| Problem | Solution | Benefits |
| Getting Steam at the rated Capacity and Pressure | Steam Boilers / Thermic Fluid Heaters | Boilers and heaters of optimum capacity can help in efficient steam production. Correctly designed boilers can help save production and fuel costs greatly |
| Problem | Solution | Benefits |
| Operating Pressure Is Less Than the Required Plant Pressure | Operate The Boiler Nearer to Design Pressure Add Pressure Reducing Station | Reduction in process steam demand because of more heat content Increased fuel savings |
| Non-Uniform Blowdown | Auto Blowdown system | Adequate blowdown eliminates scale carry over and results in heat loss optimization Avoids excess chemical dosing and ensures optimum level of TDS of the water inside boiler |
| Lower Feed Water Temperature | Feed Water Management System | Directly reduces Fuel consumption |
| Lower Variation from 10% to 50% Leads to Frequent On/Off Operation | Efficiency Monitoring System | Fuel savings |
| Problem | Solution | Benefits |
| Higher Pressure Than Rated, Open Steam Is Used Without Pressure Reduction but By Throttling the Valve | Pressure Reducing Station | At lower pressure latent heat is higher so there is steam saving through PRS |
| Smaller Steam Line Size than Required | Correct Line Sizing as Per Required Steam Flow on Given Pressure | Smaller line size always creates pressure drop issues as per Barnauli’s Principle and to get the same flow velocity of steam increases resulting moisture carryover |
| No Provision of Automatic Air Venting | Automatic Air Vent for Steam Inlet Line to Equipment and Header | Automatic air vents eliminate barrier of heat transfer between steam to condensate |
| Problem | Solution | Benefits |
| Improper Trapping | Trap Module preferably SS Trap | Increased steam savings |
| Fear of Contamination | CCDS | Contamination issues are addressed |
| No Provision of Automatic Air Venting | Automatic Air Vent for Steam Inlet Line to Equipment and Header | Automatic air vents eliminate barrier of heat transfer between steam to condensate |
| Problem | Solution | Benefits |
| Uneven Temperature Profile | PID Based Temperature Control System | Increase in productivity and quality |
| Problem | Solution | Benefits |
| Temperature Overshoot / Undershoot | PID Based Temperature Control System | Increase in productivity and quality |
| Higher Pressure than Required | Pressure Control System | Increased steam savings |
| No Provision of Automatic Air Venting | Automatic Air Vent for Steam Inlet Line to Equipment and Header | Automatic air vents eliminate barrier of heat transfer between steam to condensate |
| Increased Batch Timing Due to Group Trapping | Steam Operated Pumping Trap | No need to open bypass |
| Problem | Solution | Benefits |
| Most Of the Plants Are Not Recovering Flash Steam and Condensate | Condensate Should Be Recovered by Online Steam Operated Condensate Recovery System | It helps in reduction of makeup water consumption, no need to recover evaporator water where chances of contamination are much higher All indirect injection will lead to Condensate Recovery Factor of 75% |
| Problem | Solution | Benefits |
| Many Plants Have a Problem with Valves Leaking Steam | Seatless And Glandless Valves | Piston Valves are class VI valves and by using them, we can create a plant having zero steam leak Ensures minimal pressure drops, safe working environment |
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