WATER-STEAM-CONDENSED CYCLE
BOILER WATER
A steam boiler requires softened, filtered water – crystal clear, and free of impurities.
If the available water comes from a well, it will be necessary to filter it through a silica sand filter and additionally, if it contains chlorine or odors, through an activated carbon filter, in order to eliminate all of the unwanted elements. It is also recommended to check the hardness of the available water and if greater than 80 parts per million (ppm), to run it through a water softener.
It is recommended to send to check the hardness of water is available, since if it is greater than about 80 ppm, it is recommended to pass this water
through a team water softener. (If we take water clean and crystal clear, and check off your strength and if you do not pass of 80ppm, we can skip the need for the installation of a water softener. This water can be given a chemical treatment, and a scheduled system of purges).
WATER SOFTENERS
If the available water comes free of impurities and low content of chlorine, but has a hardness greater than about 80 ppm, is recommended
soften this water passing through a water softener.
This equipment in order to operate requires a minimum pressure of 15 psi. (Depending on the size, may require a pressure
enhanced up to 45 psi).
If you don't have this pressure, it will be necessary to install a device hydropneumatic you to provide us with the required pressure by
the water softener.
CONDENSATE TANK
Once softened water (without harshness), is deposited through a float valve in the receiver tank condensate
where with the help of a feed pump of water will be injected into the boiler.
It is called “condensate tank” because in addition to receiving via the float valve to the softened water, receives conden-
involved resulting from the steam that supplies the boiler to the heat exchangers or users once this steam releases its heat
or energy, going from the vapor phase to condensed water.
FEEDWATER PUMP
The boiler feedwater pump sucks the water from the condensate take and injects it with pressure into the boiler.
STEAM BOILER
In the boiler or steam generator is carried out the transfer of heat. On the one hand, get fuel to a burner that produces a flame and your combustion gases. The water of the
boiler cools the surfaces of heat transfer, raising its temperature to convert it into saturated steam at the operating pressure of the boiler.
(For example: If the boiler is working at a gauge pressure of 85 PSI, the boiler would be at an absolute pressure of approximately 99 PSI, producing steam with a temperature of approximately 327°F.
DEFINITION OF BHP (BOILER HORSE POWER)
Boiler horse power is a theoretical term defined as “the production of 34.5 pounds of saturated steam per hour at atmospheric pressure and a temperature of 212°F, using boiler feedwater (in the condensate tank) at the same temperature.” It is equivalent to a heat transmission of 8,436.56 Kcal/hour or 33,479 BTU/hour or 9.81 kW.
This calculation is entirely theoretical since boilers are normally fed water with a temperature of 158°F (when there is a good rate of condensate return in the tank) and operate at a higher pressure which requires a higher temperature to evaporate.
For example:
In a boiler that operates at 6.0 Kg/cm2 gauge pressure and is fed with water at 70°C, we will have a steam production of 14.31 Kg/hr for each Horse Boiler.
If it is fed with water at 60°C and operates at a gauge pressure of 7.0 Kg/cm2, we will have a steam production of 14.04 Kg/hr for each Horse Boiler.
For practical purposes, to a first approximation, it is advisable to calculate with a steam production of 14.0 Kg/hr for Horse Boiler. (And not with 15.64 Kg/hr theoretical).
Saturated steam, generated by the boiler, is sent to different end users. Normally, it passes through heat exchangers where it gives off its heat indirectly, and can as such achieve 100% condensate return.
*Note on Condensate Return: The amount of condensate that returns to the boiler is of utmost importance, requiring the installation of a good steam filter and a reliable steam trap in good working order. The boiler operator must continuously check that the trap is functioning correctly and that the condensates are successfully
returning – uncontaminated – to the condensate tank.
A good rate of condensate return – free of any type of contamination – enables the boiler to achieve a higher level of operating efficiency, reducing the consumption of soft water, chemical treatments, energy (as the condensates return hot), and fuel, and improving the evaporation capacity of the boiler.
If upon selecting the required boiler, you are aware that it will operate efficiently, with a high rate of condensate return, it is recommended that you order a larger condensate tank at the onset so as to avoid condensate spills in the future.
BOILER WATER QUALITY CONTROL
It is critical to carefully monitor boiler water. It should not contain even minimal amounts of acidity (corrosion), hardness (scale), contaminants, nor be subject to an ill-advised chemical treatment, as any of the above can lead to the formation of binding masses which prevent the internal surfaces of the boiler heat transfer area from cooling down. This, in turn, can cause serious damage to the boiler.
A good boiler water quality control system should include weekly, biweekly, or monthly reviews by a qualified chemical engineer, as well as the administering of a customized chemical treatment. Additionally, a scheduled system of purges is required to rid the water of sludge and chemical products resulting from preexisting contamination.
BLOWDOWN SEPARATOR TANK
The blowdown separator tank is a pressure vessel that receives the sludge and residuals extracted during the blowdowns. The extracted elements leave the boiler at the boiler working pressure and as a result, are quite dangerous.
For example: If the boiler is working at a gauge pressure of 99 PSI, then the blowdown materials leave the boiler at this pressure, the equivalent of a 230 foot column of water, which can cause serious damage to the boiler piping.
The blowdown separator tank is a high risk pressure vessel, necessary in the operation of a steam boiler and whose construction must be carried out in strict accordance with the guidelines stipulated in the ASME Code. In order to bear the force of the output of the blowdowns, it must be able to expand in small space, lowering the pressure to the drain. The hot flash steam rises and is expelled safely through the wide upper connection of the blowdown tank.
Important recommendations:
1.The design engineer of a vapor generation system must take into account the points addressed here. Especially in terms of the requirements of the water quality (softener).
2.Your calculation of requirement of steam must be based on values practical and not theoretical (14 Kg/hr by C. C.).
3.If you are going to have a high percentage of return of condensate, it is advisable to seek from the outset to a condensate tank for increased capacity.
4.The boiler room must consider the installation of a tank purges.
5.The user must be aware of the importance of steam traps and their proper operation at all times.
BOILER WATER
A steam boiler requires softened, filtered water – crystal clear, and free of impurities.
If the available water comes from a well, it will be necessary to filter it through a silica sand filter and additionally, if it contains chlorine or odors, through an activated carbon filter, in order to eliminate all of the unwanted elements. It is also recommended to check the hardness of the available water and if greater than 80 parts per million (ppm), to run it through a water softener.
Note: If the water comes from the main water line and is already clean and clear with a hardness of lower than 80 ppm, you may be able to avoid having to install a water softener and instead, treat the water with a chemical treatment and a system of scheduled blowdowns.
WATER SOFTENERS
If the available water is free of impurities and contains little chlorine, but has a hardness of greater than 80 ppm, running it through a water softener is recommended.
Water softeners require a minimum pressure of 15 PSI to operate effectively and, depending on the size, may require a pressure of up to 45 PSI.
If you don't have this pressure, it will be necessary to install a device hydropneumatic you to provide us with the required pressure by the water softener.
CONDENSATE TANK
Once the otherwise pure water has been softened, it gets deposited via a control valve into the condensate
receiver tank, from which, with the help of a feedwater pump, it is injected into the boiler.
It is called a “condensate tank” because in addition to receiving the softened water, the tank collects condensates which result from the steam that the boiler supplies to the heat exchangers or processes, once the steam transfers its heat or energy and changes from vapor to liquid water condensate.
FEEDWATER PUMP
The boiler feedwater pump sucks the water from the condensate take and injects it with pressure into the boiler.
STEAM BOILER
The heat transfer is carried out in a steam boiler. Fuel is put into a burner, which then generates a flame and combustion gases. The
boiler water cools down the heat transfer surface area as its own temperature rises until it is converted into saturated steam upon reaching the operating pressure of the boiler.
For example: If the boiler operates at a gauge pressure of 6 Kg/cm2, the boiler would be at an absolute pressure of approx. 7 Kg/cm2, taking steam with a temperature of approx. 164°C (327°F). Each Kg of evaporated water will have a heat available from approx. 493.8 Kcal/kg of latent heat to be able to give it in a heat exchanger to condense (= return to your liquid state, at the point of saturation). (You can assign a larger amount taking the heat or energy of the liquid phase and lowering its pressure by the pressure drop through the trailersbiador of heat).
DEFINITION OF BHP (BOILER HORSE POWER)
C. C. Horse Boiler is a theoretical definition and is defined as “the production of 15.64 Kg/hr (34.5 Lb/hr) of saturated steam from 100°C (212°F) and a pressure of one atmosphere, using water power (in the condensate tank) of the same temperature. This is equal to the transmission of heat from 8436.56 Kcal/hr or 33,479 BTU/hour. (=9.81 kW).
This calculation is entirely theoretical since boilers are normally fed water with a temperature of 158°F (when there is a good rate of condensate return in the tank) and operate at a higher pressure which requires a higher temperature to evaporate.
For example:
In a boiler that operates at 6.0 Kg/cm2 gauge pressure and is fed with water at 70°C, we will have a steam production of 14.31 Kg/hr for each Horse Boiler.
If it is fed with water at 60°C and operates at a gauge pressure of 7.0 Kg/cm2, we will have a steam production of 14.04 Kg/hr for each Horse Boiler.
For practical purposes, to a first approximation, it is advisable to calculate with a steam production of 14.0 Kg/hr for Horse Boiler. (And not with 15.64 Kg/hr theoretical).
The saturated steam generated by the boiler, it sends to different types of users: Normally passes through heat exchangers, where it transfers its heat in an indirect way, and where we can get up to 100% return of condensate.
*Note on Condensate Return:The amount of return condensate to the boiler is of the UTMOST IMPORTANCE. Requires the installation of a good filter and steam of a steam trap and reliable to operate in optimum state. The operator of the boiler must always be aware and check continuously the proper functioning of the trap and the full return of the condensate (without contamination) to the condensate tank.
A good return condensate (always free of any kind of contaminations) allows us to work efficiently, with a lower consumption of softened water, less use of chemical treatments, less need for energy (as condensate return hot), less amount of fuel and increased evaporation capacity on the part of the boiler.
If selecting the boiler required we are aware that we will be able to operate very efficiently with a return of condensate is very high, it is advisable to notify the manufacturer
the boiler of the need for a condensate tank for increased capacity to prevent leakage of condensate in the future.
DEFINITION OF BHP (BOILER HORSE POWER)
The water in the boiler must always be under strict control. You may not submit figures of acidity = corrosion, hardness = embedding or contaminants from a process in the
users or heat exchangers. Nor of any bad chemical treatment has been applied and form masses binders that do not allow the cooling of the surface inter-
nas transfer of heat from the boiler, being able to damage it seriously.
Requires control of quality in weekly, fortnightly or monthly by a chemical engineer, as well as the dosage of a chemical treatment-specific depending on the water quality of each user.
A good boiler water quality control system should include weekly, biweekly, or monthly reviews by a qualified chemical engineer, as well as the administering of a customized chemical treatment. Additionally, a scheduled system of purges is required to rid the water of sludge and chemical products resulting from preexisting contamination.
BLOWDOWN SEPARATOR TANK
The tank purges is a pressure vessel that receives the purges that are extracted from the boiler, sludge and wastewater. They come out of the boiler to the working pressure of the boiler, therefore, are in danger.
For example: If the boiler works at 7.0 Kg/cm2 of pressure gauge = the purges come out with this pressure equivalent to a columna water of 70 metres in height. This harms pipes so that the Official Mexican Standards require the use of a tank purges or pit to relieve this pressure.
The tank purges is a pressure vessel, high-risk necessary in the operation of steam boilers. This tank requires strict adherence to manufacturing standards code. Receive the purges of the boiler at high pressure, and must achieve its expansion in the short space. Low pressure in order to eject mud and sediment to the strainer without pressure. Because of its wide top output, expanding the hot steam which must be guided and expelled to the atmosphere in a high place and secure where there is no danger of contact with living beings or toxic chemicals or hazardous by heating (high temperature steam).
Important recommendations
1.The design engineer of a vapor generation system must take into account the points addressed here. Especially in terms of the requirements of the water quality (softener).
2.Your calculation of requirement of steam must be based on values practical and not theoretical (14 Kg/hr by C. C.).
3.If you are going to have a high percentage of return of condensate, it is advisable to seek from the outset to a condensate tank for increased capacity.
4.The boiler room must consider the installation of a tank purges.
5.The user must be aware of the importance of steam traps and their proper operation at all times.