Auditing Services in Sector 31, Chandigarh

Boiler House Efficiency Improvement : Establish the present steam generation from the boiler and the steam loading pattern of the plant i.e. peak, average and minimum loads based on the metering and system at plant Evaluate the efficacy of the present operating practices and recommend any changes to ensure optimum boiler efficiency. Study the present blow down philosophy and suggest methods to optimize blow down and heat recovery from blow down. Study the present feed water management philosophy and same will be evaluated to ensure optimum feed water temperature to the boiler. Evaluate use for LP flash steam in the plant or take it back to feed water tank of boiler  Evaluate the efficacy / feasibility of using heat from available waste heat streams in the process towards heating the feed water   Quantify the potential for steam reduction in the plant : Evaluate the steam distribution network in the plant: Line sizing and routing Distribution with respect to pressure drop if any Type, quality & health of insulation. Condensate removal from steam mains. Establish % distribution loss on account of leakages and radiation and suggest methods to reduce the same Evaluate the desired vs actual parameters for steam as required by the process equipment Evaluate the plant historic data and observe the current operations for anomalies such as batch time / throughput variations and evaluate the impact of the current steam and condensate network on such variations  Evaluate the current steam supply parameters vis-à-vis the process recipe requirements including gradients etc. and evaluate gaps within the same Evaluate the plant for any throughput bottlenecks due to the steam system Evaluation of hot water generation and utilization in the process.   Key Takeaway Points : Avoiding clinker formation inside the boiler Increase the inlet air temperature to increase boiler efficiency Avoid High Negative Draft in Solid Fuel Fired Boilers Generate Steam at Higher Pressure Dissolved oxygen should be removed from the feedwater tank Injection of flash steam and condensate into the feedwater tank should be via a deaerator head Air to fuel ratio should be monitored and controlled to minimize unburnts Efforts should be made to minimize addition of surface moisture content in fuel. To deliver the same amount of energy, the flowrate of hot water will have to be 45 times than that of steam. Monitor flue gas temperatures to control stack loss. Using steam instead of thermic fluids for indirect heating is more efficient. Monitoring flue gas temperature gives a good indication of the boiler operating conditions Operating boiler closer to full load improves efficiency Higher feedwater temperature increases the boiler output Use saturated steam for indirect heat transfer applications. Every 6 DEG. C rise in feedwater temperature reduces the fuel bill by 1%.