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e. ci i f he c i a e ia a a b he hea e i a fi ,a c bi ed effec . Tab e 2.10.1 b e ged ea c i a ica i db i e ai f he da a i c ide ab . d he he a ide ica . 'U' a e f he ab e.

A he a iab e i he c i a e ia i H e e , e a hea a fe i g c d ci i f he c i a e ia i e a hea a fe c efficie f ea e e be ee 2 ba g a

e f. The he a c d e ed a a ge e e a ig ifica a hei ai c di i f d 6 ba g h d be f

The a ge f fig e h i Tab e 2.10.1 de a e he diffic i idi g defi i i e 'U' a e . C a fig e a he highe e d f he ca e i a i a ai ha a e ied i h c ea d ea , a c i a d g d c de a e d ai age. The e e di e a icab e ai ea , gc i a d c de a e d ai age. The ec e ded e a hea a fe c efficie ec e ded a e a e e i ica de i ed, a d a ie he c i i i g. I i a i ge e a ica c di i a di e e ha a ge e a ai . The e afe a gi

he ca e f f id he ha a e , he hea a fe c efficie i a e e e ide d e he a i hich i c i a ie ih e e a e. H e e , he a e h i Tab e 2.10.2 i e e a a g ide f e c e c e ed b a ce , hi e Tab e 2.10.3 gi e ica face a ea f i e e e e e g h.

E ample 2.10.1
C i i gf E a e 2.9.1 de e ea a f i e: aed i g i ed. a . (Mea hea ad = 367 W) Part 1. The a e age Part 2. The hea Part 3. A ec Part 4. The a i a

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5. A recommendation for installation, including coil diameter and layout. i g addi i a i f ai ha bee ided:

The f

Steam pressure onto the control valve = 2.6 bar g (3.6 bar a). A stainless steel steam coil provides heat. Heat transfer coefficient from steam/coil/liquid, U = 650 W/m C Pa 1 Ca c a e he a e age ea a f a ed i g a -

Steam pressure onto the control valve = 2.6 bar g (3.6 bar a) Critical pressure drop (CPD) will occur across the control valve during start-up, therefore the minimum steam pressure in the heating coil should be taken as 58% of upstream absolute pressure. An explanation of this is given in Block 5.

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Because of the difficulties in providing accurate 'U' values, and to allow for future fouling of the heat exchange surface, it is usual to add 10% to the calculated heat transfer area.

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Maximum heat transfer (and hence steam demand) will occur when the temperature difference between the steam and the process fluid is at its maximum, and should take into consideration the extra pipe area allowed for fouling.

(a) Con ide

he ma im m hea ing capaci = UA T

of he coil (coil)

Using Equation 2.5.3:

(b) S eam flo

a e o deli e 519 kW

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5 A ecommenda ion fo in alla ion, incl ding coil diame e and la o

(a) De e mine coil diame e and leng h

From Table 2.10.3, a 100 mm pipe has a surface area of 0.358 m/m run. This application will require:

It may be difficult to accommodate this length of large bore heating pipe to install in a 3 m 3 m tank. One solution would be to run a bank of parallel pipes between steam and condensate manifolds, set at

different heights to encourage condensate to run to the lower (condensate) manifold. The drain line must fall from the bottom of the condensate manifold down to the steam trap (or pump-trap). See Figure 2.10.1 for a suggested layout.

Fig. 2.10.1 Possible la out of coils in a rectangular tank Note the steam supply is situated at one end of its manifold, whilst the trap set is at the other end. This will help steam to flow and push condensate through the coils. In the application, the steam and condensate headers would each be 2.8 m long. As the condensate manifold is holding condensate, the heat from it will be small compared to the steam manifold and this can be ignored in the calculation. The steam manifold should be 100 mm diameter as determined by the previous velocity calculation. This will provide a heating area of: 2.8 m x 0.358 m /m = 1.0 m Consequently 7 m - 1 m = 6 m of heat transfer area is still required, and must be provided by the connecting pipes. Arbitrarily selecting 32 mm pipe as a good compromise between robustness and workability:

The lengths of the connecting pipes are 2.5 m.

CHECK It is necessary to confirm the steam velocity through the connecting tubes: On the basis of proportionality of heat transfer area, the steam header will condense:

This leaves 86% of the 850 kg/h = 731 kg/h of steam which must pass through the 18 connecting pipes and also into the lower (condensate) manifold.

Other steam coil la outs

The design and la out of the steam coil will depend on the process fluid being heated. When the process fluid to be heated is a corrosive solution, it is normall recommended that the coil inlet and outlet connections are taken over the lip of the tank, as it is not normall advisable to drill through the corrosion resistant linings of the tank side. This will ensure that there are no weak points in the tank lining, where there is a risk of leakage of corrosive liquids. In these cases the coil itself ma also be made of corrosion resistant material such as lead covered steel or copper, or allo s such as titanium. However, where there is no danger of corrosion, lifts over the tank structure should be avoided, and the steam inlet and outlet connections ma be taken through the tank side. The presence of an lift will result in waterlogging of a proportion of the coil length, and possibl waterhammer, noise and leaking pipework. Steam heating coils should generall have a gradual fall from the inlet to the outlet to ensure that condensate runs toward the outlet and does not collect in the bottom of the coil. Where a lift is unavoidable, it should be designed to include a seal arrangement at the bottom of the lift and a small bore dip pipe, as shown in Figure 2.10.2.

Fig. 2.10.2 Tank with a rising discharge pipe The seal arrangement allows a small amount of condensate to collect to act as a water seal, and prevents the occurrence of steam locking. Without this seal, steam can pass over an condensate collecting in the bottom of the pipe, and close the steam trap at the top of the riser. The condensate level would then rise and form a temporar water seal, locking the steam between the bottom of the riser and the steam trap. The steam trap remains closed until the locked steam condenses, during which time the coil continues to waterlog. When the locked steam condenses and the steam trap opens, a slug of water is discharged up the riser. As soon as the water seal is broken, steam will enter the rising pipe and close the trap, while the broken column of water falls back to lie at the bottom of the heating coil. The small bore dip pipe will onl allow a ver small volume of steam to become locked in the riser. It enables the water column to be easil maintained without steam bubbling through it, ensuring there is a stead and continuous condensate flow to the outlet. When the seal is ultimatel broken, a smaller volume of water will return to the heating coil than with an unrestricted large bore riser, but as the water seal arrangement requires a smaller volume of condensate to form a water seal, it will immediatel re-form.

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Fig. 2.10.3 Side hung coils I , . T .H , . Whilst the next two headings, 'Si ing the control valve' and 'The condensate removal device' are included in this Tutorial, the new reader should refer to later Tutorials for full and comprehensive information, before attempting si ing and selection of equipment. .A , .W

Control valve arrangement

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Using one valve

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this at a pressure of 1.1 bar g. A steam valve sizing chart would show that a Kv of about 20 is required to pass 850 kg/h of steam with a pressure of 2.6 bar g at the inlet of the control valve, and Critical Pressure Drop (CPD) across the valve. (Tutorial 6.4 will show how the valve size can be determined by calculation). A DN40 control valve with a larger Kvs of 25 would therefore need to be selected for the application. If one valve is to be used, this valve must ensure the maximum heat load is catered for, while maintaining the required steam pressure in the coil to assist the drainage of condensate from it at start-up. However, for reasons previously explained, two valves may be better. The running load is 52 kW and with the coil running at 1.1 bar g, the running steam load:

The steam valve sizing chart shows a Kv of 2 is required to pass 85 kg/h with 3.6 bar upstream, operating at critical pressure drop. A DN15 KE type valve (Kvs = 4) and a DN25 piston actuated valve (Kvs = 18.6) operating together will cater for the start-up load. When approaching the control temperature, the larger valve would be set to shut down, allowing the smaller valve to give good control.

The condensate remo al de ice

The selection and sizing of the condensate removal device will be very much influenced by the condensate backpressure. For the purpose of this example, it is assumed the backpressure is atmospheric pressure. The device should be sized so it is able to satisfy both of the following conditions: Pass 850 kg/h of condensate with 1.1 bar g in the coil, i.e. the full-load condition. Pass the condensate load when steam pressure in the coil equals the condensate backpressure, i.e. the stall load condition. If the steam trap is only sized on the first condition, it is possible that it may not pass the stall load (the condition where the product approaches its required temperature and the control valve modulates to reduce steam pressure). The stall load may be considerable. With respect to non-flow type applications such as tanks, this may not be too serious from a thermal viewpoint because the contents of the tank will almost be at the required temperature, and have a huge reservoir of heat. Any reduction in heat transfer at this part of the heating process may therefore have little immediate effect on the tank contents. However, condensate will back up into the coil and waterhammer will occur, along with its associated symptoms and mechanical stresses. Tank coils in large circular tanks tend to be of robust construction, and are often able to withstand such stresses. Problems can however occur in rectangular tanks (which tend to be smaller), where vibration in the coil will have more of an effect on the tank structure. Here, the energy dissipated by the waterhammer causes vibration, which can be detrimental to the life of the coil, the tank, and the steam trap, as well as creating unpleasant noise. With respect to flow-type applications such as plate heat exchangers, a failure to consider the stall condition will usually have serious implications. This is mainly due to the small volume in the heat exchanger. For heat exchangers, any unwanted reduction in the heating surface area, such as that caused by condensate backing up into the steam space, can affect the flow of heat through the heating surface. This can cause the control system to become erratic and unstable, and processes requiring stable or accurate control can suffer with poor performance. If heat exchangers are oversized, sufficient heating surface may remain when condensate backs up into the steam space, and reduction of thermal performance may not always occur. However, with heat exchangers not designed to cope with the effects of waterlogging, this can lead to corrosion of the heating surface, inevitably reducing the service life of the exchanger. Waterlogging can, in some applications, be costly. Consider a waterlogging air heater frost coil. Cold air at 4 C flowing at 3 m/s can soon freeze condensate locked in the coils, resulting in premature and unwarranted failure. Proper drainage of condensate is essential to maintain the service life of any heat exchanger and air heater. Steam traps are devices which modulate to allow varying amounts of condensate to drain from applications under varying conditions. Float traps are steam traps designed to modulate and release condensate close to steam temperature, offering maximum plant performance, maximum plant life, and maximum return on plant investment.

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