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

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

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

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

... 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)

Metering for Energy-conservation How much steam is worth metering ? -1 tph of 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%

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 !)

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

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

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

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

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 !