Steam Systems Solutions for Food Process

To,
The General Manager Crown Dairy Industry P O Box 286
Dubai, UAE

Ref: FM/SSD/CDI/S&C/01020720
Kind Attention: Mr. Emadadeen Khaleel CC: Mr. Gerine Aguilar
Date: 02/07/2020
SUB: Steam & condensate survey report and recommendations. Dear Sirs,
First of all, I would like to thank you for kind courtesy extended towards visit of Forbes Marshall engineer to your plant and the study
16th June 2020 to discuss the subject matter for improving the overall steam and condensate system.
With reference to the steam system study conducted in the factory, we have identified avenue for savings in the steam utilit
means of recovering condensate and flash, correction of pressure and steam traps in the different process.
We have consolidated the observations in boiler house and steam consumption in different segment of the plant. And section wise
consumption has been plotted with avenue for the improvement.
With reference to the discussion, we are proposing the condensate and flash steam recovery as the initial step towards the
direction of energy conservation. Please contact us for any clarifications on the report and proposal.
Thanking you and assuring of our best of attention at all times.
Yours faithfully,
For, FORBES MARSHALL PVT. LTD.
Madhusoodhanan Steam Systems Division, Forbes Marshall -­‐ UAE
0551144345
 Table of Contents
1. Boiler House Observations 3
2. Steam Distribution 4
3. Equipment wise steam load 5
4. Ideal Steam pressure in Process 6
5. Understanding steam pressure and flash steam generation 7
6. Understanding steam pressure and effect on steam traps 8
7. Understanding drawback of direct heating sterilizers 10

1. Boiler house Observations

Sr. Boiler No.

No. 1
Description

A. Boiler Data
1 Boiler capacity (Kg/hr) 16000
2 Boiler type 3 PASS WET
BACK
3 Boiler make Thermax
4 Year of Installation 2018
5 Normal steam demand (Kg/hr) 2500 (Avg)
6 Mainline steam flow meter present? Yes
7 Feed water meter present? No
8 Design pressure (Kg/cm (g))2
10.54
9 Operating pressure (Kg/cm2(g)) 8
10 Type of fuel used HSD
11 G.C.V. of fuel (Kcal/KG) 10200
12 Fuel consumption (LPD) 975 GPD
13 Fuel consumption / month 29256 Gal
14 Fuel bill (AED/Year) 2,808,576
15 Feed water TDS (ppm) 140
16 Boiler water TDS (ppm) 3500
17 TDS measurement frequency Daily
18 Blowdown frequency Manual
19 Blowdown valve size 40NB
20 Average boiler operation (hrs/day) 24
21 Cost of fuel (AED/Gal) 8
22 Boiler operating day/year 300
B. Feed Water Tank Data
1 Feed water quality ( Soft/DM/etc) SOFT
2 Feed water temperature (°C) 98
3 Feed water tank capacity (KL) 10000
4 Present level maintained in the feed water tank (% / KL) 70%
5 Direct steam injection? No
6 Deaerator head present? Yes
7 Level control system present? Yes
 eer to your plant and the study during

e for savings in the steam utility by

ocess.
of the plant. And section wise

as the initial step towards the

al.
 3
4
5
6
7
8
10

Boiler No.
2

5000 X 2
3 PASS WET
BACK
Loos
2005
2500 (Avg)

No
13.00
8
HSD
10200
975 GPD
29256 Gal
2,808,576
140
3500
Daily
Manual
40NB
24
8
300

SOFT
98
10000
70%
No
Yes
Yes
 2. Steam Distribution in different sections
Both the steam boilers have steam header and interconnected using another steam header. Steam boilers oper
8.5 barg pressure and 5 Pressure reducing stations are located in the boiler house area.
Different sections of the plant and the steam pressures are listed below

Sl Section Temperature profile

(Min/Max) – deg C

1 Cream / Milk Preparation 30 / 70

2 Cream / Milk Pasteurization 65 / 85

3 Cream Sterilization (Retort) 80 / 120

4 Tetrapak UHT Pasteurizer 80 / 142

5 MEE – Condense milk 75 / 85

6 Evaporated milk Str. (Retort) 5 / 120

7 Tomato Sterilizer 30 / 112

8 CIP Sections – 2 nos 30 / 90

Reducing pressure wherever required to meet the exact temperature requirement, will reduce
the steam consumption as well as the flash steam generation.
ed using another steam header. Steam boilers operate at
ed in the boiler house area.
sted below

Pressure used (barg)

6 barg

6 barg

8 barg

6 barg

6 barg

4 barg

6 barg

6 barg

t temperature requirement, will reduce

ration.
 3. Equipment wise steam load

Sl Section Equipment Flow rate Current Steam Usage

Pr. Temp.
LPH barg Deg C
TETRAPAK SECTION
1 Tetrapak Cream Mixing Water heating 1800 6 165
2 Tetrapak Cream Mixing Sterlizer 2800 6 165
3 Tetrapak UHT past. UHT-­‐Tubular 3000 6 165
4 Tetrapak Cream storage Al Safe Tank 20000 6 165
CREAM LINE
5 Cream line Water heating 4400 6 165
6 Cream line Hydration 4400 6 165
7 Cream line Sterlizer 4400 6 165
8 Retort Panini 10400 8 180
9 Retort Panini 10400 8 180
10 Retort Panini 10400 8 180
CONDENSAE MILK
11 Condense milk line Hydration 5000 6 165
12 Condense milk line Pasteurizer 5000 6 165
13 Condense milk line MEE 5000 6 165
EVAPORATED MILK
14 Evaoprated milk line Hydration 5000 6 165
15 Evaoprated milk line Pateruizer-­‐ATS 10000 6 165
16 Retort Sumpot 6280 4 150
17 Retort Sumpot 6280 4 150
18 Retort Sumpot 6280 4 150
TOMATO PASTE
19 Tomato paste line Tetrapak Asc. 2250 6 165
CHEESE
20 Cheese line Navatta 500 4 150
21 Cheese line Stephan 500 4 150
FRESH DAIRY
22 Fresh dairy Pasteurizer 5000 6 165
CIP SECTIONS
23 Cream line CIP 5000 6 165
24 Tetrapak line CIP 3000 6 165
25 Fresh dairy line CIP 1500 6 165
JUICE CONCENTRATE
26 Juice line Sugar & Conc 1500 6 165
27 Juice line Sterlizer 1500 6 165
28 Juice line CIP 1500 6 165
TOTAL CONNECTED STEAM LOAD
team Usage
Flow
Kg/hr

127
198
461
500

311
44
222
717
717
717

343
202
840

343
405
1122
1122
1122

373

56
56

190

151
90
 45

45
45
45
10609
 4. Ideal steam pressure in process
Ideal steam pressure for indirect heat transfer process can be decided based on the temperature requirement in the process.
1. Capture the pressure drop in the heat exchanger on steam side
2. Steam Temperature Required = Final Product Temperature + 35 Deg C
3. If steam temperature computed in Sr. No. 2 is -­‐
(A) Above 100 Deg C – Based on the steam temperature decide the steam pressure Do account for the pressur
(Sr. no.1)
(A) Below 100 Deg C – Recommended pressure is > 0.8 to 1.0 bar g. Do account for the pressure drop (Sr. no.1)
Properties of Saturated Steam at different pressures are plotted below. From the table it is observed that as the
pressure increases, the latent heat (heat transferred to process) portion is reducing and sensible heat (heat con
condensate) portion is increasing.

Sat. Steam Sensible Latent heat

temp. (degC) heat (kcal) (kcal)
Sl Sat. Steam pressure

1 1.014 barg (Atmospheric) 100 100 540

2 3 barg 143 144 510
3 6 barg 165 166 494
4 8 barg 175 177 485
emperature requirement in the process.

pressure Do account for the pressure drop

count for the pressure drop (Sr. no.1)

om the table it is observed that as the
reducing and sensible heat (heat content in

Excess energy
in condensate
(kcal)

0
44
66
77
 5. Understanding Steam pressure & Flash steam generation
When condensate at a higher pressure is discharged at a lower pressure, a part of the condensate is flashed. When
exposed to atmosphere, the flash steam escapes out of the system. As listed in above table, the condensate energ
be high at higher pressures of the steam. Hence the flash steam quantity will be more from the high-pressure cond

Flash steam calculations

Consider a process utilizing 1000 kg/hr of steam at 8 barg is discharging the condensate to atmospheric conditions
shall evaluate the mass and energy content of the Flash steam generated from the process as follows

1 Condensate quantity, m 1000 kg

2 Condensate pressure, p 8 barg
3 Sensible heat at 8 barg, hf1 177 kcal
4 Latent heat at atmospheric pressure, hg 540 kcal
5 Sensible heat at atmospheric pressure, hf2 100 kcal
6 Flash steam -­‐ Mass portion (hf1-­‐hf2)/hg 14 %
7 Flash steam quantity (m * flash%) 142.59 kg
8 Energy of 8 barg condensate m * hf1 177000 kcal
9 Energy in Flash steam m * (hf1 + hg) 91259.26 kcal
10 Flash steam -­‐ Energy Portion 52%
By recovering Flash steam alone, you save about 50% of total energy available in saturated condensate and 15%
of the makeup water. Hence Flash steam recovery is an essential part of achieving an energy efficient system.

6. Understanding steam pressure & effect on traps

Major issues in process traps
 • Waterlogged steam traps
• Increase in batch time
• Frequent opening of trap bypass valve
• Subcooled condensate reaching the trap
Major issues in Process Application

• Continuous variation in secondary fluid process temperature

• Reduction in productivity/Quality
• Drop in heat exchanger capacity
• Water hammering
• Frequent operation of control valve
• Leakage from heat exchanger
• Corrosion in heat exchanger

Performance of the heat exchanger depends of the removal of condensate as soon as steam liberates heat energy
liquid form. Faster the rate of condensate removal, faster will be the heating process. Float type steam traps will w
properly when the pressure inside the trap is higher than the condensate side. While the modulating control valve
regulates opening, the pressure inside the heat exchanger may even become vacuum and even negative. The cond
accumulates inside the heat exchanger causing STALL!!
Concept of Stall
STALL is reduction or inability of condensate evacuation from heat exchanger, when the pressure across steam tra
becomes equal /less than outlet pressure

Trapping

P
P1>P2

P
 P1<P
2 P

Stalling
ensate is flashed. When
, the condensate energy will
the high-pressure condensate.

atmospheric conditions. We
as follows

d condensate and 15% mass

rgy efficient system.
 liberates heat energy to form
ype steam traps will work
odulating control valve
ven negative. The condensate

ssure across steam trap

 Normal cause for stall
 Reduction of heat load as the temp. of secondary reaches set point
 Reduction of heat load due to process demand shortage
 Increase in back pressure on steam trap
 Lifting of condensate after steam trap

Parameters to consider for stall load

• Steam pressure reaching to the process( bar g )
• Back pressure on trap ( bar g)
• Secondary fluid inlet temperature (°C)
• Secondary fluid outlet temperature (°C)
% Stall = (X-­‐Y) * 100
(Z-­‐Y)
where Z= Saturation temperature of steam at operating pressure (°C)
Y= Secondary fluid outlet temperature (°C)
X= Saturated steam temperature equivalent to back pressure (°C)

Stall calculations
Consider a process with temperature requirement of 80 deg C is heated using steam as primary medium. The steam
different pressures is utilized for heating. The backpressure on the trap remains same, since the lift after trap is s
all conditions. Observations from the below table indicate that the stall in process is high at lower pressures. How
there exists stall even when the higher pressure of steam is used in process. Stall load indicates the amount of
condensate logged in the heat exchanger.

1 Steam pressure, barg 8 5 3

2 Back pressure, barg 0.5 0.5 0.5
3 Saturation temperature at op. pressure, (Z) deg C 175 158 143
4 Saturation temperature at back pressure, (X) deg C 111 111 111
5 Secondary fluid outlet temperature,(Y) deg C 80 80 80
6 Stall % 33% 40% 49%
How to overcome stall?
The only way of avoiding stall is to ensure that the pressure at the trap inlet is always higher than the back pressur
excess steam pressure should be given to the steam trap and not the heat exchanger. For this applications steam
operated pump trap is ideal, that uses motive steam to create positive pressure for evacuation of condensate from
equipment. Hence motive steam will be acting only on the trap and not in the process heat exchanger. This also en
that the steam will be available in trap even when the Temperature control valve is modulating to close the valve c
vaccum effect inside the steam trap.
 7. Understanding drawback of direct heating sterilizers
Hot Water Generation:
Hot water requirements in the plant are for hydration (mixing of ingredients), Pasteruization, Steriliza
CIP sections. The precise hot water temperature is the key to the productivity.
Most of these processes, the hot water is generated by direct steam injection in a tank. And all of them are manua
operated. However, this crude method of hot water generation has many disadvantages.
Issues with the conventional direct steam injection systems
1. Overheating of water due to direct steam injection.
2. Overflow of hot water from the tanks due to direct steam injection leads to loss of energy and increased load
effluent treatment plant. This also leads to unsafe operation for the operating personnel.
3. Uncondensed steam bubbles out from the vent of the tanks due to unsteady state of heating.
4. Steam injection leads to hammering and vibrations in the tanks, in turn unsafe work environme
the operating personnel. Tanks often needs maintenance due to leakages developed by steam hammering.
There is obvious loss of energy since the water is overheated than the required temperature. Also there ca
issues with the product quality in case the water temperature is not maintained within the required set parameter
Overflow from the tanks also lead to loss of energy since the overflown hot water is mostly sent to the effluent tre
plant. Effluent treatment has significant cost involved and the amount of overflow of hot water only adds to the effl
treatment costs
Benefits of indirect heating in HeatMax:
1. No overflow of water –Since the water is heated indirectly, there is no addition of mass in the tank, thus no lo
energy.
2. Precise temperature control – The engineered system provides the accurate temperature control enhanc
productivity.
3. Make up water savings – In direct nature of heating uses the latent heat of steam, however, 100% condensate
recovery ensures that the heat is not wasted. Also, it reduces the makeup water consumption in the feed w
tank.
4. Faster response for the varied temperature requirements – The hold up tank capacity is reduced and i
equivalent to the hold up volume of the entire loop. Hence, the initial heat up time and the response time for the
changed set temperature is also reduced substantially.
5. Condensate evacuation even under Stall – Steam heat exchangers always go under Stall under partial loads. D
the Stall, the condensate pressure is not sufficient to be evacuated from the heat exchanger. The condensate evac
system provided in the HeatMax maintains the heat exchanger free of condensate even under Stall.
6. Clean and tidy set up – Since there is no overflow or spillage of hot water, the set up remains very clean and sa
operating personnel.
7. Compact – Our engineering works to the perfection in making the skids very compact, requiring very small foot
area for the given capacities.
the Stall, the condensate pressure is not sufficient to be evacuated from the heat exchanger. The condensate evac
system provided in the HeatMax maintains the heat exchanger free of condensate even under Stall.
6. Clean and tidy set up – Since there is no overflow or spillage of hot water, the set up remains very clean and sa
operating personnel.
7. Compact – Our engineering works to the perfection in making the skids very compact, requiring very small foot
area for the given capacities.
Forbes Marshall ‘HEATMAX’ – Hot water generation System
HEATMAX is designed for applications where steam is the primary medium and water is the secondary medium. W
also provide complete solutions for other media combinations. HEATMAX is designed as a true instantaneous heat
tight temperature control at its outlet without the need for a storage or buffer tank, whatever the application. We
guarantee this performance even under the most critical application requirements.
HEATMAX is a fully assembled, tested unit that is delivered to site ready to be connected to your utilities. The who
process of assessing your requirements, through to installation, start-­‐up and commissioning can be completed in
short time.
HEATMAX is the preferred solution for a wide range of HVAC and process hot water heating applications up to 250
System Deliverables:
• Secondary fluid temperature accuracy of (+/-­‐) 0.5 deg C.
• Condensate evacuation at all loads even under Stall.
• Control system inlet & outlet
• Lowest foot print area
PID TEMPERATURE CONTROL VALVE :
In house manufacturing following German standards.
The best in class manufacturing facility to cater to sizes ranging from 15 NB to 300 NB.
Manufacturing for more than 60 years.
Innovative design of control valves offer
 Maintenance-­‐free stuffing box
 Control plug made of stain-­‐less steel SS316 with linear, modified or equal-­‐percentage characteristic
 Seat ring made of stainless steel SS316 interchangeable without special tools and useable on both sides
 Body favourable to flow behaviour
 Body made of carbon or stainless steel
These temperature control valves ensure the accuracy of (+/-­‐) 0.5 deg C.
Temperature Control On / Off system:
Main steam supply line:
In case the unfortunate event of modulating temperature control valve have any breakdown or malfunction, Heatm
system will not be able to control the steam flow as per the secondary flow. For additional safeguarding of Heatma
steam supply to system is usually provided with the installation of a temperature control valve in On/off mode. Th
temperature control system ensures that heatmax is safeguarded from any temperature
overshoot by immediately shutting off the temperature control valve if secondary flow is restricted because of any
reason.
FM Piston Valve for Steam Isolation(A SMART solution)
At the heart of the FM Piston Valve are Piston and Sealing rings. A burnished piston seals against metal reinforced
graphite rings to achieve leak proof shut off. This unique design ensures long life even at high temperatures – upto
 Burnished Piston and metal reinforced graphite sealing rings ensures perfect CLASS VI shut off, bubble tight shu
 Only one type of sealing ring to suit all application-­‐ thus ensuring minimum inventory of spares.
 Superior construction and manufacturing ensures trouble free operation.
 Low coefficient of friction and low operating torque.
Steam Operated Pump Trap (SOPT) for efficient condensate evacuation:
Condensate Evacuation System:
Stall is a phenomenon where condensate pressure is equal or less than the atmospheric pressure and does not get
evacuated from the heat exchanger. When the condensate is accumulated in the heat exchanger, it may lead to vi
or even breaking of welded joints
due to steam hammering. To avoid Stall, HeatMax is offered with a unique Steam Operated Pump Trap for conden
evacuation. The condensate evacuation system too is manufactured in house.
Please note that Stall cannot be eliminated in any steam condensing application. It cannot be either overcom
using a steam trap.
In case a normal float trap is used for condensate evacuation, then it is
seldom not to open the bye pass since the condensate during the Stall cannot be evacuated by the trap, cau
wastage of live steam.
mary medium. The steam at
ce the lift after trap is same in
at lower pressures. However,
icates the amount of

1.013
0.5
100
111
80
155%

er than the back pressure. The

this applications steam
tion of condensate from the
t exchanger. This also ensures
ating to close the valve creating
 Pasteruization, Sterilization &

d all of them are manually

rgy and increased load on

nnel.
eating.
nsafe work environment for
by steam hammering.
mperature. Also there can be
required set parameters.
y sent to the effluent treatment
water only adds to the effluent

s in the tank, thus no loss of

perature control enhancing the

wever, 100% condensate

nsumption in the feed water

apacity is reduced and is

e response time for the

all under partial loads. During

er. The condensate evacuation
nder Stall.
emains very clean and safe for

equiring very small footprint

er. The condensate evacuation
nder Stall.
emains very clean and safe for

equiring very small footprint

 e secondary medium. We can
true instantaneous heater, with
ever the application. We will

o your utilities. The whole

ng can be completed in a very

g applications up to 2500 kW.

age characteristic
eable on both sides
wn or malfunction, Heatmax
safeguarding of Heatmax, the
alve in On/off mode. This
estricted because of any

gainst metal reinforced

igh temperatures – upto 425 oC.
shut off, bubble tight shut off.
of spares.

essure and does not get

hanger, it may lead to vibrations

d Pump Trap for condensate

annot be either overcome by

acuated by the trap, causing