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Flash Separators

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CONDENSATE HANDLING AND Flash Separators
FLASH STEAM RECOVERY

• Saves Money
  Recover Valuable BTU's in Flash Steam

• Pre-engineered Design
  Convenient Charts for Easy Selection

• Smaller Size
  Replaces Larger Flash Tanks

• Quality Construction
Built to the ASME Code Sec. VIII, Div. 1

Penn Flash Separator uses a tangential inlet and cyclonic action to instantly separate steam and condensate. Our Flash separators are smaller in size and more efficient than traditional flash tanks. Because of our unique size they are usually less expensive than traditional flash tanks. The clean steam can be returned to a lower pressure saving valuable BTU's and make-up water. Return on investment can be in a matter of weeks. Easy Selection using our flash steam and selector charts assures proper sizing of a Flash Separator for your condensate requirements. Penn Separator has experience building pressure vessels to ASME Code since 1956. Each Flash Separator comes standard with ASME Code Sec. VIII, Div. I stamp.

Why Penn Flash Separators are Rapidly Replacing Flash Tanks

Flash tanks are designed to have a internal velocity slow enough so that the venting steam will not pick up any water. To accomplish this a large diameter tank is required.

The Penn Flash Separator uses a smaller diameter tank and a tangential inlet that spins the condensate around creating a low pressure area in the center of the separator. This allows the condensate to flash into the center and follow it upwards to the centrally located vent providing clean dry steam.

The smaller size and clean dry steam are the reason why Penn Flash Separator are replacing traditional flash tanks.

Dollar Savings From The Use of a Penn Flash Separator

You can put high or medium pressure condensate to work for you in the following way

10,000 #/hr. condensate at 100 psig taken to a Flash Separator and venting to a 5 psig deaerator or any low pressure steam use.

10,000 #/hr. from 100 psig to 5 psig gives 11.8% flash steam or 1180 #/hr. steam X 1156 btu's/ lbs. gives 1,364,080 btu's/hrs. recovered / 1,000,000 btu's / .80 boiler efficiency x $ 5.00 fuel cost/million BTU's.

Anticipated hourly savings from flash steam = $ 8.52/hour
Yearly Savings at $ 8.52 x * 2080 = $ 17,721.80/year (* Based on 8 hour day 5 days a week)
Equipment cost using a FS 14-34 flash separator, trap, level gauge, safety relief valve, and legs $ 2,135.00.

Suggested Specifications:

Furnish and install as shown on plans a Vertical Cyclone Flash Separator Model No. FS _____ " Dia. - _____" Height, as selected for a condensate flow rate of _____ #/hr. at _____ psig flashing to a pressure of _____ psi. The nozzles also selected for the flow rate shall include a _____" tangential inlet with stainless steel wear plate to match the condensate line size, a _____" water leg overflow type condensate drain, and a _____" centrally located steam vent to produce 97% quality flash steam. The tank shall include coupling connections for a level gauge, inspection openings and tank cleanout. Materials and locations per our spec print C-4B.

Optional accessories that can be provided include a (External Float Level Controller with a Pneumatic or Mechanical Control Valve or Armstrong Trap Model No. _____) properly sized for the condensate drain flow rate, inlet Check Valves (list sizes) as required for multiple inlets at various pressures, tank Clean-Out Ball Valve, Safety Relief Valve to protect the tank from over-pressurizing or to maintain a maximum venting pressure, a Pressure Gauge with Iron Siphon, and Industrial Type Thermometer.

Optional Supports include Angle Legs with Floor pads. Three legs are provided on 24" diameter separators and smaller and four legs are provided on larger separators. Your special mounting bracket designs are also available.

Selecting a Flash Separator:

Flash Separators are sized for the condensate flow entering the tank and the amount of flash steam that is produced when venting to a lower pressure. To select a flash separator use Chart "A" to determine the flash steam amount and Chart "8" that gives the size of tank and nozzle connection sizes required.

From Chart "A" follow the "PRESSURE FROM" (horizontal at the top) down vertically to the "FLASH TO" pressure. All pressures are in psig. Example: 100 psig condensate "pressure from" flash to a low pressure application at 5 psig gives 11.8% condensate flashed into steam.

Chart "A" - Percentage of Flash Steam
	600	500	450	400	350	300	250	200	150	100	75	50	25
500	2.8
400	5.8	3.1	1.3
350	7.5	4.8	3.0	1.8
300	9.2	6.6	4.8	3.6	1.9
250	11.1	8.5	6.8	5.6	3.9	2.1
225	12.2	9.7	8.0	6.8	5.1	3.3	1.2
200	13.3	10.8	9.1	7.9	6.2	4.4	2.4
175	14.4	11.9	10.3	9.1	7.4	5.7	3.7	1.3
150	15.7	13.2	11.6	10.4	8.8	7.0	5.0	2.7
125	17.1	14.6	13.0	11.9	10.3	8.5	6.6	4.3	1.6
100	18.6	16.2	14.6	13.5	11.9	10.2	8.3	6.0	3.4
75	20.3	18.0	16.4	15.3	13.7	12.1	10.2	7.9	5.4	2.0
50	22.6	20.3	18.8	17.7	16.1	14.5	12.6	10.4	7.9	4.6	2.6
25	25.4	23.1	21.6	20.6	19.1	17.5	15.6	13.5	11.0	7.8	5.9	3.3
15	26.9	24.7	23.2	22.1	20.6	19.0	17.2	15.1	12.7	9.5	7.6	5.1	1.8
10	27.8	25.6	24.2	23.1	21.6	20.1	18.3	16.2	13.8	10.6	8.7	6.2	2.9
5	28.9	26.7	25.2	24.2	22.7	21.1	19.4	17.3	14.9	11.8	9.9	7.4	4.2
0	30.2	28.0	26.6	25.6	24.1	22.6	20.8	18.8	16.4	13.3	11.4	9.0	5.8

Knowing the flash steam percentage use Chart "B" "next page" to select the Flash Separator by finding the flash amount across the top and going down to the total condensate flow rate entering the separator shown on the left side of the chart. Example: Referring back to "Chart A" we had 11.8% flash steam. If you have a condensate flow rate of 10,000 #/hr. entering the separator you will have (10,000 X 11.8 %) or 1,180 #/hr. flashing to steam. Find the flash amount across the top of the chart for 1,180 #/hr. Use an amount not less then the actual steam amount or column 2,000 #/hr. and follow this down to the condensate amount of 10,000 #/hr. This example would use a 14" Dia. X 34" High Flash Separator with a 2" condensate drain and 4" steam vent.

SIZING NOTES:
1. Drain and vent sizes listed in Chart B are for atmospheric operating pressures. When the flash pressure is above atmospheric pressure a smaller drain and vent size may be used. The drain can be selected not to exceed the available flash to pressure in the vessel The drain can also be selected to match the size of the trap or control valve. To select a vent for application above atmospheric pressure use the following formula:

Minimum vent size formula:

Where: Dia. Equals the minimum diameter of vent (inches), F is the amount of flash steam in Ibs./hour, the and SV is
specific volume of steam (cu.ft/lbs.) at the lower pressure.

2. The condensate from the Flash Separator operating at atmospheric conditions can be directed to a floor drain. This type of separator can use an optional Penn Aftercooler Package to automatically cool the temperature of the condensate leaving the separator drain to an acceptable temperature. Refer to page C-3 "Cooling Chart - Flash Separator Discharge for recommended drain and cooling valve sizes.

Chart "B" - Sizing Flash Separator
			100	500	700	1,000	2,000	3,000	4,000	8,000	12,000	18,000	21,000	25,000	35,000
LBS Per Hour Condensate	100,000	Height	108	108	108	108	108	108	108	108	108	108	108	108	108
		Dia.	30	30	30	30	30	30	30	30	30	30	30	36	36
		Drain	5	5	5	5	5	5	5	5	5	5	5	5	4
		Vent	2	2	2 1/2	3	4	5	6	8	10	12	14	16	18
	90,000	Height	96	96	96	96	96	96	96	96	96	96	96	96	96
		Dia.	30	30	30	30	30	30	30	30	30	30	30	36	36
		Drain	5	5	5	5	5	5	5	5	5	5	4	4	4
		Vent	2	2	2 1/2	3	4	5	6	8	10	12	14	16	18
	80,000	Height	96	96	96	96	96	96	96	96	96	96	96	96	96
		Dia.	24	24	24	24	24	24	24	24	24	24	30	36	36
		Drain	5	5	5	5	5	5	5	5	4	4	4	4	4
		Vent	2	2	2 1/2	3	4	5	6	8	10	12	14	16	18
	70,000	Height	72	72	72	72	72	72	72	72	72	72	72	72	72
		Dia.	24	24	24	24	24	24	24	24	24	24	30	36	36
		Drain	4	4	4	4	4	4	4	4	4	4	4	4	4
		Vent	2	2	2 1/2	3	4	5	6	8	10	12	14	16	18
	60,000	Height	56	56	56	56	56	56	56	56	56	56	56	56
		Dia.	24	24	24	24	24	24	24	24	24	24	30	36
		Drain	4	4	4	4	4	4	4	4	4	4	4	4
		Vent	2	2	2 1/2	3	4	5	6	8	10	12	14	16
	50,000	Height	72	72	72	72	72	72	72	72	72	72	72	72
		Dia.	20	20	20	20	20	20	20	20	20	24	30	36
		Drain	4	4	4	4	4	4	4	4	4	4	3	3
		Vent	2	2	2 1/2	3	4	5	6	8	10	12	14	16
	40,000	Height	56	56	56	56	56	56	56	56	56	56	56
		Dia.	20	20	20	20	20	20	20	20	20	24	30
		Drain	4	4	4	4	4	4	4	4	3	3	3
		Vent	2	2	2 1/2	3	4	5	6	8	10	12	14
	30,000	Height	56	56	56	56	56	56	56	56	56	56
		Dia.	18	18	18	18	18	18	18	18	20	24
		Drain	3	3	3	3	3	3	3	3	3	2 1/2
		Vent	2	2	2 1/2	3	4	5	6	8	10	12
	20,000	Height	56	56	56	56	56	56	56	56	56
		Dia.	14	14	14	16	16	16	16	16	20
		Drain	2 1/2	2 1/2	2 1/2	2 1/2	2 1/2	2 1/2	2 1/2	2 1/2	2 1/2
		Vent	2	2	2 1/2	3	4	5	6	8	10
	10,000	Height	34	34	34	34	34	34	34	56
		Dia.	14	14	14	14	14	14	14	16
		Drain	2	2	2	2	2	2	2	1 1/2
		Vent	2	2	2 1/2	3	4	5	6	8
	5,000	Height	34	34	34	34	34	34	34
		Dia.	10	10	10	10	14	14	14
		Drain	1 1/2	1 1/2	1 1/2	1 1/2	1 1/2	1 1/2	1 1/4
		Vent	2	2	2 1/2	3	4	5	6
	3,000	Height	34	34	34	34	34
		Dia.	10	10	10	10	14
		Drain	1 1/4	1 1/4	1 1/4	1 1/4	1 1/4
		Vent	2	2	2 1/2	3	4
	2,000	Height	34	34	34	34
		Dia.	8	8	8	10
		Drain	1 1/4	1 1/4	1	1
		Vent	2	2	2 1/2	3
	1,000	Height	34	34	34
		Dia.	6	8	8
		Drain	1	1	1
		Vent	2	2	2 1/2

USES OF FLASH SEPARATORS


Sketch #1 Typical Flash Separator application flashes high or medium pressure condensate to supplement a low pressure steam use.	Sketch #3 Staged Flash Separators use two separators to supply medium and low pressure steam from high pressure condensate.

Sketch #2 Flash Steam from a high pressure process to supply medium pressure steam to heaters.	Sketch #4 Waste condensate that needs cooled to drain can use a Flash Separator with our automatic aftercooler fitting and accessories.

PENN SEPARATOR CORPORATION
5 South Pickering
P.O. BOX 340
Brookville, PA 15825
(814) 849-7328
Fax: (814) 849-4510
TOLL FREE: 1-888-PENN-SEP (7366-737)