Boilers &

Steam Systems
Packaged Boiler
Three pass Fire tube Boiler
Cochran
Boiler
Locomotive Boiler
Locomotive Boiler
Lancashire Boiler
Lancashire Boiler
Lancashire Boiler
Water tube Boiler
Water tube Boiler
Water tube Boiler….
Water tube
Boiler
Agro waste fired water tube Boiler
Coal fired water tube Boiler
Steam Drum
Electric Boiler
Pressure gauge
Siphon for Bourden tube Pressure guage
Dead weight Safety Valve
Dead weight Safety Valve
Rams bottom Safety Valve
Safety Valves…….
Spring loaded Safety Valve
Water level Indicator
Water level Indicators……types
Water level Indicator
Three Element Control
Three Element Control
Fusible PLug
Fusible Plug
Pressure Reducing Valve
PRV
PRV
PRV
Blow Down Valve…..Manually Operated
Swing Check Valve
Ball Valve
Ball Valve
Ball Valve
Butterfly valve
Butterfly Valve
 Why Steam ?

 Highest specific heat and latent heat

 Highest heat transfer co efficient
 Easy to control and distribute
 Cheap and inert
 Uses
 For power generation
 For process industries
-- For process heating
-- For drying
Some user industries
Sugar
Paper
Fertilizer
Refinery
Chemical
Food
Petrochemical
 Length
1 inch =2.54 cm

Weight
1 Kg = 2.205 Lb

Area
1sq inch = 2.54 x2.54 =6.45 cm2
 Volume
1 litre = 1000 cc
1 cubic feet = ?
Temperature
0
C = [0 F –32] x 5/9
0
F = [0 C x 9/5 ] + 32
Pressure
1 Kg/ cm 2 = 2.205 / 1/2.54 x 1/2.54
= 2.205x2.54x2.54 =14.23 psi
 PROPERTIES OF STEAM
Heating water at constant pressure
Weight

Piston

Water

Heat
 Saturation
curve
T

Sat temp
Super heated
Liquid steam
Liquid +
vapour

hf hfg hg

Enthalpy
 Specific heat
The quantity of heat required to raise the
temperature of One Kg of material by 10C
For water =1 Kcal/Kg/ 0C

Sensible heat [hf]

The heat required to change the temperature
of a substance is called sensible heat

[ 1 Kg of water at 250 C is brought to 1000 C by

adding 75 Kcal]
 Saturation temperature

The temperature at which the water changes

into steam is called the boiling point or the
saturation temperature

[The temperature of the saturated steam is the

same as the water from which it is generated
and corresponds to a fixed and known
pressure]
 Latent heat [hfg ]

To change water to steam an additional 540

Kcal would be required.The quantity of heat
required to change the chemical from liquid to
gaseous state is called latent heat.

The phase change occurs at constant

temperature
 Degree of super heat

Super heating is the addition of heat to dry

saturated steam with out increase in pressure

The temperature of super heated steam

expressed as the degrees above the
saturation temperature corresponding to the
pressure is referred to as the Degree of super
heat
 Enthalpy of dry steam
This is the total heat content of steam
hg = hf + hfg
Dryness fraction
x = mass of dry vapour / mass of
contents
= mg / m f + m g
 Wetness
= mf / mf+ mg
=1-x

Enthalpy of wet steam

h = hf + x hfg
Heat addition due to super heating
=Cp [ tsup –t]

Enthalpy of super heated steam

= hg + Cp [ tsup –t]
 Volume of steam
V = Vf + m[Vg-Vf]
= mVg

Superheated steam-volume
Behaves as a Perfect gas
Pg Vg / Tg = Psup Vsup / Tsup
Vsup = Vg Tsup / 273 + t
 Question: ???
Boiler operates at 8 Kg/cm2 Steam sat temp
–170 0C

a] Find the total heat

b] If the steam contains 4 % moisture find

the total heat
 Ans:
a] Total heat
hg = hf + hfg

=171.35 +489.46 =660.81 Kcal/Kg

b] wetness = 4%
dryness fraction = x = 1- .04 =0.96
Total heat of wet steam
hg = hf + x hfg
=171.35 +0.96 x 489.46 =641.23
Kcal/Kg
 Critical Pressure
The pressure at which the latent heat of
vapourisation is zero ie; water will directly
change into steam if the temperature is
raised to the saturation temperature

Psup cr = 3206.2 psi

= 225.3 Kg/ cm 2
Tsup cr = 705.40F
= 374.10C
REMAINING SLIDES FOR
REFERANCE AND ADDITIONAL
INFORMATION
 STEAM DISTRIBUTION

Pipe sizing
Mains drainage
General lay out and fittings
Boiler

Equip-3

Equip-1

Equp-2

Too long – radiation loss

high cost
small - starvation
 STEAM PIPE SIZING

Pressure drop
Frictional resistance
Fittings
Usual allowance for fittings is 10 % for
30 metres
 Velocity

Superheated 50 – 70 m/sec
Saturated – 30 – 40
m/sec
Wet 20 – 30 sec
Inversely proportional to 5th power of
diameter
D = 12√CFM
0.7854F

CFM – Cubic feet /minute

D – Dia inches
F – Velocity f/minute
 PIPE REDUNDANCY

Avoid redundancy (usually 10 – 15 %)

Use the shortest route

Care should be taken to include the

thermal expansion
 DRAIN POINT
100 mm lagged pipe 30 metres
length 7kg/cm2 can condense
10kg/hr.

may result in water hammer

wet steam
150 km/hr

150 km/hr
 PROVISION FOR EXPANSION
Pipes filled cold will expand when steam
passes

May result in the loss of original slope

Anchorage to be provided for the expansion

fittings

Feed line, main steam line etc. to be

anchored
 Types
Loop
Slip bellows
Bellows
Corrugated pipe
Smooth sleeve with slide
 LENGTH OF EXPANSION

(t1 – t2) x L x 0.00065) inches

t1= steam temperature

t2= room temperature
L = horizontal length
 Expansion joint

Smooth sleeve with slides in an out

through a packing box (Used for LP
steam)
 Pipe supports

Side /forward movement – allowed

Vertical movement - not allowed
Supports – to carry full load
Hanger type - have adjustable turn
buckle
 BRANCH LINE & FITTINGS

All branch lines should be from top

900 elbow – No
concentric reducer - no
eccentric reducer – yes
900 bend (wide sweeping) - yes
 Steam Separator

used for separating moisture carried by

the steam.

centrifugal steam separator

baffle type
 STEAM TRAPS
1. bucket traps
-- open bucket
-- inverted bucket
the movement of a bucket as it is
filled and emptied causes the discharge
valve to open and the steam pressure then
forces the condensate out of the traps. As
the bucket empties it returns to the
original position and closes the discharge.
BUCKET TRAP
 2. Ball and float type
contains a hollow metallic float. As
the trap fills with the condensate the
float rises and open the discharge
valve. As steam pressure empties the
trap the float sinks and the discharge
valve closed.
FLOAT TRAP
 3. Thermostatic (expansion type)
the expansion and contraction of
metallic element in the trap by oil in
sealed cartridge acting upon a sealed
plunger(usually a metallic bellows to
facilitates to the expansion)
 4. Bimetallic trap
the above action is caused
instead of the bellows by a
bimetallic element
 5. Thermo dynamic
as the condensate enters it lifts
the disc allowing the condensate flow.
When steam enders the flow velocity
is high resulting in reduced pressure
below valve seat and higher pressure
above the seat, causing it to close.
 p

condensate
Valve lifts

P
b) steam

Valve closes

p
TD TRAP
TD TRAP
Steam traps…….
 INSTALLATION OF STEAM TRAPS
Drain point
Pipe sizing
Air lock
Group vs individual traps
Dirt
Water hammer
Condensate lifting
 MAINTENANCE
Dirt / scale
Use strainers
Sight glass
Maintenance schedule
GUIDELINE FOR SELECTION
 POINTS TO BE NOTED FOR STEAM
DISTRIBUTION

-Shortest route, proper size of piping

-Slope to the direction of flow (125 mm to 30
metres)
-Use of eccentric sockets for reduced mains
-Re-laying the mains for long distance
-Provision for expansion – anchoring
-Supports - no vertical movement

-Branching only from top.

-Avoid 900 elbows Use long sweep bends.

-Use reducing valves for low pressure lines

(Install pressure gauge and safety valve)
-Lagging
-Draining points, equal tee, proper traps – 30
– 45 metres interval
-Install separators
-Avoid trapping as far as possible
-Boilers to common header – slope towards
boiler ends with provision for condensate
drain out
-Steam traps – horizontal installations. (open
bucket/TD traps)
 ECONOMY MEASURES

--Lowest pressure practicable

--Right quality of steam
--Never supply more than required
--Reduce unnecessary demand by
isolating

--Condensate recovery

--Surface loss to be kept minimum

--Supply to be maintained at steady

pressure
 ENERGY SAVING OPPORTUNITIES
1. Monitoring steam traps
Condensate discharge
Flash steam
Continuous blow - leak
Intermittent blow – flash
steam
Continuous flow /no flow
2. Steam leakage (avoid)

--3 mm dia hole in pipe 7kg/cm 2

Loss = 33KL of FO /year.
--Plugging all leakes – 5% savings in
steam consumption
Plume length 700mm
Steam loss 10kg/hr
 3. DRY STEAM FOR PROCESS
Reduces total heat
Wet film - slow heat treat
Dryness fraction – 0.95 without super
heater
Lagging
Steam separator
 4. UTILIZE STEAM AT THE LOWEST
ACCEPTABLE PRESSURE FOR THE
PROCESS

-latent heat (high for LP)

-heat transfer (high at high temperature)
(balance them for indirect heating)
 5. PROPER UTILIZATION OF DIRECTLY
INJECTED STEAM.

Cheap equipment
No condensate recovery system
Used only when dilution and agitation
allowed.
Pressure – 0.5 to 1 kg/cm2
2mm – 5mm holes in the distribution pipes.
 6. MINIMISE HEAT TRANSFER
BARRIERS

Direct contact
Intermediate heating surface
Barriers
Air film
Condensate film
Inside scale
Metal
Outside scale
Stagnant product
Air - 1500 times resistance than steel

13000 times resistance than copper

air ingress during condensing / start ups

etc.
 7. PROPER AIR VENTING

-0.2 mm air film = 330 mm thick copper.

-It reduces the partial pressure
-drops the overall temperature
-provide air venting provisions.
 8. CONDENSATE RECOVERY

-25% of the total heat in steam leaves as

condensate.
-600C rise in feed water temperature – 1%
saving in fuel.
-Boiler water to be treated – condensate is
nearly pure.
-Reduces water treatment cost
9. INSULATION OF STEAM PIPE / HOT PROCESS
EQUIPMENT

-Heat loss due to radiation

One un lagged flange = 0.6 m of pipe

If dia = 15cm and 5 flanges, Loss per year = 5
tonnes of coal or 3000 litres of FO

-Insulation – detachable type

-Common materials

-Glass wool, cork, rock wool, asbestos , ceramic

fiber,
 ECONOMIC THICKNESS OF
INSULATION

Un insulated 50 mm 100 mm
275 kcal/m 25kcal/m 15kcal/m

heat loss 89MM STEEL PIPE 900C

50 mm insulation  275 – 25
= 250 kcal/m
= 260 litre/year

50 mm to 100 mm  25-15
= 10kcal/m
= 9 litre/year.
 10. Flash steam recovery

Produced when condensate at high pressure

is released to lower pressure.

It can be used for low pressure heating

Flash steam % = S1-S2
L2
S1 – sensible heat of HP steam
S2 – sensible heat of LP steam
L2 - latent heat of flash steam. (LP)
 Flash vessel

-Large dia to reduce velocity

-Height sufficient to have dry steam at
top.
-Safety valve
-Strainer and float type trap.
 11. REDUCING WORK DONE BY STEAM

Reduction in operating hours.

Reduction in steam quantity
Use of more efficient technology
Minimising wastage
?
Thank You