PURE STEAM

Pure Steam Quality Test Kit

TEK1pSQT

Operators Manual

Table of Contents

INTRODUCTION ........................................................................................................................ 4

ADDITIONAL EQUIPMENT REQUIREMENTS ..................................................................... 5

STEAM TEST POINTS ............................................................................................................... 6

ASSEMBLING THE STEAM TEST KIT ................................................................................... 7

NON-CONDENSABLE GAS KIT ........................................................................................... 7

SUPER-HEAT TEST KIT ........................................................................................................ 7

DRYNESS TEST KIT .............................................................................................................. 8

NON CONDENSABLE GAS TEST ............................................................................................ 9

S E T T I N G U P .................................................................................................................... 9

P E R F O R M I N G T H E T E S T. .10

A C C E P T A N C E C R I T E R I A .................................................................................. .11

THE SUPERHEAT TEST .......................................................................................................... .12

S E T T I N G U P .................................................................................................................. .12

P E R F O R M I N G T H E T E S T ...................................................................................... .13

A C C E P T A N C E C R I T E R I A .................................................................................. .13

DRYNESS TEST........................................................................................................................ .14

S E T T I N G U P ................................................................................................................... .14

P E R F O R M I N G T H E T E S T ...................................................................................... .15

A C C E P T A N C E C R I T E R I A .................................................................................. .16

REPORT FORMAT.............17

HEALTH AND SAFETY ........................................................................................................... .18

CARE AND MAINTENANCE .................................................................................................. .19

File (Manual, SOPs, Calibration certificate,

IQ/OQ)

Carrying case

Non condensable gas

unit

Laboratory balance

Steam sampling (service) pipe

Gloves

Temperature meter & thermocouple

Storage boxes Pitot tubes (0.4mm,

0.6mm, 0.8mm)

Sanitary diaphragmatic valve

Gaskets (spare)

TC clamp

Expansion tube

1 liter vacuum flask

(with stand, rubber

bung assembly and

SS inlet tubes)

SS hose pipe

with TC end

fitting

Rubber tube

Water pipe

4

INTRODUCTION

Thank you for choosing the TEK1 Pure Steam Quality Testing Kit (TEK1

pSQT).This kit is developed based on extensive practical experience and

has been designed to provide reliable and consistent results that conform to

the requirements of EN285/HTM2010/ISO11134.

The Non-condensable gas test method exceeds the HTM 2010 standard

equipment and also less dependent on operators skill. User will find the

test equipment provides very consistent results.

The Dryness test is similar to that described in EN285/HTM 2010, but it is

modified to make the measurements easier and it is ready to test kit.

The Superheat test equipment is identical to that in EN285/HTM2010.

Warning

Before conducting any tests the contents of this manual must be studied and

any associated hazards must be considered. It is stressed that the test

methods prescribed in this manual is defined in EN285 and HTM 2010 not

by author. EN285 and HTM 2010 are the primary reference document for

this manual. Sterilizer plant rooms are potentially hazardous areas and the

test involve live steam. It is assumed by the author of this manual that staff

performs the tests must be trained professional and can understand the

potential of danger.

5

Warranty

The TEK1pSQT is designed and manufactured to the highest standards using

top quality material. A one year warranty * is provided.

* Warranty is applicable for part only. Warranty will not be applicable if misuse or its

use outside of the operating parameters defined within the manual.

ADDITIONAL EQUIPMENT REQUIREMENTS

To enable you to perform steam quality tests, additional equipments requirements are:

Running cold water supply or bucket type water storage container may also be

used.

Extension pipe for water supply

6

STEAM TEST POINTS

In order to test the steam quality, specific test points as per the guide line on the steam

line are required.

Fig. (i) Illustrate the location of the three test points on the steam supply pipe and they

are fitted between the steam distribution system and sterilizer. It is expected that the

pressure at this point would be 2-5bar.

Fig: (i)

Note: (i) It is important that the pitot tube entry point is level and parallel with the

steam pipe as any deviation towards the edge of the pipe can influence the results

detrimentally.

(ii) All the entry points are 1/2" BSP female sockets with full size holes drilled

through the pipes.

Socket for pitot tube for Dryness and

Superheat test

7

ASSEMBLING THE STEAM TEST KIT

NON CONDENSABLE GAS KIT

Non condensable gas detection unit

Hose pipe with TC end fitting

Cold water supply (user to provide)

Radiant Flow Valve

Cooling Water Inlet pipe

Cooling Water Outlet pipe

Steam inlet

Drain Valve Fig: (ii)

SUPER-HEAT TEST KIT

Superheat expansion tube

Pitot Tubes(0.8mm,0.6mm & 0.4mm)

Temperature probe entry gland

Dual temperature meter

Sampling (service) pipe

Fig: (iii)

8

DRYNESS TEST KIT

Pitot Tube (0.8mm, 0.6mm & 0.4mm)

Rubber tubing

Rubber bung and SS tube assembly

1 Liter vacuum flask

Weighing balance

Dual temperature meter

Sampling (service) Pipe

Fig: (iv)

9

NON CONDENSABLE GAS TEST

SETTING UP

Assemble equipment together as illustrated in Fig. (v) place on table top. Check that the

steam valve on the test equipment is fully closed and that the cooling water valve is fully

open.

Fig: (v) Fig:(vi)

Connect the cooling water supply pipe to the running water source at one end and the

cooling water inlet on the condensing unit at the other (Fig. v).Connect another pipe from

the cooling water outlet to drain or a bucket. Please note that the water from the water

outlet may be very hot and care should be taken to ensure that it can run to drain without

blockage and spillage.

Isolate the steam supply and after checking that no residual pressure is present, connect

the hose pipe for steam supply tubing to the non condensable gas take off point steam

control valve. Take care, as the steam pipe may be hot and residual steam may be

present. Connect the other end of the hose tube to the steam connection of condensing

unit and turn the steam supply back on. Carefully open the Steam control valve a small

amount. 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.

Needle valve

Drain

Water Inlet

Water Outlet

10

Do not block the flow of cooling water .The cooling water outlet must be kept clear at all

times.

PERFORMING THE TEST

Turn on the water supply to supply the cold water to the cold water inlet. 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 may present a hazard. In any event,

precautions should be taken. Do not look into collecting chamber and wear eye

protection.

Fill the condense collection chamber with water either by filling with water from an

external source, or allowing condense to accumulate.

Water level should be in Zero position

Ensure that the sterilizer chamber is empty except the normal furniture etc. select a

Porous load / equipment cycle and start a run.

When the steam supply to chamber first opens, ensure the measuring cylinder is empty,

by emptying it.

Any non- condensable gases present in the steam being sampled will rise to the top of the

Collection tube when closed the valve.

When at least 100 ml of condense has been collected in the measuring cylinder note the

volume of gas collected in the non condensable gas collection tube (V1) and the volume

of water collected in the measuring cylinder(V 2).

Calculate the fraction of non- condensable gases as a percentage as follows:

Percentage of non condensable gas = 100 X (V1/V2).

11

ACCEPTANCE CRITERIA

The test should be considered satisfactory if the fraction of non condensable 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.

NOTE: Calculations are included on an enclosed pen drive.

12

THE SUPERHEAT TEST

SETTING UP

Fig:(vii)

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 centre of the steam

pipe. Insert pitot tube 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.

Insert temperature sensor through gland in expansion tube and position it so the sensing

point of the thermocouple element is in the geometric centre of the expansion tube.

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

protections must be worn.

13

PERFORMING THE TEST

Select and start a porous load / equipment cycle.

From the measured temperature, note the temperature in the steam service pipe (for use

in the dryness test) and in the expansion tube (T e) when the steam supply to the chamber

first opens.

Calculate the superheat in o C from the following equation. Superheat = T e - T o

Where T o is the boiling point of water at local atmospheric pressure.

ACCEPTANCE CRITERIA

The temperature is considered to be acceptable if it is less than 25 C above that of

the local temperature of boiling water

14

DRYNESS TEST

SETTING UP

Assemble the apparatus as per Fig. (viii)

Fig: (viii) Fig: (ix)

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 centre of the steam pipe. Insert

pitot tube 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.

15

PERFORMING THE TEST

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 ~ 80 o C is not normal. It should take no more than 5 minutes.

Weigh the whole assembly including pipe and clips and note the weigh (ME).

Remove the stopper and tube assembly and pour 650 50 ml of cold water (below 27 o

C) into the flask. Replace the stopper and tube assembly, weigh the flask and record the

mass (MS).

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.

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

(T1).

Ensure the sterilizer is empty for the usual chamber furniture. Select and start a porous

load / equipment cycle.

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.

Observe / record the steam temperature for the duration of the test and on completion of

the test calculates the average temperature (T2).

T3 = Temperature of dry saturated steam in C

16

Weigh the flask and stopper assembly including pipe and clips and note the mass (MF).

Calculate the dryness valve by using the following formula.

D = [(T1-T2) (CPW (MS-ME) +A] / [L (MF-MS)] - [(T3-T2) CPW] / [L]

Where

D = Dryness value

L = Latent heat of the dry saturated steam at T3 temperature in kj/kg.

ME = Mass of flask in Kg.

MS = Mass of (flask + water charge) in Kg.

MF = Mass fo (flask + water + condensate) in Kg.

T1 = Initial Temperature of water in flask, in C

T2 = Final temperature of water and condensate in the flask, in C

T3 = Temperature of dry saturated steam in C

CPW = Specific heat capacity of water (4.18 kj/kg. K)

A = Effective heat capacity of apparatus (0.24 kj/K)

Note. The formula has been modified for stainless steel flasks and dip tubes instead of

glass, as detailed in HTM 2010.

ACCEPTANCE CRITERIA

The dryness value is not less than 0.90 (If metal loads are processed, the dryness value

should not be below 0.95).

Throughout the operating cycle, the temperature measured in the steam service pipe is

within 3o C of that measured during the superheat test.

NOTE: Calculations are included on an enclosed pen drive.

17

REPORT FORMAT

Fig: (x)

18

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 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 fiber 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 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.

19

CARE AND MAINTENANCE

The Hose Pipe, will with bending, become work hardened, which will lead to difficult in

returning it to the tight radius required for storage. In this Instance, it may be easily

replaced.

Cleaned and dried the Equipments after completion of the test.

Electronic equipments should protect from water/steam.