Polytechnic University of the Philippines

Sta. Mesa, Manila

ENGINEERING UTILITES 2 (BASIC MECHANICAL ENGINEERING)
First Semester AY: 2020-2021
Module # 03

3-1. About the Module

3-1.1 Overview

Throughout history, mankind has reached beyond the acceptable to pursue a challenge,
achieving significant accomplishments and developing new technology. This process is both
scientific and creative. Entire civilizations, organizations, and most notably, individuals have
succeeded by simply doing what has never been done before. A prime example is the safe and
efficient use of steam.

One of the most significant series of events shaping today’s world is the industrial revolution that
began in the late seventeenth century. The desire to generate steam on demand sparked this
revolution, and technical advances in steam generation allowed it to continue. Without these
developments, the industrial revolution as we know it would not have taken place.

It is therefore appropriate to say that few technologies developed through human ingenuity have
done so much to advance mankind as the safe and dependable generation of steam.

3-1.2 Module Objectives

After completing this module, the student must be able to:

• Understand how steam is generated and used.
• Understand how steam is distributed and know the key components of the system.
• Understand how the condensate is recovered/utilized and re-circulated into the boiler.
• Draw a simple steam distribution system
3-1.3 Course Materials

To complement this learning module, the students are advised to read/watch the following
resources listed below.

Section I – III: Steam Fundamentals, Generation from Chemical Energy, & Applications
Kitto J.B., and Stultz S.C. (2005). Steam, Its Generation and Use. The Babcock & Wilcox
Company. USA

Guidelines for Steam System Efficiency

https://www.youtube.com/watch?v=6AkTNNqwtaE

Webinar: Steam System Energy Efficiency – Getting Started

https://www.youtube.com/watch?v=zgndUmJ4p_M

Boilers Basic Principles & Types | Piping Analysis

https://www.youtube.com/watch?v=nxvav0Ijd4E

3-1.4 Topics

Steam Generation and Condensate Distribution Systems

Steam Generation, Steam Distribution Economy and Optimization, Steam Traps Utilization and
Efficiency, Condensate Recovery Utilization,
3-2. Steam Generation

Today’s steam plants are a complex and highly sophisticated combination of engineered
elements. Heat is obtained either from primary fossil fuels like coal, oil or natural gas, or from
nuclear fuel in the form of uranium. Other sources of heat-producing energy include waste heat
and exhaust gases, bagasse, and biomass, spent chemicals and municipal waste, and
geothermal and solar energy.

Each fuel contains potential energy, or a heating value measured in Btu/lb (J/kg). The goal is to
release this energy, most often by a controlled combustion process or, with uranium, through
fission. The heat is then transferred to water through tube walls and other components or
liquids. The heated water then changes form, turning into steam. The steam is normally heated
further to specific temperatures and pressures.

Steam is also a vital resource in industry. It drives pumps and valves, helps produce paper and
wood products, prepares foods, and heats and cools large buildings and institutions. Steam also
propels much of the world’s naval fleets and a high percentage of commercial marine transport.
In some countries, steam plays a continuing role in railway transportation. Steam generators,
commonly referred to as boilers, range in size from those needed to heat a small building to
those used individually to produce 1300 megawatts of electricity in a power generating station –
enough power for more than one million people. These larger units deliver more than ten million
pounds of superheated steam per hour (1260 kg/s) with steam temperatures exceeding 1000F
(538C) and pressures exceeding 3800 psi (26.2 MPa).

Today’s steam generating systems owe their dependability and safety to the design, fabrication
and operation of safe boilers Because the production of steam power is a tremendous resource,
it is our challenge and responsibility to further develop and use this resource safely, efficiently,
dependably, and in an environmentally-friendly manner.

3-2.1 Fire Tube Boilers

Fire tube boilers are steam generators which hot combustion gases were passed through tubes
inserted into the water container, increasing the surface area through which heat could be
transferred. The saturated steam was led out from the top. The main use was to run steam
engines for motive power: It was used to power steamboats, railroad engines and run industrial
machinery via belt drives. Fire-tube boilers were limited in capacity and pressure and were also,
sometimes, dangerously explosive.

Fire Tube Boiler

3-2.2 Water Tube Boiler

The water tube boiler was patented in 1867 by the American inventors George Herman Babcock
and Stephen Wilcox. The boiler had larger heating surfaces, allowed better water circulation,
and, most noteworthy, reduced the risk of explosion drastically. In the water-tube boiler, water
flowed through tubes heated externally by combustion gases through radiation and convection
and steam was collected above in a drum. The large number of tubes and use of cross gas flow
increases the heat transfer rate. Boilers of this type could be built with larger heat transfer
surface per unit of working fluid than the previous design. Due to the higher rate of heat transfer
cooler flue gases could be used. Tubes could be made inexpensively and with higher quality
than plate.

The water-tube boiler became the standard for all large boilers as they allowed for higher
pressures than earlier boilers as well. Their first use was to run the largest steam machines, but
it quickly became the boiler type of choice for a steam turbine.

Two Drum Water Tube Boiler

3-2.3 Steam Generation Cycle

The steam boiler provides steam to a heat consumer, usually to power an engine. In a steam
power plant for example, a steam turbine is used for extracting the heat from the steam and
turning it into work. The turbine usually drives a generator that turns the work from the turbine
into electricity. The steam, used by the turbine, can be recycled by cooling it until it condensates
into water and then return it as feedwater to the boiler. The condenser, where the steam is
condensed, is a heat exchanger that typically uses water from a nearby sea or a river to cool the
steam. In a typical power plant, the pressure, at which the steam is produced, is high. But when
the steam has been used to drive the turbine, the pressure has dropped drastically. A pump is
therefore needed to get the pressure back up. Since the work needed to compress a fluid is
about a hundred times less than the work needed to compress a gas, the pump is located after
the condenser. The cycle that the described process forms, is called a Rankine cycle and is the
basis of most modern steam power plant processes.
Rankine Cycle

3-3. Steam Distribution

After steam is generated by boilers, it needs to be delivered by steam distribution system for
use. A steam distribution system includes distributing mains, other steam piping, condensate
return piping, and all related equipment and accessories; in short, everything which conveys
steam from the boiler plant and brings the condensate back.

3-3.1 Gravity Circulation Systems

In a gravity circulation or gravity return system, condensate returns to the boiler under its own
hydraulic head. This system is common in single building heating plants and especially in
groups of buildings where the boiler plant is at a lower elevation than the buildings served. Since
no condensate return pumps are needed, the system is usually simple. Several modifications of
the piping arrangement are used.

A. One-Pipe Systems
In one-pipe systems, steam flows into the radiators and condensate flows from the radiators
through the same pipe. Radiators are fitted with air-venting thermostatic valves which prevent
the escape of steam. In this arrangement, the steam outlet is, well above the boiler, and the
header slopes down about 1:10. The low end of the header returns to the water inlet of the
boiler. Risers to the radiation slope up at a steep angle or run vertically if the location dictates.
Reducing fittings, if used, should be of the offset pattern to prevent formation of water pockets.
Pipes in general must be well graded. Poor drainage results in water hammer and bumping
noises in the system.

B. Two-pipe System
Two-pipe systems employ a flow pipe for steam and a return pipe for condensate. If the return
main is below the water level of the boiler, it is called a wet return, if above this level, a dry
return. When a wet return is used, an additional main must be provided to carry air gases.
Radiators in this system have two connections, one at each end. The outlet is provided with a
thermostatic trap to pass air and water but prevent passage of steam. Air is expelled through a
common high capacity air vent. The air line and vent receiver are open to the atmosphere and
must therefore be located high enough above the boiler-water line to prevent water from backing
up because of boiler pressure. In many cases condensate is returned to the boiler from a
receiver located 1 foot or more above boiler-water level. The receiver is fitted with a float valve
which admits boiler steam
above the water when the level of condensate rises to a predetermined point. When pressure is
thus equalized, the hydrostatic head causes the condensate to return to the boiler.

3-3.1 Mechanical Circulation System

Mechanical circulation systems include all systems which employ pumps to return condensate
to the boiler plant. The three types of systems are atmospheric, vacuum, and sub-atmospheric.
The mechanical means used for circulation makes these systems adaptable to large areas such
as hospitals and to groups of buildings which are on different levels.
A. Atmospheric Systems
The atmospheric system is like the usual vapor system except that flash tanks or condensate
receivers, vented to the atmosphere, are used to discharge air from the system. These receivers
also serve as reservoirs to collect the condensate. Condensate is returned from these receivers
to a surge tank in the boiler house by float-controlled pumps. Traps are used on the heating
equipment to prevent steam discharge into the return system. A leaky trap can be detected by
steam blowing from the vent pipe. Such a condition must be corrected immediately.

Sometimes steam is used at intermediate or high pressure, nominally 40 or 100 pounds per
square inch (psi), respectively, in unit heaters or other equipment suitable for these pressures.
Under such circumstances the condensate discharged to the return system is at a temperature
higher than the boiling temperature at atmospheric pressure in the flash tanks: 290 °F at 40 psi
and 337 °F at 100 psi. The surplus heat converts a proportionate part of the condensate to
steam at atmospheric pressure. The amount of steam formed in this way can be easily
calculated if pressure and amount of steam flow are known. The return system acts as radiation
and will use some of this steam. However, if more steam is being flashed than can be
condensed in this way, it will be discharged through the vent pipe. If, in a system of this kind,
excess steam not coming from leaky traps is being discharged through the vent pipe, make
arrangements to vent the steam through a unit heater or other heat-absorbing unit and a back-
pressure valve on the vent. If only a back-pressure valve is used and if it is set high enough to
prevent escape of steam, trouble may result in the condensate receiver at the boiler plant.

B. Vacuum Systems
In vacuum systems, a vacuum return pump creates a partial vacuum in the receiver connected
to the condensate return line. The pump draws the air and water from the receiver. The pump is
designed to return condensate to the boiler and to discharge air to the atmosphere. The vacuum
maintained varies from 3 to 10 inches of mercury. Pump control is by a float control and by a
vacuum regulator which operates between fixed limits; each of these devices is independent of
the other. Ratings are expressed in square feet of radiation surface. Special fittings and careful
installation are necessary to insure efficient operation.

C. Sub-atmospheric Systems
Sub-atmospheric or differential vacuum systems are modifications of the vacuum return system.
They differ in that the steam flow into the main is controlled by a throttle valve, and a vacuum of
fixed differential is maintained between the supply and return. Steam is throttled to meet the
heating demands. These systems operate on steam pressures from about 5 psi down to
vacuums of nearly 20 inches of mercury. Return vacuum may be as low as 25 inches of
mercury. In this way radiator temperatures are controlled and may be as low as 140 °F. This
method is effective in eliminating m:er, heating in mild weather. Such a system is justified by fuel
savings. The vacuum pump maintains the fixed differential.

D. Laundry and Other Distribution

Laundry machinery is supplied with steam at 100 psi gage. Steam is generated at a pressure
sufficiently above this figure to take care of pressure loss in flow through supply lines. Some
boiler plants supply steam at high pressure (100 psi gage) for special applications and process
work other than laundry. Distribution in each case is similar. The action of high-pressure steam
in laundry equipment is generally the same as that described in atmospheric systems. A large
laundry has many pieces of equipment and many traps to be maintained. Too often there is a
tendency to open bypass valves around the traps and allow steam to blow through and into the
return system. There is no advantage in bypassing a trap; in fact, a reduction in pressure and
te1nperatu.re usually results. Replacing many traps by a single or master trap is also poor
practice. A master trap for a group of machines may result in poor operation of one or more
machines because of poor drainage of machine jackets. In addition, all piping up to the master
trap is high-temperature radiation surface. Bypassed traps make the entire return system a high-
temperature radiation surface. Even when steam from the return system is used for heating
water, losses ahead of the water heater may constitute a large percentage of plant output.

When large amounts of steam are used in direct-contact water heaters for laundries, a
proportionately large amount of make-up is required for the boilers. Difficulty in maintaining
proper boiler feed-water treatment and control, without resorting to excessive blowdown, is the
most common result.

3-4. Steam Traps, Equipment and Utilization

For a steam generation and circulation system to properly function, it requires necessary
equipment on its piping system. Some of the equipment used on a steam distribution system are
listed below:
3-4.1 Drainage

The water which results from steam condensing in the line must be removed to prevent water
hammer in the lines and to permit operation of heating equipment at rated capacity. In
underground ducts, provision must also be made to drain ground water away from the duct to
prevent the possibility of water leaking in and damaging insulation or pipe. Internal drainage is
usually accomplished by giving a little slope or pitch to the lines and by collecting the moisture in
drip pockets at low points of the line. Water is removed from drip pockets by traps which permit
the flow of water but prevent discharge of steam. Underground lines are drained externally by
placing porous material such as gravel around or under the duct or drain tile under the duct.

3-4.2 Vents

Air must be removed from the system or it will blanket the equipment and prevent it from
functioning. Air enters the system when it is shut down or when pressure is removed; air may
also be dissolved in the water fed to the boilers. Air can be removed automatically by certain
types of traps or manually by operating valves installed at the proper locations.

3-4.3 Insulation

'The piping of a steam distribution system is covered with an insulating material to reduce the
amount of heat lost from the line. In some cases, the insulation must be covered to protect it
from mechanical injury or moisture. All heat insulating materials are poor heat conductors. Air
conveys heat readily if permitted to circulate, but it is a very poor conductor of heat when held
motionless. An insulating material in common use, called 85 percent magnesia, is a mixture of
magnesium carbonate and asbestos fibers; while these two materials are poor conductors of
heat, they conduct heat about three times as readily as air. Insulation using these two materials
is manufactured in such a way that air is included in very small volumes and is prevented from
moving or circulating. An insulating material, to be successful, must be capable not only of
preventing the loss of heat, but also of withstanding the effects of vibration and high
temperature, and of retaining its insulating qualities throughout a period of years.
3-4.4 Valve

Valves are used to control the amount of steam flowing, to stop the flow altogether, to prevent
excess pressures, and to prevent flow in wrong direction.

Valve Parts

A. Stop Valves
Stop valves are used to stop or throttle the flow. The gate, globe, angle, plug-cock, and stop-
and- check valves are common types.

B. Check Valves
A check valve operates automatically to prevent reversal of flow of the fluid. Fluid enters below
the seat and lifts it, permitting the fluid to flow. The weight of the seat closes it as soon as flow
ceases. These valves sometimes slam when they close. Usually, this occurs ,vhen the valve
sticks open, permitting the flmv to reverse and reach a comparatively high velocity before the
valve closes: as a result, it slams shut and causes considerable shock in the pipe line. The lift-
check type causes more disturbance to the flow than does the swing-check valve. The lift-check
valve also tends to spin when open, thus resulting in wear on the piston, guide, and seat.
Valve Types

C. Relief Valves
Relief valves protect pressure vessels or lines from overpressure. Pop-safety valves used on
steam boilers are seldom used in steam distribution systems. Relief valves can be used with
liquids or gases, including steam, on installations not covered by code requirements. Unlike
safety valves, relief valves do not start to open at the set pressure; they require about 20
percent overpressure to open wide. As the pressure drops, the valve starts to close and shuts
off at
approximately the set pressure. These valves are brass or bronze in the smaller sizes and cast
iron and bronze in the larger sizes.

D. Blow-off Valves
Valves constructed specifically for blowoff service are used on steam boilers. They are designed
with special provision for passing sludge and scale without interference with the requirements of
tight seating. Wearing parts are easily accessible and replaceable. They are comparatively
expensive, and their use is limited to the boiler. Other valves installed on distribution system
equipment for drainage and cleaning of tanks, receivers, or drip legs need not be of special
construction; however, valves which permit a. straight-through blow must be used.

E. Pressure Regulators
Where high-pressure steam is supplied and lower pressures are required for space heating,
water heating, or other services, pressure-reducing regulators are used. These regulators are
essentially valving in which the seating disk is positioned automatically to maintain a set
pressure on the downstream or low-pressure side. Power to position the valve comes from a
diaphragm actuated by a connection to the low-pressure line. adjustment is obtained by
opposing part of the diaphragm thrust by an adjustable spring or a weight-and-lever
arrangement.
Pressure Regulating Valve Between 2 Valves

3-4.5 Steam Traps

A steam trap is a device to drain water from a steam pipe, separator, radiator, kettle, or sterilizer
without allowing steam to escape. The trap is an important piece of equipment, for if the water is
not removed, the associated apparatus will not heat. If steam is permitted to blow through the
trap, heat is lost. The common difficulties experienced with traps are cut seats caused by
throttling the flow, air binding, stoppage by foreign material, and worn pins or bearings. Seats of
a float trap are more liable to be cut than those of the intermittent discharge type; this is
particularly true for float traps operating at low flows. Seats which are badly cut or worn permit
the loss of steam. A trap which is air bound is inoperative. Worn bearings and pins may cause
the trap to stick and make it inoperative. Traps may he classified according to operation as
thermostatic, float, bucket, impulse, and throttling traps.

A. Thermostatic Trap
Thermostatic traps are widely used on radiators. The sylphon bellows contains a fluid which
expands and vaporizes when heated. This action builds up a pressure inside the bellows,
causing it to elongate and close the valve. When water collects around the sylphon and cools
slightly, the sylphon contracts, opening the valve and letting water escape. As water is forced
out, steam meets the bellows, causing it to close the valve thus preventing the escape of steam.
The sylphon and the lower valve seat can be removed from the trap without disturbing any of
the pipework.
Thermostatic Trap

B. Float Trap
A float trap is a combination float and thermostatic trap. The thermostatic trap normally vents the
air, but it can also discharge water if the capacity of the float valve is exceeded. Water enters
the trap and raises the float, carrying the vertical valve with it, This action opens the valve and
permits the water to discharge as the water level in the chamber drops, the float gradually drops
and closes the valve. Normally, with a constant flow of condensate to the trap, the level of water
in the trap is stable and the trap discharges water continuously at the same rate as the
condensate enters. At low rates of flow the level of water in the trap is low and throttling of the
discharge causes the seat to cut badly, a disadvantage characteristic of this type of trap. The
thermostatic trap in the top the chamber remains closed if there is steam around it. This trap can
be opened for inspection or repair without disturbing any pipe connections.
-
Float Trap

C. Bucket Trap
Bucket traps get their names from the fact that the operating element is a small bucket. The trap
may be made with the open end of the bucket at the top or bottom. When the open end of the
bucket is at the top, the device is called a bucket trap; when the open encl is at the bottom it is
called an inverted trap.

Inverted Bucket
Figure below shows an inverted bucket trap in the closed position with water entering the trap
under the bucket. The steam under the bucket slowly condenses and permits water to fill the
bucket until it sinks, opening the valve and discharging- the water. After all the ·water is
removed from the inlet line, steam discharges into the trap under the bucket, and collects
under the bucket, forcing the water out and causing the bucket to rise and close the valve. As
can be seen, the trap discharges only to the level of the valve thus, leaving the trap always
immersed. To prevent the trap from becoming air bound, the trap is provided with an air-vent
hole. This trap can be disassembled for inspection and repair without disturbing the piping.
Inverted Bucket Trap
Left: Trap closed; Right: Trap discharging water

Bucket Trap
Condensate and steam enter the body of the trap in which an empty bucket float. The water
flows over the edge of the bucket and starts to fill it. When enough water has entered the
bucket sinks. allowing the water to he forced out. When enough water has been forced out,
the bucket rises closing the valve and leaving the column from the bucket bottom to the valve
full of water. If air is present, it is drawn into the column, and the water in the column drops
into the bucket. The air is discharged the next time the valve opens.

Bucket Trap
Left: Trap closed; Middle: Trap discharging water; Right: Trap after discharging water
D. Impulse Trap
Operation of impulse traps depends on the fact that a certain amount of hot water will flash into
steam when the pressure exerted on it is reduced. The traps operate with a moving valve
impelled by changes in pressure in a control chamber. The valve has a tiny orifice drilled
through its center which allows continuous bypassing from the inlet to the control chamber. This
flow reduces the chamber pressure below the inlet pressure and the valve opens, allowing free
discharge of condensate. As the remaining condensate approaches steam temperature, flashing
results; flow through the valve orifice is choked and pressure builds up in the control chamber,
closing the valve. About 5 percent of the rated capacity of the trap flows through the valve
orifice. The pressure on the discharge side of the trap should not be over 25 percent of that on
the inlet side if the trap is to function properly.

Impulse Trap
E. Throttling Trap
A throttling trap operates on the principle that flow of water through an orifice decreases as its
temperature approaches that of the steam used. This trap has no moving parts and the rate of
flow through it can be adjusted by raising or lowering the stem which fits a tapered V-seat. With
the stem properly adjusted, the condensate, which is slightly cooler than the steam, enters the
chamber from the line, travels up through the baffle passage, and is discharged through the
orifices. If this discharge is at a rate higher than that at which it enters the trap, the level in the
inlet chamber falls until it permits a little steam to enter the baffle passage. The steam going
through this passage heats the condensate to a temperature approaching that of the steam. As
the temperature increases, the amount of water flashing into steam, and hence the volume of
the steam water mixture handled by the orifice increase and reduce the capacity of the orifice.
The reduced flow through the orifice permits the level of condensate in the inlet chamber to rise
until the hotter water in the baffle passage has been completely discharged and replaced with
water that is slightly cooled. The cycle is then repeated. The orifice vents air from the trap;
otherwise, steam would be excluded and as a result, the condensate would cool. This condition
results in a high flow through the orifice, dropping the water level and permitting the air to enter
the baffle passage and to escape.

Throttling Trap
3-5. Condensate Recovery and Utilization

An effective condensate recovery system, collecting the hot condensate from the steam using
equipment and returning it to the boiler feed system, can pay for itself in a remarkably short
period of time.

Typical Steam & Condensate Circuit

3-5.1 High Pressure Drips

When steam is used at intermediate or high pressure in hot-water generators, sterilizers,

cookers, or other equipment and the condensate is returned with that from the low-pressure
system, a flash tank or in some cases a heat exchanger ( condensate cooler) is required. This
added equipment is necessary since water at high pressure and high temperature will be
flashed into steam if discharged to a lower pressure line or receiver. This action results from the
fact that water at a given pressure has a definite saturation temperature and thermal capacity.
Since the volume of steam is 250 times that of the water, some of this steam is condensed in
the return piping systems, however, if there are several of these high-pressure units, the heat-
dissipating capacity will be
insufficient. The steam must be separated before the condensate is pumped to the boiler plant,
and for this purpose a flash tank is installed. If the steam is neither separated nor condensed,
water hammer and associated bumping and vibration of lines, severe disturbance of water level
in condensate receivers, destruction of float switches, and faulty pump action will result. If traps
leak, their leakage adds to this condition.

A. Flash Tanks
A recommended arrangement of a flash tank and piping connections is shown below. Note that
the bucket trap discharges below the low-water level. This maintains a water seal to exclude air
from the hot piping on the discharge side of the trap. Oxygen corrosion is particularly active in
this section if the water seal is not provided. Also, the discharge pipe from the bucket trap helps
condense some of the flash steam and thus prevents some loss to the atmosphere through the
vent. In a well-designed system, little steam shows at the vent if traps are not leaking. An
appreciable plume of steam from a vent pipe is usually evidence of a leaky trap or an open
bypass line. In either case prompt attention is necessary.

Method of handling condensate from high-pressure return to low-pressure system

B. Condensate Coolers
It is customary to install condensate coolers in return systems, from large installations which
utilize steam at high pressure, since a sizeable proportion of the condensate is flashed from
high- pressure drips. Examples of such systems are laundries or large high-pressure unit
heaters. If flash tanks were used, most of the flash steam ·would be vented to the atmosphere,
since the heat-dissipating capacity of the return system would be insufficient to condense it. The
condensate and steam mixture are therefore passed to a heat exchanger which heats the water
supplied to hot-water generators. A saving of 10 percent in water-heating costs is easily attained
by this method. In addition, the amount of make-up necessary at the boilers is decreased in the
same ratio. Flash tanks are provided in high-pressure unit-heater installations, and these tanks
are vented through low-pressure unit heaters.

3-5.2 Pumps

Pumps which return thecondensate are essential parts of all except the smallest and simplest of
distribution systems. From the standpoint of heating efficiency, keeping the lines and radiators
free from accumulations of condensate is as important as supplying steam to the heating
equipment. For this service there are many modifications and special arrangements of pumping
equipment. Both steam and electric-driven units are used. Most installations use electric-driven
condensate and vacuum pumps as units complete with motors and controls. Discussion here is
limited to a simple representative example of each type.

A. Condensate Pumps
A typical condensate pump with receiver and float controls. The pump operates intermittently
under the action of the float-controlled switch, as shown. The condensate returns by gravity to
the receiver from the radiator; it is therefore important that return lines be graded toward the
receiver. To prevent pockets of condensate from forming and interfering with the free flow of
condensate and non-condensable gases, offset pattern fittings are used where line sizes
change.

Condensate pumps are made in a wide range of sizes. Large units have cylindrical receivers
mounted vertically or horizontally. Usually the pump and motor are mounted horizontally. In
many cases two pump sets and one receiver are mounted as a unit. Either pump or both can he
used as needed. Receivers are vented to the atmosphere.
In many units the condensate enters near the base of the receiver. If steam traps on the system
are leaking or if bypass lines are open, steam coming with the condensate may form large
bubbles which cause rapid changes in water level within the receiver. In addition, there is nearly
always some flashing of steam in the receiver under these circumstances. The combination may
cause such serious fluctuations in water level that the float-switch mechanism may be destroyed
in a few hours or a few clays at best. Observation of the float mechanism ·will show what is
happening within the receiver. The remedy is obvious: Keep the steam traps in good repair and
the bypass valves closed.

Condensate Pump

B. Vacuum Pumps
The figure below shows the construction and general operating principle of a vacuum return
pump. Vacuum pumps maintain a vacuum on the return system and are thus able to drain return
lines which would not drain readily by gravity. As explained earlier, the vacuum system also has
certain other advantages. The pump shown is arranged so a single impeller serves to pump
both condensate and the non-condensable gases (mostly air) which leak into the system or are
released in the boiler. Other makes of pumps use similar arrangements; some use two
impellers, one for condensate and one for air. The figure indicates the path of flow through the
unit. The returns from the system enter through the strainer into a compartment near the base of
the unit. From here it passes to the ejector. Condensate supplied by the pump at high velocity
delivers the
returns through the venturi tube into the upper receiver. The non-condensable operate here and
are vented to the atmosphere. The condensate recirculates through the pump with a portion of it
going to the boiler or surge tank as indicated. The float controls the valve which determines the
rate of flow to the boiler or tank. A given water level is maintained in the receiver, and the pump
may run to maintain vacuum without any appreciable delivery from the condensate outlet.

All such units are fitted with both vacuum and float controls, but neither operating alone can fully
accomplish the proper action of a vacuum pump. If any great amount of air leaks into the
system, the pump must operate a large part of the time to maintain the set vacuum. The only
satisfactory remedy is to eliminate the leakage. Switching over to float control alone allows the
unit to operate like a plain condensate return pump and defeats the purpose for which the
vacuum pump was installed. Therefore, it is important that the distribution system, the pump,
and its controls, be maintained in correct operating condition. Manufacturers instruction sheets
for the model of pump installed are the best source of information on operating and servicing
vacuum pumps and their controls.

Vacuum Return Pump

3-6. Activities and Assessment

1. Explain how steam is used as a utility.

2. Draw a simple gravity distribution system of steam.
3. Draw a simple mechanical distribution system of steam.
4. Why does condensate is recovered on a steam utility system?

3-7. References

Ganapathy V. (2015). Steam Generators and Waste Heat Boilers For Process and Plant
Engineers. CRC Press. USA

Heselton, K.E. (2005). Boiler Operator’s Handbook. Fairmont Press. India

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 Polytechnic University of the
Philippines Sta. Mesa, Manila
ENGINEERING UTILITES 2 (BASIC MECHANICAL ENGINEERING)
First Semester AY: 2020-2021