Energy Saving Opportunities in Industries

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
nations welfare, we will adhere to all
safety norms, rules and instructions to
avoid accidents.
2/22/2014
WELCOME
SERVICES SBU
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
2/22/2014
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.
2/22/2014
TYPES OF STEAM
Dry Saturated Steam OR Saturated steam
Wet Steam
Superheated Steam
Flash Steam
Flash steam is generated when condensate pressure is reduced.
SERVICES SBU
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
2/22/2014
STEAM PROPERTIES SATURATED STEAM
SERVICES SBU
Pressure
Heat / Enthalpy
Specific Heat
Temperature
Entropy
Thermal Conductivity
Density
Entropy
Viscosity
Sp. Volume
UNITS OF MEASUREMENT OF
PROPERTIES OF STEAM
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
SERVICES SBU
2/22/2014
PRESSURE 1
SERVICES SBU
PRESSURE 2
Pressure measured in
Atmospheric Pressure
SERVICES SBU
Gauge (g) Pressure &

Absolute Pressure (a)
bar a
=
bar g + 1
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
2/22/2014
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
1,000,000,000,000,000
10 15
peta
1,000,000,000,000
10 12
tera
1,000,000,000
10 9
giga
1,000,000
10 6
mega
1,000
10 3
kilo
100
10 2
hecto
10
10 1
deca
da
0.1
10 -1
deci
0.01
10 -2
centi
0.001
10 -3
mili
0.000 001
10 -6
micro
0.000 000 001
10 -9
nano
0.000 000 000 001
10 -12
pico
0.000 000 000 000 001
10 -15
Femto
0.000 000 000 000 000 001
10 -18
atto
2/22/2014
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)
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
SERVICES SBU
2/22/2014
STEAM TABLE - TRENDS

Abs Pr
Temp
Sp Vol
steam
Sp wt
Steam
Enthalpy Enthalpy Latent

Water
Steam
Heat
Kg/cm2
oC
M3/kg
Kg/m3
Kcal/kg
Kcal/kg
Kcal/kg
119.62
0.9016
1.109
119.87
645.8
525.9
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
SERVICES SBU
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
Temperature, oC
200
150
100
50
0
1
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 M3/Kg
SPECIFIC VOLUME TREND
SERVICES SBU
2
1.8
1.6
1.4
1.2
1
0.8
0.6
0.4
0.2
0
1
9 10 11 12 13 14 15 16 17 18 19 20
Steam Pressure Kg/Cm
(a)
Steam Pressure - Spe cific Volume Re lationship
Specific volume reduces with rise in steam pressure
10
2/22/2014
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
PRESSURES
Boiler Operating at Design

Pressure
Boiler Operating at Lower

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

Loads
Difficult to Cater to Fluctuating

Loads
Reduced Risk of Water Carry Over
High Risk of Water Carry Over
SERVICES SBU
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2/22/2014
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)}
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
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
= 1:6:30
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.
D issolved O xyg en in p pm
Temp Vs Dissolved Oxygen

12
10
8
6
4
2
0
1
32
50
65
82
10 0
Temperature in Deg C
13
2/22/2014
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
14
2/22/2014
WELCOME
SERVICES SBU
TO
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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2/22/2014
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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2/22/2014
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
Dulongs 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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2/22/2014
PROPERTIES OF LIQUID / GASEOUS

FUELS
SERVICES SBU
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
Volatiles
Ash
Fixed Carbon
Heat sample in an oven at 110oC for 1 hour

Continue above at 950oC for 7 minutes, cover
Heat strongly till constant weight un-covered
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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2/22/2014
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

19
2/22/2014
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
20
2/22/2014
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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2/22/2014
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

BOILER - 2
S.N.
Description
Value
SERVICES SBU
Unit
SATURATED STEAM
0oC
30oC
85oC
110oC
Heat Av /kg of steam
539.4
539.4
539.4
539.4
kcal/kg
Heat Reqd/kg steam
663.9-0
663.9-30
663.9-85
663.9-110
kcal/kg
633.9
578.9
553.9
kcal/kg
= 663.9
3
Ratio, Av/Reqd
539.4/663.9 539.4/633.9 539.4/578.9

= 0.8125
Actual Output 1 TPH 812.5
539.4/553.9 kcal/kg
0.851
0.932
0.974
851
932
974
Kg/h
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2/22/2014
ACTUAL STEAM OUT PUT FROM A

BOILER - 2
S.N.
Description
SERVICES SBU
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
Heat Av /kg of steam
539.4
539.4
539.4
539.4
kcal/kg
Heat Reqd/kg steam
654.3-0
654.3-30
654.3-85
654.3-110
kcal/kg
624.3
569.3
544.3
kcal/kg
Ratio, Av/Reqd
0.864
0.948
0.991
Actual Output 1 TPH 824

98% dry
864
948
991
Kg/h
Actual Output 1 TPH 812.5

Dry
851
932
974
Kg/h
= 654.3
539.4/654.3 539.4/624.3 539.4/569.3

= 0.824
539.4/544.3 kcal/kg
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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2/22/2014
DIRECT EFFICIENCY
Efficiency
Output
Input
=
=
=
=
SERVICES SBU
Output / Input
m * cp * (hg fwt)
m * (hg fwt)
fuel cons (f) * Cal Value
m * (hg fwt)
Direct Efficiency ()
------------------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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2/22/2014
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

L1 gr = kgr x (t3-ta) x (1-0.01(L4gr + L5gr)) / VCO2
SERVICES SBU
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

CALCULATIONS FOR COMMON FUELS
SERVICES SBU
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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2/22/2014
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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2/22/2014
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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2/22/2014
MONITORING STEAM OUTPUT FROM

BOILER
SERVICES SBU
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
2
3
6
10
11
15
12
13
7
14
Orifice Type flow meter Installation

COMMITTED TO DELIVER INNOVATIVE ENERGY SOLUTIONS
29
2/22/2014
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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2/22/2014
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

1.
SERVICES SBU
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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2/22/2014
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
32
2/22/2014
BLOWDOWN CALCULATIONS
Feed water TDS
Permitted boiler water TDS
Percentage blow down required
200
-------------- x 100
3500 200
= 6.06%
SERVICES SBU
200 ppm
3500 ppm
For a 6000 kg /h evaporation, blow down required

= 6000 x 6.06/100
= 364 kg/h
Surface
Bottom
0.9 x 364 =
=
328
36
kg/h
kg/h
A 40 NB valve gives 6 kg/s (360 kg/min)
HEAT LOSS IN BLOW DOWN
Blow down required

Pressure
hf (from steam tables)
Total heat lost
Equivalent fuel
Annual fuel cost
90% is surface blow down
SERVICES SBU
364 kg/h
10 kg/cm2
185.6 kcal/kg
185.6 x 364
67558.4 kcal/h
67558.4/9650/0.88
8 kg/h
8 x 24 x 300 x 50
INR 28,80,000
INR 25,92,000
33
2/22/2014
HEAT RECOVERY FROM BOILER BLOW DOWN

SERVICES SBU
Qty of hot blow down water

Flash vessel pressure
hf (10)
hf(0.5)
hfg (0.5)
Excess heat
Flash steam
Recovering this
Equivalent fuel
Money saved per year
364 x 0.9
327.6 kg/h
0.5 kg/cm2
185.6 kcal/kg
110.92 kcal/kg
531.9 kcal/kg
185.6 110.92
74.68 kcal/kg of BD water
74.68/531.9 * 100
14.04%
46 kg/h
46 x 642.8
29568.8 kcal/h
3.5 kg/h
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 deaeration
Explore possibility of installing SABCO and blow down heat recovery
WELCOME
SERVICES SBU
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

TD TRAP MODULES
SERVICES SBU
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 .
m
u
a
mass flow rate of steam, kg/h

velocity, m/s
flow area of pipe, m2
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
Size
10
12
Op
Temp
Heat
Steam Heat
Stea
m
Heat
Steam Heat
Steam
Heat
Steam Heat
Steam
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 -2)

41
2/22/2014
THERMAX BI METALLIC TRAPS

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

( TTD-YS-42)
SERVICES SBU
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

WITH SELF ACTING PRV
SERVICES SBU
46
2/22/2014
P & I OF PID CONTROLLER
1 Moisture Separator
2 Drain Valve
3 Drain Isolation Valve
4 Steam Trap
5 Isolation Valve
6 Pressure Indicator
7 Isolation Valve
8 Strainer
9 Control Valve
10 GATE Valve
SERVICES SBU
11 Globe Valve
12 Globe Valve
13 Globe Valve
14 Pressure Indicator
15 Safety Valve
16 Pr. Transmitter
17 Pr. Indicator Controller
18 E to P converter
19 AFR
WELCOME
SERVICES SBU
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 subcooled condensate
Bimetallic trap
Expansion & contraction of fluid

which operates a valve. Releases subcooled 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 -2)

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

S.No.
Criteria
Desired
Float &
Therm
ostatic
Vent
Thermodynami
c
Thermostatic
Inv erted
Bucket
Condensate Discharge
Continuous
Continuous
Intermittent
Continuous
Intermittent
Service Life
High
High
Lower
High
High
Wear Resistance
High
High
Low
Lower
Lower
Corrosion Resistance
High
High
High
High
High
Resistance to hydraulic shock
High
Low
High
Low
High
Venting Capability
High
High
Lower
High
Lower
Handling start up loads
Good
Good
Poor
Good
Poor
Operation against back pressure
Good
Good
Poor
Good
Good
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
Boiler Header
Steam Line Drains Headers
End of Steam Line
Steam Separators
Tracing Lines
Storage Tank Heaters
Submerged Coils
Shell & Tube Heat exchangers
Jacketed Kettles
10
Evaporators
11
Flash tanks
12
Platen Presses
13
Rotating Cylinders
8 to 10 for variable pressure
14
Air Heaters
With Temperature Controls
15
Radiators
16
Process Air Heaters
17
VAM
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,
kg/cm2
Loss, kg/h
Trap Size
15
20
25
40
50
1.17
2.34
3.25
7.30
12.99
20.29
6.49
14.61
25.97
40.58
3.51
9.74
21.91
38.96
60.87
4.67
12.99
29.22
51.94
81.16
5.84
16.23
36.52
64.93
101.45
7.01
19.48
43.83
77.92
121.74
8.18
22.73
51.13
90.90
142.03
9.35
25.97
58.44
103.89
162.32
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
ADVANTAGES OF CONDENSATE RECOVERY
SERVICES SBU
Heat recovery
Fuel saving
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 T
Higher feed water temperature
Higher output from the same boiler

Lower fuel consumption
for the existing output
Low TDS water
Low Blow down required

Fuel saving
57
2/22/2014
EQUIPMENT FOR CONDENSATE

RECOVERY
SERVICES SBU
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

Condensate recovery from equipment
SERVICES SBU
Steam trap modules
Condensate recovery from steam piping Thermodynamic trap modules

Flash steam separation from pressurised Flash vessel
condensate
Separation of condensate from flash
vessel
Float trap module
Transfer condensate to feed water tank
Steam operated condensate transfer

pump
Mixing of condensate, flash steam &

make up water
De-aerator head with immersion tube
58
2/22/2014
CONDENSATE RECOVERY SYSTEM (CRS)

(Not for coil boilers)
Flash Vessel
De-aerator head & Immersion tube
SERVICES SBU
Condensate transfer pump
ECONOMICS OF CONDENSATE
RECOVERY
SERVICES SBU
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

OPERATION OF STEAM SYSTEM
SERVICES SBU
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

OPERATION OF STEAM SYSTEM
SERVICES SBU
1.
2.
3.
4.
5.
Steam distribution system

Correctly sized piping
All hot surfaces insulated including valves and flanges
Steam header in the boiler house
Zero leakage valves
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
WELCOME
SERVICES SBU
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

between stem & gland
Starts on wearing of
piston rings
No leaksge
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

rings leak
Nil
Safety
Unsafe with Hazardous

/poisonous media
Suitable for steam /

hot water
Safe for all media
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
NO.
TOTAL
VALVES
LEAKING
VALVES
% LEAKING
VALVES
TOTAL
STEAM
LEAKAGE,
KG
STEAM
LOSS PER
VALVE, KG
4.8
174
10
5.72
48
133
14
10.32
37
2.7
124
14
11.58
29
2.02
491
125
25.36
254
2.04
241
51
21.34
122
2.37
253
75
29.46
91
1.22
160
18
11.25
51
2.83
333
65
19.54
123
1.89
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
PROBLEMS WITH LEAKING VALVES
SERVICES SBU
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
2.
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
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)
Steam reqd
=
=
478.3 kcal/kg
25,000 x 1 x (75 30) / 478.3
2,352 kg/h
=
=
506.7 kcal/kg
25,000 x 1 x (75 30) / 506.7
2,220 kg/h
Saving in steam by using it at LP
2352 2220
Money Saved
=
=
132 x rs.3.42 x 7200 h/y

Rs. 32.5 Lakhs
Case 2:
using steam at 3.5 kg/cm2

hfg(3.5)
Steam reqd
= 132 kg/h
CASE STUDY 3 AUTOMATIC TEMPERATURE

CONTROLLERS
SERVICES SBU
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

T (Normal)
80 30
50oC
T (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
SERVICES SBU
65
2/22/2014
CASE STUDY 4
USE OF BIMETALLIC STEAM TRAP IN PLACE OF THERMODYNAMIC TYPE
For Thermax Chemical @ 6 bar
Legend
to
M1
Description
Time at start up
Mass of water initially
Unit
HH: mm
kg
T1
t1
M2
Temperature of water initially
Deg C
HH: mm
kg
T2
Temperature of water at end

Tempearature of condensate before trap
Live steam Heat content at available pressure
Mass of Live steam
Duration of trial
Mass of Live steam
Live steam saving with BM
Tc
Em
Lm
T
Lm
Time at end
Mass of water at end
For TD trap For BM trap

Readings
Readings
11:00
11:30
15.55
15.8
32
11:15
17.65
31
11:45
16.85
Deg C
54
40
Deg C
158.826
158.826
Kcal / kg
659.3636364 659.3636364
Kg
0.24
min
15
15
0.97
0.14
Kg / Hr
SERVICES SBU
kg/hr
0.03482795
0.84
For Maruti Suzuki @ 3 Bar

Legend
to
M1
Description
Time at start up
Mass of water initially
Unit
HH: mm
kg
T1
t1
M2
Temperature of water initially
Deg C
HH: mm
kg
T2
Temperature of water at end

Tempearature of condensate before trap
Live steam Heat content at available pressure
Mass of Live steam
Duration of trial
Mass of Live steam
Live steam saving with BM
Tc
Em
Lm
T
Lm
Time at end
Mass of water at end
For TD trap For BM trap

Readings
Readings
11:00
12:15
2.56
2.62
22
11:30
3
22
0:45
2.98
Deg C
75
54
Deg C
142.92
142.92
653.4
653.4
Kcal / kg
Kg
0.21 0.101529541
min
Kg / Hr
30
30
0.41
0.20
kg/hr
0.21
CASE STUDY 5 CONDENSATE RECOVERY SYSTEM
SERVICES SBU
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) =
Equivalent money (INR)
0.017 x 50
=
0.017 kg
0.87 Rs. / kg
For every 1 ton of condensate recovered
Rs. 870
0.87 x 1000
66
2/22/2014
CASE STUDY 6 BLOW DOWN HEAT RECOVERY
SERVICES SBU
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
Bottom
0.9 x 364 =
=
328
36
kg/h
kg/h
A 40 NB valve gives 6 kg/s (360 kg/min)
67
2/22/2014
HEAT LOSS IN BLOW DOWN
Blow down required

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

SERVICES SBU
Qty of hot blow down water

Flash vessel pressure
hf (10)
hf(0.5)
hfg (0.5)
Excess heat
Flash steam
Recovering this
Equivalent fuel
Money saved per year
364 x 0.9
327.6 kg/h
0.5 kg/cm2
185.6 kcal/kg
110.92 kcal/kg
531.9 kcal/kg
185.6 110.92
74.68 kcal/kg of BD water
74.68/531.9 * 100
14.04%
46 kg/h
46 x 642.8
29568.8 kcal/h
3.5 kg/h
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

We, individually and jointly , take an

WATER & STEAM

What happens when water is heated from 0oC ?

HEAT CONTENT OF STEAM

Total heat content of steam (hg) =

Steam generation and steam utilisation are

Direct steam injection Full heat of steam is used

Indirect heat transfer Only latent heat is used

Dry Saturated Steam OR Saturated steam

USE OF DIFFERENT TYPES

STEAM PROPERTIES SATURATED STEAM

Gauge (g) Pressure &

T (K) = t (C) + 273

0.000 000 001

0.000 000 000 001

0.000 000 000 000 001

0.000 000 000 000 000 001

Contains essential data of steam like pressure, temperature, specify

All properties are available if either pressure or temperature are available

Steam table is either pressure based or temperature based

For superheated steam

STEAM TABLE FOR SATURATED STEAM

Absolute Pressure, kg/cm2 (a)

Specific Volume of Steam, m3/kg

Specific Weight of Steam, kg/m3

Enthalpy of Water, kcal/kg

Enthalpy of Steam, kcal/kg

Latent Heat of vaporization, kcal/kg

STEAM TABLE - TRENDS

Enthalpy Enthalpy Latent

SUPERCRITICAL STEAM NO WELL DEFINED BOILING POINT

Saturation temperature or boiling point goes on increasing as

Specific volume reduces and specific weight increases as pressure

Enthalpy of water increases as pressure increases

Latent heat reduces as pressure increases

SATURATION CURVE TREND

Pressure Kg/Cm 2 (a)

Steam Saturation Curve

Saturation temperature increases with rise in steam pressure

Specific Volume M3/Kg

SPECIFIC VOLUME TREND

Steam Pressure Kg/Cm

Steam Pressure - Spe cific Volume Re lationship

Specific volume reduces with rise in steam pressure

Small pipelines are required at high pressure since

Boiler Operating at Design

Boiler Operating at Lower

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

Reduced Risk of Water Carry Over

High Risk of Water Carry Over

Entropy is the degree of disorder of the system and is calculated by the

Change in Energy (H) / {Average Absolute

Entropy is measured in units of kJ/kg K or kcal/kg K or kcal/kg oC

DESIRED QUALITY OF SATURATED STEAM

STEAM QUALITY AIR & NON

Solubility N:O: CO2