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S T E A M
When water is heated Steam is produced
Saturated steam has a “FIXED” table of the relationship of the steam pressure & the steam temperature.
0 barg pressure of steam Temperature = 100°C4 barg pressure of steam Temperature = 151.96°C
10 barg pressure of steam Temperature = 184.13°C
Saturated Steam
Producing steam
When we heat water, the water will receive a heating
energy that is called sensible heat. Then the
water will be boiling.
When the boiling water receive further heat energy that is called latent heat
the water will be transformed into saturated
steam.
Industrial steam
Steam is produced inside an industrial steam boiler
To view how the steam boiler operates, please visit:https://www.youtube.com/watch?v=v0lmCZVrsRw
Usage of industrial steam - HEATING
Shell & tube heat exchanger (water or oil)Steam comes into the u-tube bundle
The secondary fluid to be heated is at the outer side of the u-tube bundle (shell)Condensate is drained out through a steam trap
Usage of industrial steam - HEATING
Plate & frame heat exchanger (Beverage, Food & Medicine)The plate heat exchanger consists of a frame with end plates which squeeze the
corrugated heat transfer plates. The plates form a series of channels for the two media. Steam flows in the odd number channels
The secondary fluid to be heated flows in the evenly numbered channels.Condensate is drained out through a steam trap
Usage of industrial steam - HEATING
Steam jacketed kettle (Food & Syrup)The steam is circulated inside the outer jacket of the stainless steel tank
The food to be heated is inside the stainless steel tankCondensate is drained out through a steam trap
Usage of industrial steam - HEATING
Steam tracing (Heavy oil, Sulphur & Petrochemical products)The steam is going into the tracer pipe
The heavy oil is inside the main pipelineCondensate is drained out through a steam trap
Usage of industrial steam - HEATING
Steam evaporator (Dairy & Syrup thickener)The steam is going into the tubes
The dairy or syrup is going into the outside of the tubesCondensate is drained out through a steam trap
Usage of industrial steam - HEATING
Steam rotary dryer (paper & corrugated paper)The steam is going into the drum dyer
The dried paper is located on the velt at the outside of the drum rotary dyer Condensate is drained out through a steam trap
Usage of industrial steam - HEATINGAIR
Hot Air
Process air heater (food, paper)The steam is going into the fin tubes
The air is blown out and the air is going through the hot fin tubesCondensate is drained out through a steam trap
Latent heat
Condensate (sensible heat)STEAM
Condensate in a steam heating system
1. When steam comes into a steam heating equipment the steam will transfer its latent heat into the secondary fluid to be heated
2. Then some part of the steam will be condensed and become condensate the condensate left only with the sensible heat only
Condensate in a steam heating system
For example: When we send saturated steam into a steam jacketed kettle to heat the soup inside the kettle the saturated steam will give its latent heat to the soup so the saturated steam left only with sensible heat only the steam
become hot water that is called condensate The condensate has to be collected & is drained out through a steam trap
Condensate is a poor heat transfer
Heating with steam
Condensate
Steam trapSteam trap
Steam trap
Steam trapSteam trap
Steam trap
Steam trap
Steam trap
Steam trap
Steam trap
Steam trap
Steam trap Steam trap
Steam trap
Steam trap
Dis-advantage of condensate in steam
• Water hammer in the steam pipe• Corrosion in the steam pipe (at lower temperature than
steam CO2 gas can react with condensate to become carbonic acid)
• HEATING IS NOT EFFICIENT process heating coil full of condensate (FLOODED heating coil with condensate) do not have latent heat anymore steam keeps coming into the heating coil but the heating is not efficient anymore since the steam boiler is still generating steam the steam is wasted in the heating process it will waste the fuel etc. at the steam boiler side !
When air and other non-condensable gases enter the steam system, they consume part of the volume that steam would occupy. The temperature of the air/steam mixture falls below that of pure steam (the air & gases become a heat insulator).
Steam chamber 100 % steamTotal pressure = 1.74 bargSteam pressure = 1.74 bargSteam temperature = 131° C
Steam chamber 90 % steam & 10 % of airTotal pressure = 1.74 barg
Steam pressure = 9/10 x 1.74 = 1.57 bargSteam temperature = 128° C
Dis-advantage of air/gas in steam
Steam trap is used to get rid the condensate
• The purpose of a Steam Trap is to keep steam in the system while removing condensate (water) and air.
• Air can reduce the heat transfer ability of steam and cause corrosion.
• Condensate / Water substantially reduces heat transfer and the ability of a steam device to do work.
• When a steam trap fails, it allows steam to blow-through along with the condensate.
• This loss of steam can represent a substantial energy loss.
or bucket
Type of steam trap
Bellows Balanced Pressure trap
At start-up Cold condensate is drained out
through the steam trap
When the condensate temperature is rising near to the steam temperature the bellow will expand steam trap is closed
To watch how it works, please visit:https://www.youtube.com/watch?v=x_EVtlwPPCs
23
Cold start-up Near steam temperature
Modulating with flow change
Condensate pressure pushed wafer off seat.
Full capacity flow established
Near steam temperatureliquid fill boils raising pressure above wafer which is pushed down on seat
Condensate cools, liquid fill begins to condense, pressure above wafer decreases and wafer leaves seat enough to rebalance pressures. Flow changes adjust valve opening
Outlet Port
Inlet Port
Liquid Fill
Wafer/Diaphragm
Bulkhead
SteamCondensate
Wafer type of trap
Bimetallic type of trap
Bimetal steam trap is using bimetal strips 2 different type
of metal that have different thermal coefficient (different
expansion & contracting properties)
At start-up when the condensate temperature is still
low bimetal strips are contracting trap open
When the condensate temperature increases near to steam temperature bimetal strips are expanding trap
closeTo watch how it works, please visit:https://www.youtube.com/watch?v=5ljv7AiB2q8
Thermodynamic (disc type) trap
Flash steam
Flash steam
Live steam strong flow of steam comes out of a leaking steam trap
Flash steam flying steam comes out of a steam trap together with
condensate
Thermodynamic (disc type) trap
To watch how it works, please visit:https://www.youtube.com/watch?v=pUdt127UXqA
Inverted bucket trap
To watch how it works, please visit:https://www.youtube.com/watch?v=x4c6UN8IqOc
Float & thermostatic trap
To watch how it works, please visit:https://www.youtube.com/watch?v=nQIQzEuGaMw
Steam Trap with Universal Connector
The benefit of steam trap with universal connector:1. If we want to replace the faulty steam trap, we can just disconnect the
steam trap from the universal connector by taking out only two number of tightening bolts and replace it with a new steam trap
2. Universal connector can be swiveled fully 360° during installation of the steam trap at site. So it does not matter is the steam pipe line is not aligned (slanted a bit)
3. If we want to install a steam trap with socket weld connection, we can just weld the steam pipe into the universal connector. So next time w want to replace the steam trap, we just dis-assembly the steam trap only out of the universal connection
4. There is a universal connection with integral strainer & blow-off valve
Steam trap station model TVS-4000
TRADITIONAL INSTALLATION
Shut-off valve
Shut-off valve
TEST valve
Blow-down valve
Y-STRAINER
STEAM TRAP
TVS-4000 trap station
Steam trap station model TVS-4000
To watch how it works, please visit:https://www.youtube.com/watch?v=E5--tej_Ldo
It takes only 3 minutes to replace a new steam trap
In-Expensive solution of steam trap
station model TVS-800
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