Block 12 Pipeline Ancillaries Separators Module 12.

5
SC-GCM-98 CM Issue 1 © Copyright 2005 Spirax-Sarco Limited

Module 12.5
Separators

The Steam and Condensate Loop 12.5.1

Block 12 Pipeline Ancillaries Separators Module 12.5

Separators
Wet steam is steam containing a degree of water, and is one of the main concerns in any steam
system. It can reduce plant productivity and product quality, and can cause damage to most
items of plant and equipment. Whilst careful drainage and trapping can remove most of the
water, it will not deal with the water droplets suspended in the steam. To remove these suspended
water droplets, separators are installed in steam pipelines.
The steam produced in a boiler designed to generate saturated steam is inherently wet. Although
the dryness fraction will vary according to the type of boiler, most shell type steam boilers will
produce steam with a dryness fraction of between 95 and 98%. The water content of the steam
produced by the boiler is further increased if priming and carryover occur.
There is always a certain degree of heat loss from the distribution pipe, which causes steam to
condense. The condensed water molecules will eventually gravitate towards the bottom of the
pipe forming a film of water. Steam flowing over this water can raise ripples that can build up
into waves. The tips of the waves tend to break off, throwing droplets of condensate into the
steam flow.
The presence of water in steam can cause a number of problems:
o As water is an extremely effective barrier to heat transfer, its presence can reduce plant
productivity and product quality. This can be seen in Figure 12.5.1, which shows the
temperature profile across a typical heat exchange surface.

Steam Product
Metal wall
Scale
Air
Moisture

Scale

Steam
temperature

Product
temperature

Fig. 12.5.1 Temperature profile across a heat exchange surface

o Water droplets travelling at high steam velocities will erode valve seats and fittings, a condition
known as wiredrawing. The water droplets will also increase the amount of corrosion.
o Increased scaling of pipework and heating surfaces from the impurities carried in the water
droplets.
o Erratic operation of control valves and flowmeters.
o Failure of valves and flowmeters due to rapid wear or waterhammer.

Although there are a number of different designs of separator, they all attempt to remove the
moisture that remains suspended in the steam flow, which cannot be removed by drainage and
steam trapping. There are three types of separator in common use in steam systems:

12.5.2 The Steam and Condensate Loop

Block 12 Pipeline Ancillaries Separators Module 12.5

o Baffle type - A baffle or vane type separator consists of a number of baffle plates, which cause
the flow to change direction a number of times as it passes through the separator body. The
suspended water droplets have a greater mass and a greater inertia than the steam; thus, when
there is a change in flow direction, the dry steam flows around the baffles and the water
droplets collect on the baffles. Furthermore, as the separator has a large cross-sectional area,
there is a resulting reduction in the speed of the fluid. This reduces the kinetic energy of the
water droplets, and most of them will fall out of suspension. The condensate collects in the
bottom of the separator, where it is drained away through a steam trap.

Outlet plugged or piped to an air vent

Dry steam

Wet steam

Condensate to steam trap

Fig. 12.5.2 A baffle type separator

o Cyclonic type - The cyclonic or centrifugal type separator uses a series of fins to generate
high-speed cyclonic flow. The velocity of the steam causes it to swirl around the body of the
separator, throwing the heavier, suspended water to the wall, where it drains down to a steam
trap installed under the unit.

Wet steam Dry steam

Condensate to steam trap

Fig. 12.5.3 A cyclonic type separator

The Steam and Condensate Loop 12.5.3

Block 12 Pipeline Ancillaries Separators Module 12.5

o Coalescence type - Coalescence type separators provide an obstruction in the steam path.
The obstruction is typically a wire mesh pad (sometimes referred to as a demister pad), upon
which water molecules become entrapped. These water molecules tend to coalesce, producing
droplets that are too large to be carried further by the gas system. As the size of the droplets
increases, they become too heavy and ultimately fall into the bottom of the separator.
It is common to find separators, which combine both coalescence and cyclonic type operations.
By combining the two methods, the overall efficiency of the separator is improved.

Wet steam Dry steam

Demister pad

Wet steam

Water droplets falling

and collecting

Condensate to steam trap

Fig. 12.5.4 A coalescence type separator

Separator efficiency is a measure of the weight of the water separated out in proportion to the
total weight of the water carried in by the steam. Outside the laboratory, it is difficult to establish
the exact efficiency of a separator, as it depends on the inlet dryness fraction, the fluid velocity
and the flow pattern. Erosion of pipe bends, wiredrawing, and waterhammer are, however,
indications of the presence of wet steam in steam pipes.
One of the main differences in performance between the baffle type and the cyclonic and
coalescence types of separators is that the baffle type is capable of maintaining a high level of
efficiency over a wider pipeline velocity range. Cyclone and coalescence type separators typically
exhibit efficiencies of 98% at velocities of up to 13 m/s, but this falls off sharply, and at 25 m/s,
the efficiency is typically around 50%, according to University research in the UK.
This research has also proven that, for a baffle type separator, the efficiency remains close to 100%
over a range of 10 m/s to 30 m/s . The conclusion is that, the baffle type separator is more suited
to steam applications, where there is usually some degree of velocity fluctuation. Furthermore,
wet steam will be found to run at velocities of over 30 m/s if the pipework is undersized.
One method of overcoming this problem is to use a larger size separator and by increasing the
diameter of the pipework immediately upstream of the separator. This will have the effect of
reducing the velocity of the steam before it enters the separator.

12.5.4 The Steam and Condensate Loop

 Block 12 Pipeline Ancillaries Separators Module 12.5

Example 12.5.1
If a separator with an efficiency of 90% is fitted to a steam main containing steam with a dryness
fraction of 0.95, what would the downstream dryness fraction be?
If the initial dryness fraction is 0.95, every kilogram (1 000 g) of steam contains:
[J JRIZDWHU
Since the efficiency of the separator is 90%, only 0.90 x 50 g = 45 g of the water present is
removed. This means that the dryness fraction becomes:
 JJ 
  
 J 
In practical terms, the steam can be considered completely dry.

If however, the separator efficiency is only 50%, only 25 g of the water will be removed. This
results in a dryness fraction of:

 JJ 
  
 J 
Although an improvement on the original dryness of 0.95, the steam will still contain a significant
amount of water.
The pressure drop across a baffle type separator is very low due to the reduction in the velocity
of the steam, which is created by the large increase in cross-sectional area provided by the
separator body. The pressure drop is typically less than the equivalent length of the same nominal
diameter pipe. In comparison, the pressure drop across a cyclonic type separator is somewhat
higher, as the velocity of the fluid has to be maintained to generate the cyclone effect.
On non-critical applications, baffle type separators are typically sized according to the pipeline
size; it is necessary however to check that the chosen size ensures maximum separation efficiency,
and that the pressure drop is within acceptable limits. On critical applications, it is more common
to select the separator based on operating pressure and flowrate, so as to give a suitable efficiency
and pressure drop. Sizing a cyclonic type separator is more complicated, as it is important to
ensure that the velocity through the separator is suitable to maintain a high level of efficiency
and that the pressure drop across the separator is acceptable.
Example 12.5.2 outlines the selection of a baffle type separator from a typical manufacture’s
specification chart.

The Steam and Condensate Loop 12.5.5

Block 12 Pipeline Ancillaries Separators Module 12.5

Example 12.5.2
Using the sizing chart in Figure 12.5.5, select a suitably sized separator for a pressure reducing
station, with an upstream pressure of 12 bar g and passing 500 kg /h of steam through a 32 mm
pipeline, If the flowrate were doubled to 1 000 kg /h, what size should the separator be?
1. Plot point A where the steam pressure and the flowrate cross and draw a horizontal line
across from this point. Any separator curve that is bisected by this line within the shaded area
will operate at near 100% efficiency.
2. Select the line size separator, i.e. 32 mm at point B.
3. The line velocity for any size can be determined by dropping a vertical line from this intersection.
From point B, this line crosses the velocity axis at 18 m/s.
4. To determine the pressure drop across the separator, where the vertical line, extended from
point B, crosses the line C-C, plot a horizontal line. Then drop a vertical line from point A.
The point of intersection, D, is the pressure drop across the separator.
5. Repeating this procedure for a 1 000 kg /h flowrate, generates points X, Y and Z. It can be seen
that point Y falls outside the shaded region and the separator will not operate at maximum
efficiency. Here, it would be advisable to use a larger size separator; a DN40 separator would
be selected, as depicted by point Z, along with a pressure drop of about 0.07 bar at point W.

Steam pressure psi g (approximate) Flow velocity ft / s

0 20 40 60 80 100 120 150 180 200 250 300 350 20 50 80 120
DN150
10 000 (22 DN125
000)
DN100
5 000 (11
000) DN80
Steam flowrate kg / h (lb / h)

DN65
2 000 (4 DN50
X 400) Z Y
DN40 DN32
1 000 (2
200) DN25
500 (1 1 DN20
00)

DN15
200 (440
)

100 (220
)
10
(22 20 (4 50 (110)
) 4)

0 2 4 6 8 10 12 14 16 18 20 22 24 25 5 10 15 20 25 30 35 40
Steam pressure bar g Flow velocity m / s

)
(0.03
0.002 0.15)
0.01 (
(0.3)
0.02

(1)
0.05 0.1 (2
)
W

)
0.2 (3

Pressure drop across separator bar (psi approximate)

Fig. 12.5.5 Manufacturer’s sizing chart for a baffle type separator

12.5.6 The Steam and Condensate Loop

Block 12 Pipeline Ancillaries Separators Module 12.5

Table 12.5.1 summarises the important differences in the performance of baffle and cyclone
type separators.

Table 12.5.1 Comparison of baffle and centrifugal type separators

Baffle type Cyclonic type
Pressure drop Relatively low Relatively high
High over a wide range High over a narrower range
Efficiency
of velocities of velocities
Re-entrainment of water Little Significant above a critical velocity
Sizing Sized according to pipeline size Sized to ensure maximum efficiency

A suitable steam trap should be fitted to the condensate outlet of the separator to ensure the
efficient removal of condensate, without the loss of live steam. The most suitable type of steam
trap is the ball float type, which ensures immediate condensate removal. Some separators include
the steam trap mechanism inside the separator body.
Most vertical separators have a tapping on the top of the body. This can be used for an air vent,
facilitating the removal of air from the steam space during start-up.

Insulation
If a separator is left uninsulated, it can actually induce water droplets to form rather than eliminating
them, because of the large surface area exposed to the environment. Furthermore, significant
amounts of heat energy can be lost from the surface of the separator. For example, insulating a
separator containing steam at 150°C and exposed to ambient temperatures of 15°C, will produce
an annual energy saving of 8 600 MJ (Based on heat loss due to radiation only, assuming still air
conditions and 8 760 hours of operation per year). By fitting an insulation jacket, this heat loss
can be drastically reduced and the energy savings justify the initial cost of the insulation, within
an extremely short time.
Insulation jackets designed to fit over a particular separator should be used, as the shape of the
separator, particularly if it is flanged, makes it difficult to insulate. Standard flange covers leave
the body exposed, and therefore have a limited effect in the reduction of heat loss.
Even with the best insulation, it is not possible to eliminate all the heat loss from a product. The
efficiency of separator insulation is typically above 90%. It is important to use a jacket that is
designed for a particular separator; otherwise, the insulation efficiency will decrease. Properly
insulated separators also reduce the risk of personal injury from burns.

Fig. 12.5.6 A horizontal separator and insulating jacket

The Steam and Condensate Loop 12.5.7

Block 12 Pipeline Ancillaries Separators Module 12.5

Questions

1. Which of the following causes water entrainment in steam?

a| Priming and carryover of boiler water ¨
b| Heat loss in pipelines ¨
c| Production of saturated steam in a boiler ¨
d| All of the above ¨

2. Although in practice, it is difficult to measure the dryness fraction of steam, which

of the following factors provides a good indication that wet steam is present in a
steam system?
a| An increase in the steam velocity ¨
b| Valve chatter ¨
c| Erosion of pipe bends, wiredrawing, and waterhammer ¨
d| Increased condensate load ¨

3. The dryness factor of 10 bar g wet steam is known to be 0.9.

A separator is to be installed to increase this to above 0.98.
What is the minimum efficiency that the separator must have?
a| 64% ¨
b| 80% ¨
c| 84% ¨
d| 93% ¨

4. What is the main advantage of using a baffle type separator instead of a

cyclonic or coalescence type separator?
a| High efficiency over a wider range of flow velocities ¨
b| Very high efficiencies up to a flow velocity of 13 m / s ¨
c| Flanged versions are easy to insulate ¨
d| All of the above ¨

5. Size a baffle type separator using the sizing chart in Figure 12.5.5 for the following
conditions:
Operating pressure 8 bar g
Steam flowrate 1 000 kg / h
Pipeline size 65 mm
a| DN40 ¨
b| DN50 ¨
c| DN65 ¨
d| DN80 ¨

6. Which of the following is a benefit of using an insulation jacket specifically designed

for a particular separator?
a| Reduced heat loss ¨
b| An increase in the efficiency of the separator ¨
c| Protection from the possibility of burns ¨
d| All of the above ¨

Answers
1: d, 2: c, 3: b, 4: a, 5: c, 6: d

12.5.8 The Steam and Condensate Loop