STEAM SYSTEMS eHANDBOOK

STRATEGIZE YOUR
STEAM SYSTEMS
 www.chemicalprocessing.com

TABLE OF CONTENTS
Make the Most of Blowdown 5
Recovering thermal energy from flash steam offers energy-saving opportunities
Plant Combats Corrosion in Idled Boilers 8
Several measures provide proper protection of off-line steam generators
Get a Hold of Steam System Management 15
Software helps to maximize equipment reliability, efficiency and safety
Resources 18

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STEAM SYSTEMS eHANDBOOK: Strategize Your Steam Systems 2

AD INDEX

Armstrong International www.armstronginternational.com4

Check-All Valve Mfg. Co. www.epiccheckvalves.com 7

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PRODUCT FOCUS

VALVES OPERATE IN ANY FLOW ORIENTATION

Features ease installation and minimize pressure drop

T he Epic series check valve prod-

uct offering consists of in-line
spring-loaded poppet-type check
valves designed to be cost effective,
simple, rugged and efficient while
operating in any flow orientation.
The valves are machined from 300
series stainless steel bar stock with
Aflas seat/seals and a 1/2-psi stain-
less steel spring (cracking pressure).
It is streamlined so that media flows
through the valve over smooth, contoured surfaces with a minimum change in direction. The
check valve also achieves a high flow capacity and reduced pressure loss compared to other
poppet style check valves of similar sized connections. These features minimize the pressure
drop across the valve. The valve closes quickly and smoothly for silent operation and eliminates
water hammer.

The series incorporates a replaceable drop-in check mechanism (Replaceable Insert Kit sold
separately) that installs into the existing body without requiring additional assembly of separate
checking components. This pre-assembled complete check mechanism eliminates the need to
assemble individual checking components, creating an efficient and economical method of ef-
fectively rebuilding the entire check mechanism, if an application requires, the company says.
The check valves are suited for a range of applications in liquids, gases and steam.

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STEAM SYSTEMS eHANDBOOK: Strategize Your Steam Systems 3

 www.chemicalprocessing.com

Make the Most of Blowdown

Recovering thermal energy from flash steam offers energy-saving opportunities

By Riyaz Papar

I
rrespective of how steam is produced in tube leaks and failures, foaming resulting
in our process plants, several aspects in liquid carryover, loose sludge in the boiler
of steam generation are common; we water, etc. All of these problems could dam-
should apply standard best practices to age boiler integrity. Blowdown is the primary
them. This column specifically addresses mechanism that controls the water chemistry
the blowdown stream as well as both the of the boiler water. It regulates the concentra-
flash steam recovery and heat recovery that tion of dissolved and precipitated chemicals in
we should implement in our steam systems. the boiler and, thus, ensures steam generation
equipment functions reliably.
Every steam system has a water treatment
plant; feedwater is made up of treated make- Generally, boiler water conductivity or total
up water, returned condensate and directly in- dissolved solids is used to control blowdown,
jected steam (in the deaerator). Although the but as our steam systems get more complex,
condensate and steam are clean, the treated other parameters pH, silica, iron, etc.
makeup water still brings in dissolved impuri- also are used as secondary control points.
ties. Because these impurities are not soluble In the past 25 years, I have seen blowdown
in steam, they remain in the boiler. As a result, rates as low as 1% and in some instances as
their concentration builds and can lead to high as 15%. Blowdown rate depends on sev-
serious operational problems such as scal- eral factors; however, I will not be covering
ing on the water-side of the tubes resulting blowdown rate in this column. Please work

STEAM SYSTEMS eHANDBOOK: Strategize Your Steam Systems 5

 www.chemicalprocessing.com

with your water chemist to ensure you have occasions, I have been able to source it from
everything in place to minimize blowdown. within a plants operations that are no longer
in service. The remainder of the liquid water
CAPTURE THERMAL ENERGY from the flash tank is still hot (>225F) and
Blowdown, because it is saturated liquid can be used to exchange heat in a simple
water at steam generation pressure, con- one-pass shell-and-tube heat exchanger or a
tains a significant amount of thermal ener- plate-and-frame unit, etc. This can be used to
gy. The higher the steam generation pres- heat the makeup water going to the deaera-
sure, the higher the saturation (blowdown) tor, thereby saving on overall steam demand
temperature and the higher the thermal from utilities.
energy (Btu/lb) associated with the blow-
down. As blowdown is discharged from the Also, I have faced some challenges in plants
boiler, this thermal energy (provided by the when I tried implementing blowdown thermal
fuel or from another source) is lost. There- energy recovery. Most relate to past incorrect
fore, reducing the amount of blowdown to applications, such as a large U-tube heat
the bare minimum is an excellent best prac- exchanger used to recover heat from blow-
tice; beyond that we need to look at other down that fouled and eventually was taken
mechanisms to capture lost energy. out of service because it became a mainte-
nance headache. In other plants, because
So, that brings us to creating and recover- there is so much excess low-pressure steam,
ing flash steam from blowdown and then, if managers claim theres no benefit of low-
economically justifiable, recovering heat from pressure, low-temperature heat recovery. This
the liquid water before discharge. The sim- is not necessarily true; technologies exist to
plest configuration is to first take the blow- upgrade low-pressure steam and make use of
down stream into a flash tank whose pressure every Btu that would otherwise be lost. I
is slightly higher than either the deaerator realize the overall blowdown energy recovery
pressure or the lowest-pressure steam header and cost savings may not be huge (<2%) but,
in the steam generation area. The blowdown as one of the simplest and most cost-effective
flashes and produces low-pressure steam best practices, it should never be ignored!
that can be recovered and used within the (For more on improving boiler management
steam system to offset deaerator steam to help save energy, see Optimize Boiler
demand. Recovering flash steam accounts for Loads, http://goo.gl/z9c1M1 and Dont Get
6570% of the total blowdown stream energy Steamed, http://goo.gl/xoUQSM.)
that would otherwise have been lost. Inter-
estingly, the flash tank is a simple piece of RIYAZ PAPAR is a former CP energy columnist. He can

equipment with no moving parts. On several be reached at rpapar@hudsontech.com.

STEAM SYSTEMS eHANDBOOK: Strategize Your Steam Systems 6

The EPIC Check Valves Get Up To Steam

Check Valves With a World of Possibilities!

Pre-assembled
Drop-in Replaceable
Check Mechanism

Patent
Pending

Manufactured in West Des Moines, Iowa, USA

by Check-All Valve Mfg., Co.
www.epiccheckvalves.com sales@epiccheckvalves.com

Check-All Valve Mfg. Co. is proud to introduce a This pre-assembled complete check mechanism
new check valve product offering with a world of eliminates the need to assemble individual checking
possibilities. The EPIC series consists of in-line components, creating an efficient and economical
spring-loaded poppet-type check valves that are method of effectively rebuilding the entire check
designed to be cost effective, simple, rugged and mechanism, if an application requires.
efficient while operating in any flow orientation.
The EPIC is machined from 300 series stainless Due to the materials of construction, high flow
steel bar stock with Aflas seat/seals and a 1/2-PSI capacity, complete repairability and the quality
stainless steel spring (cracking pressure). These customers have come to expect from Check-All, the
materials of construction are excellent for steam EPIC check valves are uniquely suited for a very
applications. The check valve also achieves a high wide range of applications in liquids, gases and
flow capacity and reduced pressure loss compared steam.
to other poppet style check valves of similar sized
connections. These features minimize the pressure See us on the web at:
drop across the valve. Available connection options http://www.epiccheckvalves.com
are FNPT, MNPT, flared tube, and double ferule
compression tube. For additional information and a free brochure
contact:
Additionally, the EPIC series incorporates a
replaceable drop-in check mechanism (Replaceable Phone: 515-224-2301
Insert Kit sold separately) that is easily installed Fax: 515-224-2326
into the existing body without requiring additional Email: sales@epiccheckvalves.com
assembly of separate checking components.
 www.chemicalprocessing.com

Plant Combats Corrosion

in Idled Boilers
Several measures provide proper protection of off-line steam generators

By Brad Buecker, Kiewit Engineering and Design Co., and Dan Dixon,
Lincoln Electric System

S
team generation plays a critical role BACKGROUND
at many industrial facilities. Unfor- The Terry Bundy plant has three GE
tunately, the high-temperature and LM6000 combustion turbines, two of which
high-pressure environment of large steam are equipped with heat recovery steam
generators makes them susceptible to generators (HRSGs) that drive a supple-
corrosion. Even seemingly minor impurity mental steam turbine. Total plant capacity
ingress can cause problems [1]. Fortunately, is 170 MW. The units cycle on and off, often
plants can take advantage of a lot of les- on a daily basis during the summer, accord-
sons learned about preventing corrosion in ing to the requirements of the South West
boilers. However, an often overlooked issue Power Pool. At other times, a unit may be
is the risk of severe corrosion occurring dur- down for several days or perhaps even
ing those times when a steam generator is weeks during periods of mild weather or for
down due to lack of steam demand or for maintenance outages.
maintenance. This article outlines several
techniques for protecting steam generators For normal operating chemistry, the HRSG
at these times. Our examples come from feedwater is on an all-volatile treatment oxi-
a power plant, Lincoln Electric Systems dizing [AVT(O)] program, with ammonium
Terry Bundy Generating Station in Lincoln, hydroxide injection to maintain feedwater
Nebraska, but the technologies suit process pH within a 9.610 range. High-pressure
plants as well. evaporator chemistry complies with the

STEAM SYSTEMS eHANDBOOK: Strategize Your Steam Systems 8

 www.chemicalprocessing.com

Electric Power Research Institutes phos-

phate guidelines, with trisodium phosphate OXYGEN CORROSION
Figure 1. Oxygen can cause severe pitting
as the only phosphate species and control
that can penetrate the wall of a steam gen-
within a 13 ppm range. The high-pressure erator tube. Source: ChemTreat.

evaporator pH control range is 9.510. Free

caustic concentrations are maintained at or
below 1 ppm to minimize the risk of caustic
gouging.

For short-term outages, the HRSGs must

remain full of condensate to enable quick
startup. On the other hand, a maintenance tubes leads to loss of thermal efficiency
outage requires draining of the unit, prefer- and, most importantly, establishes sites for
ably while it is hot so it flash-dries. How- under-deposit corrosion, such as very in-
ever, even such drying still leaves some sidious hydrogen damage, acid phosphate
areas exposed to moist conditions and, corrosion (in units with poorly maintained
thus, vulnerable unless additional protective or monitored chemistry see: Dont Get
methods are used. Steamed, http://goo.gl/XPhl7s), and caus-
tic gouging [2].
The equipment and processes outlined
below all are designed to protect the unit Oxygen also can infiltrate steam genera-
from oxygen corrosion during any outage. tors at startup when collected condensate
Oxygen attack is extremely serious. or fresh demineralized water is needed for
filling or boiler top-off. These high-purity
The corrosion mechanism can induce severe waters typically are stored in atmospheri-
metal loss in those areas of high oxygen cally vented tanks. The water absorbs
concentration. The attack often takes the oxygen and carbon dioxide, often to the
form of pitting (Figure 1), where the con- saturation point, which may be up to 8 ppm
centrated corrosion can cause through-wall in the case of oxygen. When the makeup is
penetration and equipment failure in a short injected into a cold steam generator, signifi-
period of time. cant oxygen attack is possible.

In addition, oxygen attack will generate KEY MEASURES

corrosion products that then carry over To prevent oxygen ingress and corrosion,
to the steam generator during startups. the Terry Bundy combined-cycle plant
Deposition of iron oxides in the waterwall relies on four of the best techniques: nitro-

STEAM SYSTEMS eHANDBOOK: Strategize Your Steam Systems 9

 www.chemicalprocessing.com

gen blanketing; periodic water circulation;

dissolved oxygen removal from makeup NITROGEN GENERATOR
Figure 2. Unit uses a carbon molecule sieve
condensate and demineralized water; and
to separate nitrogen from air. Source: Lincoln
warm air recirculation to protect the low- Electric System.

pressure turbine.

Nitrogen blanketing. The first and fore-

most measure is nitrogen blanketing dur-
ing shutdown and subsequent short-term
layups. Experience has shown that intro-
ducing nitrogen to key points in the system
before the pressure has totally decayed will
minimize ingress of air. Then, as the system
continues to cool, only nitrogen enters, not
oxygen-laden air. Key points for nitrogen The process relies on a carbon molecular
protection in HRSGs include the evaporator, sieve that, when compressed air is intro-
economizer and feedwater circuits. duced at high pressure, adsorbs oxygen,
carbon dioxide and water vapor but allows
The nitrogen blanketing system was in- nitrogen to pass through (Figure 2). The
stalled in 2005, just a few years after the nitrogen then can be collected in a receiver
steam generators startup, when plant for use as needed. At a preselected interval,
personnel discovered oxygen pitting in one pressure is released from the unit; O2, CO2,
of the high-pressure evaporators as well as and H2O desorb from the material and are
other corrosion. vented to atmosphere. The nitrogen purity
from this system depends upon production
One question that often arises is how best rate, and ranges from 1,000 scfh at 99.5%
to supply nitrogen. Certainly local gas-sup- purity to 248 scfh at 99.99% purity.
ply or welding firms can provide bottles
of compressed nitrogen. Liquid nitrogen The Terry Bundy N2 generator supplies
is another possibility. Terry Bundy person- 5-psig nitrogen to the low-pressure and
nel selected a different method, nitrogen high-pressure drums during wet layups; the
generation via a pressure-swing adsorp- nitrogen also serves to push water from
tion (PSA) system. (For more on such an HRSG during dry layup draining. A nitro-
units for nitrogen generation, see: Rethink gen pressure of 5 psig is maintained during
Nitrogen Supply for Chemical Blanketing, the dry layup, provided no major tube work
http://goo.gl/btiSw3.) is required.

STEAM SYSTEMS eHANDBOOK: Strategize Your Steam Systems 10

 www.chemicalprocessing.com

An obvious major concern with nitrogen

blanketing and why some plants dont DISSOLVED OXYGEN REMOVAL
Figure 3. Hollow-fiber membranes eliminate
use it is safety. Nitrogen is an asphyxi-
oxygen in condensate return and makeup
ating agent and requires strict adherence water. Source: Lincoln Electric System.

to confined-space entry procedures and

proper ventilation of the space.

Periodic water circulation. This is another

important point with regard to wet layup
chemistry. Regular water movement mini-
mizes stagnant conditions that can con-
centrate oxygen in localized areas to cause
pitting. Both Terry Bundy HRSGs have cir-
culating systems installed on the high- and
low-pressure circuits for use during wet Dissolved oxygen removal from condensate
layups. Each circuit uses one of two redun- and makeup water. Because demineralized
dant preheater recirculation pumps, which water commonly is stored in atmospheri-
normally are in service during HRSG opera- cally vented tanks, oxygen-laden water
tion to mitigate acid dew point corrosion enters the steam generator during normal
of external circuits. Each pump provides operation and, even more critically, during
approximately 100 gpm per circuit. Valves boiler filling. In the latter case, the influx
and piping have been added to enable of cold oxygen-saturated water can cause
seamless transition from layup circula- severe difficulties. One possible method
tion to normal operation. Sample/injection to minimize this problem is to limit oxygen
systems allow operators to test the layup ingress to storage tanks but this typically
chemistry for pH and dissolved oxygen is a difficult proposition. So, instead, Terry
(using colorimetric ampules), and to inject Bundy personnel selected a gas-transfer
ammonium hydroxide if the pH must be membrane technology to treat condensate
raised. In addition, modifications made in return and makeup water (Figure 3).
each boiler drum permit the layup water to
bypass the drum baffle, promoting circu- The oxygen-laden water flows along hollow-
lation and minimizing short-circuiting via fiber membranes that let dissolved gases
the downcomers. The pumps typically are pass through but not the water. A sweep
started once drum pressure drops below gas, often nitrogen, flows along the opposite
50 psig, and remain in service for the dura- surface of the membranes and carries away
tion of the layup. the gases. The technology can reduce the

STEAM SYSTEMS eHANDBOOK: Strategize Your Steam Systems 11

 www.chemicalprocessing.com

DEHUMIDIFIER
Figure 4. Desiccant wheel
unit provides air with only
10% humidity to condenser
and low-pressure turbine.
Source: Lincoln Electric System.

dissolved oxygen concentration from satu- blades in steam turbines typically collect
rated conditions to less than 10 ppb. salts that carry over with steam from boiler
drums. The combination of a moisture-laden
DONT FORGET THE STEAM atmosphere and these salt deposits can fos-
TURBINE ter pitting and stress corrosion cracking.
Far too often in the power industry, plants
allow the condenser hotwell to remain A very practical method to combat this cor-
moist or even contain standing water dur- rosion, and the one adopted at Terry Bundy,
ing outages in which the condenser vacuum is injection of desiccated air into the condens-
was broken and air entered the condenser er during all but short-term, i.e., <72 h, layups.
and low-pressure turbine. The low-pressure This system uses a desiccant wheel dehu-

RELATED CONTENT ON CHEMICALPROCESSING.COM

Dont Get Steamed, http://goo.gl/XPhl7s

Keep Out of Hot Water, http://goo.gl/LFlVig

Rethink Nitrogen Supply for Chemical Blanketing, http://goo.gl/btiSw3

Plants Pit New Tools Against Corrosion, http://goo.gl/T2Vqj3

Should You Revamp or Replace Your Boiler?, http://goo.gl/5aahSG

STEAM SYSTEMS eHANDBOOK: Strategize Your Steam Systems 12

 www.chemicalprocessing.com

REFERENCES

1. Buecker, B., The Importance of Steam Generation Chemistry Control and Monitoring as Il-

lustrated by Case Histories, IWC 1510, Proceedings, 76th Ann. Intl. Water Conf., Orlando, Fla.

(Nov. 15-19, 2015).

2. Cycle Chemistry Guidelines for Shutdown, Layup and Startup of Combined Cycle Units with

Heat Recovery Steam Generators, Electric Power Research Inst., Palo Alto, Calif. (2006),

downloadable at http://goo.gl/85TxVl.

midifier (Figure 4) to provide 700 scfm of

100F air at 10% humidity to the condenser FOLLOW-UP INSPECTION
Figure 5. Check conducted three years after
and low-pressure turbine. This flow can low-
measures were implemented showed no
er the relative humidity from nearly 100% to new pitting. Source: Lincoln Electric System.

less than 30% in just a few hours.

IMPRESSIVE RESULTS
In 2005, drum inspections showed signifi-
cant pitting. This prompted implement-
ing the changes weve outlined. A repeat
inspection in 2008 showed no new pitting
(Figure 5). Subsequent inspections continue
to show little to no additional pitting.

Iron level monitoring, via particulate collec- the plant six hours (over dry layup) to
tion on 0.45-micron filters, showed a reach full load when needed.
significant decrease in samples from the
condensate pump discharge and both BRAD BUECKER is a process specialist for Kiewit Engi-

low-pressure and high-pressure drums. neering and Design Co., Lenexa, Ks. DAN DIXON is su-

Quicker startups than in the past are now pervisor, inter-local projects, for Lincoln Electric System,

commonplace. In addition and of significant Lincoln, Neb. E-mail them at Brad.Bueker@kiewit.com

importance, the units can be left in wet and ddixon@les.com.

layup for extended periods, which saves

STEAM SYSTEMS eHANDBOOK: Strategize Your Steam Systems 13

 LARRY SCHUBERT
FLAT LINED!
(and feels like a million bucks...)
Actually, the first thing he felt was relieved. Because Larry finally discovered absolute precision
temperature control for all his chemical processing. Thanks to Pick Direct Steam Injection Heaters, now
his process temperature graphs show one, long, beautiful, flat line. Thats because Picks exceptional
temperature control automatically holds discharge temperatures to extremely close tolerances within
1C or less, while providing rapid response to changing process conditions.

Whether you require jacketed heating or other process liquid heating applications, Pick eliminates BTU
losses for 100% energy efficiency. This alone could save Larrys company up to 20% in fuel costs. In
addition, Picks compact design along with its ease of maintenance, saves valuable space and invaluable
down time. All this, combined with an unlimited supply
of hot water, low water pressure drop, the lowest
OSHA noise level, and the widest operating range of
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flat lining can do to a guy.

262.338.1191
E-mail: info1@pickheaters.com
www.pickheaters.com
 www.chemicalprocessing.com

Get a Hold of Steam System

Management
Software helps to maximize equipment reliability, efficiency and safety

R
efineries and other chemical Escalating repair costs
plants frequently miss or have Increasing unit freeze-up issues
a delayed response to critical The inability to distinguish easily between
issues in daily operations due to failed working and nonworking steam traps
steam traps. However, failed steam traps The inability to generate work lists for
are often viewed as a routine part of run- repairs resulting from an incomplete
ning a plant or the cost of production. database
While steam traps play a crucial role in Inappropriate or insufficient repair tracking
plantwide safety, equipment reliability
and product quality, they also can cause Steam trap management can be a cum-
production interruptions if not maintained bersome task for refineries that house
properly. 2,000 to 10,000 traps, so the ability to
manage steam traps while generating data
STEAM SYSTEM CHALLENGES collection is advantageous. Without a
Refineries often experience daily issues steam system management tool, refineries
due to a lack of steam system and steam are unable to generate reports for failed
trap management. Some of the problems traps or seasonal shutoffs or provide
encountered include: reports by area or site. They also have no
Injuries and incidents related to steam access to consistent information in real
tracing time.

STEAM SYSTEMS eHANDBOOK: Strategize Your Steam Systems 15

 www.chemicalprocessing.com

Steam system monitoring software can

help refineries keep a close eye on their MOBILE APP
Figure 1. Steam system management can be
steam traps. The software uses algorithms
carried out from the palm of your hand. This
to analyze steam trap data to track be- screen shows which traps have been tested
along with pictures and trap conditions.
havior and performance for steam system
management. It tests, records, tracks and
reports on plant steam systems so that
refineries and other chemical plants can
manage multiple sites and various steam
trap types while decreasing the overall
time required for data collection, record-
ing and reporting.

MONITORING STEAM TRAPS

To address such issues, a U.S. refinery
with a capacity of 125,000 bbl/d of crude
oil turned to Sage for help with managing
9,010 steam traps. Within the first six to
eight months of starting the program, the
refinery documented savings of more than
$5 million as well as reductions in energy
and steam costs.

The software is designed to be intuitive

to use and easily accessible by an exclu-
sive mobile app (Figure 1). It offers tight payback period, and CO2 emissions.
security, instant notifications and precise
documentation and can accommodate The softwares Team System, provides
companies of any size. It allows refineries a facility summary of steam trap system
to increase equipment reliability, efficien- performance rate and daily losses. It also
cy and safety, while enabling reductions in alerts users with system notifications that
environmental emissions. Reports gener- allow for easy identification of problems
ated provide a totalized summary of se- and maintenance of equipment. It also
lected data in any of the following catego- shows annual steam loss a 12-month
ries: monetary loss, fuel used, repair cost, view of steam and monetary loss (Figure

STEAM SYSTEMS eHANDBOOK: Strategize Your Steam Systems 16

 www.chemicalprocessing.com

Steam System Monitoring Software

Look for steam trap monitoring technology tions of a certain area;

that offers features such as these that may Inventory, categorization and tracking of

be beneficial to refineries: the entire steam trap population;

Cloud-based data that provides access to Surveying, tagging and identification of

historical information for all steam traps as steam traps and in-house surveys and par-

needed, by individual location or area, for tial surveys of the traps, including photos

multiple sites, with no need to load specific of individual traps;

routes; Repair list generation;

Steam trap failure prediction based on Active steam trap testing;

historical data; Seasonal steam trap viewing and identifi-

Determine of the most appropriate steam cation of traps to be shut off;

trap for an application or unique condi- CO2 footprint monitoring.

REFINERY SEES INCREASED

DASHBOARD EFFICIENCIES
Figure 2. The dashboard displays hot water
The refinery now has access to the right
information, steam loss data and alerts.
information at the right time and by the
right people. The software improved the
refinerys ability to find and repair steam
leaks, including those not associated with
steam traps, and, as a result, it has re-
duced its steam trap failure rate signifi-
cantly. The refinerys required steam
production also has been reduced sub-
stantially, and the steam system runs with
increased efficiency and less waste.

2). Sage is engineered to work seamlessly ARMSTRONG INTERNATIONAL is a private, fifth-

with all of Armstrongs real-time monitor- generation family-owned company that provides

ing products (SteamEye, AIM, and The intelligent system solutions that improve utility

Brain), to ensure it has access to the most performance, lower energy consumption and reduce

current steam system data. environmental emissions.

STEAM SYSTEMS eHANDBOOK: Strategize Your Steam Systems 17

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Have a question on a technical issue that needs to be ad-
Jerry King. Click on an image and you
dressed? Visit our Ask the Experts forum. Covering topics
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STEAM SYSTEMS eHANDBOOK: Strategize Your Steam Systems 18