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Jayanthi Vijay Sarathy, M.E, CEng, MIChemE, Chartered Chemical Engineer, IChemE, UK
In power plants, boiler feed water is 4. Proper sizing of stem condensate return
subjected to heat thereby producing steam lines requires consideration of all
which acts as a motive force for a steam operating scenarios, chiefly start up,
turbine. The steam upon doing work loses shutdown and during normal running
energy to form condensate and is conditions. During plant start up, steam is
recycled/returned back to reduce the not generated instantly. As a result, the
required make up boiler feed water (BFW). condensate lines would be filled with
liquids which gradually turn two-phase
Recycling steam condensate poses its own
until reaching normal running conditions.
challenges. Flash Steam is defined as steam
During shutdown conditions, with time,
generated from steam condensate due to a
flash steam in the lines condense leaving
drop in pressure. When high pressure and
temperature condensate passes through behind condensates due to natural cooling.
process elements such as steam traps or 5. Condensate return line design must also
pressure reducing valves to lose pressure, the consider the effects of water hammering.
condensate flashes to form steam. Greater the When multiple steam return lines are
drop in pressure, greater is the flash steam connected to a header pipe that is routed
generated. This results in a two phase flow in to a flash drum, flash steam in the presence
the condensate return lines of cooler liquid from other streams would
condense rapidly to cause a water hammer.
General Notes
1. To size condensate return lines, the Fraction of Flash Steam
primary input data required to be Taking an example case, condensate flows
estimated is A. Fraction of Flash Steam and across a control valve from an upstream
condensate, B. Flow Rates of Flash Steam pressure of 5 bara to 2 bara downstream. The
& condensate, C. Specific volume of flash saturation temperature at 5 bara is 151.84 0C
steam & condensates, D. Velocity limits & 120.20C at 2 bara. The specific volume of
across the condensate return lines. water at 5 bara is 0.001093 m3/kg & 0.00106
m3/kg at 2 bara. The latent heat of saturated
2. Sizing condensate return lines also require
steam upon reaching 2 bara is 2201.56 kJ/kg.
lower velocity limits for wet steam since
liquid droplets at higher velocities cause The % flash steam generated is estimated as,
% 𝐹𝑙𝑎𝑠ℎ
internal erosion in pipes and excessive ℎ𝑓,1 = ℎ𝑓,2 + [ × ℎ𝑓𝑔 ] (1)
100
piping vibration. A rule of thumb, for
Where,
saturated wet steam is 25 – 40 m/s for
short lines of the order of a few tens of hf,1 = Upstream specific enthalpy [kJ/kg]
metres and 15 - 20 m/s for longer lines of hf,2 = Downstream specific enthalpy [kJ/kg]
the order of a few hundred metres. hf,g = Latent Heat of Saturated Steam [kJ/kg]
3. Condensate return lines work on the The upstream specific enthalpy, hf1 of
principle of gravity draining. To effectuate saturated water at 5 bara is 640.185 kJ/kg
this, drain lines are to be sloped downward and hf2 of 504.684 kJ/kg at 2 bara. The steam
at a ratio of atleast 1:100. specific volume at 2 bara is 0.8858 m3/kg.
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The fraction of flash steam is calculated as, The dynamic viscosity for calculating the
[640.185−504.684] Reynolds number can be chosen as the
% 𝐹𝑙𝑎𝑠ℎ = × 100 = 6.15% (2)
2201.56
viscosity of the liquid phase or a quality
Therefore the condensate fraction is, averaged viscosity, µh.
% 𝐶𝑜𝑛𝑑 = 100 − 6.15 = 93.85% (3)
𝜇ℎ = 𝑥𝜇𝑣 + [1 − 𝑥]𝜇𝐿 (8)
The steam volume is calculated as,
The homogenous model for gravitational
𝑚3
𝑉𝑆𝑡𝑒𝑎𝑚 = 0.8858 × 0.0615 = 0.05448 𝑘𝑔
(4) pressure drop is applicable for large drop in
pressures and mass velocities < 2000
The condensate volume is calculated as,
kg/m2.s, such that sufficient turbulence exists
𝑚3
𝑉𝐶𝑜𝑛𝑑 = 0.00106 × 0.9385 = 0.000995 𝑘𝑔 (5) to cause both phases to mix properly and
ensure the slip ratio (uv/uL) between the
Condensate Return Pipe Sizing
vapour and liquid phase is ~1.0. For more
To size the condensate return line, the bulk
precise estimates capturing slip ratios and
properties and mixture properties can be
varying void fraction, correlations such as
used to estimate the pipe size. It must be
Friedal (1979), Chisholm (1973) or Muller-
remembered that as the two-phase mixture
Steinhagen & Heck (1986) can be used.
travels through the pipe, there is a pressure
profile that causes the flash % to change The total pressure drop is the sum of the
along the pipe length. Additionally due to the static head, frictional pressure drop &
pipe inclination, a certain amount of static pressure drop due to momentum pressure
head is added to the total pressure drop. gradient.
To estimate the pipe pressure drop across the ∆𝑃𝑇 = ∆𝑃𝑠𝑡𝑎𝑡𝑖𝑐 + ∆𝑃𝑚𝑜𝑚 + ∆𝑃𝑓𝑟𝑖𝑐 (9)
pipe length, a homogenous model for
modelling the two phase pressure drop can The Static Head [Pstatic] is computed as,
be adopted. The homogenous mixture acts as 𝐻×𝜌ℎ× 𝑔×𝑆𝑖𝑛𝜃
∆𝑃𝑠𝑡𝑎𝑡𝑖𝑐 [𝑏𝑎𝑟] = (10)
a pseudo-fluid, that obeys conventional 105
agreement with the Darcy equation for The two phase homogeneous density is,
laminar flow, accuracy through the 𝜌ℎ = 943.4 × [1 − 0.9821] + [1.129 × 0.9821] (24)
transitional flow regime is unknown & in the
𝑘𝑔
turbulent regime a difference of around 0.5- 𝜌ℎ = 18.01 (25)
𝑚3
2% is observed between the Churchill
The two phase homogeneous viscosity is,
equation and the Colebrook equation. For
0.0615×1.28 [1−0.9821]×2.29
Reynolds number up to ~4000, 𝜇ℎ = + (26)
10−5 10−4
1⁄
8 12 1 12 𝑘𝑔
f = 8 [(Re) + 1.5
] (15) 𝜇ℎ = 0.000216 𝑚.𝑠 (27)
(A+B)
The condensate receiver operates at 1.1 bara Since the Reynolds number is much higher
pressure. The mechanical details of the piping than 4,000, the flow is fully turbulent and the
for a flow rate of 1,000 kg/h, pipe size of 1.5”, friction factor is calculated based on
100m length & pipe roughness of 45.2 m is, Colebrook equation. The friction factor is
estimated as,
Table 1. Condensate Return Line Details
𝑓 = 𝑓𝐶𝑜𝑙𝑒𝑏𝑟𝑜𝑜𝑘 = 0.0251 (33)
Parameter Value Unit
The frictional pressure drop is now calculated
Mass Flow rate [m] 1000.0 kg/h
using the Darcy-Weisbach expression as,
Volumetric Flow [Q] 55.51 m3/h 0.0251×100×18.01×11.72
∆𝑃𝑓 = (34)
Pipe Length [L] 100 m 2×0.04094×105
Pipe Outer Diameter [OD] 48.3 mm The slope angle is calculated as,
1 180
Pipe SMYS [Carbon Steel] 30,000 psi 𝜃 = [𝑇𝑎𝑛−1 (100)] × = 0.6° (36)
𝜋
Pipe Design Pressure [DP] 7 bara
The static pressure drop [Pstatic] becomes
Pipe Wall Thickness [WT] 0.08 mm 18.01×9.81×[(1+5)×𝑠𝑖𝑛(0.6°)]
∆𝑃𝑠𝑡𝑎𝑡𝑖𝑐 = (37)
Corrosion Allowance [CA] 1.0 mm 105
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