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Introduction

1.1 Steam - The Energy Fluid


This introductory module describes the many benefits and uses of steam in industry today.
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1.2 Steam and the Organisation
The benefits of steam are viewed differently by individuals according to their role and priorities. This
Module explains the issues of most importance to chief executives, managers and operators and how
steam can address these issues.
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1.3 The Steam and Condensate Loop
How is steam generated, distributed, controlled and used? How is the condensate recycled? A basic
overview of a steam system.
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Steam Engineering Principles and Heat Transfer

2.1 Engineering Units


An overview of the units of measurement used in the Steam and Condensate Loop including temperature,
pressure, density, volume, heat, work and energy.
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2.2 What is Steam?
The properties of steam explained here, including the ability of steam under pressure to carry, and then
give up, large amounts of energy. Topics include saturated steam tables, dryness fraction and flash steam.
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2.3 Superheated Steam


An explanation of the properties and uses of superheated steam (such as for electricity generation).
Including explanations of the Rankine and Carnot thermodynamic cycles, superheated steam tables and
the Mollier (H-S) chart.
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2.4 Steam Quality
Steam should be available at the point of use in the correct quantity, at the correct pressure, clean, dry and
free from air and other incondensable gases. This Module explains why this is necessary, and how steam
quality is assured.
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2.5 Heat Transfer
Steam is often generated to provide heat transfer to a process. Modes of heat transfer (conduction,
convection, radiation) within or between media are explained, together with calculations and other issues
such as heat transfer barriers.
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2.6 Methods of Estimating Steam Consumption
How to calculate steam requirements for flow and non-flow applications. Including warm-up, heat losses
and running loads.
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2.7 Measurement of Steam Consumption
Methods of measuring steam consumption, from the very basic to sophisticated flow metering, are
explained in this Module.
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2.8 Thermal Rating
Design ratings for items of plant can be both helpful and misleading, as changing any factor can alter the
predicted heat output. Also, how to calculate steam load requirements from the kW rating.
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2.9 Energy Consumption of Tanks and Vats
The heating of liquids in tanks and vats is an important requirement in process industries. There are many
types of tank with different uses. Determination of heat requirements, heat transfer and heat loss
calculations are all covered in this Module.
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2.10 Heating with Coils and Jackets


Indirect heating of fluids is covered in this module including layouts, control and drainage of coils and
jackets, and heat transfer calculations.
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2.11 Heating Vats and Tanks by Steam Injection
Direct steam injection involves the discharge of steam bubbles into a liquid at a lower temperature to
transfer heat. This Module explains the process and the methods used, including the relevant heat transfer
calculations.
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2.12 Steam Consumption of Pipes and Air Heaters
Steam will condense and give up its enthalpy of evaporation on the walls of any pipe or tube at a lower
temperature. It is not usually possible or necessary to calculate steam consumption exactly. This Module
allows satisfactory estimates to be made for most practical purposes.
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2.13 Steam Consumption of Heat Exchangers
Different types of heat exchanger are explained and compared in this Module, together with steam
consumption calculations and other issues such as the relevance of the starting load.
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2.14 Steam Consumption of Plant Items
The steam consumption of other common plant items, including heater batteries, calorifiers, drying
cylinders, presses and tracer lines.
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2.15 Entropy - A Basic Understanding
Entropy is a concept some find difficult to grasp, but in truth it does not deserve such notoriety. Look upon
Entropy as a road map that connects thermodynamic situations. This Module hopes to shed some light on
this subject, by approaching it from first principles.
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2.16 Entropy - Its Practical Use
Entropy can be used to understand thermodynamic applications from first principles. This Module gives
practical examples of how this can be done.
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The Boiler House

3.1 Introduction
An overview of boiler regulations, with an evaluation of fuel types and comparisons.
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3.2 Shell Boilers
Overview of the different types of shell boiler with layouts, heat and steam release considerations plus
pressure and output limitations.
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3.3 Water-tube Boilers
Description of water tube boilers including operation, types and benefits; also, a brief synopsis on how they
are applied to combined heat and power generation.
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3.4 Miscellaneous Boiler Types, Economisers and Superheaters
An explanation of specialist boiler types and other specialist features.
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3.5 Boiler Ratings
This Module explains the three most commonly used boiler ratings: The From and at rating for
evaporation, the kW rating for heat output, and boiler horsepower.
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3.6 Boiler Efficiency and Combustion
A broad overview of the combustion process, including burner types and controls, and heat output and
losses.
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3.7 Boiler Fittings and Mountings
An overview of the necessary fittings, accessories and controls for a boiler from nameplates and safety
valves to gauge glasses and level controls.

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3.8 Steam Headers and Off-takes
This Module looks at steam header arrangements and other design considerations necessary for efficient
warm-up, good steam quality and proper steam distribution from the boiler house.
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3.9 Water Treatment, Storage and Blowdown for Steam Boilers
A look at the chemistry of water supplies including hardness and pH values.
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3.10 Water for the Boiler
A steam boiler plant must operate safely, with maximum combustion and heat transfer efficiency. To help
achieve this and a long, low-maintenance life, the boiler water can be chemically treated.
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3.11 The Feedtank and Feedwater Conditioning
All aspects of the design, construction and operation of feedtanks and semi-deaerators, including
calculations.
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3.12 Controlling TDS in the Boiler Water
The need to measure and control the total dissolved solids (TDS) in the boiler water boiler water, and the
methods used to do so, including closed loop electronic control with conductivity sensors.
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3.13 Heat Recovery from Boiler Blowdown (TDS control only)
Boiler water is blown down to control the amount of total dissolved solids (TDS) in the boiler. This water is
pressurised, hot and dirty, creating large volumes of flash steam and possible disposal problems. A heat
recovery system can reclaim large amounts of energy during this essential process.
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3.14 Bottom Blowdown
Factors surrounding the removal of suspended solids from the boiler, including valves, piping and
blowdown vessels, with calculations.
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3.15 Water Levels in Steam Boilers

The level of water in a steam boiler must be carefully controlled, to ensure good quality steam is produced
safely, efficiently and at the correct pressure.
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3.16 Methods of Detecting Water Level in Steam Boilers
The application of level controls and alarms, plus an overview of different level detection methods,
including float-type controls, conductivity probes and capacitance devices.
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3.17 Automatic Level Control Systems
A detailed explanation of on/off, modulating, two and three element automatic level control, with a
comparison of pros and cons.
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3.18 Water Level Alarms
The function of high and low level alarms. Low-level alarms will draw attention to low boiler water level
and, if required, shut down the boiler. High-level alarms protect plant and processes.
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3.19 Installation of Level Controls
The pros and cons of direct versus externally mounted level controls.
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3.20 Testing Requirements in the Boiler House
Requirements for regular testing will vary according to national regulations, and the type of equipment
installed.
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3.21 Pressurised Deaerators
The need to remove gases from boiler feedwater and the operation of a pressurised deaerator, plus
calculations.
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3.22 Steam Accumulators
A complete overview of the need for steam storage to meet peak load demands in specific industries,
including the design, construction and operation of a steam accumulator, with calculations.
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Flowmetering

4.1 Fluids and Flow


Users may wish to measure the flow of steam to help with plant efficiency, energy efficiency, process
control or costing purposes. This Module considers the characteristics of flowing fluids and the basic
requirements for good steam metering practice.
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4.2 Principles of Flowmetering
A detailed examination of the principles and terminology surrounding the topic of flowmetering, including
accuracy, repeatability and turndown. Also included is a basic insight to Bernoullis Theorem.
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4.3 Types of Steam Flowmeter
The operation, advantages and limitations of different types of steam flowmeter, including orifice plate,
variable area and vortex shedding devices.
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4.4 Instrumentation
Apparatus for accurate steam flow measurement, including differential pressure cells and data collection &
analysis equipment. Also covers special considerations such as the effects of pressure variation, steam
dryness fraction and superheat.
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4.5 Installation
System design, installation and maintenance considerations for steam flowmeters, including the use of
strainers, separators and flow straighteners, together with piping layouts. Includes a useful checklist for
selecting the correct type of flowmeter for an application.
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Basic Control Theory

5.1 An Introduction to Controls


This Module provides an introduction to the subject of automatic control, including the basic elements of a
control system, different control functions, and relevant terminology, with some emphasis on safety, and
stability & accuracy of control.
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5.2 Basic Control Theory
This Module looks at on/off and continuous control modes. It introduces proportional, integral and derivitive
control actions and explains some of the terminology.
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5.3 Control Loops and Dynamics
An explanation of each component of a control system, including valves, actuators, sensors and
controllers; together with an introduction to methods of control and system dynamics, including simple
control loops and feedback systems.
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5.4 Choice and Selection of Controls
This Module will concentrate on available automatic control choices (such as self-acting, pneumatic or
electric) and the decisions which must be made before selection. Guidance is offered on the basis of the
three most important considerations of safety, stability and accuracy.
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5.5 Installation and Commissioning of Controls
Practical installation and commissioning advice for valves, actuators, sensors, controllers and more.
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5.6 Computers in Control
A look at the more recent developments in control involving the use of information technology.
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Control Hardware: Electric/Pneumatic Actuation

6.1 Control Valves


This Module briefly describes the basic components of different types of linear and rotary action control
valves available for use in steam and water systems.
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6.2 Control Valve Capacity
Valves need to be measured on their capacity to pass fluid. To enable fair comparison, valves are sized on
a capacity index or flow coefficient. This Module explains the different types of flow coefficient in use, how
they are established, how they compare, and typical values for different sized valves.
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6.3 Control Valve Sizing for Water Systems
This Module briefly describes how to use flow coefficients to size valves for water systems, the difference
between using two-port and three-port valves and the effect of these valves on pressure drop, flow and
water system characteristics. Also explained is the importance of valve authority, and the cause and effects
of cavitation and flashing under certain conditions.
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6.4 Control Valve Sizing for Steam Systems
Sizing a control valve for a steam application can be a complex matter. This Module attempts to throw light
on the subject by using first principles to explain the relationship between flow and pressure drop. It uses a
simple nozzle to explain the phenomenon of critical pressure, and how this can be predicted for steam flow
through a control valve. It continues by discussing other properties such as noise, erosion, and how steam
is dried or superheated as it passes through a valve, and gives various examples of such calculations. It
also briefly compares shell & tube and plate heat exchangers, and shows how to use simple Kv charts to
size steam valves.
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6.5 Control Valve Characteristics
Various types of flow characteristics are available. This Module discusses the three main types used in
water and steam flow applications: fast opening, linear, and equal percentage flow; how they compare, and
how (and why) they should be matched to the application in which they are used.
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6.6 Control Valve Actuators and Positioners
Control valves need actuators to operate. This Module briefly discusses the differences between electric
and pneumatic actuators, the relationship between direct acting and reverse acting terminology, and how

this affects a valves controlling influence. The importance of positioners is discussed with regard to what
they do and why they are required for many applications.
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6.7 Controllers and Sensors
Controllers and sensors are important parts of the control system; without information from the sensor, the
controller cannot make a decision and instruct the valve to move. This Module briefly discusses the
different types of controllers and sensors available and how they operate. A brief explanation of digital and
analogue control signals is also given.
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Control Hardware: Self-acting Actuation

7.1 Self-acting Temperature Controls


This Module gives a basic introduction to what self-acting temperature control systems are and how they
operate. The various different types of valves and controllers are briefly discussed along with typical
applications for steam and water systems.
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7.2 Typical Self-acting Temperature Control Valves and Systems
Four different types of temperature controllers are considered, including fail-safe high limit protection.
Popular applications for self-acting controls are listed for process, heating and cooling systems.
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7.3 Self-acting Pressure Controls and Applications
Various types of self-acting pressure controls are examined in this Module, including direct acting bellows
operated and diaphragm operated valves, and pilot operated valves, with guidelines on how to select and
install them correctly. Pressure reducing valves are considered together with pressure maintaining valves
and surplussing valves, alongside some typical applications.
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Control Applications

8.1 Pressure Control Applications


There are many good reasons for reducing (and sometimes maintaining) steam pressure. This Module
details common applications for direct operating, pilot operated, pneumatic, electric and electropneumatic
pressure control systems, including the advantages and disadvantages of each different control method.
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8.2 Temperature Control for Steam Applications
Temperature control of the process can be affected using electric, pneumatic, electro-pneumatic and selfacting controls. This Module details some common applications including process vessels, heat
exchangers and high temperature fail safe control.
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8.3 Level and Flow Control Applications
A range of level control systems and methods are used in industry. Systems may be based on the use of
floats, probes or even more sophisticated technology. This module studies the use of probes to provide
adjustable & non-adjustable on/off control, and modulating control of liquids. Simple flow control
applications are also considered.
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8.4 Control Installations
The service life and accuracy of a control system can be influenced by installation factors. This Module
discusses the basic important considerations including the positioning of equipment and wiring, radio
frequency interference, and protection from the environment.
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Safety Valves

9.1 Introduction to Safety Valves


Any pressurised system requires safety devices to protect people, processes and property. This module
details situations when overpressure may occur, the wide and often confusing types of device on offer,
how such devices operate and the many codes, standards and approval authorities to note.

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9.2 Types of Safety Valve
A full explanation of the many different types of safety valves available, including operation, materials of
construction and accessories.
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9.3 Safety Valve Selection
Choosing and commissioning the correct safety valve, including selection considerations, setting, sealing,
positioning and the effects of backpressure.
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9.4 Safety Valve Sizing
An in-depth study of the sizing process for a range of applications, including sizing equations for AD
Merkblatt, DIN , TRD, ASME, API, BS6759 and others. Covers more complex issues such as two-phase
flow and superheat.
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9.5 Safety Valve Installation
Important installation advice, including handling, plant conditions, pipework configuration, markings and
noise considerations.
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9.6 Alternative Plant Protection Devices and Terminology
Other methods of relieving excess pressure explained; plus a useful terminology section.
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Steam Distribution

10.1 Introduction to Steam Distribution


An efficient steam distribution system is essential if steam of the right quality and pressure is to be
supplied, in the right quantity, to the steam using equipment. This Module looks at a typical circuit.
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10.2 Pipes and Pipe Sizing


Pipe sizing is a crucial aspect of steam system design. This Module offers detailed advice on standards,
schedules, materials and sizing for various saturated and superheated steam duties.
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10.3 Steam Mains and Drainage
Issues surrounding the structure, layout and operation of a steam distribution system, including
condensate drain points and branch lines, the avoidance of waterhammer and the use of separators and
strainers for steam conditioning.
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10.4 Pipe Expansion and Support
Any steam system must be fully supported, able to expand during operation and sufficiently flexible to
allow movement as a result. This Module includes advice on different methods and full calculations.
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10.5 Air Venting, Heat Losses and a Summary of Various Pipe Related Standards
The venting of air and other incondensable gases from steam systems, and the provision of adequate
insulation, are vital to ensure steam plant efficiency, safety and performance.
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Steam Traps and Steam Trapping

11.1 Introduction - Why Steam Traps?


The duty of a steam trap is to discharge condensate, air and other incondensable gases from a steam
system while not permitting the escape of live steam. The need for steam traps, considerations
surrounding their operation, basic modes of operation and relevant standards are all covered in this
Module.
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11.2 Thermostatic Steam Traps
Thermostatic traps operate in response to the surrounding steam temperature. The operation and benefits
of 3 different types are considered here liquid expansion traps, bimetallic and balanced pressure
thermostatic traps. Each operates in a different way and is suited to specific types of application.
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11.3 Mechanical Steam Traps


Mechanical steam traps rely on the difference in density between steam and condensate in order to
operate. They can continuously pass large volumes of condensate and are suitable for a wide range of
process applications. Types include ball float and inverted bucket steam traps. This Module considers the
operation and benefits of both types.
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11.4 Thermodynamic Steam Traps
Thermodynamic steam traps have a unique operating principle which relies on the dynamics of water and
flash steam. They are simple, robust and reliable and can operate up to very high temperatures and
pressures. Their construction, use and benefits are detailed here.
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11.5 Considerations for Selecting Steam Traps
Application type, system design and maintenance needs will influence the performance and selection of
steam traps. Factors such as waterhammer, dirt, steam locking, group trapping, vacuum conditions and
temperature control of processes are discussed in this Module.
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11.6 Selecting Steam Traps - Canteen Equipment; Oil Transfer/Storage; Hospital Equipment
Selection tables and advice on trap selection for a range of different processes are included in this Module,
including steaming ovens, bulk storage tanks and autoclaves.
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11.7 Selecting Steam Traps - Industrial Dryers
Selection tables and advice on trap selection for a range of different processes are included in this Module,
including multi-bank pipe dryers and rotating cylinders.
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11.8 Selecting Steam Traps - Laundries, Presses
Selection tables and advice on trap selection for a range of different processes are included in this Module,
including calendars, garment presses, dry cleaning machines and tyre presses.
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11.9 Selecting Steam Traps - Process Equipment
Selection tables and advice on trap selection for a range of different processes are included in this Module,
including boiling pans, retorts, digesters, coppers, reboilers, evaporators and vulcanisers.
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11.10 Selecting Steam Traps - Space Heating Equipment

Selection tables and advice on trap selection for a range of different processes are included in this Module,
including heat exchangers, radiant panels, unit heaters, air heater batteries and overhead pipe coils.
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11.11 Selecting Steam Traps - Steam Mains; Tanks and Vats; Pressure Reducing Valves
Selection tables and advice on trap selection for different types of steam mains, headers and off-takes are
included in this Module, together with process vats and pressure reducing valve stations.
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11.12 Air Venting Theory
The presence of air has a devastating effect on steam systems and processes. The basic theory of air
venting is explained in this Module, plus advice on air vent location.
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11.13 Air Venting Applications
Some of the many different applications for air vents are described in this Module, including steam mains,
bypasses, jacketed vessels and rotating cylinders. Other issues such as venting large volumes of air,
group air venting and the substitution of thermostatic steam traps are also considered.
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11.14 Testing and Maintenance of Steam Traps
Indiscriminate maintenance of steam traps wastes money. This Module considers a planned approach to
steam trap testing and maintenance, with recommended methods and equipment.
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11.15 Energy Losses in Steam Traps
A large amount of inaccurate and misleading information has been written on this subject. This Module
gives clear, accurate information regarding the energy consumption of different trap types.
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Pipeline Ancillaries

12.1 Isolation Valves - Linear Movement


Isolation valves are used for diverting process media, facilitating maintenance, equipment removal and
shutdown. The operation, application and construction of gate, globe, piston and diaphragm valves are
studied in this module.

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12.2 Isolation Valves - Rotary Movement
Isolation valves are used for diverting process media, facilitating maintenance, equipment removal and
shutdown. The operation, application and construction of rotary movement (quarter turn) valves, including
ball valves and butterfly valves, are covered in this module.
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12.3 Check Valves
Check (non-return) valves are installed in pipelines to allow flow in one direction only; helping to protect
equipment and processes. The operation, benefits, applications and selection of different designs,
including lift, disc, swing and wafer check valves are explained in this module.
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12.4 Strainers
Strainers arrest pipeline debris such as scale, rust, jointing compound and weld metal in pipelines,
protecting equipment and processes. This module considers the range of strainer and filter types in use
and how to size and select them for different applications.
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12.5 Separators
Wet steam is a major concern in a steam system as it can cause process and maintenance problems,
including lower productivity, erosion and corrosion. Separators are designed to efficiently remove the
moisture from steam flow. The application and selection of different types are considered here.
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12.6 Gauges, Sight Glasses, Vacuum Breakers
These small items of equipment have a variety of important applications throughout steam systems and
process equipment. The different types available are studied in this module.
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Condensate Removal

13.1 Heat Exchangers and Stall


This Module discusses the particular problems associated with the removal of condensate from
temperature controlled heat exchange equipment, including the causes, symptoms and effects of stall.
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13.2 The Heat Load, Heat Exchanger and Steam Load Relationship
Calculations for heat exchange applications including the design loads and the steam pressure/flowrate
requirements.
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13.3 Oversized Heat Exchangers
Heat exchangers are often bought oversized for the required duty. This Module looks at the reasons why,
the effects this has and related requirements, such as trap sizing for oversized exchangers.
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13.4 Example: Selecting the Trap
A fully worked-through example for calculating stall and selecting a condensate removal solution for a heat
exchange application.
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13.5 The Stall Chart Constant Flow Secondary
Varying Inlet Temperature
Constant Outlet Temperature
A simple method of calculating stall is to use a stall chart. This module explains the use of a chart to
calculate stall for a constant secondary flowrate with a varying inlet temperature.
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13.6 The Stall Chart Varying Flow Secondary
Constant Inlet Temperature
Constant Outlet Temperature
Using a chart to calculate stall for a varying secondary flowrate with a constant inlet temperature.
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13.7 The Stall Chart Constant Flow Secondary
Constant Inlet Temperature
Varying Outlet Temperature
Using a chart to calculate stall for a constant secondary flowrate with a varying outlet temperature.
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13.8 Practical Methods of Preventing Stall


This Module considers methods of overcoming condensate drainage problems, such as ensuring gravity
drainage, installing an automatic pump trap device, or controlling the pressure in the steam space.
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Condensate Recovery

14.1 Introduction to Condensate Recovery


An introduction to the reasons for condensate recovery and return, including energy costs, water charges,
effluent restrictions and water treatment costs. Includes sample calculations for potential savings.
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14.2 Layout of Condensate Return Lines
Considerations surrounding the design and layout of condensate return pipework, including drain lines to
steam traps, discharge lines from traps, common return lines and pumped return lines. Includes the effect
of trap types used, the effect of different pressures and discharging condensate into flooded mains.
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14.3 Sizing Condensate Return Lines
A guide to sizing condensate lines to and from steam traps, including examples and calculations using the
condensate pipe sizing chart.
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14.4 Pumping Condensate from Vented Receivers
A basic introduction to pumping terminology, including vapour pressure and static head. Includes a
description of the operation, application and comparable benefits of electrical centrifugal and mechanical
condensate pumps, with sizing examples for pumps and pump discharge lines.
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14.5 Lifting Condensate and Contaminated Condensate
Recommendations for special circumstances, including lifting condensate to a higher level return line, and
dealing with contaminated condensate.
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14.6 Flash Steam


The benefits of recovering flash steam, how it is done and how flash steam can be applied elsewhere in
the plant to maximise overall efficiency.
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Desuperheating

15.1 Basic Desuperheating Theory


Superheated steam has important advantages on certain applications, for example, when used in power
stations to drive turbines. For efficient use on heating applications however, the steam must be
desuperheated. This Module considers basic desuperheating theory and calculations.
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15.2 Basic Desuperheater Types
This Module introduces the common types of desuperheater in regular use, their limitations and typical
applications.
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15.3 Other Types of Desuperheater
Additional desuperheater designs such as the venturi and variable orifice types are covered in this Module.
A comparison of all types is included at the end.
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15.4 Typical Installations
A number of important considerations need to be taken into account when installing desuperheaters. This
Module covers issues such as water quality and pressure control. A desuperheater selection chart and a
list of applications are also included.
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Equations

16.1 Equations
This Module lists in order of appearance all equations used throughout The Steam and Condensate Loop.
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