Energy Saving Opportunities in Industries PDF

2/22/2014
WELCOME SERVICES SBU
TO
ENERGY SAVING
OPPORTUNITIES IN
INDUSTRIES
COMMITTED TO DELIVER INNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
SAFETY OATH SERVICES SBU
We, individually and jointly , take an

oath that for the observance of safety
cause for ourselves our family, our
organization , our society and our
nation’s welfare, we will adhere to all
safety norms, rules and instructions to
avoid accidents.
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2/22/2014
TO
STEAM BASICS
WATER & STEAM SERVICES SBU
• What happens when water is heated from 0oC ?

– Temperature of water starts rising using the heat as
sensible heat till temperature reaches boiling point
– Water starts boiling and vaporises to form saturated

steam without rise in temperature till all water vaporises
– Further addition of heat rises temperature of steam and

we get superheated steam
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HEAT CONTENT OF STEAM SERVICES SBU
Total heat content of steam (hg) =
Sensible heat (hf) + Latent heat (hfg)
hg = hf + hfg
Steam generation and steam utilisation are

reversible processes
STEAM USE SERVICES SBU
• Direct steam injection – Full heat of steam is used

– Steam distillation
– Hot water generation by steam sparging
– Vacuum jet ejectors
– Textiles plants
• Indirect heat transfer – Only latent heat is used
– Heat exchangers, jacketed reactors
– Multi effect evaporators, crystallizers
– Sugar plant, chemicals & pharmaceutical plants, bulk
drugs, etc.
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TYPES OF STEAM SERVICES SBU
• Dry Saturated Steam OR Saturated steam
• Wet Steam
• Superheated Steam
• Flash Steam
– Flash steam is generated when condensate pressure is reduced.
– The specific heat capacity of liquid is lower at reduced pressure and the
excess heat (hf at P1 – hf at P2) is converted to steam at low pressure.
– The flash steam generated is calculated by formula (hf at P1 – hf at P2) /

(latent heat at P2). P1 is higher pressure and P2 is lower pressure.
– This steam is used in plant operating at lower pressure or sent to boiler

feed water tank for pre heating boiler feed water by direct injection.
USE OF DIFFERENT TYPES

OF STEAM SERVICES SBU
Saturated Steam
• Running of steam engines to do mechanical work.
• As energy storage which is extracted by heat transfer.
• Process heat transfer
• Pipeline tracing for maintaining constant process temperatures.
• Motive fluid for pumping hot steam condensate for reuse to boiler feed
water tank.
• Domestic use for cooking, steam cleaning of fabrics, aircraft food
trolleys and heating of buildings.
Superheated Steam
• Generation of electricity in steam turbines.
• Co generation of electricity in cogeneration steam at high pressure is
first used to generate electricity and then the low pressure steam is
used for other applications
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SERVICES SBU
STEAM PROPERTIES – SATURATED STEAM
• Pressure Heat / Enthalpy Specific Heat
• Temperature Entropy Thermal Conductivity
• Density Entropy Viscosity
• Sp. Volume
UNITS OF MEASUREMENT OF
PROPERTIES OF STEAM SERVICES SBU
SI Units MKS
Pressure Pa (N/m2) kg/cm2

Temperature oK oC
Density kg/m3 kg/m3
Sp Volume m3/kg m3/kg

Enthalpy J/kg kcal/kg
Sp. Heat J/(kg.K) kcal/(kg.oC)
Heat kJ kcal
Entropy J/kg K kcal/kg K

kcal/kgoC
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PRESSURE 1 SERVICES SBU
PRESSURE 2 SERVICES SBU
Pressure measured in Gauge (g) Pressure &

Absolute Pressure (a)
bar a = bar g + 1
Atmospheric Pressure 1 bar a
0 bar g
Other units of pressure are Pa, kPa, MPa, atm, kg / cm2, mm Hg, MWC, psi.
1 atm = 14.696 psi = 1.013 bar = 101.3 kPa = 0.1013 MPa = 760 mm Hg=1.033 Kg/cm2
1 bar = 14.504 psi = 0.1 MPa = 100 kPa = 105 Pa = 0.9869 atm = 1.02 kg/cm2
1 kg/cm2 = 14.223 psi = 0.9806 bar
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TEMPERATURE SERVICES SBU
T (K) = t (C) + 273
SI Prefixes SERVICES SBU
Multiplication Factor Facotr Prefix Symbol

1,000,000,000,000,000,000 10 18 exa E
1,000,000,000,000,000 10 15 peta P
1,000,000,000,000 10 12 tera T
1,000,000,000 10 9 giga G
1,000,000 10 6 mega M
1,000 10 3 kilo k
100 10 2 hecto h
10 10 1 deca da
0.1 10 -1 deci d
0.01 10 -2 centi c
0.001 10 -3 mili m
0.000 001 10 -6 micro µ
0.000 000 001 10 -9 nano n

0.000 000 000 001 10 -12 pico p
0.000 000 000 000 001 10 -15 Femto f
0.000 000 000 000 000 001 10 -18 atto a
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STEAM TABLE SERVICES SBU
• Contains essential data of steam like pressure, temperature, specify

volume, enthalpy of saturated water, steam and latent heat
• Steam tables for saturated steam and superheated steam are different
• For saturated steam steam

• All properties are available if either pressure or temperature are available
• Steam table is either pressure based or temperature based
• For superheated steam

• Bothe pressure and temperature are required to get the properties of steam
STEAM TABLE FOR SATURATED STEAM

(Refer Thermax Technical Memento)
SERVICES SBU
Col 1 Absolute Pressure, kg/cm2 (a)
Col 2 Saturation Temperature, oC
Col 3 Specific Volume of Steam, m3/kg
Col 4 Specific Weight of Steam, kg/m3
Col 5 Enthalpy of Water, kcal/kg
Col 6 Enthalpy of Steam, kcal/kg
Col7 Latent Heat of vaporization, kcal/kg
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STEAM TABLE - TRENDS SERVICES SBU
Abs Pr Temp Sp Vol Sp wt Enthalpy Enthalpy Latent

steam Steam Water Steam Heat
Kg/cm2 oC M3/kg Kg/m3 Kcal/kg Kcal/kg Kcal/kg
2 119.62 0.9016 1.109 119.87 645.8 525.9
6 158.08 0.3213 3.112 159.3 657.8 498.5
10 179.04 0.1981 5.049 181.2 663 481.8
30 232.76 0.068 14.7 239.5 669.7 430.2
50 262.7 0.0402 24.85 274.2 667.3 393.1
70 284.48 0.0279 35.78 300.9 662.1 361.2
225.65 374.15 0.0031 315 501.5 0
SUPERCRITICAL STEAM – NO WELL DEFINED BOILING POINT
TRENDS SERVICES SBU
1. Saturation temperature or boiling point goes on increasing as

pressure increases
2. Specific volume reduces and specific weight increases as pressure

increases
3. Enthalpy of water increases as pressure increases
4. Latent heat reduces as pressure increases
5. Total heat of steam does not show much change but the distribution
of total heat changes
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SATURATION CURVE TREND SERVICES SBU
250
200
Temperature, oC
150
100
50
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Pressure Kg/Cm 2 (a)
Steam Saturation Curve
Saturation temperature increases with rise in steam pressure
SPECIFIC VOLUME TREND SERVICES SBU
2
1.8
Specific Volume M3/Kg
1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
2
Steam Pressure Kg/Cm (a)
Steam Pressure - Spe cific Volume Re lationship
Specific volume reduces with rise in steam pressure
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APPLICATION OF STEAM
TABLE TREND SERVICES SBU
• Small pipelines are required at high pressure since

less volume has to be transferred
• Higher latent heat is available at lower pressure
• Generate and transport steam at high pressures but

use at low pressure
COMPARISON
BOILER OPERATING AT DIFFERENT
SERVICES SBU
PRESSURES
Boiler Operating at Design Boiler Operating at Lower

Pressure Pressure
Dry Steam Wet Steam
Low Specific Volume High Specific Volume
High Free Board Area Low Free Board Srea
Correct Steam Velocity High Steam Velocity
Efficiently Caters to Fluctuating Difficult to Cater to Fluctuating
Loads Loads
Reduced Risk of Water Carry Over High Risk of Water Carry Over
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ENTROPY SERVICES SBU
Entropy is the degree of disorder of the system and is calculated by the

following mathematical equation
∆s = Change in Energy (∆H) / {Average Absolute

Temperature (∆T)}
∆T Average absolute system temperature, K
Entropy is measured in units of kJ/kg K or kcal/kg K or kcal/kg oC
Change in specific entropy (∆s) = (∆h) / (∆T)

∆h is change in specific enthalpy
Similarly we get ∆sf, ∆sg and ∆sfg which represent change in specific entropy of water,
steam and vaporisation.
When the above changes are referred to 0 oC (273 K) as reference temperature and at
saturated conditions of pressure and temperature with we get the specific entropy as
reported in steam tables. Just like specific enthalpy specific entropy is written as sf, sg
and sfg
Specific entropy of steam decreases with increase in temperature & pressure.
DESIRED QUALITY OF SATURATED STEAM

SERVICES SBU
• Dry saturated
• Dryness fraction as high as possible
• No air or non condensable gases
• Right quantity at right temperature
• No solids
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STEAM QUALITY – AIR & NON

CONDENSABLE GASES SERVICES SBU
• Air enters as dissolved gases in boiler feed water and at every shutdown and gets carried to
heat transfer equipment traveling ahead of steam
• CO2 gets generated if bi carbonates are present in feed water which decompose at high
temperature in the boiler
• CO2 gets absorbed in condensate water due to its lower temperature from atmosphere
• Solubility N:O: CO2 = 1:6:30
• Both O2 and CO2 cause corrosion
• N2 and O2 is removed by thermal de-aeration and final traces of O2 by dosing with

chemicals or O2 scavengers
• Non condensable in steam lowers its partial pressure resulting in lowering of effective
steam temperature
DE-AERATION..
SERVICES SBU
Oxygen and many other non-condensable gases enter the steam system through flanged
joints, rusted & leaking fittings.
Oxygen promotes corrosion of pipes and fittings. It affects the heat transfer in equipment.
The
Removal of Oxygen and Non condensable gases is termed as De-aeration.

Temp Vs Dissolved Oxygen
12
D issolved O xyg en in p pm
10
0
1 32 50 65 82 10 0
Temperature in Deg C
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STEAM QUALITY – RIGHT

TEMPERATURE & QUANTITY SERVICES SBU
• Elimination of air and non condensable gases by

air vents
• Proper steam traps selection having high air

venting capacity
• Supervised start up of the plant
• Proper pipeline sizing & proper thermal insulation

STEAM QUALITY - SOLIDS SERVICES SBU
• Generally present at the start up of the plant due to weld

burrs / welding rods / leftover solids of fabrication jobs
• Proper line flushing eliminates this problem
• On going contaminants are only corrosion products or

carbonates or water treatment chemicals which come as
carryover from boiler
• Solution - Strainers
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STEAM GENERATION
STEAM GENERATION SERVICES SBU
• Source of energy
– Combustion of fuel
• Fuel conditioning
– Mechanism of burning the fuel efficiently
• Efficient burner
– Efficient transfer of heat to water
• Geometry of heat transfer area
– Effective absorption of heat by water in the boiler
• Adequate turbulence / velocity
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FUEL TYPES SERVICES SBU
• SOLID FUELS
– Coal, Wood, Husk, Bagasse
• LIQUID FUELS
– Furnace Oil (FO) Light Diesel Oil (LDO)
– High Speed Diesel(HSD) LSHS / HPS
• GASEOUS FUELS
– Liquefied Petroleum Gas (LPG) Natural Gas (NG)
TYPICAL SOLID FUELS SERVICES SBU
• Coal, Indonesian coal, Pet coke
• Wood, Paddy husk, Bagasse, Ground nut husk,

Mustard husk, Sunflower husk, Jute waste, Saw
dust
• Palm kernel (DOC), De oiled Bran (DOB), Spent

coffee seeds, spent earth, paper sludge, Rubber
wood chips, Briquettes
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TYPICAL LIQUID / GASEOUS FUELS

SERVICES SBU
• LIQUID FUELS
– Furnace Oil (FO)
– Light Diesel Oil (LDO)
– High Speed Diesel(HSD)
– Low Sulphur Heavy Stock (LSHS)
– Heavy Petroleum Stock (HPS)
• GASEOUS FUELS
– Liquified Petroleum Gas (LPG)
– Natural Gas (NG)
PROPERTIES OF SOLID FUELS SERVICES SBU
• Most important property of interest is Calorific value of fuel

– Kcal/kg kJ/kg btu/lb
Gross Calorific Value (GCV) or HCV

Dulong’s Formula for GCV
GCV = 1/100 * [8,080*C+34,500*(H-O/8)+2,240*S]
–Net Calorific Value (NCV) or LCV

NCV = GCV – [5.84*H2O+52.56*H]
Considering water at 25 oC and hfg as 584 kcal/kg
• Solid Fuels
–Composition C, H, N, S, O2, H2O, Ash
–Composition H2O, Ash, Volatile matter, Fixed Carbon, GCV, NCV
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PROPERTIES OF LIQUID / GASEOUS

SERVICES SBU
FUELS
• Liquid Fuels
– Composition C, H, N, S, O2, H2O, Ash, GCV, NCV
– Density, Flash point, Pour point, Sediments
• Gaseous Fuels
– Composition C, H, N, S, O2, H2O, Ash, GCV, NCV
(Normally N, S, O2, Ash is absent)
– Density
– Chemicals present like Methane, Ethane, Propane,
Butane, etc. in volume percent
FUEL ANALYSIS – SOLID FUELS SERVICES SBU
• PROXIMATE ANALYSIS (Dry Basis)

– Moisture, Ash, Volatile matter, Fixed Carbon, GCV
Moisture Heat sample in an oven at 110oC for 1 hour
Volatiles Continue above at 950oC for 7 minutes, cover
Ash Heat strongly till constant weight un-covered
Fixed Carbon 100 – (Moisture + Volatile + Ash)
• Site Analysis
– For Moisture % as fired condition
• ULTIMATE ANALYSIS
– C, H, N, S, O2, Ash, GCV, NCV
• BED ASH / FLY ASH

– Carbon, GCV
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COMBUSTION OF FUELS - 1 SERVICES SBU
• Combustion is fast oxidation of fuel by combining with O2 from

combustion air with large quantity of heat and light.
• Only C, H & S contribute to heat generation. Sulphur increases to the risk

of acid corrosion due to formation of Suphurous and sulphuric acid
• N2 & Ash just increase the load on combustion equipment. Ash is also
responsible for clinker formation
• H2O increases the heat loss
• O2 is required for combustion but is accompanied by approx 4 times N2

from atmospheric air. High amount of air leads to increased dry flue gas
loss
COMBUSTION OF FUELS - 2 SERVICES SBU
• For Efficient combustion

– Condition the fuel
• For solid fuels correct size, proper support system like grate
bars
• For liquid fuels minute size of fuel particles surround by
combustion air as achieved by pressure jet burner
• For gaseous fuels proper mixing of fuel and air
– Combustion air
• Minimum quantity of excess air
• Pre heated combustion air if possible
• Good heat transfer arrangement
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BOILER CLASSIFICATION SERVICES SBU
• Based on capacity and pressure
• Based on water / flue gases

– Water tube boiler
– Smoke tube boiler
– Shell boiler
• Packaged boilers / Field Erected boilers
PACKAGED BOILERS SERVICES SBU
• Water tube boilers

– Coil boilers
• Pressures can be quite high
• Fast steaming / quick start up since hold up is low
• Generally outside the purview of IBR
• A battery of such boilers may be connected together if the steam
demand is high
• No qualified boiler operator is required
• All steam piping also become outside the purview of IBR
• Low capacity upto 850 kg/h
• Give wet steam 80% dryness Furnace is made from pipe wound in the
form of a coil
• Water in tubes and flue gases outside
• Once through boilers
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PACKAGED SMOKE TUBE

BOILER SERVICES SBU
• Generally horizontal design with

– Single large plain or corrugated furnace
– Bank of horizontal tubes arranged in second pass
– Bank of horizontal tubes arranged in third pass
– Standard design upto 10 TPH
– Pressures upto 21 kg/cm2, standard being 10.54, 17.5 and 21
kg/cm2
– Flue gas inside tubes and water outside
– Pool boiling takes place
– Adequate free board area and height gives dryer steam of 98%
dryness
– High efficiency 88%
BOILER RATING SERVICES SBU
Boiler is rated on the basis of From and At 100oC basis written as F & A
100oC
Actual output from a boiler is always less than the F & A 100oC rating
Actual output from a boiler depends upon the feed water temperature.
Higher the feed water temperature higher is the output
If a boiler is rated as 1,000 kg/h F & A 100oC it means the boiler is rated
to give output of 539.4 kcal/kg of steam
But the process conditions determine the heat load or steam requirement
in a plant
This means higher the feed water temperature lower will be the fuel
consumption
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ACTUAL STEAM OUT PUT FROM A BOILER -1

SERVICES SBU
Boiler rating 1,000 kg/h F & A 100oC
Operating pressure 10 kg/cm2(g)
Calculate steam output from feed water

temperature of 0, 30, 85 and 110oC ?
ACTUAL STEAM OUT PUT FROM A

SERVICES SBU
BOILER - 2
S.N. Description Value Unit

SATURATED STEAM
0oC 30oC 85oC 110oC
1 Heat Av /kg of steam 539.4 539.4 539.4 539.4 kcal/kg
2 Heat Reqd/kg steam 663.9-0 663.9-30 663.9-85 663.9-110 kcal/kg
= 663.9 633.9 578.9 553.9 kcal/kg
3 Ratio, Av/Reqd 539.4/663.9 539.4/633.9 539.4/578.9 539.4/553.9 kcal/kg
= 0.8125 0.851 0.932 0.974
4 Actual Output 1 TPH 812.5 851 932 974 Kg/h
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ACTUAL STEAM OUT PUT FROM A

SERVICES SBU
BOILER - 2
S.N. Description Value Unit
98% DRY STEAM
Heat Reqd / kg steam = 663.9 x 0.98 + 0.02 x 185.6
= 654.3 Kcal/kg
0oC 30oC 85oC 110oC
1 Heat Av /kg of steam 539.4 539.4 539.4 539.4 kcal/kg
2 Heat Reqd/kg steam 654.3-0 654.3-30 654.3-85 654.3-110 kcal/kg
= 654.3 624.3 569.3 544.3 kcal/kg
3 Ratio, Av/Reqd 539.4/654.3 539.4/624.3 539.4/569.3 539.4/544.3 kcal/kg
= 0.824 0.864 0.948 0.991
4 Actual Output 1 TPH 824 864 948 991 Kg/h
98% dry
5 Actual Output 1 TPH 812.5 851 932 974 Kg/h
Dry
COMMITTED TO DELIVER I DrNNOVATIVE ECO-FRIENDLY ENERGY SERVICES & SUSTAINABLE SOLUTIONS GLOBALLY
EFFICIENCY ESTIMATION SERVICES SBU
• TWO METHODS
– Direct Efficiency
– Indirect Efficiency
• As per some standard like BS 845 Part 1 Or ASME PTC 4.1
• As per good engineering practice
• Evaluate only the major losses
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DIRECT EFFICIENCY SERVICES SBU
• Efficiency = Output / Input

• Output = m * cp * (hg – fwt)
= m * (hg – fwt)
• Input = fuel cons (f) * Cal Value
m * (hg – fwt)
Direct Efficiency (η) = -------------------
F * GCV
BOILER EFFICIENCY SERVICES SBU
• INDIRECT METHOD
• Efficiency = 100 – all losses
– Losses are
• Dry flue gas loss
• Moisture loss
• Hydrogen loss
• Un burnt loss
• Refuse loss, Un burnt in fly ash and bed ash
• Radiation loss
• MAXIMUM OF THESE LOSSES IS DRY FLUE GAS LOSS
= K x (ts – ta) / %CO2

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ESTIMATION OF LOSSES SERVICES SBU
• Either on gross calorific value (GCV)

• OR on Net calorific value (NCV)
• For liquid or gaseous fuels use NCV
Losses are:
L1 Loss due to sensible heat of flue gases
L2 Loss due to Hydrogen and moisture in fuel and moisture in
combustion air
L3 Loss due to un-burnt gases in flue has (CO loss)
(required if CO>1000 ppm as per BS 845)
L4 Un-burnt loss – bed ash
L5 Un-burnt fly ash loss
L6 Radiation loss
FORMULAE FOR LOSS CALCULATIONS

SERVICES SBU
L1 gr = kgr x (t3-ta) x (1-0.01(L4gr + L5gr)) / VCO2
L1 net = knet x (t3-ta) x (1-0.01(L4net + L5net)) / VCO2
Wherer k is Siegert constant =

255 C/Qgr Or 255 C / Qnet C is carbon content of fuel on
the same basis as Q. For all fuels Qgr, Qnet and C are on
mass basis. Q in kJ/kg
VCO2 = (1 – VO2/21) x (VCO2 Th)
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TOTAL LOSSES AND EFFICIENCY SERVICES SBU
Total loss, Lt
Lt gr = (L1 + L2 + L3 + L4 + L5 + L6) gr
Lt net = (L1 + L2 + L3 + L4 + L5 + L6) net
Thermal Efficiency, E
E gr = 100 – Lt gr
E net = 100 – Lt net
IMPORTANT CONSTANTS FOR LOSS

SERVICES SBU
CALCULATIONS FOR COMMON FUELS
Fuel Kgr Knet VCO2 Th H2 Constant k1

Coke 0.75 0.76 20.6 0.4 70
Anthracite 0.67 0.69 19.1 3.0 65
Coal 0.62 0.65 18.4 4.0 63
Fuel Oil E,F,G* 0.51 0.54 15.8 11.5 54
Fuel Oil D* 0.48 0.51 15.5 13.0 53
LPG Butane 0.43 0.46 14.1 17.2 48
LPG Propane 0.42 0.45 13.8 18.2 48
Natural Gas 0.35 0.39 11.9 24.4 40
* As per BS 2869
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BOILER PERFORMANCE MONITORING

SERVICES SBU
• Fuel consumption
• Water consumption
• Steam output
• Stack temperature
• O2 / CO2 in flue gas from chimney
MONITORING WATER CONSUMPTION

SERVICES SBU
• Use Flow Meter

– Positive displacement type
– DPT type (Orifice plate)
– Vortex type
– Electromagnetic type
• Fall in tank level method
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SERVICES SBU

*
FLOW METERS –
WATER
TM
A ZFLO-W
WFM ELECTROMAGNETIC TYPE SERVICES SBU
• Need electrical conductivity of min 5 Micro

Siemens / cm
• Not suitable for DM water
• Need lining material Hard rubber for cold
water and Teflon for hot water
• Very low pressure drop
• Ideal for installing in boiler feed water line
on suction side of feed water pump
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MONITORING STEAM OUTPUT FROM

SERVICES SBU
BOILER
• Using steam flow meter

– Orifice plate type with Differential pressure
transmitter (DPT)
– Vortex type
• Using water flow meter or fall in feed water
tank level
• Matching Water flow mwter and steam flow
meter
SERVICES SBU
5 5
6 6
10 2
11
15 9 12
13
7
8 14
8
Orifice Type flow meter Installation

COMMITTED TO DELIVER INNOVATIVE ENERGY SOLUTIONS
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16
 45°
SERVICES SBU
D
17
5xD
MASS FLOW COMPUTING UNIT
Orifice Type flow meter Installation

MONITORING O2 / CO2 IN FLUE

GASES SERVICES SBU
• Use Effimonitor or SAVEX
• Monitor O2 and Stack temperature
• Monitor Dry flue gas loss which is the

maximum in value
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ENERGY SAVING COMBUSTION

SERVICES SBU
• REDUCE STACK LOSS

– Reduce stack temperature
• Install heat recovery equipment
• Air Pre Heater (APH)
• Install Water pre heater (WPH) if no condensate return
is done
• Install economiser
• Install hot water generator
– Increase CO2 / Reduce excess air / O2 in flue gas
by adjusting damper in combustion air line
BOILER BLOW DOWN SERVICES SBU
1. Why boiler blow down

1. Dissolved solids enter boiler through feed water
2. Steam is formed and taken out of the boiler continuously and does not carry and dissolved solids.
3. If operated like this quantity of solids will go on increasing and will exceed the maximum solubility
at operating temperature. Solids will start separating out and will start depositing on the heat transfer
surfaces in the form of scale.
4. This scale is hard and can cause mechanical damage to the boiler as well as hinder heat transfer as it
is bad conductor of heat
5. Such scale forming is to be prevented and is dine by ensuring that the quantity of dissolved solids
never exceed the maximum solubility level with adequate safety margin
6. This limit is 3500 ppm and is achieved by draining calculated amount of boiler water continuously in
a controlled way (SABCO) or periodically manually.
7. The quantity of water to be drained is calculated by mass balance as per the following formula;
Blow down percentage = { Feed water TDS / ( Boiler water TDS – Feed water TDS) } x 100
(Page 58 Technical Memento)
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BLOWDOWN LOCATIONS IN
STEAM BOILER SERVICES SBU
Purpose of blow down

To prevent scaling
1. Due to high boiler water TDS
- From steam disengaging surface
area
- Surface blow down control
- 90%
2. Due to sludge and heavier in
soluble particles in boiler water
- Boiler bottom sludge removal
- 10%
MANUAL BOILER BLOW DOWN

DISCHARGE RATE SERVICES SBU
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BLOWDOWN CALCULATIONS SERVICES SBU
Feed water TDS 200 ppm

Permitted boiler water TDS 3500 ppm
Percentage blow down required
200
-------------- x 100
3500 – 200
= 6.06%
For a 6000 kg /h evaporation, blow down required

= 6000 x 6.06/100
= 364 kg/h
Surface 0.9 x 364 = 328 kg/h

Bottom = 36 kg/h
A 40 NB valve gives 6 kg/s (360 kg/min)
HEAT LOSS IN BLOW DOWN SERVICES SBU
• Blow down required 364 kg/h

• Pressure 10 kg/cm2
• hf (from steam tables) 185.6 kcal/kg
• Total heat lost 185.6 x 364
67558.4 kcal/h
Equivalent fuel 67558.4/9650/0.88
8 kg/h
Annual fuel cost 8 x 24 x 300 x 50
INR 28,80,000
90% is surface blow down INR 25,92,000
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HEAT RECOVERY FROM BOILER BLOW DOWN

SERVICES SBU
Qty of hot blow down water 364 x 0.9

327.6 kg/h
Flash vessel pressure 0.5 kg/cm2
hf (10) 185.6 kcal/kg
hf(0.5) 110.92 kcal/kg
hfg (0.5) 531.9 kcal/kg
Excess heat 185.6 – 110.92
74.68 kcal/kg of BD water
Flash steam 74.68/531.9 * 100
14.04%
46 kg/h
Recovering this 46 x 642.8
29568.8 kcal/h
Equivalent fuel 3.5 kg/h
Money saved per year 3.5 x 24 x 300 x 50
12,60,000
P & I FOR BOILER SURFACE

BLOW DOWN SERVICES SBU
• 70% of conductivity is TDS
• Measurement of conductivity can be used as

a measure of TDS and controlled
34
2/22/2014
ENERGY SAVING
OPPORTUNITIES - BOILER SERVICES SBU
• Monitor boiler efficiency regularly
• If not matching with the rated value analyze for losses
• Reduce losses – The maximum being stack loss

– Reduce Stack temperature
– Reduce excess air
– Increase CO2
• Supply hot feed water to boiler economically
• Install SOTC on boiler feed water tank for efficient thermal de-
aeration
• Explore possibility of installing SABCO and blow down heat recovery
TO
STEAM DISTRIBUTION
35
2/22/2014
STEAM DISTRIBUTION SERVICES SBU
• Install header in boiler house near ground level with valves and an air
vent
• Use zero leakage valves like bellow seal valves
• Use NRV in steam line if more than one boilers are connected to the
header
• Ensure correct size of Piping
• Provide header drain arrangement every 30 m of horizontal steam pipe
run
• Provide air vent, vacuum breaker and drain steam trap at the end of
steam header
• Provide moisture separators at entry to each steam using plant or
critical equipment
• Insulate even valves and flanges in steam lines
• Use pressure reducing stations
STEAM HEADER SCHEMATIC WITH AIR VENT AND SERVICES SBU

TD TRAP MODULES
36
2/22/2014
STEAM LINE SIZING SERVICES SBU
• Process Design
– Superheated steam
• Lines sized at velocity of upto 45 m/s
– Saturated steam
• Lines sized at velocity of 30 m/s for long lines
• Lines sized for 35 m/s for short lines
– Wet Steam
• Lines sized at velocity of 10 to 15m/s
– Steam Header
• 10 to 15 m/s
STEAM LINE PROCESS DESIGN SERVICES SBU
m = 3600 . u . a . ρ
m mass flow rate of steam, kg/h

u velocity, m/s
a flow area of pipe, m2
ρ Density, kg/m3
37
2/22/2014
STEAM LINE SIZING

SERVICES SBU
• Higher cost of piping and

insulation
• Increased heat loss
• higher rate of
condensation
• Frequent pressure drop at
user
• Steam Starvation
• Water hammer and
erosion
USE OF ECCENTRIC REDUCERS

SERVICES SBU
38
2/22/2014
POTENTIAL SOURCES OF WATER HAMMER

SERVICES SBU
STEAM TRAPS INSTALLATION

SERVICES SBU
Thermodynamic trap (TD)
39
2/22/2014
DRAIN POCKET DIMENSIONS SERVICES SBU
ENERGY SAVING IN STEAM

DISTRIBUTION SERVICES SBU
• Use correctly sized steam lines

• Use Pressure Reducing Stations
• Periodically drain condensate from piping (Every 30 m)
• Stop all visible leakages
• For leaking valves use zero leakage valves like Bellow Seal
Valves
• Repair and maintain good insulation at all times
• Insulate even flanges and valves
• Use efficient steam traps like Bi-metallic traps instead of
Thermodynamic type
• Install Moisture separators, air vents, vacuum breakers
40
2/22/2014
ENERGY SAVING BY INSULATION OF VALVES SERVICES SBU

(Flanged valves 150#, insulation density 130 kg/m3)
Valve 3” 4” 6” 8’ 10” 12”

Size
Op Heat Steam Heat Stea Heat Steam Heat Steam Heat Steam Heat Steam
Temp m
oC kcal/h kg/h kcal/h kg/h kcal/h kg/h kcal/h kg/h kcal/h kg/h kcal/h kg/h
100 426 0.85 509 1.01 761 1.51 1016 2.02 1207 2.40 1525 3.03
150 915 1.82 1094 2.17 1638 3.25 2185 4.34 2596 5.15 3279 6.51
200 1578 3.13 1882 3.74 2825 6.61 3765 7.47 4473 8.88 5650 11.21
250 2444 4.85 2943 5.84 4379 8.69 5839 11.59 6933 13.76 8757 17.38
300 3566 7.08 4259 8.45 6386 12.76 8515 16.90 10113 20.07 12774 25.35
THERMAX BI METALLIC TRAPS

(TBM) SERVICES SBU
(DN 15- 50 / BSP ½”-2”)
41
2/22/2014
THERMAX BI METALLIC TRAPS

(TBM) SERVICES SBU
1. Body
2. Cover
3. Cover Gasket
4. Bi-metallic Plate
5. Strainer
6. Seat
7. Valve
8. Adjustment Screw
9. Cover Bolts
THERMODYNAMIC STEAM TRAP

SERVICES SBU
( TTD-YS-42)
42
2/22/2014
THERMODYNAMIC STEAM TRAP ( TTD-YS-42)
SS STRAINER
SERVICES SBU
BODY
DISCHARGE
BOLT
SS COVER SS DISC
THERMODYNAMIC TRAP MODULE

SERVICES SBU
43
2/22/2014
THERMOSTATIC STEAM TRAP - TTS-FS-SS

SERVICES SBU
SS COVER
SS BODY
SERVICES SBU
THERMOSTATIC CAPSULE
SS STRAINER
THERMOSTATIC STEAM TRAP - TTS-FS-SS INTERNALS
44
2/22/2014
AIR VENT MODULE SERVICES SBU
VACCUM BREAKER TVB-16 SERVICES SBU
45
2/22/2014
VACCUM BREAKER TVB-16 INTERNALS

VALVE SERVICES SBU
SS COVER
SS BALL
SS GASKET
PRESSURE REDUCING STATION

SERVICES SBU
WITH SELF ACTING PRV
46
2/22/2014
P & I OF PID CONTROLLER SERVICES SBU
1 Moisture Separator 11 Globe Valve

2 Drain Valve 12 Globe Valve
3 Drain Isolation Valve 13 Globe Valve
4 Steam Trap 14 Pressure Indicator
5 Isolation Valve 15 Safety Valve
6 Pressure Indicator 16 Pr. Transmitter
7 Isolation Valve 17 Pr. Indicator Controller
8 Strainer 18 E to P converter
9 Control Valve 19 AFR
10 GATE Valve
TO
LEARNING THE BASICS OF
STEAM UTILISATION
&
CONDENSATE RECOVERY
47
2/22/2014
STEAM UTILISATION SERVICES SBU
• Use correct type of steam trap

– Having adequate condensate handling capacity
– Adequate air handling capacity with built in
thermostatic air vent
– Built in strainer or a separate strainer
– A trap performance test valve
– Most suitable steam trap is a float trap
– Use condensate recovery system for indirect utilistion
of steam w/o contamination
STEAM UTILISATION SERVICES SBU
• Direct Heating
– Total enthalpy of steam available for heating which is higher that
latent heat
– Product gets contaminated
– Product gets diluted
– No steam traps are required
– Condensate can not be recovered for re use
• Indirect heating
– Only latent heat available for heating which is lesser than total
enthalpy of steam
– Most of the industries use indirect method of heating
– Condensate can be recovered for re use provided same heat
transfer area is not used for heating and cooling like coil in a
reactor
48
2/22/2014
STEAM TRAPS SERVICES SBU
• Steam traps are automatic valves which work on the principle of difference in
property of steam
• Thermodynamic trap Thermodynamic property
• Float trap Buoyancy
• Thermostatic trap Expansion & contraction of fluid

which operates a valve. Releases sub-
cooled condensate
• Bimetallic trap Expansion & contraction of fluid

which operates a valve. Releases sub-
cooled condensate
HEAT CONTENT IN STEAM

CONDENSATE SERVICES SBU
• 25% Heat is present in steam condensate
• Unless efforts are made to recover this condensate

the heat will be wasted as heat in flash steam and
heat in condensate at lower pressure
• Quantity of flash steam is less but heat content in

it is high
49
2/22/2014
SOURCE OF CONDENSATE SERVICES SBU
• Indirectly heated equipment like heat exchangers, jacketed

kettles, Plate heat exchangers, etc.
• There should be no contamination of condensate like in

– common coil used for heating and cooling
– Solvent recovery
– Where contamination may take place like in edible oil plants,
pickling plants, etc.
• No condensate recovery for once through coil type boilers

due to limitation on temperature of feed water temperature
SERVICES SBU
RIFOX THERMODYNAMIC TRAP WITH BLOWDOWN VALVE

50
2/22/2014
TTS-FS-SS SERVICES SBU
BSP 3/8” –1”

TBM SERVICES SBU
(DN 15- 50 / BSP ½”-2”)

51
2/22/2014
EXPECTATIONS FORM A
STEAM TRAP SERVICES SBU
EXPECTATIONS FORM A STEAM TRAP

S.No. Criteria Desired Float & Thermodynami Thermostatic Inv erted
Therm c Bucket
ostatic
Vent
1 Condensate Discharge Continuous Continuous Intermittent Continuous Intermittent
2 Service Life High High Lower High High
3 Wear Resistance High High Low Lower Lower
4 Corrosion Resistance High High High High High
5 Resistance to hydraulic shock High Low High Low High
6 Venting Capability High High Lower High Lower
7 Handling start up loads Good Good Poor Good Poor

8 Operation against back pressure Good Good Poor Good Good
9 Operation at low loads Good Good Poor Good Good
10 Response to slugs of condensate Immediate Immediate Delayed Delayed Immediate

11 Dirt handling capability Good Poor Poor Fair Good
12 Physical size Small Intermediate Small Small Large
13 Flash Steam handling capability Good Fair Poor Poor Good

14 Mechanical failure Open / Closed Closed Open Design Based Open
STEAM TRAP SELECTION

GUIDE SERVICES SBU
Steam trap selection guide

1. Use Thermodynamic traps for line drainage and very
small capacity traps
2. Bimetallic traps may be used for steam line drainage if

sufficient cooling leg is available
3. Use float traps for removal of condensate from process

heating equipment
4. Use Thermostatic steam traps where sub cooling of

condensate is desired like tracing lines
52
2/22/2014
Recommended Serv ice Factors
STEAM TRAPS
SERVICES SBU
S.No. Application Service Factor Remarks
1 Boiler Header 2
2 Steam Line Drains Headers 2
3 End of Steam Line 3
4 Steam Separators 3
5 Tracing Lines 2
6 Storage Tank Heaters 2
7 Submerged Coils 2
8 Shell & Tube Heat exchangers 2
9 Jacketed Kettles 3
10 Evaporators 2
11 Flash tanks 3
12 Platen Presses 2
13 Rotating Cylinders 3 8 to 10 for variable pressure
14 Air Heaters 3 With Temperature Controls

15 Radiators 2
16 Process Air Heaters 2
17 VAM 2
Note:
If the operating pressure differential varies to a very low value increase the safety factor
RECOMMENDED STEAM
TRAPS FOR EQUIPMENT SERVICES SBU
• Float tarps
– With thermostatic vent
• These are the normal traps
– With steam lock release (SLR)

• Applicable where the trap is likely to get steam or vapor locked like in
rotary dryers in paper application
– Float traps need installation of a separate Y strainer
– A disc check valve is recommended if the discharge of the trap is

to be connected to a common condensate return header
53
2/22/2014
FLOAT TRAP MODULE

SERVICES SBU
SERVICES SBU
RIFOX Float controlled steam trap

54
2/22/2014
SERVICES SBU
BODY
SS DISC
DISC CHECK VALVE (TDCV-N)
SS SEGMENT
SERVICES SBU
CENTERING
HOOP SS
DISC CHECK VALVE (TDCV-N)
55
2/22/2014
STEAM TRAP LEAKAGE

SERVICES SBU
• Normally steam trap testing is carried out by sound method using an

automotive type stethoscope or an ultra-sound device
• A steam trap blowing live steam will make a low pitch whistle
• A steam trap draining condensate will have a wet gurgling sound
• When a test valve is provided you can open it and observe the operation
STEAM LEAKAGE THROUGH STEAM TRAPS

SERVICES SBU
Pressure, Loss, kg/h

kg/cm2
Trap Size
15 20 25 40 50
1 1.17 3.25 7.30 12.99 20.29
2 2.34 6.49 14.61 25.97 40.58
3 3.51 9.74 21.91 38.96 60.87
4 4.67 12.99 29.22 51.94 81.16
5 5.84 16.23 36.52 64.93 101.45
6 7.01 19.48 43.83 77.92 121.74
7 8.18 22.73 51.13 90.90 142.03
8 9.35 25.97 58.44 103.89 162.32
9 10.52 29.22 65.74 116.87 182.62
10 11.69 32.46 73.05 129.86 202.91
56
2/22/2014
TRAP PROBLEMS SERVICES SBU
• Water hammer
water hammer can destroy thermostatic element or crush ball float
• Dirt
Dirt can plug strainer or lodge on the pin or seat. Dirt can plug the vent
hole in bucket traps causing them to fail shut
• Pressure rating
the trap seat pressure rating must be higher than the maximum steam
pressure or the trap will fail closed
SERVICES SBU
ADVANTAGES OF CONDENSATE RECOVERY
1 Heat recovery Fuel saving

2 Thermal de-aeration Removal of O2 & other non condensable
gases
-Boiler will not corrode
due to O2 corrosion
-Steam will have reduced non condensable
-Traps will work better
-HX will work better
-Higher ΔT
3 Higher feed water temperature Higher output from the same boiler
–Lower fuel consumption
for the existing output
4 Low TDS water Low Blow down required
–Fuel saving
57
2/22/2014
EQUIPMENT FOR CONDENSATE

SERVICES SBU
RECOVERY
1. Indirectly heated steam consuming

equipment
2. Steam trap module
3. Condensate recovery piping
4. Flash vessel
5. Steam operated condensate recovery pump
6. De-aerator head with immersion tube
EQUIPMENT FOR CRS SERVICES SBU
Condensate recovery from equipment Steam trap modules
Condensate recovery from steam piping Thermodynamic trap modules
Flash steam separation from pressurised Flash vessel

condensate
Separation of condensate from flash Float trap module

vessel
Transfer condensate to feed water tank Steam operated condensate transfer
pump
Mixing of condensate, flash steam & De-aerator head with immersion tube
make up water
58
2/22/2014
CONDENSATE RECOVERY SYSTEM (CRS) SERVICES SBU

(Not for coil boilers)
Flash Vessel De-aerator head & Immersion tube Condensate transfer pump
ECONOMICS OF CONDENSATE
SERVICES SBU
RECOVERY
• Short payback period
• Shortest pay back period if you are using expensive fuel

like furnace oil, HSD, etc.
• Good payback period for low cost fuels like agro waste,
wood brickets, etc.
• Pay back period can be as low as 3 months
59
2/22/2014
INSTRUMENTS REQUIRED FOR EFFICIENT

SERVICES SBU
OPERATION OF STEAM SYSTEM
• Boiler
1. Efficient burner operating at low excess air so that we
get low excess air and high CO2 in flue gas
2. Instruments for O2, and stack temperatures
3. Fuel flow meters for liquid / gaseous fuel, steam flow
meter and water flow meter
4. Boiler performance monitoring system
5. Boiler surface blow down control and heat recovery
system
6. Heat recovery units for extracting heat from flue gas
INSTRUMENTS REQUIRED FOR EFFICIENT

SERVICES SBU
OPERATION OF STEAM SYSTEM
• Steam distribution system

1. Correctly sized piping
2. All hot surfaces insulated including valves and flanges
3. Steam header in the boiler house
4. Zero leakage valves
5. Steam line drain traps at every 30 m of horizontal run
pipeline and at risers
6. Drain traps, air vents and vacuum breakers at end of headers
7. Pressure reducing stations before steam consuming
equipment
60
2/22/2014
TO
CASE STUDIES ON ENERGY SAVING

EQUIPMENT
CASE STUDIES SERVICES SBU
1. USE OF BELLOW SEAL VALVES
2. USE OF PRESSURE REDUCING STATION
3. USE OF CONTROL VALVES
4. USE OF SABCO WITH HEAT RECOVERY
5. USE OF CONDENSATE RECOVERY
61
2/22/2014
CASE STUDY 1 USE OF BELLOW SEAL VALVES

SERVICES SBU
COMPARISON BETWEEN CONVENTIONAL, PISTON & BELLOW SEAL
VALVES
PARAMETER CONVENTIONAL PISTON BELLOW SEAL
Primary seal Gland packing Piston Rings Metallic bellows
Stem Leakage Very high due to friction Starts on wearing of No leaksge
between stem & gland piston rings
Replacement cost Low High NA
Maintenance Cost Very high High Nil
Equipment downtime Very high High Nil
Packing Replacement Very often Rings, 1-2 years Nil
Media Loss High High when piston Nil
rings leak
Safety Unsafe with Hazardous Suitable for steam / Safe for all media
/poisonous media hot water
Valve life Low , months > conventional High - Years
Initial cost Low High High

Cost of ownership Very high High Low
STUDY OF LEAKING VALVES IN INDUSTRY

SERVICES SBU
PLANT TOTAL LEAKING % LEAKING TOTAL STEAM
NO. VALVES VALVES VALVES STEAM LOSS PER
LEAKAGE, VALVE, KG
KG
1 174 10 5.72 48 4.8
2 133 14 10.32 37 2.7
3 124 14 11.58 29 2.02
4 491 125 25.36 254 2.04
5 241 51 21.34 122 2.37
6 253 75 29.46 91 1.22
7 160 18 11.25 51 2.83
8 333 65 19.54 123 1.89
9 168 36 21.46 79 2.19
10 49 12 23.65 48 4.14
11 1101 197 17.85 313 1.59
12 321 63 19.76 128 2.02
13 164 12 7.28 43 3.6
14 568 37 6.54 64 1.72
15 198 18 9.24 41 2.24
62
2/22/2014
SERVICES SBU
PROBLEMS WITH LEAKING VALVES
1. Loss of money due to media loss like steam

2. Average valves leaking in an industry is 16%
3. Average steam loss from leaking valves is 2.49
kg/h/valve
4. Production loss on account of down time due to
maintenance
5. Safety issues in case of high temperature media
like steam / thermic fluid
6. Pollution problems
STEAM LOSS FROM LEAKING VALVES

SERVICES SBU
1. Cost of steam with Furnace oil as fuel
Heat output from FO = 9,650 x 0.88 = 8,492 kcal/kg

Heat reqd / kg of steam = 663.9 – 85 = 578.9 kcal/kg
Steam produced/kg fuel = 8492/578.9 = 14.6 kg steam/kg fuel
Cost of steam = INR 50/14.6 = Rs. 3.42
2. Annual steam loss considering 300 valves
300 x 16% x 2.49 x 300 d/y x 24 h/d = 8.6 Lakh kg steam
3. Annual loss of money = 8,60,000 x Rs.3.42 = 29,41,200
say Rs. 29 Lakhs/y
This does not include production loss and maintenance cost of valves
63
2/22/2014
CASE STUDY 2 USE OF LP STEAM SERVICES SBU
A process requires 25,000 kg/h of water to be heated from 30oC to 75oC. Steam
is available at 10 kg/cm2 as well as 3.5 kg/cm2. Select the steam pressure
Case 1: Using steam at 10 kg/cm2

hfg(10) 478.3 kcal/kg
Steam reqd = 25,000 x 1 x (75 – 30) / 478.3
= 2,352 kg/h
Case 2: using steam at 3.5 kg/cm2
hfg(3.5) 506.7 kcal/kg
Steam reqd = 25,000 x 1 x (75 – 30) / 506.7
= 2,220 kg/h
Saving in steam by using it at LP = 2352 – 2220 = 132 kg/h
Money Saved = 132 x rs.3.42 x 7200 h/y
= Rs. 32.5 Lakhs
CASE STUDY 3 AUTOMATIC TEMPERATURE

SERVICES SBU
CONTROLLERS
64
2/22/2014
USE OF TEMPERATURE
CONTROLLERS SERVICES SBU
• 1000 kg/h steam is used for heating water

from 30oC to 80oC. If the water gets
overheated by 5oC due to manual control
then what is the cost implication?
• The boiler uses Furnace oil and cost of

steam is calculated as Rs. 3.40 per kg.
WATER HEATING CALCULATIONS SERVICES SBU
ΔT (Normal) 80 – 30 50oC
ΔT (Overheating) 85 – 30 55oC
Steam cons with 5oC shoot-up 1000 x (55/50) 1100 kg/h
Excess steam consumed 1100 – 1000 100 kg/h
Additional Cost of steam (Rs.) 100 x 20 x 300 x 3.4 20,40,000
65
2/22/2014
CASE STUDY 4
USE OF BIMETALLIC STEAM TRAP IN PLACE OF THERMODYNAMIC TYPE
For Thermax Chemical @ 6 bar
For TD trap For BM trap
Legend Description Unit Readings Readings SERVICES SBU
to Time at start up HH: mm 11:00 11:30
M1 Mass of water initially kg 15.55 15.8
T1 Temperature of water initially Deg C 32 31
t1 Time at end HH: mm 11:15 11:45
M2 Mass of water at end kg 17.65 16.85
T2 Temperature of water at end Deg C 54 40
Tc Tempearature of condensate before trap Deg C 158.826 158.826
Em Live steam Heat content at available pressure Kcal / kg 659.3636364 659.3636364
Lm Mass of Live steam Kg 0.24 0.03482795
T Duration of trial min 15 15
Lm Mass of Live steam Kg / Hr 0.97 0.14
Live steam saving with BM kg/hr 0.84
For Maruti Suzuki @ 3 Bar

For TD trap For BM trap
Legend Description Unit Readings Readings
to Time at start up HH: mm 11:00 12:15
M1 Mass of water initially kg 2.56 2.62
T1 Temperature of water initially Deg C 22 22
t1 Time at end HH: mm 11:30 0:45
M2 Mass of water at end kg 3 2.98
T2 Temperature of water at end Deg C 75 54
Tc Tempearature of condensate before trap Deg C 142.92 142.92
Em Live steam Heat content at available pressure Kcal / kg 653.4 653.4
Lm Mass of Live steam Kg 0.21 0.101529541
T Duration of trial min 30 30
Lm Mass of Live steam Kg / Hr 0.41 0.20
Live steam saving with BM kg/hr 0.21
SERVICES SBU
CASE STUDY 5 CONDENSATE RECOVERY SYSTEM
Condensate recovery form plant operating at 3.5 kg/cm2 pressure

hf (3.5) 148 kcal/kg
Flash steam formed at 0.5 kg/cm2 6.97%
Equivalent fuel (kg) 148 / (9650 x 0.88) = 0.017 kg
Equivalent money (INR) 0.017 x 50 = 0.87 Rs. / kg
For every 1 ton of condensate recovered 0.87 x 1000 = Rs. 870
66
2/22/2014
SERVICES SBU
CASE STUDY 6 BLOW DOWN HEAT RECOVERY
BLOWDOWN CALCULATIONS SERVICES SBU
Feed water TDS 200 ppm

Permitted boiler water TDS 3500 ppm
Percentage blow down required
200
-------------- x 100
3500 – 200
= 6.06% (also refer page 58 of technical memento)
For a 6000 kg /h evaporation, blow down required

= 6000 x 6.06/100
= 364 kg/h
Surface 0.9 x 364 = 328 kg/h

Bottom = 36 kg/h
A 40 NB valve gives 6 kg/s (360 kg/min)
67
2/22/2014
HEAT LOSS IN BLOW DOWN SERVICES SBU
• Blow down required 364 kg/h

• Pressure 10 kg/cm2
• hf (from steam tables) 185.6 kcal/kg
• Total heat lost 185.6 x 364
67558.4 kcal/h
Equivalent fuel 67558.4/9650/0.88
8 kg/h
Annual fuel cost 8 x 24 x 300 x 50
INR 28,80,000
90% is surface blow down INR 25,92,000
HEAT RECOVERY FROM BOILER BLOW DOWN

SERVICES SBU
Qty of hot blow down water 364 x 0.9

327.6 kg/h
Flash vessel pressure 0.5 kg/cm2
hf (10) 185.6 kcal/kg
hf(0.5) 110.92 kcal/kg
hfg (0.5) 531.9 kcal/kg
Excess heat 185.6 – 110.92
74.68 kcal/kg of BD water
Flash steam 74.68/531.9 * 100
14.04%
46 kg/h
Recovering this 46 x 642.8
29568.8 kcal/h
Equivalent fuel 3.5 kg/h
Money saved per year 3.5 x 24 x 300 x 50
12,60,000
68
2/22/2014
SABCO SCHEMATIC SERVICES SBU
CONTACT DETAILS SERVICES SBU
• V K TRAMA
MOBILE 09890040272
E MAIL vktrama@yahoo.co.in
• Sushama Garud
Mobile 02066155577
E mail info.c&hservices@thermaxindia.com
69
2/22/2014
SERVICES SBU
THANK YOU
70

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2/22/2014

WELCOME SERVICES SBU

SAFETY OATH SERVICES SBU

We, individually and jointly , take an

WELCOME SERVICES SBU

WATER & STEAM SERVICES SBU

• What happens when water is heated from 0oC ?

– Water starts boiling and vaporises to form saturated

– Further addition of heat rises temperature of steam and

HEAT CONTENT OF STEAM SERVICES SBU

Total heat content of steam (hg) =

Sensible heat (hf) + Latent heat (hfg)

Steam generation and steam utilisation are

STEAM USE SERVICES SBU

• Direct steam injection – Full heat of steam is used

TYPES OF STEAM SERVICES SBU

• Dry Saturated Steam OR Saturated steam

– The flash steam generated is calculated by formula (hf at P1 – hf at P2) /

– This steam is used in plant operating at lower pressure or sent to boiler

USE OF DIFFERENT TYPES

• Pressure Heat / Enthalpy Specific Heat

• Temperature Entropy Thermal Conductivity

• Density Entropy Viscosity

Pressure Pa (N/m2) kg/cm2

Density kg/m3 kg/m3

Sp Volume m3/kg m3/kg

Entropy J/kg K kcal/kg K

PRESSURE 1 SERVICES SBU

PRESSURE 2 SERVICES SBU

Pressure measured in Gauge (g) Pressure &

1 kg/cm2 = 14.223 psi = 0.9806 bar

TEMPERATURE SERVICES SBU

T (K) = t (C) + 273

SI Prefixes SERVICES SBU

Multiplication Factor Facotr Prefix Symbol

0.000 000 001 10 -9 nano n

STEAM TABLE SERVICES SBU

• Contains essential data of steam like pressure, temperature, specify

• For saturated steam steam

• Steam table is either pressure based or temperature based

• For superheated steam

STEAM TABLE FOR SATURATED STEAM

Col 1 Absolute Pressure, kg/cm2 (a)

Col 2 Saturation Temperature, oC

Col 3 Specific Volume of Steam, m3/kg

Col 4 Specific Weight of Steam, kg/m3

Col 5 Enthalpy of Water, kcal/kg

Col 6 Enthalpy of Steam, kcal/kg

Col7 Latent Heat of vaporization, kcal/kg

STEAM TABLE - TRENDS SERVICES SBU

Abs Pr Temp Sp Vol Sp wt Enthalpy Enthalpy Latent

TRENDS SERVICES SBU

1. Saturation temperature or boiling point goes on increasing as

2. Specific volume reduces and specific weight increases as pressure

3. Enthalpy of water increases as pressure increases

4. Latent heat reduces as pressure increases

SATURATION CURVE TREND SERVICES SBU

Steam Saturation Curve

Saturation temperature increases with rise in steam pressure

SPECIFIC VOLUME TREND SERVICES SBU

Steam Pressure - Spe cific Volume Re lationship

Specific volume reduces with rise in steam pressure

• Small pipelines are required at high pressure since