Written as a practical guide to ensure a steam system is operated and maintained properly and efficiently, this book provides comprehensive information for ensuring process steam system reliability, informed design, and preventative maintenance practices.
The second edition remains a key reference for process engineers, plant engineers, facility managers, operations managers, and mechanical engineers. Updated to reflect current codes, sustainability measures, and case studies, this edition ties theoretical heat transfer and thermodynamics into practical applications though new application problems, thereby helping both professionals and those involved in training.
Preface xi
Acknowledgments xiii
List of Examples xv
List of Tables xvii
1 Steam: a Heat Transfer Fluid 1
Why Steam? 1
The Concept of Steam Formation: Boiling 3
2 The Development of Boiler Safety 9
How It All Began 9
The Consequences of Development 10
Development of Asme Code 12
Future of Steam 13
3 Understanding Heat Transfer 15
Radiation-Type Heat Transfer 15
Conduction-Type Heat Transfer 18
Convection-Type Heat Transfer 21
The Heat Transfer Equations 23
Heat Flux 30
4 Steam Formation, Accumulation, and Condensation 31
The Boiling Process 31
Condensation of Steam 34
The Formation of Flash Steam 36
Steam Accumulation and Storage 38
5 Steam Quality: It Matters 41
Why Steam Quality Is Important 42
Poor Steam Quality Causes and Cures 42
Steam Classifications 45
Measuring Steam Quality 47
Superheated Steam 48
6 The Steam System Design 53
Steam System Types 53
The Process Steam System: An Overview 55
7 The Steam Generator 59
The Ideal Steam Generator 60
Fossil Fuel-Fired Boilers 62
Solid Fuel-Fired Boilers 68
Electric Boilers 70
Unfired Steam Generators 73
Heat Recovery Steam Generators 74
8 Boiler Operation and Trim 75
The Packaged Boiler Concept 76
Fuel Delivery and Combustion Systems 83
Low Emissions 91
Multiple Boiler Sequencing 94
9 The Steam Delivery System 97
Steam Flow 97
Steam Distribution Piping 98
Control Valves 111
Steam Accumulation 116
Steam Filtration 120
Sensors and Meters 122
Stop and Safety Valves 123
10 The Condensate Recovery System 129
Condensate Line Sizing 131
Steam Trap Applications 134
Flash Steam Utilization 142
Condensate Collection 146
Surge Tank Application 152
11 The Feed Water System 153
Feed Water Deaeration 153
Feed Water Tanks 156
Feed Water Pumps 160
Feed Water Piping 166
12 Steam System Chemistry Control 169
Basic Water Chemistry 169
Scale Control 171
Fouling Control 174
Corrosion Control 175
Boiler Blowdown 178
Chemical Feed Systems 181
Chemistry Limits 183
Steam System Metallurgy 183
13 Mechanical Room Considerations 187
Codes and Standards 187
Steam Load Profile 190
Steam System Performance Considerations 192
Environmental Considerations 194
Boiler Room Utilities 200
14 Steam System Applications 207
Low-Pressure Steam with High Condensate Returns 209
High-Pressure Steam with High Condensate Returns 210
High- or Low-Pressure Steam with Little or No Returns 212
High-Pressure or Superheated Steam with Condensate Returns 214
Multiple Boiler Installations 215
15 Specialized Steam Equipment 223
Back Pressure Turbine 223
Steam Hydro Heater 225
Steam Superheaters 226
Steam Dump Mufflers 229
Jacketed Kettles 230
Sterilizers 230
Reboilers 231
16 Steam System Efficiency/Sustainability 233
The System Heat Balance 233
Boiler Efficiency 234
Steam System Efficiency 239
17 Shutdown, Startup, Inspection, and Maintenance 249
Shutdown and Startup Practices 249
Boiler Safety Checks 251
Maintenance and Inspection Practices 253
Boil Out and Layup Practices 257
18 Troubleshooting and Commissioning Basics 261
19 Commissioning and Troubleshooting the Steam Generator 265
20 Commissioning and Troubleshooting the Steam Delivery System 279
21 Commissioning and Troubleshooting the Condensate and Feed Water System 283
22 Commissioning and Troubleshooting the Water Treatment
Equipment 289
23 Sample Problem Sets 293
Appendix A References and Reference Information 297
Appendix B Operations, Maintenance, and Inspection Guidance 313
Appendix C Steam System Design and Commissioning Guidance 323
Appendix D Problem Set Answers 331
Index 341
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