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 dont 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)

Courtesy of Barclay Water

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 Dry Steam

Steam

Condensate Outlet
 Steam Conditioning
Dry Steam saves energy
Example: Process requires 4,645,000 Btus / 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