| 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 |
| With Sudden Peak Demand Requirements, Boiler Pressure Drops, Resulting in Water Carryover, Steam Quality Degradation and Increased Process Time | 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 Feedwater Temperature | Feedwater 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 saving as well |
| Problem | Solution | Benefits |
| Huge Steam Consumption Due to Improper Trapping | Ball & Float Trap | Bypass is kept closed, resulting in huge steam savings |
| 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 |
| Manual Temperature Control Can Cause Undershooting G Or Overshooting Problems | Automatic Temperature Control Systems | Quality improvement |
| Problem | Solution | Benefits |
| Bypass Opening as A Result of Thermodynamic Trap or Undersized Traps. | Ball & Float Trap Module | Increased steam savings |
| Uneven Temperature Profile as A Result of Manual Control | PID Type Temperature Control | Ensures that the temperature limit is maintained in the process Reduced steam consumption and batch times |
| Problem | Solution | Benefits |
| Condensate Evacuation Problem Due to Group Trapping | Correctly Sized Traps | Increased productivity and steam saving |
| Condensate Evacuation Problem Due to Group Trapping | Replace Group Trapping to Individual Trapping for Each Coil of Radiator | Steam and condensate saving Heat exchanger (radiator coil life) enhancement |
| 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 90% |
| Problem | Solution | Benefits |
| Many Plants have a Huge 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 Also ensures minimal pressure drops, safe working environment |
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