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What We Do?
o Forbes
Marshall is an ISO 9001 company specializing in the Field of Steam Engineering & Control Instrumentation o We are working with steam for last 106 years and have our manufacturing facility in India and others in joint venture with Spirax Sarco, ARCA, Krohne, Codel & Vynce. o We manufacture Steam Boiler (NG/Diesel/Solid fuel fired), Exhaust Gas Boiler and almost all the steam system accessories.
Energy Audit
o Forbes Marshall has an Energy Audit division having expertise in
specific fields.
oForbes Marshall has conducted over 100 detailed energy audits across
the industry covering each and every process including dyeing units, washing units, denim plants etc.
Why Steam?
o Fuel used for generating steam accounts for about 50% of total utility cost. o Scarcity of Natural Gas, increase in cost of fuel and hence the steam costs oEffective steam management plays a role in Fuel Savings - which can be leveraged for cost competitiveness . Reducing fuel cost is the only route to cut costs substantially. Product Quality Maintaining proper steam parameters ensures product
textile plants reveal differences in fuel consumption within the industry. 39% difference in Specific Fuel Consumption (SFC) between the best and average plants. The worst plant consumes more
Comparative Study
Capacity Ideal Steam Consumption with (Kg) Right Steam and condensate loop (Without Heat Recovery/With Heat Recovery* (Kg/Batch) Light 250 400 600 750 461/281 660/460 863/563 Medium 559/379 711/511 1227/927 Dark 641/461 770/570 1698/1398 Actual Steam consumption (Kg/Batch) Required Actual Steam Steam Pressure Pressure (Barg) (Barg) Batch time (mins) Max Gradient (C/min)
Dark 769 890 1950 3.5 3.5 3.5 6-7 6-7 6-7 400-450 450-500 500-550 5 5 5
1358/758
1980
2160
3.5
6-7
550-650
1500
2982
3187
3.5
6-7
650-700
Common issues found because of not adopting right steam engineering practices Not getting right pressure & temperature in the m/c Batch time goes high and product quality hampered Proper steam trapping is not in practice Running boiler at lower pressure Not using PRV before Process machine Not using temperature control Many of the time traps are bypassed Steam distribution system is not proper Steam mains are oversized or undersized Traps and valves leakage Insulation of Steam & Condensate line is not proper Not recovering condensate & flash steam Feed water temperature is ambient Boiler blowdown is manual
Valve Leakage
A 1/8 inch hole in
steam main can waste 15 tons of coal or 9 tons of fuel oil per year.
A leaking 25 NB Thermodynamic Trap on a 7 bar line will lose steam at the rate of 18 kg/hr. This translates to a loss of more than 150 Tons of steam annually.
Group trapping
Recommended Hookup
Pan
Pan
Boiler
Feed Pump
100% Input
Boiler
Process
20% Condensate
So, for 1 Ton steam for process, fuel used equal to 1.67 Ton
Steam Generation
Two things are directly effect boiler steam generation
- Boiler operating pressure & Feed water temperature
Boiler
Blow down
Air
Radiation
BOILER HOUSE
Number of On-Offs
Scaling on tubes Soot Deposition Blow down TDS Moisture in Fuel
2. Steam Pressure
3. Fuel Flow 4. S: F ratio 5. Stack Temp 6. % O2 in Flue gas 7. Feed Water Temp 8. Blow down TDS 9. Furnace Pressure
Factuals
Deviation in 2% oxygen Results in 1.5 % Excess Fuel Consumption
10 % Excess Blowdown will amount to
Boiler Efficiency
Losses
Stack Enthalpy Un Burnt
100 - {
Burner
Draft
+ +
Steam Flow
Boiler
Blow down
+
Air Radiation
Conclusion
Fuel Scope for savings (%)
Gas
Liquid Solid
11.2 %
11.8 % 17.1 %
No Matter which fuel type you look at, the scope of savings is 10 % to 15 % at least. No boiler is an exception
Steam Distribution
High distribution loss across plants on account of o Improper line sizing
o Improper insulation o Improper line routing & condensate removal from steam lines
These losses can be addressed by o Proper design of the distribution network, i.e.; proper line sizing without extra
provisions for expansions o Proper insulation and efficiency checking mechanism o Proper condensate removal from steam lines o Diagnostics pressure and temperature gauges, steam flow meters, etc.
Pipe Sizing
Greater Cost Greater Heat Loss Greater Volume of Condensate Formed
Lower Pressure to Steam Users Not Enough Volume of Steam Water Hammer and Erosion
Waterhammer
Sagging Main
Condensate
Steam
Steam Flow
Correct
Condensate
Cross Section
Steam Flow
Incorrect
Steam Trap Set
Cross Section
Branch Connections
Steam
Steam
Condensate
Incorrect
Correct
Separator
Steam Utilization
Steam Trapping o In most plants, trap selection is an issue on heating
applications. o Group trapping on equipment also needs to be addressed. o Across textile plant audits and surveys we have conducted we find that only 50% of the installed traps are OK.
Disadvantages of TD: -Intermittent discharge. -Condensates not removed properly, get water logged. -Increase steam
consumption by 8~10%
-Increase process time By 25~30%
Ball Float Trap: Ensures proper removal of condensate from the process as soon as it forms. Recommended for process application.
oCondensate water contains 20% energy of steam. Returning condensate improves the feed water temperature and thus lowers fuel bill. o Returning condensate to feed water tank cuts the makeup water requirements. o The condensate returned does not need to undergo water treatment and thus saving treatment cost. o It has no TDS. It reduces the requirement of blowdown thereby
Energy Content
45 %
Enconomy opportunities
Trap Management Selection of right Trap Bypass Leakage Stop Leakages Insulation Condensate Recovery Flash Steam Recovery Stop Blowdown Losses Feedwater tank Management
Encon opportunities
Steam Flowmetering Dye Liquore Heat Recovery Efficiency Optimisation Liquor ratio control Steam Pressure Control Temperature Control Instant Hot water supply Dryness of Steam Waste Management Capacity Utilisation
Optimization ( 8-10%)
Encon Opportunities
Boiler Efficiency Monitoring Waste Heat Recovery Boiler from Generator Thermic Fluid GeneratorEfficiency % optimisation Hot water from DG set Jacket
Optimization
Waste Management
Forbes Marshall has a Consultancy Division worked for the project design and consultancy for steam, water & air distribution system to make the industry energy efficient and sustainable. Forbes Marshall has done Consultancy in many industries of Bangladesh. Few of them are, Hameem Denim, DBL, Ecotex, GMS composite, Graphics Textils, etc.
Knit Concern
Cutting
Costs
Before Energy Audit -They have a requirement of 3~4 TPH boiler - Their machine was starving for steam After Energy Audit & Implementing Recommendations
Till now they have no shortage of steam and no requirement of steam boiler
Reason found : Wastage and leakage of steam in different points Condensate was not recovered Boiler was running under pressure Too much blowdown losses Live steam wastages from garments section.
Copyright Forbes Marshall, 2006-07
Costs
The objective - Improve SPFC from 0.33 kgs wood/mt cloth (Rs 0.66/ mt cloth). Energy conservation recommendations implemented by customer -optimized fuel management sizing. -Optimized steam generation -undertook better management of process like temp control. -optimized waste heat recovery -reduced losses on account of inappropriate / in-operational trapping
The Results?
Kg/Meter cloth
0.34 0.33 0.68 0.66
0.32
0.64
Cutting
Down
Costs
The objective Reduce Fuel Consumption Energy conservation recommendations implemented by customer -Optimized steam generation -Reduced losses in steam distribution circuit -undertook better management of process like temp control. -optimized waste heat recovery dye liquor, condensate & flash recovery. -reduced losses on account of inappropriate / in-operational trapping
The Results? Before Fuel Consumption (lts/day) Costs (Rs/day) 1,150 17,250 After Audit 820 9,020
Cutting
Down
Costs
Cutting
Down
Costs
continue to spiral
upwards. & so would your losses!
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