VMcieacy of Steam Separators

J. H. Felgar

D. E. Willard

H. A. Dnrr

905

621.17 F33

ARMOUR

INST.OFTECH.UB

CHICAGC.

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Felgar, J, h. Efficiency of steam separators

EPPICIENCY OF STEAM SEPARATORS. A THESIS PRESENTED

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PRESIDENT AND FACULTY

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ARMOUR INSTITUTE OF TECHNOLOGY

for the degree

of

BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING,

Having completed the prescribed course of study- in

MECHANICAL ENGINEERING.

ILLINOIS INSTITUTE OF TECHNaOGY Chicago, June 15, 1505, PAUL V GALVIN LIBRARY 35 WEST 33RD STREET CHICAGO, IL 60615

^2^3

The object of this thesis was to determine the efficiency of a horizontal and a vertical separator of the baffle plate type under the varying conditions of quality -.vith the velocity constant, and also under the varying conditions of velocity with quality con- 3 tant .

IT95?

Xhe Efficiency of Steam Separators.

The separators wore already in place as described below, with each separator and the connecting pipes well lagged. It was necessary ho^Tever to arrange appai^atus to take care of certain con- ditions, (l) Some method of obtaining the desired quality <5f steam, (P.) Some way of taking care of the water separated so as to determine its weight accurately, {?>) Means by -.Yhich the vel- ocity could be changed at will, as the maximum velocity v;ith the engine running was only about 1000 feet per minute, (4) The accuracy of the calorimeters.

Firdt, the higher qualities were obtained by the use of two coils inserted in the unlagged joints of 4" pipe, with water pumped through them at different pressures. For lower qualities a nozzle was used and the water pumped directly into the steam line. A combination of these two methods was used for the lowest quali- ties.

Second, the amount of water separated vms first measured by weighing it, but a large error was introduced here on account of the water under a reduced pressure flashing into steam, and also by the water splashing over the sides of the weighing can. These difficulties were overcome by attaching to Ho. 1 separator an ad- ditional chamber with a gauge glass calibrated to read to hundredths of a pound at steam temperature the quantity of water separated.

and the gauge glass of No. 2 was calibrated.

Third, '.vith the engine running at full load, the velocity of the steam was about 1000 feet per min- ute. To obtain greater velocity the steam and exhaust valves in the high pressure cylinder wore removed, the lower pressure cylinder by-passed, and the steam al- lowed to pass directly to the condenser. Any velocity could be obtained by this method.

Fourth, in order to get some basis from v/hich to compute the qualities, the throttling calorimeter was taken as correct, results checking very satisfactorily with the Sf'parr.ting calorimeter.

In the ?iorizontal separator the corrugated baffle plate extends vertically, and at right angles to the direction of the flow of the steam; the steam striking this plfte and losing its entrained water, passes over the top of the baffle plate, and on to the engine. The water drops by gravity into the chamber below.

2.

In the vertical separator the steam enters from the top, strikes '"^n oblique corrugated baffle plate, and passes to the en- gine throu'-h an opening directly under this baffle. Drawings of cross section of the separators are appended.

These separators are connected to the steam of a cross compound Corliss engine. The tal-e-off from the steam header con- sists of two sections of unlagged 4" pipe, Z and X, which lead into another line of 4" pipe Y; at the middle of this is the boriztonal separator No, 1, In this same line, just above the throttle vnlve of the engine, is the vertical separator No. 2, Below the separa- tor Ko. 1 is the reservoir No. r^, with the gauge glass and a scale graduated to read to hundredths of a pound, Tliere is also a grad- uated scale on separator Ko. 2,

A separating calorimeter (a) is in the steam line lnr:ediat ly before the separator No. 1. Li]<:ewise a separating calorimeter (b) is betviTeen separators No. 1 and No. 2, A throttling calori- meter is placed after the separator No. 2, and before the throttle valve.

The steam gauge (D) is placed at th^ throttle; a vacuum gauge (e) on the condenser; a water pressure gauge (p) on the water line to t' e nozzle (V.) ; and the coils in X and Z. A I'arsh steam pump is sho"m at (g) which is used to force water into the main steam line to decrease thr3 quality. Drain pipes are shown at R and 0, which are used to draw off the water from the separators No. 1 and Ko. 2, respectively, into a pit between the high and lov/ pressure cylinders. In order to obtain wet steam an p< ft, length of pipe, X and Z before mentioned, is left unlagged. It was found

tliat this unlagfTcd section, together with a water cooled copper coil in the pipe Z, wo g not sufficient to give thn required rneunt of moisture, r-o that the remaining section X was replaced by r sec- tion containing a water cooled iron coil, With these two coils and a 40-lb. w^ter pressure a qualitjr of only 88% could be ob- tained. This steam did not contain sufficient moisture, so som.e other means had to be devised to obtain wetter steam. This was done by inserting a l/4" pipe into the steam line just before the copper coil, A cap in waich eight l/r^2" holes were drilled rad- ially was screwed on the end of this l/4" pipe. This nozzle was placed at the center of the steam pipe. In order to force water through this nozzle against steam pressure a small Liarsh pump, sho'.vn at S,was used.

It v;aG found that practically any desired quality of steam could be obtaified by using the nozzle and cooling coils com- bined, but the bad feature here was that with low quality the sep- arating calorimeter did not seen to read correctly. • This was readily explained, for the sampling pipe connected with the sep- arating calorimeter was situated in the center of the 4" steam line, and therefore showed the quality of the steam at that point, but with these low qualities so much water flowed through the pipe that the water w^s not thoroughly mixed v/ith the steam, and a part of it ran along the bottom of the steam line, A different quality was shown by v/orking back from the throttling calorimetei* readings taken at the engine proper. It was assumed that the latter method was the fairer and for that reason the initial qual- ities of the steam v/ere all calculated from the throttling calor-

iraeter reading and considered to be correct. Other nozzles with smaller hol-^s were tried to give the water entering an incre-ced velocity, but on checking the qualities shown by the calorimeter with the calculated quality the same result was obtained. IVith a velocity of 1000 feet per minute the separating calorimeter would not show a quality lower than 88%,

It was found that with the 40 pound v;ater pressure of the Institute mains a sufficient amount of water would not pass through the coijs. It isltherefore necessary to increase the pressure to 120 lbs. per square inch.. A quality as low as 69% was obtained v/ith both coils and a velocity of steam of 1000 feet, and with one coil a quality of 87/^. Y/ith both coils a nozzle liaving seven No, ?. drilled -.oles and a velocity of steam of 2000 feet per minute, a qu^ility of 4". 5^ was obtained, and under the same conditions, '.vith a velocity of 5000 feet per minute a quality of (^0.^^ was objjained.

Description of the Conditions for Each of the Runs. (Reference made to result sheets.)

Sheet 1^0. 1, May 5, 1905.

This run vr^s made :7ith a high quality of steam and neither the noazle nor coils were used. The engine was running under full lo?.d, and a steam velocity of 889 feet per minute was obtained. The initial quality of the steam for separator No. 1 was 95.9^ and the quality after separation was 97.1?^^, giving an efficiency of ?.9 ,5%, The initial quality of separator No. ? w^.s ^-^.lo^o, and the; final 97.78^, giving an 'Efficiency for No. ? of 2?.15f=.

Sheet Ko. 2, May 5, 1905.

In this run the copper coil wrs used with a 40 pound water pressure and an initial quality of 97.57^ was obtained for separator No. 1, and a quality after separation of 9^.1/^, giving an efficiency for No. 1 of •'^6.79;^. For No. H there was an initial quality of 96. 1^^, and a quality after separation of 97.78?^, giving an efficiency of 4:? ,6%, The velooity through the pipe was 980 feet per minute.

Sheet No. r., May 10th, 1905.

Doth coils were used in this run under a 40-pound water pressure, giving an initial quality of 88.9*^ for separator No. 1, wi'h a quality of 95.7;^ after separation and an efficiency of 61%. For No. 2 the initial quality was 95.7^, the final 98.83^, and the efficiency 7?. 4??. The velocity in this run w- s 918 feet per minute.

G.

Sheet No. 4, l.:ay 18, 1905.

In tiie time between the run sheet No. 7 and this run, thejnozzle had been inserted and trial runs innde as described elsewhere and the two coils had also been arranged so tho.t v/rter could be pumped through then by means of the I/Iarsh pump. In order to get a higher velocity the valves in the head end of the high pressure cylinder had been rernoved, the steam being allowed to pass directly to the condenser. This run w^s made v;ith a l-'rge nozzle only, and a steam velocity of 2100 feet per minute. The initial quality was 25, &% for No. 1, with a final quality of 77 ,7% , giving an efficiency of 15.5/?, The initial quality for No. 2 was 37.!^^, and the quality after separ?.tion 4R,5/^, giving an efficiency

of le.nB^.

(Vith a steam velocitj'- of 51^55 feet per minute, an initial quality of 59.8^ for No. 1 was obtained, a final quality of 77.4^, giving an efficiency of 4',7/b, v/hile for No. P. the initial quality was 77.4fr and the final 85.7/^, giving an efficiency of 7<':,7%,

Sheet No. 5, May 19, 1905, 11: "5 A.M.

This was a run with comparr.tively dry steam and a high velocity (6910 feet per minute) and neither the nozzlenor coils were used. The initial quality was 98,84J!^ for No. 1, the final quality 98,98^, giving an efficiency of 1?:^. For No, !? the ini- tial quality of 98.98^, and the final quality 99.1 H/^jgiving an efficiency of \7.%*

7.

Shc-:t No. 6, May 19, 10C5, in:05 P. I!.

Water was pumped through both coils p;iving an initial quality of 91.9/C for a velocity of the stean at ^9fi0 feet '^er minute. The quality after No. 1 was 9?,?9^, and the^^ff iciency 17.14<. The quality before No. 2 '7as 9:^.?,9^ and after 9''.0rf., giving an efficiency of 70,^6^.

Sheet No. 7, Kay 19, 1905, f? P.K.

In this Kun the v/pter was piomped throu^^h the iron coil only, and the velocity of the steam w^s 4350 feet per minute. The quality before No. 1 was 91.54^, after, w?s 94.75J^, giving an ef- ficiency of ?",?>&%, The quality of the steam entering No. ?, was 94.7^, leaving was 98. G5^, giving an efficiency of 73.1^.

Sheet No. 8, May 19, 1905, 2:55 P.M.

V/ater was pumped through both coils and the steam vel- ocity 3910 feet per minute. The quality of the steam entering No. 1 W"s S7.85^, leaving 98.1^, giving an efficiency of 34.89^. The quality of the ste?m entering rio. ?_ was 9?.,1%, leaving 98.49/^, giving an efficiency of 8?!. 15^.

Sheet No. 9, liay 17, 1905.

In this run the engine was operated under full load and the water wrs pumj)ed through the coils. The steam velocity w"s 1260 feet per minute. The quality of the steam entering No. 1, was 76. "9/^, leaving 92.42^, giving an efficiency of ^.7.9% For No. 2 the quality entering -.vas 92.42^, leaving 97*7^, giving an ef- ficiency of 69.5%,

8.

Sheet 10, Hay ^0, 1905, 7r.45 P.M.

In this run the water was pumped through both coils, the stearc velocity was ?258 feet per minute, and the valves were removed from the engine as in thejother runs on this date. The steam entering Mo. 1 had a quality of 82,1^, leaving, 91^, giv- ing EB efficiency of 49.6^. The steam entering No. 2 had a quality of 91?-, leaving 9P..?Af,, giving an efficiency of RO.45^.

Sheet Wo. 11, Llay 19, 10C5. 4:?,5 P.M.

V.'ater was pumped throj^gh" the iron coil only. The steam had a velocity of ?,2.70 feet per minute. The quality of steam entering No. 1 was P7 ,0%, leaving 9:^.7$4, giving an effi- ciency of 48.51^. The quality of the steam entering No. 2 was 97.7?^, leaving 98.59^, giving an efficiency of 77.4^. ■

It must be noted that the qualities given by calorimeter No. 1 for May 19, 1905, are unreason'-^ble , because the calorimeter indicated a poorer quality than that calculated from the actual weights of entrained water in the steam. It is therefore ob- vious that separating calorimeter (A) was at fault. Tlie ori- fice mSs probably obstructed, causing most of the steam that en- tered the calorimeter to condense.

9.

Example of the Method of QalculatinA the Results. Calculationc:

Quality of steam after separator #1.

VV Quality =

T7tW

where w = weight of water in separating calorimeter,

M = weight of condensed stean fron the calorimet "r,

.108 + ?.61 r^.7l8 Quality of steam according to throttling calorimeter readings,

X - q, 4- .4BD

^,

where X = quality

X= total heat of steam at calorimeter pressure, q = heat of liquid at steam pressure, r, = latent heat " " "

D = superheat in degree F. ,48 = specific heat of steam,

X = lli!lP-r_±2?-f_t_lf^i^2l = 97.85^ 887.9

Quality tetween #1 and #2 computed.

167 = quantity of condensed steam in ten minutes,

167 X 9-7.85 = T6r^.4 dry stean,

167 + 2.09 (moisture from #2 in 10 minutes) = 169.09.

16?, 4 -f 169.09 = .966 = 96.6^.

169.09 t 1.36 (moisture from #1 in 10 min.) = 170.45

165.4 4 170.45 =.96 = 9C;^ = initial quality.

10

'r?ff iciencies:

100/^ - 9(i% = 4/c noisture in steam before sop-rator #T . 97.13 - 9^% = 1.1 3 percent separr'ted, 1.15 + 4 X 100 = 28,2% eff. of #1. 100 - 97.1? = 2,P,7fo moisture before #2. 97. PO - 97.1:^ = .72% separated .7r^ 4 2B7 = r!5.2(i^ eff. of ^1^2,

In the above calculations the quality before separator #1 was 96% and after 97.17^-^.

Then quelitj' before separator #r! was 97 ,17:%,, and after was 97.80?^.

11.

Conclusions,

Separator No. 1.

(a). Considering runs with practically a constant quality, it is foiond that the efficiency decreases as the velocity increases. This may be due to the fact that the steam of high velocity does not deposit the water on the baffle, but drives it through the opening at the top of the separator,

(b) Considering runs \Tith constant velocity, it is found that the efficiency increases as the quality decre.TSos.

Separator No. 2,

(a) The efficiency of separator r2 is practicall^r constant for all velocities with a possible maxinun efficiency at about 4000 ft. per nin. The point shovrn on the curve whose abscissae is r'.QOG ft. per min. would approach the curve if the quality were the same as the other :^oints plotted,

(b) The efficiency increases very rapidly as the quality de- creases, or as the percent moisture increoses.

Pomparison of Separators No, 1 and No. ?■» For the same qualities separator #? shows a higher effi- ciency than i'l for ^-ny velocity.

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