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NEWS
volume 7 no 3

IS YOUR STEAM SYSTEM

WORLD CLASS?
E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
 CONTENTS NEWS

4 IS YOUR STEAM SYSTEM 14 EXPAND YOUR KNOWLEDGE!

WORLD CLASS?

8 EDUCATIONAL NEWS BRIEF 16 STEAM SYSTEM MAINTENANCE

FOCUS ON CONDENSATE

12 9 REASONS TO INVEST IN TRAINING 23 CLICK AND LEARN ABOUT

CONDENSATE RECOVERY

MORE
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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
 CONTENTS NEWS
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SPIRAX SARCO ▪ THE HOOK-UP BOOK

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SARCO

Spirax Sarco, Inc.

1150 Northpoint Blvd. SPIRAX
SARCO

Blythewood, SC 29016
800.883.4411
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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
 IS YOUR STEAM SYSTEM
WORLD CLASS?
By Robert Crone, Southwest Account Executive for Spirax Sarco

W
hat if you had a World Class Steam System? How would it make you feel?
Would you have extra time to focus on other projects? Would you sleep
better at night? How would your manager react? Would they even care?
Would you want a world class steam system?

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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
 No matter your industry (food & beverage, hospital, university, pharmaceutical,
refinery, petrochemical, etc.), we can all agree a world class steam system has
many advantages.

Unfortunately, Webster’s dictionary does not define a world No matter your industry (food & beverage, hospital, universi-
class steam system, but common characteristics among ty, pharmaceutical, refinery, petrochemical, etc.), we can all
steam system users include the following: agree a world class steam system has many advantages.

 Reduced total cost of ownership What does a world class steam system look like
and what equipment do we need?
Increased system and equipment reliability to lower
 
maintenance requirements Boiler Room:

 Highly efficient use of steam for all applications Steam boilers are correctly sized, exceeding all environ-


mental regulations, and running at maximum efficiency.
Ability to meet all steam system and
 
production requirements Steam, water, and natural gas meters are installed to


track and trend steam system usage and efficiencies.
Lower fuel and water costs due to excellent
 
energy efficiency Additional energy saving devices (economizers,


boiler blowdown heat recovery units, controls logic,
 Lower environmental impact etc.) are installed for maximum energy efficiency.

 Ability to monitor and adjust key system parameters Steam system has a high condensate return percent-


age (90 to 95% plus).
 Improved safety

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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
Steam Traps/Piping: Steam Applications

All steam traps are working properly (not failed open


 All steam applications (heat exchangers, steam coils,


or failed closed) and are the correct technology for the cooking kettles, humidifiers, steam injection, etc.) are
application. running as efficiently as possible.

Steam traps have gone thru a rationalization program,


 Steam applications are wired into the building man-


so a minimum number of traps and spares are kept in agement system and can be monitored or modified as
stock to handle a multitude of applications. needed.

Dangerous or damaging waterhammer in the steam


 Steam meters are installed in the plant to monitor


or condensate piping during system start-up or during steam to certain areas/applications.
low, normal, and high steam loads does not occur.
For food & beverage plants, all cooking systems are meet-


All steam piping has an adequate number of properly

 ing production requirements. All CIP systems are heating
sized drip legs with steam traps to remove condensate. up quickly and meeting temperature requirements.
Both steam and condensate lines are properly insu-
lated and labeled. Insulation blankets are installed on For hospitals and universities, buildings are staying


equipment (regulators, control valves, unions, flanges, warm during the coldest days in winter.
etc.) which require maintenance.
Both steam and condensate systems require “no” to


No steam or condensate leaks in the system.
 “low” maintenance requirements.

All condensate return systems use pressure powered



pumps to return condensate.

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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
Personnel:

All operators and maintenance personnel are properly

 
trained in steam system safety and understand the
steam equipment and applications.

Ability to call a steam system expert when needed to

 
aid in solving issues with steam system equipment.

Have regular steam system audits, minimum of one

 
per year.

For those of you with World Class Steam Systems, we

salute you! If you are still working towards a World Class
Steam System, then commit to the goal, create a plan,
and make it happen. n

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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
 Educational News Brief
By Joe Radle, Senior Applications Engineer for Spirax Sarco
IS IT RECOMMENDED TO PLACE A
FLASH TANK AHEAD OF AN ELECTRIC
CONDENSATE PUMP?
T
condensate receiver, which is part of every
electric condensate pump, is designed as a
holding tank to collect and store liquid con-
densate and allow the pump to cycle on and
off draining the receiver tank intermittently.
Electric pump condensate receivers are sized to have
at least 3 minute storage capacity, and the receiver will
lose some heat during the filling cycle from the tank sur-
face area which will help in lowering the temperature of
the condensate and with the available net positive suc-
tion head (NPSH). If there is steam entering the receiver
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the cooling affect won’t drop the condensate and increase
the risk of pump cavitation. The pump receiver vent is
only sized to allow air to flow in and out of the tank. As
the condensate runs into the receiver, the air flows up the
vent so we don’t have any back pressure created in the
tank. When the pump is in the discharge mode the air
flows back into the receiver through the vent to prevent
vacuum from occurring. If a standard electric pump re-
ceiver is piped up with no flash tank ahead of the pump,
the receiver could pressurize because the vent is not
large enough to handle flash steam or live steam if the
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 If a standard electric pump receiver is piped up with no flash tank ahead of the
pump, the receiver could pressurize because the vent is not large enough to
handle flash steam or live steam if the steam traps are leaking.

steam traps are leaking. Vented condensate pump receiv- the vessel at zero pressure, with a velocity that does not
ers are not designed for pressure conditions as stated on allow carryover of water droplets.
the nameplate. The electric pump receiver also does not
For an electric condensate pump to be able to pump the
have enough physical space above the water to allow for
liquid, it must have the NPSH on the inlet suction. When
proper separation of the flash steam from the water and
the pump is functioning, it is bringing condensate in and
would allow for condensate carry over up the vent pipe.
drawing a slightly negative pressure. If the condensate
The receiver is not designed as a flash tank, only a collec-
is too hot, the water will boil and cause cavitation in the
tion vessel.
pump. By having a high enough level of liquid above the
The Flash Tank pump suction, it can keep the condensate from boiling.
The flash tank that is ahead of the pump receiver is de- Cavitation of the pump will destroy the impeller over a
signed to allow for separation of the flash steam away short period of time.
from the condensate, making sure only water flows out of
What is NPSH?
the flash tank drain and into the electric pump receiver.
NPSH is the head that causes liquid to flow through the
The flash tank is a pressure vessel and can withstand
suction piping and finally enter the eye of the impeller.
pressure and compensate if live steam from leaking steam
NPSH becomes very important to the successful operation
traps reaches it. The vent connection is designed to keep
of the pump. There are two values of NPSH to consider.

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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
 Keep in mind that many pumps have much higher NPSH requirement than 2 ft.,
and thus, need lower condensate temperatures to prevent cavitation.
Required NPSH is a function of the pump design. It var-
ies between different makes of pumps, between different
pumps of the same make, and changes with the capac-
ity and speed of any one pump. The maker of the pump
must supply the NPSH value.
Available NPSH is a function of the system in which
the pump operates and it is calculated for any installa-
tion. Any pump installation, to work correctly, must have
the available NPSH equal to or greater than the required
NPSH.
A 2 ft NPSH pump, with the pump mounted directly on the
side of the receiver will have virtually no static head when
the liquid level is at the bottom of the discharge cycle
where the pump shuts off. The pump can only accept wa-
ter at a maximum of 209 °F or cavitation will occur. If we
tried to use the receiver as a combination receiver and
flask tank, the condensate would be at 212 °F or greater
and pretty much guarantee cavitation.
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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
To have the 2 ft NPSH pump be able to operate correct-
ly at 212 °F temperature the receiver would have to be
mounted 2 ft above the pump suction on a stand to insure
it would not have cavitation. Even if we did install the re-
ceiver 2 ft above the pump suction, the receiver is still not
designed to handle the flash steam.
Keep in mind that many pumps have much higher NPSH
requirement than 2 ft., and thus, need lower condensate
temperatures to prevent cavitation. A pump with a 5 ft.
NPSH, mounted directly to the receiver, would need the
condensate temperature down to 204 °F temperature to
not have cavitation. That pump, to be able to pump con-
densate at 212 °F, would need to have the receiver raised
5 ft. above the pump which would not be practical.
The table on the next page shows NPSH required at dif-
ferent temperatures and different pump NPSH. n
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NPSH TABLE FOR WATER AT SEA LEVEL* AND ATMOSPHERICALLY VENTED SUPPLY TANK

Temp.
Static Suction Head in Feet
0 1 2 3 4 5 6 7 8 9 10
°F
NPSH
212° 0 1 2 3 4 5 6 7 8 9 10
211° 0.5 1.5 2.5 3.5 4.5 5.5 6.5 7.5 8.5 9.5 10.5
210° 1.4 2.4 3.4 4.4 5.4 6.4 7.4 8.4 9.4 10.4 11.4
208° 2.6 3.6 4.6 5.6 6.6 7.6 8.6 9.6 10.6 11.6 12.6
207° 3.6 4.6 5.6 6.6 7.6 8.6 9.6 10.6 11.6 12.6 13.6
206° 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0
205° 4.7 5.7 6.7 7.7 8.7 9.7 10.7 11.7 12.7 13.7 14.7
204° 5.1 6.1 7.1 8.1 9.1 10.1 11.1 12.1 13.1 14.1 15.1
200° 7.5 8.5 9.5 10.5 11.5 12.5 13.5 14.5 15.5 16.5 17.5
190° 12.5 13.5 14.5 15.5 16.5 17.5 18.5 19.5 20.5 21.5 22.5
155° 24.3 25.3 26.3 27.3 28.3 29.3 30.3 31.3 32.3 33.3 34.3
116° 30.5 31.5 32.5 33.5 34.5 35.5 36.5 37.5 38.5 39.5 40.5
100° 31.7 32.7 33.7 34.7 35.7 36.7 37.7 38.7 39.7 40.7 41.7
70° 33.1 34.1 35.1 36.1 37.1 38.1 39.1 40.1 41.1 42.1 43.1
*Boiling point decreases 1°F for every 500 feet of elevation above sea level. (@500' above sea level, boiling point is 211°F).

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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
 REASONS TO
INVEST IN
TRAINING
I
nvesting in human capital is critical if manufacturers want
to compete in a fluctuating marketplace. However, some
companies put workforce training on the back burner, either
because they have been doing their job for years or do not un-
derstand why training is necessary. Other reasons why workforce
training may not be a top priority is because they do not have the
budget for it or they simply don’t see the return on investment (ROI)
when it comes to employee education programs. This mentality fails to
acknowledge that professional development is much more than a mere box-
ticking exercise – it’s a valuable asset to your organization. Below are nine rea-
sons why you should give training the investment it deserves.

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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
1. Improve staff retention and motivation
Supplying relevant training demonstrates your commitment
to your team. The opportunity to up-skill shows that you
value their dedication and contribution to the organization.
2. Provide the knowledge for your team to
work safely
Effective training allows you to ensure regulations and pro-
cesses are met correctly – particularly in the case of health
& safety related training and areas of the business which
require a prescribed process to be followed.
3. Increase productivity
A highly trained workforce enables you to make the most of
their skills and knowledge. A team of specialists will have a
deeper understanding of what is required of them, and how
this plays a part in the organization’s process efficiency.
4. Stay current
Processes, requirements and legislation all evolve over time,
so it’s important your teams are working to the latest stan-
dards rather than those who may have been superceded.
5. Create a diverse skill set
Raises the bar when it comes to sharing knowledge with your
team. Training provides an opportunity to share best practices,
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to allow individuals more opportunity for career progression,
and to give the organization a more robust succession plan.
6. Turn the theory into practice
Team members who know the job and understand its back-
ground can make a much more valuable contribution to the
plant they’re working in. By turning your training experience
into practice, you can be much more confident and efficient
in everything you do.
7. Increase your competitive advantage
When your team is confident in its knowledge base, it can
address an array of site queries, no matter how complex –
and there aren’t many teams who can say that.
8. Support specific roles with specific skills
Specific job roles need specific skills which can only be
achieved through specific training sources.
9. Attract the best talent
Investing in your staff sends a clear message that you value
their contribution and are willing to invest in their future with
you. This is a hugely attractive proposition and could be the
difference in you hiring the best talent. n
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EXPAND YOUR KNOWLEDGE…
INCREASE YOUR PERFORMANCE
Are you looking to sharpen your skills in a particular area of steam systems? Do
you have certification requirements you need to meet?

F
ind effective ways to save energy within your steam system
by staying abreast of the latest techniques and requirements.
Discover where energy is being wasted and identify poten-
tial savings. There's a wide variety of training opportunities
at our five world-class training centers throughout the USA. Whether
you're an engineer, project manager, or even facilities and operations
personnel, we have training classes to suit your needs. You may need
instruction on flowmeters, heat transfer, pressure and temperature
control, saving energy and reducing your carbon footprint, or even the
basic fundamentals of steam.

There's a wide variety of training opportunities at our five world class training centers
throughout the USA. See available classes by clicking on any city on the map on the next page!
Ü
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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
 GET MORE FROM STEAM, WE’LL SHOW YOU HOW
*Class scheduling is subject to change throughout the quarter.

Click on city to see

available classes
and dates for
February - April 2018
Allentown, PA
Longmont, CO Chicago, IL

Blythewood, SC

Houston, TX

LIMITED SEATING, BOOK TODAY!

Click button to see all 2018 course listings
and to register online.

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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
STEAM SYSTEM MAINTENANCE
FOCUS ON CONDENSATE
Maintaining steam systems is all about designing, choosing the right products and
using the correct operation that will prevent the need to repair damage caused by
condensate.

C
ondensate is a fact of life in a steam system and
needs to be dealt with correctly. Improper removal
of the condensate can cause corroded metal pipes,
erode fittings and valves, and cause waterhammer that can
damage pipe fittings, valves, and hangers. Properly de-
signed condensate drainage systems significantly reduce
maintenance on the steam system and allow for a long trou-
ble-free productive life.
Condensate forms when steam gives up its latent heat. It
cannot be eliminated. Whether in distribution mains or heat-
ing coils, condensate is produced wherever steam transfers
heat. The more heat the steam system demands, the more
condensate is produced.

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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
 Whether in distribution mains or heating coils, condensate is produced wherever
steam transfers heat. The more heat the steam system demands, the more conden-
sate is produced.
The damaging effects of condensate, however, can be re-
duced, and even eliminated, by following two simple rules:
 Minimize condensate formation in steam
distribution lines
 Wherever condensate forms, remove it as quickly
as possible
Condensate is usually removed through a steam trap, a
self-actuated valve that opens in the presence of conden-
sate and closes in the presence of steam. It relies on the
pressure of the steam to force condensate out through its
valve head and seat.
There are several types of steam trap designs, each us-
ing different mechanisms to detect steam and condensate,
and various types of valves. Each trap design can operate
under a wide range of conditions, but reliability and service
life depend on choosing the right trap for the service and
application.
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Hazards of condensate
Although condensate is “only water,” it can corrode metal
piping and equipment. It can become especially aggres-
sive if it collects in puddles or “dead” areas where it can ab-
sorb trace amounts of carbon dioxide and air present in the
steam. When combined with only slight amounts of oxygen
or carbon dioxide, hot condensate can silently corrode pipe,
fittings, valves, coils, and other steam equipment. Not only is
drainage of the condensate very important, so is the proper
chemical treat of the boiler feed water.
Condensate forms on the cooler walls of pipe and equipment
where it can drain away from the steam flow. But in distribu-
tion lines, high-velocity steam can entrain small droplets of
condensate. Conveyed at high speed, these tiny droplets
can behave like solid particles and “sand blast” pipe fittings,
valves, and anything else that gets in the way. As with corro-
sion, this damage can occur silently, without warning, until the
pipe leaks or a valve fails.
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Waterhammer, as its name implies, is not silent. It occurs
when condensate puddles collect in a distribution pipe. As
the puddle grows and deepens, it takes up more space in
the line. When the puddle encroaches on the space needed
by the steam, high-velocity steam picks up a slug of water
and carries it along. When the steam changes direction at
a pipe elbow, a tee, or a valve, the water slug keeps going
straight, crashing into the pipe or valve wall. This collision
sounds, and has the same effect, as if the pipe were hit
with a hammer. The impact can loosen pipe supports and
joints and can even crack the pipe or fittings.
Protect steam mains
Poorly insulated steam pipes waste costly heat energy and
contribute to the formation of potentially damaging con-
densate. A 100 ft. length of uninsulated 4in. pipe indoors at
70°F, carrying 150 psig steam produces about 266 lb/hr of
condensate. 3” insulation that is 95% efficient reduces the
condensate production to only 13 lb/hr.
The exact amount of heat loss and condensate production
depends on ambient conditions and the type and the amount
of insulation used. Insulation specifications are determined
when the line is installed and are usually based on balancing
the cost of insulation with the cost of energy.
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No matter what type of insulation is used, it must be protect-
ed. Insulation that has been crushed or soaked with water
(or condensate) will not insulate. Outdoor insulation must be
waterproofed, and both indoor and outdoor insulation must
be inspected periodically to assure that it remains dry and
intact.
Because of their large surface areas, flanges and valves
also must be insulated. If they are left uninsulated, the con-
densate formed can contribute to valve seat damage.
No amount of insulation prevents condensate – it only re-
duces the amount of condensate. To keep condensate from
collecting and causing corrosion, erosion, or waterhammer,
it must be drained soon after it forms, using the following
guidelines:
 Slope the steam line downward in the direction of
steam flow, at least ½ in. per 10 ft. of run, so that con-
densate flows toward collection legs.
 Install collection legs at least every 100 to 150 ft. If the
steam line sags or if there is a low spot for any other
reason, install an additional collection leg at the point.
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 Steam traps are inexpensive; do not try to save a dollar by ganging several collection
legs into a single trap. If a steam trap fails, replace it immediately.
 Make sure collection legs are 8 to 28" long, depending
on startup procedures used, and the same diameter
as the steam main. (For mains larger than 4", collec-
tion legs can be one to two pipe sizes smaller than the
main, but at least 4" diameter.)
 Install a steam trap at the bottom of each leg and test
the tap frequently to make sure it is operating correct-
ly. The thermodynamic disc trap is often recommended
for steam main drainage for pressures above 30 psi.
For lower pressures, float and thermostatic steam
traps are recommended.
Steam traps are inexpensive; do not try to save a dollar by
ganging several collection legs into a single trap. If a steam
trap fails, replace it immediately. If you merely isolate the
trap, condensate flowing to that collection leg will back up
into the steam pipe and transfer the condensate to the next
trap downstream or if there is a change in elevation cause
waterhammer.
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Prevent erosion
Wire drawing often occurs in steam control valves and pres-
sure regulating valves (PRV). A type of seat and trim ero-
sion, it is caused by the impingement of high-velocity, en-
trained condensate as it flows through the valve. A similar
type of erosion also can occur at the entrance to heating
coils and other sites where the steam flow is restricted. This
type of erosion can be prevented by keeping the steam well
drained of condensate.
If erosion occurs, in spite of a well-drained steam main, or if
a control valve or PRV is in critical service requiring excel-
lent control and positive shutoff, one technique can be used
to eliminate condensate from the steam, which is a steam
separator.
A separator consists of a large-diameter chamber with in-
ternal baffles that catch entrained condensate droplets by
impingement. The collected condensate drains to the bottom
of the collector where it is removed through a steam trap.
A steam separator has no moving parts, so it requires no
maintenance. The steam trap should be a mechanical type
which has no backup of condensate.
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If superheated steam is available, it also can eliminate ero-
sion because it does not produce condensate until it cools
to the saturation temperature. Although superheated steam
can protect equipment against condensate damage, it is
no cure-all. Unless it is desuperheated before use, super-
heated steam reduces heating coil capacity. Steam is de-
superheated by spraying water into the steam. The excess
entrained water must then be separated from the steam
through the use of a steam separator, as mentioned previ-
ously.
Using superheated steam does not eliminate the need to
drain condensate from steam mains. Even with superheat-
ed steam, condensate can form in dead spots (for example,
blank tees), and condensate will always be produced dur-
ing startup when hot steam contacts cold pipes.
Don’t forget vents
Air gets into steam lines when they are shut down for repair
or when vacuum breakers open when a control modulates
on a gravity open loop system. Air can also be in the steam
itself if deaerators feeding the boiler are not working cor-
rectly. This air causes two major problems: it reduces the
heating capacity of the steam, and it makes condensate
more corrosive.
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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
Many steam traps can remove air. However, most of them
should not be relied upon to remove air at high rates, such as
when steam is first introduced to a system that is full of air.
When a large amount of air is present, it should be removed
quickly through vents installed at high points on the steam
mains and steam heating equipment.
Air can be removed with a manual valve that is open to blow
off steam and air and then closed as the system nears op-
erating pressure, but that is not very practical as it requires
manual intervention. The automatic balanced pressure ther-
mostatic air vent is the widely used device to remove air
from steam systems. A thermostatic air vent automatically
opens when the air is present and closes when it is not.
Rugged and inexpensive, thermostatic air vents minimize
steam loss, is tightly closed when at saturated steam tem-
perature and provides automatic venting if air builds up dur-
ing routine operation.
Remove condensate
Steam traps do not remove condensate – they just open a valve.
Steam pressure then forces condensate through the open valve.
If the steam pressure ahead of the steam trap is not higher than
the pressure in the condensate return line, condensate cannot
drain; it will back up into the system.
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 The only solution to these pressure problems is to drain the steam trap into a vent
receiver and pump the condensate back to the power house. Centrifugal pumps are
often used, but they usually require high maintenance because of frequent cavitation.
Heating coils that use modulating steam control valves are
notorious for backing up with condensate when the con-
densate return has back pressure. With low steam pres-
sure, condensate does not drain through the trap; it backs
up into the coil. As the coil fills with water, it reduces heat
output. The steam control valve then opens and responses
to the low output temperature forcing the condensate out.
This results in placing too much temperature on the process
side forcing the control valve to slam closed. The filling then
cycle repeats as the pressure is again too low to allow for
drainage.
Condensate recovery also can contribute to condensate
backup. Plants in the past drained condensate onto the
ground or directly to a sewer, wasting energy and water re-
sources. But today, condensate is recycled for low-temper-
ature heating and used as boiler feed water. Condensate
cannot drain through a trap unless the steam pressure is
high enough to push the condensate into the recovery sys-
tem.
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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
The only solution to these pressure problems is to drain the
steam trap into a vented receiver and pump the condensate
back to the powerhouse. Centrifugal pumps are often used,
but they usually require high maintenance because of fre-
quent cavitation. Cavitation, caused by the evaporation of
condensate and the subsequent collapse of these bubbles
in the impeller, erodes and pits the impeller and casting and
creates a vibration that damages bearings and mechanical
seals.
Cavitation occurs because condensate is very near its boil-
ing point and the pump suction is a slight negative. It can be
controlled by maintaining a high head of condensate above
the pump suction to prevent negative pressure or by cooling
the condensate before it reaches the pump. However, cool-
ing condensate wastes its heat content, eliminating its major
value.
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A pump powered by steam or compressed air pressure can
be used for pumping hot condensate. This type of pump
consists of a condensate receiving vessel, a float connected
to a motive pressure valve, a vent valve, and check valves
on the condensate inlet and outlet lines to direct flow. When
the vessel fills with condensate, the float opens a valve that
introduces high-pressure steam (or other gas) to force con-
densate out through the discharge line. When the vessel is
drained, the float drops, closing the motive valve and open-
ing the vent valve. The pump will not have cavitation and
requires little static head on its condensate inlet.
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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
Keep it running
Steam traps, condensate pumps, and other steam system
components are simple and rugged. Applied properly, they
should last up to 7 years or more. If they fail frequently, it is
usually because they are applied incorrectly or because of
deficiencies in the design or construction of the steam sys-
tem.
Get help
If you are having a problem or think you have a problem
with your steam system – if it costs too much to maintain,
you don’t have the resources or if you can’t solve a problem
– contact Spirax Sarco and ask for help. Someone will be
there with a solution. n
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CLICK AND LEARN
ABOUT CONDENSATE RECOVERY
Introduction to
Condensate Recovery

Layout of Condensate
Return Lines

Sizing Condensate
Return Lines

Pumping Condensate
from Vented Receivers

Lifting Condensate and

Contaminated Condensate

Flash Steam

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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
 NOW AVAILABLE:
THERMOCOMPRESSOR
HIGH-EFFICIENCY ENERGY SAVINGS SOLUTIONS

A
re you wasting potential energy by
venting flash steam? If so, Spirax
Sarco’s Steam Jet Thermocompressor
is an energy saving device that com-
presses low-pressure steam, often waste steam,
to a higher acceptable pressure that can be re-
cycled back into the process.

The Steam Jet Thermocompressor

Offers:
 A simple, compact and lightweight construction
which is easy to install into a pipeline and en-
ables overhead installations

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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
 N
o moving or rotating parts and can be installed in Oil free discharge ensuring there is no lubrication contamination
 
remote or inaccessible locations  Suitable for hazardous areas
Minimal maintenance is required
   Virtually silent operation
spiraxsarco.com/global/us

How it Works
How it Works
Our Steam Jet Thermocompressor uses high pressure steam to entrain low pressure steam and discharges at a pres-
Our Steam Jet Thermocompressor uses high-pressure steam to entrain low-pressure steam and discharges at a pressure
sure that lies somewhere between the two pressures.
that lies somewhere between the two pressures.
High pressure
High-pressure motive motive
steamsteam enters
enters and passes
and passes through
through the nozzle
the nozzle andand enters
enters the the suction
suction chamber
chamber where
where it isit brought
is brought
in
in with
contact contact
the with the low pressure
low-pressure steam. steam. This mixture
This steam steam mixture then enters
then enters the diffuser
the diffuser wherewhere its kinetic
its kinetic energyenergy is convert-
is converted to
ed to
pressure pressure
energy. Theenergy.
steam The steam discharged
discharged is then putisback
theninto
put the
backprocess.
into the n
process.

Low pressure water vapour inlet

Please note that for clarity welds are not shown.

Diffuser

High pressure
Intermediate pressure outlet
steam inlet

Nozzle Diffuser

Construction
Each unit is available in many materials and is designed specifically to suit your process requirements to ensure maximum
First for Ste am Solutio n s email print contents full screen on/off 25 34
operating efficiency.
of
E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
Typical Applications Industries
D
 rum dryers  Chemical CLICK IMAGE
 Flash evaporators  Petro-chemical TO SEE TECHNICAL
C
 ondensate receivers  Oil and Power ​ INFORMATION SHEET
Generation
 Exhaust steam lines
 Food, Dairy, Brewing
B
 lanching machines
 Most Process industries
V
 ulcanizers
 Rubber
P
 aper and Board

FIND OUT MORE:

If you would like to learn more
about Thermocompressor’s,
contact your local Spirax Sarco
sales representative today!

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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
 The foundation for a winning team is trust.
As your trusted steam partner, we will
succeed together.
Spirax Sarco not only guides you through the world’s most extensive range of steam
and condensate loop products, we also apply our expertise into comprehensive and
measurable cost-savings programs tailored for your steam process.

Gain total control, starting with a steam trap optimization survey.

Call for your complimentary on-site visit: 800.883.4411

www.spiraxsarco.com/global/us

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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
 SAVE THE
DAT E!
JOIN US AT THE INTERNATIONAL AIR CONDITIONING,
HEATING, REFRIGERATION EXPO (AHR)
Who should attend:
HVACR, Mechanical & Plumbing Contracting, Consult- fer solutions, flowmeters, steam traps, control valves,
ing, Project & Design Engineering, Architecture & Design/ pumps and Services. Visit the Spirax Sarco booth #4712
Build, Facility & Operations Management/Building Owner, to speak to a steam expert who will be there ready to an-
Importing/ Exporting, Manufacturer's Agent/Rep, Manu- swer any questions you may have regarding your steam
facturer of HVACR and allied equipment and components, system. ■
Technician, Purchasing Agent, Public Utilities/Government
Agency, Editor, Publisher, and Educator & Student. Visit Spirax Sarco booth #4712 at AHR
Spirax Sarco will be exhibiting at AHR in Chicago at Mc- in Chicago, IL at the McCormick Place
Cormick Place on January 22- 24, 2018, to give expert on January 22-24, 2018.
advice on how to improve your steam system efficiency.
Among the range of solutions on display will be heat trans-
Learn more at spiraxsarco.com/global/us

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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
NOW AVAILABLE:
WE’VE UPDATED OUR
HOOK-UP BOOK!
T
0
psi

Spirax Sarco
he guide has been revised and refreshed with a new
look to better serve our audience. It is divided into
SPIRAX SARCO ▪ THE HOOK-UP BOOK

0
psi

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three sections. The first section is a compilation of

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Next is a collection of detailed illustrations showing typical

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THE
HOOK-UP guide detailing pipe sizes and connections, as well as oper-
BOOK ating temperature and pressure limitations.
DESIGN OF FLUID SYSTEMS

Purchase now for $29.95

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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
YOUR ESSENTIAL GUIDE TO
STEAM ENGINEERING
T
his is the most comprehensive practical guide to the design and operation of
steam systems ever created. At nearly 1,500 pages, The Steam and Condensate
Loop book covers all aspects of steam and condensate systems, helping engineers
to optimize plant operations and save energy.

FEATURES:
• 16 Chapters
• Comprehensive short modules
• Comprehensive index
• Equations summary section
• Full color and illustrated throughout
• Practical application techniques

FIND OUT MORE!

Priced at just $129.00, this essential best
practice guide is available for ordering
from Spirax Sarco.
Click to Purchase!

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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
TELL US YOUR TIP
In each issue of SteamNews, we try
to give some practical and useful tips
to help you maintain and improve your
own steam system. But we’d like to hear
yours. If you have any steam system
energy saving tips, please let us know
and we’ll pass them on. n

Email your tip to us at

spiraxinfo@spirax.com.

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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
 LET'S CONNECT!
Follow Spirax Sarco on Subscribe to Spirax Sarco’s Post on our Facebook page
Twitter for links to great ar- YouTube Channel to view and stay connected to industry
ticles, communicate with our our latest products, services news, technical tips, and much
staff and share your opinion and see various demonstra- more. POST A COMMENT
with us. FOLLOW US tions. SUBSCRIBE NOW

Join the Spirax Sarco net- Add Spirax Sarco USA to

work on LinkedIn to be part your circle on Google+ and
of the discussions that are share your insight on engi-
shaping the steam industry. neering topics. ADD NOW
JOIN US

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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
DID YOU KNOW
SPIRAX SARCO HAS ITS
OWN COMPANY STORE?
You can purchase an array of items, conveniently online, that proudly display the Spirax Sarco
brand and logo. Great clothes and useful accessories are available for purchase with your credit
card via the website and will be shipped promptly to the address you specify. Happy Shopping! n

SHOP THE STORE NOW

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E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
 TECHNICAL
PROBLEM SOLVER
Real Technical Support Issues
and Their Solutions
PROBLEM
Sometimes we hear complaints about hammering in pumped
condensate return pipes with pressure driven and electric
pumps. The first question we need to ask, “Is the hammer
occurring during the pump discharge cycle or right after the
pump stops?”
SOLUTION
Hammer occurring during the pump cycle is generally due to
velocities that exceed 7 feet per second. There are quick,
simple tests for pressure powered and electric pumps to de-
termine if velocity is the cause of the hammer. In the case of
a pressure driven pumps, it is recommended to reduce the
motive pressure, if possible, taking care not to reduce it so
much that the pump can no longer meet the required pump-
ing capacity. If the hammering stops, we know we had excess
First for Ste am Solutio n s email
E X P E R T I S E S O L U T I O N S S U S T A I N A B I L I T Y
velocity. In the case of the electric pumps, it is recommended
to throttle the discharge isolation valve to reduce the flow with
the added backpressure, again being careful not to run the
pump off its performance curve. If the hammer subsides, we
can be sure that velocity was the issue. If these adjustments
cannot be made on a permanent basis, then the line size will
need to be increase to reduce the pumped velocities. n
Have a problem? Simply send your question to the
Technical Problem Solver:
Spirax Sarco, Attn: Dawn Dukes, 1150 Northpoint Blvd.
Blythewood, SC 29016 or
email us at spiraxinfo@spirax.com.
Kindly indicate if you do not wish to have your name and/or
your company’s name published. We reserve the right to edit
the question or choose not to publish them. If your question is
published, you will receive a a Spirax Sarco branded Viking Tumbler.
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