HRSG

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 Table of Content
1. Steam
2. Heat Transfer & Thermodynamics
3. Steam Generators
4. Power Plants
5. HRSG
6. Inspection and Maintenance
7. MARAFIQ Plant
 Learning methods
 PowerPoint

 Videos

 Computer Based Learning

Steam

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 What is Steam?

 Why is Steam Used?

 How Do We Create Steam?

 How Do We Identify Steam Properties?

 Steam is a vapor form of
water, and is colorless,
tasteless, and odorless
Three principle forms of energy used in industrial
processes

Electricity Direct fired Heat

Electricity is used in many different ways
 Mechanical Drive
 Heating
 Electrochemical Reactions

Direct-fired energy directly transfers the heat of fuel by combustion

to a process
Steam provides
 Process Heating
 Pressure Control
 Mechanical Drive
 Component Separation
 A Source Of Water For Many Process Reactions
Steam has many performance advantages that
make it an indispensable means of delivering
energy
 Low Toxicity
 Ease Of Transportability
 High Efficiency
 High Heat Capacity
 Low Cost
Steam holds a significant amount of
energy on a unit mass basis (between
1,000 and 1,250 [Btu/lb]) that can be
extracted as mechanical work through
a turbine or as heat for process use
Steam is also used in many direct contact
applications
 A Source Of Hydrogen In Steam Reforming
 To Control The Pressures And Temperatures Of Many
Chemical Processes.
 To Strip Contaminants From A Process Fluid
 To Facilitate The Fractionation Of Hydrocarbon
Components
 To Dry All Types Of Paper Products
Steam is an efficient heat transfer medium
We have already developed the equipment
and expertise to design and install steam
systems for many different applications
We have a lot of knowledge concerning
steam
Steam is easily controlled
 Steam is created by adding Heat Energy to water.

 Heat Energy is expressed in Btu’s.

 1 Btu is the amount of Heat Energy required to raise

the temperature of 1 pound of water by 1°F.
The Heat Energy required to create steam has two
forms:

Sensible Heat

Latent Heat
 Sensible Heat is the amount of Heat Energy
required to raise the temperature of water from
32°F to the boiling point (saturated liquid) at a given
pressure
 Sensible Heat raises the temperature of the water
and can be sensed with a thermometer
 O PSIG
212° F.

1 lb. Water

1 Lb. of Saturated Water at

Atmospheric Pressure Contains
180 Btu’s of Sensible Heat
HEAT
 Adding Heat Energy – Sensible Heat
250 °F. 15 PSIG

1 Lb. of Saturated Water at

15 PSIG Contains
218 Btu’s of Sensible Heat
HEAT
 Heat Energy – Sensible Heat

308 °F. 60 PSIG

1 Lb. of Saturated Water at

60 PSIG Contains
277 Btu’s of Sensible Heat
HEAT
 Latent Heat is the amount of Heat Energy
required to transform water at the boiling point
(saturated liquid) to steam
 Adding Latent Heat does not raise the
temperature – saturated liquid and steam
have the same temperature for a given
pressure
 O PSIG
212° F.

1 lb. Steam

1 Lb. of Steam at Atmospheric

HEAT Pressure Contains
970 Btu’s of Latent Heat
 Adding Heat Energy – Latent Heat
250 °F. 15 PSIG

1 Lb. of Steam at 15 PSIG

Contains 945 Btu’s of
Latent Heat
HEAT
 Adding Heat Energy – Latent Heat

308 °F. 60 PSIG

1 Lb. of Steam at 60 PSIG

Contains 904 Btu’s of
Latent Heat
HEAT
Increased Pressure:
 Decreases the amount of Latent Heat
 Increases the amount of Sensible Heat
1000
900
800
700
600
500 0 psig
400 15 pig
300 50 psig
200
100
0
Latent Sensible
Heat Heat
BTU/lb BTU/lb
 Increased Pressure:
 Decreases the Specific Volume

Spe cific Volume v s. Pre ssure

(cu. ft / lb) (psig)

26.8
30
0 PSIG
25
15 PSIG
20
13.8 60PSIG
15
10 5.8
5
0
1
 Increased Pressure:
 Increases the Steam Temperature

Steam Temperature vs. Pressure

(Deg. F) (psig)

400 308 0 PSIG

250 15 PSIG
300 212
60PSIG
200
100
0
1
Steam Pressure

Sensible Heat

Latent Heat

Specific Volume
Steam Tables
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 Steam tables allow us to
identify all of the important
properties of steam, given
either the steam temperature or
the steam pressure
Example: Steam at 250oF is at 15 psig, with 945 Btu’s/lb of Latent Heat
Steam at 5 psig is at 228oF, with 196 Btu’s/lb of Sensible Heat 32
Generation

Distribution

End Use

Recovery
 Steam is generated in a boiler or a heat
recovery steam generator by transferring the
heat of combustion gases to water.
 When water absorbs enough heat, it changes
phase from liquid to steam.
 In some devices, a super heater further
increases the energy content of the steam.
 Under pressure, the steam then flows from the
boiler or steam generator and into the
distribution system.
 The distribution system carries steam from the boiler or
generator to the points of end use.
 Many distribution systems have several take-off lines
that operate at different pressures.
 These distribution lines are separated by various types
of isolation valves, pressure regulating valves, and,
sometimes, backpressure turbines.
 A properly performing distribution system delivers
sufficient quantities of high-quality steam at the right
pressures and temperatures to the end uses.
 Effective distribution system performance requires
proper steam pressure balance, good condensate
drainage, complete and optimum insulation with regular
repair and maintenance, and effective pressure
regulation
 There are many different end uses of steam
 In a turbine, the steam transforms its energy to
mechanical work to drive rotating machinery such as
pumps, compressors, or electric generators.
 In a heat exchanger, the steam transfers its latent heat
to a process fluid. The steam is held in the heat
exchanger by a steam trap until it condenses.
 In fractionating towers, steam facilitates the separation
of various components of a process fluid.
 In stripping applications, the steam pulls contaminants
out of a process fluid.
 The condensate return system sends the condensate
back to the boiler.
 The condensate is returned to a collection tank.
 Sometimes the makeup water and chemicals are
added here, while other times this is done in the
deaerator.
 From the collection tank the condensate is pumped to
the deaerator, which strips oxygen and non-
condensable gases.
 The boiler feed pumps increase the feedwater
pressure to above boiler pressure and inject it into
the boiler to complete the cycle.
What Do We Do With It
Since Steam is used to Transfer
Heat Energy From One Location
to Another . . .
It only makes sense that we take
the heat energy back out and
use it to do work.
1 lb. of Steam at 212°F, with a TOTAL HEAT content
of 1150 Btu/lb. – 970 Btu’s of LATENT HEAT
= 1 lb. of boiling water (Saturated Liquid) at 212°F
with a heat content of 180 BTU’s/lb.

1200 1150
970
1000
800
Btu's
600
400 212
180 212
200 32
0
Atmospheric Pressure
 Remember:

The Latent Heat added at the boiler is what we have available to do work in
our equipment
BUT . . .
When we remove Latent Heat we create Condensate

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 Latent Heat can be removed
intentionally, in a piece of heat
exchange equipment, or
unintentionally, from radiation
heat loss in piping
 Condensate Steam Vapor
50.3 psig
297.97°F

100 psig
PRV
337.9°F
Trap
Trap

Trap
Trap Trap
Trap

Vent
The Steam System is Constantly Being Filled With Water
(Condensate)

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Your Steam System is Subject to Corrosion

( CO2 + H2O = H2CO3 )

Subcooled Condensate + CO2

Forms Carbonic Acid
Your Steam System is Subject to Water Hammer
Your Heat Exchange Equipment is Less Efficient
Your System Must Be Properly Piped
Your Equipment Must Be Properly Trapped