Nashik, INDIA STEAM AND CONDENSATE AUDIT REPORT · 2012. 1. 8. · ©2011 AIPL GlaxoSmithKline Nashik, INDIA STEAM AND CONDENSATE AUDIT REPORT Project No: 90153 Prepared for: Mr

©2011 AIPL

GlaxoSmithKline Nashik, INDIA

STEAM AND CONDENSATE AUDIT REPORT Project No: 90153

Prepared for:

Mr. Rajesh D. Kirtane

A-10, M.I.D.C. Indl. Area, Ambad, Nashik - 422010

July 13, 2011

Prepared By:

Armstrong Service Inc 8615 Commodity Circle, Suite 17

Orlando FL-32819 Ph: 407-370-3301 / Fax: 407-370-3399

STEAM AND CONDENSATE AUDIT

Project:90153

GlaxoSmithKline Pharmaceuticals Ltd Ambad, Nashik - 422010

Date: 13/07/2011

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To the attention of Mr. Rajesh D. Kirtane

Prepared by

P. Ternikar

© 2011 AIPL

NOTICE This proposal has been submitted to GlaxoSmithKline (GSK) Pharmaceuticals Ltd, Nashik - INDIA in confidence and it contains trade secrets, as well as privileged information, and/or proprietary work product of Armstrong Service, Inc. (ASI). In consideration of the receipt of this Proposal and the information and data herein, Recipient agrees that it will use this document and the information contained herein only for internal use and only for the purpose of evaluating a business transaction with Armstrong. Recipient agrees that it will not disclose this Proposal or any part thereof to any third parties and Recipient may only disclose this document to those employees involved in the evaluation of a business transaction with Armstrong, on an as need basis. Recipient may make only those copies needed for such internal review. Upon conclusion of business discussions, this document and all copies shall be returned to Armstrong upon its or their request.


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TABLE OF CONTENTS

EXECUTIVE SUMMARY .......................................................................................................... 4

STEAM BUDGET AND SUMMARY OF POTENTIAL SAVINGS ............................................... 6

OPTIMIZATION PROJECTS ..................................................................................................... 8

1.1 OPTIMIZATION PROJECT # 1: REDUCE EXCESS AIR TO BOILER NO. 4 ....................................... 8

1.2 OPTIMIZATION PROJECT # 2: REPLACE FURNACE OIL BY BIOMASS AS BOILER FUEL .............. 12

1.3 OPTIMIZATION PROJECT # 3: REPAIR LEAKING BLOWDOWN VALVE AND MONITOR BOILER WATER

PARAMETERS .......................................................................................................................................... 14

1.4 OPTIMIZATION PROJECT # 4: REMOVE CONDENSATE LINE FROM AHU HOT WATER TANK ........ 17

1.5 OPTIMIZATION PROJECT # 5 RECOVER CONDENSATE FROM LIQUID AND OINTMENT PLANT...... 19

1.6 OPTIMIZATION PROJECT # 6 INSTALL DIGITAL TEMPERATURE SENSOR AND ALARM FOR

SANITATION APPLICATION ......................................................................................................................... 21

1.7 OPTIMIZATION PROJECT # 7 REDUCE NOZZLE SIZE FOR STEAM CLEANING APPLICATION.......... 22

1.8 OPTIMIZATION PROJECT # 8 CORRECT DRIP LEG DESIGN ...................................................... 24

1.9 OPTIMIZATION PROJECT # 9 ARREST ALL DIRECT STEAM LEAKS ............................................ 27

3.0 CHECK LIST VERIFICATIONS COMPLETED DURING THE AUDIT .............................. 29

4.0 BOILER EFFICIENCY CALCULATION SHEET .............................................................. 30


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EXECUTIVE SUMMARY

During the period of July 4th through July 9th of 2011, Armstrong conducted an energy audit of the steam system (generation, distribution, and users), and condensate return at GSK, Ambad, Nashik, India.

Armstrong estimated the potential energy savings of at least 26% of the current yearly steam

generation budget which represents a yearly saving of about 127 MWh, 3016 tons of CO2, and

INR 7828950.

The major saving in the steam generation lies in change of fuel from Furnace oil to Briquette

/ Biomass firing. Boiler house also had scope for improvement in reducing the excess air and

repairing the leaking blowdown valve of Boiler no.4. The combustion analysis conducted during

audit indicated that the boiler no 2 was operating at good efficiency levels by maintaining close

to best in class excess air levels.

In general the steam distribution system was found good. The insulation was satisfactory and

there were no major steam leaks which is an indicator of a very good maintenance program

being in place. Armstrong congratulates the Utility and Maintenance team for excellent efforts to

keep distribution loss to minimum.

The plant utilises steam for a majority of sanitation, sterilisation and heating applications either

for heating water or for product heating in the production process. The production process is a

batch operation and the production schedule changes depending upon product variant to be

manufactured. The condensate recovery from the Ampoule plant is partly done where as the

condensate from liquid, ointment, tablet plant was not recovered.

As discussed during the kick off meeting, the major focus of the audit was to improve steam

generation efficiency and associated costs that will lead to energy and carbon dioxide emission

reduction.

Based on Armstrong audit a minimum of 25% of the savings are expected from the steam

generation areas, related to conversion of furnace oil fired boiler to Biomass fired boiler,

repairing the blowdown valve and operating boiler at low excess air less.

There is minimum 1% energy savings, related to the steam distribution (steam traps are

not included) by arresting leaks. In general, the steam distribution system is well maintained

and insulated including the pressure reducing and control valves and their surrounding


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equipment. The condensate drip legs on the main distribution header are not correctly designed

and result in clogging of steam traps thereby accumulating condensate.

There is also potential for energy savings, related to the steam users, there is room for

improvement in the operation practices and reducing the steam wastage.


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STEAM BUDGET AND SUMMARY OF POTENTIAL SAVINGS

Total annual steam generation (Estimated) - 15 000 ton/yr Steam Cost - 2 018 Rs/ton Annual Steam Fuel Budget - 30 313 600 Rs/year

Project Description

Fuel

Savings

(MJ)

Fuel

Savings

MWh

Monetary

Saving

(INR/year)

CO2

Emission

reduction

(m tons)

Investm

ent (INR)

Simple

Payback

(year)

Reduce excess air to Boiler no 4 (*) 482768 134 338500 34 NIL Immediate

Replace Furnace Oil by Biomass as

boiler fuel NIL NIL 7494090 3016 15000000 2.00

Repair leaking blowdown valve and

monitor boiler water parameters (*)84945 24 59560 6 25000 0.4

Remove condensate line from AHU

hot water tank (*)46057 13 38494 3 50000 1.3

Recover condensate from Liquid and

Ointment plant(*)298324 83 247924 21 650000 2.6

Install digital temperature sensor and

alarm for sanitation application

NA NA NA NA 15000 NA

Reduce nozzle size for steam cleaning

application81891 23 68505 6 5000 0.1

Correct drip leg design NA NA NA NA NA NA

Arrest all direct steam leaks 374586 104 266354 26 50000 0.2

TOTAL 456477 127 7828950 3048 15055000 1.92

(*) :- Not considered for implementation and Total savings after discussion with GSK, Nashik The above savings are calculated based on utility data and costs for the past 12 months, and information gathered during the audit. For the systems in which information was not available, engineering assumptions were made based on observations and standard engineering practices. The investment costs are estimated based on data and experience from similar projects implemented in the past.


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During the audit, one of the three 6 TPH boilers was operated to cater plant steam demand

while one was on standby and the third was under inspection. Average steam generated by the

boiler is 4 ton/h at 8.5-9 kg/cm2g with fuel consumption of 3.8 Ton/day. Average feed water

temperature measured as 85 deg C.

A summary of Boiler efficiency calculations as below:

Boiler Efficiency – Indirect method Boiler No 4 :

Flue Gas Analysis

O2 9.2 %

CO2 9.0 %

Tstack 214 OC

Tambient 33.4 OC

Ex Air 79.2 %

Combustion Loss, L1 10.7 %

Loss due to Hydrogen in fuel, L2 5.8 %

Blowdown Loss, L3 0.7 %

Radiation Loss, L4 1.00 %

Boiler Efficiency on HCV 81.8 %

Boiler No 2 :

Flue Gas Analysis

O2 3.4 %

CO2 13.4 %

Tstack 212 OC

Tambient 33.2 OC

Ex Air 19.4 %

Combustion Loss, L1 6.6 %

Loss due to Hydrogen in fuel, L2 5.8 %

Blowdown Loss, L3 0.3 %

Radiation Loss, L4 1.00 %

Boiler Efficiency on HCV 86.3 %


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OPTIMIZATION PROJECTS

1.1 OPTIMIZATION PROJECT # 1:

Reduce excess air to Boiler no. 4

Current System Description and Observed Deficiency

During the audit, boiler flue gas analysis was conducted on both the operational boiler i.e. Boiler

no 2 and Boiler no 4. The flue gas analysis revealed that the boiler no.4 is operating at high

excess air level whereas the boiler no 2 is operated within standard limits.

Below is the flue gas analysis summary conducted on both boilers:

Average Boiler no 4 Boiler no 2

Ambient Temp 33.4 33.2

Flue gas Temp 214.5 212.7

Oxygen 9.2 3.4

Carbon Monoxide 31.6 9.3

Carbon di Oxide 9.0 13.4

Excess Air 79.2 19.4

The flue gas analysis could not be conducted on Boiler no.1 as it was under inspection and

Boiler no. 3 is out of service.

It was also understood from boiler attendants that, instead of FD fan damper, the oil pressure is

modulated to change the air to fuel ratio.

Technical Discussion

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 volume of oxygen brings four

volumes of nitrogen along with it. This unwanted nitrogen leaves the boiler stack as a part of

waste 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 excess oxygen level in stack

gases.


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If not enough O2 is available for the reaction, the fuel combustion will be incomplete, CO will be

formed and the result will be a low efficiency. If too much excess O2 is sent to the combustion

are, useless O2 (and N2) is heated which will also have as consequence lower efficiencies.

The below table shows that optimum efficiency in a oil fired boiler is obtained when a slight

excess of Air is used in the combustion between 2 and 3.5% O2 in the Stack.

Table 11: Excess Air recommended for boilers depending on fuel used

(Reference: Steam System Survey Guide, DOE, ORNL/TM-2001/263)

The two main designations in Table are automatic control and positioning control. Positioning

control is generally accomplished as part of an overall boiler control system without flue gas

oxygen measurement. Typically, a pressure controller observing steam pressure is the main

system controller. As the steam pressure decreases, the controller will increase fuel flow to

increase boiler steam output. Combustion air flow will be increased in a preset manner in

response to the fuel flow setting. Combustion air is not adjusted based on flue gas oxygen

content. Periodically the relationship between the combustion air setting and the fuel flow is

verified and adjusted through flue gas oxygen content evaluation. Here, a good quality burner

with proper CAM design will help in proper tuning of boiler for entire firing range. Non automatic

control is also accomplished through monitoring of the flue gas oxygen content and manually

adjusting the quantity of combustion air. This type of operation is usually found on boilers with

constant load. Automatic control refers to any type of boiler control that continually monitors flue

gas oxygen content and adjusts the combustion air flow to maintain required limits. Any type of

control will result in a range of flue gas oxygen content. Most boilers operate with less excess

oxygen requirement at higher loads than at lower loads primarily because of the improved

mixing and combustion parameters at higher loads.

Recommended Optimization

Armstrong recommends maintaining correct air to fuel ratio in boiler no.4. The following

procedure can be followed for this exercise:


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1. Stabilize the boiler at given operating loads. Note: A minimum of three firing levels is

required: low, medium and high.

2. Verify the present combustion conditions with a portable flue gas analyzer. The analyzer

must be capable of measuring O2, minor combustibles, and CO in the stack gases.

3. Once the analyzer is in place determine the levels of the combustion gases. If major

combustibles in grate ash and CO are not present, then (in small steps) adjust the

fuel/air ratio to reduce the excess air supply.

4. Verify the combustion conditions again after 10 minutes of stable boiler operation.

5. If major combustibles and CO are still not present, repeat steps 3 and 4 until the oxygen

in stack gas reaches the level recommended by the manufacturer.

Estimated Benefit:

The estimated benefits by reducing excess air are as below:

Reduce excess air in Boiler 4

Present Excess Air 78%

Recommended Excess Air 15%

Stiochiometric air requirement 14 kg/kg FO

Avg Fuel Firing 3789 kg/day

Actual Combustion Air 94427 kg/day

Recommended Excess Air 61006 kg/day

Reduction in Excess Air 33421 kg/day

Avg Flue Gas temp 210 Deg C

Specific heat of flue gas 0.23 kcal/kg K

Heat Saving 1383619 kcal/day

Equivalent Fuel Saving 127 kg/day

Annual Fuel Saving 10578 kg/year

Annual Monetary Saving 338500 Rs/year

Annual CO2 Saving 34 ton/year

The implementation of this optimization will lead to an approximate annual fuel saving of 10 ton/year and carbon dioxide emission reduction of 34 MT/year. Estimated Investment and Payback:

The implementation of this energy conservation measure does not require any investment and can be done during the regular maintenance schedule.

The payback for this optimization measure would be immediate.


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NOTE: The above savings are calculated based considering that the boiler no 4 is operation for one third of the total operational days (i.e. 83 days of 250 operational days). However the plant officials informed that the high oxygen level in the combustion air of the boiler is not a regular incident and the annual maintenance contract for flue gas analysis rectifies the off limit oxygen levels. So, after discussion with GSK it was decided to, NOT to consider the annualized savings as once a while indescripency cannot be extrapolated to continuous year round scenario.


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Replace Furnace Oil by Biomass as boiler fuel


The present fuel for boiler, furnace oil, is responsible for significant part of the total carbon foot

print of the facility. During the discussion with plant officials, it was understood that the

possibility of conversion of boilers to fire biomass instead of furnace oil is being probed.


Biomass is a renewable energy

resource derived from the

carbonaceous waste of various

human and natural activities. It is

derived from numerous sources,

including the by-products from the

wood industry, agricultural crops, raw

material from the forest, household

wastes etc.

Biomass does not add carbon dioxide

to the atmosphere as it absorbs the

same amount of carbon in growing as

it releases when consumed as a fuel.

Its advantage is that it can be used to

generate steam with the same equipment that is now being used for burning fossil fuels.

Biomass is an important source of energy and the most important fuel worldwide after coal, oil

and natural gas. Bio-energy, in the form of biogas, which is derived from biomass, is expected

to become one of the key energy resources for global sustainable development.

Biomass Briquetting

The process of densifying loose agro-waste into a solidified biomass of high density, which can

be conveniently used as a fuel, is called Biomass Briquetting. Briquette is also termed as "Bio-

coal". It is pollution free and eco-friendly. Some of the agricultural and forestry residues can be

briquetted after suitable pre-treatment.

Some of advantages of biomass briquetting are high calorific value with low ash content,

absence of polluting gases like sulphur, phosphorus fumes and fly ash- which eliminate the

need for pollution control equipment, complete combustion, ease of handling, transportation &

storage - because of uniform size and convenient lengths.


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Armstrong recommends converting one of the three furnace oil fired boilers to biomass firing.

Estimated Benefit:

The estimated benefits by fuel conversion are as tabulated below:

Bio mass Fuel conversion

Calorific Value of FO 10900 kcal/kg

Annual Fuel Consumption 947300 kg/year

Steam generation 15235 ton/year

Briquette Calorific value 3000 kcal/kg

Boiler efficiency with briquette 75%

Briquette required 3901 ton/year

Cost of Briquette 4500 Rs/ton

Annual Briquette cost 17553469 Rs/year

Additional Misc Expense (30%) 5266041 Rs/year

Total Expense 22819510 Rs/year

Present fuel bill 30313600 Rs/year

Savings 7494090 Rs/year

CO2 saving 3016 ton/year

The implementation of this measure will lead to a Carbon dioxide emission reduction of 3000

ton/year.

Estimated Investment and Payback:

The implementation of this energy conservation measure is capital intensive and the

approximate Investment is Rs. 1,50,00,000 which includes,

External furnace with refractory

Briquette Storage yard

Briquette Conveyor

The payback for this optimization measure would be 2 years .

Note: The investment mentioned above is tentative and based upon cost incurred on kind of

projects elsewhere. A site visit of the biomass fuel conversion specialist is required for the

estimating exact investment. The implantation of this ECM will not result in any Energy saving

but there will be cost and CO2 emission reduction.


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Repair leaking blowdown valve and monitor boiler water parameters


During the audit, boiler water analysis was conducted and it was observed that the blowdown

valve of Boiler no.4 was leaking because of which the boiler TDS remains close to 950 ppm; the

maximum permissible boiler water TDS is approximately 2500 ppm.

Below is the water analysis for boiler no 4:

Description 4th July'11 (1:00 PM) 5th July (11:00 PM)

Raw water 207 214

DM water 46 38

Boiler (Blowdown) Water 942 946

Condensate 12.7 52.5

Boiler Feed water 52 46

In between the two readings taken on 4th July and 5th July, there was no blowdown given but the

steam generation was approximately 50 ton, which ideally should have increased the boiler

water TDS. The readings above show that the TDS of the boiler water is almost unchanged.


Even with the best pre treatment 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 “blowdown” 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.

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)


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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 rate.

Water Chemistry for Water tube Boilers - ASME Guidelines


Armstrong recommends repairing the blowdown valve. The same was brought to notice of

plant officials during the daily debrief, and it is understood that the maintenance of the valve is

already planned during the IBR inspection.

Estimated Benefit:

The estimated benefits by reducing blowdown are as below:

http://www.gewater.com/handbook/boiler_water_systems/Table13-2.jsp

http://www.gewater.com/handbook/boiler_water_systems/Table13-2.jsp


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Boiler No 4 Blowdown Valve Repair

Feed water TDS 52 ppm

Boiler water TDS 950 ppm

Boiler Permissible TDS 2500 ppm

Present Blowdown quantity 2316 kg/day

Required blowdown 850 kg/day

Sensible heat @ 7 barg 166 kcal/kg

Heat loss 243453 kcal/day

Annual heat loss 20287761 kcal/year


Annual Monetary saving 59560 Rs/year


The implementation of this measure will lead to an annual reduction in furnace oil consumption

by approximately 1800 kg/year. The total CO2 reduction will be approximately 6 ton/year.


The implementation of this energy conservation measure does not require any major investment

for repair, but if valve is beyond repair then an approximate replacement cost of Rs.25,000 is

estimated.

The payback for this optimization measure would be 5 months.

NOTE:

The plant officials informed that the leaking blowdown valve is not a regular incident and the maintenance schedule identifies and arrests the leakage. So, after discussion with GSK it was decided to, NOT to consider the annualized savings as once a while indescripency cannot be extrapolated to continuous year round scenario.


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Remove condensate line from AHU hot water tank


The condensate from the drip legs on the main distribution line from boiler to Liquid, Ointment,

Tablet and Zantac is connected to the AHU hot water tank. The condensate flows by gravity into

the AHU hot water tank. The tank also has a steam connection to provide make up heating.

This arrangement is done so as to recover heat from the condensate and avoid use of steam in

AHU for dehumidification.

The hot water from the tank goes to the AHU unit dehumidification coils and returns back to the

tank. During the Audit, it was observed that the hot water, approximately 50 kg/h, was drained

from the AHU tank overflow.


The distribution losses from the insulated and un-insulated steam lines result in drop of steam

enthalpy which results in condensate formation. This phenomenon of condensate formation,

thus, is a continuous process and the steam traps on the distribution line ensure that the

condensate so formed is removed from the steam lines to avoid water hammer and corrosion in

the steam lines.

The hot water supplied to the AHU, enters the hot water coil and heats up the incoming air to

remove the humidity. The hot water in the coil after giving up its heat, returns back to the hot

water tank to gain heat and circulate back in the AHU coil. There is no loss or addition of water

in this circulation (except only for making up for any leaks, which ideally should not be present).

From the above argument it is understood that, the condensate addition into the hot water tank

is a continuous process whereas the AHU hot water return only requires heat addition and not

water.

The excess condensate flowing in to the tank then overflows from the tank.


Armstrong recommends disconnecting the condensate line from the AHU unit and connecting

it to a common condensate tank (please refer Optimization 5 for details).

Estimated Benefits:

The implementation of this optimization measure will save energy as well as water. The

estimated savings are as tabulated below:


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Remove Condensate from AHU hot water tank

Condensate Overflow 50 kg/h

Operational Hours 16 h

Condensate temp 85 Deg C

DM water temperature 30 Deg C

Energy saving 11000000 kcal/year

Equivalent fuel saving 1009 kg/year

Water Saving 200000 kg/year

Monetary Saving 38494 Rs/year

CO2 Saving 3 ton/year

The implementation of this measure will lead to an annual reduction in furnace oil consumption

by approximately 1000 kg/year. The total CO2 reduction will be approximately 3 ton/year.


To preheat investment is estimated as Rs 50000 which include:

Piping

Support

Fabrication

Erection

The payback of the implementation of this project is approximately 1.3 years.

NOTE:

It was informed by GSK that the condensate cannot be used either for mixing in product or for

sanitation as the Indian as well as the US laws and regulations for pharmaceutical industry

prohibit use of condensate or DM water directly for even cleaning activity. The DM water too

needs to be treated prior to be used for sanitation activity. Hence this ECM is NOT considered

for implementation but still kept in record so as to mark that the measure was identified during

the audit but was not implemented due to concern raised by GSK.


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1.5 OPTIMIZATION PROJECT # 5

Recover condensate from Liquid and Ointment plant


During audit it was noticed that the condensate from

various equipments and heat exchangers like, the DM

water heating tank, syrup manufacturing tanks was not

recovered and drained locally.

The reason for this as informed by plant personnel is that

the hot water from the Distillation unit condenser is

sufficient for boiler and so the condensate return to boiler

house is not possible.

In the plant DM water is utilized for various applications,

and for some of the applications like bottle washing the DM water is heated by steam / electric

heating coils.


Condensate is the liquid produced when

steam condenses on a heater surface.

The loss of hot condensate wastes

energy and money in several ways:

Heating up cold make-up water is

part of energy delivered from

combustion to the steam system.

Makeup feed water must be

chemically treated and heated from

30ºC to 95 ºC - 105ºC to replace

the lost condensate.

The condensate contains more

than 10% of the steam heat.

Condensate is essentially pure

water. Having to replace it with

“makeup” water containing impurities increases the amount of blowdown required.

Chemical treatment of the makeup feed water, the cost of the water itself and the sewage

cost can be avoided.


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Armstrong recommends recovering the condensate from Liquid and ointment plant along with

the distribution line condensate (refer Optimization 4). The condensate can be used along with

the DM water for bottle washer and sanitation.

The condensate can also be used as feed water to the syrup preparation or in the hot water

generation tank in the liquid manufacturing.

Estimated Benefits:

The implementation of this optimization measure would lead following benefits:

Liquid and Ointment plant Condensate Recovery

Condensate Recovery 5000 kg/day

DM water Temp 28 Deg C

Condensate Temp 85 Deg C

Energy Saving 285000 kcal/day

Equivalent fuel saving 6537 kg/year

Equivalent water saving 1250 m3/year

Annual Monetary Benefits 247924 Rs/year

Annual CO2 saving 21 ton/year

The implementation of this project would approximately save 4500 kg/year of boiler fuel and

carbon dioxide emission reduction of 15 ton/year.


The investment required for implementation of this optimization measure is approximately

Rs.6,50,000 which includes:

Condensate Pump

3 KL SS storage tank

Piping

Fabrication and Erection

The Payback for this project is approximately 2.6 years.

NOTE:

It was informed by GSK that the condensate cannot be used either for mixing in product or for

sanitation as the Indian as well as the US laws and regulations for pharmaceutical industry

prohibit use of condensate or DM water directly for even cleaning activity. The DM water too

needs to be treated prior to be used for sanitation activity. Hence this ECM is NOT considered

for implementation but still kept in record so as to mark that the measure was identified during

the audit but was not implemented due to concern raised by GSK.


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Install digital temperature sensor and alarm for sanitation application


During audit it was noticed that the low pressure steam

(1.2 barg) is utilized for sanitation of the vessels and equipments used in the manufacturing of

various pharmaceutical products. For this purpose, a SS cabinet with connection to attach

steam on top is utilized. The parts for sanitation are loaded in the cabinet and then steam is

plugged to the top port. Steam freely flows over the parts in the cabinet and is vented out from

the bottom opening.

The temperature requirement for sanitation process is 80oC, but the cabinet does not have a

temperature indicator; so after some time of steam flow, based upon judgment, the operator

introduces a thermometer in the cabinet and notes down the reading. If the temperature has

exceeded 80oC, the steam connection is removed.


The present operation practice is not perfect and has probability for steam waste. This is so

because the operator does not have a temperature display to recognize that the temperature

inside the cabinet has been achieved.


Armstrong recommends installing digital temperature indicator with alarm to alert the operator

that the set temperature is achieved and steam valve needs to be shut off

Estimated Benefits:

The exact saving from this optimization is difficult to quantify as the steam loss may vary from

time to time and operator’s judgment skills.

In addition to the steam and cost savings associated with energy savings, the major advantage

of implementation of this optimization measure is the better control on sanitation process.

Estimated Investment:

To preheat investment is estimated as Rs. 15000 which includes:

Temperature Sensor

Digital Temperature Indicator

Alarm Buzzer


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Prepared by

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© 2011 AIPL


Reduce nozzle size for steam cleaning application


During the Audit, it was observed that the steam hose used for cleaning the equipment parts

and the conveyor lines of the ointment and liquid section were fitted with an orifice of ¾”. The

steam is used for removing stains from the steel surface and there is no specific temperature

requirement.


A small orifice size on the cleaning hose results into lower steam flow. In application of cleaning

or stain removal the steam quantity is difficult to control. Also the process time for cleaning is

not as critical as the production cycle time, so a smaller orifice would lead to reduced steam

loss.


Armstrong recommends reducing the nozzle size from ¾” to ½”.

Estimated Benefit:

The estimated benefits by reducing the orifice are as below:

Reduce Orifice Size

Steam flow with 3/4" orifice 230 kg/h

Steam flow with 1/2" orifice 133 kg/h

Steam saving 97 kg/h

Actual Saving (70%) 68 kg/h

Operation 2 h/day

Annual Steam Saving 33950 kg/year

Annual Monetary Saving 68505 Rs/year


CO2 Saving 6 ton/year

The implementation of this optimization measure would lead to fuel saving of approximately

1800 kg/year and carbon dioxide emission reduction of 6 ton/year.


Project:90153


Date: 13/07/2011

Page 23 of 30


Prepared by

P. Ternikar

© 2011 AIPL


The implementation of this energy conservation measure would require an investment of

approximately Rs.5000 which includes:

½” SS orifice plates – 5 nos

The Payback for this project is less than one month.


Project:90153


Date: 13/07/2011

Page 24 of 30


Prepared by

P. Ternikar

© 2011 AIPL


Correct drip leg design


It was observed during the audit at many locations the drip legs were incorrectly designed which

resulted into clogging of trap. The manufacturing plant operates in two shifts and so there is

condensate formation during the night time when steam is not supplied to the plant.

Fig 1

No Drip Pocket

Fig 2

Incorrect trap bypass

(Safety Hazard)

Fig 3

Water filled Steam Main

header


The insufficient or clogged drip legs lead to condensate accumulation in the main steam

distribution line. This accumulated condensate leads to increasing the wetness of steam. Wet

steam contributes to a series of problems, some of them are indirect, the cause-to-consequence

link not always well understood.

Wet Steam is very erosive; it will generate erosion of the steam lines, and in the long

term leaks that will be a maintenance and safety concern.

Water in a steam system can also be a source of water hammer and pipe destruction.

Wet steam is very bad for control valves and pressure reducing stations, the continuous

abrasion of the valve and seat very quickly generate internal leaks wich have as

consequence energy losses


Project:90153


Date: 13/07/2011

Page 25 of 30


Prepared by

P. Ternikar

© 2011 AIPL

Finally wet steam has very poor heat transfer.

So, removing water in a steam system is critical

and the correct designing the drip leg is as

shown in the adjacent figure.

Also 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 through the

pipes.

It is also important to avoid water accumulation

upstream valves or in low points. Water

accumulation will lead to erosion of the valve seats

as well as may lead to e water hammer which

cause leaks.


Project:90153


Date: 13/07/2011

Page 26 of 30


Prepared by

P. Ternikar

© 2011 AIPL


Armstrong recommends correcting the drip leg design where ever practically possible in the

existing system. Also it is recommended that the drip legs future expansions or new projects be

designed upon the above guidelines.

Estimated Benefits

The main benefits from this optimization are

Reduced valve maintenance cost

Reduced steam pipe erosion and corrosion

Reduced down time

Increased Heat transfer efficiencies


Project:90153


Date: 13/07/2011

Page 27 of 30


Prepared by

P. Ternikar

© 2011 AIPL


Arrest all direct steam leaks


The plant does not have significant steam leaks, especially considering the fact that the plant

operates in two shifts and undergoes every morning start up activity. The condensate

accumulation and resulting water hammer pose a threat to the steam lines and many times

result in leaks from flanges and valves.

The leaks observed were recorded during the audit and are tabulated below:

Sr. No Location Estimated Loss (kg/h)

1 Safety valve of Boiler no 2 3

2 PRV bypass in the boiler room 5

3 Steam distribution line air vent valve (Tablet) 7

4 Steam distribution line air expansion loop (Tablet) 3

5 LPST line (Tablet) Valve gland leak 15

Total 33

The steam leaks in the plant were minimal and difficult to find. The plant maintenance team

needs to be congratulated for timely and periodic maintenance which has kept a check on the

leaks.


Armstrong recommends arresting all steam leaks as quickly as possible.

Estimated Benefits

The main benefits from this optimization are as tabulated below:

Arrest Direct steam leaks

Steam leak 33 kg/h

Operational hours 4000 h/year

Annual Fuel Loss 8208 kg/year

Annual Monetary saving 266354 Rs/year



Project:90153


Date: 13/07/2011

Page 28 of 30


Prepared by

P. Ternikar

© 2011 AIPL

The above savings are indicative are recorded in the report to drive to attention the cost

associated with seemingly small leaks and the importance to attending to each leak as soon as

observed.


The implementation of this optimisation measure is estimated to be Rs. 50000.

The payback is 0.2 years.


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Date: 13/07/2011

Page 29 of 30


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© 2011 AIPL

3.0 CHECK LIST VERIFICATIONS COMPLETED DURING THE AUDIT

Potential Optimization Status Comments

OVERALL STEAM SYSTEM

Costs Tracking To be improved Oil to each boiler is not metered

No fuel oil meter for boiler

Steam flow meter location to be changed to measure flow from boiler 4

No records for Make up water flow

Benchmarks To be improved Specific steam to fuel ratio to be recorded every day

Steam meter required to relocated as soon as possible

Excess Blowdown from boiler 4

All steam lines well insulated

Drip leg trap bypass to be opned close to ground

BOILER HOUSE

Steam Pressure setting OK Correct

Stack temperature Slightly high Periodic tube cleaning and flue gas monitoring required

Oxygen in flue gas High For boiler no 4

Combustion Air temperature Ambient No air preheating

Refractory Ok Good Insulation health

Boiler/ Burner tune up OK Periodic maintenance

Gauges OK Available at important locations

Boiler Sizing and reliability OK The boiler is correctly sized for the present steam requirement

Boiler Blowdown To be improved Blowdown valve of boiler 4 leaking

De-aerator Pressure OK Atmospheric de-aerator

Feed Water Temp OK Hot water from Distillation condnesor

Oxygen rate in feed water NA Not checked

Feed water pre-heating NA No preheating

Steam Quality NA Not checked

Steam Distribution

Leak of steam or condensate OK Few leaks but excellent maintenance program in place

Steam Quality OK NO corossion or erosion problems reported

Steam Pressue OK No pressure drop problem

Proper Piping OK Drip legs properly designed and condensate connected back to boiler

Insulation OK Excellent

Steam Consumption

Point of use pressure OK Low temp application have LP steam

Usage OK No abnormalities observed

HE condensate drainage, Vacuum breaker and air

ventTo be improved Condensate not recovered

Steam traps To be improved Steam traps missing at few locations and many traps on drip legs are plugged

CONDENSATE AND FLASH STEAM RECOVERY

Condensate discharged to drain To be improved Low condensate recovery

Sizing of condensate return lines NA

Water hammer OK No water hammer observed

Piping Practices - Users OK Generally good.

Piping Practices - Return Ok Generally good.

Flash steam recovery NA Low pressure steam application

Utilities Metering To be improved

Safety To be improved

To be improvedSteam System Measurements and Monitoring


Project:90153


Date: 13/07/2011

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Prepared by

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© 2011 AIPL

4.0 BOILER EFFICIENCY CALCULATION SHEET

Boiler operating hours (incl. hot stand-by hours) 8,760 hours/year 8,760 hours/year

1. Fuel power input %LHV %LHV

Fuel type: 52 Fuel oil heavy n°2 HTS%HHV 52 Fuel oil heavy n°2 HTS%HHV

Fuel consumption during operating hours 160.0 l/h 160.0 l/h

Boiler capacity 6.0 ton/h (=4MW) 6.0 ton/h (=4MW)

Specific weight of the fuel 1.02 kg/l 1.02 kg/l

Fuel consumption 163.2 kg/h 163.2 kg/h

Lower heating value (LHV) 39896 kJ/kg 39896 kJ/kg

Higher heating value (HHV) 42182 kJ/kg 42182 kJ/kg

Fuel unit costs 50 €/MWh HHV (= 0.6€/l) 50 €/MWh HHV (= 0.6€/l)

Fuel power input (LHV) 1808.6 kW 100% 1808.6 kW 100%

Fuel power input (HHV) 1912.2 kW 1912 kW

Steam pressure 7 Bar(g) / 170.4°C sat. 7 Bar(g) / 170.4°C sat.

Enthalpy steam 2768 kJ/kg 2768 kJ/kg

Temperature feed water to the boiler/eco 85.0 °C 85.0 °C

Enthalpy feed water 355 kJ/kg 355 kJ/kg

Heat added to feedwater 2413 kJ/kg 2413 kJ/kg

Max. theoretical steam production 2.70 ton/h (=2.3 ton/h actual) 2.70 ton/h (=2.5 ton/h actual)

2.1 - Combustion losses (dry)

Temperature stack after boiler 214 °C 212.7 °C

Temperature ambient air 34 °C 32 °C

Excess air 79.2 % 19.4 %

Oxygen % flue gas (Dry volume) 9.59 % 3.58 %

Specific Stack flow (dry) 18.07 Nm3/kg fuel 11.85 Nm3/kg fuel

Total stack flow (dry) 2949.0 Nm3/h 1934.3 Nm3/h

Total stack flow (wet) 3154.9 Nm3/h 2129.1 Nm3/h

Specific heat stack 1.38 kJ/Nm³.K -10.7% 1.41 kJ/Nm³.K -6.6%

Energy loss in dry stacks 204.69 kW -11.3% 125.80 kW -7.0%

2.3 - Losses due to H2 of Fuel

Moisture in Stack 0.882 kg/kg fuel 0.882 kg/kg fuel

Specific heat water in fuel 4.18 kJ/kg.K 4.18 kJ/kg.K

Specific heat water in stacks 1.8696 kJ/kg.K 1.8691 kJ/kg.K

Energy losses due to moisture in fuel 110.4 kW on HHV -5.8% 110.6 kW on HHV -5.8%

Energy losses due to moisture in fuel 10.3 kW on LHV -0.6% 10.5 kW on LHV -0.6%

5. Radiation losses

Boiler AverageLoad 7.27 % 7.27 %

Water Tube Radiation Losses (as per Abma) 10.00 % 10.00 %

Fire Tube Radiation Losses (Manufacturer Data) #N/A % #N/A %

Radiation losses considered in calc. 1.0 % -0.9% 1.2 % -1.1%

Radiation losses 18.1 kW -1.0% 21.7 kW -1.2%

6. Blow down

Conductivity boiler feed water 81.0 µs/cm 81.0 µs/cm

Conductivity boiler water 1470.0 µs/cm 3750.0 µs/cm

Boiler water lost by blow down + carry over 5.8 % of steam output (18.1cycles) 2.2 % of steam output (46.3cycles)

Boiler feed water flow 2.466 ton/h 2.509 ton/h

Boiler water lost by blow down + carry over 0.136 ton/h 0.054 ton/h

Ratio of blow down vs carry over 100% blowdown 100% blowdown

Carry over 0.000 ton/h 0.000 ton/h

X-value of the steam from the boiler 1.000 1.000

Blow down flow remaining 0.136 ton/h 0.054 ton/h

Enthalpy blow down water 721 kJ/kg 721 kJ/kg

Temperature make up water 25.0 °C 25.0 °C

Enthalpy make up water 104.5 kJ/kg 104.5 kJ/kg

Total Blow Down losses (Boiler + Deaerator) 23.3 kW -0.7% 9.3 kW -0.3%

Blow down losses compensated by boiler only 13.8 kW -0.8% 5.5 kW -0.3%

7. Boiler Efficiency and Fuel Costs

Net power output in steam from the boiler 1561.7 kW ( 13680 MWh) 1645.7 kW ( 14416 MWh)

Net dry steam production boiler (x=1) 2.330 ton/h = 20410 t/year 2.455 ton/h = 21508 t/year

Net wet steam production boiler 2.330 ton/h 2.455 ton/h

Boiler efficiency on LHV 86.35 % 90.99 %

Boiler efficiency on HHV 81.67 % 86.06 %

Annual Fuel costs 837,564 €/year 837,564 €/year

Fuel costs / ton dry steam 41.04 €/ton 38.94 €/ton

BOILER HOUSE SIMULATION BOILER 4 BOILER 2

Documents

Nashik, INDIA STEAM AND CONDENSATE AUDIT REPORT · 2012. 1. 8. · ©2011 AIPL GlaxoSmithKline Nashik, INDIA STEAM AND CONDENSATE AUDIT REPORT Project No: 90153 Prepared for: Mr