the PDF file
STEAM QUALITY
TEST KIT SQ1
Set Up And
User Guide
Distributed by
Steam Quality Test Kit SQ1
User Manual Version 1.5 USA
Acknowledgments made to HTM2010 & EN285
 Keith Shuttleworth & Associates Ltd. 2009
Keith Shuttleworth & Associates Ltd
Unit D5 Basepoint Business Centre
110 Butterfield
Luton LU2 8DL
Telephone +44 (0)1582 433723
Fax +44 (0)207 1173251
United Kingdom Email [email protected] ksapharma.com
Web www.ksapharma.com
Table of Contents
Introduction
4
Additional Equipment Requirements
5
Steam Test Points
6
Assembling
7
The Coolant Transfer Unit
9
Non-Condensable Gas Test
10
Superheat Test
12
Dryness Test
13
Health and Safety
15
Care and Maintenance
15
Equipment Specification
15
Appendix 1 (Steam Tables)
Back Cover
Introduction
Thank you for choosing the KSA Steam Quality Testing Kit
SQ1. This kit was developed through extensive practical
experience and has been designed to provide reliable and
consistent results that conform to the requirements of EN285/
HTM 2010.
The non-condensable gas test has been designed to be more
robust than the standard equipment and also less dependent
upon the skill of the operator. It will be found that it will provide
results that are more consistent than the EN285/HTM 2010
method.
The dryness test equipment is similar to that described in
EN285/HTM 2010, but has been modified to make it more
robust. If the calculation provided within and on the CD is
used, results identical to EN285/HTM 2010 will be obtained.
The superheat test equipment is identical to that in EN285/HTM
2010.
Warning
Before conducting any tests the contents of this manual must
be studied in depth and any associated hazards considered. It
is stressed that the test methods are defined in EN285 and
HTM 2010 and not by the authors of this manual, and that
these documents are the primary references. Sterilizer plant
rooms are potentially hazardous areas and the tests involve
working on live steam. It is assumed by the authors of this
manual that staff conducting steam quality testing will be
trained and understand the potential dangers involved with
respect to burning, due to contact with either steam or hot
surfaces or any other related hazards.
Warranty
The SQ1 Steam Quality Test Kit is designed and manufactured
to the highest standards, using top quality materials. A one year
parts only warranty applies from the date of delivery to the
customer. The warranty does not apply to abuse or misuse of
the equipment, or its use outside of the operating parameters
defined within this manual.
4
Additional Equipment
Requirements
To enable you to complete the steam tests, additional
equipment is required.
1.
Two temperature sensors and indicator/recorder capable
of measuring over a range of ambient water temperature to
maximum steam supply temperature (Typical 0 – 150o C).
The sensor used for the superheat test should not exceed
4mm diameter.
2.
1 thermocouple entry gland for the steam supply pipe
work.
3.
A balance capable of measuring up to 2Kg with 0.1g
accuracy.
4.
1 or two buckets or other water storage container. A
permanent water supply may also be used.
5.
A mains power source (optional).
6.
A supply of cold water
5
Steam Test Points
In order to test the steam quality specific test points on
the steam line are required.
Fig. 1 Illustrates the location of the three test points on
the steam supply pipe and they are fitted between the
steam distribution system and the sterilizer. It is expected
that the pressure at this point would be 2-5BarA.
It is important the pitot tube entry point is level and parallel
the steam pipe as any deviation towards the edge of
with
the pipe can influence the results detrimentally.
Non-condensable
gas Take Off
Pitot Tube entry
point
Min 400 mm
Steam
Temperature
Probe entry Point
Fig. 1
To
Sterilizer
Note All entry points are 1/4 NPT female sockets with full
size holes drilled through the pipes.
6
Assembling the Steam Test
Kit
NON-CONDENSABLE
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
GAS
KIT
Burette Bulb
Burette Cock
Burette
Burette Guide
Condense Collection Cylinder
250 ml Measuring Cylinder
Steam Valve
Cooling Water Valve
1
Steam Condensing Unit
Cooling Water Inlet
Cooling Water Outlet
Steam inlet
2
3
4
5
6
9
Fig 2
8
7
Rear View of Steam
Condensing Unit
Fig 3
10
7
12
11
SUPERHEAT KIT
1.
2.
3.
4.
Superheat Expansion Tube
Pitot Tube
Insulation
Temperature probe entry gland
4
2
1
3
Fig 4
DRYNESS TEST KIT
1.
2.
3.
4.
5.
Pitot Tube
Tubing
Tube Clamps
Rubber Bung and Tube Assembly
1 Litre Flask
1
2
3
4
Fig 5
5
8
The Coolant Transfer Unit
To condense the steam in the non-condensable gas testing unit, a
supply of cold water is needed. Due to the difficulty that is often found
in finding an accessible supply of water in a sterilizer plant room, a
coolant transfer unit has been included in this kit.
The unit is a 110 volt, 60 Hz, alternating current pump that needs to be
totally submerged in water.
There are two methods of utilizing this pump unit.
1 The unit may be placed in the make up tank of the sterilizer or
other convenient water reservoir.
2 Alternatively, place the pump unit in a bucket of water. There
should be enough water in a standard bucket to enable testing to
continue for approximately 10 -15 minutes before replacement of
the water, with cold is required.
not place the pump in a make up tank that re Do
circulates its water, as the fluctuating temperatures
could make obtaining a consistent condensate
temperature hard to achieve and damage to the
pump may occur.
In a tank that has silt or other debris present, it is recommended that
the filter is fitted to the pump.
Note.Do not let the pump unit run dry as
damage to the pump may occur.
9
Non-condensable Gas Test
S E T T I N G
U P
1.
Assemble equipment together as illustrated in Fig. 2. Place on a
level surface. Check that the Steam Valve on the test equipment is
fully closed and that the Cooling Water Valve is fully open.
2.
Connect the cooling water supply pipe to the pump at one end and
the Cooling Water Inlet on the condensing unit at the other (Fig. 3).
Connect another pipe from the Cooling Water Outlet to drain or a
bucket. Place the pump unit in a suitable water source. If desired
the pump unit may be omitted and the water feed connected to a
more permanent source. Please note that the water from the
Cooling Water Outlet may be very hot and care should be taken to
ensure that it can run to drain unimpeded and without spillage.
3.
Isolate the steam supply and after checking that no residual
pressure is present, connect the 4mm copper steam supply tubing
to the non-condensable gas take of point (Fig. 1) via a ¼” isolation
valve. Take care, as the steam pipe may be hot and residual
steam may be present. Connect the other end of the 4mm tube to
the steam connection of condensing unit (see Fig. 3) and turn the
steam supply back on. Carefully open the ¼” isolation valve a
small amount. The copper steam pipe supplied will be hot. While it
is insulated, this is to protect the user against casual contact. Even
a short contact time will result in a burn, unless the necessary
precautions have been taken
Warning.
Do not block or impede the flow of cooling water
The cooling water outlet must be kept clear at all
times.
P E R F O R M I N G
T H E
T E S T
1.
Before starting the test ensure the cooling water valve is fully open
and the steam valve is closed.
2.
Turn on the water supply by supplying power to the pump. After
ensuring that the cooling water is leaving the outlet pipe, the main
steam valve may be slowly opened. Live steam and boiling water
could discharge from the condense collecting chamber if
insufficient cooling water is available and present a hazard. In any
event, precautions should be taken. Do not look into the collecting
chamber and wear eye protection.
10
3.
Slowly open the steam valve and by reducing or increasing
the flow through the steam and water valves, obtain a flow of
condense that will give a temperature of between 70o C and
90o C, as indicated on the dial temperature gauge.
4.
Fill the condense collection chamber with water either by
filling with water from an external source, or allowing
condense to accumulate.
5.
Open the burette cock and draw up condense into the burette
with the rubber bulb provided, to get a water level near the
top. Remember to isolate the burette from the rubber bulb by
shutting the burette cock before testing commences.
6.
Fill the condense collection chamber with more water, until it
overflows.
7.
Ensure that the sterilizer chamber is empty except the normal
furniture etc. Select a porous load/equipment cycle and start a
run.
8.
When the steam supply to chamber first opens, ensure the
measuring cylinder is empty, by emptying it.
9.
Make a note of the water level in the burette.
10.
Any non-condensable gases present in the steam being
sampled will rise to the top of the burette. The overflow
formed by the condensate and the water displaced by the
gases, will collect in the measuring cylinder.
11.
When the at least 100ml of condense has been collected in
the measuring cylinder note the volume of gas collected in the
burette (Vb) and the volume of water collected in the
measuring cylinder (Vc).
12.
Calculate the fraction of non-condensable gases as a
percentage as follows:
Percentage of non-condensable gas = 100 x (Vb/Vc)
A C C E P T A N C E
C R I T E R I A
The test should be considered satisfactory if the level of noncondensable gases does not exceed 3.5%.
The test should be done three times in total to check consistency. If the
results of the tests differ significantly, then the cause should be
investigated before proceeding further.
Calculations are included on an enclosed CD.
11
The Superheat Test
S E T T I N G
U P
1.
Assemble the apparatus as per Fig. 4.
2.
Isolate the steam supply and after checking that no residual
pressure is present, insert a temperature sensor entry gland into
the fitting on the steam pipe. The steam pipe may be hot and
precautions should be taken against both burning and the
presence of residual steam. The temperature probe should be at
the geometric center of the steam pipe. Insert the appropriate size
pitot tube (see Table 1 below for the correct size) into the steam
supply. Turn the steam supply back on, taking the necessary
precautions against burning/scalding from the steam that will issue
from the pitot tube.
Table 1
1.
Steam Pressure (Bar)
Up to 3
Up to 4
Up to 7
Pitot Hole Size (mm)
0.8
0.6
0.4
Insert a temperature sensor through the entry gland of the
expansion tube and position it so the sensing point of the
thermocouple element is in the geometric center of the expansion
tube. Cover the expansion tube with the lagging. Push the
expansion tube onto the pitot tube taking the necessary
precautions. This will require the tester to be in close proximity to
the steam issuing from the pitot tube and extreme care is required
to avoid scalding and/or burning. Gloves, overalls and eye
protection must be worn.
P E R F O R M I N G
T H E
T E S T
1.
Ensure the sterilizer chamber is empty except for the usual
chamber furniture. Select and start a porous load/equipment cycle.
2.
From the measured temperatures, note the temperature in the
steam service pipe (for use in the dryness test) and in the
expansion tube (Te) when the team supply to the chamber first
opens.
3.
Calculate the superheat in o C from the following
equation.Superheat = Te - T0
Where T0 is the boiling point of water at local atmospheric
pressure.
A C C E P T A N C E
C R I T E R I A
The test should be considered satisfactory if it the superheat measured
in the expansion tube does not exceed 25° C and the temperature
measured in the steam pipe did not differ by more than 3°C from that
measured in the steam pipe during the steam quality. Dryness test
Calculations are provided on an enclosed CD.
12
Dryness Test
S E T T I N G
U P
1.
Assemble the apparatus as per Fig. 5.
2.
Isolate the steam supply and after checking that no residual
pressure is present, insert a temperature sensor entry gland into
the fitting on the steam pipe. The steam pipe may be hot and
precautions should be taken against both burning and the
presence of residual steam. The temperature probe should be at
the geometric center of the steam pipe. Insert the appropriate size
pitot tube (see Table 1 below for the correct size) into the steam
supply. Turn the steam supply back on, taking the necessary
precautions against burning/scalding from the steam that will issue
from the pitot tube.
Table 1
Steam Pressure (BarA)
Up to 3
Up to 4
Up to 7
Pitot Hole Size (mm)
0.8
0.6
0.4
P E R F O R M I N G
T H E
T E S T
Important
Before performing the test ensure the pitot hole is not restricted as
this will lead to false results. This is best done prior to fitment for
safety reasons. A long heat up time for the flask reaching ~80oC
is not normal. It should take no more than 5 minutes.
1.
Weigh the whole assembly including pipe and clips and note the
weight (M1).
2.
Remove the stopper and tube assembly and pour 650 +/- 50 ml of
cold water (below 27o C) into the flask. Replace the stopper and
tube assembly, weigh the flask and record the mass (M2).
3.
Support the flask close to the pitot tube taking care to avoid the
issuing steam. Ensure that the rubber tube and flask are protected
from excess heat and draughts. Do not connect it to the pitot tube
yet.
4.
Introduce the second temperature sensor through the shorter of
the two pipes into the water in the flask. Agitate the flask and note
the temperature of the water in the flask (T0).
5.
Ensure the sterilizer is empty except for the usual chamber
furniture. Select and start a porous load/equipment cycle.
6.
When the steam supply valve to the chamber first opens, connect
the rubber tube to the pitot tube. This will require the tester to be in
close proximity to the steam issuing from the pitot tube and
extreme care is required to avoid scalding and/or burning. Gloves,
overalls and eye protection must be worn.
13
7.
Observe/record the steam temperature for the duration of the test
and on completion of the test calculate the average temperature
(TS).
0
0
0
8.
9.
When the temperature in the flask is approximately 80o C,
disconnect the rubber tube from the stainless steel tube taking the
same precautions as when fitting. Agitate the water in the flask to
make sure it is thoroughly mixed. Note the temperature of the
water (T1).
0
Weigh the flask and stopper assembly including pipe and clips and
note the mass (M3).
0
10. Calculate the dryness value by using the following formula.
0
D = (T1 - T0) (4.18 MW + 0.23) _ 4.18(TS - T1)
L
L MC
0
0
Where:
D = Dryness value
MW = The initial mass of water in the flask is M2 - M1
MC = The mass of condense collected is M3 - M2
T0 = Initial temperature of the water in the flask (o C)
T1 = Final temperature of the water and condense in the flask
TS = Average temperature of the steam delivered to the flask
L = Latent heat of dry saturated steam at temperature TS (KJ Kg-1) - see
Appendix 1 for latent heat tables.
If a computer-spread sheet is to be used then this formula can be
used in H17, as in this example spread sheet.
=(((H9-H7)*(4.18*(H3-H1)+0.23))/(H13*(H5-H3)))-((4.18*(H11-H9))/H13)
A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
B
C
D
T o t a l w e i g h t o f fla s k , p i p e s e t c
E
F
G
H
0 .8 1 4 8
T o t a l w e i g h t o f fla s k a n d 6 5 0 m l o f w a te r
1 .4 4 9
T o t a l w e i g h t o f fla s k + c o n d e n s e
1 .5 3 6 8
In i ti a l t e m p e r a t u r e o f w a t e r i n fla s k
1 1 .2
F i n a l t e m p e r a tu r e o f w a te r a n d c o n d e n s e
8 2 .4
A v e r a g e t e m p e r a tu r e o f s t e a m d e li v e r e d t o s te r i li z e r
1 5 5 .5
L a t e n t h e a t o f a v e r a g e t e m p e r a tu r e o f s t e a m d e li v e r e d t o s te r i li z e r
2 0 9 6 .7
D r y n e s s v a lu e
0 .9 6 9
Note. The formula has been modified for stainless steel flasks
and dip tubes instead of glass, as detailed in HTM 2010.
A C C E P T A N C E
C R I T E R I A
The test should be considered satisfactory if the following requirements
are met:
1. The dryness value is not less than 0.90 (if metal loads are
processed, the dryness value should not be below 0.95).
0
2.
0
Through out the operating cycle, the temperature measured in the
steam service pipe is within 3oC of that measured during the
superheat test.
Calculations are included on an enclosed CD.
14
Health and Safety
Care should always be taken when working on or near steam pipes due
to the very high temperatures involved. Thermal gloves, overalls that
cover arms and eye protection must be used.
While every effort has been made to provide protection from the extreme temperatures, care should be taken when testing with this equipment.
Do not plug or restrict the “Cooling Out” flow as this may pressurize the
heat exchanger, which it has not been designed for.
Do not look into the condense collection cylinder while the steam valve
is open, as hot condense and/or steam could be ejected.
The insulation surrounding the steam pipe is made from glass fibre and
can cause irritation to the skin in some instances. It is therefore
recommended that gloves or a good quality barrier cream be applied as
a precaution before handling the material. The insulation is designed to
prevent burns from transient contact with the pipe and is not designed
to protect against prolonged contact.
The submersible pump is electrically powered and care must be taken
to prevent hazards arising from the use of electricity in a potentially wet
environment.
Care and maintenance
No special care is required for the steam test kit. However, the 4 mm
copper tubing, will with bending, become work hardened, which will
lead to difficulty in returning it to the tight radius required for storage. In
this instance, it may be easily replaced.
Should difficulty be found in obtaining a replacement or any other
components, please contact your local Distributor in the first instance or
Keith Shuttleworth & Associates Ltd for replacements.
Equipment specifications: Non-condensable gas test kit
0-20% N/C per 100ml condensed
steam
Dryness test
Full range
Superheat test
Full range
4mm steam supply tube
Max 10 BarG Steam
8mm Coolant supply tube
Max 3 BarG at 20o C
Condensing unit (Steam side)
Max 5 BarG at 160o C
Condensing unit (Water side)
Max 4 BarG at 20o C
Pitot Tubes
Max 6 BarG at 165o C
15
Appendix 1 Steam Tables
Pr essur e Bar A
T e mp e r a t u r e
Lat ent heat
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
4.0
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
5.0
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
6.0
6.2
6.4
6.6
6.8
7.0
7.5
8.0
8.5
9.0
120.42
121.96
123.46
124.9
126.8
127.62
128.89
130.13
131.37
132.54
133.69
134.82
135.88
136.98
138.01
139.2
140.0
140.96
141.92
142.86
143.75
144.67
145.46
146.36
147.20
148.02
148.84
149.64
150.44
151.23
151.96
152.68
153.40
154.12
154.48
155.55
156.24
156.94
157.62
158.28
158.92
160.20
161.45
162.68
163.86
165.04
167.83
170.50
173.02
175.43
2201.1
2197.0
2192.8
2188.7
2184.8
2181.0
2177.3
2173.7
2170.1
2166.7
2163.3
2160.1
2156.9
2153.7
2150.7
2147.6
2144.7
2141.9
2139.0
2136.1
2133.4
2130.7
2128.1
2125.5
2122.9
2120.3
2117.8
2115.3
2112.9
2110.5
2108.1
2105.7
2103.5
2101.2
2098.9
2096.7
2094.5
2092.3
2090.2
2088.1
2086.0
2081.8
2077.8
2073.8
2069.9
2066.0
2056.8
2047.7
2039.2
2030.9
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