Steam System Design and Best Practices Related ...

1 Steam System Design and best Practices Related to Kiln Drying New England Kiln Drying Association Steam Design and best Practices HerLine Technologies What is Steam ? Like other substances water can exist in the form of a solid, a liquid or a gas. Gaseous form of water is called Steam . It's HOT. It's Powerful It's Easy New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Why use Steam ? Made from water, which is relatively inexpensive and plentiful commodity available through out the world Carries relatively large amounts of energy in a small mass Temperature can be adjusted accurately by controlling its pressure using control valves Environmental friendly Relatively inexpensive to generate when firing with wood chips New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Steam - the best choice Why other systems fail to measure up to Steam ?

2 1. Gas fired direct heating Higher operating cost than wood fired boiler More difficult to control Higher Maintenance Requires separate humidification systems 2. Electric heating Very high cost to operate Requires separate humidification systems 3. Hot water systems Carries less than 1/5th (20%) the heat (Btu's) of Steam Higher System installation cost Higher operating costs New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Requirements for an Effective, Efficient and Safe Steam System Good initial System Design High quality System equipment and components Good knowledge of System operational safeties and periodic testing of safety devices Good System operational knowledge and Practices Regular tuning and maintenance Replacement of old or worn components New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Steam System Sub-Systems Steam Generation Steam Distribution Steam Utilization Condensate Recovery New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Steam Generation New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Steam Generation the Boiler House Steam Boiler high or low pressure Boiler Feed Water Tank minimum Condensate Surge

3 Tank & DA Tank ideal Water Softeners for make-up water Chemical Treatment System for boiler water Surface blow down (TDS) control System for boiler . recommended Flash Steam and blow down heat recovery systems - optional New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Steam GENERATION. New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Generating Quality Steam Good quality Steam to plant Feed water Build up of with impurities in the impurities boiler surface blow down to drain or heat recovery Impurities - bottom blow down' to waste New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Typical Simple Boiler Feed Water Tanks Vent to Condensate Atmosphere Returns Vent to Condensate Atmosphere Return OR.

4 To Boiler To Boiler SURGE-1. BF-1 BF-1. BF-2. New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Typical Deareator Tank Direct condensate returns, Low pressure Steam pumped returns & make-up water supply to deareator 0 LB/H. To Boiler DEA-1. New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Surge and DA Tank Combination Surge tank is vented to the DA tank is 0 LB/H. atmosphere pressurized 5 PSIG ? PSIG. with Steam Make-up water is usually added here PRV-1. and pre-heated Typical Condensate 0 LB/H. pump CR-1 SURGE-1 DEA-1. New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Optional Heat Recovery Systems Typical Blow down Heat Recovery System New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Complex Flash Recovery System New England Kiln Drying Association Steam Design & best Practices HerLine Technologies The Steam Distribution System New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Steam Distribution System Proper layout Design & pipe sizing of mains Piping always pitched in the direction of flow Use of eccentric reducers to eliminate creation of condensate collection points (low spots)

5 In piping Use of separators to eliminate wet Steam Proper drip trap stations in all required locations Use of air vents at all end-of-main locations Make Steam main branch take-offs from top of pipe Use of pressure reducing valves as needed or desired Put strainers before control valves, traps and pumps New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Steam Distribution Typical Steam Circuit New England Kiln Drying Association Steam Design & best Practices HerLine Technologies New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Typical Steam Distribution Header New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Pipe Sizing Greater Heat Loss Greater Cost Greater Volume of Condensate Formed Greater System Pressure Drops Not Enough Volume of Steam Water Hammer and Erosion New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Steam Volume 1 - 12 oz Can of Soda cu ft.

6 2 - 4 Drawer Filing Cabinets - cu ft @ 0 psig [1675:1]. 1 - 4 Drawer Filing Cabinets - cu ft @ 15 psig [867:1]. 1- Drawer of Filing Cabinet cu ft @ 100 psig [243:1]. New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Sizing Steam Lines New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Steam Main Relaying to Higher Level Fall 1/250. Steam Relay to high level 150 - 300 ft Drain Points Steam Flow New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Steam Line Reducers Correct Steam Condensate Steam Incorrect Condensate New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Steam Separators How Separators Work Wet Dry Steam Steam S3 Separator New England Kiln Drying Association Steam Condensate Outlet Design & best Practices HerLine Technologies Proper Drip Trap Station Steam Flow Condensate Cross Correct Section 9.

7 Pocket Steam Trap Set Steam Flow Cross Section Incorrect Steam Trap Set 8. New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Typical Steam Main Drip Station D. H. Size of Main D' Collection Leg Diameter Length of Collection Leg H'. 1/2 to 6 Same dia. as main D' Automatic Start up: H' to be 28 or More 6 & larger 2 to 3 Pipe Sizes Smaller than Main, But Never Supervised Start up: Length to Smaller than 6 be1-1/2 times Steam Main Diameter, but never shorter than 18 . New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Steam Traps in a Typical Steam Circuit New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Air Venting Balanced Pressure Air Vent Steam Main Air Thermodynamic Steam Trap Set New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Branch Connections Steam Steam Condensate 8 Incorrect 9 Correct New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Supply Leg Main Shut Off Valve Trap Set New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Strainers Strainers should be installed ahead of pressure reducing valves, control valves, flow meters and Steam traps.

8 All these components are susceptible to scale, dirt and debris. Screens of 60/100 mesh for valves and flow meters, 20 mesh for traps. Control Valve Strainer Note: Turn Steam pipe line strainers 90 so the Y . is parallel with the floor, not pointing down at it. This will eliminate the condensate pocket shown here. New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Pressure Reduction New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Why Reduce Pressure? PRO. It's better to run boilers at higher pressure for effective System operation and best System response Steam should be used at lowest pressure to meet process System temperature requirements for highest efficiency and ease of control CON. Adds additional System devices such as pressure reducing valves and safety valves to be concerned with Lower pressures increase the size of piping and System components which add cost New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Pilot Operated PRV Cutaway New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Pressure Reducing Station New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Typical Pressure Reducing Stations New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Typical Pressure Reducing Stations New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Steam Main Piping Use schedule 40 carbon steel pipe Size

9 For proper velocity at operating pressure Size for current and future needs Pitch in the direction of flow Use eccentric reducers to prevent condensate collection pools Install proper drainable drip legs with allowance for dirt legs and trap stations Locate trap stations at 150' min and 300' max on long linear runs Locate trap stations at all changes in elevation, at the bottom of drop lines and at the end of mains All branch take offs should be from the top of the main where dry Steam is available Air vents are also recommended at the ends of the main Insulate all Steam piping New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Steam Utilization New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Steam Utilization Is the ultimate goal of any Steam System and it includes all the heat transfer systems and functions In the case of Kiln Drying, it would provide the heat for drying and the Steam for humidification New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Selection from Steam Tables GAUGE ABSOLUTE TEMP SENSIBLE LATENT TOTAL VOLUME LATENT.

10 O PRESSURE Pressure F Heat Heat Heat Steam SENSIBLE. psig psia (hf) (hfg) (hg) (vg) Ratio BTU/lb ft3/lb. 0 212 180 970 1150 : 1. 15 250 218 946 1164 : 1. 50 298 268 912 1180 : 1. 100 338 309 881 1190 : 1. GAUGE. PRESSURE. Vacuum ins Hg 1 102 70 1033 1103 333 : 1. 5 162 130 1000 1130 73 77 : 1. 10 193 161 982 1143 38 : 1. 14 209 178 972 1150 28 : 1. New England Kiln Drying Association Steam Design & best Practices HerLine Technologies PRESSURE & FLOW. Differential Pressure: Is the difference between the inlet pressure and the outlet pressure acting upon any Steam component such as a trap, valve, Elevation Changes Flow New England Kiln Drying Association Steam Design & best Practices HerLine Technologies Control Valves Kiln Typical Vacuum Steam &. Breakers Condensate System Air Vents Drip Traps Coil Traps Condensate Pump New England Kiln Drying Association Steam Design & best Practices HerLine Technologies MODULATING Steam TEMPERATURE CONTROL.