Steam & Condensate Loop

The working pressure

The distribution pressure of steam is influenced by a number of factors, but is limited by:
The maximum safe working pressure of the boiler. The minimum pressure required at the plant. As steam passes through the distribution Pipework, it will inevitably lose pressure due to: Frictional resistance within the Pipework . Condensation within the Pipework as heat is transferred to the environment.

Steam Pressure / Specific Volume Relationship

A kilogram of steam at a higher pressure occupies less volume than at a lower pressure. It follows that, if steam is generated in the boiler at a high pressure and also distributed at a high pressure, the size of the distribution mains will be smaller than that for a low-pressure system for the same heat load

Steam Pressure Kg/cm2

Pipe Sizing

Greater Cost Greater Heat Loss Greater Volume of Condensate Formed

Lower Pressure to Steam Users, or Not Enough Volume of Steam Water Hammer and Erosion

Copyright Forbes Marshall, 2006-07

Methods of Steam-pipe Sizing

Pressure Drop Method

For saturated steam system Ideally suited for Process use

Velocity Method
For superheated steam Ideally suited for Power Plants & Co-gen units

Copyright Forbes Marshall, 2006-07

Methods of Steam-pipe Sizing

Rules of thumb to be followed Maximum velocity 15 m/s for LP wet steam(flash steam) 25 m/s for sat.steam long lengths 30 m/s for sat.steam short tappings 40 m/s for superheated steam Normal Pressure Drop Less than 10% inlet pressure Less than 1 Kg/cm2 for given length of piping. Equivalent length of piping - Add 10% for fittings in the line.
Copyright Forbes Marshall, 2006-07

Line Sizing Pressure Drop Method

Line Sizing Pressure Drop Method

Maximum Pressure Loss/100m : (P1-p2/L) *100 (7-6.6/165 ) * 100 = 0.24 bar

Line Sizing Velocity Method A process requires 5 000 kg/h of dry saturated steam at 7 bar g. For the flow velocity not to exceed 25 m/s, determine the pipe size.

150 NB

Line Sizing Velocity Method

PRESSURE REDUCTION NEED,APPLICATIONS & TYPES

Steam pressures & Applications

Why is pressure important?

Why Reduce Pressure?

There are a number of very good reasons for reducing steam pressure: Steam boilers are usually designed to work at high pressures. Working them at lower pressures can result in carryover of water Steam at high pressure has a relatively small volume which means that a greater weight can be carried by a pipe of a given size. It is preferable to distribute steam at high pressure and reduce it at the point of usage Steam pressure may be reduced to save energy. Steam at lower pressures has higher latent heat. Reduced pressure of steam also leads to reduced heat loss and lower flash steam formation from open vents etc. Since the pressure and temperature of steam are related, controlling the pressure enables us to control the temperature in the heating process Pressures must be reduced so that they are within the rated safety limits In plants where steam usage takes place at many different pressures, pressure reduction allows generation of steam at a single high pressure and subsequent reduction to the desired pressure at the point of usage

Types of Pressure Reducing Valves

Pilot operated, Self-acting Pressure Reducing Valve Direct operating, self-acting pressure reducing valve - Bellows type Direct operating, self-acting pressure reducing valve -Diaphragm type Pressure reduction Pneumatic Pressure reduction Electro-pneumatic Pressure reduction Electric

PRESSURE CONTROL VALVE SELECTION Accuracy

SELF ACTING PNEUMATIC OPERATED

DIRECT ACTING

PILOT & DIAPHRAGM

CONTROL VALVE WITH ROBOTOR

CONTROL VALVE WITH POSITIONER

upto + - 25% variation under fluctuating load

upto + - 0.2 bar Variation under max to min load

0.1bar

0.05 bar

PRESSURE CONTROL VALVE SELECTION Turndown

SELF ACTING PNEUMATIC OPERATED

DIRECT ACTING 10 - 1

PILOT & DIAPHRAGM 15 - 1 to 12 - 1

CONTROL VALVE WITH ROBOTOR 40 -1

CONTROL VALVE WITH POSITIONER 40 -1

PRESSURE CONTROL VALVE SELECTION Loads

SELF ACTING PNEUMATIC OPERATED

DIRECT ACTING PILOT & DIAPHRAGM

CONTROL CONTROL VALVE VALVE WITH WITH ROBOTOR POSITIONER heavy loads medium to requiring precise heavy loads pressure

steady loads

fluctuating small to medium loads

Advantages, Limitations & Applications

Pilot operated, Self-acting Pressure Reducing Valve Advantages
Accurate and consistent pressure control, even at high and variable flowrates. A variety of pilot valves may be used on one main valve. Pilot valve options include electrical override, multi-pilot for a choice of control pressures, a surplussing option and remote control, as well as different temperature/pressure control combinations. Self-acting principle means that no external power is required. Tolerant of varying upstream pressure More expensive than bellows operated direct acting controls. Small clearances mean that steam must be clean and dry to ensure longevity, but this can be achieved by fitting a strainer and separator before the pressure reducing valve.

limitations

Applications: A system which requires accurate and consistent pressure control, and installations which have variable and medium flowrates. For example: autoclaves, highly rated plant such as heat exchangers and calorifiers. A system where installation space is limited http://www.tlv.com/global/UK/steam-theory/pressure-reducing-valves-for-steam.html

Direct operating, self-acting pressure reducing valve - Bellows type

Advantages Inexpensive. Small. Easy to install. Very robust, giving long life with minimum maintenance. http://www.tlv.com/global/UK/steam-theory/pressurereducing-valves-for-steam.html Tolerant of imperfect steam conditions. Self-acting principle means that no external power is required Disadvantages: Proportional only control. Proportional band is 30% to 40% of the upstream pressure. Wide proportional band means that maximum flow is only achieved when the downstream pressure has dropped considerably. This means that the reduced pressure will vary depending on flowrate. Limited in size. Limited flow rate. Variation in upstream pressure will result in variation in downstream pressure. Applications: Non-critical, moderate load applications with constant running flowrates, for example: Small jacketed pans,Tracer lines,Ironers,Small tanks,Acid baths,Small storage calorifiers,Unit heaters.,Small heater batteries,OEM equipment

Direct operating, self-acting pressure reducing valve -Diaphragm type

Advantages: Very robust. Tolerant to wet and dirty steam. Available in large sizes, so high flowrates are possible. Easy to set and adjust. Simple design means easy maintenance. Self-acting principle means that no external power is required. Able to handle pressure drops of 50:1 in small sizes, and 10:1 in large sizes. Disadvantages: Large proportional band means that close control of downstream pressure is improbable with large changes in load. Relatively high purchase cost, but lifetime cost is low. Bulky. Applications: Distribution mains. Boiler houses

Pressure reduction Pneumatic

Advantages: Very accurate and flexible. No limit on valve size within the limits of the valve range. http://www.tlv.com/global/UK/ Acceptable 50:1 flow rangeability (typically for a globe control valve). steam-theory/types-ofvalves.html Suitable for hazardous environments. No electrical supply required. Fast operation means they respond well to rapid changes in demand. Very powerful actuation being able to cope with high differential pressures across the valve. Disadvantages More expensive than self-acting controls. More complex than self-acting controls. Not directly programmable. Applications: A system which requires accurate and consistent pressure control, and installations which have variable and high flowrates and/or variable or high upstream pressure. For example: autoclaves, highly rated plant such as large heat exchangers and calorifiers.

Pressure reduction Electro-pneumatic

Advantages Very accurate and flexible. Remote adjustment and read-out. No limit on valve size within the limits of the valve range. Acceptable 50:1 flow rangeability (typically for a globe control valve). Fast operation - rapid response to changes in demand. Very powerful actuation being able to cope with high differential pressures across the valve. Disadvantages More expensive than self-acting or pneumatic controls. More complex than self-acting or pneumatic controls. Electrical control signal required. Costly for hazardous areas. Applications: A system which requires accurate and consistent pressure control, and installations which have variable and high flowrates and/or variable or high upstream pressure, including autoclaves, highly rated plant such as large heat exchangers and calorifiers, and main plant pressure reducing stations.

Pressure reduction Electric

Advantages Both controller and valve actuator can communicate with a PLC. No compressed air supply is required Disadvantages If a spring return actuator is required, the available shut-off pressure may be limited. Relatively slow actuator speed, so only suitable for applications where the load changes slowly. Applications: Slow opening / warm-up systems with a ramp and dwell controller. Pressure control of large autoclaves. Pressure reduction supplying large steam distribution systems.

POSSIBILITIES IN PRESSURE REDUCTION

PARRALLEL PRESSURE REDUCTION STATIONS
Pressure reducing stations may be configured as shown below for one of two reasons: The valves are serving a critical application for which downtime is unacceptable The equipment is operated on a 'one in operation, one on stand-by' basis to cover for breakdown and maintenance situations. The turndown ratio between the maximum and minimum flowrates is very high The equipment is operated on a pressure sequence principle with one valve set at the ideal downstream pressure, and the other at a slightly lower pressure. When demand is at a maximum, both valves operate; when flow is reduced, the valve set at the lower pressure shuts off first, leaving the second valve to control.

Series pressure reducing stations

A pressure reducing station may be configured in this manner if the ratio between the upstream and
downstream pressure is very high, and the control systems selected have a low turndown ability. 10:1 is recommended as a practical maximum pressure ratio for this type of reducing valve. EXAMPLE: Consider the need to drop pressure from 25 bar g to 1 bar g. The primary reducing valve might reduce pressure from 25 bar g to 5 bar g, which constitutes a pressure ratio of 5:1. The secondary reducing valve would drop pressure from 5 bar g to 1 bar g, also 5:1. Both valves in series provide a pressure ratio of 25:1.

ARCA PRS STANDARDISATION

2010STDPRSARCABOMS.XLS STANDARD PRS WITH ARCA.xls

Thank you!!!!