Steam

System
Steam 1. Natural Technology
System
2. Steam Generation
3. saturated vapor & Properties of
CONTENTS saturated vapor
4. Steam Quality & Effects of Air and
Wet Steam
5. Steam Transport and Piping

2
The designation, “steam,” alone cannot describe
everything about steam.
Steam is a NATURAL TECHNOLOGY.
Steam is environmentally friendly and a part
of everyday life.

• This amazing fluid is used as a high-efficiency

medium in a variety of industries.

• As green steam generation solutions and digital

controls further advance, steam will play a
critical role in sustainable development.

Let’s examine how steam, a natural

technology, integrates with the
world’s deoxygenation trend.
 Steam is with us
식품 in various forms.
Food Bevera
ge • Power generation
• Humidification
• Temperature rise (heat
Oil refinery and transfer)
petrochemicals
• Sterilization
• Cooking
Chemistry Pharmaceuticals • Washing
• Cooling/Freezing

Power
Playing a Key Role in the Transition to Green Energy
• It is in line with the industries’ and companies’ environmental responsibility agenda.
• Steam generation technology and digitization will pave the way for a carbon-free future.

68% 21.5% 10%

Global solar power generation We are improving steam system
We are planning to invest in
capacity increased 21.5% in 2020, maintenance and cutting costs to
clean steam
with continuous investment in instantly save energy.
technology once
COVID-19 is over. renewable power being a strong
% of survey % of survey respondents.
respondents.
trend.
2021 BP Statistical Review of World Energy Source: Aggreko Report
Source: Aggreko [M 2021.03]
Report
Characteristics Unique to Steam That Are Not Found in
Other Fluids

High energy density Accurate temperature Optimal facility size (pipe

Can effectively transfer large amounts control configuration, etc.)
of energy Requires minimal space
Pressure control for easy steam
temperature control

Natural flow according to Efficient heat transfer Recirculation

pressure difference Can be applied directly to the Can be recovered and
Can be transported without a pump surface or product to be heated reused since it is discharged
as condensate
High Energy Density Large amounts of energy can be
effectively transferred.

[ kj/kg ] 2665
Energy (kj/kg)
71 ~ 82 oC water 46 2201

60 ~ 80 oC water 84

1 bar g steam 2201

When 1 bar g steam is condensed to 10 2665 46 84

oC
Water Water Steam When 1 bar g
(71 ~ 82 oC) (60 ~ 80 oC) 1 bar g steam is
condensed to 10
oC
Accurate Temperature Control The steam
temperature can be controlled with ease through pressure
온도 ℃
control.
300

250
saturated
200 vapor saturated vapor
curve
150

100 Water

50

0
0 5 10 15 20 25 30 35 40 45
Pressure,
bar g
Optimal Facility Size (Pipe Configuration, etc.) The
value process space can be minimized.
Specific volume m3/kg
1.8

1.6

1.4

1.2

1.0
Water Steam
0.8 The main piping and Small main piping and
0.6
return piping are the even smaller
same size condensate return
0.4
piping
0.2
• Small surface area, which minimizes heat loss
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
• Small piping – cost reduction
Pressure,bar g
• Less transport time – cost reduction
• Lighter pipe – reduces the cost of support
brackets
• Requires minimal space – cost reduction
Natural Flow According to Pressure Difference
It can be transported without a pump.
Steam moves from high pressure to low pressure • Condensate can be recovered electrically, but it
without a pump. is only a fraction of the water system volume.

High electrical loads used in circulation • For example, the following table shows a
pumps and pump maintenance are comparison of the electrical loads of the
unnecessary. circulation pump of a 20°C water system and
steam condensate with a heat capacity of 2 MW
Water systems require constant in a total pipe of 400 m
circulation, whereas a plant with a
steam system consumes steam only Wate Condensate
when necessary. r recovery pump
circulatio of a steam
Even when using an electric condensate n pump system
recovery pump, a much lower load is needed kW kW
than is the case with a water system due to the General electric pump 6.5 0.7
high energy density of steam requires. requirement
Efficient Heat Transfer Steam can be applied directly to the
surface or product to be heated.
Steam is useful in a wide range of
industries.
• Food • Mining and precious
metals processing
• Beverage
• Water and
• Pharmaceuticals wastewater
and biotechnology
• Pulp and paper
• OEM machinery
• Power generation
• Oil & Gas
• Textiles
• Healthcare
• Rubber and plastics
• Chemistry
• Others
• Buildings (HVAC)

Steam is used in the manufacturing or supply process of nearly all items we use on a daily basis.
 Steam can be recovered and reused since it is
Recirculation discharged as condensate.

Steam Condensate
distribution recovery

Steam
generation
Steam
Heat
System exchanger

Heating
Distribution system
of steam
Steam Load
equipment

Use of
steam
Conde
nsate
Steam
Wat
Conde
nsate
Recovery of
er
tank
Generation condensate
of steam Steam
trap
Boiler

Water
pump

14
Steam
System

2. Steam Generation
• Steam Generation at
Atmospheric Pressure
• Steam Generation at
5 Bar G
Steam Generation at Atmospheric
Pressure
Saturated
temperatur
Superhe
e(℃)
ated
steam
Boiling
point of Evaporation line Dry
100℃ saturated saturati
0.1 0.2 0.3 0.4 0.5 0.6 0.7on 0.8
point0.9
water 1.0
Dryness fraction

Unsaturated
water

0℃ Sensible heat Latent heat (539) Enthalpy

(100) @ 0 bar g @ 0 bar g (kcal/kg)
Heat transfer (639) 639

16
Steam Generation at 5 Bar G
Saturated
temperature
Superheated
(℃)
158℃ steam
Boiling
point of Evaporation line Dry
100℃ saturated saturati
water 0.1 0.2 0.3 0.4 0.5 0.6 0.7on 0.8
point0.9 1.0
Dryness fraction

Unsaturated water

Sensible heat Latent heat : 498 658

0℃ (159) @ 5 bar g @ 5 bar g
Enthalpy
Sensible heat (100) @ Latent heat (539) (kcal/kg)
0 bar g @ 0 bar g
639
Heat transfer (639)

17
Steam
System

3. saturated vapor
• Properties of
saturated vapor
• Optimal Steam
Transport and Use
saturated vapor Table

Gauge Saturated Sensible Latent heat Heat Specific

pressure temperature heat hf hfg transfer hg volume
bar M Pa ℃ k J/kg Kcal/kg k J/kg Kcal/kg k J/kg Kcal/kg ㎥/kg

0 0 100 419 100 2,257 539 2,676 639 1.673

1 0.1 120 506 120 2,201 526 2,707 646 0.881

2 0.2 134 562 133 2,163 517 2,725 651 0.603

3 0.3 144 605 143 2,133 510 2,738 654 0.461

4 0.4 152 636 151 2,108 504 2,749 656 0.374

5 0.5 158 662 159 2,086 498 2,757 658 0.315

6 0.6 165 697 164 2,066 494 2,763 660 0.272

7 0.7 170 721 170 2,048 489 2,769 661 0.240

19
Temperature/Pressure of saturated vapor

(℃)

250

200

150

100

50

Press
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ure
(bar g)

20
Specific Volume of saturated vapor -
Pressure
Specific
volume (㎥
/kg)
1.8

1.6

1.4

1.2

1.0

0.8

0.6

0.4
Press
0.2 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 ure
(bar g)

21
Pressure/Calorific Value of saturated vapor
Heat
quantity Heat quantity
(kJ/kg) (kcal/kg)
3000 715

Steam
2500
heat 597

transfer
2000 478
Latent
heat of
1500 358
steam
1000 239

500 Sensible 119

heat
0 0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Pressure
(bar g)

22
Example of Steam Usage Calculation

The current operating pressure of the boiler is 8 bar g.

It is assumed that the amount of steam generated satisfies all
conditions.
Under these conditions,
the temperature of 8,000 kg of 10℃ water is to be raised by 80℃/hour
and the pressure of the steam used is 2 bar g.
The required heat quantity are
8,000 kg/h × (80 - 10)℃ × 1 kcal/kg℃=560,000 kcal/h
Since the pressure of the steam used is 2 bar g,
latent heat is
516.88 kcal/kg
In other words, the amount of steam used will be
560,000 kcal/h ÷ 516.88 kcal/kg = 1,083 kg/h

23
It is efficient to transport
steam at high pressure and
use steam at low pressure.

24
Low pressure is not always ideal.
First, the temperature required by
the process needs to be
determined.

25
Matters to review to lower the
pressure
Steam pipe diameter

Heat transfer area of the equipment using steam

Relationship between the discharge capacity of the

steam trap and back pressure

26
Steam
System

4. Steam Quality
• Basic Requirements of
Steam
• Effect of Air
• Effect of Wet Steam
• Cleanliness
Steam Quality

Basic Requirements
for Steam • Supply an accurate amount of
That Must Be steam
Observed by User • Maintain the steam pressure and
temperature at accurate levels
• Remove air and non-
condensable gases
• Must be dry
• Must be clean (without foreign matter,
scale, rust, etc.)

28
Problems Caused by Air

Reduced heat transfer

rate Prolonged preheating

Reduced partial
pressure of steamCold spot and non-
uniform temperature
Promotes corrosion

29
 Comparison of Thermal Conductivity
Air Water Iron Copper

Thermal
conducti
vity
w/m℃ 0.025 0.6 75 390
Comparison 1 24 3,000 15,600

30
Dalton’s Law of Partial Pressure
Voltage of gas mixture = Sum of partial pressures of the gases in the mixture
Pressure of mixture = Partial pressure of steam + Partial pressure of air
120 ℃ 111.6 ℃

1 bar g 1 bar g

100% 25% air

Stea 75%
m steam

Absolute pressure Atmospheric pressure

Partial pressure of + Gauge pressure
steam

31
Temperature of Steam and Air Mixture
Pressure of the Temperature of the mixture (ºC)
mixture 0% Air 5% Air 10% Air 20% Air 30% Air 40% Air 50% Air
bar abs
0.2 60 59 58 55 53 50 46
0.4 76 75 73 71 68 64 60
0.6 86 85 83 80 77 73 69
0.8 94 92 90 88 84 80 76
1.0 100 98 96 94 90 86 81
2.0 120 118 117 113 109 105 100
4.0 144 142 140 136 131 126 120
6.0 159 157 155 150 145 140 134
8.0 170 168 166 162 156 150 144
10.0 180 178 175 170 165 159 152
15.0 198 196 193 188 182 175 168
20.0 212 210 207 201 195 188 180
32
Air and Non-Condensable Gases

During initial
operation

Boiler feed water At 80°C, water can dissolve 0.6% (volume) air.

It absorbs gases well when exposed to

Makeup water and the atmosphere. When water is heated in
condensate the boiler, the gas is released.

Chemicals for boiler

water treatment

33
Air Vent Installation Location

Air vent
Steam
supply
Air
release

Steam
supply
Steam
trap Steam
Conde trap
nsate Conde
nsate

34
 Actual Heat Quantity of 10 bar g Steam with Dryness
Fraction of 0.95
(Dryness fraction: The ratio of steam to saturated vapor

Temper
ature 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
(℃) X=0 : Saturated
Dryness fraction
water
0 < X < 1 : Wet
steam
187 665
X=1 : Dry
Sensible Latent heat
Enthalpy saturated vapor
heat of
(kcal/kg)
(187) evaporation
(478)

Sensible heat = 187 kcal/kg

Heat transfer of steam
with dryness fraction of Latent heat of evaporation = 478 ×
0.95 = 454 kcal/kg
1: 187 + 478 = 665
Heat transfer = 187 + 454 = 641 35
kcal/kg
kcal/kg
Causes of Wet Steam

❖ Wet steam generated in the boiler

• Operation at high water level
• Peak load
• Low-pressure operation of boiler
• Excessive solids in boiler water
❖ Loss of radiant heat from the steam
transport pipe

36
Excessive Dissolved Solids in Boiler Water

※ TDS (Total Dissolved Solids)

＜ ＜

Condensate Industrial Barley

water tea

37
Amount of Condensate Generated by
Heat Loss
Steam Diameter of main steam pipe (mm) kg/h
pressure
50 65 80 100 125 150 200 250 300 350 400 450 500 600
bar g
9.5 15.1 19.7 28.1 38.1 49.4 71 105 139 164 216 272 320 436
9
9.3 11.3 14.1 16.5 20.6 24.5 31.5 39 46.5 51.5 60 64 72 88

9.9 15.7 20.4 29.2 39.6 51.3 77 109 144 171 224 282 332 463
10
9.8 11.9 14.6 16.9 21.3 25 33 41 49 54 62 67 75 90

10.4 16.5 21.6 30.7 41.7 54.1 81.1 115 152 180 236 298 350 488
11
10.9 13 15.7 17.7 22.5 26 36 45 53 59 67 73 81 97
Based on 80%
Preheating insulation
efficiency for 20℃
load
air temperature
Operati per 50m of the
main steam pipe
ng load

38
Problems Caused by Wet Steam

• Erosion of piping, fittings and internal

components of valves
• Increased likelihood of water hammer and
related problems
• Formation of a water film on the heat
transfer surface that impedes heat transfer

39
Ways to Improve Dryness Fraction

• Operate the boiler near its maximum Air vent

operating pressure Water
• Swiftly raise the pressure at the initial separator
start-up of the boiler Dry

• Peak load prevention system steam

• Boiler continuous blowdown system

• Efficient thermal insulation
• Install a water separator
• Decompression
Wet steam

Condensate outlet

40
Causes of Foreign Matter in Steam System
• Carryover of dissolved solids in the
boiler due to improper boiler
operation
• Scale in the pipes
Strainer
• Welding slags
• Incorrectly applied gasket

41
Steam
System

5. Steam Transport
and Piping
• Steam Transport
Considerations
• Steam Piping
Steam Transport Considerations

43
Steam and Condensate in Steam Piping

Steam Impact Energy

=
Steam

Mass X Velocity
Steam Tim
e

44
Water Hammer
Bent pipe
Condensate

Water slug due to

condensate

Vibration and
noise caused
by water
hammer

45
Installation of Water Separator

Boiler Critical equipment,

outlet front-end of control
valve

Flowmeter, front-end
of control valve

46
Relay Piping

1/100 slope

Steam Relay to a
piping high point
Trap
Discharg
interval
e point
30~50m
Direction of
steam flow

47
Efficient and Proper Condensate Discharge

Abnor
mal

Nor
mal
Diameter of main steam pipe, D Pocket diameter – d1 Pocket depth – d2

Minimum d2

48
Branch Pipe Connection

Problem of inflow of condensate

flowing down the pipe

The purpose is to supply steam with high dryness

fraction by preventing the inflow of condensate
flowing into the bottom of the pipe as much as
possible.

49
Reducer, Bottom of Vertical Pipe, and
Strainer

50
Installation of Strainer
Control
Strainer valve

51
Pipe Diameter Selection

• Increased cost
• Increased heat
loss
• Low pressure at places
• Increased heat where steam is used
loss
• Low pressure in steam
applications
• Water hammer and
erosion

52
Two Main Ways to Select the Pipe Diameter

Velocity
If the typical pipe is less than
50m in length

Pressure
Loss
•

m = Q = AV  3,600 = π D 2 V  3,600

•

Vg Vg 4 Vg

If the typical pipe is 50m in

length or the flow rate (velocity)
is high

53
Pipe Diameter Selection – Steam Velocity

•
• Q AV  3,600 π 2 V  3,600
m= = = D
Vg Vg 4 Vg

Q = Volumetric flow rate of steam (m3/h)

4 Vg • m = Mass flow rate of steam (kg/h)
D=  m A = Cross-sectional area of pipe (m2)
π V  3,600 D = Inner diameter area of pipe (mm)
V = Velocity of steam (m/s)
Vg= Specific volume of steam (m3/kg)

54
Pipe Diameter Selection – Steam Velocity

4 0.218
D1 = × × 1,083 = 58mm 65mm
3.14 25 × 3,600

D2 = 4 × 0.603 × 1,083 = 96mm 100mm

3.14 25 × 3,600

8 bar g 2 bar g
1,083 kg/h

D2
D1

55
Pipe Diameter Selection – Steam
Velocity
Steam Veloci 배관 공정 구경 Pipe diameter (based on Schedule 80) : mm
pressure ty (kg/h)
bar g m/s 32 40 50 65 80 100 125 150
15 70 100 182 280 410 715 1,125 1,580
2 25 112 162 295 428 656 1,215 1,755 2,520
40 178 275 475 745 1,010 1,895 2,925 4,175
15 93 127 245 385 535 925 1,505 2,040
3 25 152 225 425 632 910 1,580 2,480 3,440
40 250 357 595 1,025 1,460 2,540 4,050 5,940
15 108 156 281 432 635 1,166 1,685 2,460
4 25 180 270 450 742 1,080 1,980 2,925 4,225
40 295 456 796 1,247 1,825 3,120 4,940 7,050
15 190 285 475 800 1,125 1,990 3,025 4,540
8 25 320 465 810 1,260 1,870 3,240 5,220 7,120
40 510 730 1,370 2,065 3,120 5,135 8,395 12,470
15 250 372 626 1,012 1,465 2,495 3,995 5,860
10 25 405 562 990 1,530 2,205 3,825 6,295 8,995
40 615 910 1,635 2,545 3,600 6,230 9,880 14,390
56
Summary
•Properties of saturated vapor
•Efficiency of transfer at high
pressure and use at low
pressure
•The importance of steam quality
- Air and non-condensable gases
- Dryness fraction
•Steam piping methods and
sizing
Steam
System