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How NOT to Design a Steam System
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Sizing a Steam Boiler
▪ Many Steam boilers are undersized for the actual NET load
▪ Determine the BTU required for the heat load
▪ Add losses for the piping, distribution, etc.
▪ Correct for the operating pressure of the boiler
▪ Correct for the feedwater temperature of the boiler
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Sizing a Steam Boiler
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Calculated Load x Pick-Up Factor = Gross Load BTU/HR (BTU/HR) (1.33)
X =
NET Load
Piping and
Pick-Up
Gross Load
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Sizing a Steam Boiler ▪ The boiler rating is FROM and AT 212° F
▪ Must account for the Lower Boiler Steam Flow at pressures above 0 PSIG and for feedwater temperatures below 212°F
Example:
400 HP Boiler
Operating Pressure: 100 PSIG
Feedwater Temperature: 140 °F
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Sizing a Steam Boiler
Feedwater Heating:
Evaporation Rate:
400 (BHP) x 0.069 (GPM/BHP) x 60 (MIN/HR) = 1,656 (GPH)
BTU Content of 212 °F Feedwater:
1,656 (GPH) x 180 (BTU/LB) x 8.4 (LB/GAL) = 2,503,872 (BTU/HR)
BTU Content of 140 °F Feedwater:
1,656 (GPH) x 108 (BTU/LB) x 8.4 (LB/GAL) = 1,502,323 (BTU/HR)
Feedwater loss (from 140 °F ) = 1,001,548 (BTU/HR)
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Sizing a Steam Boiler
Rated Boiler output:
400 (BHP) x 33,475 (BTU/HR/BHP) = 13,390,000 (BTU/HR)
Output after heating feedwater:
13,390,000 ( BTU/HR) - 1,001,548 (BTU/HR) = 12,388,451 (BTU/HR)
Enthalpy of steam at 100 PSIG = 1,190 (BTU/LB Steam)
Actual Boiler output:
12,388,451 (BTU/HR) / 1,190 (BTU/ LB Steam) = 10,410 (LBS/HR Steam)
400 HP Nameplate output (At 0 PSIG and 212 °F Feedwater)
400 (BHP) x 34.5 (LBS/HR Steam/BHP) = 13,800 (LBS/HR Steam)
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Sizing a Steam Boiler Total loss:
13,800 (LBS/HR) - 10,410 (LBS/HR) = 3,390 LBS/HR or 26% less steam
Actual Steam flow Versus nameplate steam flow is 26% LESS
7
8%
18%
74%
Feedwater Temperature Loss
Operating Pressure Loss
Available NET Load
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Near Boiler Piping
▪ Poor piping examples
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Steam Outlet
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Near Boiler Piping
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Steam outlet velocity at Actual operating pressures
4,500 ft/min Ideal top end velocity which will allow for some upset water conditions
5,000 ft/min OK velocity with high quality boiler water and perfect steam system piping
5,500 ft/min Some bouncing waterline will occur even with high quality boiler water
6,000 ft/min Definite problems will occur (bouncing water line, LWCO, etc)
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Near Boiler Piping
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Steam skid with a 4” steam nozzle, steam orifice plate and set pressure of 21 psig
12 psig 5,921 ft/min
15 psig 5,365 ft/min
20 psig 4,644 ft/min
30 psig 3,669 ft/min
40 psig 3,040 ft/min
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Near Boiler Piping
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Good:
• (2) Isolation Valves
• (1) Check Valve
• High Vertical Height
Bad:
• Incorrectly sized
check valve
• Non-code spool piece
• No free blow drain in
between valves
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Near Boiler Piping
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Main Steam Header ▪ Operating pressure
▫ The header should be designed for the lowest anticipated boiler operating pressure during normal operation.
▪ Diameter
▫ The header diameter should be calculated with a maximum steam velocity of 4,500 ft./min. under full load conditions. Low velocity is important as it helps any entrained moisture to fall out.
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Main Steam Header ▪ Off-takes
▫ Always taken off of the top of the header. Gravity and low steam velocity help to allow condensate to drain from the header. This helps to ensure a high steam quality.
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Main Steam Header ▪ Poor header examples:
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Main Steam Header ▪ Poor header examples:
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Main Steam Header ▪ Poor header examples:
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Main Steam Header
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▪ Poor header examples:
Typical steam header design
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Main Steam Header
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▪ Poor header examples:
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Main Steam Header ▪ Good header example
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Main Steam Header
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Need to Properly Drain Condensate ▪ Steam trapping
▫ It is important that condensate is removed from the steam header as soon as it forms. For this reason a properly sized drip leg with appropriate steam trap must be installed at the end of the header to avoid water hammer.
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Need to Properly Drain Condensate ▪ Steam trapping/Drip Legs
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Incorrect
Correct
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Need to Properly Drain Condensate
▪ Other causes of water hammer:
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Need to Properly Drain Condensate
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Need to Properly Drain Condensate
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Need to Properly Drain Condensate
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New York Water Hammer Explosion
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A Deaerator is NOT just a Deaerator
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A Deaerator is NOT just a Deaerator
Remove Oxygen and Carbon Dioxide
To protect boiler from oxygen pitting
To protect return lines from carbonic acid tracking
Improves Heat Transfer
Air acts as an insulator in the system
Raise Feed Water Temperature Reduces thermal shock to boiler
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A Deaerator is NOT just a Deaerator
▪ Oxygen solubility chart
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A Deaerator is NOT just a Deaerator
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▪ Temperature
▪ Turbulence
▪ Time
▪ Thin Film
▪ Venting
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A Deaerator is NOT just a Deaerator ▪ Spray Type Deaerator:
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Limited Turndown
High-Maintenance
Cheap
Warranted performance per ASME test (steady-state only)
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A Deaerator is NOT just a Deaerator
▪ Tray Type Deaerator:
Unlimited Turndown
Zero Maintenance
More Expensive
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Boiler Failures Due to Low Water ▪ Low Water Failures:
▫ 85% of low pressure failures
▫ 55% of high pressure failures
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Boiler Failures Due to Low Water
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Boiler Failures Due to Low Water
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Boiler Failures Due to Low Water
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Boiler Failures Due to Low Water
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Boiler Failures Due to Low Water
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Boiler Failures Due to Low Water
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Boiler Failures Due to Low Water
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Boiler Failures Due to Low Water
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Boiler Failures Due to Low Water
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Boiler Failures Due to Low Water