English-News

Janssen Case Study

2009-09-23T12:34:03Z

A Spirax Sarco skid-mounted hot water system is enabling Janssen Pharmaceuticals, part of the Johnson & Johnson group, to more than double the capacity of part of its production facility at Little Island, County Cork.

The demand for hot water to heat five jacketed batch reactors varies depending on the number of reactors in use. A previous system fed the jackets from a 1 000 litre tank, which had to be at 65°C to 70°C before production could begin. Each jacket takes around 400 litres of hot water, so only two reactors could be heated simultaneously. Increases in production demand required more than two reactors to be heated at a time. To avoid staggering production, which reduces plant utilisation, it was decided to upgrade the hot water system.

Release date: 10th January 2003

Hot water system doubles pharmaceutical production capacity

The new Spirax Sarco system, now supplied from an insulated 6 000 litre tank, allows all five reactors on the hot water loop to start up simultaneously and almost immediately. This has allowed Janssen Pharmaceuticals to more than double the capacity of its processes that use hot water.

At the heart of the Spirax Sarco engineered system is a plate steam heat exchanger. One of the features in the Janssen Pharmaceuticals application is the wide variation in load on the heat exchanger. At low loads, the steam pressure can drop so much that it would be unable to force condensate out of the exchanger. If this occurred, a standard steam trap would be unable to drain condensate from the exchanger, causing it to become waterlogged, losing heating efficiency and even stalling.

To solve this problem a Spirax Sarco APT14 automatic pump trap is fitted to each exchanger to ensure that condensate is always removed, even under low loads when vacuum conditions could be created.

The engineered system was supplied complete with the pumps to send the water around the supply loop and a control panel that links with Janssen Pharmaceuticals’ plant-wide control system. This enables production operators to remotely monitor and control the hot water system from the central control room.

The system operates by taking cold water at around 25°C from the supply tank where it is raised to 70°C in the heat exchanger. This hot water is then fed into the pumped supply loop and tapped off to feed as many heating jackets as required.

As well as increasing capacity, the new system also improves the control of the hot water temperature over the full range of loads. It really improves production efficiency.

Caption: A Spirax Sarco skid-mounted hot water system is enabling Janssen Pharmaceuticals, part of the Johnson & Johnson group, to more than double the capacity of part of its production facility at Little Island, County Cork.

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Spirax-Sarco Limited Spirax-Sarco Limited is the world leader in the control and efficient use of steam and other industrial fluids.

Our Successful Project in BIPC

2009-09-22T10:21:14Z

Spirax Sarco STMS project enabled Bandar Imam Petrochemical Company (BIPC), to 2.2% reduction of steam consumption intensity. BIPC is one of the largest industrial establishments which is located on the North West coast of the Persian Gulf. This location has been chosen due to its easy access to feed stocks, the main national roads, railway network, as well as international waterway.

Timeworn steam trap stations were facing many defects and problems such as the excess of number of connections due to having separate elements and by the passage of time, an increase in the leakage factor. Another reason was the old version of stop valves in the station; they were gland packing type and had a great amount of steam wastage. In addition the old and rusty steam traps were not on the bases of the latest technology and therefore not working properly.

Reduction of Steam Consumption Intensity by Improving BIPC Steam Trap Stations

Short summery:

There are about 6000 steam trap stations in the steam distribution system of Bandar Imam Petrochemical Company (BIPC). The design and execution of these stations dates back to 1970s, therefore having a huge potential steam loss due to a number of reasons.
Timeworn steam trap stations were facing many defects and problems such as the excess of number of connections due to having separate elements and by the passage of time, an increase in the leakage factor. Another reason was the old version of stop valves in the station; they were gland packing type and had a great amount of steam wastage. In addition the old and rusty steam traps were not on the bases of the latest technology and therefore not working properly.

Project Aims:

The project was designed to standardize trap stations on the basis of latest technology, to reduce the potential steam loss, to reduce the steam consumption intensity and to increase the energy efficiency in the steam distribution line. Obviously by reducing the steam supplied there is a reduction in fuel consumed and a total saving.

Detailed Project Description:

For the first time in Iran, Bandar Imam Petrochemical company started a project named Steam Trap Management System (STMS). This project was offered and executed by Sazeh Paydar Ideh, the chief representative of Spirax Sarco in Iran.

From five years back, Paydar Ideh started to conduct training courses for more than 1200 personnel and consulted over different issues on the steam and condensate line in BIPC.

An office was outfit for this purpose and an excessive teamwork was started from February 07 to August 08. An appropriate time table was set, the related drawings were improved and the existing documents were checked. The technical team identified the steam distribution line and denoted them on the bases of the passing steam pressure. They surveyed, tagged and tested the steam trap stations of the whole site and filled up the related check lists.

There were three ways for testing the steam traps: visual, temperature and ultrasonic tests. It was confirmed whether the steam traps were suitable for the application, working correctly, or failed in the open or closed position. In the existing drawing the steam lines relating to the steam traps were highlighted and redrawn separately.

The information was entered into a computerized Steam Trap Management System which showed a full inventory of the traps, their location, status and suitability for the application. Failed traps were highlighted and steam losses calculated gave payback times on replacement of the failed traps.
A comprehensive report was made which contained a short summery on the project detail and different turnouts from the recorded data such as the number of steam traps facing physical problems, their failure list and the station requirements. On the other hand the stores had to be checked and the ones becoming out of order had to be removed. By analyzing the report, 4500 stations could be replaced by compact stations, but the priority was with 2700 of them; the ones having more problems and wastage.
Therefore a team was set to purchase the needed compact stations from Spirax Sarco, according to the set report. The replacement and installation of the old ones was implemented, From March 08 to March 09.

Benefits:

According to the documents, the numbers of elements are reduced from 20,651 to 6,311. The used stop valves are completely sealed. The latest technology is used, 676 ton/year potential steam loss is saved, 0.035 reduction of steam consumption intensity which is equal to 2.2% and 23 ton/hr reduction of steam consumption which costs about Euro 1,319,037 annually is achieved. Euro 140,218 fuel is saved and the payback period is about 1.5~2 years. Its environmental effect was 10% reduction of CO2 emissions.

After its successful execution, this project, this project was implemented in many companies such as Amir Kabir, Tondgouyan, Fajr, etc. Petrochemicals and Behran and Pars Oil Refineries.

Synergy Health cleans up with Spirax Sarco

2009-09-22T10:10:12Z

Synergy Health in Sheffield, has reduced gas consumption in its boiler by 11% thanks to an innovative heat recovery system from Spirax Sarco. Faced with ever-increasing fuel costs Synergy Health commissioned Spirax Sarco to supply and project manage the installation of a skid-mounted Flash Recovery Energy Management Equipment (FREME) system.

The FREME system recovers the energy in

Synergy Health in Sheffield, has reduced gas consumption in its boiler by 11% thanks to an innovative heat recovery system from Spirax Sarco. Faced with ever-increasing fuel costs Synergy Health commissioned Spirax Sarco to supply and project manage the installation of a skid-mounted Flash Recovery Energy Management Equipment (FREME) system.

The FREME system recovers the energy in condensate and flash steam from around the plant and uses it to preheat the pressurised feed water to the boiler. Before the project, water entered the boiler at around 90°C but now arrives at 130°C. Supplying hotter feed water reduces the amount of work the boiler needs to do to raise steam. Further savings are made as FREME ensures that as much flash steam as possible is condensed and returned to the feedtank, thus reducing water and chemical treatment costs.

“To validate the scheme we installed gas, water and steam meters before the FREME system was put in place,” explains Darren Haddock, Operations Manager at Synergy Health. “Since the installation we have been able to see great savings in all of these areas, specifically our gas usage.”

Synergy Health provides complete linen management services exclusively to the healthcare sector and is the 2nd largest focused healthcare linen supplier in England.

“We are happy with the new system so far, and expect payback on the project within 2 years,” says Darren. “The Spirax Sarco engineers were very helpful, their expertise and professionalism gives you confidence in the service.”

Quickheat - Your Compact Heat Exchange Solution

2009-09-22T10:09:25Z

Quickheat is the packaged solution to your heat exchange needs.
Its compact, simple design provides accurate control with low ownership cost and a long life span.

All you need to do is tell us what you want to achieve and we will provide you with the system that meets

Quickheat is the packaged solution to your heat exchange needs.
Its compact, simple design provides accurate control with low ownership cost and a long life span.

All you need to do is tell us what you want to achieve and we will provide you with the system that meets your requirements.

You will deal with Spirax Sarco throughout the whole process.
We will take on the responsibility to providie the solution, leaving you to do what you do best - running your business.

APT14 Automatic Pump Trap - CARBON STEEL

2009-09-22T10:08:21Z

The DN50x40 carbon steel APT14SHC automatic pump trap complements the already successful SG iron range of APT's. This product can also be used in general industrial and process markets where SGi ron is not allowed

* FIG 14 Carbon Steel Strainer with 100 Mesh Screen on motive

* Dual certified (EN & ASTM) Carbon STeel body & cover

* High capacity up to 2800 kg/h pumping & 9000 kg/hr trapping

* Proven APT14HC Internals

BSA Cast Steel Bellow Sealed Stop Valves

2009-09-22T10:06:39Z

No Drips... No Leaks

Zero Emissions

Environmentally Friendly

Maintenance Free

Robust & Long Life

Easy Operation

Our BSA Cast Steel Bellow Sealed Stop Valves are CRN APPROVED and

No Drips... No Leaks

Zero Emissions

Environmentally Friendly

Maintenance Free

Robust & Long Life

Easy Operation

Our BSA Cast Steel Bellow Sealed Stop Valves are CRN APPROVED and suitable for use on a wide variety of industrial and process fluids, such as steam, air, thermal fluids, oil, hot water and cold water applications.

These valves are unaffected by vibration and will operate over a wide range of pressures and temperatures.

Ranging from 1/2” to 8” and rated up to ANSI 300 and Class 800; with flanged, screwed and socket-weld connections, there is a valve to meet most process applications.

Throttling plug versions are available for applications such as balancing lines, bypass lines and “crude” control valve substitution.

Isolation Applications Include: Steam and condensate, process fluids, hot & cold water systems, hot oil systems, toxic fluids, compressed air and other gases, water/glycol systems, and thermal fluid systems (e.g., Dowtherm*, Santotherm*, Thermex*, Therminal* and Uncon*).

PANDEMIC - BUSINESS CONTINUITY

2009-09-22T10:01:30Z

Here at Spirax Sarco, we are taking the threat of the swine flu pandemic extremely seriously.

We have developed a business continuity plan encompassing our customers' needs as well as our suppliers.

This plan incorporates educating our employees on the symptoms, acting to prevent infection between employees, and ensuring that all critical business functions are fulfilled

Here at Spirax Sarco, we are taking the threat of the swine flu pandemic extremely seriously.

We have developed a business continuity plan encompassing our customers' needs as well as our suppliers.

This plan incorporates educating our employees on the symptoms, acting to prevent infection between employees, and ensuring that all critical business functions are fulfilled.

We remain focused on provided on providing you with the highest levels of service. Should there be any change to our service, we will notify you as soon as possible.

If you have any concerns please contact us at 1-877-265-7747 or email at info@spirax.ca.