Design of piping systems: Steam & Condensate

Install a water separator after the boiler to dry steam, and install float or thermodynamic steam traps at user points and risers to drain condensate into the condensate network.

Regulating valves are externally controlled with pneumatic actuators, using pressure or temperature feedback to modulate flow; include globe, ball, and butterfly types with on/off and modulating modes.

Explore how pressure reducers automatically regulate outlet pressure despite varying inlet pressure, using direct acting and pilot acting types with internal or external sensing.

Learn how pressure reduction of steam from 6 bar to 3 bar creates superheated or desaturated steam, and how drying, water content, and energy balance affect temperature.

Size up pipes using a pressure drop calculation with Dusty Whaleback formula and Duffy Weisbach equation, including fittings and bends, using Moody diagram or VBA to estimate friction factor.

Size condensate headers so the header surface is at least the sum of all branch sections, then place branches from the top to prevent flooding, back pressure, and water hammer.

Estimate the heat exchanger's installed power from water flow, cp 4.2 kJ/kgK, and a 15-70 °C temperature rise, then size the exchanger using U 2.5 kW/m²K and the log mean temperature difference with margins to achieve a 963 kW design power for steam and condensate.

Calculate pressure variations in a heat exchanger from steam and water temperatures at 100% and 10% duties. Use latent heat and the saturated steam–water relationship to infer pressures.

Condensate sizing teaches calculating steam drop pressure using elevation pressure and a worst-case five-meter water column to select a 1 1/2 inch ft 14 schedule 40 condensate line.

This lecture covers condensate line sizing after the steam trip, balancing max flow and duty with cost-effective pipe sizes, and cooling condensate with a section after the steam trap.

Analyze failure flow in piping systems to size a safety valve, considering two failures: faulty pressure control valve and supply pressure drop, and identify critical versus non-critical flow.

Explore safety preliminary selection for steam systems by reading PSV capacity tables, choosing valves with or without lifting devices, and selecting a 20 size based on operating pressure.

design a direct injection heating system using steam and condensate, calculating required power and steam flow. Then size the control valve and injection nozzles with temperature feedback.