Process steam systems : a practical guide for operators, maintainers, and designers

Content: Preface xi    Acknowledgements xiii    List of Examples xv    List of Tables xvii    1 Steam: A Heat Transfer Fluid 1    What is Steam? 1    Steam Is Safe and Flexible 2    Steam Is Easy to Control 2    Steam System Types 3    The Process Steam System 6    2 Steam Formation, Accumulation, and Condensation 9    The Formation of Steam
 Boiling 9    Pressure and Boiling 11    The Ideal Gas Law 11    The Boiling Process 13    Steaming 14    Latent and Sensible Heat versus Pressure 16    The Formation of Flash Steam 16    Steam Accumulation and Storage 18    Condensation of Steam 20    3 Understanding Heat Transfer 23    Radiation Type Heat Transfer 23    Conduction Type Heat Transfer 26    Convection  ]Type Heat Transfer 29    The Heat Transfer Equations 31    The Overall Heat Transfer Coefficient (U) 31    Mean Temperature Difference (  Tm) 33      Tm for a Steam Boiler 34      Tm for a Steam to Process Fluid Heat Exchanger 35    Surface Area (m) 35    Heat Flux 37    4 Steam Quality: It Matters 39    Why Steam Quality is Important 40    Poor Steam Quality Cause and Cures 40    Steam Classifications 43    Measuring Steam Quality 45    Superheated Steam 46    5 Boiler Room Considerations 49    Steam Generator Selection 49    Codes and Standards 49    Steam System Performance Considerations 53    Environmental Considerations 55    Boiler Room Utilities 60    6 The Steam Generator 67    The Ideal Steam Generator 68    Steam Generator Types 70    Fossil Fuel  ]Fired Boilers 70    Solid Fuel  ]Fired Boilers 76    Electric Boilers 78    Unfired Steam Generators 81    7 Boiler Trim, Fuel Delivery, and Combustion Control System 83    The Packaged Boiler Concept 83    Fuel Delivery and Combustion Systems 91    Low Emissions 98    8 The Steam Delivery System 103    Steam Flow 103    Steam Distribution Piping 104    Control Valves 115    Steam Accumulators 121    Steam Filtration 124    Sensing Equipment 126    Stop and Safety Valves 127    9 The Condensate Recovery System 131    Condensate Line Sizing 133    Steam Trap Applications 136    Thermostatic Group 136    Mechanical Group 136    Thermodynamic Group 136    Thermostatic Steam Trap Group 136    Mechanical Group 138    Thermodynamic Group 141    Flash Steam Utilization 144    How to Size Flash Tanks and Vent Lines 145    Condensate Collection 147    Electric Condensate Return System 148    Pressure Motive Condensate Pump 150    Pressure Motive Pump Installation Requirements 150    Pumped Condensate Return Line Installation 153    Surge Tank Application 153    10 The Feed Water System 155    Feed Water Deaeration 155    The Elimination of Dissolved Gases 156    Feed Water Tanks 158    Feed Water Tank Sizing 160    Feed Water Pumps 162    Feed Water Pump Sizing 166    Feed Water Piping 167    11 Steam System Chemistry Control 171    Basic Water Chemistry 171    Scale Control 172    Fouling Control 176    Corrosion Control 177    Boiler Blowdown (BD) 180    Best Operating Practices for Boiler BD 181    Automatic versus Manual BD Controls 181    Determining BD Rate 181    Chemical Feed Systems 183    Chemistry Limits 186    12 Steam System Applications 187    High  ]Pressure Steam with High Condensate Returns 189    Low  ]Pressure Steam with High Condensate Returns 190    High  ] or Low  ]Pressure Steam with Little or No Returns 192    High  ]Pressure or Superheated Steam with Condensate Returns 195    Multiple Boiler Installations 195    Specialized Steam Equipment 197    Back Pressure Turbine or BPT 197    Steam Hydro Heater 198    Steam Superheaters 200    Steam Discharge Mufflers 202    13 Steam System Efficiency 205    The System Heat Balance 205    Boiler Heat Balance 207    Boiler Efficiency 207    Steam System Efficiency 213    Boiler Internal Cleanliness 216    Steam Delivery System Efficiency 217    Condensate and Feed Water System Efficiency 217    Biomass Fuel Water Content Reduction 219    14 Shutdown, Startup, Inspection, and Maintenance 223    Shutdown and Startup Practices 223    Boiler Safety Checks 225    Maintenance and Inspection Practices 227    Inspections 228    Boil Out and Layup Practices 231    15 Troubleshooting and Commissioning Basics 235    Startup versus Commissioning 235    Approach to Troubleshooting 236    Don   t Play the Blame Game 236    Precommissioning 237    16 Commissioning and Troubleshooting the Steam Generator 239    Determining Boiler Input, Output, and Efficiency 239    Boiler Performance Test 241    Commissioning the Boiler/Burner Controls 243    Commissioning the Boiler Pressure Control System 243    Commissioning the Boiler Level Control System 244    Commissioning the Boiler Blowdown Controls 244    Steam Boiler Troubleshooting 244    17 Commissioning and Troubleshooting the Steam Delivery System 253    Steam Distribution Piping 253    Control Valves 254    Steam Piping Venting 255    Condensate Trapping/Draining 255    Troubleshooting the Steam Delivery System 255    18 Commissioning and Troubleshooting the Condensate and Feed Water System 257    Condensate Collection 257    Feed Water System 258    Troubleshooting the Condensate and Feed Water Systems 259    19 Commissioning and Troubleshooting the Water Treatment Equipment 263    Setting Up the Water Treatment Systems 263    Troubleshooting Water Treatment System Problems 264    Appendix A References and Reference Information 267    Appendix B Operations, Maintenance, and Inspection Guidance 283    Appendix C Steam System Design and Commissioning Guidance 293    Index 301