01 Paper Machine Steam & Condensate Systems PDF

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CONFIDENTIAL:
MINNESOTA TOBACCO LITIGATION
Paper Machine Steam and

Condensate Systems
Fourth Edition, Revised
A PROJECT OF THE
WATER REMOVAL COMMITTEE
OF THE
ENGINEERING DIVISION
CA4843
EDITED BY
ROBERT D. PERRAULT
it$SI856fbi
V.
http://legacy.library.ucsf.edu/tid/tbh48h00/pdf
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2030307401
CONFIDENTIAL:
The information and data contained in this document were

prepared by a technical committee of the Association. The
committee and the Association assume no liability or responsibility
in connection with the use of such information or dwa, including
but not limited to any liability or responsibility under patent,
copyright, or trade secret laws. The user is responsible for
determining that this document is the most recent edition
published.
Within the context of this work the authors may use as examples
specific manufacturers of equipmeni. This does not imply that these
manufacturers are the only or best sources of the equipment or that
TAPP1 endorses them in any way.
The presentation of such material by TAPPI should not be
construed as an endorsement of or suggestion for any agreed upon
course of conduct or concerted action.
International Standard Book Number 049952-5Q4-7
Library of Congress O t a l o f i n i - f r Publication Data
Paper machine steam and condensate systems: a project of
the Water Removal Committee of the Engineering
Division / edited by Robert D. Perrault - 4th ed., rev.
p. cm.
<^*y
T
ISBN 0-39852-504-7
^wtfO
I. Papermaking machinery. 2. Drying apparatus. V \ t " *
I. Perrault. Robert D.
TSIII8.D7P37I990
67e'.232-dc20
90-41193
CIP
Copyright 1990, 1982, 1977,1970 by

TAPPI
Technology Park/ Atlanta, P.O. Box 10S113
Atlanta, G A 30348-5113
Allrightsreserved.
Permission of TAPPI is granted to photocopy items for internal or

personal use of specific clients, for libraries or other users provided
that the copying organization pay the ease Zee of SIM VS. per
copy, plus S.50 U.S. per page directly to the Copyright Clearance
Center, 27 Congress Street, Sakm, MA, 01970, U.S.A. 089852-504-7
51.00 +$.50 pp.
fm\J 3 U u U ' ^ v t f
Printed in the United States of America

R0 96
2030307402
CONFIDENTIAL:
FOREWORD
CtK-4
The purpose of this book is to provide papermakers and those called unA^to* solve dryingrelated problems a basic understanding of the paper machine steam and condensate systems.
The original book was published in 1970 as a result of a Pressing and Drying Committee
assignment. The book was revised in 1977 and again in 1982. This fourth edition published
in 1990 has been expanded to include the new developments and innovations of the past few
years.
The material in this book is not intended to cover the theory of drying or the operations
and theory of individual pieces of equipment There are many excellent papers available on
these topics, and they will not be duplicated here.
This book is reviewed every five years by the members of the Water Removal Committee
of the TAPPI Engineering Division. The committee welcomes your comments and suggestions.
Please send your suggestions to the attention of the editor for consideration at the next revision.
2030307403
2030307403
-N^SNTJAL.
CONTRIBUTORS TO THIS AND PREVIOUS EDITIONS
C^tri^
Nick De'vich, A bitibi-Price Inc., Sheridan Park, Mississauga, Ontario, Caii^w

Horace P. Fish wick, Retired /Consultant, Norwood, MA
Thomas A. Gardner, Gardner Systems Corp., Neenah, WI
Stanley P. Garvin, Beloit Corporation, Beloit, WI
Alan F. Hartwig, Champion International, Hamilton, OH
Edward D. Hoyle, Stone & Webster Eng. Corp., Boston, MA
Robert B. Hurm, Retired, Beloit, WI
Lawrence J. McDonough, Retired/Consultant, Three Rivers, MI
John P. O'Donncll, Ametek, Schutte & Koerting Inc., Bensalem, PA
Ivan 1. Pikulik, Pulp & Paper Research Institute of Canada, Pointe Claire, Quebec
John S. Porter, Jr., Milton J. Wood Co., Jacksonville, FL
Richard A. Reese, CRS Sirrine Co., Greenville, S.C.
R. Jerry Retter, Valmet Enerdry, Norcross, GA
Travis Sizelove, Retired/Consultant, South Beach Haven, NJ
Harry J. Stratton, Retired/Consultant Cheltenham, PA
Gregory L. Wedel, Beloit Corporation, Beloit, WI
Robert E. White, Villanova University, Villanova, PA
Many of the contributors to this manual could easily write their own books covering dryer
drainage systems. It was not possible to get all the contributors to agree on all points covered
in this manual. In those cases where there was disagreement, the majority opinion as interpreted
by the editor is stated.
2030307404
A very special thanks to all the contributors who spent many long hours proofing and advising
in the preparation of this book.
2030307404
CONFIDENTIALMINNESOTA TOBACCO
UTOAVION
CONTENTS
Foreword / Hi
Contributors / iv
Introduction / vii
Steam Control and Condensate Evacuation Systems Deflgn/1

1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1. 10
General/ 1
Basic steam pressure control system / 1
Multiple pressure control sections / 1
Automatic differential pressure control / 2
Dryer temperature control using a vacuum system / 3
Pressure and temperature control for each dryer section / 3
Simple three-section cascade dryer section / 5
Positive pressure control loops for wet end dryers / 6
Low pressure wet end dryer / 6
Temperature control of wet end dryers / 7
After size drying control / 8
1.11 Single felted dryer section / 8

2
Thermocompressors (THC) / 9
2.0
General / 9
2.0.1 Construction and operation / 9
2.0.2 Advantages and disadvantages of thermocompressor systems / 9
2.0.3 Performance/ 10
Thermocompressor Systems / 13
2.1 Thermocompressor pressure control system / 13
2.2 Thermocompressor pressure control system with differential control valve / 13
2.3 Dryer differential control using the thermocompressor spindle / 14
2.4 Thermocompressor cascade system / 14
2.5 Yankee dryers/ 15
Blow Through (Flow) Control for Dryer Drainage Systems /17
3.0
3.1
3.2
3.3
General / 17
Blow through control principles / 17
Blow through control installation / 18
Yankee or single dryer blow through control system / 19
2030307405
Mechanical Vapor recompression (MVR) / 21

4.0
4.1
General / 21
Advantages/ 21
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CONFIDENTIAL:
5
Dryer Drainage System Controls and Equipment / 23

S.O feneral / 23
5. t Pressure control / 23
5.2 Differential pressure control / 23
5.2.1 Transmitter installation / 23
5.3 Separator control / 24
5.4 Vacuum system / 24
5.4.1 Vacuum pump / 25
5.4.2 Condenser (heat exchanger) / 25
5.5 Effect of air in steam / 26
5.5.1 Noncondensable bleeds / 27
5.6 Syphons for paper machine dryers / 27
5.7 Effect of centrifugal force / 28
5.8 Drive horsepower and dryer condensate load / 29
^ <
Troubleshooting, Check-out, Start-up, and Shutdown of Dryer Drainage^ fe

Systems/ 31
JP*W*"
6.0
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
Equipment Check-out / 31
General installation / 31
Control valves / 31
Separators / 32
Condensate pumps and motors / 32
Vacuum pump / 32
Heat exchanger (HE) / 32
Thermocompressor (THQ / 33
Steamfit and piping / 33
Controllers / 33
Systems checkout -flushingnew systems and rebuilds / 33
Shutdown procedures / 34
6.11.1 Cold shutdown / 34
6.11.2 Warm shutdown / 34
6.12 Sheet breaks / 34
6.12.1 Long breaks / 34
6.12.2 Short breaks / 34
6.13 Operating problems and trouble shooting / 34
6.13.1 Low differential pressure / 35
6.13.2 High differential pressure / 35
6.13.3 High drive torque / 35
6.13.4 High separator level / 35
6.13.5 Very low separator level / 35
6.13.6 High steam pressure / 35
6.13.7 Low steam pressure / 35
6.13.8 High steam usage per pound of water evaporated / 36
6.13.9 Loss in production rates / 36
'
'$3
^
2030307406
Glossary / 87
Legend for Figures / U0
w
2030307406
CONFIDENTIAL:
Introduction
The main objective of paper machine steam and condensate systems is to provide control of
steam pressure in the dryers and optimal drainage of the dryers over the range of machine speeds
and production rates, under all operating and upset conditions.
To achieve this objective, it is necessary to provide effective and efficient removal of condensate
and noncondensible gases. The intent is to provide the highest heat transfer rate possible for
a given pressure by the most economical and optimum means.
The drying of a sheet of paper is a complex process. Experience has shown that all grades
should be dried with surface temperatures commensurate with what the sheet at the first stages
of drying can withstand without loss of quality. Very hot dryers right after the press section
can create nonuniformities in the sheet, such as cockling, curling, picking, surface sealing, grainy
edges, rough sheet surface, and loss in drying rate.
The ever-increasing speed of paper machines has created new problems with respect to effective
condensate removal. These challenges have prompted the development of new, more effective
dryer drainage systems, better controls, more efficient syphons, and improved design standards
and criteria.
-.
This revised book covers the basic design, operation and control of equipment necessary fopjy
the proper operation of efficient steam control and condensate removal systems.
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2030307407
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2030307407
^ \ j t \ r
I D t z N T
A L '
Steam Control and Condensate Evacuation Systems Design
1.0 General
Each dryer drainage system should be designed to fulfill
the specific requirements of the machine and of the
various grades of paper. There are no two systems exactly
alike. Older systems are rarely designed properly and
adequately in view of recent developments and practice.
Over the years, lines and valves are often added that can
adversely affect their operation. Changes to a dryer
drainage system should be made only after a thorough
investigation, and they should be made only by persons
or companies qualified and having the necessary design
formulae and experience.
Please note that all symbols used on figures are defined
in the Legend for Figures, p. 40.
which supplies steam tA\f the dryers and dumps

condensate to the sewer as shown on Fig. 1.1. A fixed
restriction can be installed in the drain line from each
individual dryer to limit blow through steam. Some
cylinder board machines are still operating this way.
In the system illustrated in Fig. 1.1, all dryers operate
at the same pressure. Unless the operating pressures and
resultant surface temperatures are low, sheet picking and
sticking and other related problems can result on the wet
end dryers. Production is directly related to dryer
operating pressure. Therefore, if pressures are reduced
to eliminate the above mentioned wet end problems, the
capacity of the machine will be limited.
In addition, the treated boiler water (condensate) and
its heat value along with the blow through steam are
lost to the sewer, making this system thermally inefficient
1.1 Basic steam pressure control system
1.2 Multiple pressure control sections

The evolution of dryer drainage systems has been
improving with developing technology and the need for
steam economy and better control of the drying system.
The simplest but least efficient steam and condensate
system consists of a pressure-controlled steam header
The first logical step is to isolate several of the wet end

dryers into a separate dryer section with its own steam
supply and control loop. The drying pressure and
resultant surface temperature of these wet end dryers may
STEAM SUPPLY
rO PC
PCV
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DRYER SECT I Of J
PRESSES
SEWER
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2030307408
Fig. l.l Basic steam pressure control system.
2030307408
2/ P$per Machine Steam and Condensate System
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STEAM SUPPLY
PC
PCV
PCV
PCV
tf
PRESSES
WET ENo
SECTION
NTEftMEBIATE
iLtf
MAIM
SECTION
PC
REEL
SECTION
SEWER
Fig. IJ Multiple pressure controlled sections.

then be reduced without significantly reducing the drying
capacity of the machine. Should the required drying
pressure be high, it could be necessary to add a third
dryer section which would operate at some intermediate
pressure between the wet end and main dryer sections
(see Fig. 1.2.).
Dryer outlet pressures will always be above atmospheric pressure in these systems, since the dryers are
continually discharging to the sewer from the condensate
outlet lines from the dryers. As dryer operating pressures
are raised, blow through steam quantity and velocity will
increase. In addition to the waste of steam due to
excessive blow through, the increase in velocity will
accelerate the rate of erosion of dryer syphons and piping.
The fixed restrictions located in the condensate outlet
lines from the dryers may be replaced by adjustable
restrictors which are manually adjusted to compensate
for changes in dryer operating pressure. Any substantial
increase in dryer operating pressures would require that
the amount of restriction be increased to limit blow
through. Conversely, a decrease in operating pressure
must be compensated for by opening the restriction to
ensure sufficient flow of blow through steam. These
devices should be utilized only on dryers whose range
of operating pressure is somewhat limited. The major
disadvantage of adjustable restrictors lies in the difficulty
in obtaining and maintaining correct settings to ensure
proper blow through rates.
For improved drying performance, machines having
dryer sections equipped with fixed or adjustable orifices
should remove all such restrictions and install automatic
differential controls when possible.
1J Automatic differential pressure control
The next logical addition to this simple steam system
is the direct control of the differential pressures between
the supply headers and the condensate headers. This
addition is called differential pressure control.
< & *
The term "differential pressure," or "DP," can be
confusing. This term is defined as the difference in
pressure between the dryer steam supply header and
dryer condensate header. Other differential pressures will
be qualified, such as "differential pressure across the
steam joint" at the dryer or "differential pressure between
cascading sections."
The basic method of automatically controlling
differential pressure is shown in Fig. 1.3. This control
consists of a differential pressure transmitter (DPT),
which is connected to pressure taps in the steam and
condensate headers and measures the differential
pressure between the condensate header and the steam
header. It then sends a pneumatic or electrical signal to
a DP controller (DPC) which adjusts a control valve
to maintain the condensate pressure at a value lower than
that in the steam header by a set fixed amount.
The DPT measures the differential pressure between
the headers, and is used as part of the control system
to maintain the necessary DP. The most important
differential, however, is the one across the steam joint
The specified DP should be simply the pressure drop
across the steam joint. This DP may be considerably less
than the DP between headers, especially if the connecting
pipes are small. For this reason, pressure gauges should
be installed on one dryer in each steam section, in order
to relate the header DP to the specified steam joint DP
required.
The header DP includes the piping losses to and from
the steam joint, losses within t ^ f t ^ B f r o Q M j Q Q K
losses, dynamic losses or g a i n s ^ M w ^ t n f u ^ f f o r c e ,
and potential kinetic energy of the condensate. Note that
piping losses from the inside of the dryers to the drain
manifold involves two-phase flow.
The differential pressure between cascading sections
(these will be discussed later) will be more than that
measured across headers because of the additional
pressure drop which occurs in the separator, valves and
piping between cascading or recirculating sections. That
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2080301449
2030307409
ILJtZ
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Starn Control and Condensate EvMcuMtion Systems Desi

STEAM SUPPLY *
TPCV
PRESSES
WET ENO
SECTION
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-0-XDPCV
MAIN
SECTION
INTERMEDIATE
SECTION
-CHfePCV
ff
REEL
-O-XOPCV
SEWER
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Fig. 13 Automatic differential pressure control.
is, the pressure in a secondary dryer section will be less
than the pressure in the primary section minus the
previous section differential pressure.
1.4 Dryer temperature control using a vacuum system
Some grades of paper generally require low dryer surface

temperatures, especially at the wet end of the dryer
section. One way to reduce the temperature of steam is
to introduce air into the steam. This can result in uneven
drying by creating pockets of air inside the dryer due
to ineffective mixing of steam and air. Furthermore, it
causes a major loss in heat transfer as a result of
accumulating air in the film at the steam-condensate
interface. Purposely admitting air in steam is not a
common practice and is generally not recommended.
The most widely accepted method for reducing dryer
surface temperature is to reduce dryer pressure below
atmospheric pressure with the help of a vacuum system
as shown on Fig. 1.4. The resulting dryer pressure and
steam temperature available depends on the vacuum
created in the system.
Blow through and flash steam from the wet end dryers
is condensed by the heat exchanger. This becomes a
closed system, with the condensing of the steam creating
a vacuum or negative back pressure. Noncondensable
gases and some water vapors are removed from the
system through the use of the vacuum pump.
If economy of operation was not a concern, the system
design could be considered complete with the arrangement shown in Fig. 1.4. The system gives complete
control of steam and condensate pressures. The
evacuation of condensate, air and other noncondensable
gases is assured over the complete range of operating
conditions: run, start-up or break. Additional dryer
sections might be required for control from a breaker
stack or size press, for graduated pressure (temperature)
control or for trimming; however, the control of these
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sections would be* no different from those already
discussed, and the sections and individual dryers would
discharge to the sewer or the vacuum system, depending
on the minimum drying pressures required.
The continuous evacuation of condensate, air and
other non-condensible gases from the dryers assures,
within the limits of dryer drainage control, even drying
of the sheet, and heat transfer to the sheet improves.
1.5 Pressure and temperature control for each dryer
section
Fig. 1.5 shows a further improvement of the basic dryer

drainage system. Condensate is separated from the blow
through steam in the main and intermediate sections. The
condensate can be pumped back to the steam plant for
reuse. This provides a significant savings in energy use
and as boiler feedwater chemical consumption.
Design of the heat exchanger, or vacuum condenser,
plays an important economical part, in that large
quantities of water vapors may be lost to the sewer
through the vacuum pump if the condenser is incapable
of handling all blow through and flash steam under peak
load conditions. The subject is covered in detail under
the section on vacuum systems.
Condensate from the machine is approximately
saturated at the pressure in the s y ^ c P V v f t ^ i F W t c
temperatures may range from-HylQÔaiW^lUhc
vacuum system to as high as 350 "F in pressurized
systems.
Fig. 1.5 illustrates one method of maintaining the
pressure and temperature of the condensate from each
dryer section so that it may be returned at maximum
temperature to the boiler house or to some other mill
process.
Condensate and blow through steam from each dryer
section are directed to a separator tank where the velocity
of the mixture is sharply reduced, and direction of flow
2O3O30TW
2030307410
4/ Paper Machine Steam and Condensate Systems
AAMrirvi-i . . .
CONFIDENTIAL:
r O c rO PC
-QPC -QoPC
&
WET END
PRESSES
MINNESUIA rOBAfcftp I iTiriJriqa
STEAM SUPPLY -
)DPC
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SECTION
SECTION
* 5 DPCV
PCV
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MAIN
SECTION
tEEL
<H(DPCV
<H( OPCV
MANIFOLD I
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OPT
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SEWER
I vc "lny^@
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VP
CP
SEWER
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Fig. 1.4 Dryer temperature control using a vacuum system, o v ^
STEAM SUPPLY
>PC
lDPT
PRESSES
PC J ^PC
>PT
pcv
WET ENO
SECTION
AJ7
OPCV Y
)PC J }>PC
)PT
pcv
INTERMEDIATE]
SECTION
^
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MAIN
REEL
SECTION
TDPCV
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2030307411
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CP
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LCV
CP
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Fig. 1.5 Pressure and temperature control for each dryer section.
2030307411
V i / v J I M l f L/CHI N I Ir\L- B
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MINNESOTA TOBACCO LITIGAT)
3 requiring low pressure steam. Discharging to the

is reversed. This causes the denser condensate 1o
atmosphere is a last resort. Cascading ratios are designed
separated from the steam. Level of condensate in t
so that all the blow through steam can be condensed
separator tank is maintained through the use of a level
in the next dryer section under all operating conditions
controller which positions a level control valve to throttle
with a sheet on the machine. Otherwise, it would not
the discharge of the condensate pump. Control of
be possible to control differential without wasting steam.
condensate level within the tanks ensures that the system
will remain sealed and that sufficient steam space volume
Simple cascade systems such as the one shown in Fig.
is maintained above the liquid level to ensure separation
1.6 provide little flexibility of operation. Pressure in the
of condensate and steam.
cascading sections is dictated by the differential required
In order to have a truly economical system, some use
in the preceding sections to properly evacuate the
must be found for the blow through steam without
condensate. Changes in pressure or drying have to be
made with the main dryer section, and all of the dryers
limiting flexibility of operation within the requirements
in the cascaded sections will follow this pressure change.
of the machine, or sending this blow through steam to
the atmosphere or heat exchanger. Wet end steam
It is difficult to make minor changes in drying rate. This
showers or hood heaters can be two good uses for flash
is particularly a problem for machines that are dryer
and blow through steam.
limited because of the need to maintain DP's between
cascaded sections. Another limitation of cascade systems
is that all of the dryers cannot be operated at maximum
1.6 Simple three-section cascade dryer section
pressure. This results in loss of potential production.
Cascading systems may require more dryers to obtain
The cascade method of reusing blow through steam can
the same production as non-cascading systems.
provide a very efficient dryer drainage design. There are
An incidental advantage of cascade systems is that
many variations of cascade systems. A simple threecondensate pumps on the cascading separators can often
section cascade dryer section is illustrated in Fig. 1.6.
be eliminated as shown on the main section in Fig. 1.6.
Cascade systems are popular and used where steam
The differential pressure created is sufficient to push
economy is important. As a rule of thumb, blow through
condensate to the next section. This may require a slightly
from two to three dryers can be discharged or cascaded
larger intermediate separator and condensate pump, but
into one dryer, normally from the dry end of the machine
it eliminates a pump and motor.
to the wet end. The last stage at the wet end usually
In this system (Fig. 1.6), the vacuum system should
discharges to a vacuum condenser or other mill process
STEAM SUPPLY*,
Ore
iOPC
1DPCV
)PT
PRESSES
WET END
SECTION
rO'
iDPCV
INTERMEDIATE
SECTION
MAIN
SECTION
REEL
CHV
>*W- ,
DPCV
VB
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2030307412
r 4 -&r& ^znk
SEWER
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LCV
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Fig. 1.6 Simple three-section cascade dryer system.
2030307412
CONFIDENTIAL
NNES
6 / Paper Machine Steam and Condensate Systems
^ O B A C C O LITIGATION
be sized to condense all blow through from the w w e # 7 taction dryers of the system shown in Fig. 1.7 could be
and intermediate sections. It is not economical $ # as low as 15 psig and, on high speed machines requiring
1
relatively high differential pressures, probably closer 10
necessary to design die condenser to condense blow
24 to 28 psig.
through from the main section.
While minimum pressures of 24 to 28 psig are
satisfactory on many machines, some, producing fine
1.7 Positive pressure control loops for wet end dryers
papers and light weight sheets, require lower pressures
in all dryers. A method of obtaining these low wet end
The main disadvantage of the system indicated in Fig.
pressures is illustrated in Fig. 1.8.
1.6 is that operating pressures for the wet end and
intermediate dryer sections are wholly dependent on the
1.8 Low pressure wet end dryer
pressure being carried in the main section dryers. A
section which is on automatic differential control will
Several grades of paper may require one or more
always operate at a pressure less than the cascading
individually controlled dryers. A group of dryers would
section by an amount approximately equal to the
have to operate all the dryers at the lowest pressure
differential required across the cascading dryer section.
required not to pick or damage the sheet during the early
A partial solution to this problem is shown in Fig.
phases of drying. For this reason, individual dryers can
1.7. A pressure control loop is furnished for the wet end
be controlled, as shown in Fig. 1.8. This arrangement
dryers. Wet end pressures may be reduced independently
permits a gradual increase of dryer pressures and sheet
of the pressure required to maintain correct differential
temperature as required.
across the intermediate section dryer syphons. Differential control of the intermediate section remains
Individually controlled wet end dryers may reduce
unchanged. This control gives the machine operator the
picking on the wet end dryers. They also reduce the
option of controlling the wet end dryers at a low pressure
possibility of high dryer surface temperatures which can
or, by raising the set point of the wet end pressure
also cause the sheet tofloatoff the dryer surface in whole
controller to fully open the pressure control valve,
or in part.
operating the system as a straight three-section cascade.
This control gives the machine operator the option
of controlling these dryers on either "three-section
Group control of several wet end dryers may be
cascade" or "two-section cascade."
accomplished as described above.
Minimum available operating pressures in the main
STEAM SUPPLY *
PRESSES
REEL
2030307413
r i -feii zr
VP
CP
CP
SEWER
Fig. 1.7 Pressure control for wet end dryers.
2030307413
CONFIDENTIAL:
M I N N E S O T A T O B A C C O
On "three-section cascade," control is sirrujarôVBT^

described for the system shown in Figure 1.7. %a$&P
steam for the wet end dryers is supplied from thesteam
header of the intermediate section, however, this has no
effect on the control. The valve in the line between the
headers throttles makeup steam when required. When
blow through from the intermediate section exceeds the
requirements of the wet end dryers, the makeup valve
will close, and the excess steam will be throttled to the
vacuum systemTo go to "two-section cascade," the selector switch is
set to block the output of the intermediate section
differential controller and to direct a full range signal
to fully open the makeup control valve. The system
headers for the first two dryer sections are now common
and, except for a slight loss across the makeup valve,
will operate at the same pressure. Intermediate section
differential will be maintained by throttling all blow
through steam directly to the vacuum system. Reverse
flow is prevented through the use of a check valve. Main
section presure may now be reduced by an amount
approximately equal to the differential pressure required
across the intermediate dryer section.
The control is of use not only in meeting the
requirements of drying the sheet but also as an aid in
rapid evacuation of the dryers during startup due to the
elimination of one cascade section.
The basic three-section cascade system and some
variations to the system have been covered. There are
(TIP)
Systems Dtsiga / 7
many variations of the systems shown here.

The cascade system is the most efficient system from
the steam usage standpoint, providing that flexibility of
operation is not a prime requisite. If an increasing
temperature or pressure gradient is to extend the length
of the machine, the simple cascade system will usually
suffice, and steam consumption per ton of paper will
be at a minimum.
If, on the other hand, some machine flexibility is
required and a modified cascade system is used, both
equipment requirements and steam usage will increase.
The cascade system has been utilized successfully for
many years; however, it does have limitations. If these
limitations are recognized, a machine employing this
system will operate efficiently with minimum expenditure
for dryer drainage equipment
1.9 Temperature control of wet end dryers
Temperature control of dryers is largely obsolete and
generally not recommended. Some older machines still
use this method. There are many problems, and poor
accuracy is obtained with temperature control.
For those grades such as glassine that require very
accurate, low, and graduated dryer surface temperatures,
pressure control instead of temperature control of each
individual dryer is recommended.
STEAM S U P P L Y * -
Q " Q Q Q
rvn
PCV
MA I K
SECTION
J?
PC
REEL
2030307414
LCV
VP
SEWER
CP
CP
Fig. 1.8 Low wet end dryer pressure.
2030307414
CONFIDENTIAL-
81 Paper Midline Steam and Condensate Systems

IVM
1.10 After-size drying control
ig^SOTA TOBACCO LITIGA I
i w
a^ . FSingle felted dryer section

J&J^XI
After-size drying control is generally along the sanfclti&

as the main section. Ifesic concepts that are generally
agreed upon include several individually controlled
dryers to warm up the sheet and reduce dryer surface
picking, followed by separate control of top and bottom
dryers for sheet curi control. Steps to conserve steam
are also important, and some method of reusing blow
through steam by cascading or use of thermocompressors
is common. (A detailed discussion of thermocompressors
can be found in the next section.) For maximum reuse
of blow through steam, some mills install thermocompressors on individual top and bottom dryer groups.
Figure 1.9 shows a typical after-size drying control with
individual control dryers, cascading, and top and bottom
dryer pressure control for curl control.
Other variations of the typical arrangement shown by
Fig. 1.9 are as follows:
(a) Top and bottom dryers with recirculating THCs
instead of cascading as shown.
(b) Top and bottom sections can discharge optionally
into one separate tank system, instead of two as
shown. This would require one DPCV for the top
section and one DPCV for the bottom section.
This system is difficult to control and is not usually
recommended.
There are many special cases requiring customized

condensate removal design. Such a case is the singlefelted dryer section in which the top felt follows the path
of the paper web in the dryers, normally in the first wet
end group of dryers. This creates a special condition
because the top dryers which directly contact the sheet
have high condensing loads, while the bottom dryers that
only contact the felt have small condensing loads.
Excessive blow through rates result from the small
condensing loads of the bottom dryers because there is
not enough liquid in the syphons to impede the flow
Many mills have shut off steam to the fabric side (bottom)
dryers or disconnected the steam and condensate
connections altogether.
Other mills have reduced the syphon pipe size to reduce
blow through steam to less than half of previous rates.
Another option is to provide separate or individual
controls to the top and bottom dryers similar to aftersize dryer controls. In this case the bottom dryers are
set to a lower pressure than top dryers and usually not
changed from this setting. The best option is separate
control of top and bottom single-felted dryer sections.
MAIN STEAM SUPPLY
(TIP) urt
6P5
ABCDEFG Ht
,111,111,111,
DPT]
TOP
DRYERS
HE
<>
03 &07
Fig. 1.9 Typical after-size drying control with individual control dryers, cascading, and top and bottom dryer pressure
control for curl.
2030307415
-SSKSBgffib,
Thermocompressors (THC)
GÂjW&fgned unit can waste high pressure motive steam and

"
<^& suction steam if it cannot be recirculated. Under some
A thermocompressor is a device that uses high pressure
conditions of operation, usually at low steam pressures,
steam to entrain steam at lower pressure and discharge
a thermocompressor may "choke" because the diffuser
the mixture at some intermediate pressure. Thermothroat cannot pass all of the mixed steam. When this
occurs, an increase in motive steam causes a decrease
compressors have been available since the early 1900s
in suction steam.
and in recent years have enjoyed rapid growth in popularity in the paper industry. They are simple and versatile
2.0.2 Advantages and disadvantages of thermocompresand can be designed to operate above atmospheric or
sor systems
at sub-atmospheric pressures. They consist of few parts
and have a reasonable range.
Advantages:
Thermocompressors that are generally used on a paper
A. Allows maximum pressure in all dryers, resulting in
machine are either of the fixed nozzle type with a
maximum production rates, and allows independent
throttling control valve in the motive steam supply line
operation of each steam section.
or of the type with an automatically controlled spindle,
B. Allows minimum pressure in all dryers when drying
usually called variable orifice. The latter is the most
capabilities exceed demands. This reduces the need
prevalent and is more efficient because the full velocity
and frequency of shutting off dryers.
energy of the motive steam supply is utilized even at low
flow.
C Allows individual control of smaller dryer sections
and better moisture level and speed optimization
2.0.1 Construction and operation
control.
D. Recirculating steam reduces steam blowing to the
The basic thermocompressor consists of a body, diffuser,
heat exchangers or atmosphere.
nozzle, spindle, and cylinder or diaphragm actuator with
E. Provides a wide control range, especially to low
a positioner to actuate the spindle. Fig. 2.0.1 illustrates
pressures when used in conjunction with blow
this.
through control (see Section 3).
Motive steam is expanded in the nozzle from the inlet
F. More stable with blow through control because of
pressure to that in the suction chamber, where the
floating differential.
pressure energy is converted to velocity energy. The
motive steam leaves the nozzle at high velocity in the
Disadvantages:
order of 1500 to 2500 ft/s. Lower pressure suction steam
A. High pressure motive steam required. Normally
is mixed and entrained in the motive steam flow stream
requires at least SO psig above maximum dryer
as it passes through the suction chamber. Part of the
operating pressure.
momentum of the motive steam is transferred to the
B. A high pressure motive s j g i v a Q 3 Q 7 4 a B v e d
suction steam. The mixed steam at an intermediate
from the power house.
***
velocity enters the diffuser, where the mixture velocity
C. May result in less electrical power generating
decreases as the velocity energy is converted to pressure
capacity.
energy at the discharge.
D. May tend to choke at low pressure due to large
A thermocompressor can be a useful tool if the correct
motive steam flow volume filling the throat and
information is provided for design. An incorrectly
causing back pressure at the suction.
2.0 General
2030307^16
2030307416
CONFIDENTIAL:
MUNMFBnTA T D R A r m LITIGATION
HIGH
PRESSURE
MOTIVE
STEAM
P,0RPM
WtORWii
NOZZLE
PISTON ACTUATOR
DIFFUSER
ItSM
SPINDLE
POSITIONER
DISCHARGE
STEAM
P2 0RP D
Wj0RWD
BODY
SUCTION
STEAM
LOWER
PRESSURE
P30RPs W30RWS
^
Fig. 2.0.1 Basic automatic thennocompressor.

E. Have limited turndown control with differential
pressure control.
2.03 Performance
Thennocompressor performance is of two types, critical

and noncritical, based on compression ratio. Compression ratio is defined as the discharge absolute pressure
divided by the suction absolute pressure. Ratio * P2/
P (absolute units).
In general, when the compression ratio is two or more,
performance is termed critical. This type of performance
produces sonic velocity in the throat of the diffuser. While
this does not often occur in thermocompressors used on
paper machines, it can occur if wide ranges of operation
are required. An example would be a dryer section
operating at IS psig, with a 15 psi differential.
The other type of performance is termed noncritical
and does not require sonic velocity in the diffuser to
achieve the desired compression. Most dryer drainage
systems utilize noncritical compressors, and the suction
capacity varies directly with motive flow at a given
discharge pressure. If the motive flow increases and
additional suction flow is not available, differential
pressure will increase until equilibrium is established.
The performance of a thennocompressor is generally
evaluated for several anticipated operating conditions,
but normally a minimum and a maximum operating
point are sufficient. Design data required by the
thennocompressor manufacturer to properly size the unit
includes motive pressure and temperature, suction
pressure, discharge pressure, suction flow, and condensing load for the specified operating conditions. The
calculations are then made on maximum-minimum
conditions, and a design is determined. The final design

is usually determined by the minimum operating
condition. An example of initial requirements is shown
in Table 2.0.3. In this example, the motive flow and size
were based on the design for minimum conditions.
Additional calculations are made to evaluate thennocompressor performance at other operating and upset
conditions. Special thennocompressor curves such as
those in Figs. 2.0.3.1, 2.0.3.2 and 2.0.3.3 have been
developed for this purpose.
Compression pressures of 4,8, and 12 psi were selected
in these curves. The motive flow (Wi) curve moves
toward and crosses the suction flow curve (W,) as
compression increases and R* decreases. This shows the
required increase of nozzle energy to achieve higher
Table 2.03 Example of initialrequirementsfor a thennocompressor
Max.
Min.
Motive Steam, psig (Pi)
Temperature, *F
Discharge Pressure, psig (P2)
Suction Pressure, psig (P.)
Compression, psi (P2-P.)
Suction Flow, pph (W.)
Condensing Load, pph
Motive Flow, pph (Wi)
Size, in.
130
355
10
130
355
95
zo&mwft
5000*
3450
8000 22,210
5600 12,000
* Maximum thennocompressor suctionflowwith spindle

fully open would be 10,300 pph, and motive steam
requirements would be 15,000 pph.
2030307417
CONFIDENTIAL:
Thermocompnsson (THC) /It
MINNESOTA TORAnCQ LITIGATION

MOTIVE PRESS. 130 psig
COMPRESSION PRESS. 4.0 psig
too
100
- "
\
90
bo
SO
70 +
70
60
60
W, MOTIVE FLOW
" | so
a.
90
v^
s * SUCTION FLOW
40
ta
*
50
*g
40
0?
SO
30
20
104
20
10
I.S
10
LT
2.1 2 J 2.5
*V*
W-PPH XIO*
/*
Av
4v
.<Vlo
fig. 2.03.1 Motive flow, suction flow, and entrainment curves at 4.0 psi differential
pressua&^y*

COMPRESSION PRESS. 8.0 psig
s,
9080-
40-
30-
10-
-60
- *s,-MOTIVE FLOW
-so I
40
Ng*SUCTION FLOW
-70
/ /
/ /
*
//
20-
/
/
80
'
7*
/
50-
i*__
/-
70-
-90
$30307418
-20
10
W-FFH X 10*
K>
tt
|.b
(.2
(.3
0
1.4 L
B
Rg
Fig. 2.03\2 Motive flow, suction flow, and entrainment curves at 8.0 psi differential pressure.
2030307418
CONFIDENTIAL:
12 / Ptper Machine Steam and Condensate System
tiiMMFsnTA TORAcnn
LITIGATION

COMPRESSION PRESS. 12 psig
too
100
N,
90
90
80
60
70
70
60
60
W,< MOTIVE FLOW
SO
a.
SO
* s SUCTION FLOW
40+-
ao
40
30-
30
20 -f
20
10
10
0
10
12
14
.9
LO
1.1
Fig. 2.0JJ Motive flow, suction flow, and entrainment curves at 12.0 psi differential preasurt:
compression resulting in less nozzle energy available to
entrain suction steam. Note that the amount of
compression pressure includes the dryer differential
pressure plus separator and line losses from the THC
discharge to the supply manifold, from the drain
manifold to the separator, and from the separator back
to the suction side of the THC.
The practical operating limits of a thermocompressor
depends on the motive steam pressure available. As an
example, the motive steam pressures are assumed to be
100, 150, and 200 psig. A compression pressure of 12
psi is to be maintained between the thermocompressor
suction and discharge. The minimum dryer section
pressure is to be 5 psig. From Fig. 2.0.3.4, it can be seen
that maximum efficiency of the 200 psig steam is obtained
at 70 psig, and from there to 125 psig entrainment
decreases. Likewise, with 150 psig steam, maximum
efficiency is reached at 55 psig, and with 100 psig steam,
at 35 psig. From the maximum points shown, the
decrease is rapid. A lower differential across the
thermocompressor will result in increased entrainment.
At the top end of the curve, Rw is limited by the approach
of the discharge pressure to the motive pressure, and at
the low end of the curve the Rw is limited by the increase
in compression ratio (Pa/Pi).
\ 200 pif
V
\,
\
IJO
I-
I50f*i|
a ro
V
' " N
N^
>
t>
.1
.t
/
'
LO LI 14 U
4P 12 paif
14 <* I t
IT
PPH SUCTION / PPH MOTIVE STEAM (R v >
Fig, 2,03.4 Entrainment curves for 100-, ISO-, an

psig motive steam pressures. r H "^0** '** **" *
2030307419
Thermocompnsson (THC) /13
j&*P
THERMOCOMPRESSOR SYSTEMS
MAKEUP STEAM
MOTIVE STEAM
2.1 Thermocompressor pressure control system*'' /
^^'
The thermocompressor pressure control system was one

of the original applications of a thermocompressor in
the paper industry and is still used often in connection
with yankee dryers. However, it is one of the most
uneconomical. With the basic system shown in Fig. 2.1,
the thermocompressor spindle is controlled by the
pressure controller. With this method of control, the
thermocompressor is always operating in the wide open
condition (3-9 psi), and additional makeup steam is
controlled with the pressure control valve (PCV, 9-15
psi). With this method of operation, there is no control
of dryer differential. The differential is dictated by
thermocompressor design capacity, which is usually
much more than is required over most of the range of
operation. Excessive differentials cause unnecessary
erosion of condensate piping and also a waste of high
energy motive steam, unless the makeup steam pressure
is the same as the motive steam supplied. Should the
thermocompressor not be capable of controlling the set
differential, the only option left to generate the additional
differential required is to open the atmospheric or
vacuum condenser valve (DPCV).
A check valve (CHV) is extremely important in all
thermocompressor suction steam lines. Reverseflowof
steam from the thermocompressor can occur under
certain conditions, such as when critical compression
ratio is involved (Pa/Pt > 2). Without a CHV, a
thermocompressor becomes no more than an elbow in
the pipeline if the motive steam is turned off. Thus, on
failure of motive supply or of the control signal, the
pressure in the dryer supply and drain manifolds would
equalize, and differential pressures would become zero.
When the differential pressure is zero, makeup steam
flows from the makeup valve (PCV) to the blow down
valve (DPCV), without a CHV in the line.
Fig. 2.1 Thermocompressor pressure control system.
MAKEUP STEAM
MOTIVE STEAM
DPftC
PRC
O
THC
te
PCV
PIT
PAPER
DRYERS
l2f '
OPCV
2.2 Thermocompressor pressure control system with

differential control valve
SYSTEM
A significant improvement over the thermocompressor

pressure control system is the simple addition of a
differential pressure control valve (DPCV) as shown in
Fig. 1 1 This provides better control of the required dryer
differential. The thermocompressor operates in the wide
open condition with the sheet on the dryers and is split
range operation with the makeup valve.
The differential pressure is controlled by a split range
controller using the differential pressure control valve
DPCV with a 9-15 psig A/C signal and the blow down
valve DPCV with a 3-9 psig A/C signal. Valve DPCV1 closes first with a 3-9 psig signal and does not normally
open during normal operation, but it is open on
sheetbreak and start up conditions. Valve DPCV closes
y^-v
OPCV-I
rQ\Z_
203(ft0?420
30B<
Fig. 12 Thermocompressor pressure control system with
differential control valve.
next with a 9-15 psig signal, and this valve generally
provides the operating control of the dryer section
differential pressure.
T'^'-V
iVilNNESOTA TOBACCO UTIQAriON

2030307420
13 Dryer differential control using the thermocomp"resj^jj$a which they must operate to assure proper sheet warmup and drying. That is, if the condenser is sized to
sor spindle
condense at the minimum required pressure based on
blow through and flash steam from the wet end (and
An improved system * wide use that uses only enough
lead in after size dryers, if applicable) only, the addition
high pressure motive steam to control the set differential
of condensing blow through from the main and
is shown in Fig. 2.3. This system is also called the low
intermediate section dryers will overload the condenser
pass control loop.
to the point where it will be incapable of evacuating the
The thermocompressor is supplied with a 3-9 psi split
dryers at the low pressures required by the lead dryers.
range positioner and PCV with a 9-15-psi positioner.
Valve DPCV, which is air-to-close, is supplied with a
9-15-psi reverse acting positioner so that it will function
MAKE UP STEAM
as a normal air-to-open valve and yet fail open should
MOTIVE STEAM
there be an air failure. The item shown as SR is a low
pass selecting relay which will select the lower of the
signals from the pressure controller or the differential
controller to modulate the thermocompressor. This is
extremely important so as not to overpressurize the dryer
above coded pressure with high pressure motive steam
during a sheet break or similar loss of condensing load.
The instrument DPC will be initially set to maintain the
required differential across the steam joint and syphon
pipes.
During normal operation, makeup steam will always
PAPER
DRVERS
be required; therefore, the PCV will be throttling on a
pressure instrument output of 9-15 psi. Differential will
be maintained by modulating the thermocompressor
SYSTEM
spindle. The lower signal from DPC (3-9 psi) will pass
OR
OPCV
to the thermocompressor, and the higher output signal
0
(9-15) from PC will be blocked by the relay SR. The
higher signal (9-15 psi) will throttle the makeup valve.
On a paper break, pressure in the steam header will
rapidly increase because the condensing load in the
LCV
y
section is drastically reduced. To maintain the set
pressure, the signal from PC will decrease, tending to
close PCV. The quantity of motive steam to the
Fig, 23 Thermocompressor using only enough highthermocompressor will still exceed the low condensing
pressure steam to recirculate blow through steam.
load on the dryer section, and the output signal from
PC will continue to decrease. When the output signal
becomes less than the output of DPC, it is automatically
2.4 Thermocompressor cascade system
transferred by means of the selector relay to control the
THC. The signal from the DPC will now be in the range
This system is not very popular and rarely recommended.
of 9-15 psi and will throttle the differential valve DPCV
It is difficult to operate and has had many reported
to maintain the required differential across the syphons.
problems. It is discussed here because there are several
The selector valve SV permits the thermocompressor to
still in operation.
be shut off during initial machine warmup so that air
This system uses a thermocompressor in a conventioncan be evacuated from the dryers. This is accomplished
al cascade system. In this combined system, the blow
by blocking the supply air to the thermocompressor
through steam pressure is increased by a thermocompositioner. With the THC closed, steam is admitted
pressor and then cascaded to another stcamêawnjin
through the PCV, while blow through and noncondenthe machine. The receiving J ^ o j O S O * * * w * d
sables will be evacuated through the DPCV. Blowing
anywhere in the dryer section as long as its condensing
the machine down while running can be accomplished
load is more than the thermocompressor discharge flow,
in the same manner.
and its operating pressure is equal to or lower than the
An important consideration when designing any
thermocompressor discharge.
thermocompressor system is that the condenser must be
One advantage of this system is that it minimizes the
sized to condense all blow through steam from the dryer
collection and buildup of noncondensable gasses in the
section(s) and the wet end dryers at the vacuum which
dryer sections. Unfortunately, the thermocompressor will
will evacuate the wet end dryers at the minimum pressure
generally be wide open, using the maximum quantity of
yp
CONFIDENTIAL:
rwhMiMESOTA TOBACCO LITIGATION
203030f-r2 ( P 7421
Thcrnocomprtssors (THQ /15
re
high pressure steam at all times in normal operation.'If ^, .2.5 Yankee dryers
the motive steam to the thermocompressor and the*5
The drying section of a paper machine making tissue,
supply to the makeup valve are from the same steam
crepe wadding, toweling, and other light sheets usually
supply header, it doesTlot matter whether the steam to
consists of one large dryer typically 10 to 20 ft in diameter.
the section is supplied by the thermocompressor or the
This is commonly called a yankee dryer. This large dryer
makeup valve. If, however, a high pressure source is used
may be used in conjunction with predrying and/or after
for the thermocompressor and a low pressure source is
drying sections with conventional dryers.
available for the makeup valve, it would generally be
Operating range of yankee dryers may range from low
more economical to use the low pressure source for
pressures to as high as 16X1 psig, with machines being
makeup.
balanced for speeds up to 7000 ft/ min. These high speeds,
A second aspect of the cascading thermocompressor
combined with large dryer diameters, require large
system is that if the receiving section is operated at a
differentials to be carried across the steam joints. These
lower pressure than the cascading section; the wide open
differentials are typically in the range of 12 to 18 psL
thermocompressor tends to choke, and the differnetial
Use of yankee dryers introduces some special control
control is forced to dump steam to the condenser to
requirements. One of these requirements is gradual
maintain differential. On the other hand, if the receiving
warmup of the dryer during the startup period. Rapid
section is at the same or higher pressure than the
inflow of steam can cause serious damage to a cold dryer
controlled section, the compression is greater than
because of thermal stresses caused by unequal distriburequired by a recirculating THC because of the additional
tion of heat through the shell. Therefore, it is desirable
pressure drop in the DPCV and may be much greater
that some provision be made to guard against accidental
for increased pressure. This usually results in loss of
shortening of the warmup period.
steam to the condenser. In paper machines that use the
Steaming and drainage control used on a yankee dryer
cascade method, it is normal to find most of the DPCV
can vary from a simple pressure control instrument
valves dumping steam to the vacuum condenser.
throttling a steam supply valve to a complex system
A further improvement of this system is to place the
employing pressure, temperature, and timing devices
thermocompressor on differential control as was shown
interlocked for maximum safety and operation efficiency.
in Fig. 2.3 while still maintaining the cascading feature
and overriding pressure relay.
If a jet compressor is used in a single dryer machine,
The biggest disadvantages of the cascading thermoall of the steam blow through must be recirculated. If
compressor system are the loss of flexibility to operate
the quantity of blow through steam is too great, motive
each section independently and the waste of steam heat
steam requirements could exceed that being condensed
to the condenser.
in the dryer, thereby choking the compressor and causing
loss of differential, which would result in afloodeddryer.
A relatively simple system which meets the requireMAKEUP STEAM
ments for warmup, Sunday drive, and run operation is

r* P STEAM
shown in Fig. 2.5. In the warmup position, the selector
valve passes a 20-psig air supply through three-way valve,
item TCV-1A, to the diaphragm operator of the valve
PCV-IA which limits initial steam flow to the yankee
dryer. Opening of this valve is limited by a stop which
has been set for an input rate which will warm the dryer
&]
fo.T,,
if&Lx^l'
over a two- to three-hour period. Setting of the limit
stop is determined by testing at the time of initial startup.
MPCR QflVCftS
M*t> MTCRS
prcv
When the safe warmup period has been completed,
~:
the temperature controller, TC, will position TCV-1A
s*
to block the 20-psig air and direct output of the Sunday
drive pressure controller, PC-I A, to warmup valve PCVIA. The warmup valve will tbgîitrtri>iffliTOpjtain
some low pressure, as set o<hP4AiMnt!lltht selector
is switched to the run position.
$
Item TC is a differential gap temperature controller.
Until the temperature of condensate in the separator
reaches the instrument set point, the output will be 0
Fig, 2.4 Thermocompressor cascade systems.
psig. When the set point is reached, the output will go
to 20 psig. The temperature at which this instrument is
set will coincide with the temperature of the condensate
in the separator upon completion of the warmup period.
CONFIDENTIAL:
^2030307422
m& means that there are fewer devices to fail, making

the detection of tampering much easier.
In the blowdown position, supply air to the positioner
of the jet compressor is blocked, and the compressor will
close. Pressure and differential control will be as
described for the system shown in Fig. 2.3. The run
position also operates with this same basic control.
Flow control is used with considerable benefit on
yankee tissue machines. Flow control is covered in the
next section.
The three-way block valve, item TCV-1, prevents air

supply from reaching the positioners of the jet
compressor and steam makeup valve should the selector
valve be switched to tfc run position before warmup has
been completed. The system will remain in Sunday drive
until the selector is placed in the run position.
While it is obvious that this sytem can be intentionally
bypassed, this is true for most, if not all, of the more
complicated safety systems with the same potentially
disastrous results. The advantages of the system are that
it cannot be accidentally bypassed and that it is simple.
-HIGH PRESi. STEAH

IPC-IA
O,
OOPC Q f C
<M H-
;V-IA
CHVl
f
/
\YAMCEE
PRYER
PS
LOW PRESS.
STEAM
, PCV-1A
Lp TS p PS g PS q
i
.
u f l ILH I L 6 ILU
[wiPl fsoH rRUNl fBO
ATMOSPHERE
OR
VACUUM CONDENSER
DPCV
Fig. 2.5 Simple arrangement for controlling yankee dryer through warmup, Sunday drive, blowdown, and run
operation.
2030307423
CONFIDENTIAL:
FVilNNESOTA TOBACCO LITIGATION
2030307423
<*
Blow Through (Flow) Control for Dryer Drainage S^f4m v

ov
3.0 General
Blow through control is often called flow control. The
blow through control system is a different way of
controlling dryer drainage than the DP control system
outlined in the previous sections. Instead of controlling
the flow of blow through steam to maintain a fixed DP
between the supply and condensate headers, the
controller maintains a fixed DP across an orifice or
restriction in the blow through line, resulting in constant
flow of blow through steam at any given pressure.
This approach causes the DP to adjust to system
requirements rather than a fixed maximum. It automatically maintains the same rate of drainage regardless of
changes in speed, condensing load, and pressure. For
example, when pressure is increased, condensing rate
increases, and the quantity of blow through steam
increases proportionally due to the increased density of
the blow through steam.
3.1 Blow through control principles
Fig. 3.1 Basic flow control system.
In its simplest form, the blow through system replaces

the normal header DP as the control input with the
pressure drop across an orifice plate. This system is shown
in Figure 3.1. This can be compared to the normal DP
control system shown on the main section in Fig. 1.5.
Blow through control can be used in most of the
previous systems in place of DP control. It works well
in both cascading and thermocompressor arrangements.
With the blow through control system, blow through
flow is maintained at a preset value. If the dryer DP
is inadequate to evacuate one of the dryers, that dryer
will begin to fill up with condensate. This reduces the
quantity of blow through steam, causing the blow
through valve to open. This tends to increase DP and
promotes evacuation of that dryer. With the normal DP
control system, the valve would tend to close and
aggravate the flooding.
Flow control is especially advantageous during a sheet
break. During sheet break, the condensing load drops
to roughly ten percent of normal running load. With the

conventional method of differential control, the blow
through rate can increase by as much as twice or more
than the normal running requirement. This is due to a
temporary loss of syphon resistance caused by a loss of
condensing load. The differential valves and/or
thermocompressors then go wide open in an attempt to
maintain differential pressure. This is usually not enough,
and the atmospheric or heat exchanger valves open. With
a blow through control system, the blow through remains
constant during a sheet break, and the dryer DP
automatically drops. That allows the thermocompressor
to close due to the lower differential requirements. This
reduces motive steam supply so that even with lower
condensate load demand the U<Qgo$Qf)t)&4i2i$n
closed.
Figure 3.1.1 shows typical syphon blow through
curves. In the DP control system, BT would follow line
AA during a sheet break condition when the condensing
J7
^SlglÂL:
2030307424
^.^0
,
J
remains essentially constant, following line BB.
- - . - , ' t r e a s u r e the resulting differential across the steamfit

^ y ^ W h e n there is sufficient differential to evacuate
* condensate to the condensate separator, the condensate
drops out, and the blow through steam returns to the
thermocompressor for recompression.
The flow control orifice plate is usually designed for
a differential pressure of about 1 psi at maximum flow
(approx. 27 in. of H 2 0). Of course, the actual line loss
is little more than half the differential across the orifice
plate. Straight runs of pipe ahead of the orifice are not
necessary. The orifice plate may be installed in very short
pipe sections near elbows. This is because exact
gravimetric flow measurement is not required. The
relative pressure drop across the orifice can be used for
control.
Flow through the orifice plate is measured by a
differential pressure transmitter (DPT), which feeds a
differential flow controller (DFQ. The flow controller
then controls the thermocompressor and valve DV, if
required. The flow required to entrain and evacuate the
condensate for the entire range of operating conditions
is then set and maintained regardless of speeds,
condensing load, sheet break or other upset conditions.
The sizing of piping and orifice bores is critical and
DIFFERENTIAL CONTROL
FOLLOWS LINE ~A-A"
should only be done by experienced specialists. An error
AND BLOW THROUGH
in the bore affects blow through flow to the square of
CONTROL FOLLOWS
the bore, and flow affects differential by the square.
LINE "B-B"
Accordingly, differential is affected by the fourth power
of the bore. Trial and error method is not recommended.
'
I I
OFFEWNTUL PRESSURE PSQ ACHOSS THI SRAM JOMT
Fig. 3.1.1 Differential pressure, control line

blow through control line "B-B".
A-Anand
3.2 Blow through control installation

Figure 3.2 shows a standard blow through control system
for a THC loop system, in the arrangement shown, the
dryer section DP is monitored as a good troubleshooting
advantage. The DPT measures the differential between
the steam and condensate headers.
The first order of control is with the thermocompressor
(THC). When the thermocompressor is wide open and
more differential is required to maintain set point, valve
DV opens. Some machines may have a lower pressure
steam header to discharge into, and blowing to the
atmosphere will not occur when more differential is
required than can be provided by the thermocompressor.
By measuring differential between the steam inlet and
condensate headers, the resulting differential pressure
across the steamfit is not known. This will vary with each
system, depending on connecting pipe sizes and lengths.
Many mills have added pressure gauges on the steamfit
Fig, 33 Standard
through control.
thermocojaarôr^stam/iMttt^low
41)01)31/74^0
CONFIDENTS
MINNESOTA TOBACCO LITI \Ji.
2030307425
Bbw Through (Flow) Control for Dryer Damage System /19

This system is probably the most common method of
draining dryers being supplied today for new and rebuilt
re.
systems. With blow through control, the thermocompressor spindle is opened only as much as required to
Qa
maintain set blow through. This conserves high pressure
motive steam. The low pressure override is used so that
on sheet break the thermocompressor converts to
pressure control if necessary. This is not likely to occur
with flow control as compared to differential control.
During sheet breaks, the condensing load is greatly
reduced so that if the THC is not cut back, more steam
is injected into the dryers than can be condensed, causing
the pressure to rise above the set point.
With loss of paper on the dryers, the condensing load
I u n n n n
drops, and the flow of blow through steam increases if
r~i r~i n r**i
differential pressure is maintained constant With blow
MMUP9UM) MM tLON
through control, the flow of blow through steam is
Fig. 33 Yankee or single larger dryer blow through
maintained at the preset rate and the differential pressure
drops. Thus, the thermocompressor has less work to do
control.
on a break. The motive steam is therefore reduced, and
the amount of steam discharged to the atmosphere or
condenser is reduced or eliminated. Following a break,
the blow through rate continues to be maintained at the
preset rate, and differential pressures automatically
return to normal levels.
On most modern systems, the blowdown valve that
*&
r"
dumps to atmosphere or HE rarely opens during run
or break, operations. During dryer warmup, the THC^tf
is turned off, causing the blowdown valve to open and^
to discharge air to the atmosphere. This provides rapirf4 '
and effective elimination of noncondensables, which is
desirable for all steam sections.
Perhaps the most important advantage of blow
through control in a THC system is the steam pressure
turn down capacity. Turn down capacity is extremely
important for most fine and groundwood papers. With
ordinary DP control, as dryer pressure is lowered, blow
through flow increases, causing an exponential increase
in THC work, and the THC typically becomes unable
to maintain DP below pressures of 15 to 20 psi. With
blow through control, the percentage of blow through
stays constant, and the DP drops with lower dryer
pressure. Thus the THC is able to work in its normal
way at exceptionally low dryer pressures, often as low
asOpsig.
"o
3 3 Yankee or single large dryer blow through control

system
Figure 3.3 is basically the same system as described in
Fig. 2.5 except that flow control has been added. This
is one of the more popular methods of yankee dryer
control.
2030307426
CONFIDENTIAL
MINNESOTA TQBACCO LITIG
2030307426
'*;
Mechanical Vapor Recompression (MVR)
4.0 General
v*
S / . ^"
Much interest has been given recently to this new and

developing technology. This is just a short introduction
covering the basic system for paper machine condensate
systems.
Mechanical vapor recompression has been used in the
paper and other industries for many years. There are
several hundred evaporators in the paper industry using
a positive displacement pump (PDP) to create MVR very
economically. The only difference between the evaporator pumps and those used for paper machine dryer
drainage systems is the pump casing coded pressure.
Evaporators generally operate at low steam pressures,
while paper machine dryers operate up to 160 psig. PDP
can operate from -8 psig to 160 psig and create
differentials up to 20 psig.
4.1 Advantages
A positive displacement pump has all the advantages of
blow through control. It maintains constant flow and
variable differential to automatically compensate for
upset conditions that may occur, including sheet breaks
and changes in speed and condensing load.
A PDP replaces the thermocompressor as shown on
Hg. 4.1 and eliminates the use of high pressure motive
steam. This means that the high pressure steamtinefrom
the power house may be eliminated and more electrical
energy can be generated.
Steam loss to the atmosphere or heat exchanger can
be reduced or totally eliminated in many cases. This is
especially noticeable during sheet breaks. Heat exchangers can be eliminated from some dryer drainage
systems, resulting in less hot water being generated. Most
paper machines generate more hot water than they use.
The PDP is over 90% efficient. Much of the
horsepower input to drive the PDP is recaptured in the
form of heat of compression. This is in the form of
superheat which creates steam from the condensate inside
flP
jljjetdryer. This relates to less steam that has to be made

ûp to the dryer sections. Horsepower varies with the
required differential. At low speeds, low condensing
loads or sheet break conditions, very little horsepower
is required to maintain set flow.
A PDP allows all dryers to operate at the maximum
pressure without venting steam. A simple cascading
system would allow the pump to idle ^hen enough
differential between sections exists, and the horsepower
input will increase as the differential pressure requirement
increases. The no load PDP still acts as a constant
metering device to maintain set flow, even if larger than
set differential exists between sections.
A PDP will handle up to 10% condensate by volume
or a flooding separator without any damage to the pump.
It is often recommended that 10% condensate be piped
into the pump. This will serve a dual purpose of creating
better seals and helping to reduce superheat leaving the
pump.
Fig. 4.1 Thermocompressor-mechaniad vapor recompression flow control system.
21
CONFIDENTS.I
MINNESOTA TOBACCO LITlGATlO'
1 ,v
2030307427
CONFIDENTIAL:
Dryer Drainage System Controls and Equipment
5.0 Genera!
Controls for a basic dryer drainage system are very
simple. The three major control loops are pressure,
differential (flow), and separator level
It is important that all valves fail-safe in case of a power
or air failure. This means that all valves admitting steam
to a dryer section will fail shut (A/ O, air-to-open valves),
and all valves on the discharge, condensate side of a dryer
will fail in the open position (A/C, air-to-close valves).
Major lines on a dryer drainage system should be
equipped to measure flow rates. This should include
steam supply, blow through, and condensate flows for
each section, along with the total steam to the paper
machine.
5.1 Pressure control
Pressure is normally automatically controlled for a steam
header feeding multiple dryers, using one or more control
valves. Multiple valves are normally split-ranged so that
they open one at a time to satisfy steam requirements
starting with the steam to be usedfirst.Thermocompressors may also be split-ranged with makeup valves.
A safety relief valve must be installed on each dryer
steam section supply header to allow dryers to operate
as close as possible to coded pressure and prevent the
dryers from operating above dryer coded pressure. A
pressure relief valve on the main machine header or
further back in the system may result in lower than coded
maximum desired pressure in the dryers.
5.2 Differential pressure control
Control of the pressure drop across the dryers is used
to insure proper evacuation of condensate from the
dryers. This pressure drop is normally measured from
the steam supply header to the condensate header.
Normally, most of the pressure drop is taken across the
steam joint, syphon shoe, and syphon pipes in the dryer.
On&^v&veral split-range valves and/or thermocompressort may be used to control the differential. Blow through
steam normally cascades to a secondary section or is
recirculated back into the same section. Thermocompressors are often used on dryer limited machines to obtain
the necessary differentials while operating most of the
dryers at maximum pressure. Differential controls are
usually set in order of priority so that blow through steam
is reused in the dryer as much as possible and only
dumped to a condenser or to atmosphere as a last resort
Differential must be controlled over the entire range of
speed, pressure, and condensing loads.
5.2.1 Transmitter instillation
It is usually preferred to have differential pressure

transmitters mounted above both the steam and
condensate headers. If the transmitters are not mounted
above the headers, then constant equal pressure has to
be created with equal water legs on each side of the
transmitter. This is accomplished by using seal pots, as
shown in Fig. 5.Z1. Most older installations are designed
that way. Without these artificial water legs, there could
be twice as much differential from set point or twice as
little. It is difficult to be sure that these water legs are
full at all times. Seal pots must be installed at the same
elevation above both headers, unless transmitters can be
zeroed or suppression kits are provided to allow
mounting seal pots at different elevations. Newer
installations mostly use zeroing transmitters. The
pressure transmitter should not be mounted at the
bottom of the steam side water leg, as is often the case,
without using a transmitter that can be zeroed. This gives
a higher pressure reading than is normally being used
by the height of the water leg. The pressure transmitter
should be mounted in the pressure header without
creating a drop leg that can S^RCff^Q^SMJ^ See
2O3O30Tr2
23
2030307428
"CONFIDENTIAL:
""ffifWlESOTA TOBACCp jjTIGATION
24/ Piper Machine Steam nod
If transmitters are located above the headers, risers

must be one-inch pipe, no horizontal runs, no pockets
or sumps, and a minimum slope of 45*.
5J Separator control
The third major control loop is the condensate separator
tank. The main purpose of this tank is to separate
entrained condensate from blow through steam.
Condensate is returned to the power house, and blow
through steam is reused in the most efficient manner.
It is important to have sufficient controls and alarms
on the separator tank to warn operators in case of
problems. The two most important alarms are low and
high condensate level. If the pressure inside the tank is
sufficient to push the condensate out to the central
collection tank without pumping, the condensate pump
should not run until a preset high level is reached.
Separators may vary greatly in water separation
efficiency depending on entering steam velocity and
arrangement of internal baffles. Not uncommonly, a
large percentage of the condensate entering with the blow
4hreAigJêam is earned right on out without separating.

Thmw&ns that the dryers supplied with this wet blow
through steam may be much more difficult to drain.
Older low capacity separator efficiency may be
optimized by running the level set point as low as possible
to minimize blow through velocity. Install a 0,5-in. (12.7mm) line recirculation from the pump discharge back
to the separator tank below the condensate level to
prevent dead shut off of pump. Provide a 0.75-in. (19mm) line from the pump suction up to the separator
steam compartment to relieve steam collected in suction
line and reduce pump cavitation.
5.4 Vacuum system
On most machines, high dryer surface temperatures on
wet end dryers can cause dusting, picking, cockles, case
hardening, reduction of drying rate, sheet blisters,
discoloration, web flutter and other related problems.
These machines require a vacuum system to achieve low
dryer operating pressures.
The vacuum system normally consists of a vacuum
TO PUT IN SERVICE
A. With all valves closed, proceed as follows:
t* - 1 " riser pipes. No pockets

or horizontal runs.
Minimum 45* slopes.
PT
2. Crack vent screws on high & low pressure

diaphragm housing of D/P transmitter.
-OdS
DPT
A Steam
1. Open seal pot vent valves, high & low

pressure manifold valves, transmitters
& equalizing valves.
I[
(ybondensatep
Vent valves
Seal D
Q Pots
Transmitters mounted
above headers
3. Fill system with fresh water through

either vent valve until all air is
vented. (Steady air-free flow from
second vent valve,)
4. Close vent screws on D/P transmitter.
5. Close seal pot vent valves.
6. Close equalizing valves.
7. Slowly open main condensate shut-off
valve.
rpipe
a Slowly open main steam shut-off valve.

B. In order to prevent sweeping condensate out
of the chambers, the equalizing valves
should never be opened while the main
steam & condensate valves are open. .
Drain
Transmitters
below headers
C. To check the value of the transmitter output at zero differential, open the equalizing valves one at a time.
Q Check "HIGH PRESg)lS363W429

PRESSURE" and "DIFFERENTIAL
PRESSURE" readouts.
Fig. 5.2.1 Scat pot installation.
203030^^9
2030307429
^MrinCKlTI Al *
ONFIDEN I I M U . ._, jfc*
DryerDnimpSystem ControlsutdEquipment/25
Steam-out
Level
controller!
Level control valve

Condensate line
Bypass valve
piping
Fig. S3 Condensate separator

pump and condenser (heat exchanger). Dryers discharging to the atmosphere have to operate at 10 psig or higher,
depending on speed, to provide sufficient pressure
differential to evacuate the condensate. Below these
pressures, a vacuum system is required.
Vacuum systems are usually designed to generate
vacuums of 15 to 25 inches of mercury. Vacuums above
20 in. of Hg are usually diflicult to maintain because
of air leakage into the system from steam joints, flanges,
fittings, etc.
5.4.1 Vacuum pump
Any type of vacuum pump capable of operating at the
design vacuum level may be used. The pump is generally
designed to handle at least 5% of the condensing load
volume as noncondensables. The vacuum pump does not
control the vacuum level and is not be designed to do
this. The vacuum is normally controlled by theflowof
cooling water through the condenser.
Machines operating well above atmospheric pressure
do not need vacuum pumps. This is especially true for
high pressure recirculating thermocompressor systems.
5.4.2 Condenser (heat exchanger)

There are several types of condensers. The two most
popular types used on dryer drainage equipment are "IT
tube and straight tube designs, with or without
condensate impingement plates. If condensate is sent
directly to the heat exchanger along with blow through
steam to be condensed, impingement plates mounted
inside the heat exchangers will be required to deflect
condensate away from the condenser tube bundle.
Condensate impinging directly on the condenser tubes
will cause severe erosion and short life for the tube
bundle. It is often better to separate steam and
condensate before sending the blow through to the heat
exchanger. When mounting heat exchangers, space must
be reserved to pull out the tube bundle for inspection
or replacement.
Condensers should be selected to condense all of the
blow through steam at minimum and maximum
operating pressures at the designated vacuum level.
Cooling water temperature ^ r f f e f P t o & l S Q 1 6
condenser required. A fouungTanof\WXoTto 0.002
is normally allowed for the water side.
The economics of collecting the blow through steam
with a heat exchanger for systems operating above
atmospheric pressure should be weighed against the cost
20303CT743O
2030307430
26/ Paper Midline Steam and Condensate Systems
w
X
Vacuum
relief
Cooling water
control valve
Blow through
steam from dryers
valve
Level
controller
LC
Condensate
CMS
vacuum pump and motor
Condensate pump and motor
Fig. 5.4 Condensing equipment

of operating and maintaining condensing equipment,
treating additional water at the power house, and the
demand for hot water generated.
5.5 Effect of air in steam
It is well known that air in steam reduces its condensation
temperature. The question is: what is the net effect of
a given quantity of air in steam? It would be desirable
to know how to reduce the level of noncondensables to
that which would not appreciably reduce drying rates.
Air not only reduces the partial pressure of the steam
in the mixture but literally poisons the condensing film
heat transfer. Dryer steam temperature will be lowered
proportionally to the amount of air in the steam mixture,
and dryer surface temperature will drop a great deal more
as a result of loss in heat transfer.
Figure 5.5 shows the effect that air has in reducing
overall steam temperature in an ideal, uniform mixture
of air and steam in a range from 10 to 50% air. This
has a direct effect on the resulting dryer surface
temperature and production, but the effect of loss of heat
transfer is even greater. The loss in surface temperature
is substantial even for small quantities of air. Loss in
production can be estimated for any drop in effective

temperature from the TAPPI drying curves for each
grade of paper. For example, a 10* F drop in surface
temperature on dryer limited linerboard grades will result
in approximately an 8% production loss.
High pressure dryers are less affected by insufficient
purging of noncondensables at startup. For example,
with a dryer at atmospheric pressure compressed with
steam to 150 psig, the original specific volume of 28.6
ft3/ lb is reduced to 2.75. Therefore, with no purging there
will be approximately 10% air in thisfinaldryer mixture
and a substantial loss in production. If time is taken to
purge to 10% or less air before compressing to 150 psig,
approximately 1% air will be in the final dryer steam
mixture. This 1% air is considered negligible in terms
of air content When compressing to lower pressures,
proper purging becomes m u t f Q f t f Q r 3 Q 1 7 4 3 1 .
High-speed videos inside dryers nave shown very high
turbulence, indicating good mixing and relatively
uniform air-steam mixture.
The purging cycle normally requires a minimum of
one to three hours at 10 psig or less. Machines that have
full scale purging during normal operations, such as a
cascading system or blowing to a lower pressure header,
2030307*431
CONFIDENTIAL:
2030307431
* >
CONFIDENTIAL;
Dryer Dnmg&Syatah Controls tnd Equipment / 27
off and the effect measured to determine if these bleeds

are necessary for individual machines.
S u n Mrnparaiur* faducfcon i
* tttuH <X 1010 SO* r Mr
180
5.6 Syphons for paper machine dryers
140
120
60
"-
ISO
100
200
220
240 260
280 300
3J0
340
360
TEMPBWnjRE*f
Fig. 53 Steam temperature loss as a result of noncondensable gases.

do not need long periods of purging noncondensables
before startup. Machines that are not dryer limited are
less likely to have problems with short purge cycles. It
is important to remember that yankee dryers must be
warmed up much more slowly because of their structure.
5.5.1 Noncondensable bleeds
Some paper machines operate with noncondensable
bleeds. These are occasionally thermostatically controlled devices but are often simply orifice restrictors that
allow steam to bleed out of the system. Front bleeds have
been used in an attempt to purge noncondensable gases
from the front side of wide dryers, where such gases
theoretically collect.
Most modern boiler power houses have adequate
control of feedwater chemicals so that these bleeds are
not necessary. Also, most modern paper machines have
the syphons located on the opposite side of the dryer
from the steam inlet to provide a natural purging of
noncondensables.
In a modern mill, the use of noncondensable bleeds
is usually unnecessary and can be responsible for wasting
large amounts of energy. In practice, shutting off bleeds
has generally not resulted in lost production.
Condensate behavior in a revolving cylinder has been

observed and photographed. Depending on the quantity
of condensate, diameter of the cylinder, and speed of
rotation, the following observations have been made:
1. A film of condensate adheres to the dryer inside
surface at all speeds.
2. Increasing the rotational speed of a dryer will cause
a fixed quantity of condensate to progress through
the following stages:
a. At low speeds, generally below 325 ft/ min, most
of the condensate collects as a puddle or pool
at the bottom of the dryer.
b. As dryer speed is increased, up to 700 ft/ min,
the puddle, or pool, progresses up the wall of
the dryer in the direction of rotation.
c. At 700 to 1000 ft/ min, condensate drops, or
showers, separate from the wall of the dryer. This
is called cascading.
d. At dryer speeds over 1000 ft/ min, condensate
forms into a layer around the inside surface of
the dryer, as the result of centrifugal force. This
condition is called rimming.
3. The specific speed at which one stage ceases and
the next stage begins depends upon the quantity
of condensate inside the dryer and the diameter of
the dryer. Dryer internal smoothness and dryer bars
also affect rimming speed.
4. A condition of partial rimming and cascading has
been observed in the same dryer simultaneously.
There is continuing research on the effect of condensate in dryers. It has been established that syphon design
and sizing are major contributing factors to condensate
behavior, heat transfer, and uniformity of drying.
A paper machine dryer syphon is a device through
which condensate, blow through steam, air, and small
amounts of noncondensable gases pass from inside of
the dryer cylinder to the condensate outlet connection
of the rotary joint mounted on the dryer journal.
The ideal syphonand in some cases more than one
should be designed and sized to keep the thickness and
variation of the condensate film to a minimum. It is
possible with proper design, sizing, and differential
pressure to produce and maintain a thin rimming film
at low and high machine speeds. Cascading within the
dryer increases horsepower> rtquhcriQtyîgjjnay
contribute to dryer bearing pfeHemsT *"*
There are two general types of syphons: rotating and
stationary. Rotating syphons revolve with the dryer
cylinder, and stationary syphons remain fixed relative
to a point outside the dryer.
0020207*132.
2030307432
2$ I Paper Machine Stem and Condensate Systems
Differential pressure requirements necessary for

condensate flow from a dryer is a function of syphon
type, size, condensate load, speed, and dryer diameter
Stationary syphons vftth scoops require less differential
pressure than rotating syphons under similar operating
conditions since the velocity energy aids drainage. Plain
end stationary syphons need approximately as much DP
as rotary syphons for condensate evacuation.
Blow through steam, mixed with condensate, results
in a two-phase flow with an average density much lower
than liquid condensate. Therefore, the differential
pressure requirements to overcome centrifugal force in
a rotary syphon are much lower than the theoretical
differential pressure required for a solid water column.
The rotary syphon is best suited for speeds between
500 and 4000 ft/min, where rimming of condensate is
the rule. Above about 3000 ft/min, a flooded dryer
normally cannot be evacuated with the available
differential pressures. Stationary syphons with simple
vertical pipe are satisfactory for speeds below 500 ft/
min because the syphon operates in a condensate puddle
for good evacuation of condensate and excellent heat
transfer. The major problem with stationary syphons is
maintaining the desired clearance between the scoop
pickup shoe and dryer inner surface. Thermal distortion,
impact of condensate, and inadequate external support
contribute to problems with stationary syphons.
However, the rigidity of supports has improved, and it
is now easier to maintain set clearance.
Grooves are sometimes machined in the dryer bore,
under the syphon shoes to minimize condensate
thickness. This usually compensates for the overall
increase in shell thickness, equivalent to the groove
thickness, which is required to maintain code requirements. Grooves are generally placed outside the sheet
contact area because of the surface temperature
difference a groove produces. Syphon grooves tend to
increase dryer shell length. Sometimes syphon grooves
are alternated front and back and are left inside the sheet
edge at the wet end. As the sheet shrinks during drying,
it moves away from the syphon grooves.
The use of dryer bars inside dryers improves heat
transfer so that maintaining a thin condensate layer for
best or optimum heat transfer rates is not as critical.
However, there is now good evidence that excessive
condensate load (above design values) does in fact cause
loss in heat transfer even with dryer bars. This does allow
stationary syphons to be used without a groove, but
syphon clearance should be kept at the designed
clearance. This minimizes the chance of gouging damage
on the dryer inner surface and also reduces required shell
thickness. Higher condensate volumes in dryers equipped
with dryer bars require a higher torque load or drive
horsepower to get the condensate to rim. This often
results in dryer drive overload and kick out. This problem
is usually solved by rotating all of the syphons to the
same location in the puddle before startup, or the dryers
*V* r
can be rotapd ^ctyjfr until the condensate is evacuated.

A major proUftnwith heavy condensing load dryers,
such as those at the wet end of a paper machine, is that
the perimeter of the shoe may be too small to handle
the condensing load. Several mills increased the diameter
of the vertical syphon pipe and still had evacuation
problems until the shoe diameter was also increased. This
is true particularly at low operating pressures.
S.7 Effect of centrifugal force
The effect of centrifugal force is especially critical for
rotating syphons when a dryer is flooded. Very high
differential pressure may be required to evacuate dryers
once they are flooded. The pressure acting on a solid
water column at various speeds is noted on Figure 5.7.
The pressure indicated in Fig. 5.7 is the theoretical
minimum required to raise a solid water column out of
the dryer. The friction drop for the quantity offlowbeing
evacuated needs to be added to this value. (There is about
a 10% difference on the effect of centrifugal force for
cold and hot condensate at 0 psig and 150 psig as shown.)
Dryers running below 1800 ft/ min usually do not have
problems with insufficient differential to cover any
situation including flooding dryers. It should be noted
that the differential shown in Fig. 5.7 is that which is
required across the steamfit and not the headers where
most differentials are measured on paper machines.
Steamfit differential will vary between 40-80% of the
measured header differential, depending on pipe sizes and
restrictions in each system. There are many opinions as
to what the required differential across headers or
steamfits should be (see TAPPl TIS 0404-31 "Recommended Dryer Differential Pressures**). However,
professional designers have computer software programs
that accurately project syphon performance and the
relationship of blow through steam to DP. If a machine
runs slow enough and can maintain sufficient differential
across the steamfit to evacuate the dryer when the syphon
shoe is flooded, the dryers will not flood. For speeds
over about 1800 ft/min, it becomes impractical to
maintain sufficient differential across the steamfit to
cover flooding conditions. Over 1800 ft/min, the high
differential required across the steamfit to evacuate a
solid water column causes excessive blowdown or steam
loss, as well as excessive erosion problems and high
motive steam usage on thermocompressor systems. This
does not mean that high controlled differentials should
not be used for short periods of time to get out of a
problem. In normal practice on high-speed machines, the
steam system is designed to S @ J C O S K l W 4 0 9 n v
condition.
^ ^
A small 0.25-in. (6.4-mm) aspirator hole on the syphon
shoe, 2 to 3 in. (51 to 76 mm) above the dryer shell had
been proven helpful in maintaining two-phase flow by
breaking up a solid water column on some installations.
M,N.9O0NFIDENTIAL:
2030307433
I CONFIDENTIAL:
Dryer Drum ft System Controls and Equipment / 29
JuNESOTATOBACCO LITIGATIOfe
w -
t80p*Q-H0*f
<*
3200-
Ôpta
J12*F
condanaaa
atoo-
2*30-
2090-
1600-
iaoo-
00-
CtflMbgritanttora
Oinehdiyaradino
mtmmdtttwpmt
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CfeKTHFUOM. KlNCf -
PS
Fig. 5.7 Centrifugal forcerpsi.
Fig. 5.$ Horsepower required to rim various amounts

of condensate inside dryer.
5.8 Drive horsepower and dryer condensate load

It takes very little non-rimming condensate in a dryer
to create a large change in drive load when condensate
is in the cascade mode. A puddle which is only 1 inch
deep will require a drive which has two to three times
more horsepower than a dryer with little or no
condensate load at the same speed (see Figure S.8). If
most of the dryers in a drive section have more than
1 inch of condensate, chances are good that the drive
will overload and kick out during startup as the dyers
accelerate.
If excess drive loads develop, the dryers should be
stopped with the syphons in the puddle so that the
condensate may be evacuated before restarting. If felt
drives are used, the dryers should be rotated slowly until
the excess condensate has been evacuated.
2030307434
2030307434
Troubleshooting, Check-out, Startup, and Shirtrjpwn of Dryer Drainage Systems
6.0 Equipment Check-out

6.1 General installation
A. Physically trace all piping from mill supply to central
condensate receiver to make sure there are no
construction errors and that the proper equipment
is in the proper place. Piping configurations which
could cause a buildup of condensate should have
water traps. Note any piping changes (tie-ins,
additions, deletions) that may have been done over
the years, and determine their effect over the entire
range of operation.
B. Check to see that pressure relief valves are installed
on all individual headers. Dryers must not exceed
coded pressure at any time.
C. Locate check valves in each line that should have
one, and check direction of flow.
D. Be sure the main steam valve is shut and tagged
before stroking or opening any downstream valves
for check-out purposes.
E. Check out special dryers such as swing dryers. Bypass
interlocks, and run the system completely before
startup, to insure everything is functioning properly.
F. Check pipe sizes and valve sizes for excessive
velocities and excessive pressure drops and differentials. Size the condensate lines for two-phase flows.
G. Open all hand valves in each section: dryer valves,
transmitter valves to process, valves to traps, control
isolation valves, etc.
B.
C.
D.
E.
for shutoff and bypass valves required with each

control valve. See Fig. 6.1.
Check that valve position and positioner output
pressure are correct for varied controller outputs.
(Observe when stroking valve). Each valve must be
checked. Improper valve action is a common error.
Set the supply to all positioners as specified by
suppliers.
The percent opening of a valve is not an indication
of its percent of capacity. Valve curves must be
checked for capacity versus opening. This varies
greatly for different valve designs.
All valves should be installed to failsafe in case of
air or electrical failure. All inlet steam valves must
fail shut or require air to open. All downstream valves
must fail open or require air to close.
6.2 Control valves

A. Check all control valves for direction of flow, specific
size, location for ease of bonnet removal, positioner,
if required, and nameplate data, generally assuring
the proper valves are in the proper locations. If an
actuator is horizontal and large (4* control valves
or larger) it may need an external support Check
Fig. 6.1 Typical control valve piping arrangement
31
2030307435
32 / Paper Machine Steam and Condensate System
BHP
Table 6.2 POSITIONER OUTPUT PRESSUftft^ <>^

AND VALVE TRAVEL % FOR T Y J P i e S I ^ VALVES WITH POSITIONERS
^^ ^
Controller "Full
range,
range
output
valve,
pressure
3-15
Split
range
valve,
3-9
psi
psi
Split
range
valve,
9-15
psi
D.
E.
F.
% Valve Opening
3 psi
6 psi
9 psi
12 psi
15 psi
0%
25%
50%
75%
100%
0%
50%
100%
100%
100%
0%
0%
0%
50%
G.
100%
J.
H.
1
63 Separators
K.
A. Check the drain valves to carry blowdown steam
away from the condensate pump and motor (usually
piped to sewer). Drain lines should be anchored
securely. Check general steam and air piping.
B. Check liquid level controller displacer for proper
elevation on separator (suitably marked with an
arrow on the displacer housing). Too high a level
may cause condensate carryover.
C. Make sure the level glasses on the separator are tight.
D. "Stroke" the separator level control valve by means
of the surface mounted level controller (after supply
air to controller has been turned on).
E. Set the pressure switch to turn condensate pumps
on at 9 psi output from controller and off at 14 psi.
(Low level at 14 psi). Pressure inside the separator
may be sufficient to evacuate the condensate with
the condensate pump off.
F. Check and/ or calibrate the gauges on the separator.
Make sure that gauges read zero when there is no
pressure in separator. Gauges need replacing
periodically.
G. Set controllers to minimize control valve cycling at
startup (readjust after startup as necessary).
H. Set level control dial inside controller on mid-point
of float travel.
I. Action of level controller should be reverse acting
for a decreasing output signal with a rising level.
J. Replace separator sight glasses if dirty and it is
difficult to see condensate levels.
K. Each separator should have a high level flooding
alarm.
L. Each separator should have a low level alarm.
6.4 Condensate pumps and motors
A. Check for correct pump and motor (GPMt TDH,
L.
' N P S H M o t o r HP M o t o r R P M < a n d
rotation).
Check piping for bypass and piping stresses.
Check that pumps are mechanically free (rotate by
hand).
Check to see that packing glands are not cocked.
Hand-tighten packing evenly, just enough to prevent
leakage when running.
Check that pumps are properly lubricated.
Check that pump spillover lines are omitted or have
shutoff valves.
Check that discharge gauges are properly installed
and calibrated and have proper range.
Check pump rotation (start and stop pump quickly).
Pump casing vents should not be piped to the top
of the separator on vacuum receiver.
Check secondary piping (seal water and source,
cooling water and source). If condensate is used for
seal water, a condensate cooler is recommended.
After any shutdown, always let the seal and cooling
water run for about an hour before turning them
off.
Ensure that the pump is equipped with small
diameter (0.50 in.) recirculation line to prevent pump
overheating during dead shutoffs. Also a 0.75-in.
equalizing line from pump suction to the top steam
space of the tank should be included to prevent
cavitation.
6.5 Vacuum pump

A. Check for correct pump and motor (CFM, GPM,
Motor HP and RPM).
B Check for proper connections to receiver tank. Check
installation drawing.
C. Check to see that the pump is mechanically free
(rotate pump shaft by hand).
D. Check that vacuum relief is properly installed and
spring is under compression if this system is required
to operate dryers in a vacuum condition.
E. Check that pump is properly lubricated. Check seal
water lines, valves properly installed, seal water
discharge line unobstructed.
F. Check direction of rotation (start and stop pump
quickly).
G. Check that the vacuum discharge line is unobstructed
and preferably visible.
H Check that screen is in place between flanges on inlet
side of the vacuum pump. This screen can be removed
after a few days of operating a new pump.
I. After the proper a r r j ^ ^ Q Q ^ l Q g s been
determined, set plug valve to this flow, and use onoff valve in future when starting and stopping
vacuum pump.
J. Excessive discharge piping will reduce vacuum level.
Allow maximum one PSI back pressure or less in
piping design.
2030307436
CONFIDENTIAL:
2030307436
Troubkshootinjpfheplrout, Start-up, and Shutdown of Dryer Drainage Systems / 33
-^9
6.6 Heat exchanger (HE)
A. Check that it is the correct unit (size, model, size

of connections, inteMal battels, etc.).
B. Check that cooling water flow is in proper direction
through the HE.
C. Check that valves are included if vent lines are
installed.
D. Check that there is room for tube bundle removal.
Mark this area so that no future equipment is added
here.
E. Check temperature indicator controller and sensing
element tube for damage and location. Sensing
clement should be in the condensate of the vacuum
receiver.
F. Set temperature for desired vacuum level, and adjust
according with operating experience if vacuum is
desired in the wet end dryer.
G. Stroke HE cooling water valve by adjusting set point
of the condensate temperature controller.
6.7 Thermocompressor (THC)
A. Check the thermocompressor for proper connections, size and nameplate data (insure THC is in the
right location).
B. Check to see that a turndown regulator and gauge
are installed in each thermocompressor air line to
the diaphragm or piston controlling the motive steam
spindle. (Install this regulator if not already there.)
This is a very important tool for proper differential
and pressure control of each section at optimum
capacity during sheet break and warm shutdowns.
C. Stroke the THC and any split range control valves.
D. Set 20 psi air to the THC spindle positioner.
E. Be sure that shipping plugs are removed from the
THC operator. These plugs will cause erratic control
of the THC if not removed. Do not replug breather
holes.
6.8 Steamfit and piping
A. Check each steamfit for piping and proper installation. (Carbon installation, molycote, setup, etc.).
B. Check all hand valves for closed or open position
as desired, before startup.
C. Check for proper steamfit support and piping stresses
on carbon seals. There should be less than 1/16 inch
between the steamfit and piping drop leg center lines
or rigid steamfit supports may be required.
D. Install a pressure gauge across at least one steamfit
in each steam section.
E. Do not run dryers for any length of time without
some steam going into dryers. Damage to carbons
and plates may result if they are run dry.
6.9 Controllers
A. Set air supply to all pneumatic controllers at 20 psi
(if pneumatic controllers are used).
B Insure that all instruments are of proper action (direct
or reverse acting) with proper range and charts
available.
All air lines should be checked for leaks.
Check that all transmitter signab are going to the
proper controllers (air or electrical).
Set controllers on manual and stroke all valves,
making sure the correct valve is stroked with the
proper instrument.
Check the thermocompressor warmup control.
When the selector valve or switch is in the "OFF*
or "Warmup" position, the thermocompressor
should be exhausted. When in the "ON" or "RUN"
position, the thermocompressor should receive a
signal from the proper controller. If other control
valves are tied into the system, check that they
respond properly.
Check the automatic turn-down control, if installed.
When the sheet break detector opens the circuit
(selector switch in the run position), control of the
pressure recording controller switches from the
regulator marked "RUN" to the regulator marked
"TURN-DOWN." In most cases, the T U R N DOWN" regulator will be located inside the cabinet
H. Check installation of pressure transmitters and
differential pressure transmitters (high side piped to
steam header). See Figure 3.2.4.
Be sure seal pots are installed where required and
condensing reservoir is filled with water (fill water
legs if transmitters are located below headers). This
is very important and a common source of problems.
Transmitters should be installed above both steam
and condensate headers whenever possible. Transmitters below the headers must have seal pots
properly installed and filled for proper operation.
Pressure transmitter should not be installed at the
bottom of a water leg to a differentia) transmitter
(another common error).
Check calibration of transmitters for both range and
zero suppression if seal pots are not being used.
6.10 Systems checkout
rebuilds
flushing new systems and
A. Before opening a valve to admit steam to a section

or header, check for situations which would cause
a buildup of condensate in the line. Condensate
should be drained f r c g Q Q 3 C W 4 3 5 ? i is
admitted.
B. Close the isolation valves ahead and after all control
valves. Open the bypass valve around all control
valves such as the blowthrough, blowdown, and
2O3Q307437
CONFIDENTIAL:
2030307437
. ^
liquid level control valves. In most cases, co$roLp'

valves will be installed with isolation valves/anjjâ
bypass valve. Both isolation valves should be^R&ed
at all control valveaduring flushing to prevent foreign
material from lodging in the control valve.
C If bypass valves are not installed, close the upstream
shutoff at the makeup control valve and fully open
the control valve and the downstream shutoff valve
(use manual switch in controller). Fully open all the
blow through, btowdown, and liquid level control
valves.
D. High pressure motive steam may heat journals and
bearings during long breaks due to the high
temperatures and pressure of the motive steam going
through the journals with the makeup steam valve
shut. Journal insulation sleeves are a good idea to
minimize bearing heatup.
E. Oil temperature may get too hot during long breaks
with the THC operating, causing bearing oil
problems (too many bearing failures).
B. Differential Pressure or Flow Controllers Differential controllers will have to be reset at a lower
differential. Flow controllers will not have to be
adjusted, because they will automatically compensate
to the lower 1-2 PSI differential required at these
conditions.
C. Steam Pressure Controllers - The controllers
should remain in the "automatic** mode. The set point
varies according to operating conditions. Set the
pressure according to instructions from paper mill
supervision. Pressure should not fall below 10-15
psig.
D. Dryers - Stop the dryers with the manholes in the
12 o'clock position, if syphons are all in the same
position.
E. Do not stop dryers if steam to dryers is not turned
off.
F. With dryer felt drives, keep the dryers rotating until
the steam inside the dryers is all condensed and
evacuated.
6.11 Shutdown procedures
6.12 Sheet breaks
6.11.1 Cold shutdown
6.12.1 Long breaks
The following procedures are suggested when a long

shutdown is anticipated and it is desirable to cool the
dryers.
A. Steam Valves - Close the main header steam valve,
and make sure the main header bypass valve is also
closed. Call the Power Department operator to close
the steam valves located in the Power Department
feeding the papermill or machine.
B. Sheet - Take the sheet off the dryers.
C. Dryers - Stop the dryers with the manholes in the
12 o'clock position so that the syphons are in the
6 o'clock position, or in the condensate puddle.
D. Instruments - Place instruments in the "manual"
mode.
E. Separator Condensate Pumps - Allow pumps to
run until the automatic level control valves are closed.
Pumps will stop automatically if the switch is in the
"Auto" position. After the pumps stop* turn the
switches to *OFF."
F. Blowdown Valves - Open all biowd own valves if it
is desired to relieve pressure on the entire system.
This should be necessary only for long shutdowns.
G. Thermocompressor Run/Warmup Switch - Set the
run/ warmup switch to the "warmup" closed position.
H. Note that dryers filled with condensate will stay
warmer much longer than empty dryers.
A long break is a break that is likely to be 20 minutes

or longer. The following procedures apply to a long
break.
A. Run/Warmup Switch - Normally turn the switch to
the "warmup" position. When a tail or sheet is back
on the dryers, turn the switch back to "run." If the
system has a preset sheet break selector switch, this
will automatically set the THC, dryer pressure and
differential to a predetermined condition.
B. Evacuation Flow Controllers - Leave the controllers in the "automatic" mode at the same set point
as before the break.
C. Differential Pressure Controllers - Turn down
controller to 3-4 psi, then turn back up to normal
differential when sheet is on the dryers. (Do not
adjust if break switch is used).
D. Steam Pressure Controllers - Leave the controllers
in the "automatic" mode, and do not change the set
points unless instructed to do so by the shift
supervisor. Some grades require operating at half
pressure during a break so as not to overheat the
dryer surface for the sheet return.
E. Dryers - If the dryers are stopped, insure that the
manholes are in the 12 o'clock position so that the
syphons are in the 6 o'clock positioner jntoe puddle.
6.12.2 Short breaks
6.11.2 Warm shutdown

A. Thermocompressor Run/Warmup Switch - Set the
switch in the "warmup" position. This will shut off
motive steam and open the blowdown valves.
A short break is one that is less than 20 minutes.

A. Run/ Warmup Switch - Insure that the run/warmup switch stays in the "run" position.
B. Evacuation Flow Controllers - Leave the con-
CONFIDENTIAL:
MiNNEioTATOBACCO LITIGATION
2030307438
Troubkshooting, Check-out, Start-up, ami Shutdown ot Dryer Drainage Systems

trollers in the automatic mode at the same set Qpn, - < - 6.13.2 High diflercntial pressure
as before the break.
*'' * ^ ^
C Differential Pressure Controllers - Leave ^nvtne
A. See if some dryers areflooding;check drive loads.
B. Check separator for level and possible carryover of
automatic mode and at the same set points.
condensate.
D. Steam Pressure Coiarollers - Leave the controllers
C. Check differential valve or THC to see if they are
in the "automatic" mode, and do not change the set
stuck open.
points unless the supervisor so instructs or the change
D. Check separator blowdown valve to see if it is shut.
is required for the grade being produced.
. Check blowdown valves to atmosphere or HE to see
if they are open.
6.13 Operating problems and trouble shooting
F. Check and close all bleed lines.
G. Check lines blowing down to a lower pressure header.
6.13.1 Low differential pressure
H. Check controller output and signal received at
control point.
A. Check to see if the system is in the manual or
I.
Check for proper seal pot installation if transmitter
automatic control mode.
is located below either of the steam and condensate
B. If sheet break switch is used, check to see if it is in
headers.
the manual run position.
C Check to see if differential control valve or
6.13 .3 High drive torque
thermocompressor is opening to correspond to
controller output. (May not be opening at all).
A. Check separator level.
D. Check for flooded separator.
B. Check differential across steamfit. Check curves for
E. Check controller output and signal being received
the proper differential required for speed and
at the control valve or THC
condensing load.
F. Check instrument air supply to control valve or THC
C. Check for high sheet tensions on heavyweight grades
G. Check to see if check valves are stuck open or closed.
such as liner, and adjust draws, particularly at the
H. Steam may be short-circuiting through broken
dry
end.
syphons, eroded syphons, broken steamfit bellows
D. Check drive functions.
or other steamfit internal parts such as carbon.
E. Check for dryer cascade conditions and filled dryers,
I. Syphon clearances may be too high.
F. Dryers stopped under pressure without the syphon
J. Cascading sections may operate too close in pressure
in the puddle can create enough condensate torque
to allow sufficient differential pressure. It may be
to trip out drive motor at startup.
advisable to convert to a thermocompressor system
or increase differential pressure between sections.
G. Check dryer surface temperatures.
K. Low operating pressure may leave insufficient room
6.13.4 High separator level
for creating differential unless THC is used or dryers
are cut off.
A. Separator control valve not working (shut, binding,
L. Check to see if seal pots are properly installed and
operator problem).
transmitters are properly located. Differential
B. Hand valves around control valve may be closed.
transmitters below the headers must have equal water
legs to both sides of the transmitter or be properly
C. Pump may have kicked out. Motor may be damaged.
compensated for the difference. Pressure transmitters
Motor may be marginal in capacity.
should not have any water leg on the transmitter
D. Pump may not have sufficient head to overcome
input unless compensated for.
collection tank back pressure, particularly at lower
M. Check to see if the thermocompressor is choking.
dryer pressures.
Set controller to manual, and manually stroke THC
E. Impeller may be worn.
while running. If DP peaks and then drops off as
F. Controller loop may not be functioning properly.
THC opens, THC is choking. Note that THC may
G. Use separator bypass or blowdown hand valve to
choke at low pressure but not at high. Try to limit
evacuate condensate until the problem is identified
stroke at low pressure as necessary.
and fixed.
N. Check the back pressure against which blow through
H. Check pump cavitation with condensate temperature
steam is discharging. It must be low enough to allow
andNPS
required flow.
I. Separator level control displacer may be unhooked
orjammed.
2030307439
CONFIDENTIAL:
2030307439
36/ Paper Machine Steam and Condensate Systems
o^;?''
6.13.5 Very low separator level

A.
B.
C.
D.
Blowdown valve ope or leaking.

Control valve stuck open or badly worn.
Level controller not working.
Vacuum pump may be flashing all condensate out
of the vacuum receiver tank.
6.13.6 High steam pressure

A. Controller malfunction Check air supplies and
loop operations.
B. Thermocompressor override not working - When
the THC is on differential control, it may need to
be cut back on sheet break.
C. Check location of tranmitter to be sure it is not
located in a water leg adding to the signal, making
the readout pressure appear higher by the amount
of water leg.
D. Bypass valve may be open.
. Dryers may be waterlogged.
E. Additipff$fHerpentine felt will cause lost production

on di^CT limited machines.
Change in furnish or freeness could dramatically
change machine production.
Dryer felt porosity may be lowered due to felts filling
up or new press felt installed.
Sheet may be drier at the reel or may be overdried.
Press moisture may be higher than normal.
Check pocket and hood humidities compared to
good drying periods. High humidities will reduce
drying rates.
Check draws especially on those sections without
felts.
Dryers may be filling up.
6.13.7 Low steam pressure

A. Valve not opening to correspond to controller
output
B. Valve too small, taking top much of a pressure drop.
C. Main line pressure too low.
D. Isolation valves may be partially closed.
E. Check power department steam pressure swings.
6.13.8 High steam usage per pound of water evaporated
A. Too much steam vented to the atmosphere or heat
exchanger during normal running or sheet break.
B. Differential across steamfit too high.
C. Steam being metered to the machine going for other
than drying paper, such as:
1. Hood or air heaters,
2. Heating seal pit water,
3. Heating press shower water,
4. Steam leaks.
D. Noncondensable bleeds being used unnecessarily.
E. Vacuum pump being used when there is no need for
it.
F. Syphon shoe clearance too high.
6.13.9 Loss in production rates
A. Felt tensions may be low. Check and calculate.
B. Dryers may be rimming or cascading at the same
speed for the same grade on different runs, providing
two different drying rates.
C. Dryers may be coating up.
D. Reinstall removed felts.
2030307440
CONFIDENTIAL-
MINNESOTA TOBACCO LITIGAT'

Wrl
'2030307440
oggSSSSMfe-
Glossary/37
. * Ô
^4y *$
GLOSSARY
Air-to-close (A/C) - an automatic valve which closes as
instrument air pressure to the valve increases. Valve
is wide open at 3 psi and closed at 15 psi. Other
air pressure ranges can be used. Oh drawings airto-close valves are normally indicated by A/C.
Air-to-open (A/O) - an automatic valve which opens
when instrument air pressure is applied to the valve.
In a typical installation, the valve starts to open at
3 psi and is fully open at IS psi Other typical air
pressure ranges, such as 3 to 9 and 9 to 15, are used
also. On drawings air-to-open valves are normally
indicated as A/O.
occurs^Wicn the THC is wide open, trying to create

high differentials. Once this reverse flow occurs, the
THC has to be closed until it can regain proper
discharge and maintain the differential it can create.
This condition can also occur if the THC is putting
out more steam than can be condensed in the dryers.
Cockle - condition of rough paper surface, in form of
ribbed area, often created by unfelted dryers and lack
of graduated temperature control on wet end dryers
(high temperatures). Also caused by a nonuniform
sheet as a result of forming and pressing.
Condensate (Q - water which is formed when steam
condenses.
Back pressure - term used to define pressures required

in cascading sections of dryers to create sufficient
differential at a given speed, sheet weight, etc.
Sometimes also referred to as the turbine back
pressure feeding the dryer section.
Condensation - process of changing steam to water.
Blowdown valve (BV) - a valve used to create required

differential across dryers during specific phases of
operation. Steam through a blowdown valve usually
passes to a heat exchanger, atmosphere or lower
pressure header.
Curi - condition of opposite edges of aflatsample lifting

from a supporting surface whenever permitted to lie
free at specific conditions.
Blow through (BT) - steam which is used to entrain and

remove the condensate formed in the dryers on a
continuous basis. This entrainment and two-phase
flow occurs under the syphon shoe. Blow through
steam is normally 10-20% by weight of the mixture
pulled through the syphon pipes.
Blow through valve (BTV) - a valve used to control
differential across paper dryers by controlling steam
flow to a THC, cascading section, or lower pressure
header.
Cascade system - method of piping flash and blow
through steam from one dryer section at higher
pressure to another lower pressure section in series
to effect economy.
Choking thermocompressor - a condition where the
amount of motive and suction steam is greater than
can flow through the THC diffuser. Excess steam
is then pushed back into the suction pipe. This usually
Condensation rate - normally expressed as pounds per

hour steam condensed by cylinder, dryer section, or
machine.
Differential controller (DC) - instrument which receives

output signal from differential pressure transmitter,
modifies the signal through a receiver and pilot relay
system, and retransmits to thefinalcontrol element,
usually a valve.
Differential pressure (DP) - the difference in pressure
between two measured points, normally the difference in pressure between a steam manifold and
condensate manifold (header) in a dryer section.
Differential pressure control valve (DPCV) - actuated
from differential controller, can be tied in to dryer
section supply or blowdown.
Differential pressure transmitter (DPT) * instrument
provided with two pressure sensing connections (one
of which is termed high pressure, the other low
pressure) with the ability to transmit a signal in
proportion to the dif|ercjiJwttWia*Uiflli*nd low.
Signal can be pneuma
203oao|
2030307441
Differential setting - position of set point index in

differential controller.
Dryer ratio - percentage of flash steam dryers to
primary steam dryers in a given cascading dryer
section. (Flash dryers utilizing steam from
separators.)
Dryer surface temperature - temperature measured on
face of the dryer, i.e., on outer shell surface within
area covered by sheet.
Dryer syphons - pipes installed to remove condensate
and blow through steam from dryer cylinders.
Installed in a plane perpendicular to the long axis
of cylinder, on the inner dryer surface.
Fixed restrictions - small orifices, traps, or preset valves.
Flashing steam (FS) - the process of condensate
changing to steam when pressure on the condensate
is reduced below the flashing point.
Flow control (FC) - method of controlling dryer
condensate evacuation by controlling blow through
rate instead of the differential pressure across the
dryer. Flow control provides floating differential that
automatically adjusts to compensate for all dryer
conditions such as flooding, sheet break, condensing
rate changes, and speed changes. It provides a very
energy-efficient system.
Flow transmitter (FT) - instrument that measures flow
by sensing the pressure drop across a flow orifice.
The measured flow is usually transmitted to a
controller, indicator, or recorder.
Heat exchanger (HE) - a device for transferring heat
from one fluid to another, usually tube-in-shell,
singic-or double-pass, vapor to cooling water type,
with or without baffles.
Jet compressor - see Thermocompressor.
Latent heat (LH) - the heat required to change water
to steam at its boiling temperature. This heat is given
up when steam is condensed.
Level control valve (LCV) - actuated from level
controller, installed in condensate from separator
piping, usually in pump discharge.
Makeup valve (MY) - this is the normal steam supply
and pressure control valve to a group of dryers on
the same /hanifVut. This valve may operate in

sequence ym^t blowdown valve to control differential. If a differential THC is used, the THC supplies
whatever steam is necessary to maintain set
differential, then the main steam valve "makes up"
the additional steam required to maintain set
pressure. Some systems use the THC to maintain set
pressure, and the differential is adjusted with a
separate control valve; but this is not the most
economical system and should be avoided.
Manifold header (MH) - a pipe having openings far
multiple connections of steam, condensate, water,
air, etc.
Motive steam (MS, Pi) - high pressure steam used in
a thermocompressor to supply the energy to entrain
a low pressure steam for reuse at an intermediate
higher operating pressure.
Noncondensables (NQ - gases which are present to a
very small degree in all steam, which are not
condensable to a liquid-like steam. They usually
consist of air; i.e., oxygen, nitrogen and carbon
dioxide. An accumulation of these gases lowers steam
temperature and affects drying if not properly
evacuated at startup of a dryer section.
Picking - pulling of surface fibers from surface of the
sheet, caused by adherence to dryer surface.
Pressure control loop (PCL) - consists of a pressure or
vacuum measuring and transmitting device, with a
controlling device (controller) connected to a final
control element (valve).
Rotary syphon - syphon shoe rotates with dryer
cylinder. Shoe can be bolted to cylinder or
springloaded.
Saturated steam - steam existing as 100% vapor at a
temperature where any further heat removal will
cause a portion of the vapor to condense to water.
Separator (S) - vessel into which condensate and blow
through steam are discharged from a dryer group
to separate liquid and vapor. May be internally
baffled and always pressure-coded by law.
Set point (SP) - the desired value of a condition which
is set on a controller to achieve this value. S^cam
is controlled to a d e s i r e d 0 Q ^ Q f f 4 A & m
pressure controller set pom! to tne desired pressure.
203O3O7*WZ
CONFIDENTIAL:
2030307442
CONFIDENTIAL:
GlassMn / 39
?.
MINNESOTA TOBACCO L coflnccC-rrbcnth^

I T I G A Tshoe
^ -to" the dryer inlet steam spider,
Shrinkage decrease in sheet width from couch (wet

end) to reel (dry end). Expressed in percent or
absolute units.
Steam condenser (&) - also known as vacuum

condenser (VQ or a heat exchanger (HE). Consists
of a shell which contains a tube bundle through which
water is circulated to condense process steam.
Suction steam (SS, P,) - this is the blow through steam
which is recirculated by the THC and boosted to the
operating pressure.
Sunday drive (SD) - slow-speed type drive arrangement
often connected to Yankee cylinder, or calenders, to
permit continuous turning at reduced speeds during
weekends or other shutdown periods.
Superheated steam - steam existing as 100% vapor
which is at a temperature greater than the temperature of saturated steam. Superheat must be removed
before steam will condense.
Surface hardening - theoretical sheet condition created
by too rapid drying of the wet sheet. Rapid
evaporation from the extreme outer fiber layer
hardens the surface and can restrict further drying.
Syphon pipes - there are two component parts. One
calledjhp vertical syphon pipe, and a second runs

thrognthe dryer journal to the steamfit, called the
horizontal syphon pipe.
Stationary syphon - also called fixed-end* where the
shoe remains fixed relative to dryer rotation.
Syphon shoe - fitting connected to the end of a vertical
syphon pipe. Normally a separate piece, fastened to
the vertical pipe by threading, set screw, etc.
Temperature gradient - surface temperature profile of
dryers, normally in increasing value, indicated from
wet to dry end.
Thermocompressor(THQ - piece of equipment used to
boost or recompress blow through steam to operating
pressure. It uses higher pressure motive steam to
entrain blow through steam and discharge it back
to the dryer at the operating pressure.
Transmitter (TRN) - an instrument that measures a
condition and transmits information to a central
location for further use. Typical conditions measured
are: flow, pressure, temperature, etc.
Weight ratio (Rw) - weight of entrained suction steam
per unit weight of motive steam used.
2030307443
2030307443
4$/Legend of Figures
CONFIDENTIAL:
LEGENDFORFKUM/NNESOTA
A/C
A/O
ASG
A/S
ATM
BTV
BT
BV
C
CHV
CP
cv
DC
DFC
DFT
DP
DPI
DPC
DPCV
DPRC
DPT
DV
FC
FS
FT
HE
HP
HS
IL
LC
LCV
LH
LP
M
MH
MS
MV
NC
Pi or PM
P2 or PD
Pa or Ps
PC
PCL
PCV
PDP
PIT
TObnCCO LITIGAifON
Air-to-Close
Air-to-Ope^,
Adjustable Sight Glass
Automatic Switch
Atmosphere
Blow Through Valve
Blow Through Steam
Blowdown Valve
Condensate
Check Valve
Condensate Pump
Control Valve
Differential Controller
Differential Bow Controller
Differential Flow Transmitter
Differential Pressure
Differential Pressure Indicator
Differential Pressure Controller
Differential Pressure Control Valve
Differential Pressure Recorder Controller
Differential Pressure Transmitter
Differential Valve
Flow Controller
Flashing Steam
Flow Transmitter
Heat Exhanger
High Pressure
Hand Switch
Indicating Light
Level Controller
Level Control Valve
Latent Heat
Low Pressure
Motor
Manifold Header
Motive Steam
Makeup Valve
Noncondensables
Motive Steam Pressure
Discharge Steam Pressure
Suction Steam Pressure
Pressure Controller
Pressure Control Loop
Pressure Control Valve
Positive Displacement Pump
Pressure Indicator Transmitter
.^.
PRC
pph
PT
PS
Pressure Reqaftder Controller

Pounds PflFriour
Pressure Transmitter
Pressure Switch
psia
Pounds Per Square Inch Absolute
psig
Pounds Per Square Inch Gage
Recorder as in DP(R)C
R
Rw
Weight Ratio SS/MS - Wa/Wi
Separator
S
Steam Condenser
SC
SD
Sunday Drive
Set Point
SP
SR
Selector Relay
Suction Steam (PB)
SS
Selector Switch
Selector Valve
sv
TC
Temperature Controller
TCV
Temperature Control Valve
Therm ocompressor
THC
TRN
Transmitter
TS
Temperature Sensor
VAC
Vacuum Controller
VB
Vacuum Breaker
Vacuum Condenser
vc
Vacuum Control Valve
VP
Vacuum Pump
Vacuum Receiver
VR
W
Steam Flow
W,or WM Motive Steam Row
W 2 or WD Discharge Steam Flow
W 3 or Ws Suction Steam Flow
(A)
Atmosphere
(B)
Boiler House
(CW)
Cooling Water
(E)
Exhaust
(TIP)
Typical
ssw
vcv
203030744
2030307444
CONFIDENTIAL:
^yo
What is TAPPI?
<j$&*
Celebratinîts 75th anniversary in 1990, TAPPrfsyJ$# world's
largest professional society of executives, operating managers,
engineers, scientists, and technologists serving the paper and
related industries. Total membership is approximately 30,000 with
some 80% residing in the United States. The remainder live in one
of 76 other countries.
TAPPI is renowned for its industry publications. Members produce
technical books, reports, conference proceedings, course notes, and
home study courses through TAPPI PRESS. Tappi Journal,
distributed monthly to all members, is the leading publication for
technical information on the manufacture and use of pulp, paper,
packaging and converted products. Through TAPPI, Association
members develop, update and publish test methods and technical
information sheets on which much of the industry depends to
analyze its products and processes.
TAPPI sponsors a variety of technical conferences, seminars and
short courses to foster world-wide technical information exchange
and enhance the professional development of members.
For membership information, to order any of TAPPI's professional
development products, or to register for a meeting, call TAPPI's
toll-free Service Line: 1-800-332-8686 (U.S.); 1-800-446-9431
(Canada).
TAPPI's Vision
We are a global community of motivated individuals who lead the
technical advancement of the paper and related industries.
Together...
We provide outstanding educational and professional
growth opportunities.
We serve as a world-wide forum to exchange technical
information, promote research and recognize
individual achievement.
We create success by the quality, timeliness and
innovativeness of our products and services.
Integrity and fellowship characterize our association.
2020307445
2030307445
CONVERSION FACTORS FOR SI UNITS

Value in Trade or
Customary Unit
/*.._! r Tmm*
Convejflpr
Fadbr
-
Value in
SI Unit
Symbol
cm
square inches
square feet
square yards
acres
6.43
0.0929
0.836
0.403
square centimeters
square meters
square meters
hectares
Basis Weight* or
Substance
(300-sheet ream)
or Grammage* when
expressed in g/m 2
17x22
24x36
23x38
23x40
pounds per 1000 square feet
(Paperboard)
3.760
1.627
1.480
1.406
4.882
grams per square meter
Breaking Length
meters
0.001
kilometers
Burst Index
g/m 2
Bursting Strength
pounds per square inch
6.89
kilopascals
kPa
Caliper
mils
0.0234
millimeters
mm
Concora Crush
pounds
4.43
newtons
Edge Crush
pounds per inch
0.173
kilonewtons per meter
kN/m
Energy
British thermal units (Btu)
joules
Flat Crush
pounds per square inch
6.89
kilopascals
kPa
Force
kilograms
pounds
9.81
4.43
newtons
newtons
N
N
Length
angstroms
microns
mils
feet
0.1
1
0.0234
0.303
nanometers
micrometers
millimeters
meters
run
um
mm
m
Mass
tons (2000 lb)

pounds
ounces (avd p)
metric tons
kilograms
grams
t
kg
Mass per Unit Volume
ounces per gallon

pounds per cubic foot
7.49
1.60
kilograms per cubic meter

kilograms per cubic meter
kg/mj
kg/m3
Puncture Resistance
foot pounds
1.36
joules
Ring Crush
pounds (for a 6-in length)
0.0292
kN
Stiffness (Taber)
gram centimeters (Taber Units)
0.0981
millinewton meters
mN.m
Tear Strength
grams
9.81
millinewtons
mN
Tensile Breaking Load
pounds per inch

kilograms per 13 millimeters
0.173
0.634

kN/m
kN/m
Volume, Fluid
ounces (US fluid)

gallons
29.6
3.79
milliliters
liters
mL
L
Volume, Solid
cubic inches
cubic feet
cubic yards
16.4
0.0283
0.763
cubic centimeters
cubic meters
cubic meters
cm
Area
ft/cm,
0.0981
1033
0.907
0.434
28.3
ha
g/m 2
it
it
It
it
it
it
It
n
km
kPa
g/m 2
See TAPPI Technical Information Sheet 0800-01.
MINNESOTA TOBACCO L m L o N
2030307446
CONFIDENTIAL:
MINNESOTA T96ACQ9 WTIÂTtp.^
About the Editor:
cfl^'"
Robert D. Perrault has been active in the Engineering Division

since he joined TAPPI in 1968. He served as chairman of the
Pressing Subcommitteefrom1977 to 1982. In 1983 and 1984 he was
secretary of the Pressing and Drying Committee. In 1985 and 1986
he was chairman of the Pressing and Drying Committee. When the
name of the Pressing and Drying Committee was changed to the
Water Removal Committee, Mr. Perrault served for another two
years as its chairman from 1987 to 1988. For the past six years, he
has been chairman and one of the instructors for the Pressing and
Drying Short Course. From 1984 to 1987, he was on the Tappi
Journal Editorial Board. He has been a return speaker for the
Energy Conservation Seminar, ISA Conference and other speaking
engagements. Mr. Perrault has several publications and patents to
his credit.
For several years Mr. Perrault was group leader for the dryer
drainage group of a major paper machine equipment supplier
company, in charge of design, installation, start up and
troubleshooting dryer drainage systems. He has been a pioneer
and leader in curving and dryer drainage systems for over 30 years.
Perrault is manager of the paper and finishing groups for SimonsBrazil in Sao Paulo.
2030307447
2030307447

01 Paper Machine Steam & Condensate Systems PDF

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Paper Machine Steam and

The information and data contained in this document were

Copyright 1990, 1982, 1977,1970 by

Permission of TAPPI is granted to photocopy items for internal or

Printed in the United States of America

Nick De'vich, A bitibi-Price Inc., Sheridan Park, Mississauga, Ontario, Caii^w

Steam Control and Condensate Evacuation Systems Deflgn/1

1.11 Single felted dryer section / 8

Mechanical Vapor recompression (MVR) / 21

Dryer Drainage System Controls and Equipment / 23

Troubleshooting, Check-out, Start-up, and Shutdown of Dryer Drainage^ fe

MINNESOTA TOBACCO LITIGATION

Steam Control and Condensate Evacuation Systems Design

which supplies steam tA\f the dryers and dumps

1.1 Basic steam pressure control system

1.2 Multiple pressure control sections

The first logical step is to isolate several of the wet end

Fig. l.l Basic steam pressure control system.

2/ P$per Machine Steam and Condensate System

MINNESOTA TOBACCO LITIGATION

Fig. IJ Multiple pressure controlled sections.

Starn Control and Condensate EvMcuMtion Systems Desi

MINNESOTA TOBACCO LITIGATION

Some grades of paper generally require low dryer surface

Fig. 1.5 shows a further improvement of the basic dryer

4/ Paper Machine Steam and Condensate Systems

MINNESUIA rOBAfcftp I iTiriJriqa

MINNESOTA TOBACCO LITIGAT)

3 requiring low pressure steam. Discharging to the

Fig. 1.6 Simple three-section cascade dryer system.

Fig. 1.7 Pressure control for wet end dryers.

On "three-section cascade," control is sirrujar^oVBT^

many variations of the systems shown here.

Fig. 1.8 Low wet end dryer pressure.

81 Paper Midline Steam and Condensate Systems

ig^SOTA TOBACCO LITIGA I

a^ . FSingle felted dryer section

After-size drying control is generally along the sanfclti&

There are many special cases requiring customized

MAIN STEAM SUPPLY

G^AjW&fgned unit can waste high pressure motive steam and

19 / Paper Machine Steam and Condensate Systems

Fig. 2.0.1 Basic automatic thennocompressor.

Thennocompressor performance is of two types, critical

conditions, and a design is determined. The final design

* Maximum thennocompressor suctionflowwith spindle

Thermocompnsson (THC) /It

MINNESOTA TORAnCQ LITIGATION

MOTIVE PRESS. 130 psig

12 / Ptper Machine Steam and Condensate System

MOTIVE PRESS. 130 psig

PPH SUCTION / PPH MOTIVE STEAM (R v >

Fig, 2,03.4 Entrainment curves for 100-, ISO-, an

Thermocompnsson (THC) /13

2.1 Thermocompressor pressure control system*'' /

The thermocompressor pressure control system was one

Fig. 2.1 Thermocompressor pressure control system.

2.2 Thermocompressor pressure control system with

A significant improvement over the thermocompressor

iVilNNESOTA TOBACCO UTIQAriON

14 / Paper Machine Steam and Condensate Systems