ct541 got steam process solutions summit - rockwell automation · what is dryness fraction slide 6...

08/27/2014

Products Solutions Services

Got Steam?

New Techniques for Measuring Steam Quality in Utilities

Slide 1 Adam Battinieri

08/27/2014

Got Steam? New Techniques for Measuring Steam Quality in Utilities

How does steam safety impact you?

Adam BattinieriSlide 2

08/27/2014


What we don’t measure- we can’t control


What is Wet Steam?

Do you know the quality of your Steam?

100% steam quality

80% steam quality

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How do you measure steam quality?


3 Components:• Pressure

• Temperature

• Amount of liquid (condensate)

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Where am I on the steam curve?


08/27/2014


What is Dryness Fraction


• Mass Fraction vs. Volume Fraction – Quality is the % mass that is vapor

• Quality = 1 Saturated Vapor

• Quality = 0 Saturated Liquid

08/27/2014


Application Example – Why dryness fraction is a mass term


Low Pressure Steam: Steam Quality 90%• In volume terms: 99.9% of the volume is Vapor

Low Pressure Steam: Steam Quality 10%• In volume terms: 98.9% of the Volume is Vapor

Conclusion: 90% steam quality to 10% steam quality has a volume difference of 1% resulting in a 340% difference in Energy

08/27/2014


Dangers of Wet Steam


• Water Hammer

• Erode control valves

• Premature failure of steam system

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Impact: Supplying values you need

NEW direct 4-20mA input allows temperature and pressure

correction with an output format a customer desires



Direct Mass and Energy

08/27/2014


Impact: Poor steam quality - expanded


Dryness fraction

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Value: Steam quality energy correction


08/27/2014


Prowirl 200 is optimized for steam measurement

Slide 12

IAPWS - table

• Mass and energycompensation for wet/saturated and superheated steam

• Compensation with temperature and pressure (fixed or dynam

The International Association for the Properties of Water and Steam

08/27/2014

Causes of Wet Steam



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Application example: How improving steam quality impacts the bottom line

Improving your steam quality from 0.8 to 0.95 on a 13000 lb/hr Boiler

How Much Money does improving my Steam quality from 0.8 to 0.95 save?

95k/year



95% steam quality

80% steam quality

95% steam quality

08/27/2014

Application Example: Measuring in Mass vs. Energy

• How much are you being over charged if the steam you are receiving is 0.9 dryness fraction?

• Utility bill will be 8%higher than it should be



08/27/2014


What have we learned?

Boilerhouse, Marstons Brewery, UK

“Your meter is wrong!!”


08/27/2014

Brewery Flow Measurement


8017FT

8017

FT8023

FT8023

FuelFuel

FT03

FT01

FT8022FT

8022

Blo

w d

own

FT02

Air

Air

Feed water tank

FT8016FT

8016

FT8023Saturated Steam

P = 8.5 bara / 123psiT = 173°C / 343°F

Q_m = 4.6t/hDN 100


T = 155°C / 311°FQ = 2.4t/h

DN 80


T = 155°C / 311°FQ = 2.4t/h

DN 80


No insulationT = 173°C / 343°F

Q = 1.55t/hDN 80

L = 300 mQ_loss = 182kW

Q_m_cond. = 0.32t/h

FT 01Combustion AirP = 1bara / 15psiT = 20°C / 68°FQ = 13.650t/h

DN 250V = 61.8m/s

FT 02Fuel Oil (Middle)P = 2bara / 29psiT = 25°C / 77°F

Q = 0.785t/hDN 8

V = 4.3m/s= 913.31kg/m³ = 121.8cP

FT 03Feed Water

DN 40V = 2.6m/s


08/27/2014

Your flowmeter is wrong!


Comparison of boiler outlet and sub-meters:

FT8023 (Boiler outlet): 4.6t/hSum of FT8017, FT8022 and FT8016: 2.4t/h + 2.4t/h + 1.55t/h = 6.35 t/h

Deviation of 38%

Reason: Prowirl 73


08/27/2014


What is your boiler operation & efficiency plan?


Classification:

Public

Slide 20

Thank you very muchfor your attention

ct541 got steam process solutions summit - rockwell automation · what is dryness fraction slide 6...

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