How Much Steam is Really in Your "Steam"?

If you could find extra BTUs in your heat exchanger steam supply, wouldn’t you jump at the chance? ?Our friends at TLV have the answer to your poor-quality steam supply issues and it’s their DC- series steam/moisture separators with integral steam traps.

Almost all steam has some entrained moisture due to the impacts of boiler carryover, undersized steam main drip pockets, failed (or missing) steam traps on the supply headers or poor thermal insulation. In many cases, it’s a combination of all of these issues that cause reduced heat transfer performance in your critical heat exchanger equipment.

Sudden fluctuations in boiler loads can cause carryover that puts water in the steam flow. Here in the Deep South of the USA, sudden rain showers can bring on boiler carryover due to the sudden cooling of exposed steam piping and related components that suddenly condense steam, leading to increased boiler demand.

In many cases, the steam main drip pockets designed to allow condensate to collect and gravity drain to an appropriate steam trap are undersized. For example, a 6 inch steam main should have a drip pocket that is the same size as the main: 6 inch. We frequently see drip pockets on steam mains that are as much as three or four sizes smaller than the main pipe size. Since the steam flow moves at a rapid rate, this means that the condensate is moving just as quickly and can flow right over the opening of the undersized drip pocket.

Steam traps that service these drip legs should be appropriate for the steam conditions and installed in accordance with the manufacturer’s instructions. And they should be frequently tested by a competent steam trap surveyor using the correct equipment and methods. ?We have found steam traps in a state of closed failure on numerous supply header drip legs which can cause condensate backup into the steam header.

Thermal insulation does its part to reduce radiant heat losses, too but its effectiveness can be reduced over time due to moisture intrusion through damaged weather barriers. And in some cases, insulation is just missing.

Moisture-laden steam is problematic especially where steam makes direct with the product, such as found in food processing or in rubber or fabric products. And wet steam will damage components such as control valve trim and steam turbine blades.

Marspec Technical Products recommends the use of TLV DC3S steam separators to remove entrained condensate from the steam flow. In fact, these highly engineered devices are capable of mechanically removing up to 98% of entrained moisture in the steam flow. For heat exchange applications, this means that more BTUs are delivered where they are needed while extending the life of inlet control valves and other heat exchanger system components.

And TLV DC3S steam/moisture separators are equipped with a time-proven free float steam trap built into the separator body. Simply pipe the condensate to the appropriate return line.

TLV has this same advanced steam and moisture separation technology built into a family of steam pressure control valves, too. The COSPECT range of valves offers pressure control, steam separation and condensate discharge in one compact package. You can specify manual pressure setting, as well as electric or pneumatic control from your process control system.

Marspec Technical Products can help you improve the quality of your heat exchanger steam supply. Give us a call for the details about these groundbreaking products.