Steam and Plate Heat Exchangers

A technical guide to the effective use of steam in plate heat exchangers

Introduction
Both Spirax Sarco and Alfa Laval are the acknowledged experts and
world-leaders in the control of steam and heat exchange. Our customers
rely on our technical knowledge and high quality products in all industries
around the world.
When steam is the primary medium in a heat exchange application, we
have agreed to co-operate, using our combined strengths, to offer a
complete control, plate heat exchanger and condensate removal
solution.
This reference manual has been jointly written by Spirax Sarco and Alfa
Laval to show our customers how this co-operation can help them find
solutions to all of their steam heat exchange needs.

Steam and Plate Heat Exchangers

Index
1.

Steam fundamentals
- What is steam?
- Why use steam?
- The formation of steam
- Terminology and units
- Steam quality
- Steam tables
- Mollier diagram

2.

The steam load

- Types of heating
- Steam consumption
- Examples

3.

19
19
20
24
27
28
30
32

Temperature control of plate heat exchangers

- Heat exchanger design
- Stall condition
- Temperature control methods
- Automatic temperature control

5.

15
15
18

System design
- Steam system elements
- Steam generation
- Steam line sizing
- Draining steam lines
- Air venting
- Pressure reduction
- Flash steam
- Condensate return system

4.

7
7
7
8
9
11
11

41
42
48
51

Plate heat exchangers

- General
- The gasketed plate heat exchanger
- The brazed plate heat exchanger
- The all-welded plate heat exchanger
- Compabloc The fully welded and accessible plate heat exchanger
- Comparison of the plate heat exchanger and the shell & tube heat exchanger
- Steam as the heating medium in plate heat exchangers
- Design calculations of plate heat exchangers

59
60
62
63
64
65
68
71

Appendices
- Appendix I. Steam Tables
- Appendix II. Condensate line sizing
- Appendix III. Stall Chart

73
77
79

Illustrations, Formulae and Tables

Illustrations
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 25
Fig. 26
Fig. 27
Fig. 28
Fig. 29
Fig. 30
Fig. 31
Fig. 32
Fig. 33
Fig. 34
Fig. 35
Fig. 36
Fig. 37
Fig. 38
Fig. 39
Fig. 40
Fig. 41
Fig. 42
Fig. 43
Fig. 44
Fig. 45
Fig. 46
Fig. 47
Fig. 48
Fig. 49
Fig. 50
Fig. 51
Fig. 52

Saturated steam - temperature vs pressure

Saturated steam - specific volume vs pressure
Mollier diagram
Mollier diagram example
Simplified Mollier diagram
Heat exchange
Packaged boiler
Steam and condensate system
Pressure drop in steam lines
Heat loss from a steam pipe
The cause of waterhammer
Steam line drainage point
Steam trap types
Steam trap set
Steam line air venting
Steam pressure reducing valves
Steam pressure reducing station - with pilot operated valve
Steam separator
Pressure reducing valves fitted in parallel
Pressure reducing valves fitted in series
Flash steam per kg of condensate
Flash vessel
Condensate systems
Condensate line sizing
Multiple condensate line sizing
Long pumped delivery line
Electric condensate pumping unit
Automatic pump operation
Automatic pump packaged unit
Automatic pump operation
Stall chart
Use stall chart to establish flow rate at stall point
Use stall chart to establish secondary inlet temperature at stall point
Primary steam control
Primary steam control + active condensate drainage
Secondary side three port control
Condensate control
Elements of a simple closed loop automatic temperature control system
Flow characteristic curves
Characterised valve plug
Typical system characteristics with valves sized for small pressure drops
Valve with pneumatic actuator and positioner
Proportional control
PID controller
Instability caused by increasing controller gain, with no I or D action
Performance limits for plate heat exchangers
Flow principle in a plate heat exchanger
The gasket plate heat exchanger
A Clip-on gasket
A glued gasket
A channel plate with herringbone pattern
The gasketed PHE is very resistent to thermal fatigue...

8
9
10
12
13
17
19
20 -21
23
24
24
25
26
27
27
28
29
30
30
31
31
32
33
34
35
36
37
38
38
39-40
45
46
47
46
47
48
51
52
53
53
54
54
55
56
56
59
59
60
60
60
61
61

Steam and Plate Heat Exchangers

Fig. 53
Fig. 54
Fig. 55
Fig. 56
Fig. 57
Fig. 58
Fig. 59
Fig. 60
Fig. 61
Fig. 62
Fig. 63
Fig. 64
Fig. 65
Fig. 66
Fig. 67
Fig. 68
Fig. 69
Fig. 70
Fig. 71
Fig. 72
Fig. 73
Fig. 74
Fig. 75

Flow principle in a brazed plate heat exchanger

Cross section of the channel arrangement in a brazed plate heat exchanger
Laser welded plate pack
The all-welded plate heat exchanger, the AlfaRex
Semi-welded plate pack
CompaBloc heat exchanger
Flow principle in a CompaBloc heat exchanger
Comparisons in size between a S&T, a gasketed PHE and a BPHE in the...
A close temperature approach is possible in a plate heat exchanger
Comparisons between a gasketed PHE and a S & T
The swirling motion of the fluid retards fouling
Typical temp. fluctuations due to load change for PHE and S&T
Small contact area between steam and condensate
Large contact area between steam and condensate
Correlation between temp. and scale build-up over time
Plate without and with scaling
Condensation at 150C / 120C
A secondary side by-pass arrangement
Extra steam inlet
Reduction valve
Condensation on the upper part of the plate and condensate...
Thermal design data
Mechanical configuration

62
62
63
63
63
64
64
65
65
66
66
67
67
67
68
68
69
69
69
70
70
71
71

Formulae
Formula 1
Formula 2a
Formula 2b
Formula 3a
Formula 3b
Formula 4
Formula 5
Formula 6
Formula 7
Formula 8
Formula 9
Formula 10
Formula 11
Formula 12
Formula 13
Formula 14
Formula 15
Formula 16

Specific enthalpy calculation

Heat required to produce a rise in temperature
Steam flow rate required to produce a rise in temperature
Heat required to balance heat losses
Steam flow rate required to balance heat losses
Calculating steam load on a heat exchanger from secondary flow rate
Calculating steam load on a heat exchanger from kW...
Calculating steam load on a heat exchanger from MW energy rate...
Calculate flash steam quantity
Calculate common line size for non pumped condensate
Calculate heat exchange area
Calculate arithmetic mean temperature difference
Simplified calculation for arithmetic mean temperature difference
Calculate heat load (full load)
Calculate actual arithmetic mean temperature required
Calculate actual primary temperature
Calculate stall fraction for variable flow condition
Calculate stall fraction for variable T condition

9
15
16
16
17
17
18
18
32
35
41
41
41
42
43
43
44
44

Relative density and specific heat of various liquids

Overall heat transfer coefficient for steam to various liquids
Pipeline steam capacities at specific velocities
Warm up and running condensate loads for steam lines
Ziegler-Nicholls calculation
Impact of changing PID settings

16
17
22
26
57
57

Tables
Table 1
Table 2
Table 3
Table 4
Table 5
Table 6

Steam and Plate Heat Exchangers

1. Steam fundamentals
What is steam?

The formation of steam

Water can exist in the form of a solid, when we

call it ice; as a liquid, when we call it water, or a
gas when we call it steam. This reference manual will concentrate on its liquid and gas phases.

We use as a datum point the heat energy

content, or enthalpy, of 1 kg of water at
atmospheric pressure, and at the temperaure of
melting ice, 0C.

If heat energy is added to water, its

temperature rises to a point at which it can no
longer exist as a liquid. This is called the
saturation point and any further addition of
energy will cause some of the water to boil off as
steam. This evaporation of the water into steam
requires large amounts of energy, and while it is
being added, the water and the steam released
are at the same temperature.

If we take this as zero and then add heat to this

1 kg of water, its temperature will begin to rise.
At atmospheric pressure water cannot exist as a
liquid above 100C, so any additional heat added
after it reaches this temperature will cause some
of the liquid to boil off as steam.

If we then encourage the steam to release the

energy that was originally added to evaporate it,
the steam will condense back into water at the
same temperature.
A heat exchanger is where we arrange for this
release of energy to take place.

Why use steam?

Steam has been used as a carrier of heat since
the Industrial Revolution and continues to be a
modern, flexible and versatile tool wherever heating is needed.

It is produced by the evaporation of

water; a relatively inexpensive and
plentiful commodity which is
environmentally friendly.

Its temperature can be adjusted very

accurately by the control of its pressure.

It carries a large amount of energy in a

small mass.

The total amount of heat energy or enthalpy

held by each kilogram of liquid water at its boiling temperature is called the specific enthalpy of
saturated water, recognised by the symbol hf.
This is sometimes referred to as sensible heat.
The extra heat energy required to then turn
each kilogram of liquid water into steam is called
the specific enthalpy of evaporation and is
recognised by the symbol hfg. This is sometimes
referred to as latent heat.
The total heat energy or enthalpy in each kilogram of steam is the sum of the above two and
called the specific enthalpy of steam or total
heat. This is shown by the symbol hg = hf + hfg.
When all of the specific enthalpy of steam has
been added to the kilogram of water, then all of
the water will exist as steam at atmospheric pressure.
The volume of this steam will be greater than
the volume of the water by a factor of over 1,600
times at atmospheric pressure.
The molecules of water in the liquid condition
are bound together much more closely than are
the steam molecules. The process of evaporation can be thought of as one of adding sufficient
energy to each molecule so that it can break the
bonds holding it to its neighbours. The molecules
then leave the liquid and move freely in the gas
phase.

If the pressure on the liquid increases, the molecules find it more difficult to leave. More energy
needs to be added before the molecules can
break free and enter the gas phase.
Therefore the temperature of the water
increases to over 100C before boiling occurs.
For any given pressure there is a corresponding
temperature above which water cannot exist as a
liquid.
Equally, if the pressure on the water is below
normal atmospheric pressure, then it is easier for
the molecules to break free. Lower energy levels
are required, and boiling will occur at a
temperature below 100C.
This relationship between pressure and
temperature is constant for saturated steam, and
is shown in Fig. 1 and the 'Steam Tables' in Appendix I.
Fig. 1 Saturated steamtemperature vs pressure
Steam temperature C

250
200

Is the enthalpy (total energy) of a unit mass

(usually 1 kg). Therefore the usual unit of
measurement is kJ/kg.

Specific heat capacity

A measure of the ability of a substance to
absorb heat. It is the amount of energy (joules)
required to raise 1 kg by 1C. Therefore specific
heat capacity is expressed in kJ/kg C.
The specific heat capacity of water is
approximately 4.19 kJ/kgC. This means that
an increase in enthalpy of 4.19 kJ will raise the
temperature of 1 kg of water by 1C.

Entropy
Entropy is a measure of molecular order.
A change in entropy corresponds to a change in
the molecular order, or organisation of a system.
As entropy increases, molecules move more
freely, e.g. entropy increases when a solid melts
to become a liquid, or when a liquid evaporates
to become a gas.
Entropy is sometimes referred to as a measure of the amount of disorder in a system; high
disorder = high entropy, and low disorder = low
entropy. The molecules confined to a drop of
water are seen to be in a more orderly state than
if they were scattered about in the form of steam.

150
100
50
0

Specific enthalpy

10 12 14 16 18 20

Steam pressure bar g

Terminology and units

The Second Law of Thermodynamics states

that "The entropy of the universe shall never
decrease and shall increase whenever possible".
Because of this desire to increase:

Heat flows from a hot object to a cold

object.

Gas flows from a high pressure source to

a low pressure area.

Enthalpy
This is the term given to the total energy, due to
both pressure and temperature, of a fluid or vapour (such as water or steam) at any given time
and condition.
The basic unit of measurement is the joule (J).
Since one joule represents a very small amount
of energy, it is usual to multiply it by a thousand
and use kilojoules (kJ).

Absolute pressure and gauge pressure

The theoretical pressureless state of a perfect
vacuum is 'absolute zero'. Absolute pressure is
therefore a pressure above absolute zero. The
pressure exerted by the atmosphere is 1.013 bar
absolute, at sea level.

Steam and Plate Heat Exchangers

Other units often used are the kilopascal (kPa),

1 bar = 100 kPa, and the millibar (m bar), 1 bar =
1,000 m bar.

Heat and heat transfer

Heat is a form of energy and as such is part of
the enthalpy of a liquid or a gas.
Heat transfer is the flow of enthalpy from matter
at a high temperature to matter at a lower
temperature.

Density of saturated water

The density of water changes little with
temperature. At 100C, saturated water has a
specific density of 0.958 kg/litre. Heated water is
a little less dense than cooler water.
A 10.65m column of water at 100C will exert a
pressure at its base of 1 bar g.

Specific volume
If a 1 kg mass of water (1 litre or 0.001 m3 by
volume at 20C) is all converted into steam, the
result will be exactly a 1 kg mass of steam.
However, the volume occupied by the steam
will be far greater. At atmospheric pressure, 1 kg
of steam occupies nearly 1.673 m3. As steam
pressure increases its specific volume (Vg)
decreases. At 10 bar g. the specific volume of
steam is only 0.177 m3. This relationship is illustrated in Fig. 2.

Fig. 2 Saturated steam - specific

volume vs pressure
1.8

Specific volume m2/kg

Gauge pressure, as shown on a standard

pressure gauge, is the pressure above
atmospheric pressure. Therefore 0 bar gauge
(bar g) is the equivalent of 1.013 bar absolute
(bar a). Sometimes, bar g is simply referred to as
bar.

1.6
1.4
1.2
1.0
0.8
0.6
0.4
0.2
0

6 8 10 12 14 16 18
Steam pressure bar g

20

In practice, steam often carries tiny droplets of

water and is not totally dry saturated steam.
Steam quality is described by its 'dryness fraction' - the proportion of completely dry steam
present in the sample of steam being considered.
If steam is described as having a dryness fraction
of 0.95, 95% of its mass will be dry saturated
steam and 5% will be water. The water droplets
carry no specific enthalpy of evaporation.
The specific enthalpy of steam at 7 bar g with
a dryness fraction of 0.95 can be calculated as
shown in Formula 1.
Each kilogram of 'wet' steam will contain the
full enthalpy of saturated water, 721.4 kJ/kg, but
Formula 1. Specific enthalpy calculation

Steam quality
Dry steam and wet steam
Steam tables show the properties of 'dry
saturated steam'. This is water that has been
completely evaporated into steam, containing no
droplets of liquid water.

as only 0.95 kg of dry steam is present with 0.05

kg of water, there will only be 95% of the enthalpy of evaporation, 2047.7 kJ/kg, present.

This figure represents a reduction of

102.4 kJ/kg from the specific enthalpy of steam
at 7 bar g, 2769.1 kJ/kg, shown in the steam
tables in Appendix I. Clearly, 'wet' steam has a
heat content substantially lower than that of dry
saturated steam at the same pressure.

If heat continues to be added after all the water

has evaporated, the steam temperature will again
rise. The steam is then called 'superheated', and
this superheated steam can be at any
temperature above that of saturated steam at
the corresponding pressure.

The droplets of water in the steam have weight

but occupy negligible space and therefore have
little effect on the overall volume.

Saturated steam will condense readily on any

surface which is at a lower temperature,
immediately giving up its enthalpy of evaporation.

Pure dry saturated steam is a colourless gas.

It is water droplets suspended in the
steam that give it a white cloudy appearance.
Superheated steam

When superheated steam gives up some of

its enthalpy, it initially does so by virtue of a fall
in temperature. No condensation will occur
until its temperature has fallen to its saturation
temperature, and the rate at wich energy flows

Fig. 3 Mollier diagram

on
pc

Specific enthalpy, h kJ/kg

sta

nt

Superheat
Area

t constant

tan

s
on

c
t, t

tan

s
on

Sa

tur

dr

yn

pc

es

sf

ra

Wet Area

Specific entropy, s kJ/kg K

10

ct

ion

atio

n li

ne

Steam and Plate Heat Exchangers

from superheated steam is often less than that
achieved with saturated steam, even though its
temperature is higher.
Superheated steam, because of its properties,
is usually the first choice for power generation
requirements, whilst saturated steam is ideal for
heating applications.

Dryness fraction (x) in the wet area

of the diagram.

Constant pressure (p) lines in both the

wet area and dry area of the diagram.

Constant temperature line (t) in the

superheat region. In the wet area the
pressure and temperature lines are
parallel.

Mollier diagram example

Steam tables
It has already been explained that a relationship
exists between steam pressure and saturation
temperature: that enthalpies of saturated water, evaporation and saturated steam vary with
pressure and that specific volume changes with
pressure.

The usefulness of a steam Mollier diagram can

be demonstrated by giving an example of how
the various states of steam and condensate can
be plotted when it is used in a heat exchanger.
For the sake of clarity, only the lines necessary to
illustrate the example are shown in Fig. 4.

For saturated steam these relationships are

fixed and recorded in 'Steam Tables' as set out
in Appendix I.

Mollier diagram
A steam Mollier diagram is another means of
recording the properties of steam and
condensate under various conditions. It shows
the properties of steam and condensate under
any specific condition, or state. If the initial and
final state point of a process are known, a line
joining these state points can represent that part
of the process itself.
A steam Mollier diagram will contain the
following features:

Specific enthalpy (h) and Specific entropy

(s) values plotted on the axes of the
diagram.

A steam saturation line dividing the

chart into a superheated steam region
and a wet steam region. The line itself
denotes dry saturated steam.

Steam is available in the distribution

system at 15 bar a, and is 94% dry. Its
specific enthalpy (h) at this point is
2,673 kJ/kg
- Point A

The steam is now reduced in pressure

from 15 bar a to 4 bar a through a
pressure reducing valve. Its specific
enthalpy remains constant at 2,673 kJ/kg
and at the new reduced pressure of
4 bar a it is now 97% dry.
- Point B

It then passes through the temperature control valve with a pressure drop
of 50%. The steam now enters the heat
exchanger at 2 bar a, and the specific
enthalpy still remains constant at
2,673 kJ/kg. It is intersting to note that
even though the steam pressure has
been reduced from 15 bar a to 2 bar a
it does not become superheated in the
process. At the start point it is 94% dry
and at the reduced pressure it is 99% dry.
- Point C

11

ra

ra

2 ba

Superheat
Area

4 ba

15 b

ar a

Fig. 4 Mollier diagram example

198C
144C

Specific enthalpy, h kJ/kg

120C

9
,1

ra

ba

Sa

tur

4C

14
15 ar a,
C
4 b a, 120
r
a
2b

atio

n li

x=
x=
x=

ne

0.9

0.9

0.9

Wet Area

Specific entropy, s kJ/kg K

In the heat exchanger, the steam now

condenses at constant pressure and
gives up its specific enthalpy of
evaporation. When it gives up all of its
specific enthalpy of evaporation it will
have condensed back into water. At this
point its pressure will still be 2 bar a, but
its enthalpy will now be 505 kJ/kg
- Point D

12

Some sub-cooling of the condensate

may occur within the heat exchanger
and cooling and some re-evaporatio
will occur when the condensate passes
through the heat exchanger steam trap
into the condensate system. The final
condition will depend on the condensate
removal arrangements and the pressure
within the condensate return system
- Point E

Steam and Plate Heat Exchangers

Simplified Mollier diagram
It is not practicable to reproduce a full Mollier
diagram in a publication such as this, because
of its large size and complexity. Full diagrams are
available in both hard copy and electronic format
from technical publishers.

A simplified Mollier diagram is reproduced in

Figure 5. showing sufficient detail to be able to
plot state points around the saturated steam line
in the pressure ranges used by the majority of
steam heat exchange applications.

Fig. 5 Simplified Mollier diagram

3000

2900

2800

Specific enthalpy kJ/kg

2700
Satur
at

ion Lin
e

2600

x=0.98

2500

x=0.96
x=0.9

2400

x=0.9

2300

x=0.9

x=0.8

2200

x=0.8

x=0.8
4

x=0.8
2

x=0.8

6.0

6.2

6.4

6.6

7.4
7.2
7.0
6.8
Specific entropy kJ/kg K

7.6

7.8

8.0

13

14

Steam and Plate Heat Exchangers

2. The steam load

Types of heating
Before it is possible to select a correctly sized
steam control valve, a supply main, or even a
steam boiler, it is necessary to know, with as
much accuracy as possible, how much steam is
required.
Almost all heating loads fall into one of two
categories.

Temperature increase - heating a material

from a lower temperature to a higher
temperature.
Temperature maintenance - making up
heat losses to maintain a fixed
temperature.

Normally, in the case of a steam heat exchange

application it is the former case, with a product
entering the secondary side of the exchanger
at a lower temperature and leaving at a higher
temperature.

Two methods of measurement are available;

the measurement of steam flow into the process,
or the measurement of condensate condensed
by the process.

Manufacturer's ratings
Some items of manufactured plant are supplied
with information on thermal output.
These ratings will usually be based on raising
a stated amount of air or water through a given
temperature rise, using steam at a specified
pressure.
It should never be assumed that the
manufacturer's rating equates to actual load.
A heat exchanger may be capable of a given
duty, but the actual connected load may only be
a fraction of this, or occasionally may exceed the
design rating

Calculation
The amount of heat required to produce a rise
in temperature is given by Formula 2a

Formula 2a

Steam consumption
Steam consumption can be arrived at in one of
three ways.

Heat required to produce a rise in

temperature
where:
Q = heat load, kJ

Measurement

M = weight of material to be heated, kg

Manufacturers rating

Cp = specific heat of material, kJ/kgC

Calculation.

= temperature rise, C

Measurement
Obviously, steam flow cannot be measured at
the design stage of a installation. Measurement
of steam flow can only be used to establish the
steam flow rate on an existing installation.

The specific heat of a material is the amount of

heat required to raise a unit mass (1 kg) through
1C. A table of the specific heats and specific
gravities of various liquids is set out in Table 1.

15

Table 1.

Liquid

Relative density and specific

heat of various liquids

Relative
density

Acetone
0.79
Alcohol, ethyl, 0C
0.79
Alcohol, ethyl, 40C
0.79
Alcohol, methyl, 4 - 10C
0.80
Alcohol, methyl, 15 - 21C
0.80
Ammonia, 0C
0.62
Ammonia, 40C
Ammonia, 80C
Ammonia, 100C
Ammonia, 114C
Anilin
1.02
Benzol
Calcium chloride
1.20
Castor oil
Citron oil
Diphenylamine
1.16
Ethyl ether
Ethylene glycol
Fuel oil
0.96
Fuel oil
0.91
Fuel oil
0.86
Gasoline
Glycerine
1.26
Kerosene
Mercury
19.60
Naphthalene
1.14
Nitrobenzene
Olive oil
0.91 - 0.94
Petroleum
Potassium hydrate
1.24
Sea water
1.02
Sesame oil
Sodium chloride
1.19
Sodium hydrate
1.27
Soybean oil
Toluol
0.87
Turpentine
0.87
Water
1.00
Xylene
0.87 - 0.88

Specific
heat
2.13
2.30
2.72
2.46
2.51
4.60
4.85
5.39
6.19
6.73
2.17
1.75
3.05
1.79
1.84
1.92
2.21
2.21
1.67
1.84
2.09
2.21
2.42
2.00
1.38
1.71
1.50
1.96
2.13
3.68
3.93
1.63
3.30
3.93
1.96
1.50
1.71
4.19
1.71

As the actual flow rate of steam is usually

required, rather than the heat load in kJ, Formula
2b will normally be more useful.

16

Formula 2b
Steam flow rate required to produce a rise
in temperature

where:
Ws = steam flow rate, kg/h
M = weight of material, kg
Cp = specific heat, kJ/kg C
t

= temperature rise, C

hfg = enthalpy of evaporation of steam, kJ/kg

h = time available, hours

Where heat is required to balance heat losses,

the heat flow rate can be calculated using
Formula 3a.

Formula 3a
Heat required to balance heat losses
where:
Qr = heat flow rate, kJ/h
k

= heat transfer coefficient, W/m2 C

= heating area, m2

= temperature difference, C

The 'k' value, or heat transfer coefficient, is a

value giving the expected overall rate at which
heat energy will travel from a hot medium to a
cooler medium through a barrier separating them.
Some typical 'k' values, expressed in
Watts/m2 C, for the flow of energy from steam
through stainless steel to various liquids in
Plate Heat Exchangers are listed in Table 2.

Steam and Plate Heat Exchangers

Table 2.

Overall heat transfer

coefficient for steam to
various liquids

Fig. 6 Heat exchange

heat exchanger primary side

'k' value
W/m2 C

Liquid
Water
Organics
Light oil
Heavy oil

5000 - 10000
4000 - 6000
1000 - 1600
600 - 1000

These coefficients are affected by other factors

and should only be regarded as approximations.
The area referred to in the previous formula is
the actual area over which this heat transfer is
taking place.

steam gives up its enthalpy of

evaporation and condenses
steam
in
heat passes from primary
side to secondary side
heated
fluid
out

fluid
in

Again, as the steam flow rate is normally required, Formula 3b will usually prove to be more
useful.

Formula 3b
Steam flow rate required to balance heat
losses

condensate
out

heat exchanger secondary side

Usually, you will be provided with a flow rate for

the secondary fluid and the required rise in temperature. A derivation of Formula 3b will provide
a steam flow rate where the flow rate through the
secondary side of the exchanger is expressed in
m3/h, as shown in Formula 4.

where:Ws = steam flow rate kg/h

Formula 4

= heat transfer coefficient, W/m2 C

= heating area, m2

Calculating steam load on a heat

exchanger from secondary flow rate

= temperature difference, C

hfg = enthalpy of evaporation of steam, kJ/kg

where:-

Steam load on heat exchangers

When considering the actual steam load on
a heat exchanger, enough steam needs to be
provided to the primary side of the exchanger
to provide the required rise in temperature in the
liquid or gas passing through the secondary side
of the exchanger.

Ws = steam flow rate kg/h

M = fluid flow rate m3/h
d

= fluid relative density

Cp = fluid specific heat kJ/kgC

t

= temperature rise C

hfg = enthalpy of evaporation of steam, kJ/kg

17

Sometimes the heat requirement in a heat

exchange application will be expressed as an
energy rate requirement given in kilowatts (kW) or
megawatts (MW).
A Watt is an energy rate of 1 Joule per second
(J/sec), where the Joule is a basic unit of energy.

Examples

If heat requirements are expressed in these

units, they can be converted to steam flow rates
using either Formula 5 or Formula 6.

Example 1

Formula 5
Calculating steam load on a heat
exchanger from kW energy rate
requirement

Calculate the steam flow rate on an exchanger required to heat 15 m3/h of water from 20C to 60C.
The steam pressure is 2 bar g.

Using Formula 4

where:
Ws = steam flow rate kg/h
kW = energy rate requirement
hfg = enthalpy of evaporation, kJ/kg

NB:Relative density of water = 1 (Table 1)

Specific heat of water = 4.19 kJ/kgC (Table 1)
Specific enthalpy of evaporation of steam at
2 bar g = 2,163.3 kJ/kg (Appendix I)

Formula 6
Calculating steam load on a heat
exchanger from MW energy rate
requirement

where:

Example 2
The energy rate requirement on a heat
exchanger is 150 kW. Calculate the required
steam flow rate, with steam at 3 bar g.

Ws = Steam flow rate kg/h

MW= Energy rate requirement
hfg = Enthalpy of evaporation, kJ/kg

It must always be remembered that even if

the correct amount of steam is provided, in the
best possible condition, the required secondary
condition will not be met if the exchanger itself
is undersized. The ability of an exchanger to
meet a given condition can be checked, using
Formula2a, if the heat exchange area and heat
transfer coefficient are known.

18

Using Formula 5

NB: Specific enthalpy of evaporation of

steam at 3 bar g = 2,133.4 kJ/kg
(Appendix I)

Steam and Plate Heat Exchangers

3. System design
Steam system elements
A steam system will normally consist of four
main elements, all of which can affect the efficient
operation of each individual piece of steam using
equipment.

Steam generation

Steam distribution

Steam using equipment

Condensate recovery and return

The condensate recovery and return system

should remove condensate effectively from the
equipment and ensure that it is returned to the
boilerhouse to be re-used in the boiler.
The following sections deal with some of the
factors that can affect the efficient operation of a
steam system and steam using equipment.

Steam generation

The purpose of the steam generation and distribution system is to provide steam at the correct
pressure, in sufficient quantity and in the best
possible condition to the equipment.
The steam users should be provided with the
steam control and condensate removal
equipment that allow it to operate efficiently.

Steam is generated by adding heat to water,

causing it to evaporate. This operation is carried
out in a boiler.
It is generated at pressures from below
1 bar a., for steam heating applications, up to
supercritical conditions above 220 bar a. and
374C for power generation. Different types of
boiler will be used depending upon the pressure,
temperature and quantity of steam required.

Fig. 7 Packaged boiler

Steam space

Water

Steam crown valve

Flue

Burner

1st. pass 2nd. pass

3rd. pass

19

Fig. 8 Steam and condensate system

1
2
3
4
5
6

Feedtank
Deaerator head
Vent head
Boiler feedwater pump
Boiler
TDS control

The most common steam boiler type in general

industrial use for steam pressures up to 25 bar g
is the packaged boiler. This type of boiler has a
water filled shell with a steam space at the top.
Immersed in the water is a combustion chamber connected to banks of tubes through which
the hot flue gasses pass. Each bank of tubes is
called a "pass". With this type of boiler it is unlikely the steam produced will be 100% dry.
For higher pressures, temperatures and capacities, water tube boilers are used. Here, the
water is circulated through tubes, hence "water
tube boiler" and the hot combustion gases are
passed over these tubes. The tubes are

20

7
8
9
10
11
12

Boiler feedwater control

Bottom blowdown control
Blowdown vessel
Steam distribution main
Steam main start-up system
Steam separator

connected to a steam drum at their top and a

water drum at their base. Often, water tube boilers have a superheater incorporated into their
design.

Steam line sizing

The correct size of pipe to carry the required
amount of steam at the required pressure should
be selected.
If the pipe is too small, a high pressure drop
and high velocity will occur, resulting in lack of

Steam and Plate Heat Exchangers

13
14
15
16
17
18
19

Steam trap set

Pneumatic pressure reducing valve station
Pneumatic actuated valve with positioner
Plate heat exchanger
Automatic pump trap
Steam flow metering system
Direct-acting pressure reducing valve station

pressure at the steam equipment, and possibly,

noise and erosion within the pipework.
If the pipework is too large it is unnecessarily
expensive to install and the heat loss from it will
be greater than it need be.
Steam pipes should be sized so that both the
pressure drop and velocity along them is within
acceptable limits. Two methods of sizing are generally used for steam pipes:

Velocity method

Pressure drop method

20
21
22
23
24
25

Flash steam recovery vessel

Electric condensate return units
Pneumatic actuated valve with positioner
Steam injection humidifier
Pressure powered pump condensate return unit
Condensate return main

Sizing on velocity
This is the quickest and most convenient method of sizing and can be used for short lengths of
steam main or branch lines. On longer pipe runs,
pressure drop should also be checked to ensure
that it is within acceptable limits.
In saturated steam lines, a reasonable maximum
velocity for large pipe diameters and high steam
pressures is 40 m/s. A velocity of 25 m/s is more
appropriate for middle ranges and 15 m/s for
small pipe diameters at low pressures.
Table 3 gives pipe line capacities of a range of
pipe sizes, at steam velocities of 15 m/s, 25 m/s
and 40 m/s.

21

Table 3

Pipeline steam capacities at specific velocities

Pressure Velocity
bar g
m/s

15
mm

20
mm

Steam flow kg/h

25
32
40
50
65
mm mm mm mm mm

80
mm

100
mm

125
mm

150
mm

0.4

15
25
40

7
10
17

14
25
35

24
40
64

37
62
102

52
92
142

99
162
265

145
265
403

213
384
576

394
675
1037

648
972
1670

917
1457
2303

0.7

15
25
40

7
12
18

16
25
37

25
45
68

40
72
106

59
100
167

109
182
298

166
287
428

250
430
630

431
716
1108

680
1145
1712

1006
1575
2417

1.0

15
25
40

8
12
19

17
26
39

29
48
71

43
72
112

65
100
172

112
193
311

182
300
465

260
445
640

470
730
1150

694
1160
1800

1020
1660
2500

2.0

15
25
40

12
19
30

25
43
64

45
70
115

70
112
178

100
162
275

182
295
475

280
428
745

410
656
1010

715
1215
1895

1125
1755
2925

1580
2520
4175

3.0

15
25
40

16
26
41

37
56
87

60
100
157

93
152
250

127
225
375

245
425
595

385
632
1025

535
910
1460

925
1580
2540

1505
2480
4050

2040
3440
5940

4.0

15
25
40

19
30
49

42
63
116

70
115
197

108
180
295

156
270
456

281
450
796

432
742
1247

635
1080
1825

1166
1980
3120

1685
2925
4940

2460
4225
7050

5.0

15
25
40

22
36
59

49
81
131

87
135
225

128
211
338

187
308
495

352
548
855

526
885
1350

770
1265
1890

1295
2110
3510

2105
3540
5400

2835
5150
7870

6.0

15
25
40

26
43
71

59
97
157

105
162
270

153
253
405

225
370
595

425
658
1025

632
1065
1620

925
1520
2270

1555
2530
4210

2525
4250
6475

3400
6175
9445

7.0

15
25
40

29
49
76

63
114
177

110
190
303

165
288
455

260
450
690

445
785
1210

705
1205
1865

952
1750
2520

1815
3025
4585

2765
4815
7560

3990
6900
10880

8.0

15
25
40

32
54
84

70
122
192

126
205
327

190
320
510

285
465
730

475
810
1370

800
1260
2065

1125
1870
3120

1990
3240
5135

3025 4540
5220 7120
8395 12470

10.0

15
25
40

41
66
104

95
145
216

155
257
408

250
405
615

372
562
910

626
990
1635

1012
1530
2545

1465
2205
3600

2495
3825
6230

3995 5860
6295 8995
9880 14390

14.0

15
25
40

50
85
126

121
195
305

205
331
555

310
520
825

465
740
1210

810
1375
2195

1270
2080
3425

1870
3120
4735

3220
5200
8510

5215
7390
8500 12560
13050 18630

Sizing on pressure drop

In lines over a few metres in length it is better
to size the pipe using the pressure drop method,
ensuring the correct steam pressure and
therefore the correct temperature is available at
the steam using equipment. Normally a pressure
drop of approximately 0.3 bar per 100 m run is
acceptable.

22

Pressure drop in steam lines can be calculated,

but is a lengthy process requiring the use of a
number of factors related to such things as pipe
wall roughness and the resistance of pipe fittings.

Steam and Plate Heat Exchangers

Use of the chart, Fig. 9, will provide a
sufficiently accurate result for practical purposes.

Example
Determine the pressure drop when
10,000 kg/h of saturated steam at an initial pressure of 10 bar g and a temperature of
184C flows through a 150mm pipeline.

Fig. 9 Pressure drop in steam lines

18
10

1
0.5
0.3

20
25
30
40
50
60
70
80
100
125
150
200
250
300
400
500
600

10

3
2

15

Pressure drop bar /100m

0.2
0.1
0.05
0.03
0.02
0.01

Steam pressure bar g

10
A

20
30

20
30
50
100
20
3000
500
10
00
20
0
30 0
5 0 00
00
10
000
20
30 000
50 000
00
100 0
0
200 00
000

10

0.5
1
2
3
5

50
75
100
100C 200C 300C 400C 500C
Steam temperature

23

Using Fig. 9, locate 10 bar g on the

saturated steam line.

Fig.10 Heat loss from a steam pipe

- Point A

From point A draw a horizontal line

across to 10,000 kg/h on the steam flow
rate scale.

Steam

Insulation

- Point B

From Point B draw a vertical line up the

150 mm line on the inside pipe diameter
scale

Pipe

- Point C

From Point C draw a horizontal line

across to the pressure drop scale.

Heat loss
Condensate

- Point D
In this case the pressure drop will be
approximately 0.4 bar per 100m length of pipe.

Draining steam lines

Even with properly selected and installed insulation, some heat will be given up by the steam
in a steam line, through the insulation to the
atmosphere. As this happens some of the steam
condenses and the condensate formed travels
along the pipework with the steam.
It is important that this condensate is not allowed to build up. It can affect the operation
of the plant if it is carried into the steam using
equipment and can cause damage to the
pipeline, pipeline fittings and process equipment.

These slugs arrive at a valve or pipe bend and

are suddenly stopped. The kinetic energy in the
condensate slug converts into pressure energy
and a pressure shock is exerted on to the obstruction which can cause considerable damage.

Steam line drainage points

To help prevent the problem of waterhammer,
steam lines should be fitted with a condensate
drainage point every 30m to 50m, also at low
points and changes in elevation where
condensate will collect.
A drainage point will consist of a condensate
collection leg and a steam trap set to drain the
condensate away from the collection leg.

Fig.11 The cause of waterhammer

When carried into heat exchange equipment

with the steam it will add to the condensate film
on the heat exchange surface and lower the efficiency of the equipment.
Carried at velocities that can exceed 300 m/s,
it can cause erosion across valve seats; known
as 'wiredrawing'.

Condensate forms due to radiation losses

from the pipe

Waterhammer
Waterhammer occurs when condensate builds
up into 'slugs' and is carried along the pipe at
steam velocity.

24

Slugs of condensate can develop and be

carried along at steam velocity

Steam and Plate Heat Exchangers

A steam trap is a device that will allow
condensate to pass through it, but will not allow
steam to pass.
Steam lines up to 100mm in size should have
a collection leg the same size as the line. Larger
pipes should have collection legs two or three
pipe sizes smaller, but not less than 100mm.
Where timed automatic slow start up
procedures are in place, the length of the
collection leg should be approximately 1.5 pipe
diameters but not less than 200mm. If the boiler
is shut down each night and automatic slow start
up procedures are not used, it may be necessary
to provide a longer collection leg of 700mm or
more.

condensate load must be known. The warm up

load, when the boiler starts up and the steam
lines are brought up to normal operating temperature, will be greater than the running load
when steam only condenses due to heat loss
from the pipe. Usually the steam trap should be
sized to handle the greater warm up load but
there are occasions where steam lines are always
live and sizing on the running load will be
appropriate.
It should also be remembered that at start up
the pressure in the steam line will be much lower
than during normal operation. Table 4. shows the
warm up and running loads for steam pipes up to
400mm.

Fig.12 Steam line drainage point

Steam flow

Steam trap
Condensate collection leg
Steam trap set

Condensate out

Blowdown valve

For a steam trap to operate it requires a

positive differential pressure between its inlet and
outlet. When a boiler first starts up, the pressure
within the steam line may not be sufficient and
this longer collection leg will provide a positive
hydraulic pressure above the steam trap.
A collection leg of 700mm will provide a hydraulic
head of approximately 0.07 bar g in addition to
the actual line pressure.
In order to size a suitable steam trap correctly
for a steam line drainage application the

Steam trap set

Many different types of steam trap are
available, each with their own particular
characteristics and method of operation. In very
general terms they can be broken down into
three distinct types:

Mechanical operation

Thermodynamic operation

Thermostatic operation

25

Table 4
Steam
Pressure
bar g
1
5
7
10
14
18

One hour warm up and running condensate loads per

50m of steam pipe
Nominal Pipe Size mm
50

65

80

100

125

150

200

250

300

350

400

5.4
4.8
8.2
7.3
8.7
8.2
9.9
9.8
10.9
11.2
17
15

8.6
5.4
13
8.9
13.8
10.2
16
12
17
14
23
16

11.2
6.8
17
10.5
18
12
20
15
23
17
31
19

16
8.5
24
13
26
15
29
17
32
20
45
24

22
10.3
33
17
35
19
40
21
44
26
62
30

28
13
42
20
45
23
51
25
57
30
84
36

44
16
63
24
68
28
77
33
85
39
127
44

60
19
70
30
97
35
109
41
120
49
187
55

80
23
119
36
128
42
144
49
160
58
255
66

94
25
142
40
151
46
171
54
189
64
305
72

123
28
185
46
198
52
224
62
247
73
393
82

Condensate loads in kg/h. Warm up load in normal type. Running load in bold italic type

A mechanical trap senses the difference in

density between steam and condensate and
will discharge condensate as soon as it forms,
at steam temperature. Mechanical traps include
Float & Thermostatic (FT) and Inverted Bucket
(IB) types

The problem of air in a steam system is

discussed in the next section, but it is important
that a steam trap selected for this application is
Fig.13 Steam trap types

The Thermodynamic type, (TD), relies on the

difference in velocity between steam and
condensate when it passes through a fixed orifice
and will discharge condensate at a few degrees
below steam temperature.
Thermostatic traps require condensate to cool
and will discharge between 15C and 30C below steam temperature dependant upon the type
of thermostatic element fitted. Thermostatic traps
include the Balanced Pressure, (BP) type, and
the Bimetallic, (SM) type.
With steam line drainage it is important that
condensate is removed as soon as it is formed.
Therefore we would recommend either a TD type
thermodynamic steam trap or an FT type
mechanical steam trap, depending upon the operating conditions. It can be seen from the condensate loads shown in Table 4., that even when
sizing for warm up conditions, a 15mm or 20mm
steam trap will normally be suitable.

26

Thermodynamic
TD steam trap

Mechanical
FT steam trap

Thermostatic
SM steam trap

Steam and Plate Heat Exchangers

also capable of passing any air trapped in the
steam line. The inverted bucket trap deals with
air poorly, whereas the float and thermostatic trap
has excellent air handling qualities. This, together
with its other attributes, makes it the first choice
for draining a plate heat exchanger.

ensure that reverse flow through the steam trap

does not occur.

Fig.14 Steam trap set

Steam trap

Isolation valve

From steam main

Isolation valve

Check valve

Condensate out

Spiratec chamber

Thermostatic type steam traps deal with air well

at start up, while thermodynamic steam traps
have a moderate air handling capability unless
fitted with special internals.
Various pieces of ancillary equipment will be
required with the steam trap to make up a steam
trap set.

Isolation valves

Spiratec chamber (or sightglass)

Strainer

Check valve

The isolation valves are needed to isolate the

trap set for maintenance.

Air venting
Air and other incondensable gases can be
drawn into a steam system through joints when
the system is shut down or can enter the steam
line with the steam from the boiler.
These incondensable gases need to be
removed as they will cause slow warm up of the
steam lines, corrosion in the steam system and if
carried to heat exchange equipment will lower its
efficiency.
Fig.15 Steam line air venting

The Spiratec chamber enables automatic checking of

the steam trap's operation to
be carried out. Some models
of steam trap incorporate an
integral sensor. If this is not
fitted a sight glass should be
fitted after the steam trap.
A strainer should be fitted
before the steam trap to protect it from pipeline debris.
A check valve should be
fitted after the steam trap to

27

Automatic air vents should be fitted to the ends

of steam lines and at strategic points along their
length to ensure that these incondensable gases
are removed.
Otherwise, they will mix with the steam, and
form an insulating barrier on heat exchange surfaces, lowering the rate at which heat is transferred, and at the same time promote corrosion.

Pressure Reduction
Often, steam pressure needs to be reduced to
meet the needs of a particular process.
Steam should be generated at, or close to,
the boiler design pressure to ensure that it is of
the highest quality. It should then be distributed
at high pressure which requires smaller diameter
distribution mains. Individual pieces of steam
using process plant may require steam at much
lower pressures, with the pressure limitation set
by either the process requirements or the
process equipment itself. Where this is necessary
the steam pressure will be reduced through a
pressure reducing station, incorporating a steam
pressure reducing valve.

Many types of steam pressure reducing valves

are available including direct acting types, pilot
operated types and electro/pneumatic types.
The choice will depend upon the steam load, the
stability of the steam load, the steam pressure
and the expected variations in the upstream and
downstream steam pressures.
A direct acting type valve is very robust and
simple in its operation. Because of its method of
operation the downstream pressure will deviate
from the set pressure if the upstream pressure
alters or the steam load changes. This is often
referred to as "droop" and this characteristic can
be acceptable where the steam load and
upstream pressure do not vary very much, or
where variations in downstream pressure can be
accepted.
A pilot operated valve provides greater
accuracy of downstream pressure while
operating under conditions where the upstream
pressure may change or there may be variations
in the steam flow rate.
Flexibility and accuracy under all operating
conditions can be achieved by using an electro/
pneumatic actuated valve arrangement.

Fig.16 Steam pressure reducing valves

Direct acting valve

Pilot operated valve

Electro/pneumatic actuated valve
with controller and pressure sensor

28

Steam and Plate Heat Exchangers

by a steam trap. Removing these droplets from
the steam will help to ensure that maximum heat
transfer rates are achieved within the heat
exchanger and that valve seats are not damaged
by wiredrawing. Wiredrawing is a name for the
erosion that occurs when the droplets are
carried across valve seats at velocities of up to
300 m/s during normal operation.

Pressure Reducing Stations

The prime purpose of a pressure reducing valve
station is to provide steam at the correct
pressure in sufficient quantity. It should also be
designed to ensure that the steam provided is
dry and clean.
To ensure this is achieved, the following
components should be provided in a pressure
reducing valve station.

Fig.17 Steam pressure reducing station - with pilot operated valve

Safety valve
Isolation
valve

Pressure
reducing valve

Pressure
gauge

High
pressure
steam

Separator

Strainer

Steam trap set

Steam separator & steam trap set

Upstream and downstream isolation

valves

Strainer

Upstream and downstream pressure

gauges

Pressure reducing valve

Safety relief valve

A steam separator removes any water droplets

suspended in the steam. It has a much larger
cross sectional area than the approach pipework;
as the steam enters the separator its velocity drops, while the inertia of the heavier water
droplets causes them to impinge on the internal
baffles within the separator. The droplets are then
directed to the drain connection and removed

Reduced
pressure
steam

Isolation
valve
Condensate

Isolation valves are required to facilitate repairs

and cleaning of the reducing valve station
components. The upstream valve is fitted after
the separator so that the approach pipework is
drained and kept free of condensate even when
the valve is closed.
A strainer is required to protect the reducing
valve from pipe debris; prior to a valve it should
be fitted with a fine 100 mesh screen, with the
basket on its side. This prevents it from filling with
condensate under no flow conditions when the
reducing valve is closed, which could then be
carried through the valve when it opens again.

29

Fig.18 Steam separator

Baffles

will cause it to close and the

other valve to
modulate down through its proportional band.

Wet steam
in

Dry steam
out

Condensate
drain

The safety relief valve fitted after the pressure

reducing valve ensures the equipment fitted
downstream from the station will not be
subjected to unacceptable high pressures should
the pressure reducing valve fail.
When widely varying load conditions are
present, two pressure reducing valves with their
pressure settings slightly offset, fitted in parallel
with a combined capacity to meet the peak load,
perform better than a single large valve. At full
load, both valves will be open. As the load
decreases, the controlled pressure will rise slightly
and the valve which is set at the lower pressure
will begin to close. Further reduction in the load

If a high pressure turndown

is required it may be advisable
to fit two pressure reducing
valves in series. When making
this decision, much will
depend upon the type of valve
being used and the operating
conditions, but as a general
guide, two valves should be
considered when the turndown ratio exceeds 10:1.

Flash Steam
When steam gives up its specific enthalpy of
evaporation, condensate forms at the same temperature and pressure as the steam from which it
condenses. When this condensate is discharged
to a lower pressure, the energy it contains is
greater than it can hold while still remaining in its
liquid state.

Fig.19 Pressure reducing valves fitted in parallel

High
pressure
steam

Reduced
pressure
steam

Condensate

30

Steam and Plate Heat Exchangers

Fig.20 Pressure reducing valves fitted in series

High
pressure
steam

Reduced
pressure
steam
Condensate

Condensate

This excess energy re-evaporates some of the

condensate back into steam at the lower
pressure. Although this steam is referred to as
"flash steam", it is just saturated steam at a lower
pressure. The amount of flash steam released
from high pressure condensate can be
calculated from Formula 7. Alternatively, the
amount of flash steam formed per kg of

condensate can be read from Fig. 21., extending

a line from the higher pressure shown on the left
axis of the chart to the relevant lower pressure
line, and then reading off the amount of flash
steam released per kilogram of condensate from
the bottom axis.
Where possible, this flash steam should be
utilised as a source of steam for low pressure

Fig.21 Flash steam per kg of condensate

0.5

1.0

1.5

2.0

2.5

Lower pressure bar g

15
14
13
12

Higher pressure bar g

11
10
9
8
7
6
5
4
3
2
1
0
0

0.02

0.06

0.1

0.14

0.18

0.2

kg flash steam released per kg of condensate

31

steam applications. A flash vessel can be used to

separate the flash steam from the condensate.

Condensate Return System

In cases where the flash steam supply does not

match the low pressure steam demand, excess
steam may be vented through a surplussing
valve arrangement. Any shortfall in supply can be
made up by steam supplied through a pressure
reducing valve from a high pressure supply.

An effective condensate return system is

required to remove condensate away from the
steam using equipment and return it to the boiler
house. Condensate is already treated for use in
a boiler and contains useful heat. This decreases
the amount of heat the boiler will need to provide
to convert it back into steam.
Condensate return systems will fall into three
main categories, as illustrated in Fig. 23.

Formula 7. Calculate flash steam quantity

= Flash steam quantity, kg/h.

hf(hp) = Specific enthalpy of water at higher

pressure, kJ/kg.
hf(Ip) = Specific enthalpy of water at
lower pressure, kJ/kg.
hfg(Ip) = Specific enthalpy of steam at lower
pressure, kJ/kg.
Wc

= Condensate load, kg/h.

Fig.22 Flash vessel

Low pressure
flash steam

Flash steam/
condensate
from higher
pressure

32

Drain lines to steam traps (a).

Non pumped discharge lines from steam

traps (b).

Pumped return lines (c).

Drain lines to steam traps

where:
Ws

Flash vessel

The flow of condensate from the process

equipment to its steam trap is usually by gravity.
This line, can be sized using the method set out
in the next chapter, but for all practical purposes,
the line size will be the same as the steam trap
size, assuming the steam trap has been sized
correctly. The steam trap should be fitted a minimum of 200mm below the equipment it's draining to provide a hydraulic head above the steam
trap.
Removing condensate from plate heat
exchangers not designed for use on steam can
present problems not found in other applications
and these are discussed in detail in the next section.

Non pumped discharge lines

On the discharge side of the steam trap,
condensate lines have to carry condensate, any
incondensable gases carried through the
process, and flash steam released from the condensate as its pressure drops through the steam
trap.
As can be seen from the previous chapter, the
mass of flash steam released can be relatively
small compared to the remaining mass of the
condensate it is released from. But the volume of
Low pressure flash steam can be very large and must be taken
condensate
into consideration when sizing the condensate
line.

Steam and Plate Heat Exchangers

Fig. 23

Condensate systems

Process
equipment
Steam
(b) Non pumped discharge lines
from steam traps.

(a) Drain line to

steam trap

Vent

Steam trap set

Electrical condensate
pumping set

(c) Pumped condensate return line

To illustrate this, if condensate is discharged

from a steam trap with an upstream pressure of
3 bar g, into a condensate line pressurised to
0.5 bar g, 6.2% of that condensate will convert
into flash steam. With each kg of flash steam
occupying 1.15 m3 and each kg of condensate
only occupying 0.001 m3, 99% of the
condensate line will be occupied by flash steam
and just 1% occupied by condensate.
Therefore, non pumped condensate lines need
to be sized with this in mind. Fig. 24, provides
a means of sizing this type of condensate line,
where steam pressure upstream of the steam
trap is known and the pressure within the
condensate system is known. It will provide a
condensate line size that keeps the flash steam
velocities inside that line within acceptable limits.

condensate line due to frictional losses will occur

at the rate of approximately 0.3 bar g per 150 m.
Example
Select a non pumped condensate line to carry
the condensate from a process operating at
3 bar g. The maximum condensate load will be
1,000 kg/h and the back pressure within the condensate line is estimated to be 0.5 bar g.

Using Fig. 24, mark Point A, the system

steam pressure in bar g.

This chart is constructed, using a velocity sizing

method. Pressure drop along the length of the

33

Fig. 24

Condensate line sizing

500

100,000

400

350

300

250

200
150
100

50,000

80

20,000

65

10,000

Condensate rate kg/h

40
32

2,000

25

1,000

20
15

500

10

200
100

Condensate line size mm

5,000

50

50

20

Steam temperature C

200
180
160
140
120
100

34

50

30

30

20

20
15
10

10

5
2
1
0.5
0

5
4
3
2
1
0.5
0

Condensate system pressure bar g

250

Steam system pressure bar g

10

Steam and Plate Heat Exchangers

Draw a line from Point A to Point B, the

condensate system pressure in bar g.

calculate the size of the common line, once each

individual line size is known.

Draw a line from Point B to Point C, the

condensate load in kg/h, shown on the
left scale of the top section of the chart.

The value calculated for D(common) will not be

an exact nominal bore (NB) pipe size, therefore

Extend the line from Point C to Point D on

the condensate line size scale.

Read off the required

condensate line size from
the scale. In this example
a 40mm NB pipe will be
required.

Fig. 25

Multiple condensate line

sizing

This method will enable the

user to accurately size single non
pumped condensate lines.
A clean chart is attached as
Appendix II for photocopying.
In many cases, individual lines
are connected into a common
line that falls to a pump receiver
or flash vessel. Where this is the
case Formula 8 can be used to

Formula 8. Calculate common line size for

non pumped condensate

the closest commercially available size should be

selected. Fig. 25 shows an example of condensate loads discharging into a common line and
the affect this will have on line sizing.
Under normal operating conditions, the back
pressure within a condensate system is the sum
of three components.

where:
D(common) = Common pipeline internal
diameter, mm
D(1)

= First individual condensate line

nominal bore, mm

D(2)

= Second individual condensate

line nominal bore, mm

D(3)

= Third individual condensate line

nominal bore, mm

The pressure at the end of the return line;

either atmospheric pressure, or the
pressure within the vessel into which the
line discharges.

The pressure imposed by the net lift in

the return system.

The pressure drop along the length of the

return system.

35

If sizing is correctly carried out, the third

component will be negligible and only one and
two need to be considered for practical
purposes.

Pumped return lines

The individual or common non pumped
condensate lines are often collected into a
receiver and then pumped back to the boiler
house.
In most instances, pumped condensate lines
carry only water, with no flash steam present.
This will always be the case where the
condensate receiver is vented.
Fig. 24 can also be used to size pumped condensate lines where no flash steam is present.

cause it to flow back along the pipe when its

momentum is exhausted. To prevent this, a suitably sized vacuum breaker can be fitted at the
start of the discharge line, together with another
check valve to protect the pump. An air eliminator may be required at the delivery end of the line
to discharge the air drawn in through the vacuum
breaker, as shown in Fig. 26.

Fig. 26 Long pumped delivery line

Air eliminator
Vacuum breaker

Condensate
pumping unit

Check valve

Example
Size a pumped condensate line to carry 10,000
kg/h of condensate.

Locate the condensate load, Point E on

the condensate rate scale at the left hand
side of the top section of the chart.

Extend a line horizontally from Point E to

Point F at the right hand side of the chart
and read off the required condensate line
size. In this case it will be a 50 mm NB
pipe.

Pumps do not run continuously and normally

have on on/off type action. This should be taken
into account when sizing the condensate line
from the pump, as the discharge rate from the
pump will be greater than the actual
condensation rate from the process equipment.
Depending upon the type of pump this discharge
rate can range from 1.5 times to 6 times the
actual condensation rate.
Long, pumped delivery lines also may need
special attention, if waterhammer within them is
to be avoided. The water being pumped can gain
considerable momentum and may carry on moving along the pipe when the pump stops. This
can create a low pressure area within the pipe
behind the moving slug of water which could

36

Problems can also occur when the discharge

lines from steam traps are connected directly
into a pumped condensate line. This should be
avoided by piping the discharge into a separate
non pumped condensate line which carries the
condensate to a pump receiver.

Sizing for combined pump/steam trap units

In the next section, which deals with the
subject of temperature control of plate heat
exchangers in some detail, reference is made to
the use of an automatic pump trap and a pump/
steam trap combination.
This is a combined steam trap and steam operated condensate pump or separate automatic
steam operated condensate pump, fitted in se-

Steam and Plate Heat Exchangers

ries with a steam trap. Depending upon the state
of the process to which it's fitted, condensate will
either flow through the steam trap or steam trap
part of the combined unit in a normal manner, or
be pumped by the automatic pump. Therefore
the condensate line from the process will be both
a non pumped and a pumped line.
For the purpose of condensate line sizing this
type of application should be treated as a non
pumped application and the line sized
accordingly.

Condensate pumping
Two main types of condensate pumping unit
are available.

Electric pumping units.

Steam or air operated automatic pumping units.

Electric pumping units

This is the most widely used type of
condensate return unit, consisting of a vented
receiver with one or more motorised pumps.
Level controls mounted in the receiver switch
the pump(s) on and off. Also, alarms can be fitted
to warn of high or low level conditions within the
receiver.
The major limiting factor in the use of this type
of pumping unit is the temperature of the
condensate that the pumps are able to handle.
If the condensate is too hot, it will flash back into
steam in the low pressure area at the pump inlet,
causing damage to the pump. This is known as
cavitation. This temperature limitation ranges
from below 90C up to 98C depending upon the
type of unit.
Also, if they are to be used in hazardous or
'wet' areas, the motors, enclosures and wiring
will have to meet the applicable standards.

Fig. 27 Electric condensate pumping unit

Receiver

Condensate
discharge

Electric motor

Condensate pump

37

Fig. 29 Automatic pump packaged unit

Automatic pump
The steam or air operated automatic pump
operates on a positive displacement principle. The pump consists of an inlet and outlet
check valve, and a body, containing an exhaust and inlet valve assembly operated by a
float mechanism. Fig. 28 shows its method of
operation.

Fluid enters the pump body through

the inlet check valve.

Residual non condensable gases

in the pump body escape through
the open exhaust valve, Fig. 28.1.
As the chamber fills, the valve change
over linkage is engaged opening the
motive inlet valve and closing the
exhaust valve, Fig. 28.2. This snap
action linkage ensures a rapid change
from filling to pumping stroke.

Condensate in
Condensate
in

Motive
steam

Condensate out

As pressure inside the pump increases

above the total back pressure, fluid is
forced out through the outlet check
valve into the return system.

As the fluid level falls within the

pump, the float re-engages the
valve change over linkage,
causing the motive inlet valve
to close and the exhaust valve
to open.

As the pressure inside the

pump body falls, fluid re-enters
through the inlet check valve
and the cycle is repeated.

Fig. 28 Automatic pump operation

Inlet
valve

Fig. 28.2

Unlike electrically operated centrifugal

pumps, this type of automatic pump
does not cavitate and can remove condensate under all load and temperature conditions. It requires no electrical
power, making it suitable for hazardous
or 'wet' environments, without modification. If required, it can be supplied in
a packaged unit, complete with receiver,
as shown in Fig. 29.

Fig. 28.1

Exhaust valve

Fluid in

Inlet
check valve

38

Vent

Fluid out

Outlet check
valve

Automatic pump trap

A recent innovation is the combination
of an automatic pump and float type
steam trap into one compact unit. It is
particularly suitable for steam heat exchange applications where, because of

Steam and Plate Heat Exchangers

changing load conditions, there will be a variable
steam pressure within the heat exchanger; falling below the pressure in the condensate return
system on low loads. Often, even under normal
operating conditions, the steam in the heat exchanger, will be at sub-atmospheric pressures.

The operation of the automatic pump trap is

described in Fig. 30.

Fig. 30 Automatic pump operation

Exhaust

1. Condensate enters through the inlet swing check

valve, filling the body and causing the float to rise.
The float is connected to the trap mechanism via a
multi-link pivot. If the inlet pressure is sufficient to
overcome the back pressure imposed on the outlet,
condensate will be discharged through the opening
two stage trap mechanism. In this way, the float will
automatically modulate according to the rate of
condensate entering the pump trap, controlling the
rate of opening of closure of the trap.

Condensate inlet
Condensate
outlet

2. With some temperature controlled equipment, it is

possible for the pressure at the inlet to be lower than
the back pressure imposed upon the outlet. When this
occurs a standard steam trap will stall, causing
condensate to flood back up into the heat
exchanger.

3. When this happens, condensate fills the main

chamber, lifting the float until the attached
change-over linkage is engaged. This opens the
Condensate motive steam inlet valve and closes the exhaust
inlet
valve.
Steam
inlet

Condensate outlet

39

Steam
inlet
4. The snap action mechanism provides a rapid
change from the trapping mode to the active
pumping mode. With the motive steam inlet valve
open, the pressure in the body increases
above the back pressure imposed on the
condensate outlet and condensate is forced out of
the pump trap.

Condensate
inlet
Condensate
outlet

Exahaust
Condensate
inlet
Condensate
outlet

5. As the condensate level falls within the main

chamber, the float falls and re-engages the valve
changeover linkage, causing the steam inlet valve
to close and the exhaust valve to open.

Exhaust
6. With the exhaust valve now open, the pressure in
the pump trap body equalises with the pressure
at the condensate inlet. This allows condensate to
flow back into the body through the inlet check
valve, while the outlet check valve prevents flow
back into the pump trap from the condensate
return line. The pumping/trapping cycle starts
again.

40

Condensate
inlet
Condensate
outlet

Steam and Plate Heat Exchangers

4. Temperature control of plate heat

exchangers
Heat exchanger design
Compared to other types of heat exchanger,
plate heat exchangers have a very high heat
transfer to size ratio. The heat transfer coefficient
attained by a plate heat exchanger is
considerably greater than that attained by a traditional shell and tube heat exchanger.
As a result of this high performance
characteristic, the physical heat transfer area
required for a given duty is relatively small.
The actual heating area necessary to provide a
given duty can be calculated from Formula 9.

Formula 9 Calculate heat exchange area

where:
A

heat transfer area, m2

heat requirement, kW

heat transfer coefficient, W/m2 C

Tlmtd= log mean temperature difference, C

NB:

With plate type heat exchangers the

'k' value will be in the range of
5,000 - 10,000 W/m2 C.

The logarithmic mean temperature difference

(Tlmtd), is the logarithmic mean, of the temperature
differences between heat exchanger primary,
and secondary, inlet and outlet temperatures. For
most practical purposes, the arithmetic mean

temperature difference (Tamtd), can be used in its

place. This calculation is shown in Formula 10.

Formula 10
Calculate arithmetic mean temperature
difference

where:
Tamtd

= Arithmetic mean temperature

difference, C

TH(in)

= Primary side inlet temperature, C

TH(out)

= Primary side exit temperature, C

TC(in)

= Secondary side inlet temperature, C

TC(out)

= Secondary side exit temperature, C

When steam is used as the primary heating

medium, it gives up its specific enthalpy of evaporation at constant temperature, therefore, TH(in)
and TH(out) will have the same value.
A simplified calculation can be used to arrive at
the arithmetic mean temperature as shown in
Formula 11.
When a plate heat exchanger is selected and
the most common form of temperature
Formula 11
Simplified calculation for arithmetic mean
temperature difference

41

control, i.e. a temperature control valve fitted

in the primary steam inlet to the exchanger, the
pressure drop on the secondary side is a major
consideration. Often, when steam is the primary
heating medium, a greater heat transfer area than
necessary is selected in order to keep this
secondary side pressure drop within reasonable
limits.
It can be seen from Formula 9., that if the heat
transfer area (A) is increased from that needed
to give output (Q), the only variable that can
change, to give the required output with this
increased heat transfer area, is the mean
temperature difference. This must decrease and
the only way this can decrease, without the secondary conditions changing, is if the primary side
mean temperature decreases.
Put another way, the steam temperature, therefore its pressure, must decrease if the desired
output is to be achieved with an
increased heat transfer area.
This over sizing of the heat transfer area in plate
heat exchangers that are not specifically
designed to operate with a steam primary, to
facilitate reasonable pressure drops on the secondary side is quite common in steam
applications. This over sizing is often in the region
of 100% to 200% and can have a considerable
effect on the actual steam pressure within the
exchanger, even under full load conditions. When
the design of the plate heat exchanger is
specifically optimised for use with steam, over
sizing is not a problem and rarely exceeds 15%.
The pressure at the inlet of the steam trap may
be less than the back pressure imposed on the
outlet of the steam trap. Where this is the case,
condensate will not be discharged and will back
up into the heat exchanger. This will certainly
cause temperature control problems and may
also cause structural damage to the exchanger
through waterhammer and thermal stress.

Stall condition
If the back pressure imposed upon a steam
trap is greater than the pressure available at its

42

inlet, the heat exchanger is described as being

in a 'stall' condition. Condensate cannot pass
through the trap and will back up, possibly resulting in the loss of effective control over the heat
exchanger.
The point at which this condition will occur in a
particular application can be predicted, either by
calculation, or by plotting the known operating
conditions onto a chart and reading off the stall
points. Both of these methods can be illustrated
by example.

Calculation
A plate heat exchanger is required to heat 4
kg/s of water from 30C to 90C. Steam is available at 4 bar g and it is initially assumed there
will be a 25% pressure drop through the temperature control valve, giving 3 bar g at the heat
exchanger. Condensate discharges to a gravity
return system at 0 bar g. To give the required
output and provide a reasonable pressure drop
of approximately 35 kPa on the secondary side,
a heat exchanger has been selected with a heat
exchange area of 2.6 m2 and a heat transfer
coefficient (k) of 7,450 W/m2 C.
First the full design heat load is calculated, using Formula 12.

Formula 12
Calculate heat load (full load)

where:
Q

heat load, kW

secondary flow rate, kg/s

Cp

specific heat capacity, kJ/kg C

(for water - 4.186 kJ/kg C)

TC(in)

secondary inlet temperature, C

TC(out)

secondary exit temperature, C

Steam and Plate Heat Exchangers

From the information available we can calculate the actual arithmetic mean temperature to
give the required output at full load, as shown in
Formula 13.

Formula 14
Calculate actual primary temperature

Formula 13
Calculate actual arithmetic mean
temperature difference required
where:
Tamtd

= arithmetic mean temperature

difference, C

TH(in)

= primary side inlet temperature, C

TC(out)

= secondary side exit temperature, C

TC(in)

= secondary side inlet temperature, C

where:
A

= heat transfer area, m2

= heat requirement, kW

= heat transfer coefficient, W/m2 C

Tamtd

= arithmetic mean temperature

difference, C

As the secondary mean temperature is fixed,

the primary mean temperature at full load, TH(in),
required to provide this overall arithmetic mean
temperature difference can be calculated using
Formula 14.
From the steam tables it can be seen this temperature of 112C equates to a saturated steam
pressure of approximately 0.5 bar g.
This example shows that irrespective of the
steam pressure available before the temperature
control valve, the pressure inside the heat
exchanger will depend upon the actual duty
required and the heat exchange area available
within the exchanger.
It can be seen that in this example, under full
load, a stall condition will not exist, as the
pressure on the inlet of the steam trap will be
0.5 bar g, providing a positive pressure
differential of 0.5 bar across the steam trap.

A stall condition will exist, when the pressure

on the inlet of the steam trap is equal to, or less
than, 0 bar g. At this pressure the steam's
temperature will be 100C.
This can occur when either, or a combination of
the following things, happen:

The secondary inlet and exit temperatures to and from the exchanger (T
secondary side) remain constant but the
flow reduces.

The flow remains constant but the

secondary T reduces - The inlet
temperature rises or the exit temperature
falls or both.

The point at which either happens can be predicted by calculation.

Either Logarithmic Mean Temperatures
Difference (LMTD), or Arithmetic Mean
Temperature Difference (AMTD) can be used in
the calculations. Using LMTD is technically correct, while AMTD is easier to use. The
calculations used in this manual use AMTD and
provide solutions accurate enough for practical
day to day use. The calculations also assume a
constant k value under all conditions; in practice

43

the k value will change as velocities and

temperatures of the media alter.
A calculation to predict the reduction in flow to
produce a stall condition is shown in Formula 15.

Formula 15
Calculate stall fraction for variable flow
condition

produce a stall condition, use Formula 16, which

expresses the temperature difference between
the steam and secondary outlet temperatures at
full load and at stall as a fraction.

Formula 16
Calculate stall fraction for variable DT
condition

where:

where:
Fs

= Stall fraction

TH(in)(stall)

= Primary side inlet temperature

at stall point, C

TH(in)(full)

= Primary side inlet temperature

at full, C

TC(out)

= Secondary side exit

temperature, C

TC(in)

= Secondary side inlet

temperature, C

Once calculated, this fraction can be applied to

the flow rate at full load to predict when stall will
occur. In our example, stall will occur when the
flow rate falls to 3.1 kg/s (4kg/s x 0.77) or below.
This calculation is, in fact, expressing the AMTD
at the stall point as a fraction of the AMTD at full
load.
To calculate the fraction to be applied to predict
by how much the secondary T (the temperature rise on the secondary side) must reduce to

44

Fs

= stall fraction

TH(in)(stall)

= primary side inlet temperature at

stall point, C

TH(in)(full)

= primary side inlet temperature at

full load, C

TC(out)

= secondary side exit temperature, C

Once calculated, this fraction can be applied to

the secondary T at full load to predict when stall
will occur.
In this case, it will be when the secondary T
falls to 27C (60C x 0.45) or below. Therefore,
if the exit temperature remains at 90C, stall will
occur if the inlet temperature rises to 63C
(90C - 27C).

The stall chart

Fortunately a simpler method of predicting
when stall will occur is available in the form of
a stall chart, shown in Fig 31. On a stall chart
a graphical representation of a heat exchange
process can be plotted from 100% load down
to 0% load. As well as predicting when stall will
occur, a stall chart can be used to show the
percentage of full load that a condensate pump

Steam and Plate Heat Exchangers

14.5

190

11.6

180

9.0

170

7.0

160

5.2

150

3.8

140

2.6

130

1.7

120

1.0

11 0

0.4

100

90

0.7

80

0.5

70

0.3

60

0.2

50

0.12

40

0.07

30

0.05

Pressure bar a
(vacuum)

200

Pressure bar g

Stall chart

Temperature C

Fig. 31

20
10
0
-10
100

90

80

70

60

50
%

should be capable of handling in an application

where a pump trap combination is used.

40

10

Mark secondary fluid outlet control

temperature and temperature of steam at
pressure equal to back pressure on right
axis; secondary fluid outlet
temperature = 90C and steam
temperature equal to
back pressure = 100C.

3.

Draw horizontal line across chart at the

back pressure.

4.

Join secondary inlet temperature to

control temperature.

5.

Find midpoint of line 4 at the 50%

ordinate. Draw a horizontal line from this
point to the right axis. This point is the
mean secondary temperature; 60C.

To establish flow rate at stall point. (Refer to

Fig. 32)
Mark full load steam temperature and
secondary fluid inlet temperature at
design condition, on the left axis. Note
that the steam design temperature should
be as calculated in the previous section;
steam temperature = 112C and
secondary fluid inlet temperature = 30C.

20

2.

A large scale stall chart that can be

photocopied for use is attached as Appendix III

1.

30

45

200

14.5

190

11.6

180

9.0

170

7.0

160

5.2

150

3.8

140

2.6

130

1.7

120
11 0

1.0

control temperature

90

0.4

100

0
0.7

80

0.5

70

0.3

60

20

0.12

40
30

0.2

50

0.07
0.05

Pressure bar g

Use stall chart to establish flow rate at stall point

Pressure bar a
(vacuum)

Temperature C

Fig. 32

10
0
-10
100

6.

90

80

70

60

Join full load steam temperature on left

axis to mean secondary temperature on
right axis. This line should terminate at
the control temperature.

7.

Where this line intersects the back

pressure line, drop a vertical line to the
Load % line.

8.

From this scale read off the % flow at

which stall will occur. In this case it is
77%. Therefore stall will occur if the flow
falls below 4 kg/s x 77% = 3.1 kg/s.

46

50
%

40

30

20

10

To establish secondary inlet temperature and

% T at which stall will occur (Refer to Fig. 33)
1.

Mark full load steam temperature and

secondary fluid inlet temperature at
design condition, on the left axis. Note
that the steam design temperature should
be as calculated in the previous section;
steam temperature = 112C and
secondary fluid inlet temperature = 30C.

2.

Mark secondary fluid outlet control

temperature and temperature of steam at
pressure equal to back pressure on right

Steam and Plate Heat Exchangers

axis; secondary fluid outlet temperature =
90C and steam temperature equal to
back pressure = 100C.
Draw horizontal line across chart at the
back pressure.

4.

Join secondary inlet temperature to

control temperature.

5.

Join control temperature to steam

temperature at full load.

6.

Where this line intersects the back

pressure line, drop a vertical line to the
% Load line.

Temperature C

8.

Where the vertical line meets the Load %

scale, read the corresponding %. Use this
figure to calculate the T at which stall
will occur; 45% x 60C = 27C.

Use stall chart to establish secondary inlet temperature at stall point

200

14.5

190

11.6

180

9.0

170

7.0

160

5.2

150

3.8

140

2.6

130

1.7

120
11 0

1.0

0.4

100

90

0.7
2

80
70

0.5
0.3

60

0.2

50

0.12

40

0.07

30
20

Pressure bar g

Fig. 33

Where this vertical line crosses line 4

draw a horizontal line to the left
axis. Read off the inlet temperature at
which stall will occur; 63C.

Pressure bar a
(vacuum)

3.

7.

0.05

10
0
-10
100

90

80

70

60

50
%

40

30

20

10

47

Temperature control methods

1. Primary steam control, Fig. 34

Various methods of temperature control are

available when steam is the primary heating
medium in a heat exchange application, using a
plate heat exchanger.

With this method of control, the heat exchanger

is sized to handle 100% of the secondary flow
rate at full load. Or, if the heat exchanger is not
specifically designed for steam use, it may be
necessary to fit a secondary by-pass in order to
optimise the heat exchanger and prevent
excessive over sizing.

It is vital to take into consideration the actual operating conditions when considering the
method of control, as discussed in this section.
The following need to be considered when
deciding upon the temperature control method to
be used.

Actual steam pressure expected in the

exchanger.

Total back pressure exerted on the

primary side (condensate) outlet of the
exchanger.
Whether the secondary T is fixed or
variable during normal operation.

Whether the secondary fluid flow rate is

constant or will fluctuate.

Heat exchanger construction.

Fig. 34

The steam flow (and therefore its pressure) is

adjusted by a two port control valve on the steam
supply to the heat exchanger. The control valve's
position is adjusted by a signal from the controller according to the information it receives from a
temperature sensor fitted in the secondary flow
from the heat exchanger.
A steam trap set is fitted on the outlet of the
primary side of the exchanger to remove
condensate.
Advantages:
Simple, easily understood design and
operation.
Easily commissioned.
Provides fast response to changing load
conditions.
Disadvantages:
With a plate heat exchanger not designed
for steam use, there is a possibility of
over sizing.

Primary steam control

separator

pressure
reducing
valve

control
valve safety
valve

air vent

flow out

steam
optional
by-pass
high limit
cut out
condensate

48

flow in
steam trap set

steam plate
heat exchanger

Steam and Plate Heat Exchangers

If secondary conditions alter or the back
pressure in the condensate system does
increase, stall could occur.
Use When:
The first choice for most applications

2. Primary steam control with active

condensate drainage, Fig. 35
With this method, the heat exchanger is sized
to handle 100% of the secondary flow at full load
and to heat it up to its design temperature.

than the back pressure, the steam trap will operate normally, allowing condensate to flow from
the exchanger into the return system. When this
is the case, condensate flows through the pump
and steam trap without the pump
operating.
If the pressure at the condensate outlet is below the back pressure, condensate is not able to
flow through the steam trap and builds up in the
pump body. This causes the pump to
operate and pump the condensate away through
the steam trap.

The steam flow to the heat exchanger is

adjusted by a two port control valve on the steam
supply to the heat exchanger. The control valve's
position is adjusted by a signal from the controller according to the information it receives from a
temperature sensor fitted in the secondary flow
from the heat exchanger.

Advantages:

The condensate outlet from the heat exchanger

is fitted with and automatic pump trap or a
pump/steam trap combination fitted in series.

Provides fast response to changing load

conditions.

A closed circuit equalises the pressures within

the pump body and the outlet of the heat
exchanger allowing condensate to drain from the
exchanger to the pump body.
With this arrangement, if the pressure at the
condensate outlet from the exchanger is greater

Fig. 35

Simple, easily understood design and

operation.
Will work under all conditions within the
operating limits of the equipment.
Easily commissioned.

Allows operation using low pressure or

even vacuum steam, against a higher
back pressure.
Disadvantages:
Extra cost of the pump.

Primary steam control with active condensate drainage

pressure
reducing valve

control
valve

safety
valve

flow out

separator
steam

high limit
cut out

flow in
steam plate
heat exchanger

condensate
Automatic pump trap

49

Use When:

Disadvantages:

The back pressure is, or can be, greater

than the steam pressure within the heat exchanger during the normal operating cycle.

The secondary circuit must be maintained at a

pressure, sufficient to prevent the secondary fluid
boiling. If the secondary fluid is water, then the
secondary circuit must be maintained at a pressure at least equal to, but preferably higher, than
the primary steam pressure.

Low temperature operation is required

because of potential scaling problems or
to reduce the volume of flash steam
released into the condensate system.

Use When:

3. Secondary side three port control, Fig. 36

With this method, a constant steam pressure is
supplied to the primary side of the heat
exchanger. Therefore the exit temperature of the
secondary flow from the exchanger will be at, or
slightly below, the primary steam temperature.
A three port blending valve is installed on the
secondary circuit. This blending valve blends
return flow with heated water from the heat exchanger, to provide the required final flow temperature.
Advantages:
Constant steam pressure on the primary
side of the heat exchanger.

The use of a constant steam pressure on

the primary side will overcome probable
stall problems. The primary steam pressure
is very low, < 1 bar g.

4. Condensate control, Fig. 37

With this method of control, the control valve,
which is installed on the exit of the primary side
of the heat exchanger, controls the level of condensate within the exchanger.
As the control valve closes, condensate will
back up into the exchanger and cover the heat
exchange surface. This reduction in effective
heat exchange area will lower the output of the
exchanger. As the valve opens, the condensate
level within the exchanger will fall, uncovering the
heating surface, increasing its output.
The exchanger will normally be sized so that

Fig. 36

Secondary side three port control

separator
steam

high limit
cut out

pressure
reducing
valve

safety
valve

control
valve
flow out
air vent

flow in
condensate steam trap set

50

steam plate
heat exchanger

Steam and Plate Heat Exchangers

Fig. 37

Condensate control

pressure
reducing valve

safety
valve

separator

air vent

steam

flow in

high limit cut

out
control
valve
flow out
steam plate
heat exchanger

condensate

the condensate covers 25% - 50% of the heat

transfer area during its normal full load operation.
The amount of condensate sub-cooling carried
out in the exchanger will be directly related to
amount of heating area covered by the condensate.
Advantages:
Sub-cooled condensate releases little, or
no, flash steam.

Automatic temperature control

The majority of control methods discussed
in the previous section require the use of a two
port control valve, fitted either on the steam inlet
to the plate heat exchanger, or the condensate
outlet from the heat exchanger.

When fitted on the steam inlet, the

purpose of this valve is to control the
amount and the pressure of the steam
that flows into the heat exchanger.

When fitted on the condensate outlet, it is

used to control the level of condensate
within the heat exchanger.

Constant pressure overcomes any stall

problems.
Reduced control valve size
Disadvantages:
Slow response to secondary load
variations.
Use When:
The secondary load is always stable and
relatively large.
The operating steam pressure is relatively
low, i.e. < 5 bar g.
Sub-cooled condensate is required. e.g.
where the release of flash steam would
cause problems.

The former requirement will be, by far, the most

common need when applying automatic
temperature control to a plate heat exchanger.

Control requirements
A correctly selected, sized and applied
automatic control system should be capable of

51

providing accurate, predictable, stable control

under all normal operating conditions.
If necessary, it should also be capable of being
integrated into a plant's existing distributed process control or data acquisition system.

Control system elements

A basic automatic temperature control system suitable for controlling the secondary outlet
temperature from a steam heated plate heat
exchanger will consist of the elements illustrated
in Fig. 38.

Sensor - This measures the actual

temperature of the secondary flow and
provides this information to the controller
via an input signal.

Controller - This compares information

received from the sensor with the
information it retains on the desired

temperature. On comparing these values

it will send instructions to the valve
actuator in the form of an output signal.

Valve & Actuator - The actuator will open

and close the steam valve, according
to the signal it receives from the
controller.

Each of the elements in a control system

should be selected carefully to ensure they complement each other, also the system as a whole
should be designed to provide optimum performance. It is beyond the scope of this publication to
provide all the information needed to understand
the process of selecting and applying components to provide automatic temperature control
to a steam heated plate heat exchanger. However, some basic information on the various components and simple guidelines for sizing a system
using a control valve on the steam inlet are given
in the following sections.

Fig.38 Elements of a simple closed loop automatic temperature

control system
Controller

Desired
temperature

Output signal

Input signal

Sensor

Actuator

Measured
temperature

Steam

Valve
Plate Heat
Exchanger

52

Secondary
fluid

Steam and Plate Heat Exchangers

The control valve

Fig.40 Characterised valve pug

All control valves have an inherent flow

characteristic which defines the relationship
between valve lift and flow rate with a constant
pressure difference. In other words, it is the
relationship between the amount of flow that this
degree of opening allows to pass.
Globe valves may be fitted with plugs of
differing shapes, each having its own
characteristic. The two main shapes available are
usually known as linear and equal percentage (or
logarithmic).
Linear valves have the plug shaped so that the
flow rate is directly proportional to the valve lift.
At 25% valve lift, the 25% opening allows 25% of
the full flow to pass. At 50 % valve lift, 50% of full
flow passes, and so on.
Equal percentage valves have a valve plug
shaped so that each increment in valve lift increases the flow rate by a constant percentage of
previous flow. For example, if the flow rate is 4%
of the full flow at a valve lift of 20 %, an increase
in valve lift to 30% may increase the flow by 50%
to 6% of the full flow; an increase of 2%. A further increase of valve lift to 40% will then provide
a flow increase of 3% (50% of 6%), to give a total
of 9 % of full flow.
The flow characteristics for linear and equal
percentage valves are shown in Fig.39.

As discussed earlier, the steam pressure in a

heat exchanger is not constant, but varies with
the heat load. As the pressure drop over the
valve changes, the relationship between flow
and valve opening is also changed. The resulting
relationship between the valve lift and the output
of the heat exchanger is often referred to as the
system or installed characteristic.
For steam systems, the pressure drop ratio
over the control valve at full flow is an important
factor in determining the system characteristic.
The pressure drop ratio is defined as the
pressure drop over the control valve (p), divided
by the absolute pressure upstream of the control
valve p1.
When the pressure drop ratio reaches a value

Fig.39 Flow characteristic curves

Flow %

1
2

p
pressure drop ratio = p
1
of approximately 0.46, steam is flowing at sonic
velocity between the seat and valve plug. The
pressure on the downstream side of the valve
seat is then 54% of upstream pressure and is
referred to as the critical pressure. The pressure
drop over the valve in this case is known as the
critical pressure drop. Fig.41 shows typical system characteristics for linear and equal
percentage valves sized for small pressure drop
ratios such as 0.1-0.2.

Valve opening %
1 = Linear valve
2 = Equal percentage valve

53

Fig.41 Typical system

characteristics with
valves sized for small
pressure drops
Fig.42 Valve with pneumatic
actuator and positioner
Flow %

pneumatic
actuator

Valve opening %
1 = Linear valve
2 = Equal percentage valve
positioner

Critical flow conditions

When the downstream pressure is lower than the
critical pressure, due to part load operation or an
over surfaced heat exchanger, steam pressure and
density is constant which results in an apparent constant pressure drop for the control valve.
Hence, the system characteristic will be the same
as that of the control valve. So, by sizing the control valve for, or close to, critical pressure drop, the
desired system characteristic will be achieved with
either a linear or equal percentage control valve. As
a simple guideline a pressure drop ratio of ~0.4 can
be recommended to obtain the preferred characteristic.

Selection of control valve characteristic

A linear characteristic, therefore a linear valve, is
the best choice in applications where good temperature control is required over the entire load range,
provided that the flow on the
secondary
side is constant. Heating buildings is a typical application where a linear valve would be suitable.
For applications where the heat load varies by
changing the flow on the secondary side, a control
valve with an equal percentage
characteristic is preferred.
An equal percentage valve is also preferable in applications when the temperature is controlled at low
loads, for example, heating tanks and vats.

54

valve

The controller
Proportional band
The most basic of the continuous control modes is
the proportional mode, simply referred to by the letter P. With this form of control the valve is moved in
a corrective manner,
proportional to the
temperature deviation that has occurred.
For example, a water heating application is using a

Steam and Plate Heat Exchangers

controller with a proportional action. The set value is
60C and the proportional band, Xp, is set to 20C.
When the temperature drops below the set value the
controller will signal the control valve to move to a
more open position. The valve opens until the rate
of heat input is altered by an amount proportional to
the fall in temperature. But the actual temperature
will be slightly lower than the desired temperature.
Sustained deviation of this nature is called offset and
is inherent in all proportional controllers.

The correcting signal S from a proportional controller may be expressed as:

With a narrower P-band a much steeper curve

results. This means that a large valve movement will

The function of the integral action is to eliminate

sustained deviation by giving a correcting signal that
is proportional to the product of the deviation and
the time the deviation exists. The correcting signal S
from the integral action may be expressed as:

Fig.43 Proportional control

where

is the deviation at a given time

Integral action

Valve position %

100%

where

is the deviation at a given time

and is the adjustable parameter, integral

time, given in time units.
Xp = 20C

be obtained for a small change in

temperature. A P-band of zero will result in an On/
Off control action. Too narrow a proportional band
will result in oscillation and unstable control.
The P-band (Pb) is often expressed as a
percentage of the span of the controller, the
difference between the maximum and minimum
set point settings. As an example, a controller has a
proportional band of 20C and a span of 200C; the
percentage proportional band is 10%. In some controllers the inverse value of the percentage P-band
is used. This is called the Gain (Kp) and is related to
the P-band as:

If this parameter is too short, the correcting signal

will be large, resulting in over reaction and instability. On the other hand, too long an integral time will
result in a very small correcting signal and effectively there will be no integral action.

Derivative action
The derivative action detects the rate at which
the deviation changes and gives a correcting signal
proportional to the rate of change of the deviation.
The correcting signal S from the
derivative
action may be expressed as:

where

In this example above the gain Kp equals 10.

is the rate of change of the deviation at a

given time and

is the adjustable parameter, derivative
time, given in time units.

55

So, when the deviation increases rapidly the D

action gives a large correcting signal and when
the deviation is constant no correcting signal is
given.

Fig.44 PID controller

The derivative action is useful in processes

where quick load changes occur, as it speeds up
valve movement.

Selecting the settings for the PIDparameters

Each controller has to be set up individually to
match the characteristics of the system. There
are a number of different techniques to get stable
and fast responding control.
A useful method, that is very effective in
establishing controller settings for the actual load, is
the Ziegler-Nicholls frequency response method.
The idea is to use the controller as an amplifier
to reach the point of instability. At this point the
whole system is operating in such a way that the
temperature is fluctuating around the set point
with a constant amplitude, see Fig.45. A small
increase in gain, or a reduced proportional band,
will make the system unstable and the control
valve will start hunting.
On the other hand, an increased proportional
band will make the process more stable and the
amplitude will successively be reduced. At the

point of instability, the system characteristic is

obtained for the actual operating conditions, including the heat exchanger, control valve, actuator, piping, temperature sensor etc..
The controller settings can be determined
through the Ziegler-Nicholls method by reading
the time period, Tn , of the temperature cycles
and the actual proportional band setting at the
point of instability.

Temperature

Fig.45 Instability caused by increasing controller gain,

with no I or D action

Set point

Tn
Time

56

Steam and Plate Heat Exchangers

The procedure is as follows.
1.

Remove integral action on the controller

by increasing the integral time Ti to its
maximum.

2.

Remove the controllers derivative action

by setting the derivation time TD to 0.

3.

Wait until the process reaches a stable

condition.

4.

Reduce the proportional band (increase

gain) until the instability point is reached.

5.

Measure the time for one period Tn and

register the actual Pb setting on the
controller at this point.

6.

Using this setting as the start point,

calculate the appropriate controller
settings according to Table 5.

Table 5

Ziegler-Nicholls calculation

Obtaining proper control for the whole

system
In almost all engineering situations the engineer
will include some margin of safety in the design
of a system. In steam heat exchange
applications, over surfaced heat exchangers and
over sized control valves give a safety margin for
the heat load, but in most cases, this can make it
difficult, or even impossible to obtain the
intended design functionality.
This is definitely the case for the control
function where an over sized control valve can
cause temperature oscillations, overshooting
temperatures etc..
To prevent these problems, an accurate design
of the entire steam system is very important.
How can the engineer also include some safety
margin in his design? The answer is quite
simple

Install a Pressure Reducing Valve!

Proportional Integral Derivative
Band
Time
Time

P+I+D Control Pb * 1.7

P+I Control
P Control

Pb * 2.2

Tn / 2

Tn / 8

Tn / 1.2

Pb * 2

These controller settings may be adjusted to

increase stability or response. The impact of
changing the setting of the PID parameters on
stability and the response of the control is shown
in Table 6.
Table 6

Impact of changing PID

settings
Stability

Response

Increase Pb

Increased

Slower

Increase Ti

Increased

Slower

Increase TD

Increased

Faster

Installing a pressure reducing valve upstream

of the temperature control valve has two major
advantages. First of all, the capacity of the
temperature control valve can easily be changed
simply by altering the upstream pressure. The
heat exchanger capacity will also increase or
decrease due to the change in temperature difference brought about by the altered steam pressures.
Secondly, by selecting a specific steam
pressure upstream of the control valve, it should
never be oversized, thus utilising all of the valve
travel.
On this basis, it is understandable that a
pressure reducing valve is necessary to obtain
optimum control.

57

58

Steam and Plate Heat Exchangers

5. Plate heat exchangers

General
A plate heat exchanger consists of a package
of thin corrugated metal plates with openings to
allow the passage of fluids between them.
The plates are arranged in such a way that
between neighbouring plates a channel
is formed. Every second channel is
open to the same fluid. The actual
heat transfer takes place between
two adjacent channels, from one
fluid to another; for example, hot
water to milk or stem to hot water. The corrugation of the plates
supports them against differential
pressure and creates turbulent
flow in the channels. In turn, the
turbulent flow provides a high heat transfer
efficiency, making the plate heat exchanger very
compact when compared with a traditional shelland-tube heat exchanger.
Depending on the method used to seal the
plates, plate heat exchanger types are divided
into three groups:

Gasketed plate heat exchangers

(or plate & frame heat exchangers)

Brazed plate heat exchangers

All-welded plate heat exchangers

Fig. 46

Performance limits for plate

heat exchangers

Bar (g)
50
40

All-Welded
Plate Heat
Brazed Plate Heat Exchangers Exchangers

30
20

Gasketed
Plate Heat
Exchangers

10

-50

100

200

300

Temp. (C)

Fig. 47

Flow principle in a plate

heat exchanger

Stea

Con

den

sate

The gasketed plate heat exchanger was

invented in the early 1930s. In those days it was
primarily used in the food industry, where a heat
exchanger that was easy to clean was
demanded to meet hygiene requirements.
The first steam heated plate heat exchangers
were launched during the 1940s, serving as
milk pasteurisers. Over the years, the plate heat
exchanger concept has proven successful and it
has evolved into a new range of product
innovations. In the late 1970s, the brazed plate
heat exchanger was launched, which uses
vacuum brazing techniques to seal the plates.
The next step in the development process was
taken in 1994, when the all welded plate heat
exchanger was introduced. Here, the plates are
laser welded, forming a very strong construction.
Today, the plate heat exchanger is used in a multitude of duties in chemical processing, HVAC,
food processing, marine / off shore applications
and refrigeration.

59

The gasketed plate heat

exchanger
In a gasketed plate heat exchanger
(frame & plate heat exchanger), the plates
are fitted with elastomeric gaskets which
seal the channels and direct the fluids
into alternate channels. The plate pack is
assembled between a frame plate and a
pressure plate, and compressed by
tightening bolts fitted between these
plates. The channel plates and the
pressure plate are suspended from an
upper carrying bar and located by a lower
guiding bar, both of which are fixed to the
support column. The physical design of the
gasketed plate heat exchanger allows easy
cleaning, and modification of capacity by
the addition or removal of plates.

Fig. 48 The gasketed plate heat

exchanger

The gaskets
The most common gasket type in steam
heaters is the glue-free Clip-on gasket.
Glue-free gaskets are easy to change and
have a longer lifetime than glued gaskets.
Glued gaskets are preferred when the duty
requires frequent mechanical cleaning of
the plates. The glue will keep the gasket in
the same position regardless of how many
times the unit is opened, which reduces
the risk of leakage. Furthermore, the gasket will not fall off if the plates are cleaned
by means of a high pressure nozzle or
manual brushing.
The most common gasket material used
in steam heaters is EPDM, and is normally
preferred when the heated medium is water or any aqueous fluid. EPDM can handle
a steam temperature up to 160C.
Nitrile rubber is used when heating mineral oils and other petroleum products. It is
suitable for temperatures up to 140C.
Fluor-elastomers are preferred for duties
where acids or other aggressive fluids are
to be heated, or when the steam
temperature is up to 180C.

60

Fig. 49 A Clip-on gasket

Fig. 50 A glued gasket

Steam and Plate Heat Exchangers

The channel plates

Various channel plate styles are
available, corrugated in different patterns,
suitable for a large number of fluids and a
wide range of thermal duties.

Fig. 51 A channel plate with herringbone

pattern

The most commonly used plate material

is stainless steel, AISI 316. Titanium plates
are used for media containing chlorides
e.g. sea water. Exotic materials such as
Hastalloy, Incoloy and graphite are
available for chemical processing duties.
The thickness of the plates is normally in
the range 0.4 - 0.7 mm.

The gasketed plate heat exchanger

as a steam heater
Because of its flexibility, the gasketed
plate heat exchanger is used in a great
number of applications in the HVAC and
other industries. It is usually the
temperature performance of the gaskets
that sets the limit of its use. Their elastic
mechanical design makes them resistant
to pressure pulsation and thermal fatigue.

Fig. 52 The gasketed PHE is very resistent to

thermal fatigue due to the "elastic"
plate pack

This unique feature makes the gasketed

plate heat exchanger the ideal solution
for batch operations and instantaneous
water heating, or other duties where the
heat exchanger will be exposed to thermal
cycling.
Any of the control methods described in
this book can be applied.

Standard Performance Limits

Capacity range:
Design pressure:
Design temperature:

100-70,000 kW
25 bar
180 C

61

The brazed plate heat exchanger

The brazed heat exchanger is a variation of the
traditional gasketed plate heat exchanger.
It evolved from the conventional gasketed plate
to answer the need for a compact plate heat
exchanger, suitable for high pressure and high
temperature duties.

Fig. 53 Flow principle in a brazed plate heat

exchanger

The brazed plate heat exchanger is, like the

gasketed PHE, constructed of a series of
corrugated metal plates, but without gaskets,
tightening bolts, frame etc.
The brazed plate heat exchanger simply
consists of stainless steel plates and two end
plates. All the plates are brazed together in a
vacuum furnace to form an extremely compact
and pressure/temperature resistant heat
exchanger with superior heat transfer
characteristics. Copper is the usual brazing material. Nickel is used in its place where the heated
media contains ammonia, which would dissolve
copper, or, in applications where the presence of
copper ions is undesirable.
Fig. 54 Cross section of the channel
arrangement in a brazed
plate heat exchanger

Unlike the gasketed plate heat exchanger, the

brazed plate heat exchanger cannot be
disassembled. The scrubbing action of the highly
turbulent flow retards fouling. If cleaning is
required, the unit can be back-flushed to prevent
clogging, or chemically cleaned to eliminate the
build up of scale.

The brazed plate heat exchanger as steam

heater
The robust design of the brazed PHE makes
it suitable for higher pressure and temperature
applications, but is also a disadvantage, as the
many contact points between the plates make
the heat exchanger prone to thermal fatigue.
This means that special attention must be paid
to the application it is used for, and the control
method which is applied.
Generally, applications where the brazed plate
heat exchanger may be exposed to large,
sudden, or frequent changes in temperature
and load must be avoided. An example of such
a duty is instantaneous tap water heating with
steam. Space heating is a suitable application for
the brazed plate heat exchanger, provided that
the proper control method is applied and the
components in the control system are correctly
sized.
Primary steam control with active condensate
drainage is the preferred method, as this system
will minimise the risk of thermal cycling, as long
as the heat exchanger and the control
components are correctly matched. Any type
of on/off control would almost inevitably lead to
thermal stress and must not be applied.
The brazed plate heat exchanger is a very price
competitive alternative to other heat exchanger
types. Its primary uses are for space heating and
applications where it is not exposed to sudden
temperature changes.

Standard Performance Limits

Capacity range:
Design pressure:
Design temperature:

62

10-5 000 kW
30 bar
225 C, Cu-brazed
400 C, Ni-brazed

Steam and Plate Heat Exchangers

The all-welded plate heat

exchanger

method is 'primary steam control', with or without active condensate drainage.

The all-welded plate heat exchanger bears a

strong resemblance to a gasketed plate heat
exchanger. The only, but essential difference is
that the gaskets have been replaced by
laser-welds. This increases the performance limits
considerably. The standard material for the plates
is stainless steel, AISI 316. Other materials, such
as titanium, nickel and various Hastalloy qualities,
are available for aggressive media applications.

Fig. 56 The all-welded plate heat exchanger,

the AlfaRex

Fig. 55

The all-welded plate heat exchanger is also

used as a process condenser and an evaporator
in the process industries.

Laser-welded plate pack

Resistance to thermal fatigue

To achieve a design, which is resistant to
thermal fatigue, attention has to be paid to the
way in which the plates are welded. Appropriate
welding techniques guarantee that the plate pack
can expand and contract due to temperature
fluctuations without breaking.
The all-welded plate heat exchanger is a less
rigid construction than the brazed plate heat
exchanger, as the only fixed contact between the
channel plates is along the welds. This makes the
all-welded plate heat exchanger very resistant to
pressure pulsation and thermal cycling.

The semi-welded plate heat exchanger

This is a hybrid of the gasketed plate heat exchanger and the all-welded plate heat
exchanger. In this heat exchanger the channels
are alternately sealed with welds and gaskets.

Fig. 57 Semi-welded plate pack

The steam heater for heavy duties

The all-welded plate heat exchanger is mainly
used in heavy process industries, where its high
temperature and pressure operating limits make
it suitable for many applications.
Any established control method can be applied
with good results, but the most frequently used

63

Compabloc The fully welded

and accessible plate heat
exchanger

Fig. 58

Compabloc heat exchanger

Fig. 59

Flow principle in a Compabloc

heat exchanger

The Compabloc is unique amongst plate heat

exchangers with its fully welded design and easy
access for cleaning or maintenance. Compabloc
consists of a fully welded plate pack surrounded
by bolted panels. The relatively short flow path,
large gap and variable nozzle sizes makes it ideal
as a steam heater. Standard material for the
plates are AISI 316L. Other materials, like
titanium, Hastelloys, nickel and even tantalum,
are available for aggressive media applications.

Steam heater for industrial applications

The Compabloc is mainly used in process
industry where its high temperature and pressure
operating limits makes it suitable for many
applications. The fully welded robust
construction of the Compabloc also makes it
more rigid and more prone to fatigue then a
normal plate heat exchanger. Therefore cyclic
operations e.g. batch heating should be avoided.

Control requirments
For the Compabloc use primary steam control
or condensate control. For primary steam control
it is very important that the control components
are correctly matched. Any type of on/off control
would inevitably lead to thermal fatigue.

Standard Performance Limits

Capacity range:
Design pressure:
Design tempearture:

64

20 - 100 000 kW
32 bar
350 C

Steam and Plate Heat Exchangers

Comparison between the plate heat exchanger and the shell & tube
heat exchanger

Fig. 60

Comparisons in size
between a shell & tube heat
exchanger, a gasketed plate
heat exchanger and a
brazed plate heat exchanger
in the same thermal duty

Thermal performance

In the plate heat exchanger the flow mode of

the fluids is truly countercurrent. This, in
combination with the high heat transfer co-efficient, makes it possible to design the plate heat
exchanger with a close temperature
approach, which means that the heated media
can be heated very close to the saturation
temperature of the steam. This feature is
particularly important when low pressure steam
or vacuum steam is used as the heating
medium.

Due to the efficient heat transfer in a plate heat

exchanger it is possible to subcool condensate
within it. This can be achieved by introducing a
condensate level control and utilising the lower
part of the plate as a subcooler. It is very difficult
to make a similar arrangement in a shell & tube
heat exchanger in an economical way. Instead, a
separate subcooler is needed.
Fig. 61

A close temperature approach

is possible in a plate heat
exchanger

Condensation temperature
Tout
Temperature

The turbulent flow encouraged in a plate heat

exchanger contributes to a very efficient heat
transfer, ie. a high k-value. Compared with a shell
& tube heat exchanger the k-value is, typically,
3-5 times higher. This high thermal efficiency
has a price, and that is the pressure drop on
the heated media side. Compared with a shell &
tube heat exchanger, the plate heat exchanger
normally requires a slightly higher pressure drop
to enable an efficient design.

Tin

65

Size and weight

The compact design of the plate heat
exchanger provides many benefits in terms of
weight, floor space requirement and hold-up
volume. The combination of low weight and size
lowers installation costs. Furthermore, a low
hold-up volume provides a low pressure x
volume rating, which for small heat exchangers,
may make pressure vessel certificates and regular inspections by the pressure vessel
authority unnecessary.

Mechanical design
The shell & tube heat exchanger can be
designed for very high temperature and pressure
applications. The operating limits of todays allwelded plate heat exchangers are 350C and
40 bar g, which is sufficient for most applications.
Exotic materials of construction, such as
titanium and Hastelloy, are standard options for
heat exchanger plates. When used in a shell &
tube heat exchanger this solution can be very
expensive, since much more material is needed.
The tubes of shell & tube heat exchangers are
sensitive to vibrations, whereas plate heat
exchangers are much more resistant to vibration,
or any other type of pressure fatigue.
The inlet and outlet connections are usually all
located in the frame plate of a plate heat
exchanger. This simplifies the piping, compared
with a shell & tube heat exchanger.
The corrugations in the plates creates a very
turbulent flow, which efficiently retards fouling of
the heat transfer surface. In a shell & tube heat
exchanger, the flow is less turbulent, and
consequently the risk of fouling is greater, which
means that a shell & tube heat exchanger has to
be cleaned more often.
The vertical orientation of the plates makes
condensate drainage easier in the plate heat
exchanger than in a shell & tube heat exchanger,
where the tubes usually are horizontal.

66

Fig. 62

Comparisons between a
gasketed PHE and a S & T

PHE

S&T

Weight ratio

Space ratio

Hold-up volume

10

Fig. 63

The swirling motion of the

fluid retards fouling in plate
heat exchanger

Steam and Plate Heat Exchangers

The combination of low hold-up volume, high

thermal efficiency and low weight makes the
plate heat exchanger outstanding in applications
where a short response time is required.
Instantaneous water heating is a good example
of an application where plate heat exchangers
are superior to shell-and-tube heat exchangers.
The graph in Fig 61 shows the outlet temperature may change with time when the heat-load is
reduced from high to low load operation. Compared to a plate heat exchanger, the shell-andtube heat exchanger shows a slower response
to load changes due to increased weight, the
large hold-up volume and the smaller transfer
coefficient.

Temperature

Fig. 64

Temperature control accuracy

PHE

S&T

Set point

Time

Fig. 65

Operation in stall condition

Typical temp. fluctuations

due to load change for PHE
and S&T

Small contact area between

steam and condensate

Stall condition means that the condensation

pressure is lower than the pressure in the
condensate line (see page 42). Under these
circumstances, condensate will back-up in the
heat exchanger. This is likely to happen in most
water heating applications, when the heat
exchanger is operating at partial load.
In a shell-and-tube heat exchanger the contact
area between steam and cold condensate is
relatively large, whereas in a plate heat
exchanger it is very small. In the shell-and-tube
heat exchanger, this could result in problems
when load changes occur. The steam will

Fig. 66

Large contact area between

steam and condensate

implode in the cold condensate and cause noise,

water hammer and poor temperature control. In a
correctly sized plate heat exchanger, implosions,
noise problems and poor temperature control
would not take place.

67

Steam as the heating medium in plate heat exchangers

A major advantage of the plate heat exchanger is its outstanding thermal efficiency, however other factors
may influence the sizing and selection of the phe.

Fouling
All heat exchangers are exposed to fouling when in operation. This is because liquids, (e.g. raw water) are often
dirty and/or unstable and cause rapid build up of fouling
deposits. These deposits are usually a combination of
different types of foulants.

Scaling

The amount of dirt/scaling on the wall surface is very

dependent on how the unit is operated. A constant heat
transfer can, in theory, lead to unlimited scaling.
Thickness and thermal conductivity are factors that
determine the fouling resistance of a plate heat exchanger.
The fouling factor (Rf 10-4M2K/W) has been used as a
measurement of the units ability to function under fouling
conditions and is a common way of expressing a margin
for shell & tube heat exchangers. However, because of the
higher k-value in a PHE, the design will be largely over
surfaced if the same Rf specified for tubular heat
exchangers is used. Instead a percentage margin should
be used. A typical value would be in the range 10 20 %.

How to prevent scaling

There are three things which should be observed when
designing steam heaters:
- The design condensation temperature should be
relatively low, typically around 120 C. When severe
scaling can be expected, an even lower condensation
temperature should be considered. This would also
minimise flash steam generation (see page 30)
- The preferred temperature control method is Steam
Inlet Control with active condensate drainage as this
method minimises the condensation temperature.(see
page 49)
- Use gasketed heat exchangers as these can be
opened and manually cleaned.

68

Fig. 67

Relative scaling rate

Scaling is a form of fouling. It is a phenomenon that can

occur on the cold side in a steam application. The greatest risk is the build up of calcium carbonate (so called lime
scale) and this is closely linked to the quality of the water.
The higher the temperature, of the heat exchanger wall, the
faster the scaling will build up (see Fig 67).

Correlation between temp.

and scale build-up over
time

5
4
3
2
1
50

100

150

200

Surface

Fig. 68

Plate without and with

scaling

Steam and Plate Heat Exchangers

Economical to size for a relatively low
condensation temperature

Fig. 69

Condensation at 150C / 120C

Due to the high thermal efficiency of the

plate heat exchanger and the low additional
cost for additional heat transfer surface in a
given frame, it is often recommended to size
the plate heat exchanger for a relatively low
condensation temperature. This is
particularly interesting when there is a risk
of scaling and/or generated flash steam
which cannot be recovered.
Condensation at 150C
Load: 1 MW, 60 - 80C
TS6-M with 20 plates

Condensation at 120C
Load: 1 MW, 60 - 80C
TS6-M with 28 plates

By-pass arrangement
When the secondary side fluid is heated just by a
few degrees, i.e. the flow rate is comparatively large,
it is actually the allowable secondary side pressure
drop that sizes the plate heat exchanger. This means
that extra plates need to be added to the design just
to fulfil the pressure drop requirement. This in turn,
leads to a thermally over-surfaced plate heat
exchanger. The over surfacing not only increases the
price, it also makes the heat exchanger more difficult
to control. In many cases, this problem can be
overcome by introducing a by-pass on the secondary
side. This allows the flow rate through the heat
exchanger to be optimised, reducing the heat
transfer area, which can lead to considerable cost
savings. The temperature rise of the heated medium
will need to increase, which will improve the stability of
the temperature control.

Fig. 70

A secondary side by-pass

arrangement

Extra steam inlet

Fig. 71

Extra steam inlet

In duties where a lot of plates are required to fulfil

the thermal requirements, an extra steam inlet
connection might be needed to handle the
comparatively high steam flow rate. This is a useful
option when the required steam pressure is low, or its
temperature is close to the outlet temperature of the
heated fluid. By adding an extra inlet, selection of a
larger unit with larger connections is avoided.
Consequently, oversizing, and the cost increase that
goes with it, is avoided.

69

Reduction of steam pressure

Steam pressure reduction may be required
when high pressure saturated steam is the available heating medium, and a gasketed plate heat
exchanger is the preferred heat exchanger type.
Steam pressure reduction can be used to reduce
steam temperature to within the
performance limits of the gasketed plate heat
exchanger. For example, if 98% dry saturated
steam at 16 bar g, 204C, is reduced to
3 bar g, the resulting temperature will be 150 C.
Note;

Reducing valve

Fig. 73

Condensation on the upper part

of the plate and condensate
subcooling at the lower end

Pressure reduction of superheated stem will give just a

small temperature drop.

Heating and condensate subcooling in one

unit
Due to the high thermal efficiency of the plate
heat exchanger it is sometimes possible to carry
out the heating of a secondary fluid and the subcooling of the resulting condensate in a single
unit. This can only be done if the criteria for the
application of condensate control can be met.
Another condition, is that the inlet temperature of
the heated medium is at least 10C lower than
the desired condensate outlet temperature.
The great advantage of heating and subcooling in one unit, is that investments in flash steam
vessels or separate subcoolers are not necessary.

70

Fig. 72

Steam and Plate Heat Exchangers

Design calculations of plate heat

exchangers
Plate heat exchangers are easily selected and
designed using software developed by the plate
heat exchanger manufacturers. Below, two interfaces of Alfa Lavals design software are shown.
Using this computer program, it is possible to
optimise the steam heater design for any given
duty. It can handle wet, saturated and superheated steam, as well as almost any medium
on the secondary side. Velocities of the fluids in
connections and channels as well as the condensate exit temperature are calculated. The steam
heater design can be tailor-made to fit any established control method. The control stall point can
also be found.
To enable a good steam heater design the following information should preferably be known.

The thermal duty

That is heat load, temperatures in/out of
the heated medium (or one temperature
and the flow rate), allowable pressure drop
on the secondary side, and the state (pressure
and temperature) of the available steam.
The pressure drop on the steam side would not
normally be considered.

Fig. 74

Thermal design data

Fouling
It is important to know whether the heated
fluid contains fibres or other fouling
substances, or, if the fluid itself is fouling.

Mechanical design data

Design pressure and temperature, pressure
vessel code, connection type; flange, pipe etc.

Type of steam heater application

The intended mode of use should be known to
the designer as this can influence the selection of
the plate heat exchanger type and its design.

Control method
The control method heavily influences the thermal design of the heat exchanger and its type.

Desired condensate exit temperature

This influences the design of the heat
exchanger, particularly when condensate control
is used.
When the above data is known, the design of a
plate heat exchanger can be completed. In addition to selecting a heat exchanger, the program
will provide print-outs of relevant data, drawings
of the plate heat exchanger, prices etc.

Fig. 75

Mechanical configuration

71

72

Steam and Plate Heat Exchangers

Appendix I. Steam tables

Water
(hf)

Evaporation
(hfg)

Steam
(hg)

Specific
Volume
Vg

kJ/kg

kJ/kg

kJ/kg

m3/kg

Specific Enthalpy
Pressure

kPa
bar
absolute
0.30
0.50
0.75
0.95
0
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
1.10
1.20
1.30
1.40
1.50
1.60
1.70
1.80
1.90
2.00
2.20
2.40
2.60
2.80
3.00
3.20
3.40
3.60
3.80
4.00
4.50
5.00

Temperature

30.0
50.0
75.0
95.0

69.10
81.33
91.78
98.20

289.23
340.49
384.39
411.43

2336.1
2305.4
2278.6
2261.8

2625.3
2645.9
2663.0
2673.2

5.229
3.240
2.217
1.777

0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
90.0
100.0
110.0
120.0
130.0
140.0
150.0
160.0
170.0
180.0
190.0
200.0
220.0
240.0
260.0
280.0
300.0
320.0
340.0
360.0
380.0
400.0
450.0
500.0

100.00
102.66
105.10
107.39
109.55
111.61
113.56
115.40
117.14
118.80
120.42
121.96
123.46
124.90
126.28
127.62
128.89
130.13
131.37
132.54
133.69
135.88
138.01
140.00
141.92
143.75
145.46
147.20
148.84
150.44
151.96
155.55
158.92

419.04
430.2
440.8
450.4
459.7
468.3
476.4
484.1
491.6
498.9
505.6
512.2
518.7
524.6
530.5
536.1
541.6
547.1
552.3
557.3
562.2
571.7
580.7
589.2
597.4
605.3
612.9
620.0
627.1
634.0
640.7
656.3
670.9

2257.0
2250.2
2243.4
2237.2
2231.3
2225.6
2220.4
2215.4
2210.5
2205.6
2201.1
2197.0
2192.8
2188.7
2184.8
2181.0
2177.3
2173.7
2170.1
2166.7
2163.3
2156.9
2150.7
2144.7
2139.0
2133.4
2128.1
2122.9
2117.8
2112.9
2108.1
2096.7
2086.0

2676.0
2680.2
2684.2
2687.6
2691.0
2693.9
2696.8
2699.5
2702.1
2704.5
2706.7
2709.2
2711.5
2713.3
2715.3
2717.1
2718.9
2720.8
2722.4
2724.0
2725.5
2728.6
2731.4
2733.9
2736.4
2738.7
2741.0
2742.9
2744.9
2746.9
2748.8
2753.0
2756.9

1.673
1.533
1.414
1.312
1.225
1.149
1.083
1.024
0.971
0.923
0.881
0.841
0.806
0.773
0.743
0.714
0.689
0.665
0.643
0.622
0.603
0.568
0.536
0.509
0.483
0.461
0.440
0.422
0.405
0.389
0.374
0.342
0.315

gauge

73

Appendix I. Steam tables (continued)

Water
(hf)

Evaporation
(hfg)

Steam
(hg)

Specific
Volume
Vg

kJ/kg

kJ/kg

kJ/kg

m3/kg

2760.3
2763.5
2766.5
2769.1
2771.7
2774.0
2776.2
2778.1
2780.0
2781.7
2783.3
2784.8
2786.3
2787.6
2788.8
2790.0
2791.1
2792.2
2793.1
2794.0
2794.9
2795.7
2797.1
2798.5
2799.5
2800.5
2801.4
2802.0
2802.6
2803.1
2803.5
2803.8
2804.0
2804.1
2804.2
2804.1
2804.1
2803.9
2803.7

0.292
0.272
0.255
0.240
0.227
0.215
0.204
0.194
0.185
0.177
0.171
0.163
0.157
0.151
0.146
0.141
0.136
0.132
0.128
0.124
0.119
0.117
0.110
0.105
0.100
0.0949
0.0906
0.0868
0.0832
0.0797
0.0768
0.0740
0.0714
0.0689
0.0666
0.0645
0.0625
0.0605
0.0587

Specific Enthalpy
Pressure

74

bar

kPa

5.50
6.00
6.50
7.00
7.50
8.00
8.50
9.00
9.50
10.00
10.50
11.00
11.50
12.00
12.50
13.00
13.50
14.00
14.50
15.00
15.50
16.00
17.00
18.00
19.00
20.00
21.00
22.00
23.00
24.00
25.00
26.00
27.00
28.00
29.00
30.00
31.00
32.00
33.00

550.0
600.0
650.0
700.0
750.0
800.0
850.0
900.0
950.0
1000.0
1050.0
1100.0
1150.0
1200.0
1250.0
1300.0
1350.0
1400.0
1450.0
1500.0
1550.0
1600.0
1700.0
1800.0
1900.0
2000.0
2100.0
2200.0
2300.0
2400.0
2500.0
2600.0
2700.0
2800.0
2900.0
3000.0
3100.0
3200.0
3300.0

Temperature

C
162.08
165.04
167.83
170.50
173.02
175.43
177.75
179.97
182.10
184.13
186.05
188.02
189.82
191.68
193.43
195.10
196.62
198.35
199.92
201.45
202.92
204.38
207.17
209.90
212.47
214.96
217.35
219.65
221.85
224.02
226.12
228.15
230.14
232.05
233.93
235.78
237.55
239.28
240.97

684.6
697.5
709.7
721.4
732.5
743.1
753.3
763.0
772.5
781.6
790.1
798.8
807.1
815.1
822.9
830.4
837.9
845.1
852.1
859.0
865.7
872.3
885.0
897.2
909.0
920.3
931.3
941.9
952.2
962.2
972.1
981.6
990.7
999.7
1008.6
1017.0
1025.6
1033.9
1041.9

2075.7
2066.0
2056.8
2047.7
2039.2
2030.9
2022.9
2015.1
2007.5
2000.1
1993.0
1986.0
1979.1
1972.5
1965.4
1959.6
1953.2
1947.1
1941.0
1935.0
1928.8
1923.4
1912.1
1901.3
1890.5
1880.2
1870.1
1860.1
1850.4
1840.9
1831.4
1822.2
1813.3
1804.4
1795.6
1787.0
1778.5
1770.0
1761.8

Steam and Plate Heat Exchangers

Appendix I. Steam tables (continued)

Water
(hf)

Evaporation
(hfg)

Steam
(hg)

Specific
Volume
Vg

kJ/kg

kJ/kg

kJ/kg

m3/kg

2803.5
2803.2
2802.9
2802.4
2801.9
2801.5
2800.9
2799.9
2799.8
2799.1
2798.3
2797.6
2796.9
2796.6
2795.2
2794.4
2793.6
2792.6
2791.6
2790.7
2789.7
2788.7
2787.6
2786.6
2785.5
2784.4
2783.3
2782.1
2780.9
2779.7
2778.5
2777.3
2776.1
2774.8
2773.5
2772.1
2770.8
2769.5
2768.1

0.0571
0.0554
0.0539
0.0524
0.0510
0.0498
0.0485
0.0473
0.0461
0.0451
0.0441
0.0431
0.0421
0.0412
0.0403
0.0394
0.0386
0.0378
0.0371
0.0364
0.0357
0.0350
0.0343
0.0337
0.0331
0.0325
0.0319
0.0314
0.0308
0.0303
0.0298
0.0293
0.0288
0.0283
0.0278
0.0274
0.0270
0.0266
0.0262

Specific Enthalpy
Pressure

bar

kPa

34.00
35.00
36.00
37.00
38.00
39.00
40.00
41.00
42.00
43.00
44.00
45.00
46.00
47.00
48.00
49.00
50.00
51.00
52.00
53.00
54.00
55.00
56.00
57.00
58.00
59.00
60.00
61.00
62.00
63.00
64.00
65.00
66.00
67.00
68.00
69.00
70.00
71.00
72.00

3400.0
3500.0
3600.0
3700.0
3800.0
3900.0
4000.0
4100.0
4200.0
4300.0
4400.0
4500.0
4600.0
4700.0
4800.0
4900.0
5000.0
5100.0
5200.0
5300.0
5400.0
5500.0
5600.0
5700.0
5800.0
5900.0
6000.0
6100.0
6200.0
6300.0
6400.0
6500.0
6600.0
6700.0
6800.0
6900.0
7000.0
7100.0
7200.0

Temperature

C
242.63
244.26
245.86
247.42
248.95
250.42
251.94
253.34
254.74
256.12
257.50
258.82
260.13
261.43
262.73
264.00
265.26
266.45
267.67
268.84
270.02
271.20
272.33
273.45
274.55
275.65
276.73
277.80
278.85
279.89
280.92
281.95
282.95
283.95
284.93
285.90
286.85
287.80
288.75

1049.7
1057.7
1065.7
1072.9
1080.3
1087.4
1094.6
1101.6
1108.6
1115.4
1122.1
1228.7
1135.3
1142.2
1148.1
1154.5
1160.8
1166.6
1172.6
1178.7
1184.6
1190.5
1196.3
1202.1
1207.8
1213.4
1218.9
1224.5
1230.0
1235.4
1240.8
1246.1
1251.4
1256.7
1261.9
1267.0
1272.1
1277.3
1282.3

1753.8
1745.5
1737.2
1729.5
1721.6
1714.1
1706.3
1698.3
1691.2
1683.7
1676.2
1668.9
1666.6
1654.4
1647.1
1639.9
1632.8
1626.9
1619.0
1612.0
1605.1
1598.2
1591.3
1584.5
1577.7
1571.0
1564.4
1557.6
1550.9
1544.3
1537.3
1531.2
1524.7
1518.1
1511.6
1501.1
1498.7
1492.2
1485.8

75

Appendix I. Steam tables (continued)

Water
(hf)

Evaporation
(hfg)

Steam
(hg)

Specific
Volume
Vg

kJ/kg

kJ/kg

kJ/kg

m3/kg

2766.7
2765.3
2763.8
2762.5
2760.9
2759.5
2758.0
2756.5
2754.9
2753.4
2751.9
2750.3
2748.8
2747.2
2745.5
2744.0
2742.3
2740.5
2737.1
2733.7
2730.2
2726.5
2722.8
2719.2
2715.3
2711.5
2707.6
2703.6
2699.6
2695.4
2691.2
2687.0
2682.7

0.0258
0.0254
0.0250
0.0246
0.0242
0.0239
0.0236
0.0233
0.0229
0.0226
0.0223
0.0220
0.0217
0.0214
0.0211
0.0208
0.0205
0.0202
0.0197
0.0192
0.0187
0.0183
0.0178
0.0174
0.0170
0.0166
0.0162
0.0158
0.0154
0.0150
0.0147
0.0144
0.0141

Specific Enthalpy
Pressure

bar

kPa

73.00
74.00
75.00
76.00
77.00
78.00
79.00
80.00
81.00
82.00
83.00
84.00
85.00
86.00
87.00
88.00
89.00
90.00
92.00
94.00
96.00
98.00
100.00
102.00
104.00
106.00
108.00
110.00
112.00
114.00
116.00
118.00
120.00

7300.0
7400.0
7500.0
7600.0
7700.0
7800.0
7900.0
8000.0
8100.0
8200.0
8300.0
8400.0
8500.0
8600.0
8700.0
8800.0
8900.0
9000.0
9200.0
9400.0
9600.0
9800.0
10000.0
10200.0
10400.0
10600.0
10800.0
11000.0
11200.0
11400.0
11600.0
11800.0
12000.0

76

Temperature

C
289.69
290.60
291.51
292.41
293.91
294.20
295.10
295.96
296.81
297.66
298.50
299.35
300.20
301.00
301.81
302.61
303.41
304.20
305.77
307.24
308.83
310.32
311.79
313.24
314.67
316.08
317.46
318.83
320.17
321.50
322.81
324.10
325.38

1287.3
1292.3
1297.2
1302.3
1307.0
1311.9
1316.7
1321.5
1326.2
1330.9
1335.7
1340.3
1345.0
1349.6
1354.2
1358.8
1363.3
1367.8
1376.8
1385.7
1394.5
1403.2
1411.9
1420.5
1429.0
1437.5
1445.9
1454.3
1462.6
1470.8
1479.0
1487.2
1495.4

1479.4
1473.0
1466.6
1460.2
1453.9
1447.6
1441.3
1435.0
1428.7
1422.5
1416.2
1410.0
1403.8
1397.6
1391.3
1385.2
1379.0
1372.7
1360.3
1348.0
1335.7
1323.3
1310.9
1298.7
1286.3
1274.0
1261.7
1249.3
1237.0
1224.6
1212.2
1199.8
1187.3

Steam and Plate Heat Exchangers

Appendix II. Condensate line sizing

100,000

500

400

350

300

250

200
150
100

50,000

20,000

65

10,000

50

5,000

40
32

2,000

25

1,000

20

500

15
10

200
100

Condensate line size mm

Condensate rate kg/h

80

50

20

Steam system pressure bar g

50
30
20
15
10
5
2
1
0.5
0

30
20
10
5
4
3
2
1
0.5
0

Condensate system pressure bar g

Steam temperature C

10

77

14.5

190

11.6

180

9.0

170

7.0

160

5.2

150

3.8

140

2.6

130

1.7

120

1.0

110

0.4

100

90

0.7

80

0.5

70

0.3

60

0.2

50

0.12

40

0.07

30

0.05

20
10
0
-10
100

78

90

80

70

60

50
%

40

30

20

10

Pressure bar g

200

Pressure bar a
(vacuum)

Temperature C

Appendix III. Stall Chart

Alfa Laval is a leading global provider of specialized products and engineering solutions.
Our equipment, systems and services are
dedicated to helping customers to optimize
the performance of their processes. Time
and time again.

How to contact Alfa Laval

Contact details for all countries are continually updated on our website. Please visit
www.alfalaval.com to access the information.

Spirax Sarco in brief

Spirax Sarco is the worlds leading provider
of knowledge, service and products for the
control and efficient use of steam.
For over 90 years we have worked in
partnership with our customers to improve
their processes and reduce energy costs, by
helping them to use steam effectively and
efficiently.
Our worldwide organisation, our unrivalled
knowledge and our portfolio of innovative
products allow us to work with users on all
steam applications, in every industry.

How to contact Spiraz Sarco

Spirax-Sarco Limited, Charlton House,
Cheltenham, Gloucestershire, GL53 8ER UK.
Tel: +44 (0)1242 521361
Fax: +44 (0)1242 573342
E-mail: [email protected]
Internet: www.spiraxsarco.com

PM68205/E 0108

GP-GCM-12 CM Issue 2

A technical guide to the effective use of steam in plate heat exchangers

We help our customers to heat, cool,

separate and transport products such as
oil, water, chemicals, beverages, foodstuff,
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Our worldwide organization works closely
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help them stay ahead.

Steam and Plate Heat Exchangers

Alfa Laval in brief