Learn Steam Generation and Distribution Systems

MODULE 14
LEARNING OBJECTIVES
General Objectives:
L
Steam Generation and Distribution.
Specific Objectives:
L
The Use of Steam in Industrial Plants and Processes,
How Steam is Generated and Distributed for End-Use,
Use of Steam Tables to Calculate Energy/Mass Balance,
Steam Quality,
Heat Recovery from Flash Steam and Blow Down,
Boiler Plant Equipment & Operation,
Boiler Plant Efficiency.
Performance Objectives:
After successfully completing this module you will be able to:
Examine steam distribution systems including steam trap

operation, steam leakage, condensate return, and water
treatment.
Evaluate the steam distribution system including boiler

combustion efficiency.
Prepare a boiler mass balance, including boiler blow-down,

make-up and feedwater quantities.
Evaluate feedwater treatment procedures.
Make recommendations for system improvement based on

your evaluations.
STEAM GENERATION
& DISTRIBUTION
In this module you will learn about:
SADC Industrial Energy Management Project

Implemented by AGRA Monenco Atlantic Limited for the Canadian International Development Agency
Module 14
Steam Generation & Distribution
TABLE OF CONTENTS
1.0
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.0
PRINCIPLES OF STEAM GENERATION AND STEAM TABLES . . .
3.0
BOILER HOUSE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1
3.2
3.3
3.4
3.5
3.6
Energy Flow and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . .

Burners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Feedwater Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler Plant Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boiler Plant Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
7
8
10
11
12
STEAM DISTRIBUTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
4.1
4.2
4.3
Steam Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steam Traps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flash Steam Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
17
20
5.0
END-USE EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
6.0
ENERGY MANAGEMENT OPPORTUNITIES . . . . . . . . . . . . . . . . . .
24
6.1
6.2
6.3
Housekeeping Opportunities . . . . . . . . . . . . . . . . . . . . . . . . .
Low Cost Opportunities . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retrofit Opportunities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
25
26
WORKED EXAMPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
7.1
7.2
7.3
Relocate Combustion Air Intake (Boiler House) . . . . . . . . . . .

Replace or Repair Leaking Traps (Steam Distribution System)
Shut Down Equipment (End-Use Equipment) . . . . . . . . . . . .
26
27
28
8.0
ASSIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
9.0
SUMMARY - Module 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
4.0
7.0
MODULE 14
STEAM GENERATION
& DISTRIBUTION
1.0 INTRODUCTION
A significant percentage of world's fuel supply is used to generate steam for power
production, industrial processes and commercial space heating. The reasons for
this popularity are simple:
<
<
<
<
<
Steam carries a very high heat content. Relatively small pipes can carry a
great amount of heat. Steam at low temperature contains about twenty-five
times as much heat as the same weight of air or flue gases at the same
temperature.
Steam gives up its heat at constant temperature. It gives a complete control
of the heating operation. When steam condenses by giving up its latent
heat to the heated surface, it does so at constant temperature at
corresponding pressure.
Steam is generated from water which is cheap and plentiful.
The heat in steam can be used again and again.
Steam can generate power first and can then be used for heating.
Figure 14.1
TYPICAL STEAM SYSTEM
Page 1 of 32
Module 14 - Steam Generation & Distribution ....
Fuel conversion systems, such as boilers, extract energy from primary sources
(fuels) and convert it into secondary form of energy such as steam, hot water or hot
air. The main task involved in assessing these systems is to determine their fuel
conversion efficiency. The combustion of fuels comprises the major part of the
steam generating process. The fundamentals and testing procedures of fuel fired
systems are described in Module 13 and apply to steam and hot water boilers.
Module 14 gives the background to the generation, distribution and end-use of
steam and provides guidelines for assessing and improving the efficiency of these
processes. Figure 14.1 shows a diagram of the overall steam system including the
inputs and losses peculiar to the production, distribution and end-use of steam.
Figure 14.2 presents a picture of a typical industrial application of steam from
generation to distribution and various types of end-use equipment.
Figure 14.2
INDUSTRIAL APPLICATIONS OF STEAM
2.0 PRINCIPLES OF STEAM GENERATION AND STEAM TABLES

As heat energy is added to water, the temperature of the water increases until the
boiling point is reached (refer to Figure 14.3). This heat, which increases the water
temperature, is called sensible heat. When the boiling point is reached, the
addition of further heat causes some of the water to change to steam, but the
steam and water mixture remains at the boiling point temperature. At atmospheric
pressure the boiling point of water occurs at 100EC. The heat which converts the
water to steam at a constant boiling temperature is called latent heat. When the
steam has been fully vaporized at the boiling temperature, it is called dry saturated
steam. This means that there are no droplets of moisture within the steam vapour.
When water is heated at a pressure above atmospheric, the boiling point will be
higher than 100EC and the sensible heat will be greater. For every pressure there
is a corresponding boiling temperature, and at this temperature the water contains
a fixed, known amount of heat. As indicated in Figure 14.4, the greater the
pressure, the higher the boiling temperature and heat content.
Page 2 of 32
Figure 14.3
ILLUSTRATION OF CHANGE OF STATE
The unit of heat energy in the SI system is the Joule. Steam Tables (Figure 14.5
presents an extraction from the Steam Tables in Appendix C) are used to establish
the energy content of water and steam. The use of steam tables is helpful in
analyzing the operating effectiveness of a boiler plant. Enthalpy is the expression
used to identify the energy content of the water, steam and water mixture or steam
on a unit mass basis.
Figure 14.4
TEMPERATURE - ENTHALPY DIAGRAM
Page 3 of 32
Under the enthalpy heading in Figure 14.5, there are three columns; enthalpy of the
liquid (hf), enthalpy of evaporation (hfg) and enthalpy of steam (hg).
<
Enthalpy of liquid (hf) is a measure of the amount of heat energy

contained in one kg of water at a specific temperature.
<
Enthalpy of evaporation (hfg) (correctly called the latent heat of

vaporization) is the quantity of heat energy required to convert one kg of
water to one kg of steam at a given pressure.
<
Enthalpy of steam (hg) is the total heat contained in dry saturated steam
at a given pressure. This quantity of energy is the sum of the enthalpy of
liquid (hf) and the amount of energy required to evaporate one kg of water
at the saturation temperature (hfg).
Figure 14.5
EXTRACTION FROM STEAM TABLE
Gauge
Pressure
bar
........
0.95
1.00
1.05
........
8.90
9.00
9.10
Absolute
Pressure
Temperature
bar
EC
1.963
2.013
2.063
9.913
10.013
10.113
Specific Enthalpy
Specific
Volume
Steam
(Vg)
m 3/kg
Water
(hf)
kJ/kg
Evaporation
(hfg)
kJ/kg
Steam
(hg)
kJ/kg
119.63
120.42
121.21
502.2
505.6
508.9
2203.5
2201.1
2199.1
2705.7
2706.7
2708.0
0.901
0.881
0.860
179.53
179.97
180.41
761.1
763.0
765.0
2016.6
2015.1
2013.5
2777.7
2778.1
2778.5
0.196
0.194
0.192
........
The three previous figures for enthalpy may be expressed in an equation

hg = hf + hfg
where
hg = Enthalpy of dry saturated steam (kJ/kg)
hf = Enthalpy of liquid (kJ/kg)
hfg = Enthalpy of evaporation (kJ/kg)
Most boilers are designed to produce dry saturated steam.
!
Examples From Steam Table (Appendix C)

The steam tables can be used to compare the energy content of dry saturated
steam at two pressures of 200 and 1,000 kPa (absolute).
Note that the steam tables give properties based on absolute values of
pressure. The steam pressure on normal gauges is usually registered in bars.
The zero bar indicated on the gauge is 1.013 bar below atmospheric pressure.
Page 4 of 32
Absolute Pressure
= Gauge Pressure (kPa) + 101.325 kPa

= Gauge Pressure (bars) + 1.013 bar
where 1 bar = 100 kPa
200 kPa (2 bar abs) Dry Saturated Steam

Sensible heat (hf)
Latent heat of evaporation (hfg)
=
505.6 kJ/kg
= 2,201.1 kJ/kg
Total heat (hg)
= 2,706.7 kJ/kg
1,000 kPa (10 bars abs) Dry Saturated Steam

Sensible heat (hf)
Latent heat of evaporation (hfg)
=
763.0 kJ/kg
= 2,015.1 kJ/kg
Total heat (hg)
= 2,778.1 kJ/kg
From the foregoing enthalpy comparison it should be noted that, as steam

pressure increases, the amount of sensible and total heat increases and the
latent heat decreases.
!
Steam Quality
The enthalpy cannot be directly obtained from steam tables when there is
moisture in the steam. The steam quality can be expressed in equation form
Steam Quality '
Mass of Steam Vapour

Mass of Steam Vapour and Water Mixture
A steam quality of 0.98 means that there is 2% moisture in the steam. The heat
content of 1,000 kPa and 0.98 quality steam can be calculated using steam
tables :
Sensible heat
Latent heat (2,015.1 x 0.98)
=
763.0 kJ/kg
= 1,974.8 kJ/kg
Total heat (hg)
= 2,737.8 kJ/kg
The heat required to eliminate moisture is:

= 2,778.1 - 2737.8 = 40.3 kJ/kg
Page 5 of 32
Superheated steam
As long as water is present, the temperature of saturated steam will correspond
to the figure indicated for that pressure in the steam tables. However, if heat
transfer continues after all the water has been evaporated, the steam
temperature will again rise. The steam is then called "superheated" and this
superheated steam can be at any temperature above that of saturated steam
at corresponding pressure.
Saturated steam will condense readily an any surface which is at lower
temperature, so that it gives up the enthalpy of evaporation which, as we have
seen, is the greatest proportion of its energy content. On the other hand, when
superheated steam gives up some of its enthalpy, it does so by virtue of a fall
in temperature. No condensation will occur until the saturation temperature has
been reached. The rate at which we can get energy to flow from superheated
steam is often less than we can achieve with saturated steam, even though the
superheated steam is at a higher temperature. Superheated steam, because
of its non-condensing property, is the natural first choice for power steam
requirements, while saturated steam is ideal for process and heating
applications.
3.0 BOILER HOUSE OPERATION

3.1
Energy Flow and Balance

The three sources of boiler heat energy input are the fuel, feedwater and
combustion air.
Figure 14.6
BOILER ENERGY FLOW
Fuel
The major energy source is from the fuel which can be expressed in terms of
MJ/m3 for gas, MJ/L for oils and MJ/kg for coal and other solid fuels. In the
case of Residual Fuel Oil (RFO), it is necessary to heat the oil in the storage
tank sufficiently to permit pumping and then to heat it further before the burner.
Page 6 of 32
The thermal energy of the oil as it is delivered to the boiler should be added to
the higher heating value (HHV) of the oil to represent the total fuel energy input.
!
Feedwater
The feedwater temperature must also be considered as part of the energy input
(i.e. higher temperature of feedwater requires less heat energy from the fuel to
be converted to steam). The feedwater temperature can be used to determine
this heat input level. The energy content of the feedwater is the enthalpy (hf)
as determined in steam tables corresponding to the feedwater temperature.
Combustion Air
Combustion air is normally drawn from within boiler plant, but may be ducted
from outside and heated with steam. Higher combustion air temperature will
reduce the energy input required from the fuel.
3.2
Burners
Burner design varies according to the type of fuel and the application objectives,
but they must all do the following:
<
<
<
<
Direct fuel to the combustion chamber.

Direct air to the combustion chamber.
Effectively mix the fuel and air.
Once the burner has been ignited it must continue to ignite the incoming
fuel.
Oil Burners
Oil must be atomized and simultaneously mixed with air to sustain combustion.
An oil burner consists of a central tube with an atomizing device at the end, and
a register that surrounds the barrel and serves to distribute the flow of air to the
boiler.
Mechanical oil burners can be used to atomize No.2 or RFO oil, but the
pressure must be very high to obtain acceptable turndown. The turndown
ratio is the ratio of the maximum to minimum fuel flows which can produce
satisfactory combustion. An example of the pressure difference for a 5:1
turndown would be that a mechanical oil burner would require 4,500 kPa oil
pressure whereas a steam atomized burner would only require 650 kPa
pressure for the same turndown.
Most No.6 (RFO) oil burners use steam-assisted atomizers where steam is
mixed with the oil in the atomizing tip to break up the oil particles. This type of
burner requires less oil pressure than the straight mechanical type and has
better turndown ratio of up to 5:1.
Page 7 of 32
Natural Gas Burners

Natural gas mixes readily with air. The ring-type gas burner consists of a
circular barrel ringed with multiple outlet ports. The register surrounds the
barrel with air.
Many boilers are equipped with a combination of natural gas and oil burners
with the second fuel used as a back up to the prime fuel.
Pulverized Coal Burners

The barrel of a pulverized coal burner consists of a large diameter steel tube
fitted with internal distribution vanes. The coal and hot primary air, which were
previously mixed in the pulverizer, are introduced tangentially to the barrel to
impart a strong rotation in the barrel. Adjustable inlet vanes also impart a
rotation to the preheated secondary air entering the register. The degree of air
and fuel swirl, coupled with the shape of the burner throat, establishes a
recirculation pattern extending into the combustion chamber. Once the coal is
ignited, the combustion heat in the furnace stabilizes the flame.
3.3
Boilers
Steam is generated in boilers, i.e. pressure vessels where water is turned into
steam on a continuous basis by application of heat.
!
Boiler Types
<
<
<
Low pressure boilers operate in the range up to 3 bars pressure.

Medium pressure boilers operate in the range up to 10 to 15 bars
pressure, mainly in industrial processes.
High pressure boilers operate above 15 bars, mainly in power
generating applications.
The principal boiler types are the firetube, watertube, coiltube and electric.
Firetube boilers
These are essentially shell-and-tube heat exchangers where combustion
gas passes through tubes which are immersed in water.
Firetube boilers usually burn natural gas or oil, although some, with a
firebox type of combustion chamber, can be installed on top of a coal or
wood stoker. They can generate dry saturated steam or hot water up to a
maximum of 1,700 kPa (17 bar) gauge. The output ranges from 350 to
28,000 MJ/h. Boilers are shop assembled and delivered with integral
burner, forced draft fan and controls.
Since firetube boilers operate at low pressures, the boiler water temperature
is correspondingly low, ranging from 110 to 200EC. By ensuring that the
Page 8 of 32
combustion gas contacts as much of the heat transfer surface as possible,

the flue gas temperature can be reduced to within 50EC of the boiler
temperature. This minimizes the flue gas heat loss and can result in boiler
efficiencies in excess of 80%.
Watertube boilers
The watertube boiler is capable of firing any type of combustible material in
a wide range of capacities. Watertube boilers operate at pressures up to
30,000 kPa (300 bars) and can produce steam at up to 565 EC. Watertube
boilers pass the combustion gases around tubes carrying water. This type
is generally used in sizes from 7,000 kg/h to about 95,000 kg/h as
manufactured units and in larger sizes with field-erected assemblies.
Normally the steam drum of the watertube boiler contains a sophisticated
system of steam/water separators to produce high quality steam at the
outlet. Steam with less than 1% entrained water droplets are common for
such boilers
Coiltube boilers
Coiltube boilers are essentially forced circulation water tube boilers which
generate steam from water circulated through a single tube or multiple
coiled tubes surrounding the combustion chamber. This type is used in
sizes up to about 10,000 kg/h. Coiltube boilers require a continuous forced
circulation of water through the tubes and usually have an inertial type
steam/water separators at the steam outlet. The quality of steam leaving
the boiler depends on the efficiency of the separator and the steam may
contain up to 10% water droplets by weight.
Electric boilers
Hot water or steam can be generated in boilers where water is heated
electrically with immersion coils. Electric boilers are more efficient than fuel
fired boilers because there are no flue gas losses to the stack. Electrical
energy is often not competitive with other fuels, but this should be checked
particularly with respect to off-peak tariffs.
New three-pass firetube boilers, with ratings of 1,600 to 16,000 MJ/h are
available with electric heaters as well as gas or oil burners. These boilers
are considerably more expensive, but provide the flexibility of fuel switching
with the use of gas during the day and electricity at night.
Basic Components of A Boiler

<
Internal :
- Water space
- Steam space
<
External:
- Combustion chamber
- Heating surfaces
- Grate surfaces for wood and coal burning
Page 9 of 32
- Burner - Combustion air blower

- Ignition and atomizer
- Feed pumps - Injectors
3.4
<
Operating Controls:
Fuel-air flow controls

Fuel-air pressure controls
Fuel-air temperature controls
Ignition control
Mud blow down
Continuous blow down
<
Safety :
Steam safety valve

Hi-Low water control
Ignition proving
Combustion proving
Fusible plug
Feedwater Treatment
The quantity and quality of the condensate returned to the boiler plant will directly
affect the extent and cost of the feedwater treatment. The feedwater conditioning
and handling system must continuously satisfy certain conditions to discourage
operating problems.
The feedwater treatment and equipment may include the following:
<
<
<
<
<
<
Filters to remove suspended matter from condensate.

De-aerating heater to preheat the boiler feedwater and remove the
dissolved oxygen, carbon dioxide and other non-condensible gases.
Water softener and/or demineralizers to remove scale forming dissolved
solids from raw feedwater required to make up lost condensate. In
demineralization, ion exchange removes ionized mineral salts.
Demineralization can yield pure water required by high pressure boilers.
Blow down tanks to allow blow down of sediment from the boiler caused
by chemical treatment of make-up water.
Dealkalizers remove the alkalinity in the form of bicarbonates from raw
water make up. Bicarbonates break down into carbonates and CO2.
CO 2 leaves the boiler with the steam and forms acidic condensate,
which causes corrosion of condensate piping system.
Chemical treatment to:
- keep suspended and dissolved solids and sludge in a form that can
be removed through blow down.
- reduce corrosion by preventing the build up of oxygen and carbon
dioxide in the water.
- control pH.
- prevent foaming conditions within the drum which allows water
carryover with the steam.
Page 10 of 32
Sample specification for feed water and boiler water for low and medium pressure
boilers:
Feed water:
Total hardness as CaCO3
pH value
Dissolved oxygen
Silica as SiO2
Total dissolved solids
10 ppm
8.5 to 9.5
0.1
0.0
100 to 500 ppm
Boiler water:
Total alkalinity
Caustic alkalinity
pH value
Phosphates
Total dissolved solids
Silica
700 ppm
350 ppm
11 to 12
30 to 50 ppm
1,000 to 2,000 ppm
40 max.
.Condensate Tanks
Condensate tanks or receivers are designed to hold the returned condensate
and treated make-up water. They can be pressurized or vented to the
atmosphere. Vented tanks lose from 2 to 10% of the heat in the condensate
as flash steam. The cost of the treated boiler water that must be replaced and
the pumping cost must also be considered. A pressurized tank avoids these
losses, but a low pressure steam system must be available to absorb the
vented steam. An alternative is to cool the condensate with cold make-up
water to reduce or eliminate flashing of the condensate.
Flash Tanks
Flash tanks are used to separate condensate and flash steam that is produced
when condensate is reduced in pressure. This may be done so that plant
discharges can be reduced to atmospheric pressure before being disposed as
effluent or to produce quantities of low pressure steam for heating or
deaerating purposes. If a plant discharge produces a consistent flow of
significant quantities, some attempt should be made to recover heat by using
the flash steam to heat domestic or service water.
3.5
Boiler Plant Monitoring

The term monitoring refers to the act of observing the overall boiler plant equipment
operation plus the actual measurement of data available. Regular monitoring of the
plant variables is an essential part of consistently maintaining energy efficient
conditions. Combustion is a complex process which is dependant on a large
number of interacting boiler plant variables. Thus, the possibility for combustion air
and fuel conditions or equipment to change and alter the combustion efficiency
must always be anticipated. A significant large change would be obvious, but a
Page 11 of 32
gradual change might only be detected quickly as a result of good consistent

monitoring habits by operating personnel.
There is a variety of monitoring equipment available to assist operating personnel
in the task of ensuring that efficient operation is being achieved.
<
<
<
An annunciator is an alarm system that brings undesirable conditions to

the operator's attention by means of audible and/or visual signals.
Combination of indicators and recorders are used to display important
information.
Totalizers are often provided for steam and fuel flows so that the direct
boiler efficiency can be calculated.
Daily Boiler Log Book

The boiler room variables should be routinely recorded in the boiler log book.
A sample " Daily boiler log sheet" is provided in Figure 14.7. Each company
can design it's own log book to record the vital parameters of steam generation
peculiar to it's production needs. For large steam producing facilities
comprehensive log books are commercially available.
For a medium size operation the boiler log book should include:
<
<
<
<
<
<
<
3.6
Fuel data: fuel consumption, fuel pump discharge temperature and

pressure.
Combustion: stack temperature, ambient temperature, combustion
efficiency.
Steam: steam pressure, steam flow if available.
Feedwater:
feedwater temperature, flow, water quality, pump
discharge pressure.
Make-up: water softener, amount, water quality, temperature.
Blow down: manual daily discharge, continuous percentage discharge.
Boiler water: water quality.
Boiler Plant Efficiency

!
Energy Balance
Boiler Thermal Efficiency (%) '
EIN '
Boiler Heat Output (EOUT)

Boiler Heat Input (EIN)
Steam % Blowdown Loss

(Combustion Efficiency & % Radiation Loss)
Boiler Plant Efficiency (%) '
Steam Produced
Total Energy Input Including Auxilliaries
Page 12 of 32
Mass Balance
Feedwater = Steam Produced + Blowdown
Feedwater = Make-up Water + Condensate Returned
Condensate Returned = Feedwater - Make-up Water
Condensate Lost = Make-up Water - Blowdown
Condensate Returned = Steam Produced - Condensate Lost
Example
A packaged watertube steam boiler supplies high and low temperature heat for
the plant manufacturing processes.
Operational data
< Boiler Output
< Operating Pressure
< Operating Time
< Feed Water Temperature
< Ambient Temperature
< Flue Gas Temperature
< Fuel Oil HHV
< Cost of Fuel
< Combustion Efficiency, measured
< Boiler Radiation Losses, estimated
< Percentage Blowdown
< Make-up Water, metered
< Make-up Water Temperature
< Cost of Water including Sewage Charges
< Cost of Water Treatment
< Cost of Electricity
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
10,000 kg/h
1,500 kPa
6,000 h/y
105EC
20EC
280EC
38.68 MJ/L
$0.50 /L
78%
3%
8%
... 3 000 L/h
15EC
$2.00 /m3
$1.00 /m3
$0.10 /kWh
Mass balance
Feed water
= steam + blow down

= 10,000 + 800 kg/h
= 10,800 kg/h
Condensate Return = Feedwater - Make-up Water

= 10,800 - 3,000 kg/h
= 7,800 kg/h
Condensate Lost
= Make-up Water - Blowdown

= 3,000 - 800 kg/h
= 2,200 kg/h
Page 13 of 32
Energy balance:
EIN '

where
Steam
= m x (h1 - h2)
where
m = steam mass (10,000 kg/h)

h1 = total enthalpy in steam (2,793.7 kJ/kg)
h2 = enthalpy of feedwater (440.4 kJ/kg)
= 10,000 x (2793.7 - 440.4)
= 23.533 GJ/h
Blowdown
where
= m x (h3 - h4)
m = blowdown mass (800 kg/h)
h3 = enthalpy boiler water (856.3 kJ/kg)
h4 = enthalpy of make-up (62.8 kJ/kg)
= 800 x (856.3 - 62.8)
= 0.635 GJ/h
EIN '

'
23.533 % 0.635
0.78 & 0.03
'
32.224 GJ/h
Thermal Efficiency '
Steam Produced
'
Fuel Energy Input
23.533 GJ/h
32.224 GJ/h
'
73 %
Boiler plant efficiency includes energy input from auxiliaries items such as
lights, blowers, pumps, etc. The total electrical load is assumed to be 20 kWh
x 3.6 MJ/kWh = 72 MJ/h or 0.072 GJ/h. This energy input is negligible in
comparison with the other items listed above but not so on an annual cost
basis. The total energy input is 32.296 GJ/h (32.224 + 0.072).
Boiler Plant Efficiency '
Steam Produced
'
Total Energy Input
23.533 GJ/h
'
32.296 GJ/h
72.9 %
Page 14 of 32
Figure 14.7
DAILY BOILER LOG BOOK
Date
Shift
Shift-in-Charge
Fuel Consumption
kg/hr
Blowdown at
Time
1
2
3
Time
Fuel Pump Return

Discharge
Oil
Pressure Pressure
kg/cm2
kg/cm2
Fuel
Oil
Temp
Boiler
Steam
Pressure
EC
kg/cm2
Feedwater pump
Discharge
Pressure
Pump
No.1
Pump
No.2
Stack
Temp
Ambient
Temp
EC
EC
Boiler
Water
Level
Water
Water Remarks
Quality Softener
Checked Regeneat
rated
at
Page 15 of 32
4.0 STEAM DISTRIBUTION SYSTEM

Saturated steam should be distributed with a minimum loss of heat, a minimum
pressure drop and at a velocity not exceeding 25 m/s, to minimize the damage to
the system due to the water-hammer effect. The distribution system should ideally
include, steam separators, traps with strainers and air vents. It should have an
adequate slope in the direction of the flow to ensure removal of the condensate
and air. It is usually economical to distribute steam at boiler working pressure with
pressure reduction, if required, immediately ahead of the user equipment.
Figure 14.8
STEAM SEPARATOR AT TAKE-OFF FROM BOILER
4.1
Steam Circuit
The steam generated in the boiler must be conveyed through pipework to the
places where its heat energy is required. There will be one or more main pipes or
"steam mains" from the boiler in the general direction of the steam using plant.
Smaller branch pipes then carry steam to the individual pieces of equipment.
Figure 14.8 shows a typical piping arrangement with steam separator on the line
from the crown valve and condensate being carried away through strainer, float
trap and check valve to the condensate tank. In Figure 14.9, the problem of water
hammer conditions resulting from sagging pipes and condensate collection are
displayed.
When the boiler crown valve is opened steam immediately rushes from the boiler
into and along the main. The pipework is cold initially and so the heat transfer
takes place from the steam. The condensate forming in the pipes falls to the
bottom and is carried away by the steam flow to the low point of the main or other
branch pipes. When the valve on a piece of steam using equipment is opened,
steam enters and gives up its enthalpy of evaporation to warm up the equipment
and to bring it up to the operating conditions.
Page 16 of 32
For an efficient operation, the condensate formed in both the steam distribution
pipework and in the process equipment must be quickly returned to the feedwater
tank for reuse.
Figure 14.9
WATER PICK-UP AT LOW POINT
4.2
Steam Traps
The purpose of installing the steam traps is to obtain fast heating of the product
and equipment by keeping the steam lines and equipment free of condensate, air
and non-condensible gases. A steam trap is a valve device that discharges
condensate and air from the line or piece of equipment without discharging the
steam. When starting up the equipment and steam systems, lines and equipment
are full of air which must be flushed out. During continuous operation a small
amount of air and non-condensible gases, which enter the system with the
feedwater, must also be vented. All traps should be protected from dirt and scale
by installation of a strainer. Unless removed, this material may cause the trap to
jam in an open position, allowing the free flow of steam into the condensate
collection system. Traps are also available with check valve features to guard
against condensate backflow.
The many different types of steam traps manufactured operate by sensing the
difference between steam and condensate using one or more of the three basic
physical properties. When classified according to these operating principles, each
design has advantages and limitations which must be considered when selecting
a steam trap for a specific application.
The three basic types of steam traps are as follows:
<
<
<
Mechanical (Density operated)

Thermostatic (Temperature operated)
Disc and Orifice (Kinetic energy operated)
Figure 14.10 displays operating characteristics of basic steam trap types.
Page 17 of 32
Figure 14.10
OPERATING CHARACTERISTICS OF
a)
TYPE
b)
OPERATION
c)
OPERATING LOAD
FACTOR
d)
AIR HANDLING
CAPACITY
e)
AIR LOAD FACTOR
f)
g)
BALANCE PRESSURE
THERMOSTATIC
LIQUID EXPANSION
THERMOSTATIC
Intermittent action. Wide open

when cold allowing free
discharge of air incondensibles
and cool condensate.
Condenate at or near steam
temperature evaporates volatile
filling in element, closing trap.
Cooling of condensate aallows
filling to condense and trap
opens. Once trap is closed,
opening may be delayed in hot
locations.
Continuous discharge at
approximately constant
temperature below 100EC.
Wide open when cold, allowing
free discharge of air and cool
condensate. Condensate
approaching 93EC (maximum
discharge temperature)
expands oil filling of element,
throttling condensate flow.
3:1
2:1
Extremely high - in fact these

traps are often used as
thermostatic air vents.
Good. Air is freely discharged

on start-up and during running
tends to reduce condensate
temperature.
1:1
1:1
APPLICATION LOAD
FACTOR
In hot locations opening may be

delayed by slow cooling of
condensate. (2:1)
Pressure increase raises

condensate temperature,
roughly balancing increased
discharge rate. Pressure
decrease reduces condensate
temperature tending to increase
valve opening and capacity.
Extremely hot locations reduce
cooling rate of condenate. (2:1)
OVERALL LOAD
FACTOR
Normal Load Factor

= cxexf
= 3x1x1 = 3:1
Hot Locations
= 3x1x2 = 6:1
Normal Load Factor

= cxexf
= 2x1x1 = 2:1
Hot Locations
= 2x1x2 = 4:1
Page 18 of 32
(Figure 14.10 cont'd)
BASIC STEAM TRAP TYPES

INVERTED BUCKET
FLOAT &
THERMOSTATIC
THERMO-DYNAMIC
Intermittent discharge. Trap is

closed by air or steam filling
inverted bucket. Air and/or
steam leaks away through vent
hole in bucket which loses
bouyancy and sinks, opening
valve. Condensate is discharged
and process repeats.
Continuous discharge.
Condensate raises float, opening
valve the required amount to
release condensate as fast as it
enters. Intermediate response to
change of load and pressure
differential.
Intermittent condensate flows

freely through trap until
temperature approaches
saturation, when disc valve is
snapped shut by flashing
condensate. Condensate at inlet
causes control chamber
pressure to fall and trap opens.
Rapid response to condensate.
2:1
1:1
1.25 : 1
Air is by-passed on start-up by a

balanced pressure thermostatic
air vent. During running, air
entering the trap cools air vent,
which opens to release air.
Air must be released through

main valve seat, slowing the flow
of condensate when amount of
air is excessive.
As air can close the trap, it can

seriously reduce discharge
capacity.
2 : 1 to 3 : 1
1.2 : 1
Normal
Excessive Air
1:1
1.5 : 1
Not affected by high ambient

temperatures. (1:1)
The trap has no closed period

unless load falls to zero.
Unaffected by ambient
temperatures. (1.2:1)
Extreme ambient temperature

may delay opening. (1.5:1)
Normal Load Factor

= cxexf
= 2x2x1 = 4:1
Excess Air
= 3x1x2 = 6:1
Normal Load Factor

= cxexf
= 1 x 1.2 x 1 = 1.2 : 1
Heavy Load Variation
= 1 x 1.2 x 1.2 = 1.5 : 1
Normal Load Factor

= cxexf
= 1.25 x 1 x 1 = 1.25 : 1
Excessive Air
= 1.25 x 1.5 x 1 = 1.9 : 1
Excessive Heat
= 1.25 x 1 x 1.5 = 1.9 : 1
Excessive Heat & Air
= 1.25 x 1.5 x 1.5 = 2.8 : 1
Page 19 of 32
4.3
Flash Steam Recovery

Flash steam is released from hot condensate when its pressure is lowered, rather
than by further addition of heat. Even water at ordinary room temperature of 20EC
would boil if the pressure was lowered below 0.02 bar abs - and water at 170EC will
boil at any pressure below 6.9 bar g. The steam released by the flashing process
is just the same as the steam released when heat is added to saturated water while
a constant pressure is maintained.
For example if a load is applied to a boiler, and the boiler pressure drops a little,
then some of the water content of the boiler flashes off to supplement the steam
which is being produced by the supply of heat from the boiler fuel. Because it is
all produced in the boiler, the steam is all referred to as "live steam".
Only when the flashing takes place at relatively low pressure, as at the discharge
side of steam trap, is the name flash steam used. Unfortunately, this usage has
led to the erroneous conclusion that flash steam is in some way different from and
less valuable than, so called live steam.
In any system where it is sought to maximize efficiency - which should mean in all
systems - flash steam will be separated from the condensate. It can then be
utilized at low pressure, to help supply any low-pressure load. Every kilogram of
flash steam used in this way is a kilogram which does not have to be supplied
directly by the boiler. It is also a kg which will not be vented to the atmosphere.
The reasons for the recovery of flash steam are just as compelling, both morally
and economically, as those for recovering condensate.
!
How much flash steam?

To make use of flash steam, we need to know much of it will be available. The
quantity is readily determined by calculation, or it can be read from simple
charts or tables. As an example, let us consider the jacketed vessel shown in
Figure 14.11.
The condensate enters the trap as saturated water, at a gauge pressure of 7
bar and temperature of 170.5EC. The enthalpy of this saturated water is 721.4
kJ/kg. After passing through the steam trap, the pressure on the condensate
is the return line pressure, i.e. 0 bar gauge. At this pressure, the enthalpy of
saturated water is 419 kJ/kg and the temperature is 100EC. If a kilogram of
saturated water at 0 bar gauge were supplied with an additional 302.4 kJ/kg
(721.4 - 419) then this enthalpy would evaporate some of the water. The
enthalpy of evaporation at 0 bar gauge is 2,257 kJ/kg. An addition of 302.4 kJ
must evaporate 302.4 / 2,257 kg of steam from the water.
Equally, when one kg of condensate containing 721.4 kJ/kg reaches the return
line where the pressure is 0 bar g, it has surplus of 302.4 kJ above the enthalpy
of saturated water that it can hold. The same proportion of 302.4 / 2,257kg of
flash steam will be evaporated. Thus :
Page 20 of 32
Enthalpy of saturated water at 7 bar

= 721.4 kJ/kg
Enthalpy of saturated water at 0 bar
= 419.0 kJ/kg
Surplus energy
= 302.4 kJ/kg
Enthalpy of evaporation at 0 bar
Proportion of flash steam
= 2,257 kJ/kg
= 302.4 / 2,257 = 0.134 =
13.4%
If the steam-using equipment were condensing 250 kg of steam, then the
amount of flash steam released by the condensate at 0 bar gauge would be :
= 0.134 x 250 kg/h = 33.5 kg/h
5.0 END-USE EQUIPMENT

Normally, saturated steam is used in industrial and space heating applications.
Two basic types of heating occur in steam heating equipment. These are direct
and indirect heating.
With direct heating, the product or material to be heated is in direct contact with
the steam and in most cases, no condensate is recovered. An example of direct
heating is the heating of the liquid by directly injecting it with steam. The steam and
condensate mix with the product. If steam injection is used to heat an aqueous
solution an allowance has to be made for the diluting effect of the condensate.
Indirect heating separates the steam and product. In most cases the condensate
from the steam is recovered and reused for boiler feed water or other hot water
requirements. Examples of indirect heating include:
<
<
<
Steam-to-liquid heat exchangers

Product heating in storage tanks
Air heaters
It must be noted that situations may occur where condensate is not recovered from
indirect heated equipment. In instances such as heating vegetable oils, glucose
or preheating fuel oils in heat exchangers, a failure in the heat exchanger could
allow the heated material to mix with the condensate. If this condensate was then
returned as boiler feedwater, this condensate would foul the internal heat transfer
surfaces of the boiler.
The three basic types of indirect steam heated equipment are the steam coil,
jacketed vessels and heat exchangers. Normally for jacketed vessels or steam
coils the liquid to be heated is not flowing. For heat exchangers the steam and
liquid are flowing.
Page 21 of 32
Figure 14.11
TYPICAL STEAM HEATED EQUIPMENT IN INDUSTRY
FIXED GRAVITY JACKETED KETTLE:
Application: Meat Packing
Paper
Sugar
Fruit
Vegetable
Operation: Steam introduced around
the kettle transfers heat to
the product.
Pressure:
Depends on type of
product.
Problems:
Trapped air
Draining:
Product - Gravity drain
STEAM JACKETED PRESS:
Application: Molded Plastics (Records)
Rubber Products
Tires
Plywood
Laundry Flat Work
Operation: See sketch.
Pressure:
Depends on type of
product.
Draining:
Each platten individually
trapped.
DRYERS:
Rotating Drums - Rotary Cookers with
PRODUCT INSIDE
Application: Meat Packing
Chemical Process
Food
Operation: Low RPM (1-10). A
revolving cylinder drained
with a syphon - an internal
syphon surrounded by
steam. Some condensate
flashes back to steam due
to the steam jacketed
syphon pipe and syphon
lifting during evacuation.
Pressure:
0 - 1000 kPa
Draining:
Syphon drainage.
Page 22 of 32
Figure 14.11 (Cont'd)

TYPICAL STEAM HEATED EQUIPMENT IN INDUSTRY
DRYERS:
Rotating Steam Filled Drums with
PRODUCT OUTSIDE
Application: Paper - Making Paper
Textile - Drying and
Conditioning Fabrics
Plastics Food Laundry Operation: 1-2 RPM
25 m/s surface velocity
Pressure:
Ranging from subatmospheric to 1380 kPa.
Diam. Range 0.15 - 4.3 m.
Draining:
Syphon drainage required.
DIRECT STEAM INJECTION INTO
PRODUCT CHAMBER:
Application: Sterilization Autoclaves
Rubber
Plastics
Retorts for cooking food in
already sealed cans
Operation: See sketch.
Pressure:
Depends on type of
product.
Draining:
See sketch.
Industrial Steam Heating Equipment

Samples of typical industrial steam heated equipment with a brief description
of operating characteristics are shown in Figure 14.11.
Unit Heaters
The unit heaters are heat exchangers that use steam or hot water forced
through metal tubes, to heat air blown over the tubes. (Refer to Figure 14.12.)
Normally the tubes are finned or passed through thin metal plates to increase
the surface area and heat transfer rate. A low room temperature signal from
a thermostat starts the fan and blows air over the heated surfaces, increasing
the heat transfer rate to the air. As soon as the thermostat senses the desired
temperature, the fan shuts off.
Page 23 of 32
Figure 14.12
TYPICAL UNIT HEATER
6.0 ENERGY MANAGEMENT OPPORTUNITIES

6.1
Housekeeping Opportunities
!
Boiler House - Operation

<
<
<
<
<
<
<
<
Regularly check water treatment procedures.

Maintain the total dissolved solids (TDS) of the boiler within
recommended limits, for the pressure range of the boiler.
Operate at the lowest steam pressure or hot water temperature that is
acceptable to the boiler design and distribution system requirements.
Condition fuel for optimum combustion.
Minimize load swings and schedule demand where possible to
maximize the achievable boiler efficiencies.
Regularly check the efficiency of the boilers.
After the boiler tune-up start recording and analyzing the flue gas
temperature for signs of heat transfer surfaces fouling.
Regularly monitor the boiler excess air.
Boiler House - Maintenance

<
<
<
<
<
<
<
Keep burners in proper adjustment.

Check for and repair leaking flanges, valve stems and pump glands.
Maintain tightness of all air ducting and flue gas breeching.
Check for hot spots on the boiler casing that may indicate deteriorating
boiler insulation that should be repaired during the annual shutdown
period.
Keep fireside surfaces of the boiler tubes clean.
Replace and repair missing or damaged insulation.
Replace boiler observation or access doors and repair any leaking door
seals.
Page 24 of 32
Steam Distribution System

<
<
<
<
<
End-Use Equipment
<
<
<
<
<
<
<
<
6.2
Establish steam trap maintenance and procedures.

Check and correct steam and condensate leaks.
Train operating personnel.
Check control setting.
Shut down steam and condensate branch system when not required.
Seal leaks at valves, fittings and gaskets.

Repair damaged insulation
Maintain equipment strainers and traps.
Clean heat transfer surfaces.
Ensure that steam quality is adequate for the application.
Ensure that the steam pressure and temperature ranges are within the
tolerances specified for the equipment.
Ensure that the traps are correctly sized to remove all the condensate.
Ensure that the heating coils are sloping from the steam inlet to the
steam trap to prevent the coil flooding with condensate.
Low Cost Opportunities

!
Boiler plant
<
<
<
<

<
<
<
<
<
<
Install performance monitoring equipment.

Relocate combustion air intake to the top of the boiler house to use the
heated air and save energy.
Recover blowdown heat.
Reduce boiler excess air where possible.
Recover condensate where economically feasible.

Overhaul the pressure reducing stations.
Reduce the direct use of steam where possible by using the heat
exchanger.
Remove unused steam and condensate pipes.
Reduce system pressure where possible.
Relocate the equipment to shorten the length of piping.
End-Use Equipment
<
<
<
Shut down equipment when not required.

Provide lockable type covers for control equipment such as thermostats
to prevent unauthorized tampering.
Operate equipment at or near capacity whenever possible. Avoid
running multiple units at reduced capacity.
Page 25 of 32

<
6.3
Add thermostatic air vents.
Retrofit Opportunities
!
Boiler House
<
<
<
<

<
<
<
<
<
<
<
Install economizer.
Install preheater.
Upgrade burner.
Install tubulators in fire tube boiler.
Institute steam trap replacement program.

Optimize pipe sizes.
Recover flash steam.
Eliminate steam use where possible.
Stage the depressurization of condensate.
Recover heat from condensate.
Meter all steam and condensate flows.
End-Use Equipment
<
<
<
Convert from direct to indirect steam heated equipment and recover

condensate.
Modify process, if possible, to stabilize steam or water demand.
Evaluate waste water streams leaving a facility for heat recovery
opportunity.
7.0 WORKED EXAMPLES

7.1
Relocate Combustion Air Intake (Boiler House)

The combustion air intake can sometimes be relocated to the top of the boiler
house to use heated air and thus save energy.
A boiler firing No.2 oil uses 14,500 kg/h of air at 20EC average temperature.
Installation of the duct to the top of the boiler house increases the average air
temperature to 30EC. The specific heat of air is 1.01 kJ/kg.
Page 26 of 32
The recovered heat (Q) is:

Q = m x Cp x )T
= 14,500 kg/h x 1.01 kJ/kgEC x (30 - 20)EC
= 146,450 kJ/h
Assuming the boiler operates 6,000 hours per year and fuel costs $5 /GJ, the
annual fuel cost saving is:
' 146,450 kJ/h x 6,000 h/y x $5 /GJ

1,000,000 kJ/GJ
' $ 4,390 per year

Assuming the cost of ducting is $5,000, the simple payback period (SPB) is:
SPB
7.2
' $ 5,000 ' 1.1 years

$ 4,390
Replace Or Repair Leaking Traps (Steam Distribution System)

During the steam trap survey it was noted that a steam trap with 3.17 mm orifice
on a 205 kPa(abs) heating system did not appear to be operating properly. Further
investigation indicated that the trap was stuck in the full-open position allowing the
steam to flow into the condensate return line.
From Figure 14.13, it was established that this condition would allow the trap to
pass 6.2 kg of steam per hour. The heating system in this facility was used 3,600
hours per year and the cost of steam was estimated to be $22 per 1,000 kg.
The steam loss from the leaking trap is:
= 6.2 kg/h x 3,600 h/y = 22,320 kg/yr
The cost of energy associated with this steam loss is:
= 22,320 kg/yr x $0.022 /kg = $491 /year
Assuming the replacement cost of the new trap, including labour, is $90, the simple
payback period is:
SPB
'
$ 90
$ 491
' 0.18 years (2 months)
If the system pressure was higher or the orifice larger, the quantity of lost steam
would greatly increase as would the cost of the money being lost.
Page 27 of 32
Figure 14.13
STEAM LOSS THROUGH ORIFICE DISCHARGING TO ATMOSPHERE
Orifice
Diam
(mm)
15
30
60
100
150
300
500
700
900
1400
1700
1900
0.8
1
2
0.18
0.28
1.14
0.21
0.32
1.28
0.25
0.40
1.58
0.32
0.49
1.98
0.40
0.62
2.47
0.63
0.99
3.95
0.95
1.48
5.93
1.27
1.98
7.91
1.58
2.47
9.88
2.37
3.71
14.8
2.85
4.45
17.8
3.16
4.94
19.8
3
4
5
2.56
4.55
7.10
2.89
5.14
8.03
3.56
6.33
9.88
4.45
7.91
12.4
5.56
9.88
15.4
8.90
15.8
24.7
13.3
23.7
37.1
17.8
31.6
49.4
22.2
39.5
61.8
33.4
59.3
92.7
40.0
71.2
111
44.5
79.1
124
6
7
8
10.2
13.9
18.2
11.6
15.7
20.6
14.2
19.4
25.3
17.8
24.2
31.6
22.2
30.3
39.5
35.6
48.4
63.3
53.4
72.6
94.9
71.2
96.9
127
89.0
121
158
133
182
237
160
218
285
178
242
316
9
10
11
23.0
28.4
34.4
26.0
32.1
38.9
32.0
39.5
47.8
40.0
49.4
59.8
50.0
61.8
74.7
80.1
98.8
120
120
148
179
160
198
239
200
247
299
300
371
448
360
445
538
400
494
598
12
12.7
40.9
45.8
46.3
51.8
56.9
63.8
71.2
79.7
89.0
99.6
142
159
213
239
285
319
356
399
534
598
640
717
712
797
7.3
Steam Loss (kg/h) when steam gauge pressure (kPa) is:
Shut Down Equipment (End-Use Equipment)

During the plant survey it was noted that a steam heater supplying hot air to a
drying tunnel was operating even though the tunnel was not in use. Subsequent
investigation established that the heater system ran for 8,760 hours per year,
although the tunnel only operated 6,000 hours per year. Steam used for the heater
was 689 kPa (gauge) dry and saturated. Steam flow to the unit was measured at
200 kg/h. The cost of steam was $0.022 /kg.
The annual reduction in steam usage is:
= (8,760 - 6,000) h/yr x 200 kg/h
= 552,000 kg/yr
The annual cost saving is:
= 552,000 kg/yr x $ 0.022 /kg
= $12,144 /yr
It was decided to install a relay and solenoid valve to shut off the steam when the
drying tunnel was not in operation. Estimated cost to supply and install the
hardware was $ 500. The simple payback period is:
SPB
'
$ 500
$ 12,144
' 0.04 years (15 days)
Page 28 of 32
8.0 ASSIGNMENT
The purpose of this assignment is to assess the operation of the boiler house, the
conditions of the steam distribution network and the steam end-use equipment.
After accomplishing this task, explore the potential of improving the efficiency of the
steam generation, reducing the steam distribution losses and updating the
operation of the steam using equipment. Specific tasks in this assignment include:
Assess the Boiler House Records

<
Examine the log book data. Does it describe all the regular maintenance
and operating procedure data required for a good maintenance and energy
management program? If there is no log book maintained in the boiler
house establish one, using as a guide the log book sample in this module.
<
Review the fuel consumption records. (Part of Module 2 assignment.)
<
Check the steam production records. Is there a steam meter installed in

the boiler house? If so, does it record the total steam production or the
steam production from each boiler? Has the meter been calibrated
recently?
If there is no steam meter, consider having one installed. (A more
economical approach may be to install a feedwater meter as described
below.)
<
Check the boiler feedwater records. Is the water metered per boiler or for
the total plant? Does the feedwater quantity correlate with steam
production? If the feedwater is not metered, arrange to have one installed.
<
Check the make-up water records. If the make-up water is not metered
arrange to have one installed.
<
Check the condensate return. How much condensate is being returned?

What temperature is the returned condensate? What is the temperature of
the water in the feedwater tank?
<
Check the feedwater testing procedures and establish feedwater analysis

records where none exists.
<
Check the make-up water testing procedures and establish water

analysis records where none exists.
Determine Boiler Combustion and Radiation Losses

<
Analyze the flue gas and calculate the combustion efficiency. (Part of
Module 13 assignment.)
Page 29 of 32

<
Calculate radiation losses. Should the boiler insulation be repaired or

replaced? (Part of Module 13 assignment. Also refer to Module 8.)
Calculate Boiler Plant Performance

<
Complete a mass balance of the boiler plant system.
<
Complete an energy balance of the boiler plant system.
<
Calculate the thermal efficiency and the overall efficiency for the boiler
plant using the procedure described in this module.
Check the Steam Distribution System

<
Check the insulation on the steam distribution lines. Should the insulation
be repaired, replaced or upgraded? (Part of Module 8 assignment.)
<
Check the insulation on the condensate return lines. Should the insulation
be repaired, replaced or upgraded? (Part of Module 8 assignment.)
<
Check the insulation on the feedwater tank. Should the insulation be

repaired, replaced or upgraded? (Part of Module 8 assignment.)
<
Observe and record any steam leakages around valve stems, fittings or
piping. Make repairs as required.
<
Survey and record the condition and operation of the steam traps. Have
faulty traps repaired immediately.
<
Review existing program for maintaining steam traps. Is the program

adequate?
<
Calculate applicable losses due to insufficient insulation of the steam

pipes and losses due to leaking joints and faulty steam traps.
Check Steam End-Use Equipment

<
Make sure the equipment is operating near design capacity and that the
quality of steam is according to the equipment specification.
<
Examine the production schedule for the steam operated equipment.
<
Check the shut-off valves on the equipment for leaking particularly when
the equipment is not in production.
Page 30 of 32
Assess Potential Energy Management Measures

<
Identify potential improvements to the entire steam generating, distributing

and end use systems.
<
Calculate the cost saving benefits that would be achieved by each

measure.
Estimate the cost of implementing the energy efficiency improvements.
<
<
Prepare a one page summary proposal for each recommendation, stating

initial conditions, proposed improvements, cost savings, cost of
implementation and simple payback. Use the Energy Management
Opportunities form from Module 3 or similar.
9.0 SUMMARY - Module 14

In this module you learned about:
Principles of Steam Generation,
Steam Tables,
Boiler House Operation,
Boiler Plant Monitoring,
Boiler Plat Efficiency,
Steam Distribution,
Steam Heated Equipment.
You should now be able to perform the following tasks:
Assess the Operation of the Boiler House in Your Plant,
Evaluate the Boiler House Performance,
Identify Potential Improvements,
Assess the Benefits, Cost and Simple Payback Period for

Each Measure.
Page 31 of 32
DAILY BOILER LOG BOOK

Date
Shift
Shift-in-Charge
Fuel Consumption
kg/hr
Blowdown at
Time
1
2
3
Time
Fuel Pump Return

Discharge
Oil
Pressure Pressur
kg/cm2
e
Fuel
Oil
Temp
EC
kg/cm2
Boiler
Feedwater pump
Steam Discharge Pressure
Pressure
kg/cm2
Pump
No.1
Pump
No.2
Stack
Temp
Ambient
Temp
EC
EC
Boiler
Water
Level
Water
Water
Quality Softener
Checked Regeneat
rated
at
Remarks

Learn Steam Generation and Distribution Systems

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Learn Steam Generation and Distribution Systems

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MODULE 14

Steam Generation and Distribution.

The Use of Steam in Industrial Plants and Processes,

How Steam is Generated and Distributed for End-Use,

Use of Steam Tables to Calculate Energy/Mass Balance,

Heat Recovery from Flash Steam and Blow Down,

Boiler Plant Equipment & Operation,

Boiler Plant Efficiency.

Examine steam distribution systems including steam trap

Evaluate the steam distribution system including boiler

Prepare a boiler mass balance, including boiler blow-down,

Evaluate feedwater treatment procedures.

Make recommendations for system improvement based on

In this module you will learn about:

SADC Industrial Energy Management Project

PRINCIPLES OF STEAM GENERATION AND STEAM TABLES . . .

BOILER HOUSE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Energy Flow and Balance . . . . . . . . . . . . . . . . . . . . . . . . . . .

STEAM DISTRIBUTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENERGY MANAGEMENT OPPORTUNITIES . . . . . . . . . . . . . . . . . .

Relocate Combustion Air Intake (Boiler House) . . . . . . . . . . .

SADC Industrial Energy Management Project

Module 14 - Steam Generation & Distribution ....

2.0 PRINCIPLES OF STEAM GENERATION AND STEAM TABLES

SADC Industrial Energy Management Project

Module 14 - Steam Generation & Distribution ....

SADC Industrial Energy Management Project

Module 14 - Steam Generation & Distribution ....

Enthalpy of liquid (hf) is a measure of the amount of heat energy

Enthalpy of evaporation (hfg) (correctly called the latent heat of

The three previous figures for enthalpy may be expressed in an equation

Examples From Steam Table (Appendix C)

SADC Industrial Energy Management Project

Module 14 - Steam Generation & Distribution ....

= Gauge Pressure (kPa) + 101.325 kPa

where 1 bar = 100 kPa

200 kPa (2 bar abs) Dry Saturated Steam

Total heat (hg)

1,000 kPa (10 bars abs) Dry Saturated Steam

Total heat (hg)

From the foregoing enthalpy comparison it should be noted that, as steam

Mass of Steam Vapour

Total heat (hg)

The heat required to eliminate moisture is:

SADC Industrial Energy Management Project

Module 14 - Steam Generation & Distribution ....

3.0 BOILER HOUSE OPERATION

Energy Flow and Balance

SADC Industrial Energy Management Project

Module 14 - Steam Generation & Distribution ....

Direct fuel to the combustion chamber.

SADC Industrial Energy Management Project

Module 14 - Steam Generation & Distribution ....

Natural Gas Burners

Pulverized Coal Burners

Low pressure boilers operate in the range up to 3 bars pressure.

SADC Industrial Energy Management Project

Module 14 - Steam Generation & Distribution ....

combustion gas contacts as much of the heat transfer surface as possible,

Basic Components of A Boiler

SADC Industrial Energy Management Project

Module 14 - Steam Generation & Distribution ....

- Burner - Combustion air blower