GSK - Armstrong International · GSK Nabha, India Date: 15/03/2010 Page 4 of 75 To the attention of...

GSK Nabha, India

STEAM AND CONDENSATE AUDIT REPORT

1 Das/ Provot 15-03-2010 Item Description Established Checked out Date

STEAM AND CONDENSATE AUDIT

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GSK

Nabha, India

Date: 15/03/2010

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To the attention of Mr. B. Jagdish Rao. Established by

P.Provot / S. Laldas

TABLE OF CONTENTS

1 EXECUTIVE SUMMARY 4

2 STEAM BUDGET AND SUMMARY OF POTENTIAL SAVINGS 6

OPTIMIZATION PROJECT 1: Boiler Blowdown Optimization. 8

OPTIMIZATION PROJECT 2 : Use Bio Mass in Boilers. 13

OPTIMIZATION PROJECT 3 : Reduce Oxygen Levels by O 2 Trim and Repairing Damper 15

OPTIMIZATION PROJECT 4: Steam Leaks and Piping Design 19

OPTIMIZATION PROJECT 5: Take Combustion Air of Boiler 3 on upper part of Boiler House and Remove

Blowdown Heat Recovery 25

OPTIMIZATION PROJECT 6: Optimize Temperatures in Ovens 28

OPTIMIZATION PROJECT 7: Replace Direct Steam Injection by Indirect Heating on Pasteurizer 36

OPTIMIZATION PROJECT 8: Repair All Defective Steam Traps and Implement and Annual Maintenance

Program 40

OPTIMIZATION PROJECT 9 : Avoid Disc Traps outside. 43

OPTIMIZATION PROJECT 10 : Recover Condensate from outside SDP Plant. 45

3 AUDIT CHECKLIST 48

4 PROJECTS WITH NO DIRECT ENERGY SAVINGS 52

OPTIMIZATION PROJECT 11: Improve Condensate Drainage on the “second stage evaporators” 52

5 RECOMMENDED ADDITIONAL STUDIES 57

12. Piping Rationalization in Zone 9L or Close/Isolate all PRV’s on the HP Steam 57

13. Install New Turbine for 5L (Not Recommended Currently.PBT is very High) 58


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14. Install a Reverse Osmose installation on 4th Effect Evaporator (Carryover) 60

15. Condensate overflow 61

6 ATTACHEMENTS 62

Attachement 1: Drips to be added 62

Attachement 2 Trap Survey 70

Attachement 3 Leaks 71


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1 Executive summary

GSK, Nabha is the oldest plant of GSK in India. Armstrong had the opportunity of conducting a

Steam and Condensate audit of this plant from the 25 January to 30th January 2010. The energy

audit conducted by Armstrong covered the 4 areas of the steam loop: boiler house, steam

distribution, steam consumption and condensate return.

At the onset we would like to mention that during the audit the GSK team was very active in

attending to all the small optimizations detected and they tried to conserve energy in all possible

ways. After the walk through of site on day 1, Armstrong was advised to focus on the boiler

house.. Based upon our measurements and calculations during the audit, the overall boiler

house efficiency is a reasonable 76,85% on GCV. It was found that both the boilers did not have

any oxygen monitoring system, though economiser and blow down heat recovery existed. With

O2 trim it is estimated that a saving of about 4.5% is possible.

In general the steam distribution system is old and needs revamping. Changing the layout or

changing pipe sizes however will not have a reasonable pay back but will result in less of

maintenance issues on account of leakage and also result in good house keeping. Insulation

has been taken care of by other companies, and is therefore not covered in this audit.

On the process side, we studied the ovens, which is a problem area, the kettles, the evaporators

where in we installed data loggers to show the benefit by getting rid of gang trapping. We also

conducted a trap survey. We have dealt in detail in each of these.

The Steam Trap Management needs more regular attention, during the audit several steam

traps were found positioned incorrectly, this has as consequence that they were either leaking ,

either blocked.

Condensate recovery is very high in this plant, close to 100%. This is due to the recovery of

condensate from the 4th effect evaporator. We would recommend to assess the feasibility of

installing a Reverse Osmose on the water of the 4th effect evaporator as we suspect it to be the

cause of carryover in the Boiler. We could still find some scope for the same.


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We estimate the potential energy savings of 16% of the 2009 yearly steam budget (Rs

10,58,64,478), which represents a yearly saving of about 25,360GJ, 7501 tons of CO2 and Rs

1,71,00,000.

(6% of the savings are related to the O2 excess on the Old Boilers- wich should stop being

operated soon)


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2 Steam budget and summary of potential savings

Total yearly steam consumption (in 2009): 98 817 t/year

Steam cost (in 2009): 1077 Rs/t

Total yearly steam budget (in 2009): 10,58,64,478 Rs/year

Summary of identified energy-saving optimisations and their estimated yearly results:

RESULTS OF THE DETAILED STUDIES

Optimization Project Energy Saving

GJ/year

Cost Saving

Rs/year

Decreased CO 2

Emissions

Tons/year

Project

Investment

Cost in Rs

Payback

Time

months

1. Blow Down Optimization 1 609 628,276 133 4,00,000 8

2. Use Bio Mass in Boiler Nil 82,35,059 5 310 NA

3. Reducing O2 Levels in Boiler

and repairing damper

(Boiler should stop being

operated soon)

16 384 62,06,427 1 475 27,00,000 5

4. Repair Steam Leaks and

address root cause (Drips

missing + Boiler Carryover)

3 479 15,31,510

(+ Maintenance

Savings)

313 14,00,000 12

5. Take Combustion Air from

upper part of Boiler

316 1,18,000 26 50,000 6

6. Optimizing Temperatures in

Ovens

167 62,597

(+ Process

Optimization)

15 1,70,000 31

7. Optimizing Steam in

Pasteurizer

311 1,21,616 29 2,24,000 24

8 . Steam Trap Management 618 1,82,562 55 80,000 6

11. Avoid Disc Traps Outside 24 10,908 2.2 1000 1.5

12, Condensate Recovery from

Spray Dryer Plant

181 70,391 16 10,000 2

TOTAL 25,360 17,167,346 7501.2 1,24,45,000


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PROJECT WITH NO DIRECT ENERGY SAVINGS RELATED

7.Improving Drainage in

Evaporator

Process Optimization

RECOMMENDED COMPLEMENTARY STUDIES (ROUGH ESTMATIONS )

Optimisation Project Energy

Saving

GJ/Year

Cost Saving

Rs/year

Decreased CO 2

emissions

Tons/year

Total project

investment

cost in Rs

Payback

time in

months

13. Piping Rationalization in zone 9L 6,00,000 4,00,000 8

14. New Turbine for 5L 731 12,00,000 - 70,00,000 60-72

15. Address Carryover. Install RO for

4th stage Evaporators

To decrease boiler carry over.

PROJECT COVERED BY THIRD PARTIES

Optimisation Project Energy saving

in GJ

Energy

saving in Rs

Decreased CO 2

emissions in tons

Total project

investment

cost in

Payback

time in

months

Insulation Survey


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OPTIMIZATION PROJECT 1: Boiler Blowdown Optimizatio n.

Current System Description and Observed Deficiency

There are 2 x 10 t/h boilers running at 9 bar (g). It was observed that the TDS levels in both the

boilers was far less than desired. Three (3) readings were taken on each boiler and averaged

out. Currently, the boiler blowdown is controlled by a manual valve opened continuously at a

fixed opening percentage

Reading 1.

Paramaters Boiler 3 Boiler 4

Feed Water TDS (ppm) 36 36

Boiler Water TDS (ppm) 881 1001

Blowdown 4,2% 3,7%

Reading 2.




Blowdown 7,4% 5,6%

Reading 3.




Blowdown 6,9% 4,2%

Boiler # 3 Average Blowdown:6,2%

Boiler # 4 Average Blowdown:4.5%


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Technical Discussion:

Even with the best pretreatment programs, boiler feed water contains some degree of impurities

such as suspended and dissolved solids. As water evaporates, these impurities are left behind

and accumulate inside the boiler. The increasing concentration of dissolved solids leads to

carryover of boiler water into the steam, causing damage to piping, steam traps and even

process equipment. The increasing concentration of suspended solids forms sludge, which

impairs boiler efficiency and heat transfer capability.

To avoid boiler problems, water must be periodically discharged or “blowndown” from the boiler

to control the concentrations of suspended and total dissolved solids in the boiler water. Surface

water blowdown is often done continuously to reduce the level of dissolved solids, and bottom

blowdown is performed periodically to remove sludge from the bottom of the boiler.

The importance of boiler blowdown is often overlooked. If the blowdown rate is too high, energy

(water, fuel, chemicals) is wasted. If high concentrations are maintained, (too low blowdown) it

may lead to scaling, reduced efficiency, and to water carryover into the steam compromising its

quality (wet steam). The blow down rate is calculated with the following formula:

% Blowdown = C Feedwater

(C Boiler – C Feedwater)

Where:

CFeedwater= the measured concentration of the selected chemical in the feed water (Conductivity,

TDS, Alkalinity, Chlorine)

CBoiler = the measured concentration of the same chemical in the boiler

Note that the feed water concentration depends on the make-up water quality and the

condensate return ratio.

The ASME guidelines "Consensus on Operating Practices for the Control of Feed water and

Boiler Water Quality in Modern Industrial Boilers," shown in the tables below, are frequently

used for establishing optimum blow down rates.


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Table 1 : Water Chemistry for Watertube Boilers - A SME Guidelines

Recommended Optimization:

Armstrong recommends decreasing on the intermittent and continuous blowdown in order to

achieve 3000ppm in the boiler.

During our audit, we have seen that this is feasible. As soon as the continuous blowdown is

closed the conductivity in the boiler start increasing. This process takes a significant amount of

time because the feedwater is low in conductivity.

Controlling the right blowdown can be done manually (Option a) or via an automatic blowdown

valve (Option B)


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Estimated Savings and Benefits

Optimizing blowdown would result in saving annually Rs. 628 276.

Blowdown Reduction Current New Savings Boiler TDS (1) ppm 896 3000 Feed water ppm 44 44 blowdown % 5% 1% 4% Steam flow t/h 10 10 Blowdown flow t/h 0.52 0.15 0.37 Steam Pressure bar 10 10 Sensitive Energy at 10 bar kJ/kg 752 752 Temperature of Blowdown on Boiler 3 to Sewer (2) C 65 65 MUW temperature C 30 30 Heat lost in blowdown kJ/h 200088 57691 Boiler efficiency 77% 77% Fuel used kJ/h 259855 74924 Coal GCV kJ/kg 15834 15834 Coal use kg/h 16 5 Cost coal Rs/kg 6 6 Fuel cost rs/h 97 28 Hours h/year 8700 8700 Yearly Fuel cost rs/year 842395 242887 Yearly Energy Used GJ/year 2261 652 1609 Water loss t/h 0.52 0.15 Cost water Rs/kl 9 9 Water cost Rs/h 5 1 Water cost rs/year 40422 11655 Water loss kL/year 4491 1295 3196 Total Rs/year 882817 254542 628276 CO2 Emissions ton/year 187 54 133

CO2 emissions will be reduced with 133 t/year annually

(1) Average of all measurements taken

(2) Current Blowdown Heat Recovery taken in consideration


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Investment

Option A: Manual Control

No investment required. Ensure that the Conductivity in the Boiler stays around the 3000ppm

and modify blowdown valve opening accordingily

Option B: Automatic Blowdown Control

The investment is estimated at Rs 400,000. It includes:

� 2 nos Automatic Blowdown Control System.

� Labor for installing system

Payback

Option A: Immediate

Option B: 8 Months


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OPTIMIZATION PROJECT 2 : Use Bio Mass in Boilers.


It was observed that the boiler design is of mechanical stoker fired. Presently coal is being fired

but due to non availability of good quality coal (read mineral matter % as 47.58) and high price

of coal ( due to freight) and quota system it is explored to use bio fuel in combination with coal.

The Current Boilers have a design that allows to use husk. But a test has been realized by the

plant and was not conclusive. Damage of the pipes were observed.

Discussion

Using Biomass in the boilers will allow to make financial savings, and will also allow to reduce

CO2 emissions to the atmosphère.

Optimization

Armstrong suggests to use husk mixed with coal in the ratio of 20:80. Husk being a bio fuel

also results in zero CO2 emission hence lesser pollution. The

Annual Steam Generated 98262000

Kg/yea

r

Enthalpy in Steam 54338886000 Kcal/yr

Boiler Efficiency 77 %

Energy Required 70569981818 kcal/yr

20% of this energy to be feed by husk

Equivalent of this 20% energy

is 14113996364 kcal/yr

Husk Equivalent 4704.67 Tons/yr

Husk Cost 3000 Rs/t

Coal Equivalent 3787.98 Tons/yr

Coal Cost 5900 Rs/ton

Cost of Husk Equivalent 14113996.36 Rs/yr


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Cost of Coal Equivalent 22349054.9 Rs/yr

Savings

The implementation of this project will save Rs82,35,059 annually. The overall savings from this

project are presented in the table below.

Current Proposed Savings

Cost Rs/yr 22349055 14113996 8235059

Energy GJ/yr 58997 58997 Nil

CO2 Emission Tons/yr 5310 0.00 5310

Estimated investment and Payback

Estimated investment is in doing modification in the duct feeding fuel of the boilers. An

estimated investment of about 25 lacs is estimated

The payback is expected to be around 4 months.


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OPTIMIZATION PROJECT 3 : Reduce Oxygen Levels by O 2 Trim and Repairing Damper


It was observed that the oxygen levels were exceptionally high in the boilers as a result there is

huge loss of energy. The cold air gets heated when it passes through the furnace of the boiler

and leaves through the stack with a lot of heat along with it. This is a loss of energy and results

in fuel loss.

Excess of O2 can be due to several root causes : Leaks in the furnace (due to very low

draught), Leaks in air to air preheaters, improper tuning of the boiler, bad coal quality, problems

with damper controls.

In this specific plant there are two causes to this O2 excess. The first is the very bad coal

quality. Because of this coal quality i twill be impossible to reduce O2 to the usually

recommended 5 to 7%.

The second cause is that the damper of boilers are not functional. Even when the damper was

fully closed the O2 percent in flue gas did not change. The boilers are workign at very low loads

, and there is a significant play in the dampers..Even full closed they remain open.

Discussion

All combustion requires some amount of excess air.

Essentials of low excess air boiler operation. Combustion is a chemical reaction in which a

fuel constituent reacts with oxygen and releases its heat of reaction. As a result, all fuels need

oxygen, and the natural available oxygen source is air. However, air contains nitrogen that has

no role in the combustion reaction except absorption of a portion of the released heat of

reaction. Every cubic foot of oxygen brings four cubic feet of nitrogen along with it. This

unwanted nitrogen leaves the boiler stack as a part of the waste flue gases, taking with it a

portion of the heat released from the fuel. Hence, the quantity of unwanted nitrogen has to be

kept at a minimum by controlling the oxygen level in stack gases.

There is an optimum range for O2 in the boiler. Too little will cause inefficiency due to

incomplete combustion, while too much will cause inefficiency due to high exhaust flow rates.

The recommended O2 content in the flue gas is about 9% for coal fired Boilers,


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Optimization

Armstrong recommends installing an O2 trim system. The system includes an oxygen sensor

and this gives signal to modulate the air dampers so that proper amount of air is used during

firing. A stack temperature indicator is used along with steam flow meter and temperature

transmitters to complete the control loop. .

The Dampers also need to be reviewed and repaired for a better control


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Details:

COST OF STEAM : Current Proposed Savings

Oxygen Excess. % 14 9 5

Temp Flue Gas Deg C 143.5 143.5

Ambient Air Deg C 26.8 26.8

Cost of fuel Rs/kg 5.9 5.9

Enthalpy in Steam at Operating

pressure. kcal/kg 663 663

Feed Water Temperature Deg C 110 110

Boiler Efficiency % 76.85 81.36 4.51

GCV of Coal kcal/kg 3726 3726

Heat Required kcal/kg 553 553

Energy Required Kcal/kg 719 679 39.89

Coal Required

kg Per kg of

Steam 0.19 0.18 0.01

Cost of Steam Rs/kg 1.14 1.08 0.06

Savings



Annual Steam Cost : Current Proposed Savings

Average Steam Generation kg/hr 11294 11294

Annual running hours hrs 8700 8700

Annual Coal Consumption kg/yr 18976845 17924908 1051937

Annual Energy Consumtion kcal/yr 70707724138 66788207965 3919516173

Annual Steam Cost Rs 111963385 105756958 6206427

Total Energy in GJ/yr 295558 279175 16384

CO2 Equivalent Tons/yr 26600 25126 1475


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The estimated investment is going to be about Rs 27,00,000/-



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OPTIMIZATION PROJECT 4: Steam Leaks and Piping Desi gn


There were several steam leaks noticed during the survey. The plant maintenance is doing an

exceptional job of repairing the leaks as soon as possible. The noticed leaks were significant

and the reason to be included in the report is not to point to the deficiency, but to underline the

savings realized due to the prompt actions of the plant personnel. Four of the leaks was actually

repaired during the audit.

Steam leaking from Safety Valve.

The major root causes of these recurrent leaks are : the bad steam quality (Carryover) ,the

insufficient size of drip legs on the headers and the lack of drips upstream of control valves. This

Project addressesses the drips upsteram of the valves and the Drips on the header.

A point worth noting is also on the steam distribution network. This plant is an old plant and the

steam network expanded as and when the plant expanded, based on needs. Hence the network

is quiet complicated and in fact we noticed the old piping ( directly from boiler) existing with the

new piping ( after turbine got installed).

It would not be out of context to mention that there is no drip legs before the control valve as a

result issues like water hammer and leakage occurs. Drip legs are to designed with an equal


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Tee at the bottom of the pipe at headers, loops and dead ends for effective condensate removal

as shown below.

Drip Leg to be installed before CV.

(Every time the control valve closes, water will accumulate upstream of the valve.

When the valve opens again a waterhammer will occur. This will finish causing leaks)

For detailed list of missing drip legs see attachement 1.


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The leakage is occurring from the following areas.

kg/hr

Safety Valve 9L MEE 50

Main Line to milk pasteurization 25

9L Kettel 9 at trap 2



Turbine trap bypass 30

Turbine header: Bypass valve leaking 10

Safety valve in Milk plant 20

Condensate to sewer from 9L next to condensate

tank 5

Turbine header: Trap leaking 2

Boiler House : Main Header 25

Total 173

Note : A lot of these leaks were fixed during the audit

Discussion

The basic reasons for leak repairs are:

- Energy savings: Leaks are wasting 100% of the fuel, water and chemicals used in the

process of steam generation;

- Safety/Personnel protection: Protecting plant personnel from burns.


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In order to avoid steam leaks, steam needs to be as dry as possible. Wet steam is very erosive

and will create erosion of the lines and subsequent leaks.

It also is important to avoid any accumulation of condensate upstream of control valves (Wich

generates waterhammer and leaks)

Dripping a Steam System (Size of Drip Legs) to Ensure Dry Steam

The Size of the diameter of the Drip (D) needs to be large enough so that water can fall into it.

This will ensure dry steam trough the pipes


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Dripping Valves and Low Points to Avoid Water HAmmer

It is important to avoid water accumulation upstream valves or in low points.

Water accumulation will generate waterhammer and cause leaks

Optimization

Armstrong recommends repairing the leaks as soon as possible. Wherever the isolation of the

leaking area of the steam system is not possible, an “on place” leak repair can be applied.

In addition to that, Armstrong recommends to :

• Install traps upstream of every control valve that will accumulate condensate when

closing.

• Install a moisture separator at the inlet of the turbine.

• Improve size of drips on headers and collectors (Especiall the main distribution header in

the boiler house)

Savings


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Heat Loss GJ/yr 3479 0 3479

Heat Loss kcal/yr 832320300 0 832320300

Coal Loss kg/yr 257282 0 257282

Coal Loss Rs/yr 1517964 0 1517964

Water Loss kg/yr 1505100 0 1505100

Water Loss Rs/yr 13545.9 0 13546

CO2 Reduction Tons/yr 313 0 313


“On-place” leak repairs are more expensive and have to be handled by outside contractors. A

leak where the area could be isolated can be eliminated by equipment replacement/repair by the

maintenance personnel.

The Investments required to adress to root cause (Installling drips upstream of control valve and

Improving the size of the existing drips is estimated to 14,00,000 Rs.

Payback time is less than 1 year.


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OPTIMIZATION PROJECT 5: Take Combustion Air of Boil er 3 on upper part of Boiler

House and Remove Blowdown Heat Recovery


Currently, two water tube boilers produce steam at 10 bar for the plant.

Boiler#4 takes the combustion air on the upper part of the boiler via a duct. Boiler#3 takes air at

the bottom of the boiler house, the air being partially preheated by the blowdown of the boiler

(Only a portion of the air is preheated, additional fresh air is fed to the boiler via a lateral entry).

The additional air inlet has been created because the heat recovery coil creates too high

pressure drop.

The blowdown (Bd.) heat is not fully recovered; the water leaving the installation still has 60C.

This is because there is a lot of air bypassing the Heat Recovery Unit.

During the audit the blowdown rate of the boilers was very high (5%), but this was due to an

incorrect setting of the conductivity in the boiler.

Once the conductivity is properly maintained the blowdown will be reduced to 1%. In that case

the heat recovered on this unit will be neglectable.

Boiler #3

Comb. Air

30C

Air

32C

Bd

105C

Bd

60C

Comb. Air

30C


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The warmer the inlet air to any combustion process the lower the energy value that has to be

extracted from the fuel to raise said air to the combustion temperature.

For every 12oC increase in air temperature expect approximately a 1% reduction in fuel

consumed.


Armstrong recommends removing the air preheater (that is causing too high pressure drop and

that will not bring any value once the blowdown is reduced) and taking the combustion air of this

boiler in the upper part of the boiler house.

Savings

Optimizing the combustion air temperature on Boiler 3 annually Rs. 118,000

Current New Savings

blowdown HR (1)

Conductivity feedwater (2) Ppm 20

Conductivity Boiler (3) Ppm 3000

Blowdown (4) % 0.7%

Average Steam Load kg/h 5000

Blowdown flow kg/h

33.5570469

8

Sensible heat in blowdown kj/kg 752.4

Temperature after blowdown heat

Recov C 63

Heat Recovered kj/h 16411.4094

Boiler Efficiency 77.4%

Heat Recovered GJ/year

170.508149

6 - 170.5


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Taking Air on upper part

Stack temperature 135 135

Ambient air temperature 33 38 5.0

O2 Excess 10 10

Boiler Efficiency 77% 77% 0.0

Load of boiler 3 kg/h 5000 5000

heat required in boiler 3 kj/kg 2441.6 2441.6

Heat required in boiler 3 kj/h 12208000 12208000

Energy Required in Boiler 3 GJ/year

126180.878

6

125693.693

7 487.2

Energy Savings GJ/year 316.7

Coal Savings ton/year 20.0

Financial Savings Rs/year 1,18, 000

CO2 Reductions ton/year 26.2

(1) First Calculation shows the loss in energy due to the removal of the blowdown heat

recovery unit.

(2) Conductivity in the feedwater is considered at 20ppm. This is a very conservative

number when the Carryover of the Boiler will be fixed. (Condensate should come back at

5ppm)

(3) Conductivity in the Boiler is currently around 1000TDS. But this is an abnomaly that

needs to be fixed. These savings respective ECM..

(4) Blowdown Considered is optimum blowdown once the boiler conductivity is optimized.

Currently the rate is 6,5% and not 3%

CO2 emissions will be reduced with 26t/year annually

Investment



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� Labor for installing the Duct

� Duct

Payback

The payback of this installation is expected to be 6 months

OPTIMIZATION PROJECT 6: Optimize Temperatures in Ov ens


Steam at 0.95 barg is used in the ovens (on Line 5L and 9L) to dry the product from 84% to

95%.

In 5L production unit, steam is coming from the boiler at 8barg and then reduced via a PRV to

0.95 barg. In the 9L production unit, steam is coming from the turbine at 1.2 barg and then

reduced further to 0.95 barg.

The Steam temperatures required in

the ovens for drying depend of the type

of product.

• Horlicks requires the equivalent

of 0.95 bar steam. (Temp.

required 119C)

• Boost and Junior Horlicks

require the equivalent of 0,6

barg steam.

Steam is injected at the upper part of

the ovens, and condensate is removed on the bottom via Float and Thermostatic (F&T) traps.

In several locations, ovens have been installed in series (called “Master and Slaves”). This

means steam enters the first oven, and the mix of steam and condensate at the outlet of the first

oven is send to the second and third oven. In this “master and Slave” concept there is only one

trap installed at the outlet of the third oven.

Steam

inlet

Condensate outlet


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Figure 1: Master and Slave Concept

The plant personnel confirms that they face product quality issues on some of the ovens due to

incorrect temperatures. This problem is majorly present in the 9L area in the 5th zone and on the

ovens that make Junior Horlicks.

In the 5th zone, all ovens have been modified with one steam entry per oven (removing the

master and slave concept), but this has not improved the situation.

During our audit, we have noticed that a lot of the by-passes on the oven steam traps were

open. This is done by the operators to improve condensate drainage and try to achieve the right

oven temperatures, but this has as consequence significant energy losses.

Ovens in 9L- Zone 5

During our audit, we have measured the steam and condensate temperatures of each oven in

zone 5.

In Zone 5, 16 ovens are connected to the 1barg steam line. The diameter of the line is initially 4”

and then is reduced to 2”.

The results of the temperatures measurements are detailed bellow:

oven #

T before

trap - C

T after trap

-C

T Steam

-C Hall

45 115 96 115 Hall5

44 114 102 114 Hall5

43 115 90 115 Hall5

42 114 90 114 Hall5


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41 113 90 113 Hall5

40 113 90 113 Hall5

39 113 90 113 Hall5

38 90 Hall5

37 110 90 112 Hall5

36 112 90 112 Hall5

26 ->31 112 90 112 Hall 4

The measurements show there is no accumulation of condensate in the ovens (Steam

temperature is identical to temperature upstream of trap)

The steam temperatures show there is a significant pressure drop between the first oven in hall

5 (Oven 45) and the last oven (Oven 31). The first oven is fed with 115C steam wich

corresponds to a pressure of 0.7 barg,

The last oven is fed with 112C steam wich corresponds to a pressure of 0.5 barg,

Steam Speed Calculations show that velocity of steam in the 3” line are close to 31m/s wich is

too elevated for steam at such low pressure.


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PRV in 9L zone 5.

We have also analyzed the functioning of the Pressure Reducing Valve (PRV) that is feeding

the Ovens in zone 5.

Temperature of steam before the PRV Is

122C.

The PLC shows that the pressure after the

PRV is maintained at 0.96 barg, and

indicates a steam temperature of 116C.

This temperature was confirmed by our

Infrared measurements.

The temperature does not correspond to

the saturation of steam at 0.96 barg.

(Temperature at this pressure should be 119.5 C)

Two possible root causes to this:

1) The steam system contains air, and the temperature measured corresponds to the

partial pressure of steam in the mix air/steam (In this case 77% of steam and 23% of air)

2) The pressure sensor is not working properly. It Indicates 0.96 barg, but in reality it is 0.74

barg.

The third root cause could have been an incorrect temperature transmitter reading. But this root

cause was infirmed after checking with two other temperature measurement instruments.

We have, with the help of the plant, installed an air vent on the steam line just after the pressure

reducing stations, but after being installed for several hours no improvement was observed.

5L Horlicks Junior and Boost

Horlicks Junior and Boost require very low-pressure steam (0.6 barg). This steam pressure is

not sufficient to travel trough 3 ovens in series.

We have noticed that on most of these ovens, the traps have been by-passed to be able to drain

condensate out of the ovens.

Steam Traps Positioning.

Pressure Transmitter


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Several Traps are incorrectly installed at the outlet of the ovens. We have found traps installed

with the float upwards (Trap will be blocked), with the trap

downwards (leaking).

We have also seen traps upside down and traps missing.

This bad positioning has a significant effect on the

condensate drainage and temperature achievement in

the ovens. Traps that are leaking or by-passed will create

backpressure on the other ovens. Traps that are blocked

impede the correct drainage of the ovens.


The pressure drops on the main steam line feeding the ovens, the low steam temperature (due

to air, or due to insufficient pressure), the configuration of some of the ovens (Master and

Slave), and the incorrect installation of the traps are causing of bad heat transfer in the ovens.

This is creating product quality issues (Food is more humid than it should be) and has as

consequence the operators opening the bypasses of the traps wich generates energy and water

wastage.

Trap upside down

Trap upwards


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It is important to note that steam supply to the ovens is not stopped when the ovens are

stopped. At this moment the heating load of the ovens is very low (only radiation losses of the

oven), and it will be mainly steam that will be lost trough the open by-passes

Recommended Optimization

Armstrong recommends several optimizations to improve the working of these ovens

- 9L: Disconnect the ovens in Hall 4 from the main header feeding the ovens in hall5

- 9L: Create a new header for ovens at the end of hall 4

- 9L:Review the calibration of the pressure sensor controlling steam in zone 5

- 9L:Feed each oven with steam in the Junior Horlicks ovens (no master and slave

principle)


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Date: 15/03/2010

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Figure 2: Steam injected in each oven (No Master an d Slave )

- 9L and 5L:Position all F&T traps correctly. (Perfectly horizontal, with arrow down)


This project will bring the following benefits:

- Higher steam temperatures on ovens in zone 4 and 5=>Better product quality

- Less wastage of water and energy (due to by-pass open or steam traps wrongly

installed/leaking)

In this project, the operational benefits are more important than the energy savings.

Improving the quality of the product and reducing scrap will indirectly save energy, but this

component is difficult to estimate.

The direct energy savings will be due to the by-passes of steam traps that will not be opened

any more. This Project will save annually Rs.62,597


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Date: 15/03/2010

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Savings Calculations

Bypass Valve Open 11 Qty

Steam Leak per bypass 5 kg/h

hours 24 h/day

Steam lost 43800 kg/year

Enthalpy of steam 2706 kJ/kg

Heat lost 119 GJ/year

Boiler efficiency 71%

Energy Lost 167 GJ/year

Coal 10.5

ton

coal/year

Coal Cost 5900 Rs/ton

Coal Savings 62203 Rs/year

Water Lost 43800 kg/year

Water cost 9 rs/kL

Water Savings 394 Rs/year

CO2 Reduction 15 ton/year

Total Savings 62597 Rs/year

The CO2 emission reduction Optimizing Steam and condensate systems in the oven area are

15 tons/year.

Estimated Investment

The investment is estimated at Rs. 169,000. It includes:

� New pipe header for ovens in 9L zone 4

� Direct Steam connections for all Boost and Junior Horlicks Ovens

� Pipe and valves

Payback Time


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The payback of this installation is expected to be 2.7 years

OPTIMIZATION PROJECT 7: Replace Direct Steam Inject ion by Indirect Heating on

Pasteurizer


In an average, 15t/h milk is pasteurized. The

pasteurization is done in a plate and frame heat

exchanger using water at 114C.

The water circulates in a closed loop and is heated

with direct steam injection at 2.5 barg.

Because pasteurization is a closed loop, every

quantity of steam injected in the water loop

corresponds to a quantity of water that overflows.

The overflow of water (Condensate) is currently

sent to the sewer.

Figure 3: Pasteurization with Direct Steam Injectio n


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Returning condensate allows saving energy in the boiler house as it contains calories , it also

allows to save make-up water and chemical costs.


Armstrong recommends replacing the Direct Heating System by a plate and frame heat

exchanger. This will allow returning condensate to the boiler house.

Savings

Replacing the pasteurizer with an indirect water heating will allow to save annually Rs. 121,616

Savings Calculations Steam used 218 kg/h hours 8 h/day Water lost 636560 kg/year temperature 115 C Heat lost 239473872 kJ/year Boiler efficiency 77% Energy Lost 311005029 kJ/year Coal Lost 20 ton coal/year Coal Savings 115887 Rs/year Water Savings 5729 Rs/year Total savings 121616 Rs/year CO2 emissions Reductions 29 ton/year


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Nabha, India

Date: 15/03/2010

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CO2 emissions will be reduced with 29t/year annually

Investment


� Plate and Frame HE

� Trap and valves

� Labor for installing system

Payback

The payback of this installation is expected to be 2 year.


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OPTIMIZATION PROJECT 8: Repair All Defective Steam Traps and Implement and Annual Maintenance Program


A steam trap survey was performed in the facility by a certified survey technician. There were

102 steam traps located, identified, tagged and tested to determine their operating conditions.

Subsequent detailed computer analysis and reports are provided in Attachement 2.

Totally 9.8% of the traps in operation where found leaking.

The Executive Summary is detailed bellow:


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It is to note that during our audit we have found a significant amount of steam traps that were

not positioned properly. This causes them to leak, or to be plugged. These traps were often

found with by-pass valves open.


Steam traps are one of the most critical elements in a steam system.

If they leak, they lose steam and are source of energy losses. If they are blocked they will

impede the drainage of condensate wich will have as consequence water hammers, bad heat

transfers.

It is highly recommended to verify on an annual basis all the steam traps of the installation.


Armstrong Recommends to replace all the leaking and plugged steam traps, It also

recommends to position properly all the steam traps that are in an inclined position.

Armstrong recommends to implements an annual Survey of all the steam traps.


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Replacing all failed Steam Traps will result in saving annually Rs. 169,510

CO2 emissions will be reduced with 55 t/year annually

Estimated Investments

The Estimated Investments for replacing all traps is Rs. 80,000

This investments includes:

• Steam Traps

• Labor Time

Payback

Payback time is 6 Months


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Date: 15/03/2010

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OPTIMIZATION PROJECT 9 : Avoid Disc Traps outside.

Current System Description and Observed Deficiency It was observed that there are a few traps on the outside i.e exposed to the atmosphere and that

these traps are of Thermodynamic type.

Discussion The design of these traps is such that a disc opens and closes each time it discharges

condensate. When these traps are exposed to the rain then the trap disc top gets cooled rapidly

and the trap fails to understand as to whether it is due to condensate or cooling effect of air

hence the trap remains open ( sensing it to be condensate) and thus looses live steam.

Optimization It is advised to use an inverted bucket trap or to insulate the top of the TD traps.

Total traps outside 4

Hours rain 268 h/year

Trap open 50 %

Hours open 134 hr

Steam Leakage 20 kg/h

Steam Leakage 10720 kg/year


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Savings

The implementation of this project will save Rs10,908 annually. The overall savings from this


Current Proposed Savings Heat Loss GJ/yr 24.78 0 24.78

Heat Loss kcal/yr 5928160 0 5928160

Coal Loss kg/yr 1832 0 1832

Coal Loss Rs/yr 10812 0 10812

Water Loss kg/yr 10720 0 10720

Water Loss Rs/yr 96.48 0 96.48

CO2 Emission Tons/yr 2.23 0 2.23

Total Savings Rs/yr 10908

Estimated investment and Payback The maintenance personnel were quick enough to temporarily fix it near the turbine area in two

nos of TD trap.

Estimated investment is in doing this for 4 traps would be Rs1000.

The payback is expected to be around 1.5 months.


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Nabha, India

Date: 15/03/2010

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OPTIMIZATION PROJECT 10 : Recover Condensate from outside SDP Plant.


It was observed that there is a steam header from outside SDP plant from where the

condensate was getting drained to the atmosphere.

Discussion

The steam condenses after giving off its latent heat. A sizable portion (about 25%) of the total

heat in the steam leaves the process equipment as hot water. Below graph compares the

amount of energy in a kilogram of steam and condensate at the same pressure.

The percentage of energy in condensate to that in steam can vary from 18% at 1 bar g to 30%

at 14 bar g; clearly the liquid condensate is worth reclaiming. If this water is returned to the

boiler house, it will reduce the fuel requirements of the boiler. For every 6°C rise in the feed

water temperature, there will be approximately 1% saving of fuel in the boiler. Summary of

reasons for condensate recovery is as below:

• Water charges are reduced.

• Effluent charges and possible cooling costs are reduced.

• Fuel costs are reduced.

• More steam can be produced from the boiler.

• Boiler blowdown is reduced - less energy is lost from the boiler.

• Chemical treatment of raw make-up water is reduced.


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Optimization

It is recommended to connect this condensate line to existing recovery line. This arrangement

will save about 25 kg/hr of condensate drained to sewer.

Details:

Make up water Temperature Deg C 27

Amount of recoverable Condensate kg/hr 25

Temperature of Condensate Deg C 180

Energy in Condensate kcal/hr 3825

Equivalent coal required kg/hr 1.333

Plant running hours hrs 8700

Annual Coal requirement kg/yr 11599

Savings

The implementation of this project will save Rs70,391 annually. The overall savings from this



Coal Savings kg/yr 0 2660 2660

Annual Cost of

coal Rs/yr 68433.56 0 68434

Energy Savings GJ 0 180.65 181

CO2 Reduction Tons/yr 0 16.26 3.73

Water Savings Tons/yr 0 217.5 217.5

Water Savings Rs/yr 0 1957.5 1957.5

Total Savings 70391


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Date: 15/03/2010

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Estimated investment and Payback The maintenance personnel were quick enough to temporarily fix it near the turbine area in two

nos of TD trap.

Estimated investment is in doing this would be about Rs10,000/-.



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Date: 15/03/2010

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3 AUDIT CHECKLIST

Overall

Cost Tracking OK All costs of utilities are known

Metering OK Each Boiler has steam

Flowmeters, there is a make-up

water flowmeter.

Main plan units are also equipped

with a meter

Safety OK

Boiler House

Steam Quality To be Improved Steam Is containing a lot of water

wich creates erosion and

maintenance problems.

Steam Pressure Setting OK 10 bar is higher than what the

process requires. But this High

Pressure steam is used in a

Turbine to produce electricity.

Boiler Insulation OK No Major hot spots encountered

on the boiler

O2 Excess To be Improved O2 was measured at 14%. This is

very high. Mostly due to a bad

damper control. Can be reduced

to 9%.

Boiler Efficiency To Be improved Was measured at 71% on GCV.

This is mainly due to the high

excess of combustion air.


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Date: 15/03/2010

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Combustion Air

Temperature

To be improved Air is taken on upper part of boiler

house for Boiler 4. This project

could also be implemented for

project 3

Furnace Draft To be improved Draft was positive in Boiler 3. This

is to a bad balance between the

ID and FD Fan.

Coal Quality To be improved Coal Quality is very bad. We

recommend to use alternatives as

Rice Husk ,,briquets or Imported

Indonesian Coal

Stack Temperatures OK Heat of stack is recovered with

feedwater economizers

Boiler Blowdown To be improved Conductivity in Boiler Drum is

maintained too low , wich has as

consequence a blowdown rate

close to 5%. A plant that has

100% condensate return should

achieve a blowdown close to 1%

Condensate Drainage of

Steam Main Header

To be improved The drip diameter on the boiler

house steam header is too small

and can not collect all the

required condensate

FeedWater Temperature To be Improved Feedwater is at 80C

At this temperature water

contains O2 wich will cause

corrosion problems in the boiler.

(Future installation has a

deaerator)


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Distribution System

Insulation OK All lines are insulated. We

recommend to add removable

jacquets on valves and pipes that

are not insulated today

Pressure Drops To be improved The steam pipe between the

boiler house and the turbine has a

too small diameter. This causes a

pressure drop of more than 1 bar

between the boiler and the 9L

header.

This issue will disappear once the

new header and new boiler are in

place (Pipe dimension of new

header was checked and is OK)

External Leaks To be improved Several leaks detected. The root

cause of this is the bad steam

quality

Steam Users

Pressure at Point of Use OK Overall pressures required are

achieved. With exception of

Pressure in ovens in 9L area. See

report for details

Condensate Drainage Of

HE

To be improved A lot of users where found

accumulating condensate

(Second Stage evaporators,

Ovens) see report for details.

Condensate Return


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Steam Traps To be improved A lot of steam traps were found in

wrong positions. A regular trap

survey is recommended

Condensate Back Pressure OK Condensate is recovered in an

atmospheric open system and

return with electric pumps to the

condensate tank

Condensate Return OK Almost 100%.

Condensate Quality To be improved Condensate has been measure

with 50ppm. This is pretty high

and is mostly due to the recovery

of water from the 4th effect

evaporator

Venting on Condensate

Tank

OK Very minimal vent

Water Hammer OK No problems detected during

audit or reported by plant

personnel


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Date: 15/03/2010

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4 PROJECTS WITH NO DIRECT ENERGY SAVINGS

OPTIMIZATION PROJECT 11: Improve Condensate Drainag e on the “second stage

evaporators”


GSK uses second stage evaporators in order to dry the milk from 52% to 82%.

These evaporators are one single stage. Steam enters two heat transfer zones in the bottom of

the evaporator, and condensate is drained out via steam traps to the condensate return. This is

a batch process that lasts, in an average, 3 hours.

The steam pressure used on these evaporators varies between 0.85 barg and 2.3 barg. The

pressure during a batch is stable, but is dependent of the cleanliness of the evaporator. The

evaporators are cleaned every 36 hours. The steam pressure of the first batches is close to 0.85

barg, the pressure of the last batches close to 2.3 barg.

During our Audit, we have observed that the two condensate outlets from the evaporator were

connected together before the steam trap. This is commonly known as “Gang Trapping”.

Figure 4: Gang Trapping at the outlet of the Second Stage Evaporators.


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The pipe temperatures taken during the audit show that all these evaporators are accumulating

condensate. On some of the evaporators we have measured condensate temperatures

upstream of the trap as low as 60C, when the steam temperature was 120C. This shows a

significant condensate accumulation in the equipment.

In order to analyze further the working of these evaporators we have installed dataloggers on

Evaporator D2.

One temperature sensor was installed on the steam Inlet to evaporator, and one sensor was

installed on the condensate pipe at the outlet of the equipment.

The temperature results are shown on bellow chart:

Figure 5: Datalogging on Evaporator D2 (Two Batches )


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Analysis of the Chart:

Blue Curve: Steam temperature inlet evaporator

Red Curve: Condensate outlet evaporator (upstream of trap)

On a correct working heat exchanger, condensate and steam temperatures have parallel trends

and almost identical temperatures. The above chart shows chaotic temperature trends. This

clearly shows temperature instability in the heating zone.

The time of this batch is 2h38.

We had the chance to work with a very proactive team during this audit: Once this problem was

identified, one of the evaporators was immediately modified with one steam trap per condensate

outlet.

In order to analyze the difference we did start a datalogging campaign on this modified

evaporator. Results are shown bellow


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Figure 6: Datalogging on Modified Evaporator C2 (2 batches)

Analysis of the charts:

Blue Curve: Steam Temperature inlet of evaporator

Red Curve: Condensate temperature upstream of trap

We observe that the steam and condensate temperatures are parallel and almost identical.

There is no flooding of the evaporator anymore. Cycle time was 2h 24 .

Cycle times need to be confirmed, but the first recorded batch seems to have improved with 14

min.


The installation of one single steam trap for several applications will , most of the time, cause

trouble.


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This is because two heat transfer zones never have exactly the same heat transfer rate. This

means there are differences in steam loads, and by consequence differences in pressure drops.

It is the user that has the lowest pressure drop that will be able to drain condensate, the second

user will start accumulating condensate.

It is therefore critical to always install one trap per heat transfer zone.


Armstrong recommends installing one steam trap per evaporator outlet. And this on every

evaporator in the plant.

During the writing of this report, most of the evaporators have been modified. Plant personel

confirms a decrease in the cycle time.

Savings

It is not possible to estimate direct energy savings related to this project. Main benefits are:

• Decrease in process batch time

• Less condensate accumulation in the evaporators (less corrosion risks, less water

hammer risks, less leak risk)

• More stable process temperature

Investment

Minimal

Payback


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Date: 15/03/2010

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Immediate

5 RECOMMENDED ADDITIONAL STUDIES

12. Piping Rationalization in Zone 9L or Close/Isol ate all PRV’s on the HP Steam

During our Audit we have noticed that in process area 9L, several pipes are duplicated: there is

a steam main line from the turbine feeding each of the process areas (Evaporators, Ovens) but

in addition to this there is a high pressure line going to each of these same process areas.

These HP lines have been kept to have some flexibility.

It is to note that the LP lines coming from the turbine already have a back-up located near the

turbine. If for any reason the turbine stops there is a PRV , in parallel to the turbine, that will

deliver steam at low pressure.

These line duplications in zone 9L are source of extra energy losses (leaks, Insulation) ,.but are

also source for extra maintenance costs.

Finally, We have noted that in several places the PRV’s connecting the HP to the LP Turbine

lines were partially open: so, they were feeding steam on the low pressure network from the

turbine and by this, minimizing the steam trough the turbine . We recommend at a minimum to

isolate all the PRV’s connected on the HP steam Lines.

(Savings : 600,000 Rs/year; Investments : 400,000 Rs)


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Date: 15/03/2010

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13. Install New Turbine for 5L (Not Recommended Cur rently.PBT is very High)


The 5L process Area has several Steam users:

• 4 Mashing Kettles used to heat product at 76C. This uses LP Steam (1 bar)

• Multiple Effect Evaporator. Steam is used between 1 bar and 2.5 bar

• Second Stage Evaporators. Steam is used at 1 bar.

• 17 Drying Ovens. Steam is used at maximum 1 bar

Most of the users in the are are low-pressure users. Currently Steam comes from the boiler at

10 bar and is reduced trough a PRV to 1-1.2 bar at each user.

Average low-pressure steam used in 5L, based on flowmeters data and massa balans is

1200kg/h

Technical Discussion

Reducing steam pressure through a pressure reducing station (PRS) is a waste of mechanical

energy. It is preferable to recover this mechanical energy in the form of electrical energy,

Recommended Optimization

Armstrong recommends installing an electrical turbine in 5L to reduce the pressure from 9.5 bar

to 1.2 bar.

This turbine will produce approximately 30kW and use 1200kg/h steam


Installing a small turbine in the 5L are will save annually Rs.1,114,879

Current Proposed Savvings

Mashing kettles 5L kg/h 169 169

Pasteurizer kg/h 234 234

2nd Stage evaporator kg/h 488 488


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Ovens kg/h 311 311

Electricity Cost Savings

Steam Trough PRV kg/h 1201

total steam trough turbine kg/h 1201

Electricity produced kW 30

Operation

hours

/year 8700 8700

Electricity produced kWh/year 261218

Electricity cost from the grid Rs/year 1475879 0 1475879

Extra Cost of Coal to compensate for

energy used in turbine

Pressure PRV (turbine) in bar 10 10

Enthalpy in kj/kg 2776 2776

Pressure PRV(turbine) out bar 1 1

Enthalpy out kj/kg 2776 2706 70

Feedwater Temperature C 80 80

Total Energy kJ/h 2932362 2848292 84070

Total Energy kj/year 25511545920 24780136920 731409000

Boiler efficiency % 0.77 0.77

Energy Required GJ/year 33132 32182 -950

Coal

ton

coal/year -61

Coal Costs Rs/year -361 000

Rs/year 1 114 879

Estimated Investment

The investment is estimated at minimimum of Rs. 7,005,000 It includes:

� LP steam piping to users

� Turbine

� PRV Bypass

It does not include New building costs

Payback Time

The payback of this installation is expected to 6 -7 years


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Nabha, India

Date: 15/03/2010

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14. Install a Reverse Osmose installation on 4th Ef fect Evaporator

During our audit we have noticed serious carryover on the Boilers Steam is carrying more than

10% of water. This is a serious concern as Steam Carry-over is very erosive.

Wet Steam will generate erosion of the lines will will cause leaks,.

Water Carryover being highly concentrated in salts (TDS = 1500ppm) it will also very quickly

plug the first steam traps wich will worsen the situation as the carryover will not be immediately

removed from the pipe and travel further down the lines closer to the process.

This bad Steam Quality is impacting the proper working of the steam turbine also.

Water Carryover can have several root causes:

• Conductivity in Boiler drum higher than 4000ppm

• Water levels in boiler not constants

• Significant pressure drops due to batch processes

• Fats components in the Boiler water.

In this case we have narrowed the root two a combination of two factors. The first one is a very

bad stability of the water level in the boiler. This is due to the water control to the boiler, and will

be fixed once the plant moves to the new Boiler.

The second reason (wich still needs to be confirmed with water analysis) is the quality of the

condensate coming back from the plant.

We did notice during the audit that the 4th effect evaporator was recovered directly to the boiler.

This condensate might contain fats wich create foaming in the drum and create carry-over.

Three observations have alerted us to this root cause: The vapors coming out of the condensate

tank have a smell of milk, The level glass in the boiler shows a little foaming. And third,

Armstrong has done dozens of audits in dairies, and none of them was recovering this

condensate. Usually it is recovered using a reverse osmose Installation


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15. Condensate overflow

During the first day of the audt we did notice that the

condensate tank was overflowing.

We did install dataloggers on this pipe to assess the

frequency of this overflow. But it did not happen again.

Close attention needs to be given to this . If it happens

frequently the root cause of it needs to be assessed


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Date: 15/03/2010

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6 Attachements

Attachement 1: Drips to be added

Boiler Steam Header. Size of drip on the header needs to be corrected. Too Small in diameter.

9L Behind second stage evaporators Main steam Line needs to be dripped before control valve

9L Evaporator H2 A drip is required before control valve


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9L Evaporator I2 A drip is required before control valve

9L Holding tank (Near I2) Traps to be repositioned in correct axis

9L F2 Holding tank Bypass of trap has no valve. Install Valve. Install vacuum breaker after control valve to avoid vacuum in cooker (And subséquent condensate accumulation, wich leads to operators opening the by-pass valves)


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9L Evaporator A2 A drip is required before control valve

9L Evaporator B2 A drip is required before control valve

9L Evaporator C2 A drip is required before control valve


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9L Evaporator D2 A drip is required before control valve

9L Evaporator E2 A drip is required before control valve


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9L Evaporator F2 A drip is required before control valve

9L Evaporator G2 A drip is required before control valve


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9L 3SS1 Install trap upstream of Control valve

5L MEE Ejector Install drip upstream of Ejector. To avoid érosion of nozzle


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5L Mash Kettle Install drip upstream of control valve

5L Dead End. Install drip trap at teh end of the line. To avoid hammering and leaks.


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Steam line to milk Pasteurizer : Critical. Install steam trap at the end of this header. A lot of waterhammer are faced hère, and the valves installed downstream have continuously to be replaced


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Attachement 2 Trap Survey See Attached two Reports


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GSK

Nabha, India

Date: 15/03/2010

of 75



Attachement 3 Leaks

Condensate tank : One of the pipe is continuously leaking steam. Recommendation : Close this vent line

Boiler House : Steam Header


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GSK

Nabha, India

Date: 15/03/2010

of 75



Turbine Header : By-pass of steam trap does not close anymore, continuous steam leak

Turbine : By Pass of trap is kept continuously open. If closed the turbine has immédiate water damage. This is due to the bad steam quality. Recommendation : Address Boiler Carryover and install a steam separator upstream of turbine.


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GSK

Nabha, India

Date: 15/03/2010

of 75



9L Steam Header:

Rationalize design of drip. Too

many pipes.

E2 Evaporator 9L

Leak on safety valve


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GSK

Nabha, India

Date: 15/03/2010

of 75



Left Side of MEE: Leak on 8bar

steam line

MEE, Evaporators 9L:

150C after Steam Trap, Steam trap

is fully open

9L Boost Kettle:

Trap completely by-passed.

Actions: Place trap correctly, close

by pass valve, Install vacuum

breaker after control valve


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GSK

Nabha, India

Date: 15/03/2010

of 75



9L Boost Kettle:

Reposition trap

GSK - Armstrong International · GSK Nabha, India Date: 15/03/2010 Page 4 of 75 To the attention of...

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