Energy Management

Steam
Distribution
System
1
Steam Distribution System
 Introduction
 Steam distribution system
 Assessment of steam distribution system
 Energy efficiency opportunities
 The Economics of Waste Heat Recovery
 Waste Heat Recovery Equipment
2
INTRODUCTION
About 80% electricity is produced by steam in the

whole world.
In Pakistan, thermal power accounts for 64 per cent

of the total energy production.
So, energy Management in steam distribution

system is very important.
 Introduction
 Steam distribution system
 Assessment of steam distribution
system
 Energy efficiency opportunities
 The Economics of Waste Heat
Recovery
 Waste Heat Recovery Equipment
4
What is the steam distribution system?

 Link between steam generator and point of use
 Steam generator
 Boiler
 Discharge from co-generation plant
 Boilers use
 primary fuel
 exhaust gases
5
Typical steam circuit
6
Most important components
1. Pipes 7. Steam traps
2. Drain points
3. Branch lines 8. Air vents
4. Strainers
5. Filters
9. Condensate
6. Separators recovery
system
10.Insulation
7
1. Pipes
 Pipe material: carbon steel or copper
 Correct pipeline sizing is important
 Oversized pipe work:
 Higher material and installation costs
 Increased condensate formation
 Undersized pipe work:
 Lower pressure at point of use
 Risk of steam starvation
 Risk of erosion, water hammer and noise
8
2. Drain points
 Ensures that condensate can reach steam trap
 Consideration must be give to
 Design
 Location
 Distance between drain points
 Condensate in steam main at shutdown
 Diameter of drain pipe
9
3. Branch lines
• Take steam away from steam main
• Shorter than steam mains
• Pressure drop no problem if branch
line < 10 m
A Branch Line
10
4. Strainers
 Purpose
 Stop scale, dirt and other solids
 Protect equipment
 Reduce downtime and maintenance
 Fitted upstream of steam trap, flow meter, control valve
 Two types: Y-type and basket type
11
5. Filters
 Consists of sintered stainless steel filter
element
 Remove smallest particles
 Direct steam injection – e.g. food industry
 Dirty stream may cause product rejection –
e.g. paper machines
 Minimal particle emission required from
steam humidifiers
 Reduction of steam water content
12
6. Separators
 Separators remove suspended water droplets from steam
 Water in steam causes problems
 Water is barrier to heat transfer
 Erosion of valve seals and fittings and corrosion
 Scaling of pipe work and heating surfaces from impurities
 Erratic operation and failure of valves and flow meters
13
7. Steam traps
 What is a steam trap?
 “Purges” condensate out of the steam system
 Allows steam to reach destination as dry as possible
 Steam traps must handle variations in
 Quantity of condensate
 Condensate temperature
 Pressure (vacuum to > 100 bar)
14
8. Air vents
Effect of air on heat transfer
15
9. Condensate recovery system
 What is condensate
 Distilled water with heat content
 Discharged from steam plant and equipment through steam
traps
 Condensate recovery for

 Reuse in boiler feed tank, deaerator or as hot process water
 Heat recovery through heat exchanger
16
10. Insulation
Classification of insulators
Temperature Application Materials
Low (<90 oC) Refrigerators, cold / Cork, wood, 85%
hot water systems, magnesia, mineral fibers,
storage tanks polyurethane, expanded
polystyrene
Medium (90 – Low-temperature 85% magnesia, asbestos,
325 oC) heating and steam calcium silicate, mineral
generating equipment, fibers
steam lines, flue
ducts,
High (>325 oC) Boilers, super-heated Asbestos, calcium
steam systems, oven, silicate, mineral fibre,
driers and furnaces mica, vermiculite, 17
fireclay, silica, ceramic
fibre
Assessment of steam distribution
 Introduction
 Assessment of steam distribution system
 The Economics of Waste Heat Recovery
18
Waste heat sources and their uses can be conveniently categorized by
the temperature at which the heat is exhausted, as shown in Table
19
• The use of waste heat to heat a fluid stream should

be considered if:
• The waste heat source is close enough to the fluid
stream that the fluid temperature will still be high
enough to be useful even after taking into account all
heat lost in transporting the fluid from source to
stream.
• Using waste heat from the source will not create
problems at the source.
•The transfer of heat from the source to the stream is
technically feasible.
20
21
Energy Efficiency Opportunities
 Introduction
system
Recovery
22
1. Manage steam traps
2. Avoid steam leaks
3. Provide dry steam for process
4. Utilize steam at lowest acceptable pressure
5. Proper utilization of directly injected steam
6. Minimize heat transfer barriers
7. Minimize water hammer
8. Insulate pipelines and equipment
9. Improve condensate recovery
10. Recover flash steam
11. Reuse low pressure steam
23
1. Manage steam traps
 Testing of steam traps
 Visual: flow and flow variations
 Sound: check sound created by flow
 Temperature: discharge temperature on outlet
 Integrated: measures conductivity
 Routine maintenance
 Replacement of internal parts
 Replacement of traps
24
2. Avoid steam leaks
 Repair leaks
 Regular leak detection program
 Replace flanged joints by welded joints
 Leakage estimate
 Plume length 1400 mm
 Steam loss 40 kg/hr
25
3. Provide dry steam for process

 Dry saturated steam is best steam
 Wet steam reduces total heat in steam and prevents heat
transfer
 Superheated steam gives up heat at slower rate
 Achieve dry steam by
 Proper boiler treatment
 Boiler operation
 Pipeline insulation
 Separators on steam pipelines
26
4. Utilize steam at lowest acceptable pressure
 Steam should be
 Generated & distributed at highest pressure
 Utilized at lowest pressure: latent heat highest
 Select lowest steam pressure without sacrificing
 Production time
 Steam consumption
27
5. Proper utilization of directly injected steam

 Benefits
 Equipment simple, cheap and easy to maintain
 No condensate recovery system needed
 Heating quick and process thermally efficient
 Only in processes were dilution is not a problem
28
6. Minimize heat transfer
barriers
Temperature gradient across heat transfer barriers
29
7. Minimize water hammer

 Banging noise caused by colliding condensate in
distribution system
 Sources: low points in the pipework
 Solutions
 Steam lines with gradual fall in flow direction
 Drain points at regular intervals
 Check valves after all steam traps
 Opening isolation valves slowly to drain condensate
30
8. Insulation
Economic Thickness
of Insulation (ETI)
I+H
Costs of
Cost I
insulation
H
Heat loss
31
savings
Insulation Thickness
9. Improved condensate recovery
Annual condensate recovered (kg/yr)
Heat recovered (kcal/yr)
Heat saved (kcal/yr)
Fuel saved (litres or m3 /yr)
$ saved ($ /yr) 32
10. Recover flash steam

 Flash steam released from hot condensate when pressure
reduced
 Amount available: calculation or tables/charts
 Applications: heating
 Boiler blowdown can also be recovered as flash steam
33
11. Reuse low pressure steam

 Reuse as water
 Compress with high pressure steam for reuse as medium
pressure steam
DISCHA
MOTIVE RGE
STEAM STEAM
H.P. M.P.
SUCTION 34
STEAM L.P. Thermo-compressor
Economics of Waste Heat Recovery
 Introduction
system
Recovery
35
The benefits from waste heat recovery can be substantial; therefore
the benefits included in the economic analysis must be as complete
as possible
36
The analysis must also include complete details of the costs involved
and the amount by which these costs are reduced by any tax benefits
37
The analysis must also include complete details of the costs involved
and the amount by which these costs are reduced by any tax benefits
38
Waste Heat Recovery Equipment
 Introduction
system
Recovery
39
Waste Heat Recovery Equipment
The factors that determine which

equipment to select for waste heat
recovery are
1. The fluid temperature at the source
2. The intended use for the waste heat,
and
3. The distance the heated fluid (if any)
must be transported
40
41

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Steam

About 80% electricity is produced by steam in the

In Pakistan, thermal power accounts for 64 per cent

So, energy Management in steam distribution

What is the steam distribution system?

Typical steam circuit

 Condensate recovery for

• The use of waste heat to heat a fluid stream should

3. Provide dry steam for process

4. Utilize steam at lowest acceptable pressure

5. Proper utilization of directly injected steam

7. Minimize water hammer

9. Improved condensate recovery

Annual condensate recovered (kg/yr)

Heat recovered (kcal/yr)

Heat saved (kcal/yr)

Fuel saved (litres or m3 /yr)

10. Recover flash steam

11. Reuse low pressure steam

The factors that determine which

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