Block 2 Steam Engineering Principles and Heat Transfer Measurement of Steam Consumption Module 2.

Module 2.7
Measurement of Steam
Consumption

The Steam and Condensate Loop 2.7.1

Block 2 Steam Engineering Principles and Heat Transfer Measurement of Steam Consumption Module 2.7

Measurement of Steam Consumption

The use of a steam flowmeter may be used to directly measure the steam usage of an operational
item of plant. This may be used to monitor the results of energy saving schemes and to compare
the efficiency of one item of plant with another. The steam can then be costed as a raw material
at any stage of the production process, so that the cost of individual product lines may be
determined.
It is only in comparatively rare cases that a meter cannot measure steam flow. Care should be
taken, however, to ensure that the prevailing steam pressure is considered and that no other
calibration factor has been overlooked.
Steam flowmetering is discussed in detail in Block 4.

Temperature sensor

Steam flow
Flow transducer

Differential pressure cell Display unit

Fig. 2.7.1 Typical steam flowmeter installation

A less accurate method of estimating the steam consumption is by incorporating a counter into
the body of a positive displacement pump used to pump condensate from the process. Each
discharge stroke is registered, and an estimate of the capacity of each stroke is used to calculate
the amount of steam condensed over a given time period.

Cycle counter

Condensate pump

Fig. 2.7.2 Positive displacement pump with cycle counter

2.7.2 The Steam and Condensate Loop

Block 2 Steam Engineering Principles and Heat Transfer Measurement of Steam Consumption Module 2.7

A purpose built electronic pump monitor can be used which enables this to be carried out
automatically, converting the pump into a condensate meter. The electronic pump monitor can
be read locally or can return digital data to a central monitoring system. If the pump is draining
a vented receiver, a small allowance has to be made for flash steam losses.
Steam consumption can also be established directly, by measuring the mass of condensate collected
in a drum over a period of time. This may provide a more accurate method than using theoretical
calculations if the flash steam losses (which are not taken into account) are small, and can work
for both non-flow and flow type applications. However, this method cannot be used in direct
steam injection applications, humidification or sterilisation processes, where it is not possible to
collect the condensate.

Figure 2.7.3 shows a test being carried out on a jacketed pan. In this case an empty oil drum and
platform scales are shown, but smaller plant can be tested just as accurately using a bucket and
spring balance. This method is quite easy to set up and can be relied upon to give accurate results.

Jacketed pan
Steam

Steam trap

Condensate
collection
Drain cock vessel

Weighing
apparatus
Condensate
Fig. 2.7.3 Equipment for measurement of steam consumption

The drum is first weighed with a sufficient quantity of cold water. Steam is then supplied to the
plant, and any condensate is discharged below the water level in the container to condense any
flash steam. By noting the increase in weight over time, the mean steam consumption can be
determined.
Although this method gives the mean rate of steam consumption, if the weight of condensate is
noted at regular intervals during the test, the corresponding steam consumption rates can be
calculated. Any obvious peaks will become apparent and can be taken into account when deciding
on the capacity of associated equipment. It is important to note that the test is conducted with
the condensate discharging into an atmospheric system. If the test is being used to quantify steam
consumption on plant that would otherwise have a condensate back pressure, the steam trap
capacity must relate to the expected differential pressure.
Care must also be taken to ensure that only condensate produced during the test run is measured.
In the case of the boiling pan shown, it would be wise to drain the jacket completely through the
drain cock before starting the test. At the end, drain the jacket again and add this condensate to
that in the container before weighing.
The test should run for as long as possible in order to reduce the effect of errors of measurement.
It is always advisable to run three tests under similar conditions and average the results in order to
get a reliable answer. Discard any results that are widely different from the others and, if necessary,
run further tests.
If the return system includes a collecting tank and pump, it may be possible to stop the pump for a
period and measure condensate volume by carefully dipping the tank before and after a test period.
Care must be taken here, particularly if the level change is small or if losses occur due to flash steam.

The Steam and Condensate Loop 2.7.3

Block 2 Steam Engineering Principles and Heat Transfer Measurement of Steam Consumption Module 2.7

Questions
Relative questions on this subject will be asked in Block 4, 'Steam Flowmetering'.

2.7.4 The Steam and Condensate Loop