STEAM AND CONDENSATE

SYSTEMS
Water & Steam
Steam is one of the most abundant, least expensive, and most effective heat-
transfer media obtainable. Water is found everywhere, and requires relatively
little modification from its raw state to make it directly usable in process
equipment. During boiling and condensation, if the pressure is held constant
and both water and steam are present, the temperature also remains
constant. Further, the temperature is uniquely fixed by the pressure, and
hence by maintaining constant pressure, which is a relatively easy parameter
to control, excellent control of process temperature can also be maintained.
The conversion of a liquid to a vapor absorbs large quantities of heat in each
pound of water. The resulting steam is easy to transport, and because it is so
energetic, relatively small quantities of it can move large amounts of heat.
This means that relatively inexpensive pumping and piping can be used
compared to that needed for other heating media.
Components of Steam and Condensate
Systems
Checklist of Energy Conservation
Opportunities in Steam and
Condensate Systems
General Operations
1. Review operation of long steam lines to remote single-service
applications. Consider relocation or conversion of
remote equipment, such as steam-heated storage tanks.
2. Review operation of steam systems used only for occasional
services, such as winter-only steam tracing lines.
Consider use of automatic controls, such as temperature-controlled
valves, to assure that the systems are used only
when needed.
3. Implement a regular steam leak survey and repair program.
4. Publicize to operators and plant maintenance personnel the
annual cost of steam leaks and unnecessary equipment
operations.
5. Establish a regular steam-use monitoring program, normalized to
production rate, to track progress in reduction of
steam consumption. Publicize on a monthly basis the results of this
monitoring effort.
General Operations
6. Consider revision of the plant-wide steam balance in multi
pressure systems to eliminate venting of low-pressure
steam. For example, provide electrical backup for currently steam-
driven pumps or compressors to permit shutoff of
turbines when excess low-pressure steam exists.

7. Check actual steam usage in various operations against

theoretical or design requirement. Where significant disparities
exist, determine the cause and correct it.
8. Review pressure-level requirements of steam-driven mechanical
equipment to evaluate feasibility of using lower
pressure levels.
9. Review temperature requirements of heated storage vessels and
reduce to minimum acceptable temperatures.
10. Evaluate production scheduling of batch operations and revise if
possible to minimize startups and shutdowns
Steam Trapping

Pic
 Steam Trapping
A steam trap is a device used to discharge
condensate and non condensable gases with a
negligible consumption or loss of live steam. Most
steam traps are nothing more than automatic valves.
They open, close or modulate automatically. The
three important functions of steam traps are:
Discharge condensate as soon as it is formed.(Unless
it is desirable to use the sensible heat of the liquid
condensate)
Have a negligible steam consumption.(i.e. being
energy efficient) Have the capability of discharging
air and other non- condensable gases.
 Steam Trapping

1. Check sizing of all steam traps to assure

they are adequately rated to provide proper
condensate drainage. Also review types of
traps in various services to assure that the
most efficient trap
is being used for each application.
2. Implement a regular steam trap survey
and maintenance program. Train
maintenance personnel in techniques for
diagnosing trap failure.
 Condensate Recovery

In a vented condensate recovery system,

steam trap inlet pressure or a condensate
pump is used to return condensate to an
open-to-atmosphere collection tank for use
as boiler make-up water, pre-heat or other
hot water applications.
Condensate Recovery

Pic
Condensate Recovery
1. Survey condensate sources presently being
discharged to waste drains for feasibility of
condensate recovery.
2. Consider opportunities for flash steam
utilization in low-temperature processes
presently using first-generation
steam.
3. Consider pressurizing atmospheric condensate
return systems to minimize flash losses.
Mechanical Drive Turbines
Mechanical Drive Turbines
1. Review mechanical drive standby turbines
presently left in the idling mode and consider the
feasibility of shutting down standby turbines.
2. Implement a steam turbine performance testing
program and clean turbines on a regular basis to
maximize efficiency.

3. Evaluate the potential for cogeneration

(simultaneous production of electricity and heat, both
of which are used). in multi pressure steam systems
presently using large pressure-reducing valves.
 Insulation

Material that retards or prevents the

progression or transmission of electricity,
heat, moisture, shock, or sound from one
item or medium to another.
Insulation
Insulation
1. Survey surface temperatures using infrared
thermometry or thermograph on insulated equipment and
piping to locate
areas of insulation deterioration. Maintain insulation on a
regular basis.
2. Evaluate insulation of all un insulated lines and fittings
previously thought to be uneconomic. Recent rises in
energy
costs have made insulation of valves, flanges, and small
lines desirable in many cases where this was previously
unattractive.
3. Survey the economics of additional insulation on
presently insulated lines, and upgrade insulation if
economically feasible.
 Economizer

Economizers (UK), are mechanical devices

intended to reduce energy consumption, or to
perform useful function such as preheating
a fluid. The term economizer is used for other
purposes as well. Boiler, power plant, heating,
ventilating, and air conditioning (HVAC) uses are
discussed in this article. In simple terms, an
economizer is a heat exchanger.
Economizer
De aerated

De aeration is used in the upstream oil & gas

industry to remove oxygen from seawater,
preventing or reducing corrosion, and
growth of bacteria. It is also used in the
process inks and coatings industry to prevent
foaming during production and get a higher
quality print or coating layer without air
bubble defects.
De aerated
 Air Pre Heater

An Air Pre Heater (APH) Is A General Term Used

To Describe Any Device Designed To
Heat Air Before Another Process (For
Example, Combustion In A Boiler) With The
Primary Objective Of Increasing The Thermal
Efficiency Of The Process. They May Be Used
Alone Or To Replace A Recuperative Heat
System Or To Replace A Steam Coil.
Air Pre Heater
 A Pressure Regulator

A pressure regulator is a valve that

automatically cuts off the flow of a liquid
or gas at a certain pressure. Regulators
are used to allow high-pressure fluid
supply lines or tanks to be reduced to
safe and/or usable pressures for various
applications.
A Pressure Regulator
 Induce Draft (ID) Fans

In an induced draft system, the fan is at the

exit end of the path of flow, and the system is
under negative pressure - that is, the
pressure in the flow area is below
atmospheric, because the air is being drawn
through the fan.
 Forced Draft (FD) Fans

An air pre heater (APH) is a general term

used to describe any device designed to
heat air before another process (for
example, combustion in a boiler) with the
primary objective of increasing the thermal
efficiency of the process.