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

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Process Steam Systems

A comprehensive and accessible handbook for process steam systems

The revised second edition of Process Steam Systems: A Practical Guide for Operators, Maintainers, Designers, and Educators delivers a practical guide to ensuring steam systems are properly and efficiently designed, operated, and maintained. The book provides comprehensive information designed to improve process steam system knowledge, reliability, and integration into current manufacturing processes.

The most up-to-date version of this volume includes brand-new coverage of current codes, sustainability measures, and updated applications. Heat transfer theory and thermodynamics are tied into practical applications with new practice problems ideal for both professionals seeking to improve their skills and engineers-in training.

Readers will also find:

  • Thorough design criteria for process steam systems, complete with detailed illustrations for piping and controls
  • An entirely new chapter on the history of steam systems, including the evolution of the ASME code and boiler accidents
  • Revised coverage of current NFPA, ASME, CSD-1, FM, and building codes, as well as new insurance requirements relevant to practitioners in the industry
  • Expansive design guidance for steam system efficiency upgrades

Perfect for operations and maintenance staff at manufacturing, healthcare, and commercial laundries, Process Steam Systems: A Practical Guide for Operators, Maintainers, Designers, and Educators will also earn a place in the libraries of consulting engineers and engineering students with an interest in process manufacturing.

Author(s): Carey Merritt
Edition: 2
Publisher: Wiley
Year: 2022

Language: English
Pages: 368
City: Hoboken

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