Utility Services Specialist Pvt. Ltd.

Services
(Design, Specialist
Basic & Detail Engineering Pvt.andLtd.
of Process & Utility Systems Turnkey Energy Saving Projects)

HIGH PERFORMANCE AND EFFICIENCY WITH RELIABILITY

FINAL REPORT ON FLASH STEAM RECOVERY
FROM FIBER DYERS 1,2,3 & 4

SUBMITTED DATE: 20/June/2012

SUBMITTED TO:

CUSTOMER: GRASIM INDUSTRIES LIMITED

(GRASIM CELLULOSIC DIVISION)

SUBMITTED BY:

UTILITY SERVICES SPECIALIST PVT. LTD.

Mr. Rajesh Bhavsar

Email: rbhavsar4@gmail.com

Cell No. +91 9909914765

CLIENT’S REFERENCE

PO NO. 4700067098 DATED: 20TH FEB 2012

1
 PAGE
S.N. DESCRIPTION
NO.
Brief of Project 3
1 Preamble 3
2 Design Basis 3
Instrumentation And Operation Of Flash
3 4-5
Vessel
4 Process Description & P & ID 6
5 Design of flash vessels 6-7
6 Technical parameters for instrumentation 8
7 Saving calculation 9
8 Layout / location of flash vessels 9
Annexure
1 Annexure I – Fiber dryer flash vessel P&ID
Annexure II – Instrumentation and accessories of flash
2
vessel
3 Annexure III – Fabrication drawing

2
 BRIEF DESCRIPTION OF PROJECT
Aditya Birla Group is an Indian multinational conglomerate corporation. The group is
prominent player and one of the largest producers of Viscose staple fibre. GIL is a leading
company among Viscose Staple Fibre producers. USSPL is thankful to GIL, Vilayat for
awarding the valuable order for comprehensive consultancy of Flash steam recovery from
Fibre dryers no 1,2,3 &4.

The project is very unique in nature across the fibre units of the Group. It involves
generating flash steam from the high pressure and temperature condensate by flashing it to
low pressure
1. PREAMBLE
Flash steam shall be generated from the following areas / equipment.
1) Fibre dryers nos. 1,2,3, & 4
There are total 2 no. flash vessels one each for fibre dryer 1&2 and 3&4. High pressure
condensate from respective fibre dryers shall be fed to these respective flash vessels. It will
be flashed to low pressure resulting into generation of low pressure flash steam and
condensate. Flash steam produced from the fibre dryers shall be pushed into existing LP
(Low Pressure) steam header.
Low pressure condensate generated in the flash vessel shall be used in Acid plant waste
heat recovery boilers. When we use steam condensate of high temperature of about 90 C,
in the acid plant boilers, it will increase steam generation by about 2 to 3% and reduce boiler
water blow down in comparison to using fresh soft water as boiler feed water.
2. DESIGN BASIS
Design basis flash steam recovery from fibre dryers is given below.

S.N. PARAMETER UNIT Dryer#1 Dryer#2 Dryer#3 Dryer#4

A Dryer data
Fibre drying capacity on dry
1 TPD 130 130.00 120 120
basis
2 Actual operating capacity TPD 130 130 120 120
B Steam inlet
Bar
1 Steam inlet pressure 12 to 14 12 to 14 12 to 14 12 to 14
(g)
2 Steam temperature in the inlet °C 202 202 202 202
Saturation temperature of inlet 191.8 to 191.8 to 191.8 to 191.8 to
3 °C
steam 198 198 198 198
4 Steam flow kg/hr 7313 7313 6750 6750

Design pressure and sizing of the flash vessel is done based on above steam inlet data.
Care has been taken in sizing of the volume of the flash vessel to take into account
malfunctioning of steam trap, live steam from the bypass of the trap, variations in the steam
consumptions in the dyers and peak load of HP steam condensate flow to flash vessel etc.
This will provide stability against fluctuations and shocks coming from HP condensate.

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3. INSTRUMENTATION AND OPERATION OF FLASH VESSEL

HP condensate from the fibre dryers, shall be fed to the flash vessel and flashed to low
pressure. As a result of flashing low pressure flash steam and low pressure condensate
shall be generated. Flash steam shall be taken out from the top and low pressure
condensate shall be removed from the bottom.

A capacitance type level controller shall be provided to maintain required level of

condensate in the bottom to provide sealing for the flash steam.

A pressure control valve shall be provided in the top to generate required pressure of the
flash steam.

A schematic diagram No. 1 is given below.

The above instrumentation shall be applicable to flash vessel of all the fibre dryers. A
separate header shall be made for flash steam and low pressure flash steam shall be
pushed into existing LP steam header.

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4. Process Description & P & ID

Steam is supplied to the air heating coils in the fibre dryers. Steam traps are provided in
each coil. Condensate discharge from each trap is connected with a common header.
HP condensate headers from the dryers shall be connected with the inlet header of flash
vessel.
When we supply high pressure condensate to flash vessel it will be flashed to low pressure,
as result of flashing low pressure flash steam is generated which is taken out from the top of
the flash vessel and low pressure condensate shall be taken out from the bottom. The
process shall be continuous in nature.

Based on the discussion on the draft report, it was finally decided to generate flash steam of
low pressure and fed to existing LP steam header. In this case process control is given
below.

a) Pressure of the flash steam from the flash vessel outlet is P1

b) Pressure in the existing LP steam header is say P2
c) Pressure required to transfer the condensate to acid plant waste heat recovery boilers is
say P3
d) For pushing the flash steam into the existing LP steam header will require P1>P2
e) For transferring the condensate to acid plant waste heat recovery boilers shall be P1>P3
f) So, the pressure P1 shall be set higher than P2 and P3

There will be one flash vessel for fibre dryer no. 1&2 and one for 3&4. P&ID for the same is
given in Annexure I.

5. Design of flash vessels

Care has been taken in sizing to provide stability. Adequate volume is provided for both
flash steam and condensate in the flash vessel so that fluctuations and shocks from the
incoming HP condensate shall be absorbed. A sample of the flash vessel drawing indicating
accessories and nozzles for instrumentation etc is given as Annexure II. Fabrication
drawing is given in Annexure – III.
5.1 Accessories and nozzles (List of major items)
1) Safety valve
2) Pressure gauge
3) Pressure sensor transmitter
4) Level controller nozzle from the top of flash vessel for capacitance type level sensor
transmitter
5) Side steam trap module as standby to level control system
6) View glass two nos. one in the front and one opposite to that for providing light in the
flash vessel (Optional to multiview glass)
7) Man hole
8) HP condensate in
9) LP condensate out
10) LP flash steam out
11) Lifting lugs
12) Bracket / skirt type supports
13) Name plate
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5.2 Specifications

S.N. PARAMETER UNIT Value

A Inlet

1 HP Condensate inlet flow kg/hr 15000

2 Condensate inlet pressure Bar (g) 12

3 Condensate inlet temperature °C 184.2

B Outlet

1 Flash steam pressure Bar (g) 1 to 3

2 Flash steam temperature C 120 to 140

C Pressure rating

1 Max. allowable working pressure Bar (g) 3.00

2 Design pressure Bar (g) 5

3 Test pressure Bar (g) 7.5

4 Safety release pressure Bar (g) 4

D Temperature rating °C 200

E Flash vessel volume m3 ≥2.8

ASME
F Design code SECTION VIII
Div. 1

5.3 MOC

1) MOC shall be CS (SA516 Gr.70)

2) All the nozzles shall be ANSI B 16.5 class # 300

5.4 THICKESS

1) Shell thickness – 12 mm
2) Dish end thickness – 14 mm
3) HP condensate inlet inside extended bend – 14 mm

5.5 PIPE LINE / NOZZLED SIZES

1) HP condensate inlet nozzle (Line) 6”

2) LP condensate outlet nozzle (line) 3”
3) LP condensate common transfer line to Acid / CS2 boiler 4”
4) Flash steam outlet nozzle (line) 6”
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 6. Technical Parameters for instrumentation

Fibre dryer 1 &2 Fibre dryer 3 & 4

S.N. PARTICULARS Unit
Flash vessel Flash vessel
Pressure control valve for flash
A
steam
1 Fluid - Saturated steam Saturated steam
2 Pressure control valve Bar (g) 1 to 3 1 to 3
3 Flow kg/hr 0 to 1600 0 to 1600
4 Temperature C 110 to 150 110 to 150
5 Pipe line size Inches 4 4
B Level control valve for condensate
Hot water (steam Hot water (steam
1 Fluid -
condensate) condensate)
2 Level control valve Bar (g) 1 to 3 1 to 3
3 Flow kg/hr 0 to 15000 0 to 15000
4 Temperature C 110 to 150 110 to 150
5 Pipe line size Inches 3 3
C Steam flow meter
1 Fluid - Saturated steam Saturated steam
2 Pressure control valve Bar (g) 1 to 3 1 to 3
3 Flow kg/hr 0 to 1600 0 to 1600
4 Temperature C 110 to 150 110 to 150
5 Pipe line size Inches 4 4
D Safety valve
1 Fluid - Saturated steam Saturated steam
2 Maximum pressure Bar (g) 14 14
3 Safety release set pressure Bar (g) 4 4
4 Blow out flow kg/hr 200 to 300 200 to 300
5 Temperature C 110 to 150 110 to 150
E NRV FOR FLASH STEAM
1 Fluid - Saturated steam Saturated steam
2 Pressure control valve Bar (g) 1 to 3 1 to 3
3 Flow kg/hr 500 to 1600 500 to 1600
4 Temperature C 110 to 150 110 to 150
5 Pipe line size Inches 4 4
F Pressure and temperature gauge
1 Fluid - Saturated steam Saturated steam
2 Pressure range Bar (g) 0-12 0-12
3 Temperature C 0 to 200 0 to 200

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7. Saving Calculation: Given below

Fibre dryer Fibre dryer

S.N. PARAMETER UNIT
#1&2 #3&4

1 Flash steam generations (>2.5 kg/cm2 (g) kg/hr 817 754

2 Operating hours per day hrs/day 24 24

3 No. of operating days per year days/year 340 340

4 Additional Steam generated per year T/Year 6664 6151

5 Steam price Rs/Ton 800 801

6 Financial saving per year Rs. lac/Yr 53 49

8. Lay out / Location of flash vessel

8.1 FLASH VESSEL FOR FIBER DRYER 1&2
A common Flash vessel for fibre dryer 1&2 to be located near dryers such a way that high
pressure condensate line from fibre dryer steam traps outlet to inlet of flash vessel is
minimised. Preferably condensate inlet to be at lower level than the condensate out from
steam trap because there would be two phase flow in the condensate line so it is better to
have some gradient for liquid to flow from high level to low level.
8.2 FLASH VESSEL FOR FIBER DRYER 3&4
A common Flash vessel for fibre dryer 1&2 to be located near dryers in such a way that high
pressure condensate line from fibre dryer steam traps outlet to inlet of flash vessel is
minimised. Preferably condensate inlet to be at lower level than the condensate out from
steam trap because there would be two phase flow in the condensate line so it is better to
have some gradient for liquid to flow from high level to low level.

Looking forward to serving your esteemed organization and long term business association

Thanking you

With warm regards,

RAJESH BHAVSAR
UTILITY SERVICES SPECIALIST PVT. LTD.
CELL: +91 9909914765
MAIL ID: rajesh.utility@gmail.com