Clean and Pure

steam in the
Biopharm industry

Kieran OKeeffe
European Business Manager
High Purity Products
Spirax Sarco Ltd.
 Typical Steam Circuit
Steam
Space
Heating
Tank Tank System

Condensate
Steam Process
Vessel

H/Exchanger

Make-up
Steam Water
Feed Condensate
Feed
Pump Tank
Boiler

Slide 2
 Driving standards

Filtered Clean Pure

- 3As - EN285 - EN285

- UK Heat - HTM2031 / 2010 - HTM2031 / 2010

preserved foods
guide - FDA (Material) - ASME BPE

- FDA (Materials) - FDA (Material)

- FDA cGMP

- USP

- ISPE
Slide 3
 Pure Steam Generation

Pure Steam Generator

cGMP, ISPE, BPE designed

3 phase moisture separation
External compact evaporator column
Generation Capacity from 50 kg/6T/hr
Units can be Electric or Steam/Steam

Slide 4
 Quality and purity
Quality Vs Purity
Dryness

Dryness of >95% is essential

Excess moisture can cause;

- Damp loads in porous materials
- Uneven temperature distribution in non-porous
loads
- Uncontrolled chemical composition of steam

Will have the effect of not sterilising correctly

Slide 6
 Quality and purity
Quality
Steam Vs
Dryness Purity
Testing procedure

D= (T1-T0)(4.18Mw+0.24) _ 4.18(Ts-T1)
LMc L

T0 = intial temp of water in flask

T1 = final temp of water in flask
Ts = average temp of water and condensate
in flask
Mw = Initial mass of water in flask
Mc = mass of condensate collected (kg)
L = latent heat of dry sat steam at temp Ts
(kJ kg-1)

Slide 7
 Quality and purity
Quality Vs Purity
Superheat

Superheat should not exceed 25 deg C (77 deg F)

Problems incurred with Superheat include

- Poor heat penetration resulting in Failure to sterilise
- Scorching of textiles and paper
- rapid deterioration of rubber

Slide 8
 Quality and purity
Quality
Steam Vs Testing
Superheat Purityprocedure

Superheat content =
temperature of steam
in the expansion tube
temperature of
boiling water at local
atmospheric pressure

Slide 9
 Quality and purity
Quality Vs Purity
Non-condensable gases (NCG)

Gases which can not be liquefied by compression under the

range of temperature / pressure experience in the sterilising
process.

NCGs should not exceed 3.5% by volume

High NCG content can cause Bowie and Dick test failure

Slide 10
 Quality and purity
Quality Vs Purity
Non-condensable Gas Testing procedure

Fraction of NCG = vol

of gas collected in the
burette / vol of water
collected in the
measuring cylinder.

Slide 11
Specific Volume Vs Pressure
Saturated Steam

1.8

1.6

1.4
Specific Volume (m3/kg)

1.2

0.8

0.6

0.4

0.2

0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Pressure (bar g)

Slide 12
 Steam Properties

Steam Tables
Enthalpy in kJ/kg

Volume Dry
Gauge pressure Temp. Water Evaporation Steam
Sat.

bar kPa C hf hfg hg m3/kg

0 0 100 419 2257 2676 1.673
1 100 120 506 2201 2707 0.881
2 200 134 562 2163 2725 0.603
3 300 144 605 2133 2738 0.461
4 400 152 671 2108 2749 0.374
5 500 159 641 2086 2757 0.315
6 600 165 697 2066 2763 0.272
7 700 170 721 2048 2769 0.24
8 800 175 743 2031 2774 0.215
9 900 180 763 2015 2778 0.194
10 1000 184 782 2000 2782 0.177
11 1100 188 799 1986 2785 0.163
12 1200 192 815 1973 2788 0.151
13 1300 195 830 1960 2790 0.141
14 1400 198 845 1947 2792 0.132

Slide 13
Distribute at High Pressure

Smaller bore steam mains needed and therefore less

heat (energy) loss due to the smaller surface area.

Lower capital cost of steam mains, both materials

such as pipes, support work and labour.

Lower capital cost of insulation (lagging).

Dryer steam at the point of usage because of the

drying effect of pressure reduction taking place.

Slide 14
 Pipe Distribution

Greater Cost
Greater Heat Loss
Greater Volume of Condensate
Formed

Lower Pressure to Steam Users

Not Enough Volume of Steam
Water Hammer and Erosion

Slide 15
 How is pipe sized ?

On the basis of:

Steam Velocity
Pressure Drop

Slide 16
 Pipe Sizing Chart Velocity

bar g Steam Pipe Sizing Chart (kg/h)

Pressure Velocity
m/s 15 20 25
Pipe Size Nominal / Actual Inside Diameter
32 40 50 65 80 100 125 150
15.8 20.93 26.64 35.04 40.9 52.5 62.7 77.92 102.26 128.2 154.05
15 9 15 25 43 58 95 136 210 362 569 822
0.4 25 14 25 41 71 97 159 227 350 603 948 1369
40 23 40 66 113 154 254 363 561 965 1517 2191
15 10 18 29 51 69 114 163 251 433 681 983
0.7 25 17 30 49 85 115 190 271 419 722 1135 1638
40 28 48 78 136 185 304 434 671 1155 1815 2621
15 12 21 34 59 81 133 189 292 503 791 1142
1 25 20 35 57 99 134 221 315 487 839 1319 1904
40 32 56 91 158 215 354 505 779 1342 2110 3046
15 18 31 50 86 118 194 277 427 735 1156 1669
2 25 29 51 83 144 196 323 461 712 1226 1927 2782
40 47 82 133 230 314 517 737 1139 1961 3083 4451
15 23 40 65 113 154 254 362 559 962 1512 2183
3 25 38 67 109 188 256 423 603 931 1603 2520 3639
40 61 107 174 301 410 676 964 1490 2565 4032 5822
15 28 50 80 139 190 313 446 689 1186 1864 2691
4 25 47 83 134 232 316 521 743 1148 1976 3106 4485
40 75 132 215 371 506 833 1189 1836 3162 4970 7176
15 34 59 96 165 225 371 529 817 1408 2213 3195
5 25 56 98 159 276 375 619 882 1362 2347 3688 5325
40 90 157 255 441 601 990 1411 2180 3755 5901 8521
15 39 68 111 191 261 430 613 947 1631 2563 3700
6 25 65 114 184 319 435 716 1022 1578 2718 4271 6167
40 104 182 295 511 696 1146 1635 2525 4348 6834 9867
15 44 77 125 217 296 487 695 1073 1848 2904 4194
7 25 74 129 209 362 493 812 1158 1788 3080 4841 6989
40 118 206 334 579 788 1299 1853 2861 4928 7745 11183

Slide 17
 Pipeline Capacity and Pressure Drop

P1 Fluid Flow P2

P1 - P2
F (Pressure Drop Factor)
L

Slide 18
 Steam Line Drainage

Slide 19
 Clean and Pure Steam
Distribution
Condensate removal

Adequate Support

Slide 20
 Clean and Pure Steam
Distribution
Condensate removal

- Steam traps should drain vertically downwards to avoid

condensate hold up

Slide 21
 Ineffective, and Proper Drain Points
Steam Flow

Condensate
Cross
Section

Correct
Pocket
25/30m Steam Trap Set

Steam Flow
Cross Section

Incorrect Steam Trap Set

Slide 22
 Clean and Pure Steam
Distribution

Steam take-off

Slide 23
 Steam Line Reducers

Correct
Steam

Condensate

Steam Incorrect

Condensate

Slide 24
 Steam Take - off

Drop Leg

Main

Shut Off
Valve

Trap Set

Slide 25
Recommended Support
Spacing

Nominal Pipe Size Interval of Horizontal Run Interval of Vertical Run

Steel/Copper (m) (m)
Bore O/D Mild Steel Copper Mild Steel Copper
12 15 - 1 - 1.2
15 18 2 1.2 2.4 1.4
20 22 2.4 1.4 3 1.7
25 28 2.7 1.7 3 2
32 35 2.7 1.7 3 2
40 42 3 2 3.6 2.4
50 54 3.4 2 4.1 2.4
65 67 3.7 2 4.4 2.4
80 76 3.7 2.4 4.4 2.9
100 108 4.1 2.7 4.9 3.2
125 133 4.4 3 5.3 3.6
150 159 4.8 3.4 5.7 4.1
200 194 5.1 - 6 -
250 267 5.8 - 5.9 -

Slide 26
 Expansion Chart for Mild Steel Pipe
Temperature difference oC/metre
Length of pipe (mm)

Expansion of pipe (mm)

bar g 1 2 3 4 5 7.5 10 15 20 25 30
o
C 120 133 143 152 158 162 183 200 214 225 235

Temperature of Saturated Steam

Slide 27
Warm up load/running
load per 50m of pipe``

Steam
Steam Main Size (mm)
Pressure
(bar g) 50 65 80 100 125 150 200 250 300 350 400 450 500 600
9 9.5 15.1 19.7 28.1 38.1 49.4 71 105 139 164 216 272 320 436
9.3 11.3 14.1 16.5 20.6 24.5 31.5 39 46.5 51.5 60 64 72 88
10 9.9 15.7 20.4 29.2 39.6 51.3 77 109 144 171 224 282 332 463
9.8 11.9 14.6 16.9 21.3 25 33 41 49 54 62 67 75 90
11 10.4 16.5 21.6 30.7 41.7 54.1 81.1 115 152 180 236 298 350 488
10.9 13 15.7 17.7 22.5 26 36 45 53 59 67 73 81 97

Ambient temperature 20 C, insulation efficiency 80%

Lower figures represent running loads
Slide 28
Questions