Cause of water hammer in a trap header?
I have a trap header that receives condensate from several different
steam traps (220 to 240 F condensate temperature). Fluid from the
header goes through a vertical rise of 8 feet and eventually discharges
to a deaerator tank. The problem is that when condensate (200 F) is
pumped from a flash tank into the trap header, strong water hammer
events are observed.
Water hammer is typically caused by one of four reasons;
1. Rapid
valve closure. Valve closes quickly and the fluid momentum is
changed. Quick changes in fluid momentum result in large forces applied
at the location of the momentum change, and a high energy shock wave
which must dissipate its energy. Obviously valves should be closed
slowly.
2. Introducing flow to empty piping. The empty pipe offers
very little resistance to flow through it. Therefore, the flow
accelerates to high velocities very quickly. As soon as the flow
encounters an obstrucyion to flow, such as an pipe bend, etc. a large
momentum change occurs in a short period of time and water hammer
occurs. Piping systems should be filled and vented.
3. Introducing
low temperature water into a piping system containing steam. The steam
volume collapses quickly, and the water accelerates into this voided
area. When the water runs into itself or a pipe wall , a large fluid
momentum change occurs in a very short period of time.... water hammer
occurs. Water flow systems should be vented to prevent steam pockets
from forming before water flow is introduced.
4. Introducing steam
flow into piping partially filled with water. When steam comes in
contact with the cooler water, the steam will rapidly condense. The
steam volume collapses quickly, and the water accelerates into the void
area as in above. Steam flow piping should be drained before flow of
steam is introduced.
If I understand your configuration
correctly, it may be that the 8 foot rise pipe is partially full of
cooler water sitting at ambient temperature. Just a guess. Or is the
header pipe empty.
Two phase flow can be problematic, but in my experience two phase flow
in horizontal pipes can almost be guaranteed to introduce problems. With
the bias of my previous experiences I would think that your problem is
in the horizontal section from the top of the riser to the deaerator
vessel.
One thing you can be sure of is that the condensate from
the traps is not flashing. If the deaerator is controlled at 15 PSIG,
the pressure in the header can only be higher than that. The saturation
temperature at 15 PSIG is 250 F. If your condensate is entering at 220
to 240 F it will not flash.
Depending on the diameter of the
horizontal section after the riser (you say the flow is generally "low")
this section may cope with the flowrate with the pipe being only partly
full. If this is so, it will be possible for steam to enter this
horizontal pipe from the deaerator side and you may have a significant
vapor layer above the liquid in the pipe. With the condensate being
marginally below the steam temperature, and if the vapor space is large,
you may be getting steam condensing at a low rate and not causing
problems.
However, when the cold condensate from the flash tank
gets to the horizontal section after the riser the liquid flowrate will
be higher and there will be less vapor space. Also, the lower liquid
temperature will increase the driving force condensing the steam. The
smaller vapor space and more rapid condensation may be just the right
combination to cause slugging and hammer.
If this is the cause it
is easily fixed. All you need to do is to prevent the formation of the
vapor space above the liquid in this horizontal section. Either run the
horizontal section of the pipe at the lower level (i.e. at the level of
the trap header) and then put the riser as close to the deaerator as
possible, or leave the riser where it is but cut it shorter so that the
"horizontal" section slopes upwards and stays flooded.
If the
problem is not in this horizontal section the hammer can only be coming
from the deaerator itself because with the temperatures you have given
there cannot be steam anywhere else in the system. If this is the case,
all you can do is route the cold condensate from the flash tank to a
more appropriate place.
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