Boiler

The best member to answer your questions is ................ miketheboilerguy he knows his stuff. ed

Vipin,

What is your process? Is temperature critical? What steam pressure will you operate at? How far away is your process from your boiler? Is there an elevation difference?

Share more data and I will send you a system layout.

And Guest thanks for the vote of confidence.

Mike

What is your process?

Processing of tomato paste-Only repacking-Falls into food Industry

Is temperature critical?
Temperature is Critical-Should maintain 95 Degree Centigrade Continuous

What steam pressure will you operate at?

Minimum 5 Bar

How far away is your process from your boiler?

10 Metre.

Is there an elevation difference?

Boiler will be placed slightly elevated place ...May be 3-5 Foot higher

Share more data and I will send you a system layout.

May I assume that 100% of your steam condensate is returned? And that you are heating some type of kettle or sealed vat?

I will have an answer for you soon. Are you looking for a simple,durable and easy to maintain system or one that is "high tech"?

Thanks

Mike

Sir,
We prefer to Use the Condensate to be collected and fed to feed water Tank so that it will be heated fast!

I prefer a simple, basic ,easy maintainable system... hassle free

Thanks

Vipin

There isn't any steam (or condensate!) in those conditions. At 95°C vapour pressure is ~ 845 mbar. At 5 barg saturated steam temperature is ~ 158°C.

Cheers.........Codey

I believe that is controlling temperature of his Tomato paste.

Dear Vipin,

We can meet and discuss. This topic is of interest to me as well.

We can guide you with same. Kindly let me know where are you located.

Rahul - Do you work for Forbes Marshall (Spirax Marshall) India? If not then whose Steam Equipments do you deal in? Send me your catalogs.

Vipin - What is the Boiler's Operating Pressure? 7 Bar/10 Bar?

750 KW = 2559106 BTU. Boiler Operating Pressure not mentioned.

Latent Heat Steam at 100 psig/ 7 Bar = 882 BTU & 150 psig/ 10 bar = 858 BTU

If 100 psig Boiler : 2559106/882 = 2901.5 lbs/hr = 1318.9 kg/hr => 1300 kg/hr Capacity

at 7 Bar

If 150 psig Boiler : 2559106/8582982.6 lbs/hr = 1355.7 kg/hr => 1350 kg/hr

at 10 Bar

Steam Main at 100 psig: 2" Ø velocity , 80'/s

Steam Main at 150 psig: 1.5" Ø velocity , >80'/s but , <120'/s.

( Ideal Velocity within 80'/s to 120'/s)

1. You have mentioned operating pressure 5 Bar but not mentioned the required steam capacity of the Tomato Paster ? If you do not have this then tell the steam inlet pipe size and size condensate outlet. (Is it 1"Ø inlet & ¾"Ø outlet ?)

What type is it : jacketed Kettle? What's the dimension?

2. Anyway your main should be 2"Ø since you are going to run it 10 Metres/above for future heating machines.

3. Take a 2"Ø outlet from the Boiler into a Header with a 2" Ø Globe Valve PN 16. install a ½" Thermodynamic Steam trap Spirax TD 42 with a Hill Sight Glass ½" . You can give this Trap a 3-Valve By-pass for isolation & maintenance purpose. Install an Airvent, Pressure & temperature gauge on top of the Header.

From the Header take a 1.5" Steam main again with a PN 16 Globe Valve to your Machine at 10 Metres. You need to install a Steam Pressure cum Temperature Control Valve prior feed to the machine. a Ball Float Steam Trap to be used for condensate drain. Both PRV + TC & Trap selection subject to your reply to Point No: 1.

4. The outlet condensate of the Header drain trap to be lifted and returned to the Feed Tank.

No sooner you inform me the Point No: 1 I will size the followings:

A . Pressure Reducing Valve & Temperature Control to Machine. Inlet 7 bar/10 bar , outlet 5 bar . Size as per machine steam consumption.

B. Condensate Pump to return condensate of Machine to Boiler Feed tank. Note since it will be a temperature controlled system therefore, the condensate cannot be lifted and needs a pump to return condensate to the overhead feed tank.

Vipin - What is the Boiler's Operating Pressure? 7 Bar/10 Bar?

10 Bar

750 KW = 2559106 BTU. Boiler Operating Pressure not mentioned.

Latent Heat Steam at 100 psig/ 7 Bar = 882 BTU & 150 psig/ 10 bar = 858 BTU

If 100 psig Boiler : 2559106/882 = 2901.5 lbs/hr = 1318.9 kg/hr => 1300 kg/hr Capacity

at 7 Bar

If 150 psig Boiler : 2559106/8582982.6 lbs/hr = 1355.7 kg/hr => 1350 kg/hr

at 10 Bar

Steam Main at 100 psig: 2" Ø velocity , 80'/s

Steam Main at 150 psig: 1.5" Ø velocity , >80'/s but , <120'/s.

( Ideal Velocity within 80'/s to 120'/s)

1. You have mentioned operating pressure 5 Bar but not mentioned the required steam capacity of the Tomato Paster ? If you do not have this then tell the steam inlet pipe size and size condensate outlet. (Is it 1"Ø inlet & ¾"Ø outlet ?)

It's an One Inch Dia Line.

What type is it : jacketed Kettle? What's the dimension?

We are using a tube in tube steriser comprising of 4 tubes of 4 metre length.

2. Anyway your main should be 2"Ø since you are going to run it 10 Metres/above for future heating machines.

Main Outlet from the boiler is 2 inch.

3. Take a 2"Ø outlet from the Boiler into a Header with a 2" Ø Globe Valve PN 16. install a ½" Thermodynamic Steam trap Spirax TD 42 with a Hill Sight Glass ½" . You can give this Trap a 3-Valve By-pass for isolation & maintenance purpose. Install an Airvent, Pressure & temperature gauge on top of the Header.

From the Header take a 1.5" Steam main again with a PN 16 Globe Valve to your Machine at 10 Metres. You need to install a Steam Pressure cum Temperature Control Valve prior feed to the machine. a Ball Float Steam Trap to be used for condensate drain. Both PRV + TC & Trap selection subject to your reply to Point No: 1.

Can You please mention the Spirax equivalent of the same?

4. The outlet condensate of the Header drain trap to be lifted and returned to the Feed Tank.

No sooner you inform me the Point No: 1 I will size the followings:

A . Pressure Reducing Valve & Temperature Control to Machine. Inlet 7 bar/10 bar , outlet 5 bar . Size as per machine steam consumption.

B. Condensate Pump to return condensate of Machine to Boiler Feed tank. Note since it will be a temperature controlled system therefore, the condensate cannot be lifted and needs a pump to return condensate to the overhead feed tank.

I don't wish to install a pump in the condensate return line to feed water tank.
Any other options?

If its a 1" dia inlet - then maximum steam capacity is 250 kg/hr to 300 kg/hr.

PRV:

inlet 10 Bar

Outlet 5 Bar

Capacity: 300 kg/hr

Can You please mention the Spirax equivalent of the same?

Valve Selected:

Spirax DP 17 , 1/2" Flanged . capacity 310 kg/hr.

However , since you need to also control temperature then, take Spirax DP17 E (with electric operated solenoid valve) + 1" Strainer PN16 Flanged. The PRV then becomes TC also(Pressure cum Temperature Sensing). Install an Electronic Temperature Indicator/Controller PT 100 ohms with a Thermocouple to on /off with temperature setting. The DP17 E then performs both your required function.

Line Size to Unit/machine:

Since your capacity is 300 kg/hr therefore, from the Header you need to take a 1" dia Steam Main to the Machine. Install the 1" Strainer prior the DP17 E with 1" x 1/2" eccentric reducer , reduce after strainer line 1" dia to 1/2" to DP 17 E inlet & increase outlet 1/2" to 1" dia line to feed the machine. The DP 17 E also has a pilot sensing line 1/4" to install 3.5' minimum to sense the downstream pressure. This will maintain downstream pressure 5 Bar ( or any setting within the spring range pre-set-ed) irrespective of upstream pressure variation. The Spring Range of DP 17 E to be Blue (2.5 bar to 7 Bar).

Steam Trap:

Multiply x 3 Safety factor = 900 kg/hr. Trap selected Spirax FT 14-10 TV, 1" screwed, capacity 900 kg/hr at 5 bar. Take a Trap with 1/2" Globe Valve , PN16 for Isolation, a strainer 1" prior the Trap and a Hill sight check 1" after the Trap. Drain condensate to Pump to return to Feed tank.

I don't wish to install a pump in the condensate return line to feed water tank.
Any other options?

You can lift the condensate after the Hill sight check for the trap has got provisions to withstand the back pressure due to the lift (every 2'-3" = 1 psi head).

However, you must understand that when the steam temperature reaches set point of the controller, the DP 17 E's (Electronic Solenoid Valve)/ PRV + TC will shut down steam and will not open till the temperature cuts in. During this time the steam pressure to the steam trap will become 0 psig and there will be no pressure to push the condensate overhead to overcome the back pressure . Here you will then face water logging of your system ( delayed heating/ stalling).

All steam traps needs a differential pressure to operate.If problem occurs with delayed heating then you have NO OPTION but to collect and pump condensate with electrical/mechanical power pump.

A Spirax DPE 3/4" Flanged will pass 650 kg/hr at 5 Bar. You can use this instead 1/2" DPE for at 5 Bar a 1" will pass 500 kg/hr at 120'/s. So if you do not have the steam capacity details, the DPE 3/4" will be a better safe-side choice.

Sorry Spirax DP 17 E , Size: 3/4" Flanged with Blue Spring. Getting old.