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Our Heritage

STEAM
ENERGY CONSERVATION

In 1888 Sanders Rehders and Company (Sar Co) was formed in London to sell
steam traps and other steam related products.
Today, our worldwide steam business is part of the Spirax Sarco Engineering
plc. Group, which has been listed on the London Stock Exchange since 1959.

For over 100 years Spirax Sarco has been partnering steam users and
specifier’s, worldwide, to improve the performance of their plant and
processes.

Spirax Sarco provides the steam expertise and solutions that can help the
customers meet its sustainability goals worldwide through the control and
efficient use of steam, water and other industrial fluids.

Business Overview - Global Presence Business Overview - Manufacturing

• Large component
stocks to enable
just in time
manufacturing for
quick delivery.

Operating companies
• Extensive product
Sales offices
testing including
Distributors steam testing prior
to shipment.

51 operating companies in 34 countries

1,300 direct field sales & service people for local expertise and stocks Large manufacturing sites: UK, USA, France, Italy, China, Brazil and Argentina
Other manufacturing sites: Mexico, Netherlands, Germany, Sweden, South Africa, India and Korea

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A worldwide network providing local

Regional Support A regional network supporting industry HISTORY- Indonesia
service and support

1983 – 1990 work with many distributors

1990 – 2013 work with 2 dedicated Distributors

• PT. Petrolog Multi Usaha Mandiri
• PT. Centrindo Palmax – Medan

2014 PT. SPIRAX SARCO INDONESIA

55 - Employees
20 - Sales Engineers
6 - Service Engineers
7 - Customer Service Support & Logistic

Selection of Indonesia Clients

• Clariant Indonesia • BASF Indonesia
• Cabot Indonesia • Sulfindo Adi Usaha
• Amoco Mitsui PTA • Jawa Manis Rafinasi
• Indorama Polypet • Asahimas Chemical
• Angel Product • Bluescope Steel Indonesia
• Pirelli Indonesia • Krakatau Steel Indonesia
• Styrindo Chemical • Mitshubishi Chemical

Our Solutions
Warehousing, stores, delivery, local and regional

Products are our building blocks. A broad product range, service and
expertise contribute to our ability in providing customer tailored
solutions.
Spirax Sarco – wide range of steam product solutions
Spirax Sarco has a complete range of products that cover the entire steam and condensate loop which we
design, develop, manufacture and make available to customers on a largely ex-stock basis together with
comprehensive technical advice, service and support

STEAM: Why Use It?

• Steam is still the most efficient and cost effective way of transferring heat
• Steam is easily and readily controllable, ensuring accurate and repeatable operations
• Steam fills the heat transfer space evenly, ensuring consistent product quality.

STEAM •

•
Steam is ideally suited to clean and sterile products/environments as it is inherently
sterile.
Steam is extremely flexible, as it can be generated in central boiler plant or localised
WHY USET IT boilers whichever suits the application.
• Steam can tie in with combined heat and power systems to provide motive power,
heating, and refrigeration.
• Steam and condensate pipe sizes are usually smaller and lighter than liquid systems,
minimising installation costs.
• Steam systems require no circulation pumps or circuit balancing, reducing running costs
and commissioning charges.

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Type of Steam Steam Quality Testing

THE TYPICAL STEAM SYSTEM Steam

in Oil & Petrochemical Industry

STEAM JACKETED TANK HEAT

PAN COIL EXCHANGER

FEED
WATER CONDENSATE
FEED
TANK

FEED
BOILER
PUMP

Pure Steam Distribution in Pharmaceutical Industry

Steam Distribution in Food & Beverages

Clean steam generator

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PLANT ISSUES
Fuel

STEAM
PLANT ISSUES
Operating Reliability &
Costs Availability

Legislation &
Standards

THE STEAM SYSTEM LOSSES (Sankey Diagram)

Typical Losses Flue Radiation
Distribution Flash
STEAM SYSTEM AUDIT
Losses Losses
20% 3% Losses Losses
5% 5%
Kegiatan steam system audit merupakan evaluasi terhadap
kinerja sistem uap yang ada, baik secara individu maupun
komprehensif, dan diikuti oleh identifikasi potensi perbaikan dan
penghematan energi di bagian ruang boiler, distribusi uap,
mesin pengguna uap, steam trapping, pengelolaan kondensat
Fuel Input dan flash steam, serta sistem pengendalian proses dan
100% Heat Output Heat To User monitoring.
75% 55%

Plant Survey Laporan Implementasi

Inventarisasi Presentasi Prioritas
Boiler Distribution Pengumpulan data Diskusi Biaya
Assesmen Rekomendasi ROI
Diskusi Potensi Monitoring
Condensate
Blowdown Losses
Losses 10%
2%

Steam System Audit Boiler House

Feedtank/
Dearator
Make up water Flash Steam Recovery Steam Main Header
Steam Meter

TDS/Turbidity Meter

Blowdown
Vessel

Boiler c/w Steam Accumulator

Heat Pipe HE for Exhaust Heat Recovery

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BOILER EFFICENCY THE STEAM SYSTEM LOSSES

Flue Flue Losses Flue Radiation
Losses Losses Distribution Flash
Losses
20% 3% Losses Losses
5% 5%
Steam
THE Energy
BOILER

Fuel Input
Water Radiated Fuel 100% Heat Output Heat To User
Energy Heat Energy 75% 55%

Boiler Distribution

Blowdown
Condensate
Losses Blowdown Losses
Losses 10%
2%

BOILER EFFICENCY BOILER EFFICENCY

Flue Gas Losses Flue Gas Losses
• Heat lost in heating nitrogen and discharging it up the flue Unburned Fuel
Losses
Air/fuel ratios
• Heat lost by burning hydrogen in the fuel and discharging
steam up the flue Fuel
Combustion Useful heat
• Heat lost by the flue gases being too hot Process
Burner is producing more heat than required; maintenance Air

Heat transfer surfaces not functioning correctly; cleaning

Stack Losses

We can measure CO2 plus the exhaust gas

temperature to evaluate the above losses

BOILER EFFICENCY BOILER EFFICENCY

Stack Losses

∆T
Flue Gas Losses Flue Gas Losses
TFG = 180 °C
CO2 = 10%
Calculate combustion efficiency ∆T (°C) 80 100 120 140 160 180 200 220 240
by flue gas temperature and CO2
4 17.2 19.0 20.9 22.7 24.5 26.4 28.2 30.1 32.0
content
Chimney 5 15.9 17.4 18.9 20.4 21.9 23.4 24.9 26.5 28.0
CO2 6 15.0 16.3 17.6 18.9 20.1 21.4 22.7 24.0 25.3
% 7 14.4 15.5 16.6 17.8 18.9 20.0 21.2 22.3 23.4
8 13.9 14.9 15.9 16.9 17.9 19.0 20.0 21.0 22.0
9 13.6 14.5 15.4 16.3 17.2 18.1 19.1 20.0 20.9
Boiler
CO2 % 10 13.3 14.1 14.9 15.8 16.6 17.5 18.3 19.2 20.0
Air 11 13.0 14.6 14.6 15.4 16.1 16.9 17.7 18.5 19.3
Percentage heat loss in flue gas for natural gas
TAMB = 20 °C

Fuel Gas Losses = 16.6%

∆T = TFG - TAMB

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BOILER EFFICENCY THE STEAM SYSTEM LOSSES

Economisers Flue Radiation
Losses Losses Distribution Flash
• Average savings of 5% for gas fired boilers. 20% 3% Losses Losses
5% 5%
Economiser

Fuel Input
100% Heat Output Heat To User
75% 55%

Boiler Distribution

Condensate
Blowdown Losses
Losses 10%
2%

BOILER EFFICENCY
Thermal Imager
Boiler Shell Heat Losses
Uninsulated
Steam pipe
at Boiler House

Uninsulated
Feedtank
at Boiler House

Insulated Steam Pipe THE STEAM SYSTEM LOSSES

Typical Losses Flue Radiation
Losses Losses Distribution Flash
20% 3% Losses Losses
5% 5%

Fuel Input
100% Heat Output Heat To User
75% 55%

Boiler Distribution

Condensate
Blowdown Losses
Losses 10%
Insulated steam pipe 2%

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BOILER EFFICENCY 37 BOILER EFFICENCY

Blowdown Blowdown Rate Calculation
Steam Rate (S)
• Blowdown is required to control solids 10,000 kg/hr
in the boiler water
• Solids enter the boiler with the make- Feed Water (F) Boiler Max TDS (B)
up water 250 ppm TDS 2500 ppm
• As steam is generated the solids
remain thus increasing their
concentration
• If solids are not purged they can lead
to:
o Scale Formation
o Carryover
F×S
Blowdown Rate =
B-F
o Corrosion
250 × 10000
o Embrittlement =
2500 - 250
= 1111 kg/h or 11%

Automatic TDS Control BOILER EFFICENCY

Manual Blowdown

Boiler pressure % Fuel Saved for 1% Maximum allowable TDS

Boiler water TDS

(bar g) Saving in Blowdown

Average TDS
7 0.19%
10 0.21%
17 0.25%
26 0.28%
0 12 24
Time in hours

• Manual blowdown creates high and low spikes

• Above max allowable levels scale forms
• Below acceptable levels there is an increase in waste water
• Due to spiking action levels are normally set lower so average TDS is low
∴ high waste water and energy

BOILER EFFICENCY CASE STUDY

Automatic TDS Control Steam Rate (S)
2,500 kg/hr

Maximum allowable TDS

Feed Water (F) Boiler Max TDS (B)
Boiler water TDS

Average TDS
400 ppm TDS 3000
3500ppm
ppm

F×S
Blowdown Rate =
B-F

0 12 24 400 × 2500
=
Time in hours Boiler Pressure % Fuel Saved for 1% 3000 - 400
(barg) Blowdown Reduction = 384 kg/h or 15%
• Minimisation of blowdown rate: reduction in waste water, chemicals and energy loss 0.3-0.4%
7,0 0,19%
• Labour saving advantages from automation Fuel Saving
10,0 0,21% 400 × 2500
• Closer control of boiler TDS levels =
Water Saving 3500 - 400
• Boiler maintained at design conditions
Cost of water = $2.16 / m³ = 322 kg/h or 13%
• Heat recovery savings = 62 kg/h blowdown saving
• Reduced maintenance issues = 8064 hours / yr
= $1080 / yr

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CASE STUDY CASE STUDY

Heat Recovery from Boiler Blowdown Flash Steam Recovery
Pressure Temp Specific Enthalpy (kJ/kg) Volume
Flash Steam (barg) (°C) (m³/kg)
0.5 barg Evaporation
Cold Break
Tank 0.5 112 468 2225 2694 1.149
5.0 159 670 2086 2757 0.315
Extract from steam tables
Boiler Pressure
5.0 barg
Blowdown
Enthalpy of saturated water at 5 barg = 670 kJ/kg
Enthalpy of saturated water at 0.5 barg = 468 kJ/kg
Surplus = 202 kJ/kg
Enthalpy of evaporation at 0.5 barg = 2225 kJ/kg
Proportion of flash steam = 202 / 2225
= 0.09 kg flash/kg of condensate
Heat To Recovery = 9%
Exchanger Percentage of Energy = 202 / 670 = 30%
Blowdown flowrate = 0.09 × 322 kg/h
= 29 kg/h

CASE STUDY CASE STUDY

Fuel & Water Savings Heat Recovery from Boiler Blowdown

Flash Steam
Flash steam recovered = 29 kg/h 0.5 barg Cold Break
Running time = 8064 hours Tank
Annual flash steam recovered = 233,856 kg/year
Boiler Pressure
5.0 barg
Fuel Saving Blowdown
Cost of steam = $85 / 1000 kg
= ($85 × 233,856) / 1000
= $19,877 / year

Water Saving Blowdown Blowdown

To Recovery
Cost of water = $2.16 / m³ 100°C 50°C
= ((29 × 8064) / 1000) × 2.16
= $505 / year

CASE STUDY CASE STUDY

Heat Recovery

Heat recovery project

Blowdown discharge rate = 322 kg/h - Flash steam
Flash steam recovered = 29 kg/h
Residual flow to heat recovery = 293 kg/h

Sensible Heat Recovery

= 293 × 4.2 × (100-50)
= 61,530 kJ/h
= 496,177,920 kJ/yr
80% boiler efficiency = $17,627 / yr

Heat savings
Assuming 40% operation = $17,627 × 40%
= $7050 / year

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CASE STUDY
ENERGY SAVING OPPORTUNITIES AT BOILER HOUSE
Savings
Fuel from flash recovery $19,877 3

Blowdown residual heat $7,050

Water savings $1,585
Total Savings $28,512 4

Investment c.$55,000: <24mth ROI (conservative) 1 Burner control

- Fully modulating control
- Use of variable speed fan
- O2 trim 2
…can save up to
Plus…. 2 % thermal energy
30 % electric energy 5
Boiler insulation…
5 6
Water treatment savings 2 Auto TDS control
- High density and thickness
insulation lagging
7
- Reduces amount of boiler blow down required - Elimination of heat bridges
Waste water treatment savings - Reduces water carryover with steam
-Use of air actuated valve instead of electric
between hot vessel and cladding
…can save up to
Chemical savings …can save up to
0,4 % thermal energy 1
0,1 % thermal energy

5 % salts and chemicals 6 Feed water control… 7

Improvement in boiler efficiency – additional fuel savings
3 - Use of variable speed feed water pumps
Waste heat recovery…
- Use of flue gas economizer
- Use of flues / air pre heater
…can save up to
5 % thermal energy
Water treatment…
4 Deaerator…
- Use of multistage high efficiency pumps - Reduces amount of boiler blow down required
- Avoids scaling inside the boiler which affect
- High density and thickness
- Use of modulating feed water system for heat transfer rate between the water and the hot
insulation lagging
feed water rating matched to steam gases
…can save up to
demand …can save up to
0,45 % thermal energy
…can save up to 5 % thermal energy
70 % salts and chemicals
15 % electric energy

THE STEAM SYSTEM LOSSES THE STEAM SYSTEM LOSSES 52

Typical Losses Flue Radiation

Improving Condensate Return
Losses Losses Distribution Flash
20% 3% Losses Losses Increase condensate return
5% 5% WHY?

Condensate can contain over 20% of total steam enthalpy

Further savings: Water consumption

Fuel Input Reduced Effluent
100% Heat Output Heat To User Boiler Chemicals
75% 55%

Pressure Condensate Lost Condensate Returned Condensate Returned

(barg) Flash Lost Flash Lost Flash Recovered
Boiler Distribution
10,0 72,5% 86,5% 100%
7,0 75,0% 89,1% 100%
Condensate 3,5 78,3% 92,4% 100%
Blowdown Losses
Losses 10%
2%

Condensate Recovery PEMETAAN SISTEM UAP (EXISTING)

Reduce fuel consumption by approximately 1%
for every 6°C rise in feedtank temperature

FEEDTANK FUEL
TEMPERATURE = CONSUMPTION

1 2 3

1. Boiler Water
2. Feedwater
3. Condensate

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PEMETAAN SISTEM UAP (IMPROVEMENT) POMPA KONDENSAT

- Pompa elektrik sentrifugal kondensat panas

- Kavitasi, karena efek penguapan kondensat panas
STEAM - Biaya perawatan lebih mahal
TRAPPING - Membutuhkan energi listrik
- Sering diperlukan penggantian seal

- Pompa mekanik (motive pressure pump, Ogden Pump)

- Tidak ada kavitasi, bahkan dapat bekerja pada
kondisi vakum
- Biaya perawatan lebih murah
PENGEMBALIAN - Membutuhkan steam sebagai pendorong, 20 kg/h
KONDENSAT - Explosion proof / hazardous
- Remote area

THE STEAM SYSTEM LOSSES

Typical Losses Flue Radiation
Losses Losses Distribution Flash
20% 3% Losses Losses
5% 5%

Fuel Input
100% Heat Output Heat To User
75% 55%

Boiler Distribution

Condensate
Blowdown Losses
Losses 10%
2%

FLASH STEAM 59
FLASH STEAM
This is a natural occurrence when condensate drops in pressure after leaving a steam
trap. The condensate is at steam temperature and cannot maintain this temperature at
a lower pressure. This results in the condensate flashing off into steam to lose the
excess heat.

Steam supply
8 bar g

0.5 bar g

% Flash Steam = 12%

Flash steam = 12 kg/h
Condensate = 88 kg/h Flash steam
100 kg/h

Condensate

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THE STEAM SYSTEM LOSSES THE STEAM SYSTEM LOSSES

Flash Steam Recovery Flash Steam Recovery

• Large wastage of energy in flash steam Recovered

Flash
• Loss of condensate (from flash steam) Vent

• Unsightly discharge from the vent • Flash steam is recovered

before it’s lost via the
• Possibility of the receiver overflowing due to receiver vent Condensate
pressurisation
• Energy and water saved from Plant
• No unsightly loss of flash
Condensate steam from the vent pipe
from Plant
• Less likelihood of receiver
overflowing
To Boiler
To Boiler House
House

THE STEAM SYSTEM LOSSES THE STEAM SYSTEM LOSSES

Flash Steam Recovery Flash Steam Recovery

Requirements for flash steam usage Condensate

• Enough condensate
Flash

• Use for low pressure steam

Feedwater Condensate

• Application needs to be close to high pressure

condensate source

THE STEAM SYSTEM LOSSES THE STEAM SYSTEM LOSSES

Flash Steam Recovery Flash Steam Recovery

BEFORE…

…AFTER

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THE STEAM SYSTEM LOSSES THE STEAM SYSTEM LOSSES

Typical Losses Flue Radiation
Distribution Losses
Losses Losses Distribution Flash
20% 3% Losses Losses
5% 5%

Fuel Input
100% Heat Output Heat To User
75% 55%

Boiler Distribution

Condensate
Blowdown Losses
Losses 10%
2%

THE STEAM SYSTEM LOSSES THE STEAM SYSTEM LOSSES

Distribution Losses Distribution Losses
Steam DN50
7 barg Pipe
• Steam leaks
How much are they costing you?
Ambient Temperature 21 °C

∆T =~150°C • 25 mm valve stem 8 barg

Heat Loss = 514 W/m
For 100m = 51.4 kW
Condensing Rate = 90 kg/h
Cost = ~$60,000 per annum
3.5 kg/h ~$1200 per annum
• 2 mm hole, steam at 7 barg
9 kg/h ~$3000 per annum
• 5 m of 50 mm pipe $1500 per
annum (insulate reduce to 1/10th)
• Incorrect installed drainage points
• Correct pipe sizing

Insulation can reduce losses • Condition of steam

to 1/10th (e.g. dryness fraction)

Heat emission from bare pipes

KEBOCORAN UAP THE STEAM SYSTEM LOSSES

Distribution Losses: Steam Traps

Failed Open Steam Trap Failed Closed (Cold) Steam Trap

PANJANG
FLUME Plant will waterlog
Waste of energy/money
Reduced plant output
Increases production costs
Spoilt product
Plumes of steam visible form vents
Under heating
Can cause problems in pipes
Safety hazard – waterhammer
Plant will still operate
Freezing

Failed open steam trap with a 5 mm orifice, operating at 7 barg will lose
Contoh : Kebocoran uap dari gasket pada sambungan pipa = 11 kg/jam
approximately 30 kg/h. Over 260 t per annum
dengan panjang ‘Plume’ 750 mm

Kerugian biaya = 11 kg/jam x Rp 600/kg x 5400 jam = Rp 36 juta/tahun

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THE STEAM SYSTEM LOSSES THE STEAM SYSTEM LOSSES

Distribution Losses: Steam Traps Trap Monitoring

Open Discharge

Sound /
Temperature Ultrasonic
Trap Monitoring

Sight Glass Combined Conductivity

& Temperature
Conductivity

STEAM TRAP SURVEY

1. Uji kinerja steam trap dengan bantuan ultrasonic trap tester dan peralatan
pendukung seperti infrared
2. Uji kebocoran lain, seperti valve steam trap set
3. Tagging and numbering steam trap
4. Tabulasi steam trap
5. Pengambilan gambar setiap steam trap set, jika diperlukan
6. Mengolah dan menampilkan data dalam STMS (steam trap management
system)
7. Perhitungan kebocoran steam dan emisi karbon
8. Laporan steam trap survey

THE STEAM SYSTEM LOSSES

Typical Losses Flue Radiation
Losses Losses Distribution Flash
20% 3% Losses Losses
5% 5%

Fuel Input
100% Heat Output Heat To User
75% 55%

Boiler Distribution

Condensate
Blowdown Losses
Losses 10%
2%

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THE STEAM SYSTEM LOSSES CARBON EMISSION

Ideal System Flue Radiation
Losses Losses Distribution Flash
20%
15% 2%
3% Losses Losses
5%
4% 5%
0%

Fuel Input
100% Heat Output Heat To User
75%
82% 55%
77%

Boiler Distribution

Condensate
Blowdown Losses
Losses 10%
<1%
2%
<1%

SUMMARY
Case Study
Example : KEEPING IN THE HEAT
Good design and installation
Calculate the CO2 produced from generating steam at 10 bar from a boiler supplied with
Insulate efficiently
Natural Gas and 80% efficient. Feedwater temperature = 30 degC
Consider heat recovery
From steam tables: hg = 2781 kJ/kg
For 1 kg steam, energy required = 2781 – 4,2 x 30 = 2655 kJ
KEEPING IN THE STEAM
Actual energy needed = 2655/(80%) = 3319 kJ/h Cure leaks
Monitor steam trap operation
Therefore 3319 kJ = 0.922 kWh

CO2 conversion factor for Natural Gas = 0.1836 kg/kWh

KEEPING IN THE WATER
Therefore CO2 released per kg steam produced = 0.1836 x 0.922 = 0.169 kg Return condensate for re-use
Review contaminated condensate arrangements
or 169 kg CO2 per tonne steam

Rusmanto
Area Sales Manager
rusmanto@id.spiraxsarco.com
M (+62) 8156 159 711

PT. Spirax Sarco Indonesia

Kawasan Infinia Park Blok C-99
Jl. Dr. Saharjo No. 45, Manggarai, Tebet
Jakarta Selatan 12850 - Indonesia

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