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 ASHRAE
January 10, 2017
Steam Properties, Production, and Uses

Kevin Foley
Chief Engineer and Property Manager
Lowell General Hospital

MA 1st Class Steam Engineer, BSME, CEM, CHFM

 Presenter
• MA 1st Class Steam Engineer
• BSME – UMass Lowell
• Certified Healthcare Facility Manager
• Certified Energy Manager
• 30+ Years in Steam and Power Generation:
– Industrial/Healthcare/Food and Beverage/Tech.
– Utility Sized Combined Cycle – Gas Turbine and Steam Turbine
– Cogeneration – (“waste” thermal energy is used)
– Natural Gas, Coal, Tires, Rice Hulls, Trash
• National Association of Power Engineers Past President
and Lifetime Member
 ASHRAE Guide
• FUNDAMENTALS OF STEAM SYSTEM DESIGN
– Self-directed Learning Course
– 236 Pages
• Chapter 1. Introduction to Steam System Design
• Chapter 2. HVAC Steam Systems
• Chapter 3. Terminal Units I [heaters]
• Chapter 4. Terminal Units II
• Chapter 5. Boilers
• Chapter 6. Steam Valves, Steam Traps, Flash Tanks, and
Condensate Receiver Tanks
• Chapter 7. Steam Piping Design
 Steam Properties
– Steam is a gas at defined pressures and
temperatures and some examples are:
• 0 PSIG - 212⁰ F
• 10 PSIG - 239⁰ F
• 150 PSIG - 335⁰ F
• 3200 PSIG - 696⁰ F
– Steam exists as low as 32⁰ F - in a perfect vacuum
– Steam is the same density as water at 3,206 PSIG
• Super High Critical Boilers operate in this range
– Normal speed in pipe is 80 ft/s – 55 MPH
 Steam Properties Continued
– Steam Pressure corresponds to a temperature in its
“saturated” state
– Steam contains energy added in several steps
1. Portion greater than 32°F or starting temperature. – if
condensate is returned at 140°F you need to add the
energy to raise the temperature to the boiling point.
– adding 1 BTU per lb to water increases it temperature 1°F
– Example: you have to add 108 BTUs to 1 lb of water to raise its
temperature from 32°F to 140 °F
2. Latent Heat of Evaporation – conversion from water to
Steam (and you have to remove the same energy to
change it back)
3. Superheat to raise the temperature
– Enthalpy is the amount of heat in steam in BTUs
 Steam Properties Continued
• Water expands 1,600 times in the conversion to gas
“steam”
– In the atmosphere this is the plume that we see
– In a pressurized vessel full of hot water the same
expansion takes place if the pressure is suddenly dropped -
leading to explosive pressures and possible rupturing of
pipes and tanks.
• Example – weekend shutdown in a factory where a main steam
line trap failed and condensate filled the steam line. The Monday
morning startup steam flow created a large pressure drop and the
condensate at 335⁰ F flashed into steam and ruptured a 12” steam
main for about 18”.
• The lab estimated the pressures exceeded 4,000 PSIG
• Boiler Explosions are catastrophic because of this expansion rate
Steam – Ruptured Pipe
Boiler Pressure Vessel Explosion
 Saturated Steam
• Saturated Steam - Steam is “saturated with energy”
– If you add (1) more BTU the temperature will rise above the
corresponding temperature in the steam table and the steam will
become superheated
– Steam can be saturated and dry
– Steam Quality less than 100% is “wet”
– Steam Quality Measurement is complicated – you need an Isokinetic
probe to take samples and specialized metering.
– Saturated Steam Meters apply a Steam Quality factor – say .98
– Steam can be Saturated from perfect vacuum to Supercritical
 Superheated Steam
• If you add any more energy to saturated steam – even by just 1 BTU the
temperature will rise above the temperature for the corresponding pressure
• Example:
• Saturated Steam @ 650 PSIG Steam is 497 °F contains 1,202 BTUs per pound.
• Superheated Steam @ 650 PSIG and 740° F contains 1,678 BTUs per pound
• Superheated steam is used where dry steam is needed through an entire process
- Steam Turbine and Engines need superheated steam and very long runs of
piping.
• Superheating steam improves the processes thermal efficiency - most BTUs put
in can be taken out as the Latent Heat of Evaporation has already taken place.
• Superheating is accomplished by running steam that has left the boiler through
another heating section in the boiler casing or a separately fired heater.
• Running steam through a PRV can generate some superheat by reducing pressure
and holding the temperature constant.
Steam Tables – in PSIA
 Steam Production
WaterTube Boiler
Pressure Vessel Watertube Boiler Finished
Steam Production Continued
FireTube Boiler
Pressure Vessel Firetube Boiler Finished
Steam Production Continued
HRSG Tube
HRSG 13X the area of a bare tube
 Steam Production
Utility Boiler Nuclear Reactor
 Steam Uses
• Heating - Coils, pipes, hoses
• Cooling – Absorption Chillers
• Mechanical/Physical use
– Steam Turbines – Pumps, Compressors, Generators,
– Steam Turbines - Ships/Submarines for generators and
propellers
– Steam Engines – Still in use
– Simplex and duplex pumps
– Aircraft Carrier Catapults
– Humidification
– Cleaning
 Steam Uses - Continued
• Thermal:
– Sterilization – Hospitals
– Manufacturing parts – Steam quickly melts out
wax in investment castings
– Kitchens - Kettles
– Large Scale cooking – Retort Ovens and Blanchers,
bakeries – prevent bread from bursting
– Generate vacuum – for processes and cooling
• Cools 1 Ton of cooked potatoes in 40 minutes
Steam Turbine
Steam Turbine Rotor
Blades/Buckets
Steam Retort Cooker
Cooks Tons of vegetables
Steam Continuous Cooker
 Steam Venturi for Vacuum
Venturi Principle Venturi
 Steam – How it works
• Useful energy available to do work is the amount of energy
used to raise the temperature to the boiling point, the
Latent Heat of evaporation and the energy to Superheat
Steam:
– Sensible Energy used to raise water to the boiling point.
• ex. @ 650 PSIG @ 497°F (497°F- 110°F) = 387 BTUs
– Latent Heat of evaporation:
• 970 BTU’s per pound at 0 PSIG
• 881 BTU’s per pound at 100 PSIG
• 717 BTU’s per pound at 650 PSIG (Saturated or Superheated)
– Superheated Steam Enthalpy above Saturated
• 173 BTU’s per pound at 650 PSIG and 750°F
– Total Energy Available Example @ at 650 PSIG and 750°F:
• (497-110 = 387) +717+173= 1,277 BTUs per lb
 Steam Plant Maintenance
• Daily Low Water Cutoff and Alarm testing – ensures the boiler will shutdown if there is no
water
• Boiler Water Chemistry
– Feedwater pre-treatment – softeners, demineralizers, RO
– Water Treatment Vendor – Service and Chemicals
– Chemicals can also be injected into steam lines and condensate reeivers
– I have minimized or eliminated automated chemical controls where boiler operators are available
– Daily checks by operators and monthly checks by 3rd party is an industry standard
– Commercial building steam or hot water systems - $100/month per building for a Water Treatment
Vendor is a reasonable investment for your assets
• Safety Valve Maintenance – lift annually and rebuild every 3-5 years
• Annual Boiler Pressure Vessel inspections
– By Insurer in most states
– By the State if there is no insurer - in ASME states
– Clean the water and fire side surfaces as needed – saves money and cleanliness can be monitored by
watching the exhaust temperature
• Annual Boiler Tunes ups for efficient Combustion required by EPA/DEPs – this saves $$
• Annual Boiler Combustion Device Inspections
– Low Water cutoff, Gas/Oil/Air pressure witches, Gas Valves, Flame detectors
 Boiler Water Chemistry
• FDA and Non-FDA programs
• pH of 9-11
– Usually add Caustic Soda (Sodium Hydroxide) and/or use Mono,
Di or Tri Sodium Phosphate
• Mono-Sodium Phosphate – lowers ph
• Di-Sodium Phosphate – pH neutral
• Tri-Sodium Phosphate – Increases pH
– High pH may lead to Caustic Embrittlement
• Dispersant – keeps solids in suspension to be blown down
• Amines – designed to leave with the steam and adjust pH
of the condensate as the steam condenses – Types depend
on the system size and distance from the boiler
 Steam Line Maintenance
• Steam Traps – PM Saves $$$$
– Energy($) blows through a leaking trap without doing any work
– MassSaves pays 100% of annual surveys and 50% of repairs - Payback is in months
– Prevent water hammer – steam at >>> 80 ft/sec on start up will push water right through 90’s,
valves, strainers… rupturing them and causing significant losses or even injury or death.
– Prevent flashing discussed earlier
• Pipe and Boiler Insulation
– Type and protection from environment
• Wet location?
• Abuse – workers, forklifts, washable?
– Terminal thickness – there is a point where there is no benefit to adding more insulation
– MassSaves now pays 100% for insulation repairs - Insulation vendors will come back annually
and inspect and replace insulation blankets that were removed and not put back
– Corrosion Under Insulation “CUI” is a big concern – water gets under and rusts causing pitting
• Hangers – always overlooked.
– Loose nuts on threaded rods and hangers
– Creep – the hangers move along the pipe during start up and shutdown and away from
hanging plumb.
– Rust and damaged – forklifts push up and bend the rods
• Ultrasonic Thickness testing on older pipe and welds – especially at turns
 Water Hammer
• Water Hammer 1 – Condensate moving at a high speed
bursting through turns or fittings
• Water Hammer 2 – Steam contacting cold or cooler
condensate
– Steam condenses as it contacts water/condenate
– The steam volume decreases 1600 times
– Water rushes in and makes a pinging sound – and in severe
cases can shake piping or tanks
In both cases – start-up drains discharging to the floor
and/or drain are used to supplement traps and are
operated manually by the boiler operators and can be
used when traps fail
 Steam System Design
1. Determine the process temperature
2. Determine the heat load – Convert to steam flow
3. Determine the location of the boilers in relation to the process
4. Using Items 1, 2 and 3 - determine the pressure and temperature (superheat?)
1. High or Low Pressure Steam – Boiler Operators needed?
2. Initial Pipe size
5. Select Boilers - Using Item 4
1. Watertube vs. Firetube or Field Constructed
2. Efficiency – can you use an economizer to heat the feedwater with the boiler exhaust?
3. Fuel(s)
4. Permit requirements - DEP/EPA regulations
6. Determine pipe Material, size and run
1. Material – based on pressure and temperature
2. Pipe Size – see table
3. Runs - accommodate expansion including anchors, hangers, flexible loops or joints
• Rule of Thumb for expansion – 1” per 100’ per 100°F
7. Determine Steam trap location and steam trap type
1. How often is the steam system shut down – weekly vs. yearly makes a big difference on traps
2. Prevent Water Hammer
3. Place start-up drains in strategic locations
8. Determine insulation type and thickness
 Steam pipe selection example:
10,000 pph at 10 PSIG and 100 PSIG
Capacity (lb/hour)
Steam Pipe Size (inch)
Pressure (psi) Velocity
(ft/sec) 1/2" 3/4" 1" 1 1/4" 1 1/2" 2" 2 1/2" 3" 4" 5" 6" 8" 10" 12"
50 12 26 45 70 100 190 280 410 760 1250 1770 3100 5000 7100
5 80 19 45 75 115 170 300 490 710 1250 1800 2700 5200 7600 11000
120 29 60 110 175 245 460 700 1000 1800 2900 4000 7500 12000 16500
50 15 35 55 88 130 240 365 550 950 1500 2200 3770 6160 8500
10 80 24 52 95 150 210 380 600 900 1500 2400 3300 5900 9700 13000
120 35 72 135 210 330 590 850 1250 2200 3400 4800 9000 14400 20500
50 21 47 82 123 185 210 520 740 1340 1980 2900 5300 8000 11500
20 80 32 70 120 190 260 520 810 1100 1900 3100 4500 8400 13200 18300
120 50 105 190 300 440 840 1250 1720 3100 4850 6750 1300 19800 28000
50 26 56 100 160 230 420 650 950 1650 2600 3650 6500 10500 14500
30 80 42 94 155 250 360 655 950 1460 2700 3900 5600 10700 16500 23500
120 62 130 240 370 570 990 1550 2100 3950 6100 8700 16000 25000 35000
50 32 75 120 190 260 505 790 1100 1900 3100 4200 8200 12800 18000
40 80 51 110 195 300 445 840 1250 1800 3120 4900 6800 13400 20300 28300
120 75 160 290 460 660 1100 1900 2700 4700 7500 11000 19400 30500 42500
50 43 95 160 250 360 650 1000 1470 2700 3900 5700 10700 16500 24000
60 80 65 140 250 400 600 1000 1650 2400 4400 6500 9400 17500 27200 38500
120 102 240 410 610 950 1660 2600 3800 6500 10300 14700 26400 41000 58000
50 53 120 215 315 460 870 1300 1900 3200 5200 7000 13700 21200 29500
80 80 83 190 320 500 730 1300 2100 3000 5000 8400 12200 21000 33800 47500
120 130 290 500 750 1100 1900 3000 4200 7800 12000 17500 30600 51600 71700
50 63 130 240 360 570 980 1550 2100 4000 6100 8800 16300 26500 35500
100 80 102 240 400 610 950 1660 2550 3700 6400 10200 14600 26000 41000 57300
120 150 350 600 900 1370 2400 3700 5000 9100 15000 21600 38000 61500 86300
50 74 160 290 440 660 1100 1850 2600 4600 7000 10500 18600 29200 41000
120 80 120 270 450 710 1030 1800 2800 4150 7200 11600 16500 29200 48000 73800
120 175 400 680 1060 1520 2850 4300 6500 10700 17500 26000 44300 70200 97700
50 90 208 340 550 820 1380 2230 3220 5500 8800 12900 22000 35600 50000
150 80 145 320 570 900 1250 2200 3400 4900 8500 14000 20000 35500 57500 79800
120 215 450 850 1280 1890 3400 5300 7500 13400 20600 30000 55500 85500 120000
50 110 265 450 680 1020 1780 2800 4120 7100 11500 16300 28500 45300 64000
200 80 180 410 700 1100 1560 2910 4400 6600 11000 18000 26600 46000 72300 100000
120 250 600 1100 1630 2400 4350 6800 9400 16900 25900 37000 70600 109000 152000
 Boiler Operator License Laws
• MA – All boilers greater than 15 PSIG and 9 HP
– 9-250 HP Periodic Attendance
• Daily Maintenance, Stay in same building, Auto shutdown
– 251-500 HP Non-Continuous Attendance
• Same as above, Remote Station, 4-6 rounds per shift
– 501 HP and above - Continuous Attendance
• NYC – Large boilers and most turbines – utilities
and high rises
• NJ – Utility sized boilers
• Connecticut, Wisconsin – large boilers
 Power of Steam
• https://www.youtube.com/watch?v=jbreKn4P
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