# One equation comprising two independent variables gives an accurate assessment of steam quality

# |

# Reprinted from Plant Services

Steam quality is a measure of the amount of saturated steam that coexists with its condensate in a given system. Calculate it by dividing the mass of steam by the total mass of steam and condensate.

## Steam quality = Msteam/(Msteam + Mcond) (Eqn. 1)

Others have pointed out the importance of identifying steam quality in systems supporting industrial applications. For example, excessive moisture in the form of free droplets carried along with the main steam flow might impinge on turbine blades and cause mechanical damage. Likewise, high-velocity condensate can score valve seats and cause other erosionand corrosionrelated problems.

Ganapathy(1) gives a detailed explanation of how to calculate steam quality with a throttling calorimeter. A small quantity of the steam is throttled through an orifice from system pressure **(PS) **down to atmospheric pressure. The steam temperature at the orifice exit **(TE) **is recorded. This expansion is adiabatic. The following expression describes the energy balance associated with the throttling process: **HM = HL (1-X) + HGX (Eqn. 2)**

And after rearranging:

## X = (HL-HM)/(HL – HG) (Eqn. 2a)

Where:

**HM **= enthalpy of superheated steam at temperature.

**TE **= exit temperature at atmospheric pressure.

**HL **and **HG **= the enthalpy of condensate and steam, respectively, at system pressure **PS**.

**X **= the steam quality.

Thermodynamic data for calculating steam quality may be obtained from *ASME Steam Tables(2) *or any other library source(3). Ganapathy developed a diagram, which displays **TE **on the abscissa and **X **on the ordinate. A series of isobars for **PS **in the 50 to 500 psia range also is shown on the diagram. The diagram provides a quick estimate of steam quality when **TE **and **PS **are known.

Liley(4) calculated steam quality at pressures ranging from 2 bars (29 psia) to 20 bars (290 psia) in one bar increments. He developed an equation of the form:

## X = A + BTE (Eqn. 3)

It describes the steam quality at each pressure, **PS **as a function of **TE**. Each set of coefficients **A **and **B **is valid for only a single pressure.

Coefficients for pressures not included in the list must be interpolated. Solving equations 2a and 3 requires a user to look up recorded data.

The following equation was developed to quantify steam quality when the pressure and calorimeter temperature are known. It is valid for a steam quality between 0.95 and 1.00 and for pressures between 30 psia and 600 psia:

## X = 0.9959 – 0.000442TE – ln[(PS + 6.8)0.03218(PS + 374)-0.0001581TE] (Eqn. 4)

Solving for **TE**:

## TE = [0.9959 -X – 0.03218 ln(PS + 6.8)]/[0.000442 – 0.001581 ln(PS + 374)] (Eqn. 4a)

Expressing steam quality by means of a single continuous function eliminates the need for graphical data representation or interpolation. The equations can be used for online steam quality monitoring with a programmable process controller using orifice exit temperature and steam system pressure as input values, or they can simply be stored in the memory of a pocket calculator for use when the information is required.

By curve fitting available data in the *ASME Steam Tables*, the P-T relationship for saturated steam in the 30 to 600 psia range can be expressed as:

## PS = 1.5 + (TS/120.62)4.5886 (Eqn. 5)

Solving for the saturated steam temperature **TS**:

## TS = 120.62 (PS – 1.5)0.21793 (Eqn. 5a)

Substituting Eqn. 5 into Eqn. 4 allows the latter to be expressed entirely in terms of **TE **and **TS**. The graph in Figure 1 gives a quick method for calculating steam quality when saturation pressure and temperature and calorimeter temperature are known.

The validity of the above equations has been tested against a known example presented in one of the referenced articles and, at a more elevated pressure level, against steam data obtained from the *Engineering Data Book(3).*

*Figure 1. Steam quality ***X **can be quickly assessed graphically when the exit temperature **TE **and the saturated steam temperature **TS **and pressure **PS **are known.

## Try these examples

**Example 1. **Calculate the steam quality of a 200 psia system when the orifice exit temperature is 250 F.

Liley, using the method described in his article, calculates the steam quality to be 0.9636. Applying Eqn. 4 with **TE **= 250 and **PS **= 200 gives an answer of 0.9649a difference of 0.13 percent.

**Example 2 **uses thermodynamic data obtained from the *Engineering Data Book*. It calculates steam quality at a pressure higher than that described in either of the two referenced articles:

Example 2. Calculate the quality of steam at 566.1 psia, when the throttling calorimeter temperature is 300 F.

The calculations use available data from the *GPSA Engineering Data Book*. At 566.1 psia, the enthalpy of the condensate is 464.5 Btu/lbm while the enthalpy of the saturated steam is 1204.1 Btu/lbm. The enthalpy of expanded steam at 300 F and 14.696 psia is 1,192.8 Btu/lbm. Substituting into Eqn. 2 gives: 1,192.8 = (1-**X**)(464.5) + 1,204.1 *X*. Solving for **X **yields 0.9840. Using Eqn. 4 instead results in an answer of 0.9836a difference of 0.004 percent.

**Example 3. **Steam at 500 psia is to have a quality of not less than 0.9775. What should be the expanded steam temperature?

Eqn. 4a provides the answer. The calculated temperature is 289.5 F. This means the steam temperature at the orifice exit must be no less than 290 F.

**Example 4. **A saturated steam system has a temperature of 460 F. Expansion in a throttling calorimeter results in a steam temperature of 300

- Calculate the steam quality.

Start with Eqn. 5 to calculate system pressure when the temperature is 460

- This gives a calculated pressure of 466.58 psia. This answer differs by

0.06 percent with the value noted in the *Steam Tables*. The calculated pressure and expanded steam temperature are then entered in Eqn. 4. The steam quality is 0.9844.

**Example 5. **Calculate steam quality when saturated steam at 420 psia shows a temperature difference of 165 F between steam temperature and calorimeter temperature.

Use Eqn. 5a to calculate the saturated steam temperature: **TS **= 449.50 F. Then **TE **= 449.5 – 165 = 284.50 F. Now substitute **PS **= 420 and **TE **=

284.5 into Eqn. 4. Answer: **X **= 0.9756. Also refer to Figure 1 for comparison.

*References:*

- Ganapathy, , “Calculate the moisture content of steam,”
*Chemical Engineering*, p. 127, August, 1993.
- Meyer, A., McClintock, R.B., Silvestri, G.J., and Spencer, R.C., Jr.,

*ASME Steam Tables*, 5th edition, A.S.M.E., New York, 1983.

*Engineering Data Book*, Section 24, “Thermodynamic Properties,” Revised 10th edition, Gas Processors Association, Tulsa, Oklahoma,
- Liley, Peter , “A simple equation for steam quality,”
*Chemical Engineering*, p. 140, August, 1994.

*Frank A. Rusche is a process engineer with Kellogg-Brown and Root in Houston, Texas. He can be reached at **Frank.Rusche@Halliburton.com* *or 281-575-3432.*

## ELLISON-STYLE STEAM THROTTLING CALORIMETER

**Exclusive U-Path Principle**

Pioneered by Ellison in the early 1900’s to provide accurate readings for pressures down to 26 PSIG. The steam flows through the inlet holes of the sampling nozzle, through the valve assembly and the orifice plug, expanding into the steam chamber. The steam flows into the bottom of the inner chamber, flashing moisture, then up the sides to the top where it encapsulates inner chamber before exhausting at the bottom of calorimeter. This process causes inner chamber to have stable thermal properties.

## Throttling – Why?

Throttling of steam provides accurate steam quality results over a wide range of process conditions. If superheat is maintained within Ellison calorimeter, exacting calculations can be performed.

## High Moisture Content

Small amounts of moisture separated in the inner chamber are re-evaporated when unit returns to superheat temperature range. A drain valve connected to inner chamber is used to collect separated liquid during high moisture periods.

## Insulation

The steam chamber is designed so escaping steam flows around inner chamber to ensure a uniform temperature within the calorimeter. The steam jacket is packed with one inch of very low thermal conductivity insulating material to give additional thermal protection.

**NOTE: **Cal Research’s study has found the indicated steam quality is that of the steam sample entering the calorimeters and if the sample is not iso- kinetic to the steam within the line, errors will occur. Herein lays the importance of a well designed steam sampling probe assembly. This means if the sample is from the side or bottom of the line, the steam sample will be wet.

## Accuracy

The Ellison Steam Calorimeter has a general accuracy of the +/- ½% total reading when operating temperature of unit indicates superheat. This can be enhanced, with corrections for sample flow, orifice flow, line thermal losses, and isokinetic condition, to +/- .1% total reading.