SC-GCM-65 CM Issue 1 Copyright 2005 Spirax-Sarco Limited

Block 8 Control Applications

Temperature Control for Steam Applications Module 8.2

Module 8.2
Temperature Control for
Steam Applications

The Steam and Condensate Loop

8.2.1

Block 8 Control Applications

Temperature Control for Steam Applications Module 8.2

Temperature control for steam applications

There are a number of reasons for using automatic temperature controls for steam applications:
1. For some processes, it is necessary to control the product temperature to within fairly close
limits to avoid the product or material being processed being spoilt.
2. Steam flashing from boiling tanks is a nuisance that not only produces unpleasant environmental
conditions, but can also damage the fabric of the building. Automatic temperature controls
can keep hot tanks just below boiling temperature.
3. Economy.
4. Quality and consistency of production.
5. Saving in manpower.
6. Comfort control, for space heating.
7. Safety.
8. To optimise rates of production in industrial processes.
The temperature control system employed should be matched to the system, and capable
of responding to the changes in heat load. For example:
o

8.2.2

On a low thermal mass system experiencing fast load changes, the control system needs to be
able to react quickly.
On massive systems, such as oil storage tanks, which experience slow changes in temperature,
the control may only have to respond slowly.
The temperature control system selected may need to be capable of coping with the start-up
load without being too big, to provide accurate control under running conditions.

The Steam and Condensate Loop

Block 8 Control Applications

Temperature Control for Steam Applications Module 8.2

Direct operating, self-acting temperature control

Description

The direct operating, self-acting type of temperature control uses the expansion of liquid in a
sensor and capillary to change the valve position.

Advantages:
1.
2.
3.
4.
5.
6.
7.
8.
9.

Inexpensive.
Small.
Easy to install and commission.
One trade installation.
Very robust and extremely reliable.
Tolerant of imperfect steam conditions and of being oversized.
Self-acting principle means that no external power is required.
Simple to size and select.
Many options are available, such as different capillary lengths and temperature ranges.

Disadvantages:

1. The control is stand-alone, and cannot communicate with a remote controller or

PLC (Programmable Logic Controller), although a high temperature cut-out may signal
closure via a switch.
2. Limited sizes.
3. Limited pressure ratings.
4. Limited turndown.
5. Sensors tend to be much larger than the pneumatic and electronic equivalents and also much
slower acting.

Applications:

Applications would include those with low and constant running flowrates:
1. Small jacketed pans.
2. Tracer lines.
3. Ironers.
4. Small tanks.
5. Acid baths.
6. Small storage calorifiers.
7. Small heater batteries.
8. Unit heaters.

Point to note:

The proportional band is influenced by the size of the valve.

High
limit
valve

Separator

Steam
supply

Spring loaded
cut-out unit

Control
valve

Vacuum
breaker

Flow

Calorifier

Return

Condensate
Fail-safe control system

Cold water
make-up

Condensate
Fig. 8.2.1 General arrangement of a direct operating, self-acting temperature control system
on a DHWS (Domestic Hot Water Services) storage calorifier
The Steam and Condensate Loop

8.2.3

Block 8 Control Applications

Temperature Control for Steam Applications Module 8.2

Pilot operated, self-acting temperature control

Description

The pilot operated self-acting type of temperature controller uses the expansion of liquid in
a sensor and capillary to operate a pilot valve, which in turn changes the main valve position.

Advantages:
1.
2.
3.
4.
5.
6.
7.
8.

Easy to install and commission.

One trade installation.
Very robust.
Self-acting principle means that no external power is required.
Simple to size and select.
Remote adjustment (option).
Can be switched on and off (option).
Dual set point (option).

Disadvantages:

1. The control is stand-alone, and cannot communicate with a PLC.

2. Small clearances within the valve body mean that steam should be clean and dry to ensure
longevity, but this can easily be achieved by fitting a separator and strainer before the valve.
3. Proportional only control, however, the proportional offset is much smaller than for direct
operating, self-acting controls.

Applications:
1.
2.
3.
4.
5.
6.
7.

Jacketed pans.
Tracer lines.
Tanks.
Acid baths.
Hot water storage calorifiers.
Heater batteries.
Unit heaters.

Points to note:

1. The temperature ranges of controllers tend to be narrower than direct operating, self-acting
controls.
2. Installation must include a strainer and separator.
Pilot operated
temperature
control valve

Separator

Vacuum breaker

Steam in

Sensor
Condensate

Injector

Tank

Fig. 8.2.2 General arrangement of a pilot operated, self-acting temperature control injecting steam into a tank

8.2.4

The Steam and Condensate Loop

Block 8 Control Applications

Temperature Control for Steam Applications Module 8.2

Pneumatic temperature control

Description

These control systems may include:

o

P + I + D functions to improve accuracy under varying load conditions.

Set point(s), which may be remotely adjusted.

Advantages:
1.
2.
3.
4.
5.
6.
7.

Very accurate and flexible.

No limit on valve size within the limits of the valve range.
Excellent turndown ratio.
Suitable for hazardous environments.
No electrical supply required.
Fast operation means they respond well to rapid changes in demand.
Very powerful, and can cope with high differential pressures.

Disadvantages:

1. More expensive than direct operating controls.

2. More complex than direct operating controls.

Applications:

1. Which need accurate and consistent temperature control.

2. With variable and high flowrates, and / or variable upstream pressure.
3. Which require intrinsic safety.

Points to note:

1. A clean, dry air supply is required

2. A valve positioner is generally required except for the smallest and simplest of applications.
Air is continually vented from the positioner and controller, and there is a need to ensure that
this quiescent air flow is acceptable to the surroundings.
3. A skilled workforce is required to install the equipment, and instrument personnel for calibration
and commissioning.
4. The control is stand-alone, and cannot directly communicate with a PLC.
5. The failure mode must always be considered. For example, spring-to-close on air failure is
normal on steam heating systems, spring-to-open is normal on cooling systems.
Pneumatic
temperature
control valve

Pneumatic
controller

Temperature sensor
Separator

Hot water out

Vacuum
breaker

Steam in

Heating calorifier
Cold water in

Condensate

Condensate
Fig. 8.2.3 General arrangement of a pneumatic temperature control system on a heating calorifier

The Steam and Condensate Loop

8.2.5

Block 8 Control Applications

Temperature Control for Steam Applications Module 8.2

Electropneumatic temperature control

Description

These control systems may include:

o

P + I + D functions to improve accuracy under varying load conditions.

Set point(s) may be remotely adjusted, with the possibility of ramps between set points.

Advantages:
1.
2.
3.
4.
5.
6.

Very accurate and flexible.

Remote adjustment and read-out.
No limit on valve size within the limits of the valve range.
Excellent turndown ratio.
Fast operation means they respond well to rapid changes in demand.
Very powerful, and can cope with high differential pressures.

Disadvantages:

1. More expensive than self-acting or pneumatic controls.

2. More complex than self-acting or pneumatic controls.
3. Electrical supply required.

Applications:

1. Which need accurate and consistent temperature control.

2. With variable and high flowrates, and / or variable upstream pressure.

Points to note:

1. A clean, dry air supply is required.

2. A skilled workforce is required to install the equipment, electrical personnel are required for
power supplies, and instrument personnel to calibrate and commission.
3. Can be part of a sophisticated control system involving PLCs, chart recorders and SCADA
systems.
4. The failure mode must always be considered. For example, spring-to-close on air failure is
normal on steam heating systems, spring-to-open is normal on cooling systems.
5. Probably the most common control system - it has the sophistication of electronics with the
pace / power of pneumatics.
Electronic
controller

Pneumatic
temperature
control valve
Vacuum
breaker

Separator

Temperature sensor
Hot water out

Steam in
Heating calorifier

Cold water in
Condensate

Condensate
Fig. 8.2.4 General arrangement of an electropneumatic temperature control system on a heating calorifier

8.2.6

The Steam and Condensate Loop

Block 8 Control Applications

Temperature Control for Steam Applications Module 8.2

Electric temperature control

Description

These control systems may include:

o

P + I + D functions to improve accuracy under varying load conditions.

Set point(s), which may be remotely adjusted.

Advantages:

1. Both controller and valve actuator can communicate with a PLC.

2. No compressed air supply is required.

Disadvantage:

The relatively slow actuator speed means they are only suitable for applications where the load
changes slowly.

Application:

Space heating of large volumes. For example; warehouses, workshops, aircraft hangars, etc.

Points to note:

1. Safety: If electrical power is lost the valve position will not change unless a spring return
actuator is used.
2. Spring return actuators are expensive, bulky and can only shut off against a limited pressure.
Electronic
controller
Electronic
temperature
control valve
Temperature
sensor
Separator
Steam in

Hot water out

Vacuum
breaker
Heating calorifier

Cold water in

Condensate

Condensate
Fig. 8.2.5 General arrangement of an electric temperature control system on a heating calorifier

The Steam and Condensate Loop

8.2.7

Block 8 Control Applications

Temperature Control for Steam Applications Module 8.2

Temperature control (other possibilities) Parallel temperature control station

Description

An arrangement, as shown in Figure 8.2.6, can be used where the ratio between maximum and
minimum flowrates (the flowrate turndown) is greater than the maximum allowable for the
individual temperature control valve.
For example, if a specific application has to be brought up to operating temperature very quickly,
but the running load is small, and plant conditions dictate that self-acting controls must be used.

To satisfy the application:

1. A valve and controller, which could satisfy the running load, would be selected first, and set to
the required temperature.
2. A second valve and controller, capable of supplying the additional load for warm-up would
be selected, and set to a couple of degrees lower than the running load valve. This valve is
likely to be larger than the running load valve.

With this configuration:

1. When the process is cold, both control valves are open, allowing sufficient steam to pass to
raise the product temperature within the required time period.
2. As the process approaches the required temperature, the warm-up valve will modulate to
closed, leaving the running load valve to modulate and maintain the temperature.

To temperature
sensor and controller

Warm-up load valve leg

Separator
Steam in
Running load valve leg

To temperature
sensor and controller

Condensate
Fig. 8.2.6 General arrangement of a parallel temperature control station

8.2.8

The Steam and Condensate Loop

Block 8 Control Applications

Temperature Control for Steam Applications Module 8.2

High temperature fail safe control

Description

There are many applications where a totally independent high limit cut-out device is either
desirable, or even a legal requirement.

Options:

1. A self-acting control, where the expansion of the fluid releases a compressed spring in a
cut-out unit, and snaps the isolating valve shut if the preset high limit temperature is exceeded.
This particular type of self-acting control has additional advantages:
a. It can incorporate a microswitch for remote indication of operation.
b. It is best if it has to be reset manually, requiring personnel to visit the application and
ascertain what caused the problem.
2. Spring-to-close electrical actuator where an overtemperature signal will interrupt the
electrical supply and the valve will close. This may be accompanied by an alarm.
3. Spring-to-close pneumatic actuators where an overtemperature signal will cause the
operating air to be released from the actuator. This may be accompanied by an alarm.

Application:

Domestic hot water services (DHWS) supplying general purpose hot water to users such as
hospitals, prisons and schools.

Points to note:

1. There may be a legal requirement for the high temperature cut-out to be totally independent.
This will mean that the high temperature cut-out device must operate on a separate valve.
2. Generally, the high temperature cut-out valve will be pipeline size, since a low pressure drop
is required across the valve when it is open.
High limit
valve

Separator
Steam
supply

Spring loaded
cut-out unit

Control
valve

Flow

Calorifier

Return

Condensate
Fail-safe control system

Cold water
make-up

Condensate
Fig. 8.2.7 General arrangement of a high temperature cut-out on a DHWS storage calorifier

The Steam and Condensate Loop

8.2.9

Block 8 Control Applications

Temperature Control for Steam Applications Module 8.2

Questions
1. Name one disadvantage of direct operating temperature control
a| It is relatively inexpensive

b| The sensors tend to be large compared to EL (electronic) and PN (pneumatic) sensors

c| Systems are difficult to size and select

d| Systems are difficult to install and commission

2. A temperature control application in a hazardous area, and which has

low thermal mass, is subject to fast load changes and periods of
inoperation. Which would be the best control solution from the following?
a| A direct operating temperature control system

b| A pilot operated self-acting temperature control system

c| A pneumatic temperature control system

d| An electric temperature control system

3. In Figure 8.2.6, the warm-up valve is shown in the upper leg of the
parallel supply system. Is this logical?
a| Yes, otherwise condensate would tend to collect in the warm-up leg during low loads,
when the warm-up valve would be shut

b| Yes, it makes maintenance easier

c| No, either leg is acceptable

d| Yes, the warm-up valve needs more installation space

4. Is the fail-safe self-acting high limit temperature cut-out only suitable for
DHWS storage calorifiers?
a| Yes

b| It is suitable for any application requiring high limit temperature control

5. In Figure 8.2.5, a shell and tube heating calorifier uses electrical control.
Is this really suitable for this type of application?
a| No, it was the only example drawing available

b| No, the valve would not react quickly enough

c| No, an electropneumatic system should always be chosen for this type of application,
especially when steam is the energy provider

d| Yes, because changes in load will occur slowly

Answers

1: b, 2: c, 3: a, 4: b, 5: d

8.2.10

The Steam and Condensate Loop