Steam specialist TLV Euro Engineering has launched the FJ32, a range of free-float steam traps designed for process applications including jacketed pans, heat exchangers and vulcanisers that, while adopting the universal QuickTrap® connection, can be regularly, safely and easily removed, repaired and reused.
Commenting for TLV Euro Engineering, General Manager Michael Povey says: “The new FJ32 steam traps really are exceptional! The FJ32 is a maintainable process steam trap with QuickTrap connections that, when used in conjunction with TLV’s recently-launched QuickStation™ QS10 steam trap station, can be safely isolated, the system blown down, existing trap removed and new trap installed and reopened for getting the process back up and running quickly. The FJ32 can then be maintained and put back into stock for future use.”
A reliable and durable stainless-steel steam trap for use on steam mains and process equipment, the two models in the FJ32 range – FJ32-X and FJ32-B – feature a two-bolt universal QuickTrap connector that facilitates inline steam trap replacement in either vertical or horizontal piping. This significantly reduces the time required for installation, removal, repair and maintenance; with removal of the old and installation of the new traps undertaken in a matter of minutes. This connection also allows traps to be positioned correctly regardless of pipeline configuration.
Utilising TLV’s Free Float technology, the trap quickly adjusts to changes in the condensate load, with the three-point seating ensuring a steam tight seal even under low load conditions. The precision ground float provides an infinite number of contact surfaces with the orifice, ensuring negligible wear.
The high temperature (max. 350ºC) FJ32-B and low temperature (max. 240ºC) FJ32-X models come with different air venting methodologies to minimise start-up time. This, coupled with the maximum operating pressure of 32barG, offers a versatile trap suitable for a variety of applications.”
For further information, call TLV Euro Engineering on +44 (0)1242 227223, email sales@tlv.co.uk or visit www.tlv.co.uk.
A pressure reducing valve from steam specialist TLV Euro Engineering has been installed at King’s College Hospital in London and operating on a daily basis for nearly 14 years without an overhaul or spares fitted.
The COSPECT pressure reducing valve was originally specified by TLV Euro Engineering and installed by a contractor in 2008 for the King’s College Hospital NHS Foundation Trust’s Ruskin Wing, the tallest building in the Denmark Hill campus and one housing many of the hospital’s neurological departments. Originally installed outside between two buildings at the site, the COSPECT valve has since been enclosed by further building works at the hospital campus.
Installed to reduce pressure in the main steam line from 8 bar to 2 bar, indirect steam is used for the hospital’s heating batteries and domestic hot water purposes, so the COSPECT valve is operating 24 hours a day, 365 days a year.
It is estimated that the valve has achieved an average throughput of 950kg/h over its 14-year life, equivalent to 117,000 tonnes of steam. And in that time, the pressure reducing valve has never had any spares fitted, never been overhauled and has only occasionally had the operating pressures adjusted by the end user.
Commenting for TLV Euro Engineering, general manager Michael Povey says: “We were approached by Joji Abraham, the hospital’s estate officer, who was so impressed with the durability and longevity of the valve that he had no hesitation in contacting us when seeking a quote for a new plate heat exchanger system for the refurbishment of the Trust’s bone marrow ward.
“The age of the COSPECT was subsequently confirmed by our regional sales engineer during an initial site audit for the planned ward refurbishment project, with the programme since being fully commissioned and featuring two new plate heat exchangers from TLV Euro Engineering.”
When the COSPECT was first introduced in 1985, TLV had been manufacturing steam traps and related steam products for over 30 years and was well aware of the limitations and inadequacies its customers were experiencing with conventional PRV’s. Based on this feedback, TLV applied its fluid control technology to solve the many associated problems including fluctuations in primary and secondary pressures and valve hunting and vibration.
The renowned COSPECT, which many believe to be the ultimate pressure reducing valve (PRV), uniquely combines three components in a single valve – a piston-operated pressure reducing valve, a cyclonical effects separator and a free-float steam trap. This innovation not only saves space but also simplifies system layout, piping and maintenance. The COSPECT also ensures that dry saturated steam is provided at constant pressure and temperature, which helps to improve product quality.
COSPECT’s separator achieves 98% condensate separation efficiency and the strainer removes any remaining rust or scale. In addition, the condensate that is separated out is quickly removed through the built-in free float trap. All of which produces a noticeable improvement in the quality of the steam, and its heat conductivity. This can lead to increased valve life as well as increasing the service life and performance downstream equipment.
Maintenance is also simplified thanks to the COSPECT’s modular construction and use of PTFE gaskets, which makes the unit quick and easy to remove, or to maintain inline.
For further information, call TLV Euro Engineering on +44 (0)1242 227223, email sales@tlv.co.uk or visit www.tlv.co.uk.
TLV Euro Engineering has launched QuickStation™ QS10, a compact, reliable steam trap station for use with TLV QuickTrap® to allow for condensate drainage from steam mains, tracers and light processes, which is suitable for use in pharmaceutical, food and beverage applications or where ease of steam trap installation and maintenance is critical.
The QuickStation QS10’s compact, all-in-one design and reliable operation enables simple, inline trap installation in either the horizontal or vertical plane in minutes. It is constructed from stainless-steel for durability and corrosion resistance and is suitable for applications with maximum operating temperature of 185ºC and maximum operating pressure of 10 barg.
The four models in the QS10 range are offered with multiple piping arrangements and either single or double upstream/downstream isolation valves. The double isolation, along with optional BD2 blowdown valve, allows operators to blow out condensate/steam to prove safe isolation and allow for a safe replacement. An integrated strainer helps to prevent equipment damage or production issues due to entrained material, and an integral check valve prevents backflow.
TLV Euro Engineering also offers a range of precision-engineered QuickTrap models compatible with QuickStation for numerous applications, including its renowned Free Float® traps to minimise steam loss and save energy, and balanced pressure thermostatic and thermodynamic models for specific applications.
By making trap installation, replacement, and maintenance simple, costly steam trap problems can be rectified quickly, preventing energy loss, preventing system damage and improving energy efficiency.
For further information on the QuickStation QS10 and other steam solutions, call TLV Euro Engineering on +44 (0)1242 227223, email sales@tlv.co.uk or visit www.tlv.co.uk.
Following an initial site audit and steam trap survey, steam solutions specialist TLV Euro Engineering has supplied and installed a number of efficient solutions on an existing steam line at Innovia Films, with energy savings from the installation already reaching 10MW per day and £80,000 per year!
Innovia Films is a major producer of highly differentiated speciality Biaxially Oriented Polypropylene (BOPP) films for some of the world’s best-known brands across a wide variety of everyday consumer goods, including home and personal care products, food and beverage, confectionery, tobacco, luxury goods and industrial applications.
The company’s manufacturing facility houses film-making machines, with steam used throughout the 24-hour bubble and coating processes as well as for space heating during colder seasons.
For the bubble process, films are blown into a bubble to thin the material, which is then passed through one of eleven machines that convert the film into split sheets. These sheets are then passed through steam-heated rollers to reheat it, allowing it to relax before it is wound onto reels.
Steam is also used for the three machines on the coating process line, where various acrylic and latex coatings are applied to films that are subsequently reheated via steam batteries that blow warm air through fans to dry the coatings onto the film. While there are only three machines on the coating line, this process requires 3 and 10 BarG of steam pressure, consuming most of the steam raised at Innovia.
For many years, these processes have always seen a percentage of flash steam (steam formed from hot condensate when the pressure is reduced) vented to atmosphere. So Innovia invited tenders from several steam specialists that would look at engineered solutions to recover the flash steam energy rather than it simply re-entering the atmosphere.
The solution proposed by TLV Euro Engineering replaced the existing spray condenser with a pair of atmospheric heat exchangers to recover the flash steam energy and divert it back to the feedwater in the plant room. This meant more pre-heated boiler feedwater was available, which subsequently reduced the energy required for heating new, cooler feedwater. TLV Euro Engineering also installed a new electrical condensate return package and several flow meters at various locations throughout the steam and condensate lines to collect data.
Explaining the process, TLV Euro Engineering’s regional sales engineer John Lea says: “Innovia now has a higher volume of heated water going back to the plant room and boiler because the new recovery system sends treated water from the boiler plant out to the large condensers that we specified and installed.
“This warms the water with steam that’s vented off the condensate which, combined with the condensed flash steam, returns to the feedwater tank. This combination of using the steam to heat water and condensing steam to provide hot water means approximately three tonnes of steam per hour is being saved!”
Innovia had attempted flash steam recovery in the past, but the process didn’t work because the adopted open-vessel system – which sprayed water into the flash steam to condense it – couldn’t get enough water in to condense the steam effectively.
“Unlike our existing attempt at a direct injection flash steam recovery system, the TLV system adopts shell-tube condensers, which separate the water from the steam to increase the surface area and condense the flash steam more efficiently.” says Michael Edmondson of Innovia Films.
Commenting on the decisions to approve the tender from TLV Euro Engineering, Michael says: “The solution from TLV was more cost-effective than the others we received, and they were working with us to design a solution that worked for us and our processes, rather than something off-the-shelf. We were also impressed with the after-sales support TLV promised, which was something we weren’t confident of getting from the other suppliers that tendered.”
Looking at the data compiled to date, Innovia estimates a possible return on investment within two years and savings of approximately £80,000 a year. “We’re in the process of quantifying savings, but steam on site costs £26 per tonne so the predicted saving of over 3,000 tonnes of steam results in the anticipated £80,000.00.” says Michael.
For further information on the COSPECT and other steam solutions, call TLV Euro Engineering on +44 (0)1242 227223, email sales@tlv.co.uk or visit www.tlv.co.uk.
