2. From generation to distribution to utilization and back to the boiler — Spir
Energy Services
Our services are tailored and integrated to suit your resources, plant requirements and
available budget. Spirax Sarco engineers will work with you to implement improvements
to your system and help you maintain the resulting performance gains. Our services can
be split into three categories:
Surveys and audits
• Steam trap surveys • Thermal imaging
• Steam, air, N2 and O2 leak surveys • Ultrasonic pipewall thickness testing
• Steam system audits • Seismic and structural analysis
• Steam quality testing • Compressor performance analysis
• Process audits • Product health checks
• Energy audits • Faultfinding & rectification
Installation and service
• Installation • Project and site management • Commissioning
• Maintenance contracts • Start-up • Service and repair
• On-site training
Engineering and design
• Steam system design • Pre-engineered packaged solutions • System efficiency calculations
• Assessment of savings • Product/package performance calculations
• Certification and other documentation • Return on investment calculations
Engineered Systems
Spirax Sarco’s Engineered Systems Division offers pre-engineered, compact skid
mounted packaged solutions. The Engineered Systems advantage expedites the
installation process and delivers a quality solution. Benefits include:
• Type and size of components carefully • Shortened overall project lead times
selected to ensure system compatibility • Simplified maintenance and prolonged
• Reduced engineering, piping layout and service life
procurement costs • Pre-tested for faster start up
• Conserved plant space and optimized • Reduced plant down time
operating efficiency • Single source supply for greater
• Minimized field labor and job site welding accountability
• Potential for fewer installation errors and
safety mishaps
Spirax Sarco’s packaged solutions include:
• Manifolds and trap stations • Condensate recovery solutions
• Heat exchanger solutions • Vessels and receivers
• Heat recovery solutions (e.g. boiler blowdown and flash steam)
• Steam conditioning stations • Deaerators and surge tanks
• Control valve and flow metering stations • Clean steam generators
• Specialized packages
3. rax Sarco has the answer
Boiler Controls & Systems
Requirements for greater productivity have led to increasing boiler house automation
and limited levels of supervision. Spirax Sarco has developed a range of boiler controls
that improve levels of both efficiency and safety in the boiler house.
• Surface (TDS) Blowdown Systems • High and Low Level Alarm Systems
• On/Off and Modulating Level Controls • Boiler Bottom Blowdown System
• Condensate Contamination Detection Systems
• By measuring boiler water conductivity, Spirax Sarco surface blowdown systems
provide automatic TDS control. The same operating principle is used to monitor and
control retuning condensate lines ensuring contaminated condensate is not retuned
to the boiler house.
• Using “state-of-the-art” conductivity and capacitance probes, Spirax Sarco systems
provide automatic On/Off and Modulating level controls for boilers, deaerators,
feedwater tanks, etc.
• High integrity, self-monitoring level alarm systems incorporating conductivity probes
offer low maintenance, high and low alarms that provide warnings of system faults
and allow safe shutdown of plant. These systems are suitable for steam boilers,
particularly for those operating with only limited supervision, and can be used with other vessels.
Flow Meters
EMCO Flow Systems has been in the metering business for over 45 years with field
proven flowmeters offering solutions for measurement including industrial inline vortex,
industrial insertion vortex and turbine, and variable area flow products. Now part of the
Spirax Sarco group of companies, our global network of over 1,300 dedicated industry
engineers in 34 different countries, and with over a combined 150 years of experience,
we can give you access to the expertise and resources you need to improve the
performance of your plant, comply with legislation, meet environmental goals and stay
ahead of even the most intense competition.
Spirax Sarco’s range of precision flowmeters for liquid, gas, and steam applications
provide a wide range of metering solutions to diverse industries, including the military,
hospitals, universities, and many Fortune 500 companies.
spiraxsarco.com/us
4. USA’s leading provider of Steam System Solutions
Control Systems
Maximum productivity requires delivering the steam at its most energy efficient pressure
and temperature resulting in optimum energy usage, and a safe, comfortable environment.
Spirax Sarco has a complete range of controls to efficiently provide the right heat transfer
for any process or heating application.
• Automatic Control Valves • Direct Operated Temperature Regulators
• Direct Operated Pressure Regulators • Pilot Operated Temperature Regulators
• Pilot Operated Pressure Regulators • Safety Valves
Ranging in sizes from 1/2” to 6”, operating pressures up to 600 psi, and capacities up to
100,000 lb/hr, the complete range of controls and regulators provide steam system solutions industry wide. Available in iron, steel,
stainless steel, and bronze, Spirax Sarco controls and regulators are suitable for virtually all control applications.
Steam Traps
Spirax Sarco designs and manufactures all types of steam traps in a variety of materials. Whether it be for steam mains, steam tracing,
or heating and processing equipment, Spirax Sarco has the knowledge, service and products to improve your steam system.
• Balanced Pressure Thermostatic • Bimetallic
• Float & Thermostatic • Inverted Bucket
• Thermo-Dynamic®
• Liquid Expansion
• Steam Trap Fault Detection Systems • Steam Trap Diffuser
• Steam Trap management Systems
Mechanical steam traps are available in iron, steel and stainless steel with NPT, socket weld,
or flanged connections in sizes ranging from 1/2” to 4”. Thermostatic types are available in
brass, forged steel, stainless steel, cast alloy steel with stainless steel internals with NPT and
socket weld connections and are available in sizes 1/2” to 1-1/2”. The thermo-dynamic®
types
are available in stainless, alloy and forged steel and range in sizes from 1/2” to 1” with NPT, Socket Weld and ANSI connections. Bimetal trap
available in steel and stainless steel 1/2” to 2”. Several styles are available with Universal connectors.
Condensate Pumps & Energy Recovery
Spirax Sarco offers the solutions to maintaining efficiency in all areas of condensate
recovery. For the total system solution, Spirax Sarco’s non-electric pumps drain and return
condensate and other liquids from vacuum systems, condensers, process equipment, or
any other steam condensing equipment. The Pressure Powered Pump can handle liquids
from 0.65 to 1.0 specific gravity and capacities up to 39,000 lb/hr. Available in cast iron or
fabricated steel (ASME code stamped) with stainless steel internals and stainless steel
check valves. The rugged body allows a maximum pressure of 125-300 psig. This system
solution saves energy and provides optimum system efficiency with low maintenance.
• Pressure Powered Pump • Packaged Pressure Powered Pumps
• High Capacity Pressure Powered Pump • Electric Pumps
• Combined Automatic Pump Traps
For easy installation, Pressure Powered Pump packaged units are pre-piped and combine any Pressure Powered Pump, with a
receiver, strainer, isolation valves and traps as requested. Electric pumps are packaged units, assembled, wired and tested. Electric
condensate return pumps are available in simplex units with an integral float switch or a mechanical alternator on the duplex units.
5. High Purity Products
Avoidance of the risk of contamination across many industries has resulted in a growing
need for clean steam, pure steam and water of WFI (Water For Injection) quality.
Products suitable for these high purity systems must be designed and manufactured
to a high standard to ensure compliance with the exacting rules and regulations set for
example by the biopharmaceutical and healthcare industries. Spirax Sarco’s extensive
range of high purity products extends from generation through distribution to usage.
• Sanitary control and instrumentation
• Pure and clean steam trapping
• Sanitary ancillary products
• Fabrication and service
Pipeline Ancillaries
The Spirax Sarco line of Pipeline Auxiliaries complete the steam system and are
available in a variety of materials and sizes to suit your needs.
• Flash Vessels • Steam Separators
• Strainers - Pipeline and Basket • Sight Glasses/Checks
• Air Removal Equipment • Trap Diffusers
• Radiator Valves • Vent Heads
• Ball Valves • Vacuum Breakers
• Steam Injectors
Training
Years of accumulated experience has enabled the development and nurturing of
in-depth expertise for the proper control and conditioning of steam. Experienced
field personnel work closely with design, operations, and maintenance engineers,
continuously evaluating ways to improve productivity. Often, these solutions pay for
themselves many times over.
The four U.S. training centers located in Chicago, Houston, Los Angeles, and Columbia,
SC., have on-site steam systems providing hands-on training. Education programs
include the theory of steam, the application of steam products, plant design, energy and
system efficiency, to name just a few. Programs also can be tailored to meet individual
needs. Thousands of engineers, maintenance personnel, operations managers, energy
and plant managers complete Spirax Sarco training programs each year and return to
continue broadening their knowledge of steam systems.
spiraxsarco.com/us
6. 28
Cold water header tank
Cold
water
make-up
Live
steam
supply
Steam
boiler
General layout only, some of the detail has been omitted for clarity. Your local Spirax Sarco engineer will be pleased to advise.
4
13
12
1
3
6
19
2 4
5
13
24
8
10
11
Feedwater storage
and conditioning
1 Feedtank
2 Deaerator heads
3 Steam injection and temperature control systems
4 Level controls
5 Recirculating systems
6 Air vent and vacuum breakers
Feedwater supply
and boiler level controls
7 Modulating feedwater valve controls
8 Water level alarms
9 Feedpump check valves
Also available:
- On / off feedpump controls
Boiler blowdown
TDS controls
10 Auto TDS control systems
11 Sample coolers
Also available:
- Blowdown systems for coil and
other boilers
Steam generation
35
7. From
second boiler
Overflow
To others
Cooling
water
supply
7
9
14
16
15
18
17
19
22
43
23
36
21
20
Blowdown heat
recovery
12 Flash vessels
13 Residual blowdown heat exchangers
and circulating pumps
Bottom blowdown
valves and vessels
14 Timed, bottom blowdown valves
15 Inlet manifolds
16 Isolation and check valves
17 Blowdown vessels
18 Cooling water systems
19 Vent heads
Also available:
- Manual bottom blowdown valves
Steam start-up
and flowmetering
20 Steam main start-up systems
21 Steam separators
22 Steam flowmeters
Condensate monitoring
23 Condensate contamination detectors
24 Condensate dump valves
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8. Air
Flow
Return
Make-up
Heat Exchanger
General layout only, some of the detail has been omitted for clarity. Your local Spirax Sarco engineer will be pleased to advise.
41
46
36
36
41
27
36
31
38
28
25
28
39
46
40
33
29
26
20
41
46
Pressure control
25 Pneumatic pressure control systems
26 Direct acting pressure reducing valves
27 Pilot actuated pressure reducing valves
28 Safety valves
Temperature control
29 Self-acting controls
30 Pneumatic temperature control systems
31 High temperature cut-off valves
32 Electric temperature control systems
Flowmetering
33 Plant metering and point
of use metering
Steam distribution and utilization
35
35
35 35
10. feedtank To condensate re
Air duct
Air
General layout only, some of the detail has been omitted for clarity. Your local Spirax Sarco engineer will be pleased to advise.
26
28 46
46
30
44
44
38
35
36
19
48
50
Steam humidification
47 Steam injection humidifiers
Also available:
- Self-generative humidifiers
Clean / pure steam
Many of the products shown are
also available for clean or pure steam
applications in the biotechnology,
pharmaceutical, food and drink
industries.
Flash steam recovery
48 Flash vessels are used to convert
pressurised condensate into useful flash
steam - used here on the first stage of
an air heater battery.
Steam specialization, condensate handling and the environment
35
11. eceiver unit
Flow
Plate heat
exchanger
Return
26
47
44 37
44
49
30
Condensate recovery
49 Combined pump traps and pressure
power pumps for condensate
removal and return (no electrics).
50 Electric pump sets used where
condensate can freely drain
into a receiver.
Engineered systems
A complete, compact steam heat
exchange solution for process, heating,
and domestic hot water requirements.
The environment
Steam has always been environmentally friendly
- modern, highly efficient centralized boiler plant
ensures emissions are minimized and the steam
itself condenses to pure, unpolluted water. Spirax
Sarco remains at the forefront of improving the
efficiency of the entire steam and condensate loop
and is the only company with this total capability.
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