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Culture Documents
250
by a pipework distribution system. At the corrugator it
gives up heat to the various processes and condenses. 200 Steam saturation
curve
A very important property of saturated steam is that its 150
temperature is directly related to its pressure. Therefore
the temperature of the heated cylinders and hot plates 100
on a corrugator can be accurately controlled by
controlling the pressure of the steam. 50
2
Spirax Sarco
in the corrugating industry
For most of the 20th century Spirax Sarco has been the leader
in improving steam plant efficiency, providing knowledge
and high quality products to all branches of industry,
including the corrugating industry.
Steam
distribution
Steam control
Steam and
generation management
Condensate
management
3
Spirax Sarco and steam generation
Steam leaving the boiler house should contain as We have technical and sales literature available on
little moisture and incondensable gases as possible. the subject of boiler house applications and
equipment available upon request.
This will ensure that the maximum amount of heat is
available at the corrugator and minimise the risk of An essential part of boiler house design and
pipeline damage from waterhammer. operation is ensuring the boiler operates at the
highest possible efficiency. Every effort should be
Spirax Sarco has the expertise to help you produce
made to recover and reuse the heat available from
high quality steam from your boilers, at the most
secondary sources such as boiler blowdown.
economical cost, with a wide range of products
specifically designed for the boiler house, all Your local Spirax Sarco engineer will be able to help
manufactured to the highest standards. and offer advice on how this can be achieved.
4
Spirax Sarco and steam distribution
Various outputs
Air alarms
vent RS232C Interface
timers
Condensate out
Air
vent
Steam flow
5
Spirax Sarco and
Steam in Steam in
Rotary Rotary
joint joint
Float and thermostatic steam Float and thermostatic steam trap set
trap set with blow through connection
Spirax Sarco steam trap set for low speed Spirax Sarco steam trap set with provision for
cylinder blow-through
Upper
corrugating
cylinder
Steam shower
Preheater
Controller
Air
supply Pneumatic valve and actuator
with positioner
Power
supply
6
the corrugator
Flash steam
Air
from cascade
supply Pneumatic reducing
system
valve station
Live steam
Hot plates
Glue
Machine Felt
shower
Hot plates
Triplex
Preheater
Signal from
drive control system
Separator
Air supply
Actuated
Steam trap set ball valve
Steam shower
Steam trap
7
The steam supply Space heating and humidification requirements must
Corrugators require a primary steam pressure of be taken into consideration in order to provide the
between 7 bar for older style machines, up to 16 bar optimum conditions for board preparation and storage.
for the newer high speed machines.
Spirax Sarco has extensive experience in this area and
Whatever type of steam or condensate management can provide advice on your heating and humidification
system is used, the primary steam pressure onto the systems.
corrugator must be correct and stable. The corrugating
rolls, small preheaters, press rolls and first section of Static heated cylinders
the double backer usually operate at the highest Some corrugators will have static cylinders used as
temperature. They require high pressure steam within preheaters. Depending upon the temperature required,
± 0.3 bar ( ± 2°C ). these are provided with steam at pressures ranging
from 3 bar up to 16 bar. Because they are static, steam
Different types of reducing valve are available, from
inside will condense and form a puddle in the bottom.
simple direct acting valves to the more flexible
pneumatic actuator, valve and electropneumatic Normally a syphon pipe will be fitted inside and the
positioner combinations. pressure differential between the steam inlet and the
condensate outlet will allow condensate to flow up the
The choice of main reducing valve type should depend
syphon pipe and out of the cylinder.
on the needs of the corrugator.
Spirax Sarco can supply many different types of steam Condensate puddle
pressure control system, and can advise on the best Static cylinder section
choice for your particular application.
8
To maintain the correct cylinder surface temperature, On low speed rolls, where rimming does not occur, a
the steam pressure should be accurately controlled and ball float (FT) steam trap fitted with a thermostatic air
the condensate removed as soon as it forms. vent and steam lock release valve, to prevent steam
locking, should be suitable. Other types of steam trap
The way that condensate behaves in a rotating cylinder
may also be suitable depending upon the operating
is influenced by many factors, including cylinder
conditions.
diameter, machine speed, condensation rate and the
depth of the condensate rim inside the cylinder. Where it is known that rimming will occur it may be
Depending upon these various factors it can be either necessary to provide a steam trap / blow-though
'puddling', 'cascading' or 'rimming'. combination or even a total blow-through system
without a steam trap.
Rimming
Hot plates
Groups of steam heated hot plates provide final
conditioning to the board before the finishing processes.
9
Steam showers
Low pressure steam showers are found in two locations It is important that this steam is dry and does not
on a corrugator. contain any entrained water droplets that could spray
onto the board and mark it or cause it to break.
The first location is the single facer where steam is
Therefore a steam separator should always be fitted
used to moisten and heat the corrugating medium prior
before a steam shower to remove any entrained water
to passing through the corrugating rolls.
in the steam.
The second location is the double backer where steam
Provision should also be made to shut the steam
showers heat, moisten and clean the felt that presses
supply to the shower when the corrugator stops
the board onto the hot plates.
running, preventing localised wetting. This can be
The showers are fed with low pressure steam either accomplished by fitting an actuated ball valve in the
through a pressure reducing valve set, or with flash steam supply line to the shower, operated from the
steam from the cascade system together with low drive control system.
pressure steam make-up.
Flash Flash
separator separator
vessel vessel
Condensate to
boiler house
Condensate return unit
10
Medium pressure flash steam out
Level controller
Flash separation vessel
Level
control
probe
Condensate
from high
pressure steam
Motorised
control
valve
Pump
sets
Condensate out
For condensate to be removed from any process, Your local Spirax Sarco engineer will be pleased to
there needs to be a pressure drop between the steam advise on the most cost effective means of achieving
inlet and the condensate outlet. On a corrugator, a a highly efficient condensate return system.
Medium pressure
flash steam out
Condensate out
11
A partnership with Spirax Sarco Our comprehensive
product range
provides knowledge, service and products includes:
worldwide for the control and efficient use of
steam and other industrial fluids. l Boiler controls
l Flowmeters
l Worldwide support from a team of 3 900 dedicated
employees.
l Pneumatically and
electronically actuated
l Local access to Spirax Sarco's expertise and products control valves
through 39 group companies in 32 countries.
l Pressure reducing valves
l Valuable information, advice and interchange of ideas
from customer training courses held in any of our l Self-acting temperature
control valves
31 training centres worldwide.
12
SB-GCM-03 CM Issue 3