Best Practises in Steam System
1st Nov 2014
Hyderabad
Copyright Forbes Marshall, 2009-10
We Are Steam
Knowledge, Services and Products for the efficient
use of steam
• Steam Distribution and Metering
• Steam Trapping Solutions
• Condensate and Flash Steam Recovery
• Automatic Blowdown Controls
• Pressure and Temp Steam Distribution & Metering
Knowledge Partners
• Detailed knowledge of steam systems and process
covering all industry segments.
• Thousands of detailed plant surveys conducted over
60 years.
• Industry wise Specific Fuel consumption norms
from detailed studies of hundreds of plants.
• Three rounds of benchmark studies with CII.
• Hundreds of crores of savings achieved through our
focused energy conservation efforts
New initiatives
• Spreading awareness throughout industry through initiatives
like Energy Conservation Tip of the week program and online
forums like [Link]
• Growing beyond energy efficiency by focusing on safety, ease of
operation & maintenance, conformance to environment and
pollution norms and reliable life cycle.
Our Services
• Over 130 engineers who visit plants daily for sales, customer support and plant studies.
• Comprehensive coverage in the Indian sub-continent (27 Indian offices alone) pro-actively to
identify energy saving potential at plant specific level.
• Dedicated helpline for prompt solutions on Everything in steam
• No hidden cost of ownership
• Monthly customer training programs for operations, maintenance and design of steam systems
• State of the art, fully equipped Steam Engineering Centre where separate training programs are
conducted for working engineers, fresh engineering graduates and teachers as a part of industry
– academia interaction.
New initiatives
• Pro-active installed base health check MOMs with plants.
• Hand-holding programs for sustaining savings achieved by implementation of product
proposals (efficient product does not guarantee efficiency!).
Our Products
• A to Z in steam
• A 60 year partnership with Spirax Sarco, the world leaders in steam engineering
• All the building blocks of an efficient steam system
• A World leader in –
– Steam traps (> 3 m; more than everyone else put together)
– Steam operated Condensate Pumps (over 6000 installations)
– Steam Pressure Reducing Stations
– Instantaneous Hot Water Systems
• Constant innovation; a strong R&D team evolving solutions for higher savings and
easy day-to-day management of steam systems.
• State of the art manufacturing facilities
Forbes Marshall
• Partnership in Energy conservation
• One stop shop for all knowledge , services and products
• The plant with best SPFC for Solvent Extraction, Brewery &
Beverage, Rubber, Dairy etc have all been designed by Forbes
Marshall.
• Refinery and Fertilizer plants with minimum steam loss through
steam traps and valves—FM has partnered them with Steam
Trap Management Programme.
• ---and Many More .
Copyright Forbes Marshall,
2006-07
Energy Conservation Redefined
-Need for Energy Conservation well established
-Some obvious areas already taken care of
- Cost of generating steam – some major investments done , but still
large scope exists
- Efficient process technology, Condensate recovery etc
-Shift to “Time to get Specific”
-Specific Fuel Consumption
- Directly relates to your product cost
- Enables benchmarking!!
-FM Study on Time to get Specific
Copyright Forbes Marshall,
2006-07
Taming your Running Costs…
?
Is your Energy Consumption
burning a hole in your profits
While cos would differ in their strategic approach towards Energy Efficiency all
approaches have following elements in common..
– Monitoring Energy Usage (Indexed to Production - SPFC)
– Recognizing that Management is as important as technology
– Identifying potential routes to save through an audit
Copyright Forbes Marshall,
2006-07
Benchmarking in Process
Industry & our role
- Undertook a study across industry segments to establish “
Best” & Average for Specific Fuel Consumption & utilities.
Published the study in association with CII in 2003-04.
- Identified the opportunities for savings in each of the Industry
Sectors factually.
% REDUCTION IN FUEL BILL
FM ENCON STUDY
Industry Steam Distribution Condensate & Capacity Total
Generation & utilization Flash Recovery Utilisation
Tyre 9% 7% 7% 0% 23%
Solvent 7.5% 3.5% 3% 12% 26%
Brewery 7% 1.5% 2.5% 13.5% 24.5%
Beverage 9% 9.5% 2.5% 11% 32%
Textile 12% 7% 7% NA 26%
Average 9% 6% 4% 9% 26%
Copyright Forbes Marshall, 2006-07
Boiler Efficiency & Cost of Steam
Fuel Avg S:F Avg Cost of Steam (Rs./Kg)
Furnace Oil 12 4
HSD 13 4.5
Natural Gas 12 3.0
Coal 4.5 1.45
Petcoke 7 1.2
Rice Husk 3.2 1.2
Briquette 3 1.8
Specific Fuel consumption trends
Industry 2003 Best/Average 2011 Best/Average Units
Brewery 44/58 30/42 Ltrs of FO/ KL of
Brew
Tyre 162/210 140/190 Kg FO/ Ton of
Rubber
SEP ( Rice Bran) 100/130 90/110 Kg Rice husk/ Ton of
seed crushed
Paper ( Kraft) 330/400 270/330 Kg Coal/ Ton of
Paper
Textile 170/390 170/330 Kg Coal/ 1000Mtrs
of cloth
Hospitality 5.7 (Coil Boilers) 3.8 (shell Boilers) KgHSD/room/day
SFC, Cost of Processing
Industry Cost in 2003 Cost in 2013
Brewery Rs 1200/KL Brew Rs 400/KL Brew
Tyre Rs 3500/ T of Rubber Rs 1700/ T of Rubber
SEP Rs 180/ T of seeds Rs 315/ T of seeds
Paper Rs 1100/ T of Paper Rs 2000/T of Paper
Textile Rs 600/ 1000 mtrs Rs 1100/ 1000mtrs
Hospitality Rs 180/ room/day Rs 170/ room/ day
SPFC Varies basis
-Technology
-Installed Capacity
-Capacity Utilisation
-Product Mix
-Quality of Raw Material
-Steam & Condensate Loop
Copyright Forbes Marshall,
2006-07
Optimal Steam System
Meeting the process demands in
a manner which is:
Important areas for SSE
Improvement
-STEAM GENERATION : STEAM BOILER HOUSE
- STEAM DISTRIBUTION
-STEAM UTILIZATION
-HEAT RECOVERY SYSTEM
Copyright Forbes Marshall, 2009-10
Steam & Condensate Loop
3% distribution losses
80% steam 77%
Process
consumption 57%
100% fuel
energy
20%
Unburnt
Stack
Copyright Forbes Marshall, 2009-10 Blowdown
Steam Generation-Boiler House
• Criteria for Selection of Boiler
- Steam Demand : Peak /Average load
- Steam Consumption pattern
- Fuel selection w. r. t. availability, cost
- Feasibility of COGEN
Copyright Forbes Marshall, 2009-10
Cost of operation-Solid fuel
Copyright Forbes Marshall, 2009-10
Cost of operation–Oil\Gas fuels
Copyright Forbes Marshall, 2009-10
Measured Losses
Copyright Forbes Marshall, 2009-10
Factors affecting boiler efficiency
An increase of 2% efficiency in a 5 TPH boiler results in a saving of 53,200 liters of
Copyright Forbesoil per year
Marshall, 2009-10!
Comparison of Efficiency Methods
• Direct Efficiency • In Direct Efficiency
• Useful Heat output / total • Efficiency = 100 – Losses
heat input • Considers Stack,
• Covers all losses Enthalpy, Radiation,
• Simple to implement Blowdown and unburnt
• Instrument accuracy has losses
a significant affect on • Gives detailed break up
final efficiency of losses
• Not affected too much by
instrument accuracy
Copyright Forbes Marshall, 2009-10
Real life scenario
• The measured efficiency of Process boilers varies a lot
Min. Avg. Max.
Direct Efficiency 61 % 72 % 82 %
Indirect Efficiency 63 % 78 % 84 %
• Efficiency is dynamic – It WILL keep on changing.
Copyright Forbes Marshall, 2009-10
What leads to variations
• Air temperature
• Fuel temperature
• Fuel pressure
• Moisture in fuel
• Loading pattern
• Changing calorific value of fuel
• Use of multiple fuels
Copyright Forbes Marshall, 2009-10
Perception and Reality
Diagnostics in the Boiler House
Parameter General practice Required
Fuel consumption 1 to 15% inaccuracy, daily-- Online, Continuous, 1% accuracy
monthly
Feed water 1-15% inaccuracy Online
Feed water tank temp Hourly readings in log book Online with graphical trends
Boiler Efficiency Once in a month indirect, “direct”
Online for both with comparison
daily to steam loading & other
Before & After Online Efficiencyvariables
Monitoring
25 120 25 120
100 100
20 20
80 80
15 15
O2 O2
60 Load 60 Load
P Stm P Stm
10 10
40 40
5 5
20 20
0 0 0 0
Copyright
1 2 3Forbes
4 5 6 Marshall,
7 8 9 10 112009-10
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Online Efficiency Monitoring
Copyright Forbes Marshall, 2009-10
Online Efficiency Monitoring
Copyright Forbes Marshall, 2009-10
Copyright Forbes Marshall, 2009-10
Latest Industrial Trends
Modular Boilers
Only utility connections to be
provided.
Modular
-Feed water tank
-Day Oil tank
-FW tank accessories
-Day oil tank accessories
-Interconnecting piping
Copyright Forbes Marshall, 2009-10
Modular Boiler Contd
Advantages
20% more compact
15% price reduction on site
jobs
Complete control
instrumentation available on
unit
Erection time reduced by 80%
Copyright Forbes Marshall, 2009-10
Steam Distribution
• Pipe Sizing & Layout
- Check adequacy & recommend improvement
- Identify redundant piping & optimise layout for reduced losses.
• Insulation
- Check adequacy & estimate losses
- Recommend improvements
• Air Venting
- Identify locations
- Recommend right type, size & quantity
• Metering
- Identify locations
- Recommend right type & size.
• Trapping
- Trap survey & recommendations
- Estimation of loss through leaks
- Recommendations of trap monitoring
Copyright Forbes Marshall, 2009-10
Steam pipe layout
CORRECT
Steam
INCORRECT
Steam
Copyright Forbes Marshall, 2009-10
Steam Mains –Condensate drain
INCORRECT
Flow
Condensate to Steam trap
CORRECT
Steam Flow
Condensate to Steam trap
Pocket
Copyright Forbes Marshall, 2009-10
Importance of Correct Pipe Sizing
Copyright Forbes Marshall, 2009-10
Insulation
Copyright Forbes Marshall, 2009-10
Need for Air Venting
Copyright Forbes Marshall, 2009-10
Air Venting….
Copyright Forbes Marshall, 2009-10
Distribute at High Pressure
This will have the following advantages:
– Smaller bore steam mains needed so less heat (energy) loss due to
smaller surface area.
– Lower capital cost of steam mains, both materials such as pipes,
flanges and support work and labour.
– Lower capital cost of insulation (lagging).
– Dryer steam at point of usage due to drying effect of pressure
reduction taking place.
– Boiler can be operated at higher pressure corresponding to its
optimum operating condition, thereby operating more efficiently.
– Thermal storage capacity of boiler increases, helping to cope more
efficiently with fluctuating loads, & a reduced risk of priming &
carryover
Copyright Forbes Marshall, 2009-10
Pressure Reducing Station
Copyright Forbes Marshall, 2009-10
Electro-pneumatic Temp control
SX65 Controller
KE valve with PN actuator and EP5 Positioner EL2270 Sensor
Pneumatic power and electronic intelligence
on a steam to liquid heat exchanger
Copyright Forbes Marshall, 2009-10
Trapping Issues
Not Fit For Purpose Not in service
Plant Start Up
Copyright Forbes Marshall, 2009-10
Commonly Prevailing
• Failed Closed
• Failed open
• Not in service
• Not fit for purpose
• Installation
Copyright Forbes Marshall, 2009-10
The cost of Leaks??
Copyright Forbes Marshall, 2009-10
Cost of Steam Leaks….
Copyright Forbes Marshall, 2009-10
Maintenance addresses only 20%!
20%
Maintenance
Procedures
40%
Improper
Selection/
20% Installation
Manufacturing
Defects
20%
Site Conditions
Copyright Forbes Marshall, 2009-10
Steam Trap Selection Criteria
Steam Application Present type of Trap Benchmark Key Selection Factor
Quick condensate
Steam Main Line Drain Thermodynamic (TD) Thermodynamic (TD)
removal
Steam Tracing for Balance Pressure Energy
Thermodynamic (TD)
product line Thermostatic (BPT) Conservation
Copper Tracing for Energy
No Traps Thermostatic (MST)
instrument tracing Conservation
Process Heating Mechanical (Float Process Efficiency
TD / IB / FT
Equipments Trap - FT) and time
Quick condensate
Pump Casing Thermodynamic (TD) Thermodynamic (TD)
removal
Copyright Forbes Marshall, 2009-10
Steam trap selection….
Copyright Forbes Marshall, 2009-10
Compact Steam Trapping Station
Assembly Parts & Labor
5 ea. 600# rated globe or gate valves 1 ea. Line strainer
8 ea. Sch 80 nipples 16 ea 1/2’’ welds
2 ealine “tee” 1 ea. Steam trap
1 ea. elbow
720mm
160 mm
245mm
Estimated weight : 13 kg 4.0 kg
CONVENTIONAL
Copyright Forbes Marshall, 2009-10
Modern Process Trap Assembly
PRODUCT MARKING
TOFTIntegrated design for base
and Cover
Aesthetic Features
n Float Trap Assembly
TOFT VIEWS
Steam Trap Monitoring System
Indicates steam leak
Indicates
Display of actual water
Condensate logging
temperature
Trap working
correctly
Copyright Forbes Marshall, 2009-10
Glandless Piston Valves
FEATURES
– CLASS VI, BUBBLE TIGHT SHUT-OFF
Ensures Positive Isolation
– SS REINFORCED GRAPHITE SEALING
RINGS
Asbestos free Sealing rings,
– FORGED CS BODY FOR SIZES UPTO 1
½”
Max. Pressure : 78 Kg/cm2
Max. Temperature : 427 °C
Copyright Forbes Marshall, 2009-10
Condensate Recovery
Condensate contains 25% of
Total Energy Supplied – Using
this can make a difference
To Drain!
Copyright Forbes Marshall, 2009-10
Why Return Condensate?
• Monetary Value
• Water Charges
• Effluent Restrictions
• No Boiler Derating
•Reduced water treatment costs
Every 6 deg increase in feed water temp from
return of hot condensate & recovery of flash
steam cuts your fuel bill by 1 %
As per our audit findings Average CR factor in
industry is 50-60%(energy recovered still less)
& very few recover Flash steam
Copyright Forbes Marshall, 2009-10
Monetary values for Condensate
Copyright Forbes Marshall, 2009-10
Higher FW Temp. leads to fuel
savings
Copyright Forbes Marshall, 2009-10
Conventional Method - CR
• Back Pressure on Steam Traps
•Flash Steam vented
•Drop in Condensate Temp
•Electrical cost of pumping – besides pump problems
•Too many components to maintain
Copyright Forbes Marshall, 2009-10
Effective CR
Copyright Forbes Marshall, 2009-10
FW Tank size matters….
Illustration:
Consider 4KL of condensate at 90 deg C held up in a tank. Now even a 10 deg. C drop here means a loss of 32KL of
FO or 91tons of coal annually!
Copyright Forbes Marshall, 2009-10
Heat Content-Steam & Condensate
Copyright Forbes Marshall, 2009-10
Thermocompressor
Copyright Forbes Marshall, 2009-10
Thermocompressor
Copyright Forbes Marshall, 2009-10
Benefits of optimum SSE
Reduced Specific Energy Conservation.
Increased process output.
Improved product quality.
Reduced down time.
Improved monitoring and control process.
Direct monetary savings.
Copyright Forbes Marshall, 2009-10
Fuel prices would
continue to spiral
upwards……. & so would
your losses!
Find out where you
stand.
Act fast and grow your Profits!!!
Copyright Forbes Marshall, 2009-10
Thank you
Copyright Forbes Marshall, 2009-10
