| 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 Pressure Reducing Station | Reduction in process steam demand because of more heat content
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| Variation In Steam Loads Due to Multiple Processes | Efficiency Monitoring System | Adequate combustion through I/D and FD control systems |
| 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 |
| Water Carryover | Moisture Separator | Ensures removal of moisture carry over to the process, resulting in dry steam to the process, which helps in improving productivity, quality and 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 |
| Uneven Temperature Profile | PID based Temperature Control System | Increased production as a result of reduced batch timing |
| Due to Improper Condensate Evaporation, Batch Time Increases | Proper Trapping System | Reduction in batch timing |
| 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 |
| Due to Manual Throttling of The Steam Valve, De-Waxing is not Carried Out at Required Temperature, Leading to Crystallization of Saturated Triglycerides & Amalgamation of Waxes & Saturated Triglycerides | PID based Temperature Control System | Increased steam savings |
| Problem | Solution | Benefits |
| Uneven Temperature Profile as the Temperature is not Controlled | PID based Temperature Control System | Increase in productivity and quality |
| Problem | Solution | Benefits |
| Direct Injection of Live Steam is at a Higher Pressure | Pressure Reducing Station | Proper de-aeration, proper heating, deodorization cum de-acidification and easily cooling of the oil |
| Problem | Solution | Benefits |
| Higher Pressure at Process | Pressure Reducing Station | Steam savings |
| Oil is Cooled with Water and Waste Heat Recovery is not Done | Separate Tank is Required for Heat Recovery and to Store the Heated Oil | Significant increase in energy savings |
| Undersized Traps Installed to the Process and Bypass Kept Open | Correctly Sized Float Trap Module | Steam saving and reduction in batch timing |
| Problem | Solution | Benefits |
| Oil Temperature Required at the Outlet of Pre-Hot Press Filter is About 90 Deg C, Which is Cooled Down to 20-21 Deg C Using Chilled Water and then Heated Up to 100 Deg C | PID Based Temperature Control System | Steam savings |
| Oil is Cooled Down to 20-21 Deg C from 90 Dec C Resulting in Huge Steam Losses | Cool the Oil From 90 Deg C To 45 Deg C by Heating the Chilled Water from 4 Deg C to 20-21 Deg C and then Rise the Oil Temperature to 85 Deg C | Steam saving |
| Undersized Trapping Resulting in Bypass Opening and Steam Loss | Float Trap Module | Steam saving |
| Heat Present in Oil After Hot Press Filter is Generally not Recovered | Properly Sized Heat Exchanger | Steam saving |
| Problem | Solution | Benefits |
| Steam is Directly Injected Without Any Reduction in Pressure | Pressure Reducing Station to Reduce it to the Pressure for Which Nozzles are Designed | Steam savings |
| Problem | Solution | Benefits |
| Higher Actual Pressure at Process than Recommended | Pressure Reducing Station | Steam savings |
| Thermodynamic Traps are Installed and the Bypass is Kept Open | Ball & Float Type Trap | Steam savings |
| Radiation Losses as the Bottom of the Tray is Uninsulated | Insulation to be Done at the Bottom and the Side of the Tray | Steam savings |
| Problem | Solution | Benefits |
| 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 |
| Thermodynamic Traps are Installed and the Bypass is Kept Open | Float Traps | Faster heating of tankers |
| Problem | Solution | Benefits |
| While Actual Temperature is 110-112 Deg C, The Required Temperature is 85 Deg C | PID Based Temperature Control System | Steam savings |
| Undersized Traps Installed Leading to Steam Loss by Trap Leaking or Bypass Opening | Install Ball & Float Type Trap to Avoid Bypass Opening | Steam savings |
| Problem | Solution | Benefits |
| Start Up Module not Installed | Start Up Module | Ensures removal of air at the time of start-up |
| No Temperature Control | On/Off Type Temperature Control System | Steam savings |
| Thermodynamic Traps are Installed and the Bypass Is Kept Open | Ball & Float Type Trap | Steam savings |
| Problem | Solution | Benefits |
| Many 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 45% |
| 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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