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144188195215245280

Forbes Marshall Pvt. Ltd.

Pune, Maharashtra

| GST  27AAACF2630E1Z5

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Oil Boiler

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Fired Boiler

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Modular Boiler

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Turnkey Boiler

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Compact Steam Trap

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For over half a century, Forbes Marshall has been building steam engineering and control instrumentation solutions that work for process industry. Forbes Marshall's goal is to provide solutions in Energy, Efficiency and Process Automation, using the best technology the world has to offer. 50 years ago we started out with steam generation solutions. Today we are comprised of twelve business divisions; most of them partnering with the world technology leaders in respective fields, manufacturing products that cover the entire spectrum of energy generation, energy efficiency, control and instrumentation for the process and power industry.
But we are proud of much more than just the products we make. We are committed to creating a progressive work culture that uniquely puts people first. We are concerned with the community beyond our factory's gate. Putting people first is the way we have become industry's first choice in their efforts to better harness steam, air and water. We do much more than sell products. We build steam engineering and control instrumentation solutions that work for you.
From our unique corporate structure and commitment to quality, to our extensive community and social service programs, there's a lot that makes us stand out from the rest.
In the last five decades Forbes Marshall has grown from a modest, Mumbai based trading company to a multi-divisional, ISO 9001 certified global company manufacturing advanced engineering products for process and power industries across the World. Forbes Marshall is probably the only company in the world to have extensive expertise in both steam and control instrumentation. The dual expertise has allowed us to engineer industry specific systems that focus on energy efficiency and utilities management for sectors as diverse as textiles, food processing, paper, power and chemicals etc.
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Nature of Business

Manufacturer

Total Number of Employees

501 to 1000 People

Year of Establishment

1950

Legal Status of Firm

Private Limited Company

Annual Turnover

Rs. 100 - 500 Crore

GST Number

27AAACF2630E1Z5

Oil Boiler
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Oil Boiler

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Capacity of 500 & 750 kg/ hr (F & A 100 Deg C) operating at 10.54 kg/ cm2Only IBR boiler in its range
Truly 3-pass wetback boilerdesigned to international standards
Ideal for hospitals, hotels, garments formulation units, food, cattle feed units etc
Substantial savings possible by replacement of NIBR installations

  • Compact Three Pass Wet Back Boiler
  • Skid Mounted Boiler with Accessories complete with insulation, cabling and monobloc burner.
  • 98 % Dry Steam – forget the wet steam from smaller capacity coil type boilers
  • 100 Deg C Feed Water Temperature
  • Optimization of Usage of Heat, as Feed Water Tank is maintaining the temperature of Fuel Oil Tank
  • No limitations to use FO/HO with this boiler as coil type boilers
  • No civil work for boiler house as complete
  • Built to rigorous JNM and IBR Quality Standards

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Fired Boiler
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Fired Boiler

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Capacity(TPH) 5.0 6.0 8.0 10.0 12.0 15.0 18.0 20.0 25.0 30.0 40.0
Pressure Kg/cm2
10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5
14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5
17.5 17.5 17.5 17.5 17.5 17.5 17.5 17.5 17.5 17.5 17.5
High Pressure upto 66.0 kg/cm2

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Coal Fuel Fired Boiler
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Coal Fuel Fired Boiler

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Capacity(TPH) 0.5 0.6 0.8 1.0 1.2 1.5 1.8 2.0 2.5 3.0 4.0
Pressure Kg/cm2
10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5 10.5
14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5 14.5
17.5 17.5 17.5 17.5 17.5 17.5 17.5 17.5 17.5 17.5 17.5
High Pressure upto 66.0 kg/cm2
Fuels Indian/Indonesia Coal
Agrowaste Brquette
Wood Blocks

Power Plants - 0.5 Mwe

Products :

Process Boilers & Mini Power Plants
Hot Water Boilers - 3.0 Million Kcal/h & above
Thermic Fluid Heaters - 5.0 Lac Kcal/h and above
Power Plant High Pressure Boilers for Biomass & Industrial Waste
Horizontal Tail Boilers for High Fouling Fuels and Solid Recovered Fuel
Multi-Media Plants - "Single Boiler - Multiple Energy Media" - Combination of Steam + Thermal Oil + Hot Gas + Hot Water

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Exhaust Gas & Heat Recovery Boiler
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Waste Heat Recovery Boiler

The Waste Heat Recovery Boiler from Gas Gensets offered by Forbes Marshall is a package consisting of the following 1. Boiler
Feed water pumps
3. Control panel4. Instruments & controls.. Gas bypassdiverter dampers (Supplied Loose)6. Expansion joints (Supplied Loose)7. Pressurised Economiser.8. Single Element Level Control System.9. Feed water tank along with Deaerator head

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Modular Boiler
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Modular Boiler

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The thought of a very compact boiler house is not just a refreshing prospect for utility managers worried about space and mobility in the utility room, but also a tool to cut down on the stretched budget of industrial projects. The Modular Boiler was an idea conceived to tackle not just the issues of space but also add a value proposition to a boiler which would get the customer more that what he had obtained for.


The efforts of the engineering and design team had to be secured and hence a patent was filed in May 2006 for the modular design and finally it was formally given in March 2009.


The modular boiler has in its wake provided a choice to the customer which is very attractive in terms of the following –

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Turnkey Boiler
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Turnkey Boiler

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Forbes Marshall has executed several jobs of balance of plant on turnkey basis. In house project execution capabilities enable the organization to handle project worth crores to be executed timely.

Forbes Marshall Consultancy division undertake project management consultancy apart from detail engineering activities.

Some of the site photographs are shown below :

 

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Thermodynamic Steam Trap
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Thermodynamic Steam Trap

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Thermodynamic steam trap with inbuilt strainer and full stainless steel construction, best suited for header and mainline drains and drop legs.The TD-3 Thermodynamic Steam Trap is suitable for draining main steam distribution lines where prompt removal of condensate is essential. The TD-3 uses the velocity and phase change of pressurised condensate flashing to lower pressure steam to operate the disc. Its hardened seat and disc and absence of moving parts ensures a long service life. Although the trap operates in any position, horizontal orientation is preferred.Spirax TD 55 BD thermodynamic steam trap is suitable for draining main steam distribution lines where prompt removal of condensate is essential. The TD-55 BD uses the velocity and phase change of pressurized condensate flashing to lower pressure steam to operate the disc. Its hardened seat and disc and absence of moving parts ensure a long service life. Although the trap operates in any position, horizontal orientation is preferred. Integral blowdown valve allows on-line cleaning of strainer screen. During startup air is trapped in the control chamber of TD. Being air, it cannot condense and hence the pressure will not drop. This causes the trap to fall in closed condition. TD BDA is specially designed trap to overcome this air binding problem. It is a trap with a 100 mesh stainless steel screen & a special anti-air-binding disc.The TD-62 is a maintenance high pressure Thermodynamic Steam Trap with integral strainer designed specifically for steam main drainage applications up to 100 bar g.
The TD-62 is a thermodynamic steam trap which uses a disc to control the release of condensate and to trap steam. The disc which is the only moving part rises and falls in response to the dynamic forces produced by the partial re-evaporation (flashing) of hot condensate. Cool condensate, air and other, non-condensable gases enter the trap through central orifice, lift the disc and discharge through outlet orifice when the condensate approaches steam temperature a part of it flashes as it enters the trap. The flash steam passes at high velocity over the underside of the disc and collects in the control chamber above the disc. The resulting pressure in balance forces the disc downward on to the seating surfaces, stopping the flow. The trap remains tightly closed until the loss of heat through the trap body lowers the control chamber pressure, allowing the inlet pressure to raise the disc and repeat the cycle.

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Compact Steam Trap
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Compact Steam Trap

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At present , in any process plant , where ever steam is involved & it has to be transported from Boiler (Point of Steam Generation ) to the equipment (Point of usage ) , it has to get distributed through headers & run through main lines. While traveling through the main lines, due to radiation heat loss, condensation of the steam takes place, which has to be drained out at definite intervals. Thermodynamic Steam traps are used at the drip legs of these main lines to trap the steam & remove / drain out the condensate. Certain steam trap assembly is used to remove this condensate & keep the plant alive without affecting the process, which is called as condensate drain trap module. Condensate Drain Module is an arrangement of different components, used for handling steam trap , either having open loop where in condensate is discharged to atmosphere or Closed loop where in condensate is recovered & taken back to the boiler (like in non critical Tracing line in Refinery & Petrochemical Industry ) .A conventional drain module particularly contains two isolation valves, one by-pass valve, and finally a steam trap along with strainer. The figure shows one typical example of open loop in case of discharging the condensate through atmosphere .The above figure shows one typical example of closed loop in case of returning the condensate through atmosphere .

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Glandless Piston Valve
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Glandless Piston Valve

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FM PISTON VALVE is a zero leak isolation Piston Valve, in which the seat & gland are replaced by Lower & Upper Sealing rings along with a Piston. This overcomes the difficulties usually associated with the replacement of conventional seats.The FM Piston valve is the name for prevention of inline leakage as well as leakage through glands, making for leakproof isolation in the pipelines.The FM Piston valve is a seat less & gland less Piston Valve. At the heart of the FM piston valve are Piston & sealing rings. A burnished piston seals against SS reinforced graphite rings to achieve a leak proof shutoff. This unique design ensures a long life even at high temperatures up to 427 deg CA Burnished piston is connected to the Piston Valve stem & hand wheel. The piston passes through two sealing rings separated by a lantern bush. Each sealing ring is Stainless steel reinforced graphite, which has both features of sustaining compression exerted by Bonnet & providing soft seal against piston. The upper sealing ring acts as a conventional gland packing and prevents leakage towards atmosphere. The lower sealing ring acts as the seat which prevents in line leakage. The lantern bush is required to maintain separation between the upper & lower rings & to allow flow through the Piston Valve.FEATURES :
Larger effective sealing area :
Leak proof isolation - Class 6 shut off achieved.
Durability - Piston unexposed to media
Absence of Gland & Seat
Maintenance friendly - Uniform sealing rings on both the sides & maintenance can be done without removing the Piston Valve from the pipe line. (On-line Maintenance)
User Friendly - It does not need Piston Valve Key
The Only Scrap Free Piston Valve
Self Lubricating
Self CleaningRANGES :

Piston valves provide perfect tightness and durable stability on
different mediums such as steam,superheated steam,heat transfer
fluid,ammonia,L.P.G,acids,alkalies etc

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Fabricated Strainer
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Fabricated Strainer

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One Spirax Strainer upstream of every trap, control valve, and flowmeter can save you a bundle in annual maintenance and wear & tear costs. Available in Y or T type designs, our Strainers remove suspended grit from steam and condensate that would otherwise damage your downstream equipments with no additional pressure drop.FIG 12 Strainer
The FIG 12 Y-type Strainers with stainless steel screens have 0.8 mm diameter perforations as standard.
Available sizes and pipe connections :
15 NB, 20 NB and 25 NB Screwed BSPT/NPT
40 NB & 50 NB Screwed BSPT/NPTFIG 14 Strainer
The FIG 14 Strainer is available in the following sizes : 25 NB, 40 NB & 50 NBFIG 32 Strainer
FIG 32 Strainers are available in cast iron/cast steel with stainless steel screen and have 0.8 mm diameter perforations as standard.
Available sizes and pipe connections :
Cast Iron FIG 32 Strainer - NB 40, 50, 80,100, 150 & 200. Flan

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Moisture Separator
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Moisture Separator

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Moisture in steam blocks heat transfer. In compressed air, it fouls your application. Spirax separators are a simple and effective way to improve both your processes. Installation upstream of pressure reducing valves and steam meters ensures accuracy and a long mechanical life.For more information, download a Technical Information Sheet from the Technical Documents Tab at the bottom of the page.

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Disc Check Valves
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Disc Check Valves

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Spirax Disc Check Valves are recommended after traps discharging into closed systems to guarantee against return or spill back. DCVs feature a compact and rugged stainless steel design and are suitable for any process liquid & gas, not just steam. Main advantage of these check valves is they can be mounted between pipe flanges in any direction.DCV 1,2,3
DCV 1, 2 and 3 Disc Check Valves are designed to be sandwiched between flanges i.e. wafer type. They are suitable for use on a wide range of fluids for applications in process lines, hot water systems, steam and condensate systems etc.
For more information, download a Technical Information Sheet from the sidebar on the right.DCV 4 Wafer Check Valve
The DCV 4 Disc Check Valve is designed to be sandwiched between ANSI flanges. It is suitable for use on a wide range of fluids for applications in process lines, hot water systems, steam and condensate systems etc.
For more information, download a Technical Information Sheet from the sidebar on the right.

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Safety Valve
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Safety Valve

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Safety valve model SV 11 is a high lift safety valve with gun metal seat, valve and body and brass internals suitable for use on steam, air and water.Available sizes and pipe connections : 20, 25, 40 & 50 NB. Screwed BSPT.For more information, download a Technical Information Sheet from the Technical Documents Tab at the bottom of the page.

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Float Traps
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Float Traps

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Float Traps is the best choice for process applications. The only ball float steam trap with over 50 years of experience and constant development The Spirax Marshall Ball Float Trap (FT) is the product of experience. First launched in the 1940's the F 1 has become the most advanced ball float steam trap available. Constant design improvements have "ace today's FT an extremely robust steal trap.ideally suited to the ngorous demands of any steam system. Unique amongst all pail float steam traps is the self alogning main valve, water hammer proof float assembly and corrosion resistant air vent Such attention to detail ensures complete shut-off at all pressures and reliable operations which lead to an extended product life and minimal maintenance. Having an integral thermostatic air vent and options of a steam Sock release (SIR) and drain cock tapping, the FT range is adaptable to all applications where ball float traps are recommended and instantaneous removal of condensate is required.W'th over 3 mllion Spirax Marshall float traps supplied to over 15000 customers the Sptrax Marshal F 1 has become the most widely used ball float steam trap in the world today.Keep your steam costs at the lowest possible by eliminating all possibility of steam leaks and waterlogging with the continuous discharge Float trap. A float type steam trap is the right choice for process applications. By continuously discharging condensate as it forms, float steam traps eliminate the problems of increased steam consumption and water-hammer. A single steam trap can save you more than Rs 20,000 per year in steam costs! Spirax Marshall’s Process Float steam traps are the preferred choice of leading process plants across the country. Scores of Tyre, Pharmaceutical, Textile, Chemical and Paper plants have already benefitted by replacing their old Thermodunamic and inverted bucket steam traps with the Process Float steam trap. With paybacks in just days instead of months, it’s a small investment for big profits!

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Sight Glasses
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Sight Glasses

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The 'Spirax Marshall' Spiraview is a novel product that allows you to visualise the flow of steam, water or oil inside pipelines. The visualisation of flow helps diagnose problems occuring in equipment upstream or downstream of the Spiraview.
Spiraview overcomes the problems of poor visibility and improper distinction between vapour and condensate flow by using a deflector plate to separate the vapour and condensate. This new design is ideal for applications in which one wants a clear indication of flow, such as downstream of paper drying cylinders, in DM water lines or monitoring steam traps and heat exchangers.

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Steam Pressure Reducing Valves
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  • Steam boilers are usually designed to work at high pressures. Working them at lower pressures can result in carry over of water.
  • Steam at high pressure has a lower specific volume which means that a greater weight can be carried by a pipe of a given size. Spirax recommends distribution of steam at high pressure and reduction at the point of usage. This reduces capital loss for piping and insulation and also reduces distribution losses.
  • Steam pressure may be reduced to save energy. Steam at lower pressures has higher latent heat. Reduced pressure of steam also leads to reduced heat loss and lower flash steam formation from open vents etc.
  • Since the pressure and temperature of steam are related, controlling the pressure enables us to control the temperature in the heating process.
  • Pressures must be reduced so that they are within the rated safety limits.
  • In plants where steam usage takes place at many different pressures, pressure reduction allows generation of steam at a single high pressure and subsequent reduction to the desired pressure at the point of usage.

 

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Steam Humidifiers
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Steam Humidifiers

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Hygromatik Humidifiers Type DB 4 to DB 45
This DB range of self generating humidifiers covers outputs from 1 to 45 kg/h. It is supplied ready for connection in a cabinet housing of compact design, with manifolds or fan units. The DB humidifier uses the electrode heating principle and incorporates an integral electronic control system.
These models are available with three control options, L, EM and MP.Hygromatik Humidifiers Type DB 4 to DB 90
Hygromatik Humidifiers Type DB 4 to DB 90 are electronically controlled and adapt automatically to the water supply quality. All control options have a supervised blowdown routine which will switch the unit off if actual blowdown does not take place.ygromatik Humidifiers Type DB 60 and DB 90
This DB range of self generating humidifiers covers outputs from 6 to 90 kg/h. It is supplied ready for connection in a cabinet housing of compact design, with manifolds or seperate fan units. The DB humidifier uses the electrode heating principle and incorporates an integral electronic control system.
These models are available with two electronic control systems, EM and MP.

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Forbes Marshall Liquid Drain Trap
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The Forbes Marshall Liquid Drain Trap is a condensate drain trap ideal for removing condensate from pressurized gas and compressed air systems. The trap body is pressure balanced with the system of the main media through the balancing connection on top of the trap body. This ensures the media (Compressed air or gas) is locked in the trap body.

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Forbes Marshall Air Eliminator
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Forbes Marshall Air Eliminators are ideal for air removal from liquid lines. Presence of air and other non-condensible gases in liquid lines can result in a number of problems. Removal of such gases from the system is hence essential.

Forbes Marshall Air Eliminators are robust and efficient and offer a cost effective solution for removal of non-condensible gases.

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Gas Boilers

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1000 of our three-pass wetback boilers are generating steam in plant all over India, the Gulf, Africa and South East Asia. These boilers provide the driest steam possible from the least amount of fuel & floor space. The true three pass fully wetback design ensures low flue exit temperatures resulting in high thermal efficiency.

Our boilers are designed for easy maintenance and inspection. Hinge – mounted front doors and rear lift-off doors give you clear and instant access. Every Marshall B Boiler is manufactured with the latest submerged arc fabrication technology to ISO 9001, IBR standards. Every boiler is a complete packaged unit.

Knowledge Products Services

Study of plant steam system
Energy Audit of plant
Detailed Engineering Consultancy
Selecting optimally sized boiler capacity
Boiler efficiency enhancing packages
Project Management
Steam System Management
O&M Services for Boiler
AMC for Boiler
Customer Training Programmes

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Sight Glasses

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The Spirax Sarco Hosedown Station is designed for use on any hot or cold water wash down and cleaning hose application. The Spirax Sarco Steam/Water Mixing Station is designed to provide instantaneous hot water economically by blending steam and cold water to the required user temperature through simple rotation of the handwheel. The mixing valve has fail safe operation. If the cold water supply stops, the steam supply is automatically turned off preventing live steam reaching the hose.
Each Steam/Water Mixing Station is supplied with isolation valves, check valves, union joints, strainers and thermometer. 1/2 inch and 3/4 inch stations can be supplied with an optional high quality hose, hose rack and gun for hosedown purposes. High capacity 1 inch and 1 1/2 inch stations are intended for fixed installation such as periodic filling of tanks. The Hosedown station has a spray gun with automatic shut off which can save upto 60% of your hose water cost and is built to give years of reliable service.

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Forbes Marshall is involved in building solutions to engineering problems concerning Steam Engineering and Control Instrumentation for more than 50 years. It provides comprehensive training programmes on maintenance & servicing of our Boilers .
Our endeavour is to take it beyond product purchase, and strengthen it further by offering to train your instrument technicians and supervisors on how to use our products/systems installed in your site effectively. The intention is to derive maximum benefit by reducing your down-time, and independently carry out maintenance/servicing without any external assistance.
This programme can be clubbed with

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Forbes Marshall Clean Steam Pressure Reducing Valve is an angle pattern, self-draining, sanitary pressure regulating valve. Its all steel construction makes it suitable for clean steam applications involving steam, water and gases. This valve has been designed in accordance with ASME BPE guidelines.

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Burner
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Burner

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Q Series of burners are the result of Forbes Marshall’s in house R&D and meet stringent demands of safety, reliability and flow maintenance cost. They are designed to fire liquid and gaseous fuels, the most common being furnace oil, light oil, natural gas and LPG. In heat throughput terms, the burners vary from 200 KW to 12000 KW.
For 1-4.5 TPH capacities, the burners are monobloc construction, with mechanical compound regulation as a standard.
For 5 – 9 TPH capacities, the burners are in monobloc construction with electronic compound regulation or mechanical compound regulation.
* For capacities up to 9 TPH, the combustion air fan is integral with the monobloc burner. For capacities from 10 TPH to 16 TPH, the burner construction is dual bloc with separate combustion air fan.

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Monitoring Control System
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The cost of buying a new boiler is small compared to the amount of money spent in operating the boiler year on year. This is a known fact and also known is that this expense is governed by boiler efficiency. Although "Boiler Efficiency" is an important parameter in the boiler specification when buying a new boiler, little attention is given to it once the boiler is steaming. The myth is that the boiler will always continue to generate steam at the rated efficiency. The truth is that one of the most critical parameters in boiler operation is its delivered efficiency in actual operation. We say boiler efficiency is the most critical parameter of boiler operation because every boiler generates steam ( its primary function and we have not yet come across a boiler that does not generate steam). What distinguishes one boiler from another is actually at what cost steam is generated.

Our surveys plant after plant after plant show the true delivered boiler efficiency to be lower by 3% to 12% than rated. And yes, all these plants thought they are getting the rated efficiency, or may be just slightly lower. Usually ignored, the boiler continues running at lower efficiency and consuming much more fuel than it actually should. Data collected from a hundred different boilers show boilers operating at very low efficiencies. This definitely would not been the case had people not thought their boiler were operating efficiently. It is expensive to turn a blind eye to boiler efficiency !

No matter how noble the boiler manager's intentions of reducing fuel consumption are, without useful data, that's what they will remain - Intentions. The reason of EffiMax series of online boiler efficiency analyzers is to provide critical data for analyzing these sources of fuel consumption.

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Forbes Marshall Consultancy Services
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Forbes Marshall Consultancy
Forbes Marshall provides solutions in Energy, Efficiency and Process Automation, with Six decades of utility performance and steam generation solutions. Our seven business divisions encompass the entire spectrum of energy generation, energy efficiency, process automation and energy conservation. We also offer utility consultancy services to form a properly designed system thus helping you optimize operational costs.Good Engineering Practices:
• Process equipment receives utilities in the right quantity and of right quality.
• Pressure drop and utility starvation is avoided.
• Energy conservation to save on input costs of utilities.
• Proper equipment layout facilitating maintenance-friendly operation and reduced downtime.
• Piping layouts ensuring optimum specific utility consumption norms for process.
• Reduced project and running cost.Utility Generation:
Steam is required at various pressures and quantities depending on the process needs at each moment - the load on the boiler is never constant. During heating cycle, machines require instantaneous supply of large amounts of steam in order to achieve correct process temperatures in the stipulated time. Hence selection of boiler capacity & generation pressure becomes very critical to ensure good efficiency and lower fuel bills. This is also true for other utilities like soft water, cooling water and compressed air.Utility Distribution:
Equipment requires utilities at correct flow rates, velocities and pressures to give desired process output.The heating & cooling cycles of the process need to be examined. Constantly varying steam-demand requires careful pipe sizing to accommodate peak loads & ensure minimum pressure drops in distribution. Therefore sizing of utility piping network is crucial for smooth and energy efficient plant operation.

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Feedwater Tank Systems
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Feedwater Tank Systems

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The FeedWater Tank System supplied by Spirax Marshall for complete Boiler Feed Water Management comprises of :
MS or Stainless steel feedtank
Flash condensing deaerator head
Steam injection and Temperature Control System
Make-up water and Condensate Flow Meter on water lines to Deaerator Head.Feedtank Level Control System
Vent Head
Recirculating Pump

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Blowdown Heat Recovery Units
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BHRS comes as a skid mounted package
Steam boilers need to be blown down to control the level of total dissolved solids (TDS) in the boiler water. This is best achieved by using a TDS control system which will open a valve to allow boiler water to discharge when the TDS level rises above a pre-set limit. Relatively low TDS feedwater then replaces the discharged boiler water.
Upto 80% of the heat in this discharged boiler water can be recovered with a properly designed heat recovery system.

How the system works :
Flash steam is released from the hot blowdown water when the pressure drops after the TDS blowdown control valve. This mixture of flash steam and blowdown water is allowed to separate in the flash vessel. The design of the vessel ensures that flow velocities are low to promote good separation. The dry flash steam is then introduced, at low pressure, into the feedwater storage tank through the steam distributor or the flash condensing deaerator head. A float trap fitted to the outlet of the flash vessel drains the residual blowdown water.
From the float trap, the residual blowdown water which is still hot at this point, is allowed to pass into the heat exchanger where it gives up its heat to the circulating cold make-up water. The cooled blowdown water then flows safely to drain. To conserve energy, the circulating pump is activated by a thermostat mounted on the blowdown water inlet to the heat exchanger. It will therefore only run when blowdown water is flowing.Blowdown Flash Vessel is a specially designed vessel for handling blowdown water at required pressure and temperature. The design ensures easy separation of flash steam at low velocities. It has accessories such as Safety Valves, Pressure Gauges, Disc Check Type NRV at Flash Steam Outlet and Ball Float Trap at the outlet of blowdown water. Ball Float Trap ensures that no flash steam goes to the heat exchanger and maintains the pressure balance. All components are properly sized depending on the blowdown parameters. Blowdown flash vessel is manufactured to specifications of Indian Boiler's Regulation (IBR) Act with IBR certification.

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Deaerator Head-Flash Vessel
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Fitted on your feedtank, the Spirax Deaerator Head mixes cold make-up water, hot condensate, and flash steam in a single stainless steel (SS) head to get the most out of your captured heat.Cold make-up water atomizes in the mixing head releasing 90% of dissolved oxygen, a primary source of downstream corrosion. The single head design eliminates the need for cumbersome sparge pipes.Spirax Steam Injectors are available in three sizes to cover most of direct steam injection requirements. They ensure quiet but vigorous mixing of steam and feedwater to drive off the dissolved oxygen content down to approximately 2 ppm. This action minimises the amount of oxygen scavenging chemicals required. The temperature of the feedwater is maintained at a high steady level for smooth boiler operation.
Spirax Sarco steam injectors use steam to raise the temperature of water or other liquids. The injector draws in cold liquid, mixes it with steam inside the injector and distributes the heated liquid in the tank. In many applications the circulation induced by the injector is an advantage ensuring thorough mixing and avoiding temperature stratification.
Boiler feed tank applications:Dissolved oxygen must be removed from boiler feed water if corrosion is to be prevented in the boiler. Oxygen can be removed either by chemicals or by heating. The dissolved oxygen content of water at 20°C is 9 ppm, at 60°C is 5 ppm and at 90°C is just under 2 ppm.
Typical injector systems -examples;A typical electro pneumatic system and a selfacting control system are shown below. Selfacting controls offer an economical solution for boiler feed tank applications.By heating the boiler feed water to typically 85 - 90°C to remove most of the oxygen, and introducing an oxygen scavenging chemical into the boiler feed line to remove the small quantity of remaining oxygen, chemical usage can be minimised. Additionally, boiler efficiency may be increased since blowdown requirements may be lowered.
Fitting;The injectors can be fitted to the steam supply pipe work or installed directly onto the tank wall using a female threaded connection. For very large installations, multiple injectors may be
used. Pneumatic or electric systems can offer close temperature control for process applications. Pipe work can be routed inside or outside the tanks. Your local sales engineer will be pleased to advise on the most suitable system for your plant requirements.

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Medium And High Pressure Blowdown Systems
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Automatic Blowdown Control System (ABCO) Range
If the level of total dissolved solids (TDS) in your boiler gets higher than desired limit, you could be facing serious scaling on your boiler tubes and downstream equipments, foaming inside the boiler and water carry over along with the steam. So you periodically blowdown your boiler to keep it safe. The problem is, you are not only blowing down more than just high TDS water but you are blowing down money . With manual blowdown methods, you have no way of knowing your boiler's current TDS levels or optimal blowdown amount, so you don't know when to blow down or for how long.
With our Spirax Automatic Blowdown Control System (ABCO) your boiler is blown down only when, and for as long as required thus protecting your boiler and money from being blown down the drain.Why Blowdown?
As steam is generated, the TDS level of your boiler water starts to increase. At levels above the manufacturer’s specified maximum TDS range, scale deposits begin to form on your boiler drum & tubes. The high TDS water begins to foam which, when carried over by steam, leads to corrosion and deposits on heat transfer surfaces. This affects the heat transfer efficiency resulting in higher steam demand, and increased fuel bills. To protect your boiler and downstream systems, high TDS water must be blown down and replaced with lower TDS feedwater before it reaches danger levels. Manual blowdown never lets you maintain these levels because of the risk of crossing them. Only the Spirax ABCO can guarantee protection for your boiler by ensuring that the set level is never exceeded.

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Inverted Bucket Trap
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Inverted Bucket Trap

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Inverted Bucket Traps have been popular although in every application, superior results can obtained with float type of steam trap. They consume a small amount of steam during operation but can blow fully open if they lose their prime, due to over sizing or a rapid drop in inlet pressure. Their discharge is intermittent.OPERATION :
The trap body is normally filled up with condensate to maintain a seal water around the inverted bucket. Live steam enter the bucket, floats it, to close the valve. Steam leaks through a small hole in the top of bucket, and opens the valve to discharge condensate. Some inverted bucket traps are fitted with an auxiliary bimetal air vent.Spirax Sarco' SIB 45 Sealed IBST
The SIB 45 is an all stainless steel sealed inverted bucket steam trap provided with pressure change assemblies for pressure differentials between 0.5 and 45 bar. Traps for 45 bar are provided with an inbuilt check valve as standard.
For more information, download a Technical Information Sheet from the Technical Document Tab at the bottom of the page.

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Filters-Vrs Control Panel
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The model VRS Control Panel provides a fully automatic filtration system to operate all functions of the motorized rotary filter product line eliminating manual labour and possible human error. Rotor (cleaning function) and purge (blowdown function) is controlled by timer operation.

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Diffuser
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Diffuser

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The Spirax Diffuser is a compact unit designed to be fitted to the outlet of a steam or air trap discharging to atmosphere. The Diffuser reduces the problems of noise and erosion by dampening high velocity discharge. It can be fitted to any trap where conditions promote blast discharge similar to that associated with balanced pressure, inverted bucket or thermodynamic traps.
More than 80% reduction in the sound pressure level can be expected when measured at 1 meter from the discharge point.

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Vacuum Breaker
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Vacuum Breaker

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The VB 14 is a small purpose designed vacuum breaker for general purpose applications on condensing vapour(steam) or liquid systems.For more information, download a Technical Information Sheet from the Technical Documents Tab at the bottom of the page.

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Automatic Pumping Trap
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Automatic Pumping Trap

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Spirax Marshall brings to you the Automatic Pumping Trap - the world's smallest condensate drainage system that works under all the load conditions, even vacuum. It's compact design makes it convenient to install within 200 mm of the installation head. The Automatic Pumping Trap is fully mechanical with no requirement for electrical power, pnuematic supply, motors or level switches.What do you mean by Stall ?Stall is the reduction or the cessation of condensate flow from the steam space, and occurs when the pressure in the steam space is equal to, or less than, the total backpressure imposed on the steam trap.

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Utility Automation Module
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The general trend which is found in the bulk drug/API plants is that the condensate is drained due to the fear of Contamination. This contamination occurs as a result of usage of various utilities like Brine, Chilled Water, cooling water, and steam in the same jacket and if sent to the boiler feed water might scale its tubes.The actual fact is that all the condensate in the reactor jacket does not get contaminated and it’s only a part of it. The cooling utilities left in the jacket gets mixed up with the incoming steam and as a result a part of the condensate gets contaminated.
But due to the lack of a system available to actually recover the condensate the easy option is to drain it.
The draining of this useful condensate which is non contaminated leads to the wastage of precious energy which can be easily recovered by recovering condensate.


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Balanced Pressure Thermostatic Trap
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Balanced Pressure Thermostatic Traps have a blast discharge with high air venting capacity. Their valve & seat are wide open when cold.Operation:
The trap is operated by a thermostatic fluid filled capsule. When steam is turned on, air discharges through the open valve orifice. Cold condensates enter & passes out. At a temperature t below the saturated steam temperature corresponding to the pressure at the trap, the mixture boils & exerts a vapour pressure. While the outside of the capsule is at steam pressure, the inside, because of the temperature head, is at a pressure higher by p . This excess pressure p closes the valve on its seat before steam temperature is reached. Condensate help in the trap, cools by t below steam temperature, until the vapour pressure in the capsule is below the steam pressure. The capsule contracts & the valve opens.
Since the curves of the fluid inside the capsule & water are parallel, it does not matter what the steam pressure is in the trap. At any pressure p there will be an unbalanced force p holding the valve shut, after a temperature t below saturated steam temperature is reached.
If superheat is present an internal pressure higher than p, is taken up by the flexible diaphragms in the capsule.Balanced Pressure Thermostatic Trap (BPT 21/AV 21)
The BPT 21/AV 21 is a Thermostatic Steam Trap/Air Vent fitted with an inbuilt flat strainer screen having 0.8 mm diameter perforations. These traps are mainly used on Steam Tracing application. When installed at the end of steam line or process equipment, BPT traps functions as steam trap and when installed on steam line header, it acts as air vent.Thermostatic Instrument Tracer Steam Trap MST 21
The MST 21 steam trap is a maintainable balanced pressure trap designed for small condensate loads usually associated with instrument tracing applications. Manufactured in stainless steel it is corrosion resistant and is easily maintainable.Spirax Sarco' Bimetallic Steam Trap SM 45
The SM 45 is a medium pressure, temperature sensitive, maintainable steam trap. The operating element comprises a stack of bimetal discs which control the flow of condensate at a preset temperature below steam saturation.

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Wireless Steam Trapping
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Wireless Steam Trapping

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Problem: Process industry uses steam for heating. Steam condenses on heating the product; traps are used to remove this condensate.
A leaky Steam Trap - results into Steam Loss
A water-logged Steam Trap - results in Process downtime and / or Product/Batch rejectionRecognized as “Innovative Energy Saving Product at CII 10th National Award for Excellence in year 2009."Wireless Trap Monitoring System is a network for monitoring the health of steam traps at dispersed locations in a plant. It is a wireless network of steam traps used to:
Provide alarm when there is a Steam Leak in Steam Trap
Provide alarm when trap is Water Logged and it is not ejecting the condensate
Monitor the condensate temperature online to check the health status of the trap
Monitor and report overall plant status, steam loss, monetary loss, deviation from the benchmarks, etc. via a centralized web based Graphical Interface
Analyse online data on the backend to intelligently generate the reports that enable the user to take decisions on existing plant conditionThis system is based on the principles of Wireless Sensor networks which involve Sensors, Routers and Coordinators. This forms a cluster tree network of devices where sensor is child and router or coordinator is Parent.Sensor measures the Steam temperature and Conductivity and decides the trap fault based on Algorithm built in the sensor electronics. The temperature signal and alarm sent by the radio signal of 2.4 GHz (ISM band) which is a free band available all over the world. User can also set the desired channel (11 to 26) to nullify the interference with other devices if any.This signal received by routers (Parent) and sent to the coordinator either by single or multiple hops.
The coordinator is connected to the server machine which does the further processing on the signal and updates the web pages, generates the health reports which can be sent directly to the plant engineers and managers by email.

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Temperature Control
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Temperature Control

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Many types of steam plants need to be fitted with some form of temperature control. In any process, product quality is often dependent upon accurate temperature control, while heating systems need to be thermostatically controlled in order to maintain optimum comfort conditions. From an energy saving point of view, the ideal temperature is obviously the lowest, which can be accepted for any given application. Spirax self-actuated temperature controllers TR121 control the temperature of the process within an accuracy of +/- 2deg C by controlling the flow of steam.37 D Temperature Control
The 37 D is a self operated temperature control for use on steam. By virtue of its pilot operation, it has a comparatively small control brand.
For more information, download a Technical Information Sheet from the sidebar on the right.TR-121 Temperature Controller
The self actuating temperature controller TR-121 offers cost effective temperature control for steam and water.
Available Sizes and Pipe Connections are :
TR-121 with 15, 20 & 25 NB 'SB' valve
40 & 50 NB 'NS' valve.
For more information, download a Technical Information Sheet from the sidebar on the right.

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Compact On-Off Valve
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Compact On-Off Valve

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Spirax On-Off temperature control system comprises PT-100 based RTD, On-Off temperature controller and Piston Actuated Valve (PAV).

  • Accuracy depends on the band set on the controller. Factory pre-set is ± 2 degree C.
  • Finer accuracy can be set for systems having high thermal inertia and vice-versa.
  • PT-100 based RTD designed for the most rugged applications.
  • On-off controller with modular plug-in PCB construction easy for maintenance.
  • Spirax PAV is a robust, compact valve having SS316L body, tight shut off is guaranteed by using a PTFE plug seal, valve stem sealing is provided by self aligning PTFE chevrons for maximum sealing integrity.

 

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Pid Based Tempeartuer Control System
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The system comprises:

  • PT 100 based Resistance Temperature Detector
  • Forbes Marshall 'D'tron series PID controller
  • Spiratrol control valve with 830 WP - Forbes Marshall Electro pneumatic positioner.The SPIRA-TROL has been developed using the very latest in computational Fluid Dynamics and rapid prototyping techniques to provide a modern valve for today’s demanding industries.

    The control valve has a modular design concept and incorporates many options within one body envelope.Both ANSI and EN versions share the same internals and only two pneumatic actuators are required for valves up to DN50, 2" in size.This leads to a low number of components and a highly flexible system, where one valve can satisfy the needs of numerous industrial requirements. The outcome for the user is a general service control valve with exceptionally low cost of ownership.

 

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Steam Pressure Reducing
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Steam Pressure Reducing

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The Spirax pressure reducing station is an engineered and factory assembled unit. It is designed in line with good steam engineering practices using our proprietary software. Spirax Marshall manufactures all the components of the pressure reducing station in-house, which enables quality control for each component to Spirax standards. Every component is tested on live steam & the entire assembly is hydro tested.Steam should be available to the process in the right quantity, should be of the right quality and should be at the right pressure and temperature.The reducing valve should be selected to ensure that the right quantity of steam, at the right pressure, is available to the process consistently. The turndown is an important parameter to be selected. Spirax with its wide range of pressure reducing valves is fully equipped to select the right valve for your needs.Clean dry steam is necessary for achieving maximum process efficiency with minimum wastage of steam. The Spirax baffle design moisture separator is designed for high separation efficiency. Clean and dry steam also prevents pitting and erosion of the valve trim and seat.

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Accuflo Steam Metering
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Accuflo Steam Metering

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Measure every unit of steam, generated or distributed. After generation, the steam is distributed to various sections from the main steam pipe/header. But it is necessary to know the exact steam consumption in the individual departments within the production plant or in the individual production lines. Any indicated increase in steam consumption above the accepted norm for a given production rate will indicate some inefficiency developing in that section of steam using production plant, which can be investigated for corrective actions. The other perhaps obvious reason for the monitoring of steam consumption is the ability to operate accurate cost accounting for a specific product line. The steam flow meter Accuflo is a perfect tool for providing exact information about the steam consumption and steam quality.AccuFlo Steam Flowmeter
AccuFlo is a steam metering system, complete with the Vortex Steam Flowmeter, Local Flow Indicator, the required straight lengths with flanges, flow straightners, foolproof gaskets, steam conditioning equipment(optional).The purpose of plant metering is served only when the available data is collated for effective analysis. The user interface for plant metering is our data analysis software "Accusoft" . Accusoft helps the user in historical data logging and trending, generating management reports, charts/graphs, log of daily, weekly, monthly generation/consumption reports, specific steam consumption, energy billing reports, alarms for budget exceed, percent deviation from set benchmarks etc.

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Packaged Plant Room System
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Packaged Plant Room System (Instantaneous Hotwater Generation System)
The Spirax Packaged Plant Room System provides instantaneous temperature controlled hot water using steam as the heating medium.

Description of the picture:
1. Plate heat exchanger for efficient heating complete with demountable plates for easy cleaning.
2. Safety Valve to protect the heat exchanger.
3. Pressure Reducing Valve to maintain correct pressure on to heat exchanger.
4. 2-port control valve with correct valve characteristics for the application.
5. independent high limit control to provide overheat protection.
6. receiver to allow collection of condensate.
7. Pump Trap combination to remove condensate under all load conditions.
8. Controller for accurately maintaining desired water temperature.

User benefits:
· Correctly installed controls give accurate temperature control & instantaneous heating.
· Effective design provides efficiently heated hot water in a compact package.
· Effective condensate removal under all load conditions increases the efficiency and life of the system.
· Reduced installation costs and downtime as the equipment is preassembled and mounted in a frame.
· Has inbuilt condensate pumping system

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Waste Heat Recovery System
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Nowadays Textile wet processing operations are coming under increased scrutiny from environmental regulators because of the complex wastewaters and air emissions they generate.
Wastewater temperature is major form of pollution. In dyeing processes, so much hot water is discharged that, in the absence of any counter-measures, total wastewater temperatures may exceed 40°C, even though 35°C is the maximum permissible temperature. This new regulatory effort comes at a time when textile companies are already faced with the need to reduce costs to respond to increasing competition.As Textile industry, which consumes energy in the form of heat. With the increasing scarcity of natural resources and spiraling costs of energy, energy conservation today is an absolute necessity to sustain any business , for that new technologies are required to recover some percentage of loss of energy. Spirax Marshall offers an opportunity for textile companies to reduce heat releases and save money; at the same time, it helps you become more efficient.

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Pressure Powered Pump
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Pressure Powered Pump

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Flash steam can be effectively recovered by using a Condensate Flash Vessel as a part of a Flash Steam Recovery System. The flash steam is free steam and can be used to supplement the normal steam requirement. Flash steam should be separated from the condensate to maximise the system's efficiency. Since the flash steam is utilised, it will not be vented to the atmosphere where it is wasted and can be a safety hazard.Pressure Powered PumpHot condensate still contains 20% of the energy you used to make steam in the first place. And since condensate is distilled water, it makes perfect boiler feedwater. Our positive displacement pressure Powered Pump is the heart of a money and energy saving Condensate Return System.The PPPU pumps condensate at 100 oC without electricity, using just a small blast of steam or air pressure, even under vacuum and stall conditions. Due to its sealed & gland-less design, the collected condensate can be pumped immediately, without waiting for it to cool, and with no risk of cavitationPressure Powered Pumping Packaged Unit is a positive displacement pump unit operated by steam, compressed air or pressurized gas. The unit is specifically designed to pump hot liquids of specific gravity 1.0 down to 0.9. Condensate Recovery (CRM) is also an integral part of the PPPPU. It is an effective management tool which not only shows the condensate quantity & condensate temperature, but also shows the energy saved through condensate return.

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Thermocompressors
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Thermocompressors

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Thermocompressors are used in wide range of processes to save energy. They compress low pressure steam to usable pressure levels and thereby reclaim the heat energy in the low pressure steam, which otherwise would have been wasted.
Spirax Thermocompressors are backed by reliable design which has been validated on a comprehensive, well instrumented test rig, a feature which very few manufacturers can offer. Our Thermocompressors are custom built to suit your specific needs and can therefore effectively contribute to your energy conservation plans.

Note: The Thermocompressor is the heart of the Thermocompressor System and is sold as a complete TC system.

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Condensate Contamination Detection Systems
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Why use CCDS ? Most of the times it is observed that condensate contains acidic or alkaline impurities. This is mostly because of leakage in condensate lines. But not always and not all the processes are acidic and alkaline and condensate is then not contaminated. This condensate can then be recovered and impure condensate can be drained out by using suitable system.The CCD system monitors the conductivity of condensate being returned to the boiler and diverts contaminated condensate to drain.

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Steam Engineering Programme Service
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The 5 day workshop is specially designed, combining hands-on time on our unique simulation rigs to help you evolve Energy Conservation Measure / Plans for your plant.Inplant Training on Steam Engineering Principles & Energy Conservation Potential in Steam Usage
It is now fairly regular for the Center to move over with faculty to the actual user where more engineers are trained in shorter modules on different aspects of Steam Generation and Utilization.
Correspondence Course
A Steam Engineering Correspondence course where you can learn the essence of Steam Engineering from your desk and at anytime as per your convenience.

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Products Operation & Maintenance Programme Service
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Forbes Marshall is involved in building solutions to engineering problems concerning Steam Engineering and Control Instrumentation for more than 50 years. It provides comprehensive training programmes on maintenance & servicing of our Spirax Products .
Our endeavour is to take it beyond product purchase, and strengthen it further by offering to train your instrument technicians and supervisors on how to use our products / systems installed in your site effectively. The intention is to derive maximum benefit by reducing your down-time, and independently carry out maintenance/servicing without any external assistance.
The programme is specially designed and combines hands-on time on our unique simulation rigs with relevant theoretical input.
This programme can be clubbed with

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Air Eliminators Filters

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AE 30 and AE 30H
The 'Spirax Sarco' AE 30 and AE 30H automatic air vents are designed for use on hot and cold water installations and are manufactured using materials which meet the requirements of the National Water Council. The body and cap are of a special brass alloy which is resistant to dezincification.
Versions are available with a check valve fitted in the discharge orifice and are designated AE 30 CV and AE 30H CVFor more information, download a Technical Information Sheet from the Technical Documents Tab at the bottom of the page.AE 20 and AE 20S
The AE 20 and AE 20S are float type automatic air and gas vents for liquid systems.The body and cover are of steel and the valve head is available in synthetic rubber designated AE 20 or in stainless steel designated AE 20S.For more information, download a Technical Information Sheet from the Technical Documents Tab at the bottom of the page.AE 10
The Spirax AE 10 is an automatic air eliminator suitable for application on liquid lines.

For more information, download a Technical Information Sheet from the Technical Documents Tab at the bottom of the page.

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