Reducing Maintenance and Saving Fuel with Ellison s Portable Steam Calorimeter
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1 900 SERIES ELLISON STEAM CALORIMETER OPERATION AND MAINTENANCE MANUAL Reducing Maintenance and Saving Fuel with Ellison s Portable Steam Calorimeter Ellison's unique Calorimeter combines the advantages of throttling, separating, and re-evaporating calorimeters into a single chamber. Its design has the remarkable accuracy of being within 2 degrees F of theoretical temperature. The Ellison Calorimeter is recognized as the exacting criteria for measuring comparative steam quality by turbine and boiler engineers around the world. FEATURES / SPECIFICATIONS * EXCLUSIVE U-PATH PRINCIPLE - Pioneered by Ellison for accurate readings on pressures down to 26 PSIA * HEAVY DUTY VALVE - Stainless steel alloy is rated for 1500 PSI. * STEAM PATH - The steam flows through inlet holes, along the sampling nozzle to the orifice plug. The orifice plug controls both the quantity of steam sampled and the point of pressure drop. The sample expands as it enters the steam chamber, releasing heat and re-evaporating entrained moisture. The throttled steam in the steam chamber flows in a U-Path. Down to bottom of inner chamber then up its sides to the top where the steam jacket causes steam to pass around the outside of the inner chamber before it escapes at the bottom. * RE-EVAPORATING - Momentary excess moisture that is separated in the steam chamber is re-evaporated when superheated steam returns the chamber to normal temperatures. Therefore, the single chamber gives accuracy possible only with throttling, separating and re-evaporating techniques. Ellison Throttling Steam Calorimeter Model 915 * INSULATION - Steam chamber is designed so that escaping steam flows around the inner chamber, insuring a uniform temperature of expansion with minimal energy loss. The entire housing is packed with one inch of insulating material with a very low thermal conductivity to give additional protection. Manufactured Cal Research, Inc. Quality Comes First
2 DRY STEAM DESIRABLE Moisture in steam represents a loss which may be expressed in many ways according to the application. If we consider it from the point of view of energy use in heat transfer equipment, it is apparent that a given weight of hot water can impart only a fraction as much heat as the same weight of steam. For example at 100 PSIG, a pound of dry saturated steam will give off 880 BTU in the form of latent heat alone plus 126 BTU in condensing to atmospheric pressure whereas the hot water alone could only give off 126 BTU per pound in dropping it's temperature to 212 degrees F. Thus the ratio in favor of steam is as 1006 is to 126. Water in steam lines is not only annoying due to the sound and vibration caused by "water hammer," but this hammer action can break valves and fittings and injure steam using equipment. Moisture also commonly carries solids in suspension or in solution, which deposit in the line or in strainers, traps, regulators, etc. This shows up as an added expense for maintenance unless the moisture is eliminated by line separators or traps. Further line condensation/heat loss can be minimized by insulating the steam pipes with suitable covering. Steam turbines using saturated steam may have their blades eroded by moisture in the steam. More commonly superheated steam is used in turbines but here too trouble may develop if moisture is not eliminated from the steam before it enters the superheater tubes. Here moisture entering the superheater will be evaporated leaving behind a fine earthy deposit which will be carried along with the steam to turbines. This will practically sand-blast the turbine blades unless special precautions are taken to eliminate it. There are still other ways in which moisture in steam is objectionable but we can think of no way in which it is beneficial, except perhaps in cloth steaming operations, and even there it might be desirable to measure and thus assure a fixed percentage of moisture. Hence the importance of measuring the moisture in the steam with a calorimeter and taking steps to reduce it. The percentage by weight of steam in a mixture of steam and entrained water is known as the "quality" of the steam. This would also be represented by 100 percent minus percentage of moisture as determined by calorimeter. THROTTLING AND SEPARATING PRINCIPLES The basic principle of the throttling calorimeter is that dry saturated steam, in passing through an orifice to a lower pressure, becomes superheated. This superheat will show as such on the thermometer of the calorimeter if no moisture is present in the steam. However, when moisture is present, the superheat in the steam will act on it, converting it into steam and if enough moisture is present all superheat will disappear and the steam will attain the temperature of no superheat that is 212 degrees F, at atmospheric pressure, i.e PSIA. Table 2 shows the maximum amount of moisture that will flash into steam in the calorimeter. Any moisture beyond the percentages shown in Table 2 will simply drop out into the separating chamber or be carried along with the expanded steam to the exhaust port. For moisture in amounts up to the figures given in Table 2 the throttling calorimeter gives very accurate results. For amounts in excess of such percentages the separating principle must be used and, while inherently the separating principle is not as efficient as the throttling principle, the U-path flow of the steam in the Ellison Calorimeter gives more efficient separation of moisture than previously obtained, especially if this chamber is kept drained as suggested in this bulletin. To get local atmospheric pressure, it is advised to check with a local airport and request the uncorrected barometric air pressure. If unavailable, the use of 14.7 PSIA or locally known pressure, due to altitude, is generally acceptable. 2 In order to embody a more efficient separating chamber into a calorimeter, it would be necessary to greatly enlarge this member in order to provide baffles or centrifugal elements. The increased volume would defeat its own purpose by increasing the radiation, producing additional water within the calorimeter, so in the final analysis nothing would be gained by such change. We believe most plants strive to keep moisture in steam below 2 percent and 4 percent is often enough to warrant drastic measures to reduce the percentage. Up to 4 percent moisture is measurable by the calorimeter using throttling principles only at 80 PSIG (refer to Table 2 for additional pressures). For steam lines with low pressure and/or high moisture content, where temperature within the calorimeter will not reach superheat, Cal Research manufactures a separating calorimeter that can be used in conjunction with throttling calorimeter. Using the two calorimeters in tandem allows accurate measurements at low pressures and high moisture content. Contact Cal Research for information regarding separating calorimeter. DETERMINING ATMOSPHERIC PRESSURE If it is required to measure the pressure within the calorimeter, insert the static tube through the packing cup and gland. Tighten gland. Connect static tube to manometer or suitable pressure measurement device and determine pressure reading. The static tube is in the thermowell when the calorimeter is received.
3 ESTIMATING STEAM FLOW Napier's approximate rule for steam flow in pounds per hour = (absolute pressure x area in square inches x 3600) / 70. The charts on adjoining page will simplify the selection of a throttling plug for the proper sizing (Table 3 A-C). Table 4 provides the steam flow in pounds per hour at a given absolute line pressure, based on Napier's formula (reduced by CV of orifice plug). Keep in mind that the absolute pressure is gage pressure plus Napier's rule applies to steam flowing through an orifice having a sonic velocity as it goes to atmosphere, as shown on the chart. It will be noted that the lines on the chart are straight down to 26 PSIA. Below this pressure the flow will decrease more rapidly and at atmospheric pressure, the flow will be zero. The rates of sample steam flow below 26 PSIA are much less than recommended for the throttling calorimeter, it was thought unnecessary to show them. At 10 PSIG, the throttling calorimeter will re-evaporate 1.07 % entrained moisture from the extracted sample. The balance of moisture in steam is separated and collected in the inner chamber of calorimeter. A drain valve is provided on the calorimeter for the propose of removal for measurement. Review Abnormally High Moisture section. Orifice Plug Sizing The orifice dimensions of the six standard orifice plugs furnished with the calorimeter are as follows: NOTE: Diameter (Inches) Area (Sq. In.) 1/ / / / / / Table 1 - Throttling Plug Orifices Where close tolerance of indicated steam quality is required, special sampling nozzles and orifice plugs can be designed and manufactured for the application. This will ensure that the sample of steam reaching the calorimeter is Isokinetic. SAMPLING LOCATION The choice of steam sampling location is very important when it comes to extracting an accurate sample. If the sample is not the same as that which is in the line, the calorimeter will indicate an incorrect reading of steam quality. Sampling location preference in descending order: 1) Vertical descending 2) Vertical ascending 3) Horizontal It is not always possible to insert the sampling nozzle in the most desirable location. The ideal sampling location is where the steam flows downward in a vertical pipe. There should not be a valve, elbow or other disturbing element, upstream of the sampling nozzle, for a minimum of ten pipe diameters and downstream for five plus diameters. The second choice is a pipe in which the steam ascends vertically with other conditions the same as are described in the forgoing. In this case, the results may be erratic at low steam velocity, particularly if there is an orifice or restriction in the pipe below the sampling nozzle. Under such conditions the condensation on the sides of the steam line runs back against the flow of steam and is caught by the higher velocity at the re- stricted portion and thrown upward into the calorimeter nozzle. An installation with the sampling nozzle in such a position has to be used with great care. Note: The pipe in which the steam ascends will usually show more moisture, with the same nozzle and steam than when the steam descends, but it is not possible to recommend a correction factor. In choice number three, the horizontal pipe, the nozzle should be placed in a horizontal orientation, if low moisture in line, or in a vertical orientation, if high moisture in line, three to five pipe diameters from a valve or a device that will cause a disturbing influence. This will serve to mix the water and steam so that the extracted sample will be representative of line steam. The pipe bend should at all times be avoided, if an accurate determination of the quality of the steam is to be obtained. In the case of a bend, provided no other location is possible, the sampling nozzle should be placed in the straight part at the upstream end of the bend and in the plane of the bend. 3
4 THROTTLING LIMITS Accuracy of the Ellison Throttling Steam Calorimeter is controlled by the presence of superheated steam within the calorimeter. When this is achieved, we know that all the moisture in the sample has been flashed to steam and a finite thermodynamic reaction has occurred. The temperature indication from the calorimeter will be greater than 212 degrees F or local water boiling point. The difference between boiling point and indicated calorimeter temperature is the degrees of superheat. The percentage of moisture evaporated by the calorimeter at zero degree superheat in the calorimeter and at absolute steam line pressure in pounds per square inch, calculated from Keenan and Keyes steam tables, is shown in Table 2. If the moisture exceeds Table 2 percentages momentarily, the excess will be separated in the steam chamber. If the separated liquid is due to a slug within the steam line, it will be evaporated by the return of drier steam to both line and calorimeter, resulting in a true average steam quality. If temperature within calorimeter remains at 212 degrees F or local water boiling point, the steam sample contains more moisture than is possible for the throttling calorimeter to flash. (See Abnormally High Moisture) This creates a situation where the calorimeter s accuracy drops. The mathematics to determine steam quality go from a single thermodynamic equation to a set of equations for separated liquid mass plus thermodynamic reaction, hence increasing the margin of error. Cal Research builds a Separating Calorimeter that will remove a high percentage of moisture from extracted line sample. Installed prior to Throttling Calorimeter, it allows for finite measurements from both of the calorimeters. This divides the equations for steam quality into separate entities, decreasing error span. PSIA % PSIA % PSIA % Table 2 - Maximum Moisture That Can Be Measured By the Throttling Principle Alone ABNORMALLY HIGH MOISTURE Should the percentage of moisture exceed the figures on Table 2 for a protracted period during the test, the throttling calorimeter will separate the excess moisture from the steam sample. The temperature reading during this period will be 212 degrees F at atmospheric (14.7 PSIA) pressure or local water boiling point. The moisture can/should be drawn off periodically through the drain valve and its total weight, expressed as a percentage of the steam flow for the period, should be added to the percentage of moisture obtained from Table 2. (See High Moisture Formula) Care must be used in collecting this moisture to insure that steam vapor does not escape through drain valve. The separated moisture may also be drained off automatically and continuously from the calorimeter by allowing the hot water to flow out of drain through a short piece of small bore rubber tubing into a glass U-tube, thence overflowing into a collecting vessel. By taking the difference in weight of the vessel of water initially and after conclusion of the test the total weight of moisture separated is determined, or the percentage by weight of total flow separated for the time period. The U-tube would give visible evidence of overflow, at the same time cooling the water enough to prevent loss of weight by evaporation. Another method of collecting the separated hot water would be to let it escape directly into a bottle or other vessel through small bore rubber hose, the outer end of which is immersed below water to the bottom of the bottle. An approximate 2 inches of immersion will suffice to avoid escape of any steam. As the bottle gradually fills, of course the immersion will progressively increase. To convey some idea of how large a bottle or other vessel to provide, 4 percent of separated moisture in 100 pounds of steam flow per hour would produce 4 pints (1/2 gallon) of water. 4
5 HOW TO INSTALL A standard installation of a calorimeter is as follows. Special applications have instructions included with package. A B C D E To Valve Body A Steam Nipple B Thread-o-let C Locking Nut D Steam Line E Sampling Nozzle Thread-o-let to Steam Line Isolation Valve Assembly, Thread-o-let, and Sampling Nozzle Installation Figure 1 Sampling Nozzle and Valve Assembly 1) Determine the location and orientation of sampling nozzle and sampling nozzle support weldment. 2) Turn off steam line to be tested. 3) Remove insulation from steam line around the installation site. 4) A 1/2" NPT thread-o-let is attached in a fashion that the center line of fitting bisects the center line of steam line and is perpendicular to the run of the line. 5) Attach thread-o-let using welding procedures conforming to local standards. Thread-o-let should be a minimum of 3000# class. The fitting bore center line must pass through the center line of the steam line. In order for the sampling nozzle to set in the correct location within the steam line, it must bisect the steam line and be able to traverse the entire inside diameter. Take patience and care when tacking. 6) Once satisfied with the orientation of the thread-o-let, weld into place. 7) Spot hole into steam line through thread-o-let and drill 5/8" diameter. (This operation can be performed prior to the welding of the thread-o-let to steam line.) 1) Thread steam nipple attached to valve assembly into thread-o-let and snug. Measure engagement and note. Remove. Measure distance between the inside diameter - back wall - of steam line and the shoulder on thread-o-let and note. 2) Select appropriate sampling nozzle for steam line being tested. Thread locking nut on to nozzle if not present. 3) Screw sampling nozzle into steam nipple in manner that the total length of exposed sampling nozzle and 1/2" NPT thread engagement is 1/8" to 3/16" less than measured depth into steam line. 4) Orient the ports in the sampling nozzle to face the direction of steam flow when the valve assembly is threaded into the thread-o-let and the union cone adapter is facing downward (6 o'clock). 5) Tighten locking nut on sampling nozzle. 6) Wrap 1/2" NPT on steam nipple with Teflon tape and insert into thread-o-let. 7) Tighten insuring that the ports in the sampling nozzle to face the direction of steam flow and the union cone adapter is facing downward. 8) Check to make sure valve assembly is in closed position. 9) Steam line may be turned back on at this point. 5
6 Figure 2 Orifice Plug and Calorimeter 1) Review Table 1 for selected sampling nozzle. The graphed lines represent the ideal, Isokinetic, sample attainable with given Sampling Nozzle and Orifice Plugs. Locate line pressure on left hand side of graph and line flow rate along the bottom. Choose the orifice plug closet to the point where these two converge. The sampling flow rate can be determined for the orifice plug on Table 2. Locate line pressure on left hand side and follow across to the intersection with the orifice plug line. Follow this point to the bottom of chart for steam sample flow rate. For special applications, an orifice plug of specific size can/will be supplied. 2) Screw into the union cone adapter (A) on valve assembly the selected throttling plug (B) using Orifice Plug wrench supplied with kit. 3) Attach calorimeter to valve assembly cone adapter by means of the union arrangement (A &C). Snug union nut. The union cone and nut assembly, being exposed only to atmospheric pressure, should not be tightened more than necessary for a sound joint. 4) Remove Static tube from thermowell. Insert temperature probe into thermowell until it comes to a stop. Slide the thermometer back about 1/4 to 3/8 of an inch. Tighten packing gland. 5) Where space is available, connect exhaust tube to the calorimeter outlet. Slide extension tube on to bottom of calorimeter and rap tube bottom with block of wood or with an item that will not mar tube. 6) Wrap valve assembly and union nut area with 1" minimum of insulation. A wrap of insulating material around the body of the calorimeter is also suggested but not required. 1) Open drain valve on the calorimeter. Open valve at valve assembly and allow steam to flow through calorimeter. Allow thirty plus minutes for the calorimeter to get thoroughly heated prior to collecting data. OPERATION AND TESTING PROCEDURES 4) Observe temperature indication. Once this stabilizes above 212 degrees F, the calorimeter has evaporated all of the moisture entrained within the extracted sample. Steam quality testing can proceed. 2) When the thermometer indicates 212 degrees 14.7 PSIA, close drain valve. 3) If the internal temperature of the calorimeter does not pass 212 degrees F and/or liquid continues flowing from the drain valve, it is probable that the steam within line has more moisture than is capable for the calorimeter to flash. If this is the case, review Table 2 for the flashed moisture content. Review section Abnormally High Moisture for additional information. 5) Record temperature and line pressure after five minutes of no to very minimal temperature change. Do mathematics to determine steam quality. See Formulae section. 6
7 FORMULAE FOR STEAM QUALITY DETERMINATION Throttling Formula The formula for determining the quality of steam in the Ellison U-path Steam Calorimeter is same as for a throttling calorimeter and is as follows: m = 100 x H - h - K (T-t) / L SQ = m Where: m = percentage of moisture H = total heat (BTU) of steam at line pressure at saturated condition h = total heat (BTU) of steam at calorimeter pressure at saturated condition K = specific heat of superheated steam T = temperature of superheat in calorimeter t = temperature due to the pressure in the calorimeter L = latent heat in steam line H, h and L are readily found in the Steam Tables in Mark's, Kent's or other standard reference books. Some textbooks refer to H and h as "total heat" or "heat content" in steam whereas others call it "enthalpy-vapor." Likewise some books refer to "latent heat" (L) as such, whereas others refer to it as "enthalpy-evaporation." Example: Absolute pressure in steam line at calorimeter 200 pounds, total heat ; absolute pressure in calorimeter 14.7 pounds, total heat ; specific heat of superheated steam.48; temperature of superheated steam in calorimeter 280 degrees F; temperature due to the pressure in the calorimeter 212 degrees; latent heat in steam line m = 100 x (( ) - (.48 x (280*-212*)) / 843.0) = 1.82 % SQ = = % Separation Formula The formula to compute the steam quality from the separated liquid from calorimeter shall be as follows: X2 = (F / (W + F)) x 100 Where: X2 = steam quality from separating effect, in percent W = weight of water collected from drain, in pounds per hour F = weight of steam passing through calorimeter, in pounds per hour The overall steam quality shall be determined as follows: SQ = 100 [(X1 x.01) +(X2 x.01)] Where: SQ = total steam quality of line sample extracted, in percent X1 = steam quality determined by throttling calorimeter X2 = steam quality determined by separated liquid at drain valve on calorimeter 7
8 Calibration of Calorimeter To determine the radiation of the calorimeter, use a calibrated thermometer and a calibrated steam gage. With the valve assembly covered with insulation, the throttling orifice plug free of obstructions, and the boiler water clean and free from foaming material, operates the boiler at about 20 percent rating with lowest permissible water level. At this rating the quality of the steam in the line is assumed to be 100 percent. Any moisture indicated is assumed to be the radiation of the calorimeter. In the Ellison calorimeter, the pressure in the steam chamber is assumed to be atmospheric, requiring no pressure gage, which minimizes the radiation and simplifies the determination of moisture. Atmospheric pressure is assumed to be 14.7 PSIA. CALIBRATION Atmospheric pressure may also be determined with a barometer, contacting local airport for uncorrected barometric pressure, or by other means if additional accuracy is required. If it is desired to test the pressure within the calorimeter, insert the static tube through the packing cup and gland. Connect static tube with rubber tubing to a U mercury gage or manometer. Static tube is in thermowell when unit is received. STEAM PURITY Determination of Steam Purity Steam purity represents the quantity of solids in the steam, and is expressed in parts per million (PPM) of impurity. As an example, 1 PPM represents 1 part by weight of solid contaminants as compared to 1 million parts of steam. Impurity in boiler water can be readily determined by evaporation. Therefore a reasonable determination of steam purity can be made under normal conditions by using the following formula: Impurity in PPM = (PPM in boiler water x % moisture) / 100 * * = Kent 7-9 8
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