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  • Water Hammer Problem: Here Are The Top Solutions from the TRAP Magazine Challenge

    Condensed from Armstrong TRAP Magazine PROBLEM: With the steam line pressure running from 125 lbs. to 150 lbs. there will always be sufficient differential for the traps to discharge to the return line. But this is not an ordinary condensate return line -- with the condensate temperature fairly close to the steam pressure in the return line. The return line is handling the discharge from condensate pumps which are assumed to be taking condensate from low pressure traps and boosting the pressure so that it will flow back to the boiler room. The return line, is therefore, probably running full of condensate at the temperature of anywhere from 180˚F to 210˚F. Very likely it will be a lot lower than the temperature of the flash and condensate from the drip trap. Under these conditions water hammer could be quite a problem. What do you think? If you agree that water hammer is likely, what do you suggest as an alterative hookup to the one shown in the accompanying sketch? Please give full reasons for your conclusions. The engineer that offers the best practical solution will receive an award post haste to compensate for their effort. ANSWERS: Ninety-three percent of those replying said there would be water hammer. In fact, several engineers proved with calculations that flash steam would form in sufficient quantities when the high temperature trap discharge met the lower pressure to make water hammer almost inevitable. The TRAP Magazine judges agreed that under the conditions stated in the problem, water hammer would very probably occur, even though some readers reported that under somewhat similar conditions they had no problem. Suggested solutions fell into the following categories: 1. Discharge the trap to atmosphere. This was eliminated as being unnecessarily wasteful. 2. Discharge the trap to a receiver. 3. Discharge the trap to a heat exchanger. 4. Discharge the trap to a flash tank. Solutions 2, 3, and 4, while perfectly valid means of avoiding water hammer, generally would be more expensive and complicated than the situation calls for. Again, it’s recognized that there are circumstances where any one of these solutions could be considered ideal, but the solution named as best must apply generally. 5. External radiation. These included long drip legs ahead of the trap, long return lines from the trap, fin type radiation, tempering coils, etc. Such systems did not get the nod because of the needless expense, as well as the waste of heat. 6. Ejectors. Solutions employing ejector ran a very close second to the winner. Reader T. Mackie, Head Plumber, Royal Alexandra Hotel, Winnipeg, Manitoba, exemplifies this school: “It is my belief there will be water hammer and to overcome this difficulty it would be my suggestion to install an ‘ejector’ such as Penberthy XL96” of the proper size and installed as illustrated in the accompanying sketch (Figure 2). “The high pressure discharge from the trap while passing through the ejector will pick up water from low pressure return and so will reduce the temperature of the high pressure discharge to nearer the low pressure temperature and in this way avoid water hammer.” The advantages of such a system are obvious. It is simple and inexpensive. It works. It wastes no heat. 7. Special means of admitting the high pressure discharge into the 50 psi return header. THE WINNER: This category contained the winner. W.F. Gundlack, C.E., Twin Cities Arsenal, Federal Cartridge Corporation, New Brighton, MN, came up with a hookup remarkable in its simplicity. Figure 3 demonstrates this. In the opinion of the TRAP Magazine judges, admitting the flash steam in the direction of the flow of the condensate in the manner shown will be sufficient to prevent water hammer. Mr. Gudlack also offered the installation of tempering coils (Figure 4) in conjunction with the curved nipple as an even surer cure for water hammer, but this should not be necessary in most cases. The award therefore goes to W.F. Gundlack on the basis of providing the simplest, most practical and proven solution. NEAR MISSES: J.M. Parish, Mechanical Engineer, Dow Chemical Company, Freeport, TX was close to the winning solution when he stated “...inject the trap discharge into the condensate line though a properly designed nozzle,” but did not include enough detail. A similar solution employing the same method of admitting the flash steam but using perforated piping (Figure 5) was advanced by readers, P.F. Krol, Cranford, NJ and J.M. Perish, Freeport, TX. In this system, flash steam is admitted more gradually and over a greater area, though still at right angles to the condensate flow, which may cause some turbulence. TIPS ON IMPROVING PIPING PRACTICES With the water hammer problem out of the way, several engineers went on to improve the general piping from that which was originally shown, particularly in consideration of the fact that this is an outdoor installation and freezing is a definite consideration. The TRAP Magazine presented an unmodified customer’s drawing and was criticized about some omissions. Figure 6 therefore rights this situation by revising the original to conform with the “American Standard Code for Pressure Piping”. 1. Drip pocket. 2. Shut off valve as close as possible to steam main and at high point on outdoor installation. 3. For free blow to atmosphere also getting sediment out of dirt pockets. 4. Permit shut off for trap inspection or removal; necessary if bypass is used, otherwise convenient. 5. Strainer -- not necessary on larger Armstrong inverted bucket traps. 6. Test valve -- optional. 7. When valve (3) is opened for manual blowdown, there will be a pressure drop in the line to the trap which may cause trap prime to flash and make the trap lose its seal. Such traps should be protected by installing an Armstrong Internal Check Valve, (7) or by a swing check valve between the trap and valve. 8. Pop Drain protects trap against freezing, automatically drains trap when the steam pressure is below 8-9 psi. Check valve (7) should not be used with pop drain, although strainer (5) with blow down valve is essential. Check valve (9) may also be omitted. 9. This check valve prevents backflow into the trap. 10. Permit shutoff for trap inspection or removal; necessary if bypass is used, otherwise convenient. 11. Bypass valve 12. Shutoff valve as close as possible to return header and at high point on outdoor installation. One reader questioned the use of a bypass on an outdoor installation. Many would subscribe to omitting the bypass particularly when using Armstrong traps which seldom need attention. If a bypass is used, provision for draining it to prevent freezing is recommended.
  • Test Your Knowledge: Emergency Low Boiler Water Level

    You find the boiler water-level gauge glass to be empty and the burner firing. What is your course of action? (Assuming the gauge glass to be clear & good working order) A. Blow down the gauge glass to determine where the water level is B. Increase the feedwater supply to maintain the water level C. Start the emergency feedwater injector to restore normal water level D. Shut down the boiler to minimize damage to the boiler tubes And the answer is... Answer: D. Shut down the boiler Normally a boiler is provided with two independent sensors for emergency low water level burner cut-outs. So this would never happen. However, if it does, don't take any chances! Shut off the burners immediately! Before you start raising the level in the boiler you have to find out if any part of the furnace walls has been overheated. If you raise the level over a glowing steel-wall then the boiler might produce more steam than the safety valves can handle and a nasty explosion would be the result.
  • Where are Heat Exchangers Used in Industrial, Educational and HealthCare Steam Systems?

    Shell and tube heat exchangers or plate heat exchangers use a primary fluid such as steam to heat a process fluid. What many people don't know is that heat exchangers, like the Graham Heliflow Heat Exchanger, have many applications, even in difficult conditions. Graham created the Heliflow to be exceptionally versatile, yielding heat transfer rates that can be more than 40% better than typical shell and tube designs. The Heliflow Heat Exchanger encompasses a spiral coil, comprised of multiple parallel tubes mounted within a casing. The case/coil construction creates a spiral flow path providing true counterflow. The many advantages of the unique Graham Heliflow make it an efficient heat exchanger for a wide range of applications; some of which include:
    • Liquid-to-liquid
    • Cryogenic
    • High pressure
    • Clean steam generators
    • Blowdown
    • Natural gas heaters
    • Vent condensers
    • Mechanical seal coolers
    • Compressor inter/aftercoolers
    • Supercritical fluid
    • Feedwater preheaters
    • Lethal service
    • Steam or process fluid vaporizers
    • Boiler or process sample coolers
    • Hot water heaters
    • High temperature
    • Freeze condensers
    • Hydraulic/lube oil coolers
    Liquid-to-liquid The Graham Heliflow is ideally suited for applications that have a liquid-to-liquid service requiring a heat exchanger. When designing the exchanger, the "dirty" fluid should be on the shellside of the unit. The Heliflow makes shellside cleaning easy. Cleaning can be done in-place, without breaking shellside or tubeside pipe connections. The flow pattern is 100% countercurrent that maximizes the temperature differential and thermal efficiency. Cryogenic Graham has conducted extensive research and development in the area of cryogenic vaporizers. Our research and many years of proven experience in this area confirm that the Heliflow heat exchanger is excellent for cryogenic applications. The unique tube coil of the Heliflow can easily accommodate the large temperature differentials that are typical in cryogenic units. Heliflow Heat Exchangers often use cryogenic fluids as the cooling medium; alternately, Heliflows can be used to vaporize fluids, such as N2, O2, CO2, or other fluids. For information on this subject, refer to the Graham article titled Convective flow boiling in coiled tubes. High pressure High pressure applications are another way to utilize the Heliflow Heat Exchanger. The tubeside of the exchanger does not rely on gaskets for sealing, and can be designed to 15,000 psig. A key advantage that a Heliflow offers is that it has no flat sided pressure bearing surfaces that quickly become thick as design pressure increases. A Heliflow uses tubing and pipe to contain the tubeside's usually high operating pressure fluid. The shellside of the unit can be rated for pressures up to 5,000 psig.

    To read more on the subject, go to:   Flyer-High_Pressure_Application

    Clean steam generators The Graham Heliflow meets the need for clean, chemical-free steam. This technology has been developed over the past 60 years to take advantage of the Heliflow coiled tube geometry. The stacked tube layout eliminates problems caused by thermal expansion and cycling. In addition, this design promotes nucleate boiling, resulting in superior heat transfer efficiency. The Graham Clean Steam Generator is designed to produce clean, chemical-free steam from clean feed water, using plant steam as the energy source. Blowdown Boiler blowdown and process sample coolers are perfect applications for a Heliflow heat exchanger. The compact size of the Heliflow fits into tight spaces. Also, the Heliflow design can withstand the cyclic nature of blowdown service. Natural gas heaters When natural gas is passed through a pressure reducing station, it decreases in temperature. The compact Heliflow design is often used to increase the temperature of the natural gas. Vent condensers Heliflow Heat Exchanger technology is at the heart of Graham's vent condensers. Vent condensers are often used on storage tanks to reclaim products contained in the tank and control the harmful emissions that escape from the tank to atmosphere. During the day, the sun heats the fluid in the tank. The increase in the system's temperature will cause the vapors in the tank to expand and increase vaporization of the volatile components as their vapor pressures increase. By installing a vent condenser on the vessel, the condensable vapors are reclaimed and refluxed back into the storage tank. In addition to the venting caused by temperature changes, vapors are exhausted to atmosphere as the tank is filled. The vent condenser experiences the greatest thermal duty when the tank is being filled. The heat exchanger, therefore, should be sized based on the filling case. Graham has taken the lead in reducing VOC (volatile organic compound) emissions with our design of specialized vent condensers. These units often are used to recover valuable product and reduce the load on downstream pollution control equipment at the same time. Contact Campbell-Sevey To learn more about which heat exchanger is right for your situation, contact the team at Campbell-Sevey.
  • How Webster Boiler Burners Reduce Energy Costs for Hospitals, Schools & Industrial Applications

    Engineers and plant managers in hospitals, schools and industrial facilities are constantly looking to drive down costs by improving energy efficiency in their steam boilers. Most run boilers constantly to produce steam and require high turndown and short payback on their equipment purchases For new applications and retrofits alike, Campbell-Sevey suggests replacing conventional burners with high efficiency Webster boiler burners. They are low excess air burners that incorporate a unique high swirl firing head to achieve boiler horsepower ratings in the 200 to 2,200 HP range using less fuel and electricity than conventional burners. And the lower horsepower blower motors on JBE(X)’s models can result in significant total energy savings depending on the burner size and operating conditions. What's unique about Webster is that they combined their unique high swirl firing head technology with a more efficient in-line combustion air fan to provide superior mixing of the fuel and air, and lower motor horsepower requirements. This combination allows the JBE series burners to operate with low excess air across a large operating range. Less excess air means high fuel efficiency, and high efficiency combined with high turndown means very low heat loss in your boiler that can result from cycling when a burner is stopping and starting. The end result is that the new Webster JBE will provide fast payback and the best possible return on your burner investment. For more information on Webster boiler burner options, contact the team at Campbell-Sevey.
  • Are Your Energy Dollars Vaporizing Into Thin Air?

    During combustion of natural gas, water in the combustion air changes phase from liquid to gas. As a result, combustion products of natural gas typically contain 11% to 12% moisture, which represents up to 9% of beginning fuel content. With typical economizers, this energy escapes into the atmosphere with heated boiler gases. But a condensing economizer allows its recapture. Using feedwater-cooled finned tubing, a condensing economizer cools exhaust gases below their dew point, releasing latent heat bound up in the vapor. The amount of recaptured heat is considerable — about 1,000 Btu per pound of condensate. The CO2 reduction is also significant: one cubic foot for each cubic foot of natural gas saved. E-Tech condensing economizers yield extremely high efficiencies — upward of 96%. Their vapor-condensing environment presents an ideal heat recovery solution for industries that use non-sulfur bearing fuels, whose acidic by-products can corrode most carbon and alloy materials.

    For more information, click to download this two page overview or contact the team at Campbell-Sevey.

  • Bad Practices Reveal Inefficient Valve Insulation Cover Jackets

    The purpose of installing insulation blankets is to prevent radiant heat loss and save energy. However the wrong blanket styles or poor installation can result in exposed surface areas and unnecessary heat loss. Check out these videos of bad practices we highly suggest avoiding. For highly efficient blankets, Campbell-Sevey recommends Shannon Insultech Thermal Blankets. These blankets provide immediate energy savings, with the added benefits of quick installation, quick removal and quick reinstallation. A Unique Insulation System INSULTECH Thermal Blanket Systems are offered for the purpose of “Energy Savings” on steam valves and fittings. INSULTECH is a high quality insulation, custom fit to match Gate Valves, Pressure Reducing Valves, Flanges, Strainers, Steam Traps, Heat Exchanger Heads, Boiler Heads, PRV Stations, Condensate Pumps and similar equipment. This blanket system is CAD designed to match each and every fitting. They guarantee the fit and the blankets carry an 18 month warranty. Contact Campbell-Sevey to see how these custom fit blankets can reduce your energy costs and provide fast payback.
  • Steam Tip 25: Installing Turbulators on Firetube Boilers

    Consider Installing Turbulators on Two- and Three-Pass Firetube Boilers Firetube Boilers The packaged firetube boiler is the most common boiler design used to provide heating or process steam in industrial and heavy commercial applications. The American Boiler Manufacturers Association (ABMA) surveyed sales of high-pressure [15- to 350-pounds-per-square-inch-gauge (psig)] firetube and small watertube boilers between 1978 and 1994. ABMA found that firetube boilers comprised more than 85% of the sales of these boilers to industry. Although firetube boilers are available in ratings up to 85,000 pounds of steam per hour (lb/hr), they are generally specified when the required steam pressure is under 150 psig and the boiler capacity is less than 25,000 lb/hr. Watertube boilers are designed for larger, high-pressure, and superheated steam applications. In a firetube boiler, hot combustion gases pass through long, small-diameter tubes, where heat is transferred to water through the tube walls. Firetube boilers are categorized by their number of “passes,” or the number of times that the hot combustion gases travel across the boiler heat-exchange surfaces. For example, a two-pass boiler provides two opportunities for hot gases to transfer heat to the boiler water. Hot combustion gases enter the tubes in a turbulent flow regime, but within a few feet, laminar flow begins and a boundary layer of cooler gas forms along the tube walls. This layer serves as a barrier, retarding heat transfer. Turbulators, which consist of small baffles, angular metal strips, spiral blades, or coiled wire, are inserted into the boiler tubes to break up the laminar boundary layer. This increases the turbulence of the hot combustion gases and the convective heat transfer to the tube surface. The result is improved boiler efficiency. Turbulators are usually installed on the last boiler pass. Turbulator installers can also balance gas flow through the tubes by placing longer turbulators in the uppermost tubes. This practice increases the effectiveness of the available heat-transfer surface by eliminating thermal stratification and balancing the gas flow through the firetubes. Applications Turbulators can be a cost-effective way to reduce the stack temperature and increase the fuel-to-steam efficiency of single-pass horizontal return tubular (HRT) brick-set boilers and older two- and three-pass oil- and natural-gas-fueled firetube boilers. Turbulators are not recommended for four-pass boilers or coal-fired units. A four-pass unit provides four opportunities for heat transfer. It has more heat exchange surface area, a lower stack temperature, higher fuel-to-steam efficiency, and lower annual fuel costs than a two- or three-pass boiler operating under identical conditions. New firetube boilers perform better than older two- and three-pass designs. Turbulators can also be installed to compensate for efficiency losses when a four-pass boiler is being converted to a two-pass boiler because of door warpage and loose and leaking tubes. Turbulators are substitutes for more costly economizers or air-preheaters. They are simple, easy to install, and low cost. Their installed cost is about $10 to $15 per boiler tube. Current turbulator designs do not cause a significant increase in pressure drop or contribute to soot formation in natural-gas-fired boilers. Turbulators are held in place with a spring lock and are easily removed to allow for tube brushing. Turbulators come in various lengths and widths and should be installed by a qualified installer. To avoid combustion problems, the boiler burner should be retuned after the turbulators have been installed. The installer must also verify that the stack temperature does not fall below the flue gas dew point. Price and Performance Example A manufacturing facility installed 150 turbulators into its firetube boiler. Tests conducted both before and after turbulator installation indicated a reduction in the stack gas temperature of 130°F. More combustion heat was being transferred into the boiler water. Because each 40°F reduction in the boiler flue gas temperature results in a 1% boiler-efficiency improvement, overall boiler efficiency has improved by about 3.25%. Fuel costs have decreased by approximately 4%. A manufacturing facility installed 150 turbulators into its firetube boiler. Tests conducted both before and after turbulator installation indicated a reduction in the stack gas temperature of 130°F. More combustion heat was being transferred into the boiler water. Because each 40°F reduction in the boiler flue gas temperature results in a 1% boiler-efficiency improvement, overall boiler efficiency has improved by about 3.25%. Fuel costs have decreased by approximately 4%. Example Consider a two-pass firetube boiler that consumes 60,000 million Btu (MMBtu) of natural gas annually while producing 15,000 lb/hr of 100-psig saturated steam. What are the annual energy and cost savings, given that the installation of turbulators improves the boiler efficiency from 79% (E1) to 82% (E2)? Natural gas is priced at $8.00/MMBtu.
    • Annual Energy Savings = Annual Fuel Consumption (MMBtu) x (1 – E1/E2) or 60,000 MMBtu x (1 – 79/82) = 2,195 MMBtu 
    • Annual Cost Savings = $8.00/MMBtu x 2,195 MMBtu/yr = $17,560 
    If the boiler has 250 tubes and the installed cost for the turbulator is $15 per tube, the simple payback on the investment in the energy efficiency measure is:
    • Simple Payback = (250 tubes x $15/tube)/$17,560/year = 0.21 year 
    This tip is provided by the U.S. Department of Energy - Energy Efficiency and Renewable Energy and is adapted from material provided by Brock Turbulators and Fuel Efficiency, LLC, and reviewed by the AMO Steam Technical Subcommittee.For suggested actions and resources, click to download the complete US Department of Energy Tip Sheet.
  • What Type of Manufacturer Should You Use for Heating and Cooling Coils?

    In the HVAC Coil Manufacturing Industry there are primarily three types of manufacturers – OEM, Air Handler, and Custom. Which you use depends largely on your application and the reliability needed, but only one provides the perfect fit and capacity every time. OEM Coil Manufacturers build coils specifically for equipment with larger production runs. Because of the large volume, production efficiency reduces overall costs so they are an ideal fit for manufacturing companies installing coils in their equipment. Air Handler Manufacturers typically design and build coils for their own equipment. In the event that they have extra capacity they will build coils for other companies, however their first priority is to their own manufacturing needs. Custom Coil Manufacturers are an ideal fit for many HVAC situations. The coils are custom built to nearly any type and capacity to fit your precise replacement or new design needs. We know that there are several custom coil manufacturers out there. Through Campbell-Sevey, our customers have access to both plate-fin HVAC and heavy-duty coil designs. Modine is a top tier provider of custom-designed and built coils for the industrial and commercial heating, cooling, air conditioning, ventilation, and refrigeration markets. Their ability to offer heating and cooling coils for indoor comfort as well as building heat recovery for energy savings allows them to create the right coil solution for our customers' applications. They are also highly responsive in cases where quick manufacturing is needed. They can, and do, build custom coils in 48 hours when needed. Armstrong's heavy duty coil division is a great solution for industrial or power plant applications. Whether it's combustion air preheat for large boilers, high temperature product processes, or spray dryer applications where plate fin coils would experience inadequate discharge temperatures or premature failure, they have the proper materials and construction methods to build the heaviest duty coils on the market. They understand appropriate internal circuiting construction methods for steam coils to prevent freezing and water hammer that would lead to premature failure. At Campbell-Sevey, we also size inlet piping, strainers, control valves, steam traps (for steam heating), vacuum breakers, check valves, and outlet piping to operate properly together. We take responsibility for the whole package. Get the solution that best fits your needs At Campbell-Sevey, we work directly with you to determine your needs and provide solutions that best fit your requirements. To learn more contact the team at Campbell-Sevey.
  • How to Resolve Low Temperature Issues in Food Processing Sanitization

    Within the Food Processing Industry in the Midwest, there were numerous instances of companies requesting assistance in their wash down stations. These food plants include beef, pork and chicken processor companies where the processing areas must be sanitized using very hot water at 165 degrees F or higher. The stations might or might not use a nozzle delivering the water through a hose. There are strict temperature regulations for the decontamination of processing areas within these applications. Often there are no reliable check valves installed around the mixing valve, which has been proven unreliable because it allows the cold water supply to enter the hot water supply system during periods of non-use. During these non-use periods the water migrates, causing the hot side of the system to lose temperature. Migration over the weekends can really develop low temperature problems. When temperature is not correct the operators turn up the heat which puts them at risk for scalding. Solution: Campbell-Sevey recommends the DFT model SCV Check Valve to meet safety needs and criteria. This is not a new application for the BSS model as they have been used in this application dating back to the 1950’s & 60’s. DFT has proven to be the valve that holds up for long periods of time and eliminates the hot to cold-water migration problem. If you have have steam, air or hot water issues within your plant. Contact the steam at Campbell-Sevey. We are experts in full system applications and can help solve your most challenging issues.
  • The New T-Shirts Are In! Pick Yours Up!!!

    We are Livin The Dream! Campbell-Sevey's new "Livin' The Dream With Steam" t-shirts are hot off the press. So get yours now! These shirts are extremely comfortable, even during the heat of summer. Stop by the office to pick up your FREE T-SHIRT in the size that is fit for just for you – 15350 Minnetonka Blvd., Minnetonka, MN.
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Products We Carry

  • Hot Water Boilers
  • Watertube Steam Boilers
  • Firetube Steam Boilers
  • Deaerators
  • Heat Recovery Steam Generators (HRSG’s)
  • Automatic Recirculation Valves
  • Economizers
  • Gas-Fired Water Heaters
  • Gas-Fired Humidifiers
  • Boiler/Generator Flue Stacks
  • Continuous Emissions Monitors (CEMS)
  • Pressure Reducing Valves
  • Safety and Relief Valves
  • Control Valves
  • Pressure Independent Control Valves
  • Expansion Joints, Guides, Anchors
  • Flash Tanks
  • Flow Meters
  • Balancing Valves
  • Check Valves
  • Separators
  • Pumps
  • Pressure Booster Systems
  • Piston Valves
  • Heating/Cooling Coils
  • Plate and Frame Heat Exchangers
  • Shell and Tube Exchangers
  • Water Heaters
  • Steam Humidifiers
  • Vacuum Systems
  • Condensers
  • Steam Traps
  • Wireless Steam Trap Monitors
  • Tube Bundles
  • Direct Gas-Fired Space Heaters
  • Direct Gas-Fired Make-Up Air Units
  • Unit Heaters
  • Strainers
  • Air Vents
  • Liquid Drainers
  • Heat Transfer Packages
  • Digital Water Mixing Valves
  • Air Cooled Condensers/Dry Coolers
  • Steam Filters
  • Electric Condensate Pumps
  • Steam/Air-Powered Condensate Pumps
  • Packaged Condensate Pump Skids