Steam Theory 1. Basics of Steam What is Steam? Principal Applications for Steam Types of Steam Flash Steam How to Read a Steam Table 2. Steam Heating Heating with Steam Steam Heating Mechanism Overall Heat Transfer Coefficient What is Vacuum Steam? Tracing the Causes of Heat Maintenance Issues 3. Basics of Steam Traps What is a Steam Trap? The History of Steam Traps #1 The History of Steam Traps #2 How Mechanical Traps Work: A Look at their Mechanism and Merits How Disc Traps Work: A Look at their Mechanism and Merits How Bimetal-Type Thermostatic Steam Traps Work: A Look at their Mechanisms and Merits 4. Steam Trap Selection Steam Trap Selection: How Application Affects Selection Steam Trap Selection: Understanding Specifications Steam Trap Selection: Safety Factor and Life Cycle Cost Traps and Orifices Part 1 Traps and Orifices Part 2 Casting vs. Forging Applications of Different Types of Steam Traps Don't Get Steamed : Selecting Steam Trap Design Understanding Steam Traps Compare Two Fixed Orifice Venturi Products to a Variable Orifice Free Float Steam Trap 5. Steam Trap Problems Is My Trap Leaking Live Steam? Temperature Control Trap Precautions Trap Installation Orientation Trap Back Pressure Double Trapping Group Trapping Steam Locking Air Binding My Steam Trap Is Good - Why Doesn't It Work? 6. Steam Trap Management Introduction to Steam Trap Management Steam Trap Losses - what it costs you A Guide to Steam Trap Testing Implement a Sustainable Steam Trap Management Program Impact Plant Performance by Improving the Steam System 7. Water Hammer Water Hammer: What is it? Water Hammer: The Mechanism Water Hammer: Cause and Location Water Hammer: In Steam Distribution Lines Water Hammer: In Equipment Water Hammer: In Condensate Transport Piping Identifying Water Hammer Using a Thermal Camera Mitigation of Water Hammer in Vertical Flashing Condensate Transport Piping Stop Knocking Your Condensate Return Steam Trap Management: Do Something; Anything. Please! 8. Risk Mitigation Steam System Optimization and Risk Mitigation Risk Based Methodology for Industrial Steam Systems Why Bad Things Happen to Good Steam Equipment Beware of the Dangers of Cold Traps Steam System Winterization: How to Protect Your Plant 9. Steam Quality Wet Steam vs. Dry Steam: The Importance of the Steam Dryness Fraction Separators and their Role in the Steam System Clean & Pure Steam Temperature Problems Caused by Air Removing Air from Steam Equipment Air Vents for Steam Steam Quality Considerations 10. Steam Distribution Best Practices for Condensate Removal on Steam Lines Installation Tips for Steam Traps on Steam Mains Erosion in Steam and Condensate Piping Corrosion in Steam and Condensate Piping Allocate New Plant Focus to Steam System Design—Part 1 11. Condensate Recovery Introduction to Condensate Recovery Returning Condensate and When to Use Condensate Pumps Condensate Recovery: Vented vs. Pressurized Systems Condensate Recovery Piping What is Stall? Methods of Preventing Stall Cavitation in Condensate Pumps Steam Heat Exchangers are Underworked and Over-Surfaced Allocate New Plant Focus to Steam System Design—Part 2 Optimize Reboiler Performance via Effective Condensate Drainage Vent Away Condensate Pump Frustrations in a Flash 12. Energy Efficiency Tips to improve steam plant efficiency Advice on Winter Preparation for Steam Systems Insulating Traps Steam Compressors Why Save Energy? Management Strategies for Conserving Energy Recovering Steam Clouds and Waste Heat Waste Heat Recovery Boiler Energy Saving Tips Steam Line Energy Saving Tips Steam-Using Equipment Energy Saving Tips Preventing Steam Leaks Handle Steam More Intelligently Optimize the Entire Steam System Use Available Data to Lower System Cost 13. Compressed Air / Gas Removing Condensate from Compressed Air Preventing Clogging of Air Traps Air Compressor Energy Saving Tips Improving Compressed Air Quality and Countermeasures Against Leaks 14. Other Valves Types of Manual Valves Bypass Valves Check Valve Installation and Benefits Pressure Reducing Valves for Steam Recovering Steam Clouds and Waste Heat Contents: Steam Clouds: Energy Going to Waste Clouds of steam vapor are a common sight in some process plants. These clouds are often considered to be an inevitable by-product of steam heating processes. However, in the least sense, steam clouds are an eyesore, and worse they can create a safety issue from subsequent algae growth or freezing of falling water. Vapor clouds can also make a plant hot and unpleasant if vented internally. On top of this, what may be missed is that they constitute potentially valuable heat energy going to waste. When used in heating processes, steam loses its latent heat energy and condenses. The resultant condensate is usually over 100°C [212°F], and may contain as much as 30% of the heat energy originally held by steam. When flash steam from condensate is vented to atmosphere, this valuable heat energy, much of which can be recoverable, goes to waste. If Condensate is Not Collected If Condensate is Collected Some heating processes that use direct steam injection, such as steamers, autoclaves, sterilizers, and rubber vulcanizers, need to release steam from their systems. These vents may provide an opportunity for energy use rather than venting to atmosphere. By collecting and reusing viable heat from condensate and steam, plants can reduce unwanted steam clouds, save energy, and lower operating costs—all at the same time! Below are some common examples of steam clouds in steam-using plants. Steam Vented to Atmosphere from a Condensate Collection Tank Steam billowing from a condensate collection tank is a sign that although condensate is being properly collected in the tank, excess heat is escaping from the condensate and venting to waste. Plants with this problem can implement one of the following countermeasures to make better use of the excess heat energy. High Pressure Condensate Recovery The condensate can be returned directly to the boiler using a specialized, high pressure condensate pump rather than sent to the feed tank. Steam Compressor The condensate can be allowed to flash, then used for preheating other applications or sent to the boiler. The low-pressure flash steam can be pressurized and reused in various processes. Steam Compressor Steam Condensing Heat Exchanger The flash steam can be used in a heat exchanger to heat water. Steam Condensing Heat Exchanger Steam Clouds Emitted from the Boiler There are some plants where boiler steam must be made even if there is not sufficient use for all of it. In such cases, some of this steam is vented to avoid pressure build-up. Examples include some plants burning wood chips (in the absence of an incinerator). Whenever such boilers create more steam than is needed for process applications, plant managers should consider using the steam to generate power. This extra power can be used within the plant or sold back to the electric grid. Steam Clouds Billowing from a Vent Pipe In some steam systems where condensate is recovered, clouds of steam can occasionally be seen billowing from vent pipes acting as flash vessels. Vent pipes lower the pressure on the outlet end of steam traps, thus enabling condensate to be pumped and traps from other low-pressure equipment to drain into those return lines. Flash steam billowing out of these vents can be collected and reused. This flash steam can be pressurized and used in various processes, or sent to a heat exchanger and used to heat feed water. Steam Compressor Steam Condensing Heat Exchanger Steam Clouds Emitted from Condensate Drained into a Pit Perhaps the boiler is too far away, or there is not enough condensate to justify return, or the condensate's pressure level is too low…Whatever the reason, many plants choose to waste condensate and to drain rather than recollect it. In many cases, plants can achieve energy savings by routing condensate from processes into a collecting tank to return to the boiler using a pump, or allowing it to flash and then using the resultant steam in a local heat exchanger. Condensate Recovery Steam Condensing Heat Exchanger Management Strategies for Conserving Energy Waste Heat Recovery Also on TLV.com Flash Steam Steam Compressor Steam Condensing Heat Exchanger Condensate Recovery