Good Steam Engineering means

1. Good Steam Engineering means • Proper sizing, insulation, routing and trapping • High pressure distribution and reduction at the point of use • Separating condensate and venting air • Proper process trapping • Condensate return • Temperature control • Efficient boiler operation

2. Boiler Efficiency is the beginning • Excess air control • Proper capacity-utilisation and boiler balancing • Automatic blowdown control • Close performance monitoring for tube cleaning and other maintenance

3. Making Boiler Efficiency Automatic • A textile mill operates two 10 tph boilers • Automatic blowdown control will save Rs.6.5 Lakhs per year (payback < 2 months) • Flue-gas trim can increase efficiency by 2% easily (payback < 1 year) • Shutting a third boiler run “just in case” saves Rs.5 lakhs per year • A Boiler Efficiency package pays for itself in six months

4. Steam Trap Selection ... • A continuous discharge Float Trap in place of an intermittent discharge TD - upto 4 x process efficiency - payback in days • A thermostatic trap in place of a TD or FT on tracing lines - payback in six months • A TD in place of an IB on a main-line - payback from saving radiation losses alone in 12 months

5. ... and Steam Trap Monitoring • What is the cost of a leaking Steam Trap ? • An automatic on-line trap monitoring system for 50 critical traps will cost say 5 Lakhs • One 1” trap failed open will waste that much in eight months (8 Lakhs per year)

6. Metering for Energy-conservation • How much steam is worth metering ? - 1 tph of steam @ 7000 hrs per year will cost over Rs.50 Lakhs • Does usage demand high turndown ? • Density compensation is critical - An uncompensated meter sized for 10.5 bar, operating at 7 bar will have an error > 15%

7. How Much Condensate is Worth Returning ? • 1 tph of condensate at 3 bar will save Rs.8 Lakhs in the fuel bill each year • And reduce the derating of a 2 tph boiler from 15% to 5% (so you get a 200 kg boiler for free) • And Rs.50,000 in ones water-treatment cost for DM water • And reduce heat-pollution • And save water (about 600 tankers each year !)

8. The Big Things Matter • A good boiler will - raise dry steam - have an efficiency > 82% in normal operation - be easy to maintain - just brushing soot out of tubes can increase boiler output by 10% for the same fuel-input - operate efficiently without manual supervision - be correctly sized for capacity (a new 2 tph boiler will pay for itself in a year if one is using a 4 tph “for future expansion”) and operated at rated pressure

9. The Big Things Matter - 2 • Thermocompressors give you steam for free • Boiler Efficiency Analysers automates high efficiency • Bespoke Instrumentation Systems can automate utility efficiency while improving process control

10. The Big Things Matter - 3 • Metering where every last 250 kg of steam goes • Condensate return and flash steam recovery have typical paybacks under 3 months • Trap selection, sizing and performance monitoring directly boosts machinery output, reduces maintenance and downtime, and even pays for itself in six months • Generating and distributing steam at max pressure and reducing it at the point of use

11. The “Little” things mean big savings • A few Air Vents dramatically reduces cycle time by shortening start-up time in batch processes • A Separator directly increases machine output by removing condensate and so boosting heat transfer • A Balanced-pressure trap on tracing lines “harvest” some sensible heat too • A Sight glass helps one set the SLR on a trap - and directly increases drying machine speed

12. The “Little” things mean big savings - 2 • A weekly brushing of boiler tubes can save 2% of ones fuel bill. • Daily monitoring of boiler efficiency and water quality helps diagnose problems • A Deaerator Head reduces dissolved oxygen and so reduces corrosion (=leaks!) of pipes and fittings • Automatics Blowdown Control costs < Rs.2 lakh pays for itself in months, and improves steam quality • Fix leaks and insulation before you give us any business !