steam utilization - hook up diagrams

HOOK-UPAPPLICATION

DIAGRAMS

Sectio

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Boiler Steam Headers provide collect-ing vessels for the steam flowing fromone or more boilers, and distribute it toas many mains as are needed to sup-ply the plant. Often the flow may be ineither direction along the headerdepending on which boilers and whichsupply lines are being used. Selectingthe ideal location for the drip point isthus complicated. It is recommendedto make the header of such an

Figure II-1Boiler Steam Header

To Plant

Spira-tecLoss

Detector

Thermo-Dynamic

Steam Trapwith Integral

Strainer

Figure II-2Draining End of Low Pressure Steam Main

FromBoiler

Spira-tecLoss

Detector

Thermo-Dynamic


Strainer

Float &ThermostaticSteam Trap

Spira-tecLoss

Detector

Strainer

CondensateReturn

In the case of low pressure mains,the use of Float and Thermostatictraps is recommended for the dripstations. The introduction of F & Ttraps with steel bodies, third gen-eration capsule type or bimetallicair vents, and operating mecha-nisms suitable for pressures up to465 psi, means that F & T trapscan also be used on properlydrained lines where waterhammerdoes not occur, even at pressureswhich would formerly have exclud-ed them. An auxiliary air vent isrecommended for the end of allmains where the system is startedup automatically.

LP Steam Main

increased diameter as to drop thesteam velocity through it to a low valueeven with maximum flow in eitherdirection.The header can then act alsoas a separator, and generously sizedsteam traps can be fitted at each end.

The boiler header and the separator,which should be fitted in the steamtake off from modern high perfor-mance packaged boilers, maysometimes have to cope with carry-

over from the boiler. These two loca-tions form the exception to the generalrule that mains drip points rarely needa steam trap as large as the 1/2" sizeand can usually be fitted with 1/2" LowCapacity traps. Instead, traps in 3/4"and even 1" sizes are often used. Thepotential for steam losses when theselarger traps eventually become worn isincreased, and the use of Spira-tecsteam trap monitors is especially valid.

SupervisedStart-up

Valve

SupervisedStart-up

Valve

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Drip points along the run of the steamlines, and at the bottom of any risers,should incorporate large diametercollecting pockets. Equal tees areuseful in sizes up through 6" and larg-er size pipes can have pockets 2 or 3sizes smaller than the main but notless than 6". The terminal points ofthe mains should have automatic airvents, and equal tees again provideconvenient collecting pockets for bothcondensate and air when installed asshown.

Figure II-3Draining and Air Venting Steam Lines

InvertedBucket


Strainer

Spira-tecLoss

Detector

BalancedPressure

ThermostaticAir Vent

Condensate Main

Thermo-Dynamic


Strainer

Spira-tecLoss Detector

Figure II-4Draining Expansion Loops

Condensate Return

Thermo-Dynamic


Strainer

Thermo-DynamicSteamTrap

Spira-tecLoss

Detector

Spira-tecLoss

Detector

Expansion loops are often fitted inthe vertical plane, with the loop eitherbelow or above the line. When belowthe line, condensate can collect in thebottom of the loop. Above the line, itwill collect just in front of the loop, atthe foot of the riser. Drainage pointsare necessary in each case, asshown.

SupervisedStart-up

Valve

SupervisedStart-up

Valve

Strainer

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Both HP and LP mains often must bedrained to a condensate return line atthe same elevation as the steam line.The best location for the traps is thenbelow the steam line, with a riserafter the trap to the top of the returnline.

Figure II-5Draining Steam Mains to Return Main at Same Level

Spira-tecLoss

Detector

Thermo-DynamicSteam Trap withIntegral Strainer

Connector


Strainer

Spira-tecLoss

Detector

CondensateMainHP

MainLP

Main

For supervised startup of steammains, a manual bypass is fitted sothat condensate can be drained bygravity while the line pressure is toolow for it to be handled by the trap atan adequate rate. If a second trap isfitted in the bypass line, a similarhookup is obtained which is suitablefor automatic startup.

Figure II-6Trapping Hook-up for Start-up of Steam Main

Often the normal trap discharges to areturn line at higher elevation. Thestartup trap must always dischargeby gravity so here it is separated fromthe “normal running” trap. AThermoton is used so that it will closeautomatically when the condensatetemperature shows that warm up ofthe main is nearing completion.

Figure II-7Hook-up with Condensate Return Line at High Level

Thermo-DynamicSteam Trapwith Integral

Strainer

Spira-tecLoss

Detector

Thermo-Dynamic SteamTrap with Integral Strainer

Spira-tecLoss

Detector


Strainer

Spira-tecLoss

Detector

Liquid ExpansionSteam Trap

Drain

CondensateReturn

CheckValve

CheckValve

SupervisedStart-up

Valve

CheckValve

SupervisedStart-up

Valve

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In some cases, the existence of other service or processlines alongside the stream main is combined with theneed to lift the condensate from the drip point to higherlevel. Without the loop seal, clearance of condensate fromlength L and replacement with steam means that forappreciable times steam passes up length H and holdsthe trap closed, although condensate may be collecting inthe pocket. The arrangement shown minimizes this prob-lem and gives most consistent performance of the trap.

Thermo-Dynamic


Strainer

Spira-tecLoss

Detector

Figure II-8Draining Steam Main where Trapmust be at Higher Level

SteamMain

GenerousCollecting

Pocket

Loop Seal(where “L”

exceeds “H”)

CondensateMain

L

H

Figure II-9Condensate Drainage to Reinforced Plastic Return Line, with Overheat Protection

Steam Main

CondensateReturn Pipe

CoolingChamber

Diffuser

Spira-tecLoss

Detector

Main DripSteam Trap

HighTemperature

Drain

T44 Temperature Control(set to open at temperature

limit of pipe)On some extended sites,steam distribution is under-ground and drip points areinside “steam pits”. Steammain drip traps should dis-charge into gravity returnsystems, but at times it may benecessary to connect themdirectly to a pumped conden-sate line. To avoid failure ofplastic or fiberglass pipingcaused by high temperaturefrom steam leakage wheneventually the trap becomesworn, a cooling chamber andcontrol as shown can be used.If the temperature of the con-densate leaving the chamberever reaches the safe limit, thecontrol valve opens.Condensate is dischargedabove grade, where it can beseen, until its temperature fallsagain below the limiting value.

CheckValve

CheckValve

SupervisedStart-up

Valve

Set downabout 2"

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A. TD traps on high temperature tracingapplication where tracer line must bedrained clear of condensate.

B. TSS300 traps on low temperature tracingwhere product temperature is below 150˚Fand some of sensible heat in condensatemay be utilized to improve efficiency.

Figure II-10 Typical Steam Tracer Trapping Arrangements

Thermo-Dynamic


Strainer

BalancedPressure

ThermostaticSteam Trap

Spira-tecLoss

Detector

Spira-tecLoss

DetectorStrainer

TracerTracer

Product Line Product Line

Insulation

A B

Steam will automatically shut downas ambient temperatures rise aboveproduct solidification temperature.Select self acting temperature controlfor number of tracer lines.

Figure II-11Steam Tracing System withPreassembled Manifolds

AmbientSensing

TemperatureControl

Strainer

SteamMain

SteamDistribution

Manifold

CondensateCollectionManifold

Steam Trap Stationwith Test Valves

Steam Trap Stationwith Test Valves

Steam toTracers

Condensatefrom Tracers

To Drain

ToCondensate

Return

To drain during supervisedstartup or during shutdown

Steam is uniformly distributed to tracers by forged steel manifold with integral pis-ton valves. After supplying heat to tracer lines, condensate is collected infabricated manifold preassembled with steam trap stations. Three-way test valvesallow for startup purging, checking of lines for blockage, isolation of trap for main-tenance, and visual testing of steam trap operation. Condensate manifold has aninternal siphon pipe to reduce waterhammer and provide freeze protection.

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Spira-tecLoss

Detector

StrainerSelect inlet piping for reasonablevelocity and expand downstreamfor equal flow rate.

Figure II-12Typical Pressure Reducing Valve Station


Strainer

SafetyValve

SteamSupply

Pilot OperatedPressure Control Valve

Figure II-13Parallel Operation of Pressure Reducing Valves

Set lead valve 2 psi above desiredset pressure and set lag valve 2 psibelow desired set pressure.

Spira-tecLoss

Detector

Strainer

SafetyValve

SteamSupply



Strainer

Strainer


MoistureSeparator

PressureSensing Line

PressureSensing Line

CheckValve

DripPan

Elbow

MoistureSeparator

ReducedSteam

Pressure

CheckValve

DripPan

Elbow

ReducedSteam

Pressure

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Figure II-14Series Pressure Reducing Valve Station for High Turndown Rations

Note: Intermediate pressure takeoff requires an additional safety valve.

Spira-tecLoss

Detector

Strainer

SafetyValve

SteamSupply



Strainer Strainer


MoistureSeparator

PressureSensing

Line

Spira-tecLoss

Detector

Strainer


PressureSensing

Line

Figure II-15Hook-up for Remote Operation of 25 PRM Pressure Reducing Valve




Strainer

Strainer

SafetyValve

SteamSupply

MoistureSeparator

MainControl Valve

RemotePressure

Pilot

Limit pilot to 15 ft. drop below mainvalve and drain all supply tubing. Ifpilot is mounted above main valve,pilot line drip traps can be eliminated.For longer distance an air loadedpilot should be used.

CheckValve

DripPan

Elbow

ReducedSteam

Pressure

CheckValve

DripPan

Elbow

ReducedSteam

Pressure

CheckValve

CheckValve

CheckValve

Noise Diffuser(if required)

5/16" CopperTubing or 1/4" Pipe

1/2" Pipe

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Figure II-16Installation of Pressure Reducing Valve in “Tight Spaces”

PressureSensing LinePitch Down

Spira-tecLoss

Detector

Strainer

Thermo-DynamicSteam Trap

SafetyValve

Strainer

DirectOperatedPressureReducing

Valve

ReducedSteam

Pressure

10 Pipe

DiametersMinimum

Strainer

Strainer

Strainer


SteamSupply

MoistureSeparator



Strainer

SafetyValve

DripPan

Elbow

ReducedSteam

Pressure

CheckValve

CheckValve

CheckValve


Pilot OperatedPressureControlValve

Ten PipeDiameters

DripPan

Elbow

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Figure II-1825 BP Back Pressure Controls used to Restrict Supply to Low Priority Uses at Times of Overload

Steam toNon-essential

ServiceStrainer

Thermo-Dynamic


Steam Supplyfrom Boiler

Strainer

Pilot OperatedPressure Reducingand Back Pressure

Valve

Steam toPriority Use

10 Pipe DiametersMinimum fromValve Outlet

At times of peak draw off, boilers which have sufficientcapacity to meet average load conditions may become over-loaded. This can cause carryover and priming, or evenlockout of boilers on low water. The pressure in the steamlines falls and essential services may be interrupted. Theuse of back pressure controls in the supplies to non-essen-tial loads allows these to be automatically shut down, inorder of priority, at peak load times while maintaining supplyto more important loads.

Spira-tecLoss

Detector

Header

Pilot OperatedBack Pressure Valve

Figure II-19Reducing Steam Pressure Using 25PA Control Valve with Remote Air Valve

Depending on pilot selected, reducedsteam pressure will be approximately 1:1,4:1 or 6:1 times the air loading pressuresent to the pilot.

SafetyValve

Spira-tecLoss

Detector

Strainer

Strainer


Filter/Regulator

SteamSupply

MoistureSeparator

AirSupply


Air Loaded

Pilot

Air OperatedControl Valve

DripPan

Elbow

ReducedSteam

Pressure

CheckValve

DripPan

Elbow

SafetyValve

Reduced SteamPressure to

Non-essential Service

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Figure II-20Typical Pneumatic Single StagePressure Reducing Valve Station

Figure II-22Hook-up for 25 TRM Temperature Control Remotely Mounted (within 15 ft. of Main Valve)

StrainerSteamSupply

MoistureSeparator Main

Control Valve


Strainer


RegulatedSteam toProcess

Sensor

1/2" Pipe

Figure II-21Pneumatic Temperature Control of Heat Exchanger

StrainerSteamSupply

MoistureSeparator


Strainer

SafetyValve

VacuumBreaker

Strainer

MoistureSeparator


Strainer

Spira-tecLoss

Detector


Strainer

Spira-tecLoss

Detector

SteamSupply

DripPan

Elbow

ReducedSteam

Pressure


SupplyAir

ControlSignal

PneumaticControlValve

CheckValve

Controller

Controller PneumaticControl Valve

with Positioner

Supply Air

Control Signal

Supply Air

Heat Exchanger

CheckValve

CheckValve

Sensor

Liquid in/out

CheckValve

CheckValve

RemoteTemp.Pilot

5/16" Copper Tubingor 1/4" Pipe

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Figure II-23Pressure Reducing Valve for Pressure Powered Pump Motive Steam

Figure II-24Heat-up, Pressuring and Shutdown of Steam Mainsusing On/Off Control Valves and Programmer

Thermo-Dynamic


Pilot OperatedOn/Off Control Valve

(for heatup only)

Spira-tecLoss

Detector

Strainer

SteamSupply

Strainer

Thermo-Dynamic


Spira-tecLoss

Detector

Pilot OperatedOn/Off Control Valve(for maximum flow)

SteamMain

AutomaticTime

Switch

Power

Thermo-Dynamic

Steam Trap

SteamSupply

Strainer

Strainer

SafetyValve

DripPan

Elbow

MotiveSteam

to Pump

Direct or Pilot OperatedPressure Reducing Valve

Pressure Surge Reservoir1-1/2" or 2" diameter, 6’ longwith eccentric fittings on ends

Steam toSystem

Hand Valveto adjustflow rate

AdjustablePressurestat

(with N.O. Switch)

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Figure II-25Complete CondensateDrainage from Air HeaterCoil under “Stall” withCombination Pump/Trapin a Closed Loop System

When the steam pressure within thecoil is high enough to push conden-sate through the steam trap, againstany back pressure from a lift to high-er level or into a pressurized line, thepump is inoperative. If the action ofthe temperature control lowers thecoil pressure sufficiently, the conden-sate flow stalls. Water backing up intothe PPP body brings it into operationand the pump uses motive steam topush the condensate through the trapto the return line.

At the end of each discharge stroke,the motive steam in the pump body isexhausted through a balance line tothe top of the liquid reservoir. A ther-mostatic air vent on the balance linevents air under startup conditions,even if the pump/trap is fully floodedwith condensate at this time.

Figure II-25AProcess Condensate Removal Module

A preassembled modular pumping systemprovides a sole source solution for airheater coil applications.


Direct orPilot OperatedTemperature

Control

Strainer

SteamSupply

MotiveSteamSupply

PressurePowered

Pump

MoistureSeparator

Thermo-Dynamic

Steam Trap

Reservoir

CondensateReturn

HeatedAir

Outlet

TemperatureControlSensor

Thermostatic

AirInlet

CheckValve


Strainer


Strainer

Coil

Drain toSafePlace

See Fig. II-25A for thepreassembled

Process CondensateRemoval Module

Steam Trap Station

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Figure II-26Controlling and Draining Preheat andReheat Coils in Vented CondensateSystem with Freeze Resistant Pipingfor Makeup Air

Each coil must be individually drainedto provide for proper and accuratecontrol. Strainers are not fitted in frontof the traps in case they become par-tially blocked. Freeze resistant coilsmust have vacuum breaker, trapssized for full load with 1/2 psi differen-tial and unobstructed piping to anatmospheric return system.


Pilot OperatedTemperatureControl Valve

Spira-tecLoss

DetectorMotiveSupply

PressurePowered

Pump

Thermo-Dynamic


Strainer

Vented ReceiverCondensate

Return


Thermostatic


Thermostatic


Spira-tecLoss

Detector

Strainer


Strainer

Spira-tecLoss

Detector

TemperatureControlSensorHeated

AirOutdoor

Air

VacuumBreaker

SteamSupply

SteamSupply

Thermo-Dynamic


Strainer

VacuumBreaker

LiquidExpansionSteam Trap


Drain toSafePlaceDrain to

SafePlace

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Figure II-27Freeze Proof Piping ofLarge Vertical Air Heater Coil toAtmospheric Condensate Return System

* To preclude accidental closing, these valvesshould be chain locked in open position, orthey may be omitted.

Figure II-28High Pressure SteamCoils Trapped forFlash Recovery to LPSteam System



MotiveSupply

PressurePowered

Pump

Thermo-Dynamic


Strainer

CondensateReturn

TemperatureSensor

Thermostatic


Strainer


Strainer

Spira-tecLoss

Detector

Thermo-Dynamic

Steam Trap

PackagedPressurePowered

Pump Unit

Strainer

Spira-tecLoss

Detector

VerticalAir Coil

SteamSupply

Pilot OperatedBack PressureControl Valve

Condensate ReturnPitch Down

MoistureSeparator


Strainer

FlashRecovery

Vessel


Strainer

Pilot OperatedPressure

Control Valve

SafetyValve

SafetyValve

VacuumBreaker

VacuumBreaker

**

Vent

SteamSupply

Vent

DripPan

Elbow

CheckValve

To CondensateReturn

DripPan

Elbow

AirVent

AirHeating

Coils

Low Pressure Steam

Drain toSafePlace

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Figure II-29Storage Cylinder withHigh Limit Protection

Fail safe protection against excess temperatures is provided by a separate con-trol valve, normally latched wide open. If the 130 self-acting control systemdetects a temperature overrun, or if the control system itself is damaged, a pow-erful spring is released in the HL10 unit and the high limit valve is driven closed.A switch is available as an extra to provide electrical warning that the device hasbeen actuated.

Figure II-30Condensate Drainage from Unit Heater


Spira-tecLoss

Detector

Valve

MoistureSeparator



Strainer

Self ActingTemperature

Control

Spira-tecLoss

Detector

Strainer

SteamSupply

Strainer

High Limit130 Sensor

HL10OverheatProtection

Hot Flow

Circ.Return

ColdSupply

StorageTank


Spira-tecLoss

Detector

Strainer

SteamSupply

UnitHeater

Drain condensateby gravity where

possible—especially to vac.

return system

VacuumBreaker

CheckValve

CheckValve

ToCondensate

Return

ToOverhead

Return


To Drain

AlternateLocation

Note: The Liquid ExpansionSteam Trap will automaticallydrain unit heater during peri-ods of shutdown which willprevent damage due to cor-rosion.


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Figure II-31Temperature Control of Warm-up and RunningLoads at Storage Tank

Figure II-32Draining Heat Exchanger under Constant “Stall”Condition with Pumping Trap in Closed Loop System

A control valve suitably sized to supply the start upload on a tank is often very much oversized for therunning load, and this oversizing can lead to erraticcontrol. In such cases, a large control valve may beused to meet the warm up load, arranged to closeat a temperature perhaps 2° below the final controltemperature. The smaller control valve meets therunning load, and the supply is supplementedthrough the start up valve, only when the capacity ofthe smaller valve is exceeded.

Draining L.P. Heat Exchanger toOverhead Return. Pressure at pumpoutlet P2 always exceeds supplypressure P1 to Heat Exchanger.

Completely immerse control sensorwithout well, right at hot outflow.

To prevent overheating, the sensormust not see a “dead” flow.

LowTemperature

Sensor

Spira-tecLoss

Detector

MoistureSeparator

ThermostaticSteam Trap Strainer

RunningTemperature

ControlValve

StrainerSteamSupply

CondensateReturn

StorageTank

Spira-tecLoss

Detector

StrainerFloat &ThermostaticSteam Trap

Warm UpTemperature

ControlValve

RunTemperature

Sensor

Thermo-static

Air Vent

MoistureSeparator


Strainer

SteamSupply

Heat Exchanger

Spira-tecLoss

Detector

Strainer

PressurePowered

Pump



Hot

Cold

MotiveSteamSupply

Reservoir

Sensor

PressurizedReturnSystem

CheckValve

Strainer

Check Valve

P1

P2

Drain toSafePlace

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Figure II-33Combined Pressureand TemperatureControl of HeatExchanger

When the pressure of the steam supply is higher than theheat exchanger can withstand, or is at a higher valuethan necessary to allow for fouling of the heat exchangesurfaces, a pressure reducing valve is required. This caneconomically be combined with a temperature control byusing pressure sensing and temperature sensing pilotsto operate a common main valve. Sensor bulb must befully immersed right at hot outflow and use of a separa-ble well should be avoided.

Figure II-34Draining Small Heat Exchanger andOther Loads to Pressure Powered Pump

Arrangement of Small Steam/Liquid HeatExchanger where steam space pressure may fallbelow back pressure and trap has gravity drain.

Note: Head “H” must be enough to give trapcapacity needed when steam space pressurefalls to zero.


MoistureSeparator

Pilot OperatedPressure/Temperature

Control Valve

Heat Exchanger

Spira-tecLoss

Detector

StrainerFloat &


ColdWaterSupply

Sensor

Spira-tecLoss

Detector


SafetyValve

Strainer

GravityReturn

SteamSupply

StrainerFloat &


SteamSupply


StrainerFloat &


VacuumBreaker

Temp.ControlSensor


ControlMoistureSeparator

Heat Exchanger

PressurePowered

Pump

ReceiverStrainer

Thermo-Dynamic

Steam Trap

CondensateReturn

Multiple LoadsConnected to

Vented Receiver


VacuumBreaker

Drip PanElbow

LiquidIn/OutFlow

Strainer

H

See Fig. II-34A forthe preassembled

CondensateRecovery Module

Drain toSafePlace

Steam Trap Station

Steam Trap Station

Note: scensor mustnot see a“dead” flow.

Note: scensor mustnot see a“dead” flow.

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Figure II-35Draining Equipment to PressurizedReturn with Closed LoopPump/Trap Drainage System

P1 exceeds P2 except when partialloads “stall” the exchanger. With thishook up, the reservoir pipe is alwaysconnected to, and at the same pres-sure as, the heat exchanger steamspace. Condensate drains to it freely.The pump body is connected in thesame way, except during the dischargestroke when the inlet check valve andthe exhaust valve are closed. After dis-charge, the residual steam in the pumpbody is exhausted to the heater and itslatent heat can then be recovered.Steam trap functions at full load andThermoton drains at shutdown.

SteamSupply


Strainer


PneumaticControlValve

MoistureSeparator

Heat Exchanger

PressurePowered

Pump

Reservoir Pipe

Drain

Thermo-Dynamic

Steam Trap

Elevated orPressurizedReturn

Strainer

Strainer



HotFlow

CoolReturn

MotiveSteam Supply

Thermo-static

Air Vent

P1

P2


Process CondensateRemoval Module

Figure II-35AProcess Condensate Removal Module

A preassembled modular will remove condensate from the heat exchanger under all operating conditions.

Figure II-34ACondensate Recovery Module

A preassembled modular pumping system can be usedto recover and reuse the condensate.

Sensor

Controller

SupplyAir

ControlSignal

Drain toSafePlace

Steam Trap Station


Note: To prevent overheating, the scensor must not seea “dead” flow.

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Figure II-36Low Pressure Steam Absorption Chiller

Figure II-37High Pressure Steam Absorption Chiller


PressurePowered

Pump

Reservoir Pipe

Thermo-Dynamic


Strainer

ToCondensate

Return

MotiveSteam Supply


CheckValve

AbsorptionChiller

Steam Supply(15 psig or less)

ToCondensate

Return

MotiveSteam Supply

Absorption Chiller

Steam Supply(normally 45

psig or higher)

Vent


Pump


Strainer

Note: Depending on chiller manufacturer, a steam trapmay not be required or it may be supplied with the chiller.Other specialties needed may include a steam pressurereducing valve on the inlet, steam separator with trap,steam safety valve or inlet strainer.

Drain toSafe Place

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Figure II-38 Automatic Control of Batch

Processor with Electrical Time Sequence

Programmer

Figure II-39Controlling Temperature of Open Tankfor Plating, Dyeing of Process Work


SteamSupply




Control Valvewith Solenoid

MoistureSeparator

Autoclave

SafetyValve

Strainer

Strainer

Spira-tecLoss

Detector


ElectricOperator

Spira-tecLoss

Detector

Strainer

Float & ThermostaticSteam Trap

SteamFilter

Power

Strainer


Spira-tecLoss

DetectorStrainer


Spira-tecLoss

Detector

MoistureSeparator

Strainer


Strainer

PilotOperated

TemperatureControl Valve

LoopSeal

GravityReturn

DripPan

Elbow

BalancedPressure


SteamSupply

Drain toSafe Place

SmallBoreRiser

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Figure II-40Controlling Platen Press Temperaturewith Pressure Regulator and ElectricProgrammer. Indicating Pilot PermitsFast Temperature Changes

Figure II-41Controlling Temperature of Pressurized Boiler Feed Water Tank

Note: When supply pressure is above 125 psi, install an additionalSpirax Sarco pressure control valve ahead of pressure/temperaturecontrol valve to reduce pressure to 125 psi.

Strainer

Thermo-DynamicSteam Traps withIntegral Strainer


Strainer


Spira-tecLoss

Detector

Strainer

Pressure ReducingControl Valvewith Solenoid

SteamSupply

MoistureSeparator

SafetyValve

ElectricOperator

Power



Condensate Return

Strainer

Spira-tecLoss

Detector

Strainer


Control Valve

SteamSupply(125 psior less)

MoistureSeparator

SafetyValve


VacuumBreaker


PerforatedHeater Tube

Pack HeatCompoundin Bulb Well

Make upWaterSupply

PumpSuction

CondensateReturn


DripPan

Elbow

Drain toSafe Place

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Figure II-42Controlling Temperature of Vented Boiler Feed Water Tank

Figure II-43Controlling Temperature of Large Open Tank Heated by Direct Steam Injection

Strainer

Spira-tecLoss

Detector

Strainer


MoistureSeparator


VacuumBreaker

SteamInjector

SteamSupply

OpenTank

Provide suitable supportand protection for

capillary tubing andtemperature bulbs

VacuumBreaker

Strainer

CondensateReturn

VentHead

SteamSupply

TemperatureControl Valve

Sensor

To B.F. PumpSuction

Perforated Heater Tube

Make upWater

CondensateReturn

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Figure II-44Controlling Temperature of Small Open Tank, Heated by Direct Steam Injection

Figure II-45Controlling Temperature of Water Suppliedto Spray Nozzles of Egg Washing Machine

Strainer

SteamInjector/

Thermoton

VacuumBreaker

Strainer

Spira-tecLoss

Detector

Strainer


SteamSupply

MoistureSeparator

ColdWaterSupply


VacuumBreaker

Pack Sensor Well withHeat Conducting

Compound

Steam Injector

CentrifugalPump

Float OperatedC.W. Valve

WarmWaterSupply

to WasherSpray

Nozzles

GravityReturnfrom

Washer

Open Tank

Vent

107

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Figure II-46Controlling Temperature of Greenhouse or Other Similar Buildings

Figure II-47Steam Radiator

Strainer

Spira-tecLoss

DetectorStrainer

Fin-TubeRadiation

SteamSupply

MoistureSeparator


RoomThermostat


Pilot OperatedOn/Off Control Valve

Return

ThermostaticRadiator Trap

RadiatorValve

Supply

108

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Figure II-48Trapping and Air Venting HospitalSterilizer with Dry Steam Supply

Figure II-49Control and Drainage Hook-up forHospital Blanket and Bedpan Warmer

Strainer

Spira-tecLoss

Detector

Strainer

SteamSupply

MoistureSeparator






Ball Valve

Thermo-Dynamic

Steam Trap

Filter

Spira-tecLoss

Detector

Strainer


Thermo-Dynamic


Strainer

MoistureSeparator

BalancedPressure


Spira-tecLoss

Detector


Control

HeatingCoil

Small size trapis required

Drain toSafe Place

SteamSupply

109

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Figure II-50Trapping Small Utensil Sterilizer

Figure II-51Condensate Drainage fromHospital Mattress Disinfector

Strainer

SteamSupply

Balanced PressureThermostaticSteam Trap

Strainer

SteamSupply


Spira-tecLoss

Detector

Spira-tecLoss

Detector

Strainer Float &ThermostaticSteam Trap


Strainer

Drain toSafe Place

110

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Figure II-52Float & Thermostatic TrapFreeze Resistant Hook-up



VacuumBreaker

Figure II-53Thermoton Controlling Temperatureof Large Storage Tank


SteamSupply

Strainer

Strainer

Figure II-54Equipment Drained with Permanent Connector Thermo-Dynamic Steam Trapsthat fit into both Horizontal and Vertical Pipework

Floor

Thermo-Dynamic


Strainer

Thermo-Dynamic


StrainerThermo-Dynamic


Strainer

CondensateReturn

Steam Main

StorageTank

111

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Figure II-55Draining and Air VentingFlatwork Ironer

The steam traps are often located atone end for ease of maintenance,with long pipes connecting them tothe drainage points. If steam-lockingis a problem in these long pipes,then a Float / Thermostatic steamtrap with a steam-lock release is thebest selection. The beds should beair vented at points remote from thesteam entry. Steam supply lines toironers should be drained, ideallyusing a separator.

Figure II-56System Units for Condensate Removaland Air Venting of Rotating Cylinders(for surface speeds below 800 FPM)

GravityReturn

StrainerSightGlass with

Check Valve

Steam Beds

BalancedPressure


Strainer

BalancedPressure


Float &ThermostaticSteam Trapwith SLRfeature

SightGlass

GravityCondensate

Return

AirReservoir

Steam Main

RotatingCylinder

Drain toSafe Place


Drain toSafe Place

The Spirax Sarco units (Strainers,Float & Thermostatic Steam Traps withSLR feature, Sight Glass, Air Reservoirwith Air Vent) provides for the bestdrainage of condensate and non-condensibles from rotating cylinders.

112

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Figure II-57 Draining High Speed Paper Machine using Cascading or “Blow-through” Systems

Paper Machines running at higherspeeds in modern plants usually havea cascading or “blow-through” sys-tem. Condensate is swept by the flowof blowthrough steam, up the dryercan dip pipe and into a manifold lead-ing to a blowthrough separator.Control of the blowthrough steam maybe at the separator outlet or on indi-

vidual cylinders or banks of cylinders.The blow-through steam may pass onto sections of the machine operatingat lower pressures. The blowthroughseparator is drained by an FT trap,unless the return is pressurized inwhich case a closed loop combinationpressure powered pump/trap isrequired.

Figure II-58 Draining High Speed Paper Machine using “Thermal-compressor” or Reused Steam Systems


Strainer




Strainer


Safety Valvewith Drip

Pan Elbow



Pan Elbow

Separator

Blow throughSeparator

CondensateReturn

CondensateReturn

DryerCans

CheckValve

CheckValve

L.P. SteamH.P. Steam

Thermal Compressor

L.P.Steam

By-Pass

Modern paper machines also use “Thermal-compre-sor” systems. Condensate is swept by the flow ofblow-through steam up the dryer can dip pipe andinto a manifold leading to a separator.The L.P. steamfrom the separator is then reused through an H.P.steam driven thermal compressor or by-passed. Theseparator is drained like Fig. II-57 or engineered sys-tems package, Fig. II-58A.

Figure II-58A Condensate Removal Module

High speed paper machines can be fitted witha preassembled module that incorporates theseparator and condensate removal equipment.

DryerCans

SteamTrap

Station


CondensateRemoval Module

113

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Figure II-59Air Venting and Condensate Drainage at Jacketed Kettle

Figure II-60Draining Tire Mold

Figure II-61Steam Trapping High Pressure Coil (up to 600 psig)


Strainer

BalancedPressure

ThermostaticAir VentSteam

Supply

Thermo-Dynamic


Strainer

Spira-tecLoss

Detector

Spira-tecLoss

Detector

CondensateReturn


Strainer

BalancedPressure


Strainer

HPHeating

Coil

Condensate Return

Air

SteamSupply

(Air supply temp. not lower than 32°F)

Strainer

Thermo-Dynamic

Steam Trap

SteamSupply

FlexibleQuick

DisconnectLines

Drain toSafePlace

Drain toSafePlace

114

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Figure II-62Draining High Pressure Reboiler

Figure II-63Draining Condensate to Vented Receiver andLifting Condensate to Overhead Return Main

Reboiler


Strainer

BalancedPressure


Strainer

Condensate Return

SteamSupply

Total back pressure is the height (H)in feet x .0433 plus PSIG in returnline, plus downstream piping frictionpressure drop in PSI (Determined bythe maximum instantaneous dis-charge rate of the selected pump.)

Drain toSafePlace

Thermo-Dynamic

Steam Trap


Strainer


Thermo-Dynamic

Steam Trap

VentedReceiver

Return LinePressure Gauge

CondensateReturn Main

MotiveSupply

Strainer

SteamSpace

PressurePowered

Pump

Vent toAtmosphere

FillingHead

TotalLift“H”

115

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Figure II-64Draining Evaporator whenEvaporator Steam Pressurecan fall from Above to BelowBack Pressure

Figure II-65Draining Condensate from vacuum Space to Return Main or Atmosphere Drain

Evaporator

ReservoirStrainer

ReturnMain

BalancedPressure


Thermo-Dynamic

Steam Trap

PressurePowered

Pump

1" Equalizer Line


MotiveSteamSupply

VacuumSpace

Reservoir

Strainer

ReturnMain

Thermo-Dynamic

Steam TrapPressurePowered

Pump

SteamSupply

Pipe toDrain

Pipe toDrain30"

WaterColumn

TotalLift“H”

FillingHead

1" Equalizer Line

ElevatedDischarge

Connection

1/8"Antisyphon

Hole

Drain toSafePlace

Check Valve

BackPressure

EvaporatorPressure

Drain toAtmosphere

116

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Figure II-66Lifting Fluids from Low Pressure Sourceto Higher Pressure Receiver

Figure II-67Draining Equipment with Condensate Outlet Near Floor Level using a Pump/Trap Combination in a Pit

Reservoir

Strainer

BalancedPressure


SteamSupply

Low PressureSpace

Thermo-Dynamic

Steam Trap

PressurePowered

Pump

PressurizedReceiver

Tank

Reservoir Pipe

Strainer

BalancedPressure


Motive Gas orSteam Supply

Thermo-Dynamic

Steam TrapPressurePowered

Pump


Equalizer Line

1" Equalizer Line

Total back pressureis the height (H) infeet x 0.433 plusPSIG in receiver, plusdownstream pipingfriction pressure dropin PSI (Determinedby the maximuminstantaneous dis-charge rate of theselected pump.)

Drain toSafePlace

Drain toSafe Place

Check Valve

CheckValve

TotalLift“H”

CheckValve

Check Valve

Check Valve

Drain toSafePlace

ToPressurized

Storage Tank

Plug

Condensatefrom

Equipment

117

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When multiple pumps in parallelare used to meet the load, Pump#1 fills first and Pump #2 operatesat full load. Supply piping isarranged to reduce simultaneousdischarge. Better staging occurswhen Pump #2 is elevated 3” to 6”above the floor.

Intake pipe to Pump #3 is locatedabove the Filling Head requiredby Pump #1 & #2 so it will functionas a “Standby” and only operateon peak loads or in the event ofprimary pump failure.

Figure II-68Installation of Pump/Trap Combinationwhen Vertical Space is Limited

Figure II-69Multiple Pressure Powered Pump Hookupsfor Staged Operation and Standby Duty

PressurePoweredPump #3



Receiver

Condensate

Supplies

Vent

Return

Return

Exhaust

PPF-Top

PressurePowered

Pump

Reservoir

Strainer

BalancedPressure


Thermo-Dynamic

Steam Trap

ReturnMain


Drain toSafePlace

Check Valve

Check Valve

MotiveSupply

Drain toSafePlace

CheckValve

Condensatefrom Process

Equipment

118

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Figure II-70Pressure Powered Pump Draining Water from Sump Pit

Figure II-71Pressure Powered Pump Discharging to Long Delivery Line(Air Eliminator needed above return main wherever

elevation changes form a water seal.)

Total back pressure is theheight (H) in feet x .0433 plusPSIG in return line, plusdownstream piping frictionpressure drop in PSI(Determined by the maximuminstantaneous discharge rateof the selected pump.)

ReturnMain

PressurePowered

Pump

Receiver

PressurePowered

Pump

Condensate

VacuumBreaker

Float OperatedAir Vent

ReceiverWaterSeal

Strainer

Thermo-Dynamic

Steam Trap

Pump ExhaustPiped to Safe Place

MotiveSupply

Drain

OperatingWaterLevel

15°SwingCheck

Figure II-72Pressure Powered Pump Discharging toLong Delivery Line with Lift at Remote End

See Fig. II-72 forhook-up option withLift at Remote End

Receiver

ReturnMain

Line SizeCheck Valve

Height“H”

Covering Grate



Line SizeCheckValve

Strainer

MotiveSupply

119

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Figure II-73Draining Small Condensate Loads fromVacuum using Atmospheric Pressure

Figure II-74Typical Electric Pump Hook-upfor Subcooled Condensate

Figure II-75Electric Pump Lifting Condensatefrom Vented Receiver to HigherPressure or Elevation

Vent toAtmosphere

PumpDischarge

Condensate fromLow Pressure

System

Floor

PressurePowered

Pump

Inlet Open toAtmosphere

Check valve should be vacuumtight and water sealed. Largerdrop reduces emptying time.

Sub Atmospheric Line

EqualizerLine

To Drain

SwingCheckValve

MinimumDrop 3"

Receiver

ElectricCondensate

Pump

ElectricCondensate

Pump

Strainer

PumpDischarge

Vent

H. P.Condensate

Drain

Gate &Check Valves

VentHead

120

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Figure II-76Typical Flash SteamRecovery Hook-up

Figure II-77Flash Steam Recovery with Live Steam Make upand Back Pressure Surplussing Valves

Condensate from high pressure loads releases steam by flash-ing as it passes to the lower pressures, downstream of the highpressure traps. The mixture of steam and condensate is readi-ly separated in Flash Vessels of appropriate dimensions andproportions. A supply of Low Pressure steam then becomesavailable for use on any application which can accept steam atthis low pressure, or the separated steam may simply be takeninto the LP steam mains, where it is supplemented throughpressure reducing valves, for general plant use.

Where the supply of flash steam may at times exceed thedemand from the LP system, the surplus flash steam can bedischarged through a back pressure control valve. This is setat a few psi above the normal LP steam pressure, but belowthe setting of the LP safety valve. See Figure II-77.

The condensate leaving the flash recovery vessel is at low pres-sure. Usually it is handled by a float-thermostatic steam trap andis delivered to the receiver of a condensate pump for return tothe boiler house. Any residual flash steam from the low pressurecondensate is vented from the pump receiver. (Figure II-78.)

In some cases, pressures are sufficiently high that the flashcan be taken off at an intermediate pressure and the con-densate leaving the flash vessel still contains a usefulamount of sensible heat. It can then be taken to a secondflash vessel working at low pressure, so that the maximumheat recovery is effected. The use of two flash vessels inseries, or “cascade”, means that these vessels may beinstalled generally as Figure II-76 and II-77.

Alternatively, it may be desirable to use the recovered flashsteam at a low pressure, below that in the condensate returnline or perhaps the de-aerator tank. The arrangement adapt-ed may then be either as Figure II-78 or as Figure II-79. Thislatter system uses a steam powered pump, with the bottomof the flash recovery vessel serving as the pump receiver.Power steam used by the pump is vented to the LP steamline, so that pumping is achieved at virtually zero cost and theuse of unsightly or wasteful vents is avoided.

Strainer



Strainer



Spira-tecLoss

Detector

SafetyValve

Spira-tecLoss

Detector

Strainer



SafetyValve

Strainer

FlashRecovery

Vessel

FlashRecovery

Vessel

MoistureSeparator


Control Valve

H. P. Condensate

H. P.SteamSupply

L. P.Steam


Vent

L. P.Condensate

H. P. Condensate

L. P. Steam Main

L. P.Condensate

DripPan Elbow

DripPan

ElbowH. P. Condensate

CheckValve

Drain toSafe Place

Drain toSafePlace

121

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Figure II-78Flash Steam Recovery at Pressure above Atmospheric with L.P.Condensate Returned by Packaged Pressure Powered Pump Unit


A preassembled modular pumpingsystem provides a sole sourcesolution for condensate recoveryapplications.

Strainer


Spira-tecLoss

Detector

SafetyValve

FlashRecovery

Vessel

MoistureSeparator


Spira-tec LossDetector

Strainer

Strainer

H. P. Condensate



Control Valve

PressurePowered

Pump

Strainer

Vent

DripPan

Elbow

L.P.Condensate

Inlet

Thermo-Dynamic

Steam Trap


Pump

CheckValve

High PressureMakeup Supply

Low PressureSteam System

CondensateReturn

Strainer

Vent toAtmosphere

Steam Trap Station

Steam Trap Station


CondensateRecovery Module

122

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Figure II-79Flash Steam Recovery at Pressure Above or Below Atmosphericin ASME Coded Receiver of Packaged Pump Unit

Figure II-79ACondensate and Flash SteamRecovery Module

A preassembled modular pumpingsystem will recover condensate anddirect flash steam to a low pressure user.

Strainer


SafetyValve

MoistureSeparator

Strainer


Strainer

Strainer

H. P.MakeupSupply

ToCondensate

ReturnMain

Motive SteamSupply

Vent toAtmosphere

Pilot OperatedPressure ReducingValve (for makeup)

PressurePowered

Pump


H. P.Condensate(from traps)

DripPan

Elbow

L. P.MakeupSupply

Overflowto

Drain

Packaged ASMECode Stamped

Pressure PoweredPump Unit

Steam Trap Station

See Fig. II-79A for the preassembledCondensate and Flash Steam

Recovery Module

123

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Figure II-80Heating Water using Recovered Flash Steam with PackagedPump Unit Also Handling Other Condensate

Strainer

SafetyValve

FlashRecovery

Vessel


Strainer


Thermo-Dynamic

Steam Trap

Strainer

Heated Water

MotiveSteamor Gas

Vent toAtmosphere

Heat Exchanger

PressurePowered

Pump

CondensateReturn


VacuumBreaker

Cold Water Inlet

H.P.Condensate

& Flash

PumpExhaust


Condensate from high pressure steam sources iscollected in a flash steam recovery vessel. Flashsteam is separated from the condensate which drainsthrough an F & T trap set to the vented receiver of acondensate pump.The flash steam is condensed in aheat exchanger, giving up its heat content to thewater which is to be heated (or preheated).Condensate from the exchanger also drains throughan F & T trap set to the pump receiver. Non-conden-sibles are discharged at the receiver vent.

DripPan

Elbow

Pipe toSafe Place

Steam Trap Station

Steam Trap Station

See Fig. II-80Afor the

preassembledCondensate

RecoveryModule


A preassembled modular pumping system can be usedto recover and reuse the condensate.

124

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Figure II-81Heating Water using Flash Steam Recovered in ASME CodedReceiver of Packaged Pressure Powered Pump Unit

Strainer

SafetyValve



StrainerHeated Water

Vent toAtmosphere

Heat Exchanger

PressurePowered

Pump

CondensateReturn

Cold Water Inlet

H.P.Condensate

& Flash

PumpExhaust


DripPan

ElbowPipe to

Safe Place

PackagedASME CodeStamped Unit

125

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Figure II-82Recovery of Flash Steam and Pump Power Steam on Preheater (Steam in the Shell)

Condensate from the main heatexchanger flows to a flash SteamRecovery Vessel. The flash steam isseparated and led to the Preheaterwhere it is condensed as it preheatsthe incoming cool water or other liq-uid. Any incondensibles aredischarged to atmosphere throughthe thermostatic air vent.

Residual condensate from the flashvessel, with that from the preheater,falls to the inlet of the PressurePowered Pump. Pump exhaust steamis taken to the Flash Steam line andits heat content recovered in the pre-heater.

A Packaged Pump Unit with ASMEcoded receiver can be used in placeof the component flash vessels andPressure Powered Pump.

SafetyValve

FlashRecovery

Vessel

Strainer


Strainer

Heat Exchanger

PressurePowered

Pump

ToCondensate

Return

VacuumBreaker

CoolReturn

SteamSupply

PilotOperated

BackPressure

Valve


Pre-Heater

AirVent

ToVent

MoistureSeparator

Strainer

TemperatureControlValve

ToVent

AirVent

Strainer

Thermo-DynamicSteam Trap

Sensor

HeatedOutlet

Pipe toSafePlace

CheckValve

Pipe toSafePlace

Motive Steam Supply

DripPan

Elbow

CheckValve

CheckValve

126

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Figure II-83Recovery of Flash Steam and Pump Power Steam in Preheater (Steam in Tubes)


Pan Elbow

FlashRecovery

Vessel

Strainer


Strainer

HeatExchanger

PressurePowered

Pump

CondensateReturn

VacuumBreaker

BackPressureControlValve


Air Vent

MoistureSeparator

Strainer

TemperatureControlValve


Strainer

Pre-Heater

ToVent

SightGlass

Spira-tecLoss

Detector

Strainer

CoolReturn

ToVent

HeatedOutlet

CheckValve

Pipe toSafePlace

127

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Figure II-84Flash Steam Condensing by Spray

Residual flash steam for which nouse can found often causes a nui-sance if vented to atmosphere, and ofcourse carries its valuable heat con-tent with it. This steam may becondensed by spraying in cold water,in a light gauge but corrosion resis-tant chamber fitted to the receiver

tank vent. If boiler feed quality wateris used, the warmed water and con-densed flash steam is added to thecondensate in the receiver andreused. Condensing water which isnot of feed water quality is kept sepa-rate from the condensate in thereceiver as shown dotted.

A self-acting, normally closed tem-perature control with sensor in thevent line can control the coolant flow.This minimizes water usage, andwhere condensed flash steam isreturned, avoids overcooling of thewater in the receiver.

Overflow

CoolingWater

BoilerMakeup

Tank

CentrifugalPump

TemperatureControl Sensor

Waste

(Alternate)

Strainer

Condensate Receiver

H.P. Condensate

Vent


Control

FlashCondenser

128

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Figure II-86Culinary/Filtered Steam Station

Figure II-85Clean Steam Drip Station

Strainer with aFine Mesh Screen


Strainer

Spira-tecLoss

Detector

MoistureSeparator

CleanSteamSupply

Stainless SteelThermo-Dynamic

Steam Trap

Stainless SteelBall Valve

Product/MediaLine

Sanitary DiaphragmValve with Inlet

Drain Boss

1:120 min.

1:120 min.

Condensate Manifoldmust be free draining

A

B

Install valve “A” close toproduct/media line.

Close-couple valves “A” and “B”


Steam Trap

Plant SteamInlet

SampleCooler



Steam Filterwith a 2.8 micron

absolute filterelement

AB

A All piping, fittings, valves, etc. downstreamof this point shall be of austenitic stainlesssteel and of sanitary design

B Recommended position of plant steampressure reducing valve if required

Pressure gauges, fittings, valves, etc., are notshown for clarity.

SanitaryCheck Valve

CoolingWaterOutlet

CoolingWaterInlet

CooledSample

129

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Figure II-87 Tank Sterilization

Figure II-88Block and Bleed Sterile Barriers

Stainless SteelThermostaticSteam Trap

CleanSteamSupply

Product Outlet

DiaphragmValve


Stainless SteelThermostaticSteam Trapinstalled as

Air Vent



Condensate

DiaphragmValve

DiaphragmValve

DiaphragmValve



Steam Trap


AsepticProcess

Line

Sanitary DiaphragmValve with inlet Drain Boss

AsepticProcess

Line

Condenate Manifoldmust be free draining

SanitaryDiaphragm

Valve SanitaryDiaphragm

Valve


1:120 min.

CleanSteamSupply

A

A Close-couple valves

130

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Figure II-89Product/MediaProcess Line Sterilization

Figure II-90Pressure Regulating Stationfor Pure Steam Service

Figure II-91Sterilizer Utilizing High Purity Steam


Product/MediaLine

Sanitary DiaphragmValve with inlet Drain Boss

CondenateManifold

must be freedraining

SanitaryDiaphragm

Valve


1:120 min.

CleanSteamSupply

A

A Close-couple Diaphragm Valves



Steam Trap



Stainless SteelSteam Separator

SanitaryPressureRegulator

ReducedSteam

Pressure


PureSteamSupply

See Fig. II-85for proper CleanSteam hook-up

to product/medialine

A


Steam Trap


Stainless SteelSteam Separator

PureSteamSupply


SanitaryPressureRegulator


Steam Trap

Stainless SteelBall Valves



StainlessSteel

Ball Valve

Stainless SteelThermostaticSteam Trapinstalled asan Air Vent

Stainless SteelThermostaticSteam Trapinstalled asan Air Vent


Stainless SteelThermostaticSteam Traps


Note: Provide over pressure protection forchamber and jacket with properly sizedsafety valve(s) or rupture disc(s).

Sterilizer

131

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Figure II-92Spiraflo Saturated Steam (DensityCompensated) Metering System

Figure II-93Typical Superheated Steam (Density Compensated) Metering System



Strainer

SteamSeparator

IsolatingValve

CheckValve

SpirafloSteam Meter

Gilflo Meter

IsolatingValve

IsolatingValve

PressureTransmitter

FlowComputer

DifferentialPressure

Transmitter

3-ValveManifold

TemperatureTransmitter

Note: The same configuration issuitable for the Standard Range Gilflo,Gilflo ILVA and Orifice Plate Systems.

SteamSupply

Pipe toSafePlace

SteamSupply

CheckValve

SignalConditioning

Unit

FlowComputer

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Figure II-94Typical Saturated Steamor Liquid Metering System(No Density Compensation)

Figure II-95Typical Saturated Steam(Density Compensated)Metering System

Figure II-96Typical Saturated Steam(Density Compensated)Metering System

Orifice Plate

IsolatingValve

IsolatingValve

FlowIndicator


Transmitter

3-ValveManifold

Note: The same configuration issuitable for the Gilflo, Standard RangeGilflo, and Gilflo ILVA Systems.

Note: The same configuration issuitable for the Gilflo, Standard RangeGilflo, and Orifice Plate Systems.

For Saturated Steam, DensityCompensation is achieved by theflow computer accepting a signal fromeither a Temperature Transmitter(as shown here) or a PressureTransmitter (see Fig. II-96)

Gilflo ILVA

IsolatingValve

IsolatingValve

FlowComputer


Transmitter

3-ValveManifold

TemperatureTransmitter

Gilflo ILVA

IsolatingValve

IsolatingValvePressure

Transmitter

FlowComputer


Transmitter

3-ValveManifold

Note: The same configuration issuitable for the Gilflo, Standard RangeGilflo, and Orifice Plate Systems.

For Saturated Steam, DensityCompensation is achieved by the flowcomputer accepting a signal fromeither a Pressure Transmitter (asshown here) or a TemperatureTransmitter (see Fig. II-95)

SteamSupply

Steamor LiquidSupply

SteamSupply

133

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Figure II-97Hand Operated Rotary Filter

Figure II-98Motorized Rotary Filter with Single Blowdown Valve

Figure II-99Control Panel Hook-up for One Valve Blowdown VRS-2 Rotary Filter System

MainPower

D.P.Switch

MotorWiring

Model VRSControl Panel

ValveWiring

InletPressure

Line Model VRS-2Rotary Filter

ReservoirPipe

RemovedSolids

RemovedSolids

DirtyMedia

Hand OperatedRotary Filter

FilteredMedia

HandOperatedBlowdown

Valve

RemovedSolids

DirtyMedia

MotorizedRotary Filter

FilteredMedia

Full PortQuarter Turn

Motorized Valve

Electric Supplyto Motor

Electric Supply toMotorized Valve

ReservoirPipe

Control of rotor and blowdownvalve is made with user sup-plied timers. The blowdownvalve should stay open forapproximately 10 seconds topurge filtered dirt and debrisfrom reservoir pipe. Intervaland duration of the rotor andblowdown valve will varydepending on the nature andquantity of the dirt and debris.


MotorizedValve

P1 P2

OutletPressure

Line

The Control Panel with useradjustable timers controls intervaland duration of the rotor and blow-down valve operation. The blowdownvalve opens for approximately 10

seconds to purge the reservoir pipeof filtered dirt and debris. The ControlPanel is shown with optional cyclecounter and differential pressureswitch which will activate rotor opera-

tion if excessive pressure dropoccurs. This hook-up illustrates anautomatic filtration system, providingcontinuous production flow with mini-mal product loss.

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Figure II-100Control Panel Hook-up and Operation of Two Valve Blowdown VRS-2 Rotary Filter System

Figure II-101Motorized Rotary Filter withThree Valve Blowdown Systemfor Viscous FLuids

The Control Panel operates rotor andblowddown valves CV1 and CV2automatically. Fig. II-100A shows thenormal running mode with CV1 valveopen and CV2 valve closed, to allowreservoir to fill with dirt and debris. As

the reservoir pipe fills, valve CV1closes and valve CV2 opens purgingonly material held in the reservoir leg,Fig. II-100B. CV2 closes and CV1reopens returning system to normalrunning mode with no stoppage of

flow. This hook-up illustrates an auto-matic filtration system, providingcontinuous product flow with virtuallyno loss of usable fluid.

MainPower

D.P.Switch

MotorWiring


ValveWiring

InletPressure

Line

Model VRS-2Rotary Filter

ReservoirPipe

MainPower

D.P.Switch

MotorWiring


ValveWiring

InletPressure

Line

ModelVRS-2

Rotary Filter

ReservoirPipe

MainPower

D.P.Switch

MotorWiring


ValveWiring

InletPressure

Line

ModelVRS-2

Rotary Filter

ReservoirPipe

RemovedSolids

RemovesSolids

RemovedSolids


MotorizedValves

HighPressure

PurgeSee Fig. II-100A and II-100B for sequence ofoperation. In addition tothe blowdown valves onthe reservoir pipe, a thirdvalve CV3 has been addedfor a high pressure purgefluid or air should thedebris in the reservoir pipeprove to be too viscous toflow by gravity.

P1P1

P2P2

CV1

CV2

CV1

CV2


MotorizedValve


MotorizedValve

Figure II-100A Figure II-100B

OutletPressure

Line

OutletPressure

Line

P1 P2

CV1

CV2

CV3

OutletPressure

Line

135

HOOK-U

P D

IAGRAM

S

Figure II-102Freeze Proof Safety Showerwith Antiscalding Protection

Figure II-103Automatic Contol of Smaller CompressorCooling with Overheat Protection

The T-44 control valve incorporates a bypass needle valve to keep a mini-mum flow of water past the sensor even when the main valve has closed.A float-type drainer is preferred for the separator rather than a TD drainer,to ensure immediate and complete drainage of the separated liquid.

Larger compressors or low pressure cooling water supplies may call for aseparate supply of water to the aftercooler, with a solenoid valve orsimilar, to open when the compressor runs.

Fit T-44 control (withbypass closed), 85˚Fto 135˚F range, in 1-1/4” or larger pipe.Flow crosses sensorto shower, to coolingvalve inlet ending atthe #8 that openswhen ambient dropsbelow 40°F. Line flowprevents both freezeup and solar over-heating.

Drain

Strainer

LiquidDrainTrap

Air Line

MoistureSeparator

Strainer

CoolingControl

FloatOperatedAir Vent

CoolingWater

WarmedCoolant

CompressorJacket

AfterCooler

WaterSupply

#8 set@ 40°F

Strainer

CoolingControl

Spring ClosedValve To

Shower Head

OverheatDrain

136

HOOK-U

P D

IAGRAM

S

Figure II-104Condensate Cooling System

Figure II-105Condensate Cooling and Flash Knockdown System

CoolingControlValve

Sensor

VacuumBreaker

VacuumBreaker

To Drain140°FMax.

Flash Tank

CondensateReturn

CoolingWater

ToVent

Sparge Pipe

CoolingControlValve

Sensor

To Drain140°FMax.

Flash Tank

CondensateReturn

CoolingWater

ToVent

Spray Nozzle

137

HOOK-U

P D

IAGRAM

S

Figure II-106Continuous Boiler BlowdownCooling System

Figure II-107Controlling Coolant Flow to Vacuum StillCondenser and Draining Evaporator


Strainer

Evaporator

Self ContainedTemperature

Control

Spira-tecLoss

Detector


Strainer

Spira-tecLoss

Detector

Condenser

ColdWaterSupply Waste Water

Sight Drain

Distillate

Strainer

Steam Main

CoolingControlValve

Sensor

VacuumBreaker

ContinuousBoiler

Blowdown

CoolingWater

BlowdownVessel

ToVent

SpargePipe

To Drain140°FMax.

GravityCondensate

Return

VentHead

138

HOOK-U

P D

IAGRAM

S

Figure II-108ControllingTemperatureof Ball GrindingMill Jacket

Figure II-109Controlling Temperature of Oil Cooler

Figure II-110Controlling Temperature of Horizontal Solvent Condenser

Strainer

ColdWaterSupply

CoolerFilter

Drain

Hot Solvent

CoolingWaterOut

CooledSolventCooling

WaterDischarge

Self ContainedCooling Control

SightDrain

Strainer

Cool Oil

Oil Cooler

Hot Oil


ColdWaterSupply

Strainer

Grinding Mill

CoolingControl ValveCold

WaterSupply

SightDrain

WaterJacket


SightDrain

CheckValve

139

HOOK-U

P D

IAGRAM

S

Figure II-112Cooling Water Economizerfor Multiple Rolls

Figure II-111Controlling Temperatureof Vertical Solvent Still

Strainer


CoolingWater

Discharge

Roll

Roll

Roll

FloatOperatedAir VentCold

Water

Perforated Pipe

Holes Pointing Down

Mixing Tank

CentrifugalPump

FlowBalancing

Valve

Strainer

ColdWaterSupply

Cooler

Solvent

Filter

Drain

Drain


Solvent toEquipment

Pipe WasteWater

To Drain

CheckValve

Drain

140

HOOK-U

P D

IAGRAM

S

Figure II-113Alternate Methods of Draining Compressed Air Receiver

Figure II-114Draining Compressed AirDropleg to Equipment

Figure II-115Draining Riser in CompressedAir Distribution Line

Strainer

LiquidDrainTrap

LiquidDrainTrap

Strainer

Equipment Supply

Main

Drain Drain

Main Supply

BalanceLine

Branches are best takenoff the top of main lines.Condensation sweptalong the lines when airtools are used may over-load the filter of the airset at the take-off point,so a drainer is providedat the bottom of the sup-ply leg to remove asmuch as possible of thiscondensation.

Balance lines are notalways necessary onAir Drainers. Theybecome necessarywhen the trap locationis more remote fromthe line being drainedand when condensa-tion quantities aregreater. It is preferredto connect balancelines downstream ofthe point beingdrained.

LiquidDrainTrap Strainer

Balance Line

LiquidDrainTrap

Strainer

Air Receiver

Small air receivers are often“drained” through a manual valve atlow level on a once per day basis.Continuous drainage helps to main-tain better quality in the air supplied

but small receivers may be mountedso low as to preclude the use of theCA14 or FA pattern drainers. Thedrain point may be in the center of the

dished end of even on top, with aninternal dip pipe to reach the collect-ed liquid. The only possible option isthe TD drainer.

steam utilization - hook up diagrams

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