ThermoMax Steam and Condensate Control System

A modern approach to steam system design and operation.

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Kadant Johnson Research Center

Condensate behavior and heat transfer Ensure maximum operation performance Two commercial size paper dryers Corrugator test stand and rolls Hot plate test apparatus 15 test machines; 40 test positions Two isolation rooms and seal test lab

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Corrugator Test Stand

Designed for rolls up to 36diameter Operating speeds up to 2400 fpm Supply pressure 200 psig Plain shell and drilled rolls Steam control systems
Trap systems Blow-through flow control Differential pressure control

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Corrugator Test Stand Measurements

Roll surface temperatures Roll deflection Steam flow and pressures Condensing rates Differential steam pressure Real-time video inside roll System analysis
Trapped versus blow-through Syphon types Differential requirements, warm-up rates, etc.

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Hot Plate Test Stand

600 mm plate 900 mm plate 900 mm plate with large bore
Heat transfer with traps Heat transfer with blowthrough CD uniformity Deflection Pressure drop

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Problems Identified:
Loss of roll temperature as speed increases Inconsistent heat transfer as speeds change Reduction in roll temperature over time Roll deflection when stopped Excessive/insufficient differential across drilled rolls Poor performance following system start-up

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Problems Result In:

Reduced speeds Poor runnability

Waste

Slow start-ups

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Plain Roll Testing

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Plain Roll Condensate Behavior

Ponding
Low drive power High heat transfer

Cascading
High drive power High heat transfer

Rimming
Low drive power Low heat transfer

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Rimming and Collapse Speeds:

Rimming and Collapsing Speed
1800 1600 1400 1200

Speed (fpm)

1000 800 600 400 200 0 0 0.05 0.1 0.15 0.2 0.25 0.3 Rim Layer Thickness (in)

Rimming Speed

Collapsing Speed

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

 2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Plain Rolls - What We Have Learned

Modern corrugator plain rolls operate at speeds where condensate rimming occurs Roll temperature drops quickly when the condensate is rimming
Rolls can go into and out of rimming depending on condensate load and speed leading to instability
2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Plain Roll Temperature Instability

Stationary roll has small condensate puddle Roll rotation Cascading condensate /High HT Thin condensate layer rims Low HT Condensate layer builds up Very low HT Condensate layer collapses High HT (speed reduction) Syphon reduces condensate volume Rimming

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Plain Roll Temperature Instability

Condensate can be rimming or non-rimming depending on:
Speed Syphon clearance Amount of time allowed for condensate layer to build Whether accelerating upward or downward in speed

Temperature will vary and is unpredictable

Operators will not know what to expect

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Turbulator Bar Concept

Axial bars held against the roll inside surface Bars produce turbulence in the condensate layer and increase heat transfer Same high roll temperature whether rimming or non-rimming Condensate depth is controlled for maximum heat transfer
2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Plain Shell Thermal Bowing

0.014 0.012 Without Turbulator Bars

Roll Deflection (in)

0.01 0.008 0.006 0.004 0.002 0 -0.002 0 5 10 Elapsed Tim e (m inutes) 15 20 With bars

301.4 lb/hr 1476 fpm

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Traps - What We Have Learned

Trapped system have high condensate load inside the roll High load causes dramatic loss of roll temperature when rimming
Trapped systems have poor air removal capability
Avg Temp (F)

Average Surface Temperature vs Time

305

295

285 275

265

255 0 50 100 150 200 250 300 350 400 Elapsed Time (minutes) Locking Elbow Stationary/F&T trap Locking Elbow Stationary/Bucket trap Lock Elbow Stationary/BT control Bent Pipe Stationary/F&T trap Bent Pipe Stationary/Bucket trap Bent Pipe Stationary/BT control

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Traps What We Have Learned

Average roll temperature and cross-direction temperature uniformity decrease over time when bars not used Significant roll bowing when stopped

Slow temperature response to changes

Condensate load places high stress on syphon
2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Traps What We Have Learned

Trapped rolls do not provide same heat transfer when used with Turbulator bars High residual condensate reduces effectiveness of bars Maximum heat transfer and roll temperature is achieved by tuning the condensate depth with proper syphon clearance and blowthrough steam
Slow rise due to poor air removal by trap on start-up

Comparison of trapped roll and one with blowthrough drainage both with bars.

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Approach For Plain Shell Rolls

Plain rolls require Turbulator bars
Maintain high roll temperature at any speed

Accurate syphon clearance to maximize effectiveness of Turbulator bars

Bracket mounted joint for rigid support Locking elbow syphon with shaped foot Shaped foot for improved condensate removal

Blow-through steam flow to drain rolls and minimize condensate build-up: No traps

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Balanced Seal Joint & 90 Locking Elbow Syphon

Bracket-supported balanced seal joint
Seal ring carries only sealing load Ring bracket supports the joint Mounts to bearing cover Extends seal life (x3) Rigid syphon support

90 locking elbow syphon

Stainless steel Shaped SS /Teflon foot for improved condensate removal Welded construction

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Drilled Roll Testing

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Drilled Roll Condensate Removal

Drilled rolls require blow-through steam to move condensate through drilled passages Differential pressure between steam inlet and condensate outlet causes blow-through steam to flow

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

23

Average Surface Temperature

325 305
Average Shell Temperature, F

Drilled Shell

285 265 245 225 205 185 165 145 125 0 200 400 600 800 1000 1200 1400 1600 Roll Speed, fpm

Turbulator Bars

Plain Shell

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Drilled Shell Pressure Loss

Pressure losses caused by:
Steam joint inlet (many joints are undersized) Radial passages in roll heads Axial flow passages in shell Steam joint outlet

Pressure loss depends on:

Steam pressure Condensate flow rate Amount of blow-through steam

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Drilled Roll Avg. Temperature and Blow-through

Roll temperature will decrease as pressure drop / blow-through increases. Saturation temperature is reduced.

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Drilled Roll Avg. Temperature and Blow-through

310

Average Surface Temperature, F

305 300 295 290 285 280 275 270 0 500 1000 1500 Speed, fpm 2000 2500 3000 Low blow -thru Medium blow -thru High blow -thru

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Drilled Rolls - What We Have Learned

Drilled rolls have optimum operating point for blow-through
Too much = Lower roll temperature Too little = Condensate stall

Optimum blow-through depends on roll design, speed, and pressure

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

ThermoMax Approach For Drilled Rolls

Control blowthrough from drilled rolls to optimum level based on speed and pressure
Measure and control blow-through from rolls Use supervisory control to maintain at optimum Indicate differential pressure for troubleshooting
800 700
Blow-Thru (lb/hr)

600 500 400 300 200 100 0 0 500 1000 1500 Speed (fpm) 2000 2500 3000

P=120 psig C= 500 lb/hr

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Single Facer Steam System

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

Kadant Johnson Corrugator Steam System

Drilled corrugator rolls controlled with blow-through steam to optimum level Plain shell preheater rolls have Turbulator bars and locking syphon elbows
Condensate removal with blow-through steam No traps on rolls

Thermocompressor to efficiently use blow-through steam

Manage system with PLC controls, supervisory logic, graphical user interface
2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.

ThermoMax Steam and Condensate Control System

2013 Kadant Johnson Inc. All rights reserved. Confidential property of Kadant Johnson Inc. Return upon request. Do not disclose to third parties without prior written consent. Provided to support the interests of Kadant Johnson.

2013 Kadant Johnson Inc. Confidential property of Kadant Johnson Inc.