Forbes  Marshall  

Energy  Services  Consultancy  

for  M/s  Global  Engineering  
Consultant,  Dubai  
To,  Mr.  Afsal  Hazeena,  MEP  Designing.  

 
  
 

Contents  
1.   Forbes  Marshall  in  the  F&B  Industry  .............................................................................................  2  
2.   Premise  &  Objective  of  the  service  ...............................................................................................  3  
3.   FMPL  Deliverables  for  Customer  through  Design  .........................................................................  3  
4.   Scope&  Battery  Limits  ...................................................................................................................  4  
4.1   Steam  ....................................................................................................................................  4  
4.2   Condensate  &  Flash  Steam  ...................................................................................................  5  
5.   Terms&  Conditions  ........................................................................................................................  7  
 

   
  
1. Forbes  Marshall  in  the  F&B  Industry  
 
Forbes  Marshall  has  been  extensively  working  with  the  global  Food  &  Beverage  industry  covering  
individual  plants  and  MNC/Multi-­‐plant  groups.Our  work  with  the  industry  encompasses  detailed  
energy  audits  across  existing  plants  as  well  as  utility  design  consultancies  for  Greenfield  projects  and  
expansions  including  dairies  

Key  highlights      

• Over  400+  audits  and  design  consultancies  across  the  Food  &  Beverage  sector  globally    
• Data  base  of  equipment  and  process  wise  findings  across  F&B  processes  covering  Dairy,  Frozen  
Desserts,Confectionary,Starch  &  Derivatives,  Brewing,  Carbonated  Beverages,  Juice,  Fruit  &  
Vegetable  Processing,  Fish  &  Meat  Processing,  Edible  Oil,  Potato  Chips,  Noodles,  Sugar,  
Alcohols,  Savouries,  Tea,  Coffee,  etc  
• Understanding  of  utility  specific  requirements  for  processes  including  Concentration,  
Pasteurization,  Drying,  CIP,  etc  
• Pioneered  thermal  energy  benchmarking  by  studying  plants  and  defined  best  energy  
consumption  benchmarks.    
• Delivering  an  average  Opex  reduction  of  20%  across  plants  within  the  sector  
• A  few  of  our  Energy  Services  Clients  –    
 
• Amul   • Mahananda  Dairy  
• A  B  Inbev   • Mars  International  
• Asian  Thai   • McCain  Foods  
• AdaniWilmar  (Multiple  plants)   • Mother  Dairy    
• Bikanerwala   • Metro  Dairy  
• Bunge  India   • Nestle  
• Cargill   • Naturals  Ice  Cream  
• Coca  Cola  (Multiple  Plants)   • Pepsico  (Multiple  plants)  
• Carlsberg   • Perfetti  
• Dabur   • SAB  Miller  
• Dinshaws   • Schreiber  Dynamix  Dairies  
• Gandour  Foods   • SKM  Egg  Products  
• Gopaljee  Dairy   • Unilever  (Multiple  Plants)  
• Haldirams   • United  Breweries  (Multiple  plants)  
• ITC  Foods  (Multiple  plants)   • Venkys  
• Kelloggs   • Wrigley  and  many  more  
• Mala’s    
 
FM  Energy  Services  Division  –  Key  Highlights  
 
• 4,500+  audits  and  design  consultancies  globally  
• 40+  Industry  Specific  Specialists    
• Best  Specific  Energy  Consumption  Plants  across  process  industry  segments  
• Unique  dual  expertise  of  utility  design  and  system  improvement  across  existing  plants  
o An  understanding  of  operational  issues  in  running  plants  which  are  addressed  in  our  design  
o Understand  utility  requirements  of  the  process  and  design  plant  utilities  that  not  only  
meet  process  requirement  but  also  enable  lowest  Specific  Energy  Consumption  
 
   
  
2. Premise  &  Objective  of  the  service  
 
Plant  will  be  processing  Shrimp  production  line  of  Al  Marai  Sea  Food  Processing  Plant    
 
Objective  of  the  Services  is  to  do  the  detail  engineering  for  following  utilities  for  the  process  
equipment  consuming  227  kg/hr  steam  at  6.9  barg.  
 
-­‐ Steam  
-­‐ Condensate    
-­‐ Flash  steam  
 
 
 
 
 
 
 

3. FMPL  Deliverables  for  Customer  through  Design  

 

FMPL  Engineering  Deliverables  

• Design  concept  note  with  having  validafon  of  uflity  

Basic  Engineering   generator  sizing  

•Design  Concept  Note  

•P&IDs  
Detail  Engineering   •Layout  
for  Uflifes  
•BOQs  for  Accessories  &  Piping  
•Insulafon  specificafons  wherever  required  
   
  
4. Scope&  Battery  Limits  
 
4.1 Steam  
 
4.1.1 Basic  Engineering  
 
4.1.1.1 Validate  the  steam  requirement  based  on  PFD,  equipment  details  and  process  
recipes  including  temperatures,  pressures,  flow  rates,  gradients,  etc.  
 
4.1.1.2 Define  the  steam  load  required  to  cater  to  the  plant  based  on  the  following    
 
4.1.1.2.1 Steam  loading  pattern    
4.1.1.2.2 Process  parameters  and  cycle  details  including  temperature  gradients  
4.1.1.2.3 Diversities  and  product  mix  
4.1.1.2.4 Cost  of  steam    

4.1.2 Deliverables    

4.1.2.1 Design  concept  note  specifying  the  boiler  steam  requirement.    

 
4.1.3 Detailed  Engineering  –  Steam  Distribution  System  
 
Validating   the   steam   distribution   network   to   ensure   energy   efficiency,   safety,   ease   of  
operations   and   maintenance   (Battery   limits:   Steam   line   from   the   saturated   steam   header   to  
the  inlet  of  the  new  steam  consuming  section  outside  battery  limit)    
 
4.1.3.1 Designing   the   sizing   and   pressure   drop   calculations   for   the   saturated   steam   piping  
based  on  steam  consumption  details  as  provided  by  the  plant.    
 
4.1.3.2 Designing  the  plant  header  capacity,  facility  and  distribution  system  
 
4.1.3.3 Defining  the  line  routing  
 
4.1.3.4 Designing  the  steam  distribution  network  design  with  focus  on  
 
4.1.3.4.1 Necessary   automation   wherever   possible   to   optimize   consumption   and  
eliminate  manual  intervention.  
 
4.1.3.4.2 Diagnostic   equipment   incorporated   at   strategic   locations   to   enable  
measurement  of  consumption  and  analysis.  
 
4.1.3.4.3 Correct   accessories   to   ensure   steam   quality,   pressure,   temperatures   are  
achieved  as  required  by  the  process  at  each  equipment.  
 
4.1.3.4.4 Correct   expansion   loops   with   proper   condensate   evacuation   from   steam  
lines   to   prevent   bi-­‐phase   flow   thereby   preventing   recurrent   leaks   in   the  
distribution  network.  
 
4.1.3.4.5 Ergonomic  design  to  ensure  easy  access  to  all  the  steam  system  accessories  
for  ease  of  operations  and  maintenance  i.e.  location  of  steam  accessories  at  
working  heights,  provision  of  space  for  man  and  material  movement,  etc.  
 
  
4.1.3.4.6 Safe   location   of   discharges   for   all   vent   lines   like   safety   valves,   pump  
overflow  lines,  main  line  steam  traps,  etc.  
 
4.1.3.4.7 Provision   of   relevant   isolation   and   bypasses   in   the   system   to   enable   safe  
maintenance  
 
4.1.3.5 Evaluate   the   OEM   scope   of   supply   and   suggest   changes   required  to  the  same  with  the  
objective  of  reducing  specific  steam  consumption.    
 
4.1.3.6 Deliverables  for  the  battery  limits  mentioned  above  
 
4.1.3.6.1 Design  Concept  Note  
4.1.3.6.2 P  &  I  Diagrams  
4.1.3.6.3 Piping  layout  drawings    
4.1.3.6.4 Accessories  BOQ  
4.1.3.6.5 BOQ  for  piping    
4.1.3.6.6 Insulation  specifications  
 
4.2 Condensate  &  Flash  Steam  
 
4.2.1 Design   of   the   Condensate   &   Flash   Steam   Recovery   System   to   recover   condensate   from  
the  proposed  new  process  equipment  
 
Battery  limits:    
 
-­‐ From   the   condensate   recovery   system     outside   battery   limit   of   section   to   boiler   feed  
water  tank;    
 
-­‐ Condensate  line  from  the  flash  separation  vessels  to  the  condensate  pumps  and  from  the  
condensate  pumps  to  the  boiler  house  feed  water  tank;    
 
-­‐ Flash  steam  lines  from  the  flash  separation  vessels  to  the  LP  header  /  Boiler  feed  water  
tank  based  on  feasibility.    
 
4.2.1.1 Validating  the  total  condensate  and  flash  steam  quantity  based  on  the  steam  loads.  
 
4.2.1.2 Ensuring   complete   condensate   evacuation   from   the   process   equipment   through  
correct   application   based   steam   trap   selection   and   sizing.   Selection   will   need   to   be  
done  keeping  in  mind  the  variation  in  start  up  and  running  loads.  
 
4.2.1.3 Designing  the  most  optimum  routing  of  the  condensate  lines  and  establishing  correct  
line  sizing.  
 
4.2.1.4 Incorporate   appropriate   diagnostics   at   strategic   locations   to   enable   the   plant   to  
monitor  the  condensate  recovery  factor.  
 
4.2.1.5 Ensuring  condensate  from  different  pressures  is  segregated  to  prevent  back  pressure  
on  the  steam  traps.  
 
4.2.1.6 Designing  a  system  to  maximize  recovery  of  condensate  and  flash  steam.  
 
  
4.2.1.7 Deliverables  as  per  battery  limits  mentioned  above  
 
4.2.1.7.1 Design  Concept  Note  
4.2.1.7.2 P&I  Drawing  
4.2.1.7.3 Piping  Layout  drawings  
4.2.1.7.4 Accessories  BOQ  
4.2.1.7.5 Piping  BOQ  
4.2.1.7.6 Insulation  specifications  
 
 
   
  
5. Terms&  Conditions  
 
Commercial  Terms  
 
Our  lump  sum  charges  for  carrying  out  work  as  indicated  above  shall  be  $3000  +  Taxes  as  applicable  
during  billing  for  Basic  +  Detail  Engineering.  

-­‐ 50%  Advance    

-­‐ 40%  against  Concept  Note  &  PID  
-­‐ 10%  against  submission  of  Piping  Layout  
 
ORDER  PLACEMENT  ADDRESS:-­‐  
Forbes  Marshall  Pvt.  Ltd.s  
Plot  no,  B-­‐85,  Phase  II,  
Chakan  Industrial  Area,  
Village  –  Savardari  –  Chakan,  
Taluka  –  Khed,  Dist.  Pune  410  501  
 
Other  Terms  &  Conditions:  
 
• Customer  will  provide  FMPL  all  the  relevant  data  in  respect  of  utility  consumption  of  your  
process  equipment  in  new  plant.    
• FMPL   will   provide   a   set   of   finally   approved   drawings/material   take   offs   with   a   set   of   soft  
copies  for  Customer’s  records  
• Approval  of  drawings/any  part  of  work  by  statutory  regulatory  body  where  applicable  shall  
be  Customer’s  responsibility  
• Customer  will  provide  drafting  assistance  on  AutoCAD  at  site  if  required  to  FMPL  staff.  
• In   our   quoted   prices,   we   have   not   included   any   site   visits   as   may   be   required   by   our  
engineers  &  staff.  
• Final   accessories   BOQ   shall   be   prepared   based   on   the   approved   drawing.   Number   of   free  
revisions-­‐  PID  stage  –  1  nos    
• Any   additional   revisions   sought   by   Customer   if   any   in   the   approved   drawings   shall   be   at   extra   cost  
applicable  at  $1,000  per  drawing  revision  
• Customer  will  nominate  a  management  representative  as  a  single  point  of  contact  who  will  
liaise  on  its  behalf  with  FMPL  engineer  as  required  and  take  necessary  decisions  wherever  
required  on  Customer’s  behalf.    
• Customer  to  keep  FMPL  team  updated  for  any  change  which  impacts  the  project.  
• Tentative  timelines  for  design  –  4-­‐6  weeks  from  date  of  receipt  of  PO  with  advance.  
• Exclusions  
o Work  pertaining  to  Electricals  
o Work  pertaining  to  Civil/Structure  for  the  above  scope  
o Electrical  Cable  Trays  and  Instrument  cable  trays    
o Structural  supports  for  pipe  lines  
o Work  pertaining  to  stress  analysis  
o Work  pertaining  to  Instrumentation  (DCS  systems  etc.)  
o Water  for  administration  block/plumbing  
o Approval  of  drawings/any  part  of  work  by  statutory  regulatory  body  
 
   
  
The  offer  is  valid  for  a  period  of  30  days  from  the  date  mentioned  above.  
 
We  assure  you  of  our  best  services  and  look  forward  to  your  valued  work  order.  
 
Yours  faithfully,  
For  Forbes  Marshall  Pvt.  Limited.,  
 
Thanks  &  Regards,  
 
Madhusoodhanan   Sandip  Gangane  
Sales  Manager   Energy  Services  Division  
E-­‐mail:  mmarambath@forbesmarshall.com   M:  +91-­‐9766492270    
Mobile  (971)  551144345   E:  sgangane@forbesmarshall.com  
Forbes  Marshall  Husni  –  Middle  East   Forbes  Marshall  Pvt  Ltd  |  Energy  Services  
Executive  Suite    X2-­‐12,  P.O.  Box  513103,  SAIF  Zone   PB  No:  29,  Mumbai  –  Pune  Road  
Sharjah,  United  Arab  Emirates   Kasarwadi,  Pune  –  411034  
   
 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
  
Annexure    
 Case  Studies  –  F&B  Customers  

Example  1:    We  worked  with  an  MNC  Confectionary  Giant’s  India  Operations  to  achieve  their  overall  
sustainability  target  of  5%  reduction  in  Energy,  Water  and  Waste.  We  provided  our  end  to  end  services  
solution  from  carrying  out  an  audit,  providing  detail  engineering  support,  defining  implementation  
priorities,  supervising  implementation  and  documenting  the  savings.  By  optimizing  the  steam  and  
condensate  system  we  were  able  to      
• Reduce  Overall  Energy  Reduction  by  20%  
• Reduce  CO2  by  120755kgs/annum  
• Reduce  water  consumption  by  23,000  KL/annum  
• Improve  Condensate  Recovery  from  32%  to  70%  
• Reduce  plant  steam  consumption  in  the  process  by  12%.  
Example  2:  A  renowned  pouch  milk  and  milk  products  plant  located  in  India  was  adding  an  additional  
UHT   milk   processing   section   in   its   existing   facility.   The   plant   wanted   help   to   identify   the   capacity   of   the  
new  boiler  they  would  require  to  cater  to  the  increase  in  the  steam  load  after  adding  the  UHT  section.  
The  plant  was  also  looking  for  ways  to  reduce  its  milk  processing  cost.  Our  value  addition:  
• Capex  Reduction  of  INR1.5Cr  +  Civil  &  Structure  cost  
• We   designed   the   entire   distribution   network   in   such   a   manner   that   revamp   could   be   carried   out   without  
stopping  production  in  the  running  plant  itself  
• The  steam  lines  were  optimized  to  ensure  minimum  pressure  drop  and  delivery  of  steam  to  each  process  
equipment  at  the  right  parameters.    
• By   optimizing   the   steam   hook-­‐ups   and   providing   a   steam   based   instantaneous   hot   water   system   we  
addressed  the  plant’s  problems  of  fluctuations  in  the  milk  pasteurization  temperatures.  This  eliminated  the  
need  for  milk  reprocessing  reducing  energy  consumption  as  well  as  improving  productivity.      
• We  improved  the  heat  recoveries  in  the  plant  including  the  condensate  recovery  factor  from  30%  to  95%.    
Plant  is  able  to  run  all  their  processes  including  the  UHT  with  a  2.8TPH  boiler  instead  of  earlier  4TPH  boiler  and  
has  saved  20%  in  Opex.  
Example  3:  A  Global  Food  Processing  &  Dairy  Giant  was  setting  up  a  6Lakh  litre  milk  powder  plant  
requiring  utilities  for  heating  cooling  &  chilling  as  well  as  targeting  Carbon  Neutrality.  FMPL  designed  
the  utilities  for  the  project.  Our  design  consultancy  delivered  the  following  benefits:  
• 16%  Opex  reduction  in  Steam  
• Fuel  switchover  to  achieve  Carbon  Neutrality    
• Ensured  Rack  Safety  -­‐  Calculated  and  corrected  loads  considered  for  pipe-­‐rack  design  as  the  loads  
considered  by  the  plant  were  low  and  pipe  rack  design  considered  was  unsafe  
• Designed  Zero  Leak  Plant  
• Designed  chilled  water  distribution  network  for  0.4deg  C  increase  over  250  meters  distribution  
• Right  Selection  based  on  load  with  specifications  on  modifications  in  commercially  available  pumps  to  cater  
to  head  and  flow  
Designed  the  distribution  network  to  connect  the  biomass  boiler  located  at  a  distance  of  1.2km  with  
min  pressure  drop  (including  a  25  meter  underground  section  under  a  national  highway)  
Example  4:  A  Plant  of  a  large  Indian  Alcoholic  Beverage  Grouphad  a  higher  specific  energy  consumption  
of  130  MJ/HL  against  industry  benchmark  of  95  MJ/HL.  We  carried  out  an  energy  audit  to  validate  the  
benchmark  and  identify  the  reasons  for  the  gap  against  the  industry  benchmark.  Benefits  delivered:  
• Improved  Steam  to  fuel  ratio  from  4.07  to  4.20  by  correcting  combustion  parameters  and  operating  
practices  
• Reduced  steam  consumption  by  17  TPD  by  ensuing  steam  at  correct  parameters  at  user  end  
• Reduced  evaporation  ratio  in  Wort  Kettle                                                                                                                                                                          
• Addressed  condensate  evacuation  issue  in  Bottle  washer,  VAM  and  Pasteurizer    
• Reduction  in  specific  thermal  energy  consumption  from  130  MJ/HL  to  112ML/HL*  
  
Example  5:  A  Globally  renowned  Potato  based  Food  Processing  major  was  setting  up  a  greenfield  plant  
in  India.  FMPL  was  appointed  to  design  the  utilities.  As  part  of  the  design  consultancy  we  carried  out  
the  basic  and  detail  engineering  i.e.  Defining  the  Utility  Generator  Capacities  and  Designing  the  
Distribution  &  Recovery  networks.  FMPL  covered  the  following  utilities  –  Steam,  Condensate,  Natural  
Gas,  Water  (Raw,  Treated,  Hot  and  Cooling).  Key  benefits  delivered.  Key  benefits  delivered:  
• Lowest  Thermal  Energy  Consumption  benchmark  plant  among  all  their  global  plants    
• Process  parameters  are  met  and  productivity  ensured  
• 95%+  recovery  of  condensate  and  flash  and  optimum  boiler  efficiency  
• A  safe,  easy  to  operate  and  maintain  plant  
Example  6:  We  have  been  partnering  an  MNC  FMCG  Giant  in  India  on  optimizing  their  steam  and  
condensate  system  and  helping  them  achieve  their  sustainability  and  safety  goals  for  Steam  &  Hot  
Water  systems  through  several  assignments.  A  few  key  assignments  are  
• Number  of  plants  we  have  worked  with  25  
• Reducing  water  consumption  in  15  plants  by  improving  the  condensate  recovery  system  
• Energy  audits  to  reduce  fuel  consumption,  carbon  foot  print  and  water  reduction  across  15  plants  
• Design  consultancies  for  utilities  across  3  plants  
• 8  specific  training  programs  for  key  plant  personnel  with  mentoring  of  energy  champions  
• Involved  in  developing  the  global  core  design  for  Steam  &  Condensate  which  will  be  a  standard  for  
implementation  across  any  new  plant  being  set  up  by  the  MNC  world-­‐wide  
• Reduced  specific  steam  consumption  from  1.15  to  1kg/kg  DFA  for  their  major  process  
• Developed  and  provided  a  solution  to  use  product  waste  as  fuel  for  the  boiler    
Example  7:  A  Global  Confectionery  MNC  Group  was  setting  up  their  first  plant  in  India.  The  FMPL  design  
consultancy  team  improved  the  global  core  design  and  provided  turnkey  implementation  support.  The  
value  addition  through  our  Design  consultancy  comprised:    
• Capex  Reduction  of  INR1.5Cr  +  Civil  &  Structure  cost  
• Opex  Reduction  -­‐  5  %  reduction  in  steam  consumption  &  10%  reduction  in  electrical  pumping  cost    
•  Decentralization  of  the  hot  water  generation  system  and  shifting  it  closer  to  process  
• 1  KM  Reduction  in  Hot  water  SS-­‐304  Piping  +  Instrumentation  Cabling    
• Guaranteed  negligible  product  temperature  hysteresis  which  is  critical  for  chocolate    
• Integration  of  renewable  energy  to  reduce  fuel  consumption  
• Ease  of  operations  through  complete  automation  of  utility  with  centralized  monitoring  and  localized  
control  flexibility  
• Real-­‐time  performance  diagnostics  for  each  hot  water  generator    
• Opex  reduction  in  the  hot  water  network-­‐  reduction  of  radiation  losses  through  reduced  network