1. Steam Systems Basics, Challenges and Troubleshooting
John Cilyo
Senior Account Executive Spirax Sarco Inc. For Steve Jalowiec, PE, CHFM

2. Steam Systems & Chaos Theory
In mathematics, chaos theory describes the behavior of certain dynamic systems – that is, systems whose states evolve with time – that may exhibit dynamics that are highly sensitive to initial conditions (popularly referred to as the butterfly effect). As a result of this sensitivity, which manifests itself as an exponential growth of perturbations in the initial conditions, the behavior of chaotic systems appears to be random. This happens even though these systems are deterministic, meaning that their future dynamics are fully defined by their initial conditions with no random elements involved. This behavior is known as deterministic chaos, or simply chaos.

3. Steam Systems & the 2nd Law
Second Law of Thermodynamics
The entropy of an isolated system not in equilibrium will tend to increase over time, approaching a maximum value at equilibrium.
In a simple manner, the second law states "energy systems have a tendency to increase their entropy rather than decrease it." This can also be stated as "heat can spontaneously flow from a higher-temperature region to a lower-temperature region, but not the other way around." (Heat can flow from cold to hot, but not spontaneously—- for example, when a refrigerator expends electrical power.)
A way of thinking about the second law for non-scientists is to consider entropy as a measure of disorder. So, for example, a broken cup has less order (more entropy) than an intact one, and it is more difficult to repair a broken cup (reducing its entropy) than to break an intact one (increasing its entropy). Likewise, solid crystals, the most organized form of matter, have very low entropy values; and gases, which are very disorganized, have high entropy values.

4. Basic Steam System

5. Another view of a Steam System

6. Steam System Basics Boiler Design
Water Tube, smaller steam space, need to be run closer to design pressure
Fire Tube, large steam chest, can be run a lower than design pressure.
Definitions
"Carryover" means that you have a problem with the TDS (total dissolved solids). You need to properly define the PPM values needed. Fire tube boilers have a normal TDS of 3000 ppm, while water tube designs need 2000 ppm. Everyone uses the 3000 ppm value regardless of boiler type and that is their first mistake.
"Priming" is a mechanical condition caused by too great of a takeoff velocity (50 to 100fpm).This is corrected mechanically.
Testing
With the boiler running, take a condensate sample from a drip pocket on the main header. If you see a high TDS value (say 2000 PPM), you have a carryover issue. If your value is 5 ppm or is immeasurable, you have priming. Remember, steam has no TDS!

7. Steam systems have many end uses in hospitals; radiators, heat exchangers, humidification but probably none as critical as Steam Sterilizers

8. Your Objectives (Challenges)
Deliver good quality steam to heating, humidification and process equipment.
Operate the system safely.
Get maximum efficiency from heating equipment - energy $$$
Maintain the system at a reasonable cost.

9. Steam Has Another Objective In Mind! (Challenges)
Condenses anywhere and everywhere it can.
Happily fills the system with air, in the worst possible locations.
Carries entrained water, gases, chemicals and dirt into every nook and cranny.
Will slow down and stop flowing as soon as differential pressure is lost.

10. Your Mission Is To Stay Ahead of Potential Problems (Challenges)
Test/maintain steam traps routinely.
Clean strainers!
Clean and maintain regulators/control valves
Routine maintenance of condensate pumps.
Keep an ear open for excess pipe-line water-hammer & correct the root-cause.
Watch for repeat instances of valve wire-draw & correct root-cause (wet steam, valve sizing)
Recognize that water hammer in heat exchangers and heating coils is correctable.

11. All it takes is money and manpower! Anyone here have enough of both?
Challenges
No problem – right?
All it takes is money and manpower!
Anyone here have enough of both?
But there is help:
Boiler Water Treatment Company
Steam Specialty Companies
Steam Consultants
Some of these can help for free, some will cost.

12. Steam System Challenges
Remember Steam Systems are dynamic systems
Never Steady State
Loads coming on and off
Sterilizers
Heating coils
Steam Absorption Chillers
Manual Building Heat (Old fashion radiators)
System Sizing
Sized for steady state or instantaneous loads (sterilizers)

13. Steam System Troubleshooting
Myths
My boilers never carry over, prime, etc.
The water level is always steady in the gauge glass.
I don’t need trap maintenance, failed traps will become apparent on their own. (The water hammer will tell me about a bad trap.)
Boiler water treatment is a scam.
Boiler blow-down wastes energy and water.

14. Steam System Troubleshooting
Steam System Chemistry
Feed Water Quality
Softener
Deaerator
Dissolved O2 and non-condensable gases
Chemical Treatment
Totaled Dissolved Solids (TDS)
Blow down
Continuous Surface
Bottom Blow Down

15. Typical Steam System Chemistry
(May vary with chemical supplier and boiler manufacturer)
Test
Typical
Limits
Low/Hi
Softener
Feedwater
Boiler
Condensate Return
Deaerator pH
See chart
> 8.5
8.3 – 9.4
Sulfite % So2
(Higher in lay-up)
30/60 XX
Alkalinity P
200/400
Alkalinity M
250/500
Silica
Monitor trends
< 150 mg/L
Conductivity
3000/3500
Calcium
< 0.3/FW
Iron
< 0.1/FW
Copper
< 0.05/FW
Primary
Treatment Chem.
Per
mfg
Dissolved O2
7 ppb

16. Typical Boiler Water Treatment Test Report (partial)
Courtesy of Barclay Water Management, Inc.

17. Steam System Troubleshooting
Water Level Control
Sight glass levels are not reliable
Variable feed versus on/off
Steam Flow Metering & Data
Data is invaluable for system troubleshooting “
You cannot manage what you
cannot measure”
Lord Kelvin

18. Why is proper condensate drainage important?

19. Water hammer!
Result of a drip trap being removed, that was draining a 100 psig line, before a valve

20. Steam System Troubleshooting
Steam Traps
Properly located
Drip Legs properly sized
Trap Selection and sizing
Steam Trap Testing & Maintenance

21. Steam System Troubleshooting
Steam Traps
Main Header Main header drip legs are full size
Other drip legs are properly sized
Drips located 300’ or less and any change of elevation
Drip stations located ahead of automatic valves
Steam traps are properly sized
Steam traps are working and maintained
Missing insulation
heat goes to cold
another consequence of the 2nd law thermodynamics!

23. Ineffective vs Proper Drain Points
Steam Flow
Condensate
Cross Section
Correct 
Incorrect 
Full Diameter Pocket
Steam Trap Set
Steam Flow
Cross Section
Steam Trap Set

24. Steam System Troubleshooting
Steam Trap Testing
Visual *
Temperature **
Ultrasonic ***
Continuous monitoring systems ****
conductivity

25. Steam System Troubleshooting
Belts & suspenders
Steam separators & filters
Dry Steam
Wet Steam
Condensate Outlet

26. Steam Conditioning Dry Steam saves energy
Example: Process requires 4,645,000 Btu’s / hr
Available: 30 psig 274oF
@ 100% Dry (saturated) steam supplies 929 Btu / lb.  process requires 5,000 lb/hr.
@ 90% Dryness Fraction, steam supplies 836 Btu/lb.  process now requires 5556 lb /hr. A 11% Increase
@ 80% Dryness Fraction, steam supplies 743 Btu/lb  process now requires 6251 lb /hr. A 25% increase

27. Steam System Troubleshooting
Condensate equipment operating properly
Pumps
Flash tanks
Loads
Varying loads
Instantaneous loads - Sterilizers

28. Steam System Troubleshooting Now what do I do
If you suddenly have problems
What has changed?
Go back to basics
Start at the boiler plant and work your way out into the system
Left Hand Analysis

29. Courtesy of Walt Graham Thermo Diagnostics, Co, LLC

30. Now what do I do Steam Trap Repairs Steam Trap Survey & Assessment
Steam Trap Maintenance Program
Boiler Water Treatment Modification
Steam Conditioning Equipment
Separators
Filters
Repair damaged insulation
Steam Metering (for troubleshooting)

31. Thank you! Questions or Comments Special Thanks to
John Cilyo, Spirax Sarco
William Wethey, Barclay Water Management
Contact Information
Steve Jalowiec, PE, CHFM
Waterbury Hospital, 64 Robbins Street, Waterbury CT
Work
Cell