Spirax Sarco Topics

Issue 16 - 2011 $5.95

Sustainable Water Treatment Plan 2

Steam Accumulators 3

Sustainability 4

Food for Thought 5

Spirax Sarco at your service 6

Product Release – STS17.2 7

Competition Winners 8

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Sustainable Water Treatment Plan

Spirax Chemical Water Treatment Technology

Reducing Water Usage:High performance water treatment chemical products such as Spirax Kappa Series for boilers and Gamma Series for

At Spirax Sarco we aim to meet the needs of our customers and the community in a sustainable and commercially responsible way. Not only can we help optimise the end to end steam condensate loop through our engineering products and services, we can also help maximise sustainability in the boiler house and cooling systems. Developing a “Sustainable water treatment plan” is an important part of this process.

cooling towers enables our customers to operate their systems at higher cycles of concentration. In turn this means that you benefit from a corresponding reduction in water losses through reduced blow down. Not only is this great water conservation, it reduces discharge to the environment and saves money.

Energy Efficiency:High performance water treatment chemicals and pre-treatment equipment such as softeners and RO plants, will not only reduce blow down (and the associated heat loss), but they will minimise energy-robbing scale on steam generator tubes in boilers, or heat exchange surfaces in cooling systems. This increased heat transfer means less fuel /energy consumed and consequently, less greenhouse gas and CO2 emissions.

Minimising or Eliminating Chemical use:It has always been part of the Spirax water treatment strategy to minimise or eliminate on-going chemical usage,where it can be adequately replaced by a reliable high performance engineering alternative. Not only are there long term economic benefits, but any reduction in chemical usage means reduced health & safety risk and environmental discharge. A well selected RO or softener from Spirax and a properly designed feed tank or de-aerator can often reduce the chemical dosage requirement by over 70% and the correct automated Spirax dosing pump system will maximise dosing efficiency of any chemical that must be used.

It is important that water treatment chemical programs not only meet the current performance and economic demands of boiler and cooling operations, but that those programs are developed with a view to on-going optimisation and sustainability. Consult your Spirax water treatment specialist for help.

Howard Davis, Aus / NZ Water Treatment Manager

For more information on Spirax Sarco Water Treatment, please call us on: 1300 SPIRAX (774 729) or email us at [email protected] If you are not calling from Australia, please dial: +61 2 9852 3100

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w a t e r

This issue’s pull-out-and-keep TECHNICAL INSERT

Steam Accumulators

instant knowledge

The pull-out technical insert in TOPICS this time is on Steam Accumulators. There are a number of misconceptions about these things; the main one being that they are out-dated and belong only in the golden days of steam long ago.

Not true. In fact, accumulators probably have more real potential in more steam plants these days than they ever did in the past. Why? Because boilers today are generally smaller and much less able to handle peak loads.

A properly sized accumulator (which will often be no larger, and perhaps even smaller, than the boiler it works with) is perfectly suited for peak loads of short duration (such as occur on modern hospital sterilizers) and will actually allow an even smaller boiler to be used. And what’s more, an accumulator will absolutely guarantee the supply of top quality dry steam under all operating conditions, something that modern boilers find hard to do.

So check out the enclosed article – you will be amazed!

WA Seminars:2 Day Seminar: July 2012 – Esplanade Hotel, Fremantle

NSW Seminars:2 Day Seminar: February 2012 – Sydney April 2012 – Central West June 2012 – New England

SA Seminars:1 Day Seminar: 28 February 2012 – Adelaide 1 Day Seminar: 14 August 2012 – Adelaide 1 Day Seminar: 27 June 2012 – Regional

Qld Seminars:2 Day Seminar:March 15 & 16th – Brisbane July 19 & 20th – Brisbane October 11 & 12th – Brisbane

Vic Seminars:Location Vic Office:1 Day Basic Steam Seminars: Wednesday March 14th Wednesday June 13th Wednesday October 17th

2012 SEMINARSStaying ahead of the rest...

CONTACT SPIRAX SARCO ON 1300 SPIRAX (774 729) TO LEARN MORE!If you are not calling from Australia, please dial: +61 2 9852 3100

c a s e f o r s t e a m

READ MORE IN OUR INSERT

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Download today to get access to this useful tool, and the opportunity to see what else Spirax has to offer. Plus sign up to our service to keep up to date on future enhancements and our products. For more information on Spirax Sarco go to http://www.spiraxsarco.com or visit http://itunes.apple.com/us/app/steam-tools/id378289552?mt=8#

Sustainability! You aren’t excited? Think again!

In reality however Sustainability is key in the five fundamental challenges that face organisations today. The five challenges are reducing daily costs, improving safety, boosting productivity, raising environmental performance and making wise investments.

Many businesses have their own corporate goals and with the imminent arrival of the carbon tax the pressure is on specific corporate goals and the five

When the word ‘Sustainability’ is used- it often can have a soporific effect on engineers, maintenance managers and production managers. The thought maybe that ‘Sustainability’ is the domain of tree huggers, environmental champions and the unfortunate graduate engineers who have been told to 'look at it' for the business, not those who are interested in the profitability of the company.

fundamental challenges for companies to deliver improvement and results.

Sustainability is ‘the capacity to endure’. At Spirax Sarco we believe we can add to the Sustainability of your steam plant by improving efficiencies, reducing costs and saving energy leaving a successful legacy.

The bottom line in any new energy saving proposal is in most cases ‘the

bottom line’ – How much is it costing? What’s the payback? What’s the benefit?

The real benefit of a lot if not all of the plant improvements we identify is that they will save money but also address/improve the ‘environmental’ performance of the plant - keeping the engineers, the bean counters and the ‘environment lovers’ happy!

Expertise

We provide the steam expertise and solutions that help our customers meet their sustainability goals.

Solutions

Through over 100 years’ experience, we have come across all types of industry and challenges and the chances are – whatever the situation is in your plant – we’ve seen it before.

Sustainability

We want to ensure your system is working at peak effectiveness, identify the biggest opportunities for improvement with the shortest payback. This approach helps promote long term sustainability, both for the environment and the business.

So next time senior management calls a meeting with ‘Sustainability’ or 'environment' in the agenda – don’t glaze over or pull a ‘sickie’ but see it as a commercial opportunity for improvement in your business.

By Craig McKnight, State Manager - NSW

For more information on how you can Reduce Costs, Save Water, Reduce CO2 and Save Energy, please call us on: 1300 SPIRAX (774 729) or email us at [email protected] If you are not calling from Australia, please dial: +61 2 9852 3100

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e n v i r o n m e n t

‘STEAM ACCUMULATORS’ 2011 SPIRAX SARCO

STEAM CAn BE EASILy And EffECTIvELy dISTRIBUTEd

Steam Accumulators pull-out technical insert

The purpose of a steam accumulator is to release steam when the demand is greater than the boiler’s ability to supply at that time, and to accept steam when demand is low.

Steam accumulators are sometimes thought of as relics of the ‘steam age’ with little application in modern industry. The following Sections within this Module will:

• Illustrate how a steam accumulator can improve the operation of a modern plant.

• discuss the factors which make steam accumulators even more necessary now, than in the past.

• Provide guidance on the sizing and selection of appropriate ancillary equipment.

Boiler designContemporary boilers are significantly smaller than their counterparts of only 30 years ago. This reduction in boiler size has been brought about by users, who demand that boilers be:

• More efficient in terms of fuel input to steam output.

• More responsive to changes in demand.

• Smaller, and so take up less floor space.

• Cheaper to buy and install.

These targets have been met in part by today’s more sophisticated controls / burners which respond faster and more accurately to changes in demand than those of bygone years. However, a boiler’s response to changes in demand is also affected by the laws of nature, for example: how much water is to be heated and the heat transfer area available to transfer that heat from the burner flame to the water.

Response times have been improved by physically reducing the external dimensions of the boiler for any given output, and by cramming the insides full of tubes to increase the heat transfer area. This means that the modern boiler holds less water, and the heat transfer area per kg of water is greater. Consider the situation of today:

1. Steam demand from the plant is increased, and the pressure in the boiler falls to the burner control set point.

2. The burner control purges the combustion chamber, and the burner is ignited.

3. The large heat transfer area and the lower mass of water combine to rapidly evaporate the water in the boiler to satisfy the demand for steam.

As covered in Module 3.7, ‘Boiler fittings and Mountings’, the energy stored in a boiler is contained in the water which is held at saturation temperature. The greater the amount of water inside a boiler, the greater the amount of stored energy to cope with changes in demand / load.

Table 3.22.1 compares an old Lancashire boiler of the 1950s with a modern packaged boiler. note that the modern packaged boiler contains only 20% of the water held in a similarly rated Lancashire boiler. It follows from this that the reserve of energy held in the modern packaged boiler is only 20% of the Lancashire boiler. This suggests that the modern packaged boiler cannot cope with peak demands in the way an old Lancashire boiler could.

Also note from Table 3.22.1, that the ‘steam release rate’ from the surface of the water inside the modern packaged boiler has increased by a factor of 2.7. This means that the steam has only 1 / 2.7 (40%) of the time available in a Lancashire boiler to separate itself from the water. At times of peak demand this may mean that wet steam is being exported from the modern packaged boiler, and possibly at a lower pressure than that which it was designed to operate – Covered in Module 3.12 ‘Controlling TdS in the Boiler Water’.

Water which is carried over with the steam will be dirty (approximately 3 000 ppm TdS), and will contaminate control valves and heat transfer surfaces. It may even block some of the smaller orifices in pressure sensing devices, steam traps and so on.



Peak demandsSteam demands on any process plant are rarely steady, but the size and type of the fluctuations depend on the application and the industry. Peaks may occur once a week or even once a day during start-up.

The biggest problems caused by peak demands are usually associated with batch processing industries:

• Brewing.• Textiles.• dry-cleaning.• Canning.• Lightweight concrete block manufacturers.• Specialised areas of the steel making industry.• Rubber industries with large autoclaves.

for these processes the peaks may be heavy and long-term, and measured in fractions of an hour.

Alternatively, load cycles can consist of short-term frequent peaks of short duration but very high instantaneous flowrate:

• Hosiery finishing.• Rubber.• Plastic and polystyrene moulding.• Steam peeling.• Hospital and industrial sterilisation.

figure 3.22.1, shows that in each case the demands are almost instantaneous and the peaks are well above the average load. The result of a sudden demand on boiler plant is a pressure drop in the boiler, because the boiler and its associated combustion equipment are unable to generate steam at the rate at which it is being drawn off.

Peak demands and subsequent pressure drops may have quite serious consequences on factory production.

At worst, the result is a boiler ‘lockout’, due to the elevation of water level caused by rapid boiling, followed by its collapse. This is seen as a low water level alarm by the level controls.

At best, the steam produced is wet and contaminated. This, coupled with a reduction in pressure, can lead to:

• Increased process times.• A reduction in product quality or even damage or loss of the product.• Waterhammer in the steam mains causing distress to pipework and fittings, and possible danger to personnel.

Boiler type Length x diameter ‘From and At’ rating

Water content Surface area of water in the boiler

Steam release rate from surface

Lancashire 9.1m x 2.7m (30’ x 9’)

4 540 kg / h (10 000 lb / h)

45 400 kg (10 000 gal.)

18.6 m² (200 ft²)

244 kg / m² h (50 lb / ft² h)

Modern packaged

3.9m x 2.5m (13’ x 8’)

4 540 kg / h (10 000 lb / h)

9 100 kg (2 000 gal.)

7 m² (75 ft²)

649 kg / m² h (133 lb / ft² h)

Table 3.22.1 Comparison of Lancashire and modern packaged boilers



Note: The information to create Table 3.22.1 was supplied by Thermsave. Imperial units are also shown in the Table to provide an insight into the factors applied in the designing of boilers in the past.

Fig. 3.22.1 Typical steam flow chart for a batch process plant


for the boiler plant, peak demands are responsible for:

• A higher level of maintenance.• Reduced boiler life.• Reduced fuel efficiency.

This is because the combustion equipment is continually cycling from low to high fire, and even shutting off during periods of very low demand, only to fire again a few minutes later, with all the pre and post-purge chilling effects.

Multiple or oversized boilers may be used in an effort to cope with peak demands (and the subsequent dips in demand) which inevitably result in low efficiencies.

To illustrate this point, it can be assumed that:

• for an average steam boiler, less than 1% of the losses are due to heat radiated from the boiler shell (for example: 1% of the Maximum Continuous Rating (MCR) of the boiler).

• If a boiler is then producing 50% of its MCR, the losses due to radiation are 2% relative to its production rate.• If a boiler is producing 25% of its MCR the losses are 4% of its production rate.

And so on, until a boiler is simply maintained at a pressure without exporting any steam to the factory. At this point, 1% of its MCR is a 100% loss relative to its steam production rate.

If boiler plant is sized for peak loads, problems arise due to oversizing relative to the average demand. In practice, a boiler may shut off during a period of low demand. If this is then followed by a sudden surge of demand and the boiler is not firing, an alarm situation may arise.

Alarms will ring, the boiler may lockout and steam recovery will be slow and arduous. In short, peaks are responsible for:

• Loss of production.• Reduced product quality.• Increased production times.• Poor quality steam from the boiler.• Low fuel efficiency.• High maintenance costs.• Reduced boiler life.

Load levelling techniquesModern boilers are very efficient when properly loaded and respond quickly to load increases, provided that the boiler is firing. However, conventional shell boilers are generally unable to meet large peak demands in a satisfactory way and should be protected from large fluctuating loads.

various methods are used in an attempt to create a stable load pattern to protect the boiler plant from the effects of large fluctuating loads.

Engineering methods:• Pressure maintaining valves (also called surplussing valves) can be used as load shedding devices by isolating non-essential

parts of the plant and thereby giving priority to essential plant, a typical arrangement is shown in figure 3.22.2. The success of this method again depends on the severity of the peaks and the assumption that the boiler is firing when the peak develops.

Surplussing valves can also be fitted directly to the boiler or on the steam main to the factory, as shown in figure 3.22.3.



STEAM IS CLEAn




non-essential steam supply 2

non-essential steam supply 1

Steam from boilerEssential steam supply

Condensate

Steam distribution header

Pressure maintaining valve Pressure maintaining valve

Fig. 3.22.2 Surplussing valves used as load shedding devices

Fig. 3.22.3 Surplussing valve on a boiler main

The set pressure should be:

• Less than the ‘high fire’ control pressure, to prevent any interference of the surplussing control with the burner controls.• High enough to maintain the pressure in the boiler at a safe level.

In terms of sizing the surplussing valve, the requirement is for minimum pressure drop. As a general indication, a line size valve should be considered.

• Two-element or three-element water level control. These can be successful as long as the peaks are not violent and the boiler is firing when the peak develops; the boiler must also have sufficient capacity.

• Two-element control uses inputs from the boiler water level controls and the steam flowrate to position the feedwater control valve.

• Three-element control uses the above two elements plus an input from a feedwater flow measuring device to control the incoming feedwater flowrate, rather than just the position of the feedwater control valve. (This third element is only appropriate on boilers which use modulating level control in boiler houses with a feedwater ring main.)

Surplussing valve

Condensate

Steam

Pressuretransmitter

Controller

Main stop valve

Separator andtrap set


Example 3.22.1A boiler is rated at 5 000 kg / h ‘from and At’

The high / low fire pressure settings are 11.3 / 12.0 bar g respectively (12.3 / 13.0 bar a).

The surplussing valve setting is 11.0 bar g (12.0 bar a).

1. Based on a velocity of approximately 25 m / s, a 100 mm steam main would be selected.2. Kvs of a standard dn100 surplussing control valve is 160 m³ / h3. Using the following mass flow equation for saturated steam the pressure downstream of the surplussing valve (P2) can be

calculated:

Where:

ms = Steam mass flowrate (kg / h)

Kv = valve flow coefficient

P1 = Pressure upstream of the control valve (bar a)

P2 = Pressure downstream of the control valve (bar a)

= Pressure drop ratio

In this example, at low fire, the boiler pressure is given as 12 bar g (13 bar a).

It can be calculated from Equation 3.21.2 that the pressure after the fully open surplussing valve is 11.89 bar g (12.89 bar a).

Consequently, the pressure drop is small (0.11 bar) and would not be significant in normal operation. However, if the pressure should fall to 11.0 bar g, the surplussing valve will start to close in order to maintain upstream pressure.

The proportional band on the controller should be set as narrow as possible without making the valve ‘hunt’ about the set point.

Both methods of applying pressure-maintaining valves may provide protection to the boiler plant, but they will not overcome the fundamental requirement of more steam for the process.

Management methodsThese include, for example, staggered starts on processes to keep peak loads as low as possible. This method of smoothing out peaks can be beneficial to the boiler plant but may be detrimental and restrictive to production, having much the same effect as the pressure-maintaining valve.

It is, however, impossible to smooth out short-term peaks using only management methods. In a factory where there are many individual processes imposing such peaks it is possible for this to have a levelling effect on the load, but equally so, it is also possible for the many individual processes to peak simultaneously, with disastrous effects.

If the above methods do not provide the required stability of demand, it may be time to consider a means of storing steam.



Equation 3.21.2

STEAM IS COMPETITIvESTEAM IS nOn-vOLATILE


The steam accumulatorThe most appropriate means of providing clean dry steam instantaneously, to meet a peak demand is to use a method of storing steam so that it can be ‘released’ when required. Storing steam as a gas under pressure is not practical due to the enormous storage volume required at normal boiler pressures.

This is best explained in an example:

In the example used later in this Module, a vessel with a volume of 52.4 m³ is used.

• Charging pressure is 10 bar g (specific volume = 0.177 m³ / kg).• discharge pressure is 5 bar g (specific volume = 0.315 m³ / kg).

Based on these parameters, the resultant energy stored and ready for instant release to the plant is contained in 130 kg of steam. This amounts to only 5.2% of the energy stored and ready for use, compared to a water filled accumulator.

In practice there are two ways of generating steam:

• By adding heat to boiling water, indirectly via a combustion tube and burner, as in a conventional boiler.• By reducing the pressure on water stored at its saturation temperature. This results in an excess of energy in the water, which

causes a proportion of the water to change into steam. This phenomenon is known as ‘flashing’, and the equipment used to store the pressurised water is called a steam accumulator.

There are, in principle, two types of systems available for steam storage; the pressure-drop accumulator and the constant pressure accumulator. This module only considers the former type.

A steam accumulator is, essentially, an extension of the energy storage capacity of the boiler(s). When steam demand from the plant is low, and the boiler is capable of generating more steam than is required, the surplus steam is injected into a mass of water stored under pressure. Over a period of time the stored water content will increase in temperature and pressure until it finally achieves the saturation temperature for the pressure at which the boiler is operating.

demand will exceed the capability of the boiler when:

• A load is applied faster than the boiler’s ability to respond - for example, the burner(s) may be extinguished and a purging cycle must be completed before the burner can be safely ignited. This may take up to 5 minutes, and rather than adding heat to the boiler, the purging cycle will actually have a slight cooling effect on the water in the boiler. Add to this the fact that the flashing of the boiler water will cause a drop in water level, and the boiler level control system will automatically compensate for this by bringing feedwater in at, for example, 90°C. This will have a quenching effect on the water already at saturation temperature, and willaggravate the situation.

• A heavy demand occurs over a longer than normal period.

In either case, the result is a drop in pressure inside the steam accumulator, and as a result of this some of the hot water will flash to steam. The rate at which the water flashes to steam is a function of the storage pressure, and the rate at which steam is required by the system being supplied.

ChargingThe pressure-drop steam accumulator consists of a cylindrical pressure vessel partially filled with water, at a point between 50% and 90% full depending on the application. Steam is charged beneath the surface of the water by a distribution manifold, which is fitted with a series of steam injectors, until the entire water content is at the required pressure and temperature.

It is natural that the water level will rise and fall during charging and discharging.

If the steam accumulator is charged using saturated (or wet) steam, there may be a small gain in water due to the radiation losses from the vessel. normally, a slightly greater mass of steam is discharged than is admitted.

A steam trap (ball float type) is fitted at the working level and acts as a level-limiter, discharging the small amount of surplus water to the condensate return system.

However, if the steam accumulator were charged using superheated steam, or if the radiation losses are very small, there would be a gradual loss of water due to evaporation, and a feedvalve or pump, under the control of level probes, would be required to make up the deficit.




dischargingAs a pressure drop occurs in a steam accumulator with the stored water at saturation temperature, flash steam will be generated at the rate demanded by any load above the boiler capacity; consequently the overload condition will be satisfied. When the overload is followed by a demand below the boiler capacity the steam accumulator is charged using surplus steam from the boiler. This charge and discharge cycle explains the name ‘steam accumulator’ and continually allows the boiler to fire up to its maximum continuous rating.

The charging / discharging cycleThe accumulator needs to be fully charged at the beginning of its discharge period, for it to operate correctly. To allow this, two main events must be satisfied:

1. Enough time must be available from the end of one overload period to the beginning of the next, to recharge the water stored in the accumulator.

2. The average off-load steam demand must be lower than the boiler capacity (the maximum continuous rating or MCR), such that sufficient surplus boiler capacity is available to recharge the water stored in the accumulator during off-peak times.

Other criteria are also important to ensure the accumulator has enough capacity, and these must be satisfied by the design:

1. Enough water must be stored to provide the required amount of flash steam during the discharge period. This can be satisfied by ensuring the accumulator volume is large enough.

2. Higher steam release rates will produce wet steam. The velocity and flowrate at which the flash steam is released from the water surface must be below a predetermined value. This can be satisfied by ensuring the water surface area is large enough which, in turn, depends on the accumulator size.

3. The evaporation capacity must be sufficient. This depends on the pressure at which the water is stored when fully charged (the boiler pressure) and the minimum pressure at which the accumulator will operate at the end of the discharge period (the accumulator design pressure). The larger the differential between these two pressures, the more flash steam will be produced.

4. The accumulator design pressure must be higher than the downstream distribution pressure. This is necessary to create a pressure differential across the downstream pressure reducing valve (PRv), to allow the required flow from the accumulator to the plant. The closer the accumulator pressure to the distribution pressure, the smaller the accumulator but this also gives a smaller pressure differential across the PRv. This requires a larger PRv; large enough to pass the highest overload demand when the accumulator is at its design pressure (the minimum pressure in the accumulator at the end of the discharging period).



If you would like to read the rest of this document on ‘Steam Accumulators’ , please find it in the ‘Steam and Condensate Loop’ book, or email [email protected] for a copy of the module.

STEAM IS THE BEST CHOICE AS An EnvIROnMEnTALLy fRIEndLy

EnERgy MEdIUM


QUESTIOnS

1. What would be the effect of a peak demand for steam above a boiler’s maximum continuous rating?

a| A drop in pressure and a rise in water level □b| foaming within the boiler and carryover □c| A rise in pressure as the water level rises, and burner shut-off □d| A drop in pressure and water carryover □

2. What is the purpose of a surplussing valve on the steam main leaving a boiler?

a| To remove any carryover of water □b| To open further to meet any peak demand for steam □c| To reduce the steam pressure and overloading of the boiler □d| To maintain pressure in the boiler □

3. A steam accumulator provides steam to meet peak demand

a| from the water flashing off □b| By steam generated from the steam injected into the water □c| from steam stored in the vessel □d| from steam flowing into and out of the vessel from the boiler □

4. How is the water that flashes off in an accumulator replaced?

a| By the incoming condensing steam □b| By make-up water from the boiler feedpump □c| By a connection to the boiler and a self-adjusting level □d| The water level does not change □



Water + Energy = SteamSteam + Work done = Condensate (Water)

Condensate Returned = Reduced Water Consumption, Reduced Emissions and dollars Saved

With few standards for steam quality in the food and beverage sector, should manufacturers be considering the use of clean steam as standard practice to eliminate any contamination risk? A review of their steam system will provide the right guidance.

Today’s consumers are more conscious of food safety than ever. Together with the regulators and the major retailers, they are placing food and beverage production under increasing scrutiny.

Steam is routinely used in direct contact with food products, but this can raise quality or even food safety issues if the correct standard of steam is not used.

While there is little legislation governing plant steam quality, it is important that the steam in contact with food products is clean, dry and free from boiler carryover. Low steam grades, such as plant steam, have the highest risk of potential contamination and can be determined by the steam system design; materials of construction; correct operation of the boiler; routine maintenance; the quality of water entering the boiler; and water treatment regime.

In most traditional applications using plant or factory steam, traces of feedwater chemicals, rust or pipe scale would not be a problem, particularly where heating by steam is indirect. However, where a product needs to be prepared, processed or maintained in a hygienic environment, food and beverage manufacturers should take particular care to identify and control the quality/purity of their steam systems to avoid any potential risk of product contamination.

Contamination issues associated with plant steam can be avoided easily and consistent product quality assured by ensuring all potential hazards are controlled within best practice guidelines commonly referred to as HACCP, (Hazard Analysis & Critical Control Point within the food and beverage industry).

Filtered steam

Commonly referred to as “culinary steam”, filtered steam is frequently used in applications where the product is heated by direct steam injection.

Filtered steam is produced from plant steam by passing it through a high efficiency filter, typically removing particles greater than five microns. However, filtered steam may still present a contamination risk through the traces of chemicals used to treat the boiler feedwater, or even through cross contamination from other areas of the plant.

Clean steam

Raised typically by a clean steam generator from high purity feed water produced using reverse osmosis or de-ionisation, clean steam is suitable for use wherever a higher degree of steam purity is required. Clean steam is used in the food & beverage industry to reduce the risk of product or process contamination, not only during cooking and sterilisation of the products, but also during the Sterilisation in Place (SIP) of equipment.

Clean steam requires the use of stainless steel pipework and components that eliminate the potential for corrosion of steam traps, valves and pipeline equipment made from traditional carbon steel materials.

Clean steam solves process problems

While some food & beverage manufacturers have made the step up to using filtered steam, others are opting

for the added security of a separate clean steam supply.

There may be company-specific reasons for this. For example, major brewers might be concerned about product tainting and could use clean steam to ensure a consistent taste to their product. Meanwhile, quality assurance could be a key driver for food manufacturers worried about product discolouration.

With minimal law forcing them to adopt a particular approach, food companies are largely self-regulating in their use of steam when used in direct contact with the product. Even so, following a credible set of external guidelines helps to demonstrate that they’ve done everything possible to minimise any risk that contamination may pose to consumers.

Overseas and in Australia, there are standards, guidelines and legislation in place to ensure the safe production of food. However, little regulation exists that provides specific guidelines on the quality and purity of steam when in direct contact with the process or the product.

Food for thought: how clean does steam need to be?


5

By Graham Smith, Business Development Manager, Steam Quality

continued on page 6

Spirax Sarco at your service

As the steam sector’s leading technology provider, Spirax Sarco offers an unrivalled level of support that can deliver lasting peace of mind for customers. Spirax Sarco service agreements are specified to match each steam operator’s needs and budget.

The practical benefits are clear

Protect safety A Spirax Sarco service agreement provides on-going planned maintenance to help ensure that plant and equipment is operating safely and reliably.

Boost efficiency Service agreements almost invariably increase operating efficiency. Checking and calibrating instrumentation regularly means that processes are optimised at all times, reducing the risk of product spoilage and saving energy.

Steam users often find it hard to dedicate the time and in-house resources to establish comprehensive planned maintenance, particularly on a specialised heating plant. Outsourcing some or all of the on-going maintenance work to Spirax Sarco may be the most cost-effective solution.

A better bottom line Service agreements make maintenance costs more predictable, which improves planning and forecasting, as well as minimising the need to stock spares. Optimised efficiency also delivers savings in energy, downtime and a reduced risk of product spoilage.

For more information please call us on: 1300 SPIRAX (774 729) or email us at [email protected] If you are not calling from Australia, please dial: +61 2 9852 3100

6

s t e a m d i s t r i b u t i o n

In the UK, there is the Heat Preserved Foods Guide. In Europe, there is Regulation (EC) No 852/2004 of the European Parliament and of the Council of 29 April 2004 on the hygiene of foodstuffs. The USA has the 3-A Sanitary Standard (Number 609-03) which, in the absence of anything else, is often recognised and applied in other countries, including Australia.

In Australia, AQIS (Australian Quarantine and Inspection Service) has defined certain water treatment chemicals that may or may not be used is steam systems where the steam can come into direct contact with food or drink. And Spirax Sarco in Australia offers a comprehensive Steam Quality Testing Service which will clearly identify the quality and purity of the steam currently being used.

In the absence of direct regulatory pressure to implement a particular approach, many manufacturers are 'doing their own thing' for which Spirax Sarco, through their unique knowledge and understanding of the steam business, can provide notable assistance.

Food for thought: how clean does steam need to be?

continued from page 5

Spirax Sarco proudly supports the First Australian Summer Study on Energy Efficiency: 29 February – 2 March, 2012Novotel Sydney Manly Pacific – Hosted by The Australian Alliance to Save Energy

The Summer Study is a highly successful, international program which brings together hundreds of leaders from all sectors of industry, government, research and NGOs to discuss key issues in a collegiate setting. Running for over 30 years in the US and 16 years in Europe, these sell-out events are renowned for producing tangible outcomes in a relaxed, residential environment.

Keynote speakers: Kateri Callahan, President, The Alliance to Save Energy (US); Steve Nadel, Executive Director, American Council for an Energy Efficient Economy (US); David Sweet, Executive Director, World Alliance for Decentralised Energy (US); Phillip Sellwood, Chief Executive, Energy Savings Trust (UK); and Grayson Heffner, Senior Analyst, International Energy Agency (FRANCE).

Spirax Sarco will be the Gold Sponsor for this event. Make sure you visit us!

Early Bird: $990 + GST (Closes January 2012), Full price: $1190 + GST. Find out more at: http://www.a2se.org.au/summer-overview

Key features and benefits:

The quick-fit steam trapping solutionThe STS17.2 steam trap station has been designed to provide a convenient 'ready-to-install' trapping solution which has an upstream isolation valve, quick-fit connector with strainer, check valve and a downstream isolation valve.

• Quick and simple maintenance of the steam trap with simple two-bolt connector reducing system downtime and maintenance costs compared to traditional trapping stations.

• Single permanent in-line component ease of specification and installation.

• Pre-assembled construction minimising on-site fabrication, quick and easy installation, no screwed connections therefore reducing potential leak paths.

• All stainless steel construction long and trouble-free life with good corrosion resistance and 'cleanliness'.

• Compatible steam trap options providing flexible supply and selection.

• An in-trap sensing option providing automatic steam trap operation indication.

• Replaceable internal parts maintainable internal parts of ball valves, check valve and strainer screen.

• Lockable handle as standard minimising the possibility of accidental or unauthorised operation.

STS17.2 steam trapping station

By Trevor Peeling, Product Manager

For more information please call us on: 1300 SPIRAX (774 729) or email us at [email protected] If you are not calling from Australia, please dial: +61 2 9852 3100

p r o d u c t r e l e a s e

7

Balanced pressure thermostatic steam traps

operate below steam saturation temperature,

depending on the capsule fitted. Suitable for non-critical systems.

Bimetallic steam traps operate below steam

saturation temperature, depending on the

bimetal setting. Suitable for non-critical sytems.

Ball float steam traps provide condensate drainage at steam

temperature and include excellent air venting

ability.

Inverted bucket steam traps operate at steam

temperature with complete condensate

drainage.

Thermodynamic disc type steam traps will

ensure complete condensate drainage

without energy wastage. Longlasting, compact

and robust.

Compatible steam traps

UBP32 USM21 and USM32 UFT32 UIB30 and UIB30H UTD30 series

If unclaimed please return to:Spirax Sarco Marketing Department PO Box 6308 BLACKTOWN NSW 2148

PRINTPOST

PP255003/04601

POSTAGEPAID

AUSTRALIA

You can now subscribe or unsubscribe to Australian Spirax Sarco Topics on our website at www.spiraxsarco.com/au

We hold seminars and training courses Australia wide. Call 1300 SPIRAX (774 729) and find out when we are holding one in your state!Training Courses

'The Tracer' Issue 16 - 2011 $5.95

Sustainable Water Treatment Plan 2

Steam Accumulators 3

Sustainability 4

Food for Thought 5

Spirax Sarco at your service 6

Product Release – STS17.2 7

Competition Winners 8

Win a JB Hi-Fi

Gift Card DOWNLOAD THE SPIRAX SARCO iPhone APP!

TOPICSAustralian

spiraxsarco.com/au

supporting your

sustainability goals

Congratulation to Issue 15 Competition winners!MAIN PRIZE WINNER: Wally Brien (Mars Petcare) SEMINAR WINNER: Jeff Millar (H.J. Heinz) Keep entering our competition for your chance to win and rememberALL WHO ENTER WILL RECEIVE A PROMOTIONAL GIFT FROM SPIRAX SARCO!

Snezana Novakovic, Marketing Specialist

Wally Brien (Mars Petcare)

Contacting UsNEW SOUTH WALES14 Forge Street(PO Box 6308 Delivery Centre)BLACKTOWN NSW 2148Ph: 1300 SPIRAX (774 729)Fax: (02) 9831 8519E-mail: [email protected]

VICTORIA4A/9 Jersey Road(PO Box 353)BAYSWATER VIC 3153Ph: 1300 SPIRAX (774 729)Fax: (03) 9720 5224E-mail: [email protected]

QUEENSLAND57 Distribution Street LARAPINTA QLD 4110Ph: 1300 SPIRAX (774 729) or +61 7 3441 1600 Fax: (07) 3800 9900 E-mail: [email protected]

SOUTH AUSTRALIAUnit 5/ 6 Walla St LONSDALE SA 5160Ph: 1300 SPIRAX (774 729) Fax: (08) 8307 2777 E-mail: [email protected]

WESTERN AUSTRALIA1/14 Bannick CourtCANNING VALE WA 6155Ph: 1300 SPIRAX (774 729)Fax: (08) 9455 4809E-mail: [email protected]

TASMANIASteam Plus13 Ferguson DriveQUOIBA TAS 7310Ph: 03 6424 6202Fax:03 6424 6214E-mail: [email protected]

NEW ADDRESS

NEW ADDRESS

NEW ADDRESS

The Steam and Condensate Loop Book

8

● This great book is prepared by experts from Spirax Sarco, a world leader in steam engineering.

● The ‘Steam and Condensate Loop’ book explains the principles of steam engineering and heat transfer.

If you are not calling from Australia, please dial: +61 2 9852 3100

Win a JB Hi-Fi Gift Card


To enter online visit spiraxsarco.com/auand follow the instructions

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Enter our competition for your chance to

WIN

a JB Hi-Fi Gift Card

worth $500


FIRST PRIZE:JB Hi-Fi giFt card ($500)

SECOND PRIZE:3 ‘Steam and condensate Loop’ books

Name ...................................Company ....................................

Position ....................................................................................

Phone number .........................................................................

Company address ....................................................................

.................................................................................................

Email address ..........................................................................

Q1. Does your organisation have sustainability goals?

n Yes n No

If yes, what are they?

Q2. Would you like more information on Steam Trapping Station?

n Yes n No

Q3. Do you know what water hammer is?

n Yes n No

Q4. Do you experience cracking and banging in your steam distribution system or plant?

n Yes n No

Q5. Has your current water treatment chemical supplier discussed engineering solutions with you to reduce chemical and water usage?

n Yes n No

If not would you like to hear from a Spirax Sarco representative?

n Yes n No

TERMS AND CONDITIONS: Enter the competition by answering a few simple questions on an insert placed in our quarterly Topic publication. The competition starts 12th December 2011. Closing Date of the Competition is 13th Feb 2012. Date of the draw will be 14th Feb 2012. Time will be 10.00am. Draw will take place at the Spirax Sarco Head Office at 14 Forge Street, BLACKTOWN NSW 2148. The total prize value is: $1,150.00. Main prize is JB HI-FI GIFT CARD valued at $500.00. Second Prize is a place in the next Spirax Sarco ‘Steam Engineering’ seminar when held in your state valued at $650.00. Winners’ names will be announced on the Spirax Sarco website on 16th Feb 2012 and published in the Issue 17 of Topics. All prize winners will be notified by phone call and e-mail from their local representative who will personally deliver the prize. Website address is: www.spiraxsarco.com/au in the News section. The Promoter is Spirax Sarco with registered office at 14 Forge Street Blacktown (PO Box 6308, Delivery Centre), NSW. ABN 52001 126 601. Redraw will be held on 15th June 2011. Redraw will be held at the same address and time as original draw. Prize winners will have their prizes delivered by our Spirax Sarco staff member for that sales territory and all prizes will be delivered before 21st March 2012. ACT residents excluded. NSW: LTPS/10/10821 and LTPS/11/11485

Your DetailsAbout the Prizes

WINa JB Hi-Fi Gift Card worth $500



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