Process Steam Systems: A Practical Guide for Operators, Maintainers, Designers, and Educators

Process Steam System
Contents
Preface
Acknowledgments
List of Examples
List of Tables
1 Steam: a Heat Transfer Fluid
	Why Steam?
		Steam Is Safe and Flexible
		Steam Is Easy to Control
	The Concept of Steam Formation: Boiling
		Pressure and Boiling
		The Ideal Gas Law
2 The Development of Boiler Safety
	How It All Began
	The Consequences of Development
	Development of Asme Code
	Future of Steam
3 Understanding Heat Transfer
	Radiation-Type Heat Transfer
	Conduction-Type Heat Transf
	Convection-Type Heat Tran
	The Heat Transfer Equations
		The Overall Heat Transfer Coefficient (U)
		Mean Temperature Difference (ΔTM)
		ΔTm for a Steam Boiler
		ΔTm for a Steam to Process Fluid Heat Exchanger
		Surface Area (m)
	Heat Flux
4 Steam Formation, Accumulation, and Condensation
	The Boiling Process
		Steaming
		Latent and Sensible Heat Versus Pressure
	Condensation of Steam
	The Formation of Flash Steam
	Steam Accumulation and Storage
5 Steam Quality: It Matters
	Why Steam Quality Is Important
	Poor Steam Quality Causes and Cures
	Steam Classifications
	Measuring Steam Quality
	Superheated Steam
6 The Steam System Design
	Steam System Types
	The Process Steam System: An Overview
7 The Steam Generator
	The Ideal Steam Generator
		Steam Generator Types
	Fossil Fuel-Fired Boilers
	Solid Fuel-Fired Boilers
	Electric Boilers
	Unfired Steam Generators
	Heat Recovery Steam Generators
8 Boiler Operation and Trim
	The Packaged Boiler Concept
	Fuel Delivery and Combustion Systems
	Low Emissions
	Multiple Boiler Sequencing
9 The Steam Delivery System
	Steam Flow
	Steam Distribution Piping
	Control Valves
	Steam Accumulation
	Steam Filtration
	Sensors and Meters
		Steam Metering
	Stop and Safety Valves
10 The Condensate Recovery System
	Condensate Line Sizing
	Steam Trap Applications
		Thermostatic Group
		Mechanical Group
		Thermodynamic Group
		Thermostatic Steam Trap Group
		Mechanical Group
		Thermodynamic Group
	Flash Steam Utilization
		How to Size Flash Tanks and Vent Lines
	Condensate Collection
		Electric Condensate Return System
		Pressure Motive Condensate Pump
		Pressure Motive Pump Installation Requirements
		Pumped Condensate Return Line Installation
	Surge Tank Application
11 The Feed Water System
	Feed Water Deaeration
		The Elimination of Dissolved Gases
	Feed Water Tanks
		Feed Water Tank Sizing
	Feed Water Pumps
		Feed Water Pump Sizing
	Feed Water Piping
		Feed Water-Surge Tank Controls
12 Steam System Chemistry Control
	Basic Water Chemistry
	Scale Control
	Fouling Control
	Corrosion Cont
	Boiler Blowdown
		Best Operating Practices for Boiler Blowdown
		Automatic Versus Manual Blowdown Controls
		Determining Blowdown Rate
	Chemical Feed Systems
	Chemistry Limits
	Steam System Metallurgy
13 Mechanical Room Considerations
	Codes and Standards
	Steam Load Profile
	Steam System Performance Considerations
	Environmental Considerations
	Boiler Room Utilities
14 Steam System Applications
	Low-Pressure Steam with High Condensate Returns
	High-Pressure Steam with High Condensate Returns
	High- or Low-Pressure Steam with Little or No Returns
	High-Pressure or Superheated Steam with Condensate Returns
	Multiple Boiler Installations
		Steam for Hot Water Generation
		Other Miscellaneous Steam-Use Application Designs
15 Specialized Steam Equipment
	Back Pressure Turbine
	Steam Hydro Heater
	Steam Superheaters
	Steam Dump Mufflers
	Jacketed Kettles
	Sterilizers
	Reboilers
16 Steam System Efficiency/Sustainability
	The System Heat Balance
		Boiler Heat Balance
	Boiler Efficiency
	Steam System Efficiency
		Boiler Internal Cleanliness
		Steam Delivery System Efficiency
		Condensate and Feed Water System Efficiency
		Biomass Fuel Water Content Reduction
17 Shutdown, Startup, Inspection, and Maintenance
	Shutdown and Startup Practices
	Boiler Safety Checks
	Maintenance and Inspection Practices
		Inspections
	Boil Out and Layup Practices
18 Troubleshooting and Commissioning Basics
	Startup Versus Commissioning
	Approach to Troubleshooting
	Don’t Play the Blame Game
	Precommissioning
19 Commissioning and Troubleshooting the Steam Generator
	Determining Boiler Input, Output, and Efficiency
	Boiler Performance Test
	Commissioning the Boiler Burner Controls
	Commissioning the Boiler Pressure Control System
	Commissioning the Boiler Level Control System
	Commissioning the Boiler Blowdown Controls
	Steam Boiler Troubleshooting
20 Commissioning and Troubleshooting the Steam Delivery System
	Steam Distribution Piping
	Control Valves
	Steam Piping Venting
	Condensate Trapping/Draining
	Troubleshooting the Steam Delivery System
21 Commissioning and Troubleshooting the Condensate and Feed Water System
	Condensate Collection
	Feed Water System
	Troubleshooting the Condensate and Feed Water Systems
22 Commissioning and Troubleshooting the Water Treatment Equipment
	Setting Up the Water Treatment Systems
	Troubleshooting Water Treatment System Problems
23 Sample Problem Sets
Appendix A References and Reference Information
Appendix B Operations, Maintenance, and Inspection Guidance
Appendix C Steam System Design and Commissioning Guidance
Appendix D Problem Set Answers
Index
EULA