SALES TRAINING HEAT RECOVERY SYSTEMS BLOWDOWN SEPARATORS & TANKS LIQUID SAMPLE COOLERS ORIFICE METERS

SALES TRAINING HEAT RECOVERY SYSTEMS BLOWDOWN SEPARATORS & TANKS LIQUID SAMPLE COOLERS ORIFICE METERS

COMPANY OVERVIEW Madden Manufacturing, Inc. in Elkhart, IN since 1952 Originally operating out of Chicago, all production operations now exist in Elkhart Elkhart Our Mission is to produce simple, rugged industrial quality pumps and steam system equipment that will provide excellent performance and value for our customers.

BOILER BLOWDOWN PRODUCTS Heat Recovery Systems 3 Styles with 28 Models HV, HC, and HX series Blowdown Tanks and Separators 6 models of tanks and 10 models of separators Sample Coolers 2 Types with 11 Models Orifice Meters: Blowdown flow control 8 models: 2 types OM250/650

FUNCTION OF MADDEN HEAT RECOVERY SYSTEMS Madden Heat Recovery Systems work on the flash steam principle. When hot boiler blowdown enters the HC or HV unit, it hits a baffle causing some of the water to turn to flash steam. This flash steam is then sent off to the DA to be reused. The remaining hot water is cooled to a safe temperature by the heat exchanger coil or tube bundle in the bottom of the unit. The cooled blowdown is then safely disposed and the resulting heated up cooling water is now boiler feed water supplied to the D/A tank.

HV SERIES 12 Models Blowdown capacity from 3,000-15,000 PPH Vertical Type requires less floor space No solids build up Recovers 90% of lost heat Reduces temperature of blowdown discharge to meet statute limits Pays for itself in a matter of weeks for some installations

HC Series 10 Models Blowdown capacity from 4,000-50,000 PPH Horizontal Type No solids build up Recovers 90% of lost heat Reduces temp of blowdown discharge to meet statue limits Pays for itself in a matter of weeks for some installations

HX SERIES 6 Variations Designed for blowdown flows up to 3,500 lbs. per hour from boilers up to 150 psi ASME 150 psi shell construction Inexpensive yet durable No Flash steam created Fresh make up water is the shell side counter flow cooling media Self Cleaning

ORIFICE METERS OM250 & OM650 Rated at 250 & 650 PSI Each model has four different plate sizes Plates with 17 different hole sizes Gives boiler operator precise repeatable control of the continuous blowdown flow rate Generally used on industrial boilers from 200 PPH up to over 100,000 PPH steam production Guaranteed for up to 10 years from cutting, wire drawing, or other distortion in the orifice plate

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PLATE AND SELECTOR DISC

ORIFICE FLOW CHART EX.

BDHR/ORIFICE METER SIZING EXAMPLE Example: Customer has 5 boilers operating at 125 psi Each have 50,000 PPH capacity with a maximum steam load of 130,000 PPH for the system. Average continuous blowdown is 5% and sometimes they ll have a max of 10% continuous surface blowdown. They would also like orifice meters for this application. Question: Which HV/HC unit is most appropriate for this application?

EXAMPLE CONTINUED Process: To come up with this all you need to do is find the continuous surface blowdown in PPH. Sometimes this is a percentage of steam and other times the customer/engineer can tell you what average and maximum surface blowdown they are working with. Answer: So, by taking 10% of the maximum steam load of 130,000 PPH, we know that this application will have a max of 13,000 PPH of continuous surface blowdown. HC160-150 has a max capacity of 16,000 PPH and costs $21,850 HV150A/B has a max capacity of 15,000 PPH and costs $21,700/$23,500 (depending on coil choice).

Answer for the Orifice Meter: When it comes to the orifice meters requested, you need to focus on individual boiler blowdown. An orifice meter will be connected to the top blowdown line for each boiler. In this case we would take 10% of the 50,000 PPH capacity and quote an orifice meter that could handle the resulting potential of a 5,000 PPH blowdown maximum. So go to the charts and follow the 125 psi column down until you hit a number just above 5,000. This will be the plate size and orifice meter that you will need to quote. For this example it is an OM250-3A.

BLOWDOWN SEPARATORS Purpose: The purpose of a blowdown separator is to cool off the intermittent boiler blowdown flow so the waste water can be safely discharged into a public sewer system and so that the flash steam can be safely vented into the atmosphere. Function: High temperature and pressure blowdown water impacts the striking plate. Flash steam is created and the remaining 212 F hot water drains into the aftercooler. The Flash steam exits to the atmosphere through the vent connection. In the aftercooler the hot water is mixed with cooling water to instantaneously cool the blowdown to a safe temperature. A baffle is placed to assist the mixing of the two liquids. Both the blowdown and cooling water are then sent off to the public sewer. Aftercooler kit not shown

BD SEPARATOR SIZING EXAMPLE Example: Now for that same customer, let s say this is a completely new system for a food plant that is going in, and they had no equipment to begin with. Question: How do you size the blowdown separator they need? Process: To size a Madden blowdown separator you need to know the operating pressure and the blowdown line size. So, let s say this customer got back to you and let you know that the bottom blowdown line is 2.

Answer: We know that the operating pressure is 125 psi, so we will be staying in the top half of the chart. We know the bottom blowdown line is 2, you can see that you will quote a BD230E55. The aftercooler is easy to quote as it simply falls in line on our chart. The AC500 and AC105 regulating valve would be what was needed. The aftercooler lines up with the separator drain size and then the regulating valve lines up with the aftercooler cold water inlet size.

BLOWDOWN TANKS Cools via flash steam principle as well as convection cooling Designed to breakup the blowdown flow by impacting the high pressure hot water on the steel centrifugal impact plate Water droplets give up heat as flash steam is formed Steam is vented into the atmosphere Retained water remains until cooled to statute limits

TYPE 1 SAMPLE COOLERS Cooling Water Sample Miniature heat exchangers designed to reduce high temperature liquid samples to safe, usable temperatures for analysis Tubing: 316 Stainless Steel & Copper, Inconel is also available though not common Side shell pressure rating 150 psi Stainless Steel shell available for the type 1s Type 1 sample cooler models have all the piping connections for the sample and the cooling water on the threaded cap on the top of the sample cooler. All coils are 1/4 OD tubing, and all piping connections are 1/4 NPT. Cooling water enters on the left (right in this picture, all caps are labeled) and exits opposite on the right. Sample inlet connection is vertical on the top, and the cooled sample exits from the spout.

TYPE 2 SAMPLE COOLERS Miniature heat exchangers designed to reduce high temperature liquid samples to safe, usable temperatures for analysis Tubing: 316 Stainless Steel & Copper, Inconel is also available though not common Carbon Steel shell Side shell pressure rating 150 psi Type 2 sample coolers offer both 1/4 and 3/8 OD tubing coils. Sample connections are 1/4 NPTF and are made on the top plate. Cooling water connections are 3/8 NPTF located on both top and bottom plates. Cooling water Sample

SELLING MADDEN STEAM PRODUCTS All about the bottom line and time Our products save money And systems can be disassembled to replace worn out parts

QUESTIONS/DISCUSSION? EMAIL: INFO@MADDENMFG.COM OR CALL (574) 295-4292