CENTRINDO PALMAX

Basic Steam Engineering

 STEAM

Steam

Water
(boiling)

Heat
same STEAM, just larger…
still same STEAM, but even larger…
 STEAM in Palm Oil Mill

Sterilizer Digester

Clarifier
&
Air
Storage
Heater
Tanks
 STEAM in Industry
Shell & Tube
Plate Heat Exchanger Heating Coil Ejector
Heat Exchanger

Tracing Jacketing Dryer Roll Turbine

 The Chosen One

water is could contain easy to control

safe & pure
plentiful lot of heat (press-temp relation)

has constant easy to distribute

relatively small numerous product
temperature (no pump &
pipe work support
(saturated) simple valve)
 STEAM in a Nutshell

Temperature Steam Pressure - Spec. Volume Relation

Pressure Dryness Faction
- Absolute Pressure - Dry Steam
- Gauge Pressure - Wet Steam
Density AND Specific Volume Flash Steam
Energy - Work AND Heat Superheat Steam
- Effect to Heating Application
- Superheating Effect

Three Phase of H2O

- Ice - Solid
- Water - Liquid Steam Quality
- Steam - Gas - Correct Quantity
Water Boiling Point - Correct Press / Temp
Steam Saturation Curve - Air & Incondensable Gas
Sensible Heat / Liquid Enthalpy - Cleanliness
Latent Heat / Enthalpy of Evaporation - Dryness
Saturation Steam Table Water Hammer
 Pressure

Absolute Pressure
open space AND
or Gauge Pressure
atmospheric
pressure

Absolute Pressure
1 atm

Gauge Pressure
Atmospheric 1 bar a
Pressure 0 bar g

Perfect
0 bar a
1 bar Vacuum

bar a = bar g + 1
0 bar …???
 Three Phases of Water (H2O)
Release Heat Receive Heat

Evaporating
Condensing
Freezing

Melting
Receive Heat

Release Heat
0 °C 100 °C
 A journey from WATER to STEAM

Temp (°C)
@ 1atm
0°C 100°C 0 bar.g
0% Dryness Fraction 100%
100°C

Latent Heat

0°C
Enthalpy (kJ/kg)
Liquid Enthalpy (hf) Enthalpy of Evaporation (hfg)

Total Enthalpy (hg)

Water Boiling Point vs Steam Saturation Curve

Lid Closed

184.13 °C

10 bar.g
 density VS specific volume

H2 O
(water)

100 mL

100 gr

Density Specific Volume

“how many molecule of a substance (mass) “how large of space occupied (volume)
filled in a certain volume” by a substance in a certain weight (mass)”
𝑚𝑚 1 𝑉𝑉
𝜌𝜌 = 𝜌𝜌 = 𝑉𝑉̇ =
𝑉𝑉 𝑉𝑉̇ 𝑚𝑚
1 gr/m3 1 gr/m3
Steam Pressure & Spec. Volume - Relationship

0.461 m3/kg 3 bar g 0.177 m3/kg 10 bar g

1 kg of steam 1 kg of steam

0.461 m3/kg

0.177 m3/kg
More About Steam
 Flash Steam

Steam Trap
Condensate 25 bar.g Condensate 0 bar.g
& Flash Steam

Saturation Temperature Saturation Temperature

T1 of 226 °C T2 of 100 °C
hf1 of 972 kJ/kg hf2 of 419 kJ/kg

𝐡𝐡𝐟𝐟𝐟𝐟 − 𝐡𝐡𝐟𝐟𝐟𝐟
𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩𝐩 𝐨𝐨𝐨𝐨 𝐟𝐟𝐟𝐟𝐟𝐟𝐟𝐟𝐟𝐟 𝐬𝐬𝐬𝐬𝐬𝐬𝐬𝐬𝐬𝐬 =
𝐡𝐡𝐟𝐟𝐟𝐟𝐟𝐟

972 kJ⁄kg − 419 kJ⁄kg

= 0.25 (25%)
2257 kJ⁄kg
 Temp (°C)
how STEAM become “SUPER”

130°C

0% Dryness Fraction 100%

100°C
@ 1atm
0 bar.g

Latent Heat

Enthalpy (kJ/kg)
0°C
Liquid Enthalpy (hf) Enthalpy of Evaporation (hfg) Superheat Enthalpy (h)

Total Enthalpy (hg)

Superheater in Boiler
 Reducing Steam Pressure Effect

Pressure Reducing Valve

Steam 35 bar.g Steam 3 bar.g

Saturated

hg1 = 2802 kJ/kg hg2 = 2739 kJ/kg

T1 = 244 °C T2 = 144 °C
h’g2 = hg1
∆hg2 = 63 kJ/kg
T’2 = 173 °C

Steam become
Superheat
not so super…

10 bar.g with superheat steam

300 °C

Lower heat transfer coefficient

Un-uniform heat distribution

200 °C

10 bar.g
with saturated steam
184.13 °C

Higher heat transfer coefficient

Uniform heat distribution

Condensate
 our weapon to beat the “SUPER”

VTD VAD
Venturi Type Desuperheater Variable Area Desuperheater

actuator

control valve

cooling
water
cooling
water

superheat superheat
steam steam
how clean is your pipe line?
how could a steam become wet…
separating “water” from steam
 “air” among the “steam”
air rushed in
air presence in the steam when pipe become vacuum
reducing steam temperature during shut-down
because of “Dalton’s Law”

dissolved O2 and CO2

in poorly treated feed water
carried away by steam
air film created around
the heating element
BOILER significantly dropping
heat transfer effectiveness

O2 and CO2 dissolved again

to subcooled condensate
creating corrosive solvent
CENTRINDO PALMAX

Steam Trap
STEAM TRAP
STEAM TRAP in a Nutshell

“Automatic Valve”
“Discharge (opened) CONDENSATE
but not (closed) STEAM”
 Come in Various Types

Steam Trap Types

Mechanical Thermostatic Thermodynamic

Ball Float Balanced Pressure Disc

Inverted Bucket Bimetallic

Bimetallic Steam Trap

PT. CENTRINDO PALMAX

Bimetal Plate – How it works

cold hot

heat

Valve
Valve
Open
Closed

PT. CENTRINDO PALMAX

Bimetallic Steam Trap – How it works

PT. CENTRINDO PALMAX

Balanced Pressure Steam Trap

PT. CENTRINDO PALMAX

 Balanced Pressure Steam Trap

1 2 3

PT. CENTRINDO PALMAX

Ball Float Steam TraP

PT. CENTRINDO PALMAX

Ball Float Steam Trap – How it works

PT. CENTRINDO PALMAX

Sample of Application

PT. CENTRINDO PALMAX

Inverted Bucket Steam Trap – How it works

PT. CENTRINDO PALMAX

Inverted Bucket Steam Trap – How it works

PT. CENTRINDO PALMAX

Thermodynamic Steam Traps TD42

PT. CENTRINDO PALMAX

Thermodynamic Steam Traps

Cap Hardened stainless steel disc

with “Turbulence Groove” to
provide optimal opening period

3 discharge holes

In-built Strainer Connection Options:

(stainless steel) Screwed, Socket Weld,
Butt Weld, Flanges.

Body - electroless
nickel plating finish

PT. CENTRINDO PALMAX

Thermodynamic Trap – How it works

Bernoulli Effect
Flash Steam

PT. CENTRINDO PALMAX

For Higher Pressure TD62

PT. CENTRINDO PALMAX

For Higher Pressure TD120

PT. CENTRINDO PALMAX

 Selection - Types

Storage Heat exchangers Tracers and Space

tanks
jacketed pipes heating
Mains Jackets
drainage
Air heaters

Flash vessels

Rotating Non critical Pipe AHU

Base cylinders coils
coils Frost Unit
protection heaters
Outflow Radiators Radiant
Instrument Critical
heaters Calorifiers panels

FT BP TD FT BP BP TD BP BP FT FT
(IB+AV) (SM) (BP) (IB+AV) (TD) (SM) (BP) (FT) (IB+AV) (BP)
 Selection - Types

Heat exchangers

Mains
Heating Coils drainage

Air heaters

FT TD
(IB+AV) (SM)
 Selection - Capacity

Select the most suitable steam trap for steam coils (2 lines) in a Storage Tank.
Each line consume 300 kg/hr steam at 8 barg.
Condensate is drained to atmosphere.
 Selection - Capacity

• Maximum Load = 2 x 300 = 600 kg/h

• Maximum Diff. Press = 8 bar

• Selected Type = 1” FT14-10 TV

600
• Quantity = 2 pcs

8
 Selection - Capacity

Select the most suitable steam trap for a 4” steam distribution line.
Saturated Steam working pressure is 20 barg.
Distance from Steam Header to process machinery is 250 meter.
How many pieces of traps is required?
Selection - Capacity
 Selection - Capacity

• Maximum Load = 2 x 50 = 100 kg/h

• Max. Diff. Press = 20 bar

• Selected Type = TD42L

• Pipe Length = 250 meter

• Number of traps = 8 pcs

is your steam trap working properly?

Fail to Open Fail to Close

Condensate Block Steam Leak

Slow Heating Energy Loss

Water Hammer High Cost
Wet Steam Emission CO2
Troubleshooting Ball Float Steam Trap
 Troubleshooting Ball Float Steam Trap

Check Strainer

Check Main Valve

Troubleshooting Ball Float Steam Trap
Troubleshooting Ball Float Steam Trap
Troubleshooting Ball Float Steam Trap
Troubleshooting Ball Float Steam Trap
Troubleshooting Ball Float Steam Trap
Troubleshooting Thermodynamic Steam Trap
Troubleshooting Thermodynamic Steam Trap
how do we know?

Visual
Observation

Temperature
Measurement

Ultrasonic
Detection
Visual Observation
Temperature Measurement

Cannot Identify Leakage!!!

 Ultrasonic Detection

Ultrasonic sound amplified so

operator could listen the sound

The tip touch steam trap to

detect ultrasonic sound produced
by steam/condensate flow

Amplified sound transferred to

headphone to be listened and analyzed
CENTRINDO PALMAX

Steam Distribution
Distributing the Steam
Distributing the Steam

… Distribute STEAM
at
HIGHEST pressure…
Steam Pressure & Spec. Volume - Relationship

0.461 m3/kg 3 bar g 0.177 m3/kg 10 bar g

1 kg of steam 1 kg of steam

0.461 m3/kg

0.177 m3/kg
More Benefit with High Pressure

less surface area lower capital cost for lower capital cost for
less heat loss connection & support insulation

boiler could work

dryer steam reduce risk of
at optimum
because of priming &
operating condition
superheating effect carryover
for more efficiency
choose wisely…

Greater Cost
Greater Heat Loss
Greater Volume of Condensate Formed

Lower Pressure to Steam Users

Not Enough Volume of Steam
Waterhammer and Erosion
Pressure Drop…???
 how do choose the perfect size…?
Method #1 - Steam Velocity
Pressure Velocity Pipe Size Nominal / Actual Inside Diameter
bar g m/s 15 20 25 32 40 50 65 80 100 125 150
15.8 20.93 26.64 35.04 40.9 52.5 62.7 77.92 102.26 128.2 154.05
15 9 15 25 43 58 95 136 210 362 569 822
0.4 25 14 25 41 71 Selected
97 Pipe 159 227 350 603 948 1369
40 23 40 66 113Diameter
154 254 363 561 965 1517 2191

80 mm (3”)
15 10 18 29 51 69 114 163 251 433 681 983
0.7 25 17 30 49 85 115 190 271 419 722 1135 1638
Working
40 Pressure:
28 483 78 136 185 304 434 671 Selected1815
1155 Steam 2621
barg
15 12 21 34 59 81 133 189 292
Flowrate1319
503 791 1142
1 25 20 35 57 99 134 221 315 487 839 1904
40 32 56 91 158 215 354 505 779 ±930 kg/hr
1342 2110 3046
15 18 31 50 86 118 194 277 427 735 1156 1669
2 25 29 51 83 144 196 323 461 712 1226 1927 2782
40 47 82 133 230 314 517 737 1139 1961 3083 4451
15 23 40 65 113 154 254 362 559 962 1512 2183
3 25 38 67 109 188 256 423 603 931 1603 2520 3639
40 61 107 174 301 410 676 964 1490 2565 4032 5822
15 28 50 80 139 190 313 446 689 1186 1864 2691
4 25 47 83 134 232 316 521 743 1148 1976 3106 4485
40 75 132 215 371 506 833 1189 1836 3162 4970 7176
15 Limit of59Velocity96
34 165 225 371 529 817 1408 2213 3195
5 25 25 m/s 98
56 159 276 375 619 882 1362 2347 3688 5325
40 90 157 255 441 601 990 1411 2180 3755 5901 8521
15 39 68 111 191 261 430 613 947 1631 2563 3700
6 25 65 114 184 319 435 716 1022 1578 2718 4271 6167
40 104 182 295 511 696 1146 1635 2525 4348 6834 9867
15 44 77 125 217 296 487 695 1073 1848 2904 4194
7 25 74 129 209 362 493 812 1158 1788 3080 4841 6989
40 118 206 334 579 788 1299 1853 2861 4928 7745 11183
how do choose the perfect size…?
Method #2 - Steam Velocity

DN80 ∆P = 0,29 bar/100 m

DN100 ∆P = 0,1 bar/100 m

3 barg

900 kg/hr
 Pipe Insulation

excessive heat lost from un-insulated pipe line & safety issue.
Pipe Branching
Pipe Branching
No Water Pond Allowed
Pipe Support
Drain Pocket
Drain Pocket
Drain Pocket

drain point is taken

from lowest point

debris deposited
inside steam trap
lead to steam trap fail
 Drain Pocket

debris trapped at
the lowest point at
drain point is taken the pipe elbow
from lowest point

steam trap
was blocked
Drain Pocket Position
Water Hammer
Water Hammer
Pipe Expansion
Omega Loop
Sliding Joint & Expansion Joint
CENTRINDO PALMAX

Pressure Reducing Valve

& Control Valve
 CONTROL VALVE in a nut shell

Valve that Control something

Katup yang Mengendalikan sesuatu

“Pressure”
how could the pressure decrease…???

Fluid Flow

1 2 3

PASCAL LAW…???
only applied Q 1 = Q2 = Q3
to ideal fluid V1A1 = V2A2 =V3A3
 Our Method to Control the Pressure
Mechanical PN/EL

Direct Acting Pilot Operated Control Valve

BRV - Pressure Reducing Valve
Direct Acting - Mechanism
Typical Installation
DRV - Pressure Reducing Valve
Typical Installation
DP27 - Pressure Reducing Valve
Pilot Operated- Mechanism
Typical Installation
 CONTROL VALVE in a nut shell

Controller
Actuator

Positioner Sensor
Valve
Pressure
 know more about “VALVE”

DN80 KE43PCSUSS.2 Kv 100 PN16

DN80 Valve Size
K “Spirax Sarco” K - 2-Port Valve Series
E Equal Percentage Characteristic
- EN (PN) Flange Standard Bonnet
4 Carbon Steel - Body Material
Cage & Trim
3 Flanged Connection
P PTFE - Stem Sealing
C Reverseable PEEK seat - Seating Material Stem
S Standard Trim
U Un-Balanced Trim
S Standard Bonnet
S Standard Bolting
.2 “Spirax Sarco” .2 Series
Kv 100 Valve Flow Coefficient Plug & Seat
PN16 Flange Standard
Valve Opening Character
Balanced and Multi-stage Trim Options

Balanced , 3 Stage
Balanced , 2 Stage
Balanced Trim Low Noise Trim
Low Noise Trim

Un-Balanced Trim

Un-Balanced , 2 Stage Un-Balanced , 3 Stage

Low Noise Trim Low Noise Trim

Balanced , 1 Stage
Low Noise Trim
 know more about “ACTUATOR”

Spring

PN9233E
PN Pneumatic Type
9 9000 Series
2 340 cm2 (Diaphgram Area)
3 30 mm - Stroke
3 2 - 4 bar - Spring Rate
E Spring Extend - Fail to Close
 know more about “POSITIONER”

EP5 EPL SS2L

Electric to Pneumatic Electric to Pneumatic Electric to Pneumatic
4-20mA Signal 4-20mA Signal 4-20mA Signal
HART Communication
and other “SMART” Fungtion
Recommended System Installation
Control Valve Orientation
 Kalibrasi “Positioner”

OUT1

4-20mA SUP
Loop Calibrator Span

Zero
 Kalibrasi “Positioner”
“smart”

OUT1

4-20mA
Loop Calibrator

. SUP

Hold 5.Sec