How do you calculate the quantity of condensate generated in steam lines???

 How do you calculate the quantity condensate generated in steam lines???

 

How does condensation happens in steam line?

Condensation formation in steam lines is a common issue in steam distribution systems, and it can lead to various problems, including

• Reduced energy efficiency,
• Equipment damage,
• Operational issues.
• Poor steam quality
• Disturbances in process

How does condensation happens in steam line?

Condensation occurs when hot steam comes into contact with a surface that is cooler than its dew point temperature, causing the steam to lose heat and change phase into water droplets. Here are some factors to consider when dealing with condensation in steam lines:

Calculation:

A 100 TPH Boiler operating at of working pressure 87 kg/cm2 and 515 deg C supplies steam to 20 MW Turbine.The pressure and temperature at Turbine inlet are 85 kg/cm2 and 505 deg C, calculate the quantity of condensate formed.

 

Solution:

Enthalpy of steam at 87 kg/cm2 and 515 deg C =819 kcal/kg

Enthalpy of steam at 85 kg/cm2 and 505 deg C =814 kcal/kg

Enthalpy difference = 819-814 = 5 kcal/kg

Enthalpy of evaporation at average steam pressure 86 kg/cm2 is =332 kcal/kg

There fore,quantity of condensate generated = (100 X 5 / 332) =1.5 TPH

 

A process is situated at 500 meter from Turbine exhaust line.The exhaust pressure is 3 kg/cm2 and 150 deg C temperature and the steam paameters at process are 2.2 kg/cme and 138 deg C, quantity of steam supplied for process is 75 TPH.Calculate the condensation formed in steam line

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Solution:

Enthalpy of steam at 3 kg/cm2 and 150 deg C =657 kcal/kg

Enthalpy of steam at 2.2 kg/cm2 and 138 deg C =654 kcal/kg

Enthalpy difference = 657-654 = 3 kcal/kg

Enthalpy of evaporation at average steam pressure 2.6 kg/cm2 is =519 kcal/kg

There fore,quantity of condensate generated = (75 X 3 / 519) =0.43 TPH

 

What are the factors to be considered when dealing with steam line and condensation

 

How do you reduce steam condensation?

 

Temperature Differential: The primary cause of condensation is the temperature difference between the steam and the surrounding environment. To minimize condensation, you can either insulate the steam lines to maintain the steam's temperature or increase the temperature of the surrounding environment.

 

Insulation: Proper insulation of steam lines is crucial. High-quality insulation helps to maintain the temperature of the steam and prevents it from coming into contact with cooler surfaces. Insulation materials like fiberglass, mineral wool, or foam are commonly used for this purpose.

 

Steam Traps: Steam traps are essential components in steam systems. They are used to remove condensate from the steam lines while allowing steam to pass. Regular maintenance and inspection of steam traps can prevent condensate buildup.

 

Proper Sloping: Steam lines should be installed with a slight downward slope in the direction of condensate flow. This helps the condensate to drain away from the steam-carrying pipe, reducing the chances of condensate buildup.

 

Drainage Points: Install drainage points at low spots in the steam lines or at points where condensation is likely to occur. These drainage points should be equipped with proper traps and drains to remove condensate effectively.

 

Steam Pressure: Maintaining the proper steam pressure in the lines can also help reduce condensation. Lowering the pressure can reduce the temperature differential, which decreases the likelihood of condensation.

 

Steam Quality: Ensure that the steam quality is high. Wet or low-quality steam is more likely to condense. Proper steam generation and water treatment are essential to achieve high-quality steam.

 

Air Venting: Properly vent steam lines to remove air, which can contribute to temperature variations and condensation issues.

 

Monitoring and Maintenance: Regularly monitor steam lines for signs of condensation, such as water droplets or corrosion. Perform routine maintenance to address any issues promptly.

 

Heat Tracing: In some cases, heat tracing systems can be used to maintain the temperature of the steam lines, preventing condensation.

 

Pipe Material: The choice of pipe material can also impact condensation. Some materials, like copper, conduct heat more effectively and may be less prone to condensation compared to others.

 

Addressing condensation in steam lines is essential for the efficient and safe operation of steam systems. It helps prevent damage to equipment, ensures consistent steam quality, and reduces energy losses. Proper design, insulation, and maintenance are key to minimizing condensation-related issues in steam lines.

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