.05 0.03 0.03

MR1 cond. - - - - -

Kitchen Dish. - - -

condensate

Sub base. large - - -

Feedwater 3.6 8.35 2.2 72 0.26 0.10 0.03

Recommended
Low/ __10__ _30_ _200 _250 _8.0_ Record __3000__ _< .3_ _< .1_ _< .05_
High 20 60 _ _ 8.5 3500 FW FW FW
Limits
400 500

Courtesy of Barclay Water Management, Inc.

Steam System Troubleshooting
• Water Level Control
• Sight glass levels are not reliable
• Variable feed versus on/off
• Steam Flow Metering & Data
• Data is invaluable for system troubleshooting
“
You cannot manage what you
cannot measure”
Lord Kelvin
Why is proper condensate drainage
important?
Water hammer!

Result of a drip trap being removed, that was

draining a 100 psig line, before a valve
Steam System Troubleshooting
• Steam Traps

• Properly located

• Drip Legs properly sized

• Trap Selection and sizing

• Steam Trap Testing & Maintenance

Steam System Troubleshooting
• Steam Traps
• Main Header Main header drip legs are full size
• Other drip legs are properly sized
• Drips located 300’ or less and any change of
elevation
• Drip stations located ahead of automatic valves
• Steam traps are properly sized
• Steam traps are working and maintained
• Missing insulation
• heat goes to cold
• another consequence of the 2nd law thermodynamics!
Ineffective vs Proper Drain Points
Steam Flow

Condensate
Cross Section

Correct Full


Diameter Steam Trap Set
Pocket

Incorrect
Steam Flow

 Steam Trap Set

Cross Section
 Steam System
Troubleshooting
Steam Trap Testing
• Visual *
• Temperature **
• Ultrasonic ***
• Continuous monitoring systems ****
• conductivity
 Steam System Troubleshooting
• Belts & suspenders
• Steam separators & filters

Wet Steam Dry Steam

Condensate Outlet
 Steam Conditioning
Dry Steam saves energy
Example: Process requires 4,645,000 Btu’s / hr
Available: 30 psig steam @ 274oF
@ 100% Dry (saturated) steam supplies 929 Btu / lb.
 process requires 5,000 lb/hr.
@ 90% Dryness Fraction, steam supplies 836 Btu/lb. 
process now requires 5556 lb /hr. A 11% Increase
@ 80% Dryness Fraction, steam supplies 743 Btu/lb 
process now requires 6251 lb /hr. A 25% increase
 Steam System
Troubleshooting
• Condensate equipment operating properly
• Pumps
• Flash tanks
• Loads
• Varying loads
• Instantaneous loads - Sterilizers
 Steam System Troubleshooting
Now what do I do
If you suddenly have problems
• What has changed?
• Go back to basics
• Start at the boiler plant and work your way out
into the system
• Left Hand Analysis
Courtesy of Walt Graham Thermo Diagnostics, Co, LLC
 Now what do I do
• Steam Trap Repairs
• Steam Trap Survey & Assessment
• Steam Trap Maintenance Program
• Boiler Water Treatment Modification
• Steam Conditioning Equipment
• Separators
• Filters
• Repair damaged insulation
• Steam Metering (for troubleshooting)
 Thank you!
• Questions or Comments
• Special Thanks to
– John Cilyo, Spirax Sarco
– William Wethey, Barclay Water Management
• Contact Information
– Steve Jalowiec, PE, CHFM
– Waterbury Hospital, 64 Robbins Street, Waterbury CT
– Work 203-573-7197
– Cell 203-228-3480