Optimising Steam Network to Prevent Turbine Tripping

Customer: A sugar factory in Latin America

A sugar factory in Latin America was facing operational inefficiencies due to frequent load fluctuations in its newly installed boiler. These fluctuations resulted in frequent turbine trips, leading to significant production disruptions. Additionally, the safety valve was regularly popping due to steam loss, further affecting plant efficiency and increasing maintenance requirements. These recurring problems not only hampered productivity but also led to excessive energy consumption and operational instability, impacting the overall performance of the plant.

To address these challenges, the Forbes Marshall team conducted a comprehensive survey of the entire plant to identify inefficiencies in the steam network. Based on the findings, the steam distribution system was optimised by installing isolation valves to prevent steam leakages. Steam pressure-reducing and desuperheating stations with proper feedback mechanisms were implemented to regulate steam consumption effectively. As a result, frequent boiler load fluctuations were eliminated, ensuring stable turbine operation and preventing unnecessary safety valve activations. This solution not only enhanced process efficiency but also contributed to energy conservation and sustainable operations.