Internal Steam Audit PM-3

Team Members:
•Deepak Kumar Panda
•Tushar Pradhan
•Manoj Kumar
 Contents

 Drying Capacity of PM3

 Drying efficiency
 Loss savings
 Project
 Drying Capacity of PM3

 Deckle at pope reel(meter) = 3.72

 No of dryer cylinder = 23
 Dryer cylinder diameter(meter) = 1.5
 Dryer cylinder width(meter) = 4.2
 Sheet dryness before pre dryer(%) = 48
 Sheet dryness after size press(%) = 97
 Sheet dryness before post dryer(%) = 71
 Sheet dryness after post dryer(%) = 95.5
 Moisture evaporated in predryer(T/T) = (97-48)/48 = 1.021
 Moisture evaporated in postdryer(T/T) = (95.5-71)/71 = 0.345
 Total moisture evaporated(T/T) = 1.021+0.345 = 1.366
 Dryer Surface area(m2) = 19.8
 Total available surface area(m2) = 455.4
 Evaporation rate(kg/m2/T) = 2.999
 Drying Efficiency
 Heat of vaporization of water(kJ/kg) at average temperature of 75 to 80'C = 2300

 Total heat required to evaporate total moisture(kJ) = 1.366*2300*1000 = 3141579

 Enthalpy of LP steam at 3 Bar pressure(kJ) = 2130

 Steam required to evaporate the moisture(kg/T) = 3141579/2130 = 1474.92

 Actual average steam consumption per ton of paper as per DCS reading(kg/T) =
2078


Drying efficiency (%) = (1474.92/2078)x100 =70.97%
 Loss savings
STEAM AND CONDENSATE LOSS SAVING REPORT

Sl No LOCATION REPORTED ON JOB STATUS

1 Cylinder no 9 condensate line leakage

23.12.2020 COMPLETED

Pocket ventilation condensate return

2 line leakage
18.12.2020 COMPLETED

Main condensate tank flash

3
steam leakage
19.12.2020 COMPLETED

Cylinder no 18 condensate leakage

4
from flange
23.01.2021 PENDING

5 PM3 main header steam leakage near

stock preparation DCS
18.01.2021 COMPLETED

6 Cylinder no 17 sight glass condensate leakage

17.12.2020 COMPLETED
 Project
Required temperature of sheet
before size press is 80'C

Pre Dryer Post Dryer

Size
press

During grammage change or quality change the steam pressure of pre dryer has to be set in DCS manually by operators.
As the operation is by manual, its difficult to bring the sheet temperature to exact 80'C
In case the temperature is higher side it consumes more steam which is unwanted and can lead to sheet break at size
press.

A temperature sensor has been installed before size press to measure the temperature.
A cascade logic has been also developed which will receive the output from the sensor and will control the steam input to
post dryer

The sensor is already in working condition , logic is yet to be connected .