SPIRAX SARCO S.A.

Autopista Panamericana

NESTLÉ TRINIDAD Colectora Este 24951

Joseph Chin Cheong / Jairo Alvarez Buenos Aires - Argentina

Tel.(+54) 1 4589 1300

Steam survey
E.andres.bozo@spiraxsarco.com
20th July 2014.

This report is to present analysis and evaluation of steam and condensate system from boiler house up to
consumers using data field carried.

The report is splinted in:

Boiler house

Main pipeline distribution

Sterilizers

Milk reconstitution

Additional recommendation

Participants:

Varun Habeo Nestlé TT

Joseph Chin Cheong Nestlé TT
Jairo Alvarez Nestlé Corporate
Fabian Waldisberg Nestlé TT
Victor Rodriguez Compression & Power Services
Antony Tan Compression & Power Services
Andres Bozo Spirax Sarco
Fortunato Sasaki Spirax Sarco
1 Save Energy Projects
1.1 Pressurized Feed Tank – Dearator

Oxygen is the main cause of corrosion in hotwell tanks, feedlines, feedpumps and boilers. If carbon dioxide is
also present then the pH will be low, the water will tend to be acidic, and the rate of corrosion will be
increased. Typically the corrosion is of the pitting type where, although the metal loss may not be great, deep
penetration and perforation can occur in a short period. One common practice is use a pressurized dearator.

Operating principles of a pressurized deaerator

If a liquid is at its saturation temperature, the solubility of a

gas in it is zero, although the liquid must be strongly agitated
or boiled to ensure it is completely deaerated. This is
achieved in the head section of a deaerator by breaking the
water into as many small drops as possible, and surrounding
these drops with an atmosphere of steam. This gives a high
surface area to mass ratio and allows rapid heat transfer from
the steam to the water, which quickly attains steam
saturation temperature. This releases the dissolved gases,
which are then carried with the excess steam to be vented to
atmosphere. (This mixture of gases and steam is at a lower
than saturation temperature and the vent will operate thermostatically). The deaerated water then falls to the
storage section of the vessel. A blanket of steam is maintained above the stored water to ensure that gases
are not re-absorbed.

There are 3 main observations that make difficult the correct operation

A) Orifice plate: Although the theory suggests that 22.4* kg steam / air mixture per ton of deaerator
capacity is required, in practice this is impossible to monitor or regulate successfully. It’s suggested to use
a orifice plate to control the maximum flow. Now there is no orifice plate and the suppose flow now is
definite for:
Loss = 2.8 x 6L, where L is the visible plume length in meters (DETR Energy Consume Guide
No.67 “Steam Distribution Cost”)
*Steam and Condensate Loop by Spirax Sarco and GI-203.16 by Nestlé.
It’s recommended install an orifice plate calibrated to blow dissolved gas and steam specified for the
actual flow. The average steam flow is 3000 kg/h, with actual 10% blow down, tan 3.3 ton/h water
consumes, it must leak:

3.3 x 22.4 Kg/h =~ 74 kg/h

Orifice specification:

The orifice indicated is Ø23.3mm.

It must install a vacuum brake on tank and other on head.
 B) Over flow siphon: the main function is overflowing the excess water with presetting pressure. The siphon
has defined dimension, and guarantee the 0.3 Kgf/cm2 as a maximum internal pressure. It’s because it has
a barometric leg, with column water controlling it.
But for some reason it’s has a bypass with input and output side, without pass thru siphon. May be there
are same part of siphon open with direct communication.

1.1

We estimate 30 liter of high temperature water (100°C), it means around (30 liter/h x 8104h/year) 160m3/year.

Its recommended change the actual siphon for a new one, with the dimensions recommended on standard.
C) Control valve: the control valve is old fashioned pneumatic /pneumatic controller, positioner and valve
and other pre valve self-action. Both of than has problem with wear and calibration. Some steam are
loose because of this, but it’s immeasurable.

There are two conditions:

Start up:
Initial temperature: 25°C
Final temperature: 103°C
Time: 4 hours
Volume: 4600 liters

Steam consume: 200 kg/h

Normal operation:
Mechanical pump: 23 liters / min = ~ 1380 liters/h
Estimate makeup water = (actual flow – recovery condensate) + blowdown
Estimate makeup water = (3000 – 1380) + 300 (10% blowdown) = 1920 liters/h

Balance temperature: (1380 x 85) + (1920 x 25) = 3300 x T

T = 50°C

Initial temperature: 50°C

Final temperature: 103°C
Time: 1 hour
Water load: 3300 kg/h

Steam consume: 388 kg/h

Steam leak: 74 kg/h
Total control valve flow: 462 Kg/h*

*this steam flow is necessary according condensate recovery. It’s imperative check the sparge pipe to
make sure it is under original dimensions, for this application the steam injector are recommended.

Control valve specification:

Pressure 1 = 150 psi
Pressure 2 = 65 psi
Pressure 3 = 3 psi
Low flow = 200 kg/h
High flow = 462 kg/h
Valve 1:
Self-action piloted valve CV calculated = 4.0 – CV selected = 10.5
25 P series – blue spring – Ø1”

Valve 2:
Control valve, electro pneumatic, 4/20mA, equal percentage CV calculated = 8.0 – CV selected = 16
Spira-trol I/P positioner – Ø1 1/2” TRIM 1

(Must complete control loop: Pressure transmitter 4/20mA installed on head dearator – 0 to2.0 bar and PID
controller)

Savings

Steam lost = 218 kg/h – 74 kg/h = 144 Kg/h

Steam lost = 144 x 8104 h

Steam lost = 1,167 ton steam / year

$ lost = 1,167 x U$ 8

$ lost = U$ 9,336 / year

Energy lost = 144 x 660 Kcal/Kg = 95040 Kcal/h

Energy lost = 95040 x 8104 h = 770,204,160 kcal/year

Energy lost = 3224.7 GJ / year

Carbon footprint = (3224.7 x 56.1)/1000

Carbon footprint = 180.9 ton CO2 / year

1.2 TDS CONTROL
There is a need for the boiler to operate under the following criteria:

Freedom from scale - If hardness is present in the feedwater and not controlled chemically, then scaling
of the heat transfer surfaces will occur, reducing heat transfer and efficiency - making frequent cleaning of
the boiler necessary. In extreme cases, local hot spots can occur, leading to mechanical damage or even
tube failure.
Freedom from corrosion and chemical attack - If the water contains dissolved gases, particularly oxygen,
corrosion of the boiler surfaces, piping and other equipment is likely to occur.

If the pH value of the water is too low, the acidic solution will attack metal surfaces. If the pH value is too
high, and the water is alkaline, other problems such as foaming may occur.

Caustic embrittlement or caustic cracking must also be prevented in order to avoid metal failure. Cracking
and embrittlement are caused by too high a concentration of sodium hydroxide. Older riveted boilers are
more susceptible to this kind of attack; however, care is still necessary on modern welded boilers at the
tube ends.

Control of TDS - A balance has to be found between:

- A high TDS level with its attendant economy of operation.
- A low TDS level which minimizes foaming.

Controlling TDS in the Boiler Water

As a boiler generates steam, any impurities which are in the boiler feedwater and which do not boil off
with the steam will concentrate in the boiler water.

As the dissolved solids become more and more concentrated, the steam bubbles tend to become more
stable, failing to burst as they reach the water surface of the boiler. There comes a point (depending on
boiler pressure, size, and steam load) where a substantial part of the steam space in the boiler becomes
filled with bubbles and foam is carried over into the steam main.

This is obviously undesirable not only because the steam is excessively wet as
it leaves the boiler, but it contains boiler water with a high level of dissolved
and perhaps suspended solids. These solids will contaminate control valves,
heat exchangers and steam traps.

Whilst foaming can be caused by high levels of suspended solids, high

alkalinity or contamination by oils and fats, the most common cause of
carryover (provided these other factors are properly controlled) is a high Total
Dissolved Solids (TDS) level. Careful control of boiler water TDS level together
with attention to these other factors should ensure that the risks of foaming
and carryover are minimized.

Deciding on the required boiler water TDS

The actual dissolved solids concentration at which foaming may start will vary from boiler to boiler.
Conventional shell boilers are normally operated with the TDS in the range of 2 000 ppm for very small
boilers, and up to 3 500 ppm for larger boilers, provided the:
Boiler is operating near to its design pressure.
 Steam load conditions are not too severe.
Other boiler water conditions are correctly controlled.
Blowing down the boiler to maintain these TDS levels should help to ensure that reasonably clean and dry
steam is delivered to the plant.

The table below provides some broad guidelines on the maximum permissible levels of boiler water TDS in
certain types of boiler. Above these levels, problems may occur.

Note: the figures are offered as a broad guide only. The boilermaker should
be consulted for specify recommendations.

Actual condition:

There is manual TDS control, provisory up to maintenance control valve. But any
way the control is about 900 µs/cm. It means (900 x 0.7) 630 PPM. These over
flow blowdown represent lost water and energy.

= 150 Kg/h

Safe = 150 – 45 = 105 Kg/h

Proposal

Do maintenance on control system automatic TDS

Savings

Saturated water waste = 105 Kg/h

Saturated water waste = 105x 8104 h

Saturated water waste = 850 m3 / year

Energy lost = 850000 x 185.6 Kcal/kg

Energy lost = 157,760,000 Kcal/year

Energy lost = 631 GJ / year

Carbon footprint = (631 x 56.1) / 1000

Carbon footprint = 35 ton CO2 / year

1.3 Steritube B6 Condensate over flow

Steritube B7 has direct steam mixing with water and this hot water does undirected
heat with the product. This energy came from steam condensation and it’s
overflowed to drain.

Returning this condensate to boiler house it represents energy (80°C) and water
safes. The average flow is 6 liter/min, and the savings are:

360 l/h x 8104 h = 2,917 m3 / year

Savings

Water waste = 2,917 m3/year

Energy lost = 2,917,440 Kg x 80 Kcal

Energy lost = 233,395,200 kcal / year

Energy lost = 977 GJ/year

Carbon footprint = (977 x 56.1) / 1000

Carbon footprint = 54 ton CO2 / year

Proposal

Installing automatic systems to warranty no

contamination. The control is driven by
turbidity because contamination can be
hydrocarbon based (such as milk, grease, etc.)

The turbidity system checks the

contamination, in PPM, and can have varied
set points.

The contaminate condensate are automatic

discharged.

This condensate has to be pumped to boiler

house, because its temperature it should be mechanical pump. (lo energy consumer, 3 kg steam / ton pumped).

Note: the same project can be apply on B7 Steritube

1.4 Steritube B8 – Flex 10

The steam heat water to B8, and there are modulating valve controlling
temperature. After the system is stable, the steam flow rate reduces in corporation
with startup. In these moment the residual pressure inside steam loop is low, and
the condensate don’t have enough energy to go true the line because the
backpressure. This phenomenon is called “stall point”.

The adopted solution was bypass to the drain. Recovering this condensate saves
energy and water.

Savings

Water waste = m3/year

Energy lost = Kg x 80 Kcal

Energy lost = kcal / year

Energy lost = GJ/year

Carbon footprint = ( x 56.1) / 1000

Carbon footprint = ton CO2 / year

Proposal

Substitution the steam trap for steam pump trap, which work as a
trap meanwhile there is pressure inside enough to trap the
condensate.

When the pressure below, starts works as a pump, using steam as power source (3 kg steam / m3)
1.5 Flash steam from condensate recovery pump

The estimate actual condensate recovery is 1380 Kg/h and the average steam pressure is 4.0
kgf/cm2(g). With this ΔP the saturate steam flashes.

Sensible Heat 4.0 = 152.1 Kcal / Kg

Sensible Heat 0.0 = 99.1 Kcal / Kg
Latent Heat 0.0 = 534.4 Kcal / Kg
Condensate Flow = 1380 Kg / h

Flash steam = 136.86 Kg/h

Flash steam = 1,109 ton / year

Water lost = 1,109 ton / year
Energy lost = 1109 x 660
Energy lost = 732,014,870 kcal / year
Energy lost = 3065 GJ / year
$ lost = $9,981
Footprint = (3065 x 56.1) / 1000
Footprint = 171 ton CO2 / year

Proposal

Install a condenser on vent using make

up water, this energy preheat it and
safe energy.
1.6 Steam trap Survey
2 General Recommendations

Actual installation Recommended

B8 homogenizer uses steam with a reduced

pressure valve. There is a thermodynamic steam
trap upstream. It should be a filter and it must
replace.

B8 Steritube uses a float steam trap. The picture

attached shows that the orientation of the trap is
incorrect, so condensate would not be
discharged properly. The float needs to be
rotated 45° clockwise for proper operation. There
are two installation arrows on the trap, one
indicates the direction of steam flow, and the
other indicates trap orientation, it should be
pointing downwards.
The condensate return line of this steam trap
above has a restriction due to the reduction in
pipe diameter.
This “bottle neck” has to be removed.

The control valve FCV -1-2C is working without

positioner feedback, than it’s constant flow.

The pneumatic / pneumatic positioner must be

changed or repaired.

The plate brazed heat exchange is for pasteurizer

fresh milk, it’s leaking.

Using this type for steam must have constant

conditions, otherwise the brazed suffer with
steam condensation, because of volume
variation.
Reconstitution milk pasteurizer uses a float
steam trap. The picture attached shows that the
orientation of the trap is incorrect, so condensate
would not be discharged properly. The float
needs to be rotated 90° counterclockwise for
proper operation.

Butter oil heating unit in Reconstitution Milk area

uses float steam trap. The orientation of trap is
also incorrect. It needs to be rotated 90°
clockwise for proper operation.

There are four Air Handling Units (AHU) which

have the steam supply valves closed, and do not
use the steam.

The steam traps for two units were not visible

during the audit, but may be present. If there are
none, they should be installed on the equipment.
A strainer is a reservoir of condensate, which can
produce a water hammering.
According to installations standards we install
horizontally as shown below:

There are two centrifugal separators (cooker and

sterilization area) used in the production of
culinary steam for direct injection into the
product.

According to process standards, these separators

are not recommended for varying flow rates.
The variation is present because of modulating
control valve and different process.

The recommended for these conditions are filters

with cartridges.
This exhaust pipe used can be dangerous. When the steam is
released, the expansion can cause dynamic back pressure,
reducing the nominal flow and capacity discharge.

The expansion of the released steam must be considered in

these cases.

The elbow drain must also remain open (without valve or plug)
to prevent any water accumulation at the base of the elbow
and water hammering.
The lower steam line should be used only to trap the
condensate. The current installation would lead to more
maintenance of the equipment because of erosion caused by
the settling of water.

It is recommended that steam be taken from the upper line.

3 Appendixes
4 Product technical Information

“Without continual growth and progress, such words as improvement and success have no meaning”

Benjamin Franklin

Andres Bozo Fortunato Sasaki

Applications Engineer National Service Manager - Mexico

Andres.bozo@spiraxsarco.com Fortunato.sasaki@mx.spiraxsarco.com