One of the oldest dairy factories in New Zealand, Fonterra’s Maungaturoto has a much improved steam and condensate system since the introduction of Spirax Sarco’s STMS programme almost 10 years ago. STMS – Steam Trap Management System – relies on ultrasonic technology to detect the operational condition of steam traps. Over 60 steam traps are now regularly maintained to ensure that the steam at point of use is dry and water hammer (slugs of condensate) is minimised. Universal traps have been adapted for their ease of maintenance, as they can be quickly changed out with two bolts. The STMS programme has realised significant savings over the years by ensuring that steam traps are not failed open for long periods of time. In addition to this, monitoring repeat offenders has also lead to improvement opportunities in design and supply, as well as standardising on installations and stocked spares.

Further plant improvements were made following the launch of the Spiratrol range of steam control valves. There was an opportunity to demonstrate to the site fitters and instrumentation technicians the benefits of the valves during a plant shutdown in 2007, where some of the factories original control equipment had been removed due to age and limited parts availability.

Spirax Sarco works with Fonterra to improve its overall plant performance

FonterraCASE STUDY

Objective: Improve plant performance

Solution: Offer a wide variety of Spirax Sarco products and services

Results: Plant efficiency is kept at its optimum

Company - Fonterra

Location - Maungaturoto, Northland, New Zealand

The benefits of the newly released range of control valves were beyond expectations. Accurate control for process applications is critical to any plant, and by replacing all 20 control valves complete with smart positioners, the site has seen vast improvements in process efficiency and controllability, as well as prevention of shock loading on the boiler. The valves can now be quickly serviced “in-situ” with easy isolation and minimal process interruption, without the hassle of removing the valve from the line. In addition to this, the valve internals can be easily changed to ensure optimum valve control position for applications where the parameters are not fully known. For example, the steam supply control valve to the whey plant evaporators was fine-tuned to approximately 70-75% open by altering the valve internals.

Reliability Engineer, Trevor Dickson states “As in any capital request we not only looked at replacement cost but also took into account technical support, back-up support, ease of servicing and equipment functional compatibility to our processes. Spirax Sarco were able to provide this which has enabled us to once again standardise equipment as improvements across site are made.”

Fonterra

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With steam traps and control valves upgraded, the engineers then sought further advice from Spirax Sarco on some of the plant’s original steam distribution system which needed upgrading to suit the increased output of 35,000 tonnes per year of whole, skim and buttermilk powder, whey and casein.

The first improvement project was to redesign a new steam supply line for the pasteuriser pre-heater as the original line was having reliability issues. A scaled 3-dimensional drawing was presented to reflect the scope of work, equipment supply, and ensure that the new line could be pre-fabricated and installed with no complications. Steam needed to be taken off the main line and pre-conditioned removing moisture and debris, and then reduced in pressure to 2 bar g for heat transfer in the plate exchanger. A correctly sized steam trap station was installed to effectively remove the condensate. Automated isolation valves were also added for remote control of the steam supply during the batch process. All equipment was properly sized and specified for the required duty to ensure the milk to the pasteuriser was at the optimum temperature. This was commissioned in 2007 and has had no reported issues to date, with annual preventative testing for operational functionality.

Soon after the main 10 bar gauge header to the powder P1 and P2 plants was also redesigned. More 3D designs were produced covering over 25m of new 200mm insulated piping, valving and ancillaries ensuring a safe steam supply to the evaporators. The headers included double isolation and proving valves for increased safety reassurance during maintenance, trapped drop pockets, and properly located air vents. The full scope of the project was managed on time and within budget.

Fonterra’s Maungaturoto site is continually making improvements ensuring an on-going commitment to safety and process efficiency. When this is steam related Spirax Sarco have been able to offer a breadth of products and services so that staff on site can focus on other tasks at hand. Trevor states “Spirax have been great to work with and continually identify areas of improvement on site. Their technical systems mirror industry best practice, and thinking in-line with Fonterra, are fully supported asset care packages”