High Efficiency Steam Exchangers
Steam to Building Heat
Steam to Domestic Water
Increase energy efficiency and save space
Introducing… the XE System for steam control in large
facilities. It's a skid-mounted/pre-piped design that
saves space, energy, and even water
Designed for both building heat and domestic hot water
applications. XE systems can reduce energy
consumption by between 5 – 15 percent
Toll Free 877-629-4843
website: advancedsteam.com
XE Stands for “Extra Energy Extraction”
How GREEN is your STEAM? Go outside and look at your facility. See that flash steam? It
has valuable BTU’s that are being wasted. It is pure water that could have been re-used. By
using this wasted energy the XE system saves money, reduces emissions, and can even
earn LEED points towards GREEN building construction.
Advantages of the XE Vertical
Exchanger
The direct benefits of the XE Vertical
Exchanger are threefold;
1) Reduced greenhouse emissions by
reducing fuel consumption and flash steam
2) Reduced cost of operation, and carbon
footprint, and
3) Lower installed costs for new projects
since high pressure steam can be used
directly.
These benefits will result in simpler
mechanical room design, and add
incrementally to the greening of the facility.
Besides being environmentally friendly, the
Advanced Steam Technology XE system is:
Accurate
Control liquid leaving temperature:
- at +/- 2F for Building Heat
- at +/- 4F for Domestic Water
Efficient
Utilize steam wasted by other water heaters
- Save 20% of energy usage at 125 psig steam,
- Save 5% of energy usage at 15 psig steam.
Economical
Lower installed cost than other water heaters
Space saving
Smaller footprint – typically 3ft.x 4ft.
Easy to install
Only 4 connections required
How does the XE design extract extra energy from condensate?
Simply put…By using the lower part of the heat exchanger as a water to water exchanger:
100 psi 338F steam in
180F water out
Steam side = 20% flooded
160F water in
200F condensate out
XE - Flooded Vertical Heat Exchanger
In this simplified diagram, straight 100 psi
steam fills the unit, except for the bottom 20
percent.
The condensate there is being cooled by the
entering 160F return water. The unit is sized
to cool the condensate to 200F, so it doesn’t
flash.
The primary control valve is at the bottom of
the heat exchanger, and adjusts the amount of
flooding to meet the heat demand.
Often times a pump is not needed to lift the
condensate, because unlike a modulated steam
unit, 100 psi is pushing the condensate.
New Project Benefits include:
9
LEED Certifiable for energy savings and innovation points
9
Reduce steam pipe size and total installed cost
9
Reduce or eliminate wasteful flash steam venting
9
Vertical design saves expensive mechanical room floor space
Conventional Steam Piping Requirements
Compare an example of a 500 GPM, 5 million BTU/hr,
building heat system. Let’s look at the sizing and energy
consumption for conventional equipment:
Steam is distributed at 100 psig and reduced in the
mechanical room to 15 psi. The load on a conventional
system will be 5294 #/hr of steam.
2
1
6
High Pressure Steam
3 inch line size at 100 psi
Pressure Regulating Valve
2 inch full port (or perhaps a
1/3-2/3 using two regulators
for better accuracy)
Relief Valve Size
4x6 inch with N orifice is
needed to handle the
potential flow from a “stuck
open” regulator
3
Relief Valve Vent
Pipe Size = 6 inch,
normally run up
through the roof.
This is often the
most expensive part
of the installation
5
Control Valves
Normally 2 valves are
needed, both 2 inch
They throttle steam
pressure to control water
temperature
Low Pressure Steam
6 inch line size at 15 psi
This is because steam expands
4 times in volume when
reduced from 100 psi
12
7
Condensate Return
If returned to the boiler,
the 208 #/hr flash loss must be
“made up” with fresh treated
feed water
Heat Exchanger Accessories
Thermostatic Air Vent and Vacuum
Breaker are needed for when the
control valves throttle below 50%
11
Pump Receiver Vent
208 #/hr of flash steam will be
released when operating at full
load and 15 psi
8
Primary Steam Trap
A 2-1/2 inch high capacity
trap must discharge by
gravity and be installed
18 inches below the
exchanger
4
9
Hot Flashing Condensate
Discharges into the return piping
and the temperature drops from
250F to 212F. It can damage a
condensate pump impeller and
seals due to cavitation
10
Condensate Pump
30 GPM at 20 feet head when the
condensate return line is elevated or
has back pressure. The pump will
require a power source and isolation
XE Thermal Steam Piping Requirements
Look at the same example of a 500 GPM, 5 million BTU/hr system. Let’s
look at the sizing and energy consumption for the XE Thermal System:
Steam is condensed at 100 psig, but the extra efficiency uses only 4906 #/hr
of steam, about 8% less steam than conventional.
1
2
3
Steam Line
A 3 inch line is sufficient since the
100 psi pressure is delivered directly
to the exchanger. No need for
pressure reducing valves unless
desired.
Shut-off Valve
An automatic temperature over-ride
valve is installed at the inlet as a
safety, and to allow slow start-up.
It can be an automated butterfly valve
or on some applications, a self
operated temperature regulator.
Drip Traps
Two steam traps are
furnished on the inlet. The
first keeps condensate
away from the inlet valve
on start up. The second
keeps condensate from
building up above the
exchanger
8
Condensate Injector
High pressure flashing condensate
from the drip traps is mixed with the
cooler condensate from the
exchanger through a sparge fitting.
4
7
Vertical Exchanger
The exchanger is larger and more
heavy duty than conventional. It
needs more surface area to cool the
condensate down to 200F or below.
Steam Trap
Serves as a back-up in case the
condensate control valve fails open or
the load increases.
6
5
Cool Condensate
The condensate is below 200F and
under pressure, so a long drop leg is
not needed on the drain side
Condensate Control Valve
Is the primary temperature control
device. It throttles to maintain the
flooded condition in the exchanger
which satisfies the load demand. It is
normally a ¾ inch industrial grade
unit with fail closed actuator.
Typical Systems
The XE steam exchanger systems are
available in multiple sizes:
Building heat from 10 - 1700 gpm.
Domestic water from 10 - 200 gpm.
Units can be duplexed for higher capacity and
redundancy.
High efficiency operation on steam pressures
up to 175 psig.
Duplex 400 gpm Building Heat on 60 psi steam
Duplex 125 gpm Domestic Water on 50 psi steam
Duplex 275 gpm Building Heat on 100 psi steam
Typical Specifications
(also available as text files on advacedsteam.com)
Building Heat
XE-BH XE Thermal Vertical Style Steam Water Exchanger for Building Heat.
XE Control for "extra energy extraction" from the steam and condensate. Capacity XX gpm, with EWT 85
LWT 105F, 100 psi steam in, 200F condensate out. Heat exchanger model BEM Vertical steel shell, copper
or cupro-nickel tubes & 150 psig ASME stamp. High performance industrial grade control valve for primary
condensate control. Electronic control panel with basic MODBus controls (or control can be by BAS
contractor). Self standing steel framework. Pre-piped trap, strainer, and control valve on condensate side.
Pre-piped thermometers and gages on water side.
Items delivered separately:
Double acting electric actuator on HP butterfly valve and control interface for secondary steam control.
Pressure gauge with pigtail & isolation valve for the steam side
Pressure relief valve on the water/glycol side
F&T steam trap as drip and air eliminator on steam inlet
Domestic Hot Water
Model: XE-DW Ultra High Efficiency Water Heating Skid with Vertical Flooded Heat Exchanger.
XE Control for "extra energy extraction" from the steam and condensate. Capacity: XX GPM of water, from
40F to 120F, 70 psig steam, 200F condensate out. Heat exchanger model BEM Vertical T-316 stainless steel
shell, copper or cupro-nickel tubes & 150 psig ASME stamp. Inlet and outlet thermometers. Modulating
Electric Valves: Siemens magnetic control valve for primary condensate control.
Electronic control panel with basic MODBus controls. Self standing steel framework. Pre-piped trap, strainer,
and control valve on condensate side. Pre-piped thermometers and gages on water side.
Note: If a 3-way mixing or system anti-scald device limits building recirculation back to this unit, a preinsulated, 150 psi ASME buffer tank and pump are required for unit recirculation.
The tank shall have the same “gallonage” as the unit capacity. (60gpm = 60 gallon tank)
Items delivered separately:
Double acting electric actuator on HP butterfly valve and control interface for secondary steam control.
Pressure gauge with pigtail & isolation valve for the steam side
P/T relief valve on the liquid side
F&T steam trap as drip and air eliminator on steam inlet
Double-wall Domestic Hot Water
Model: XE-DDW Ultra High Efficiency Water Heating Skid with Vertical Flooded Heat Exchanger.
XE Control for "extra energy extraction" from the steam and condensate. Capacity: XX GPM of water, from
40F to 120F, 70 psig steam, 200F condensate out. Heat exchanger model BEU-DW Vertical T-316 stainless
steel shell, double-wall copper or cupro-nickel tubes & 150 psig ASME stamp. Inlet and outlet thermometers.
Modulating Electric Valves: Siemens magnetic control valve for primary condensate control.
Electronic control panel with basic MODBus controls. Self standing steel framework. Pre-piped trap, strainer,
and control valve on condensate side. Pre-piped thermometers and gages on water side.
Note: If a 3-way mixing or system anti-scald device limits building recirculation back to this unit, a preinsulated, 150 psi ASME buffer tank and pump are required for unit recirculation.
The tank shall have the same “gallonage” as the unit capacity. (60gpm = 60 gallon tank)
Items delivered separately:
Double acting electric actuator on HP butterfly valve and control interface for secondary steam control.
Pressure gauge with pigtail & isolation valve for the steam side
P/T relief valve on the liquid side
F&T steam trap as drip and air eliminator on steam inlet
Limited Warranty and Remedy
Advanced Steam Technology Company LLC (Advanced Steam)
warrants to the original user of those products supplied by it and
used in the service and in the manner for which they are
intended, that such products shall be free from defects in
material and workmanship for a period of one (1) year from
the date of installation, but not longer than 15 months
from the date of shipment from the factory [unless a Special
Warranty Period applies, as listed below]. This warranty does
not extend to any product that has been subject to misuse,
neglect, or alteration after shipment from the Advanced Steam
factory. Except as may be expressly provided in a written
agreement between Advanced Steam and the user, which is signed
by both parties, Advanced Steam DOES NOT MAKE ANY OTHER
REPRESENTATIONS OR WARRANTIES, EXPRESS
OR IMPLIED, INCLUDING, BUT NOT LIMITED TO,
ANY IMPLIED WARRANTY OF MERCHANTABILITY
OR ANY IMPLIED WARRANTY OF FITNESS FOR A
PARTICULAR PURPOSE.
The sole and exclusive remedy with respect to the above
limited warranty or with respect to any other claim relating
to the products or to defects or any condition or use of
the products supplied by Advanced Steam, however caused,
and whether such claim is based upon warranty, contract,
negligence, strict liability, or any other basis or theory, is
limited to Advanced Steam’s repair or replacement of the part
or product, excluding any labor or any other cost to remove
or install said part or product, or, at Advanced Steam’s option, to
repayment of the purchase price. As a condition of enforcing
any rights or remedies relating to Advanced Steam products, notice
of any warranty or other claim relating to the products must
be given in writing to Advanced Steam: (i) within 30 days of last
day of the applicable warranty period, or (ii) within 30 days
of the date of the manifestation of the condition or occurrence
giving rise to the claim, whichever is earlier. IN NO EVENT
SHALL ADVANCED STEAM BE LIABLE FOR SPECIAL, DIRECT,
INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES,
INCLUDING, BUT NOT LIMITED TO, LOSS OF USE OR
PROFITS OR INTERRUPTION OF BUSINESS. The Limited
Warranty and Remedy terms herein apply notwithstanding
any contrary terms in any purchase order or form submitted
or issued by any user, purchaser, or third party and all such
contrary terms shall be deemed rejected by Advanced Steam.
Advanced Steam Technology Company LLC
PO Box 2899 – West Lafayette, IN 47996-2899
Phone 877-629-4843 Fax 765-464-8521 www.advancedsteam.com
Bulletin XE 101- 0808