HeatMax is Instantaneous Hot Water System, provided by Forbes Marshall.

1. HEATMAX System
-by-
Akash Gaware
Ankur Gaikwad
CII-FMTraining on Steam Engineering

2. Presentation Agenda
• HEATMAX – General Product Information
• Advantages
• List of Components
• HEATMAX Piping Diagram
• Working Principle
• Control System-I
• Control System-II
• Testing
• Six Sigma Sheet
• Cost Savings
• Customers
• Conclusion

3. HEATMAX - General Product Information
• Instantaneous HotWater System
• HotWater from Low-Pressure
Steam
• Compact Assembly
• In-builtTemperature-Control and
Overheat Protection systems

4. HEATMAX - Advantages
• AccurateTemperature-Control guarantees Low Steam Consumption
• Reduction in Boiler Fuel Consumption
• Easy Operation & Maintenance
• Low Running Costs – Electricity Costs

5. List Of Components
• PistonValves (PSVAL)
• Forbes Marshall Strainers (FMSTR)
• Forbes Marshall Piston-ActuatedValves (FMPAV)
• TemperatureControlValve (TCV)
• Forbes Marshall Safety ReliefValves (FMSRV)
• Plate Heat Exchanger (PHE)
• PT100Temperature Sensor
• Steam Operated PumpTrap (SOPT)
• Forbes Marshall Disc CheckValves (FMDCV)
• Forbes MarshallThermodynamicTrap (FMTD)
• Forbes MarshallAirVent (FMAV)
• Pressure Gauge
• Control Panel with PID Controller

6. HEATMAX Piping Diagram

7. HEATMAXWorking Principle
• Water Heating Circuit
• Steam Pressure controlled byTCV
• Low-pressure Steam heats water in PHE
• Resulting Condensate is discharged through SOPT
• Condensate Pumping Circuit
• Stalling forces use of SOPT
• Live steam tapping for SOPT pumping operation
• SOPT pumps the condensate continuously as formed

8. HEATMAX Control System-I
• PrimaryTemperature Control Loop
• Use: Pneumatically-actuated Steam Flow ControlValve modulates steam flow to PHE using
PT-100Temperature Sensor & PID Controller
• Control Loop Components:
• TemperatureControlValve with Electro-pneumatic Positioner having in-built I/PConverter
• PID Controller
• PT-100Temperature Sensor
• Control Loop Operation: PT-100 => PID Controller => I/P Convertor =>Valve Actuator =>
Flow is controlled

9. HEATMAX Control System-II
• Overheat Protection Loop
• Use: Loop active when primary temperature control valve loop fails and PHE water outlet
temperature exceeds ‘set temperature’. Completely stops steam supply to PHE.
• Control Loop Components:
• SolenoidValve fitted on FMPAV /Air Supply Line toTCV (TemperatureControlValve) beforeAFR
(Air Filter Regulator)
• ON-OFFController
• PT-100Temperature Sensor
• Control Loop Operation: PT-100 => On/Off Controller gives relay output => SolenoidValve
=> Stops air supply to FMPAV (NC) or starts air supply to FMPAV (NO)

10. HEATMAX -Testing
• Overheat Protection Loop tested at SSD Fabrication Shop
• TCV Lifting Characteristics tested at SSD Assembly Shop
• Other components tested at individual fabrication locations

11. HEATMAX - Six Sigma Sheet
• Each HEATMAX System has its own Six Sigma Sheet
• Verification of the following in Six Sigma Sheet
• Raw Material Dimensions
• Welding Quality
• Bought-out Parts
• Testing Parameters
• Surface Preparation, Painting
• Final Inspection, FunctionalTesting

12. Cost Savings due to HEATMAX
• Electricity saved in Condensate-pumping &Water-heating
• Steam used for heating water
• Steam used for pumping condensate

13. HEATMAX – Customers
• Centech Engineers Pvt Ltd
• Rutam Engineering
• Dhanuka Laboratories
• Kores India
• Glenmark Pharmaceuticals
• UPL Ltd
• Alembic Pharmaceuticals
• Cadila Healthcare
• Unison Pharmaceuticals
• Lupin Ltd
• Scott-Edil Advanced Research
• Dr. Reddy’s Laboratories
• Apotex Research

14. Conclusion
• HEATMAX System used where
• Hot water is required
• Low pressure steam is readily available
• HEATMAX System:The compact solution for instantaneous water heating,
with built-in temperature control & overheat protection
• HEATMAX lowers fuel and electricity cost, while needing low maintenance
• Majority of customers of pharmaceutical & agro-chemical industries

15. ANY QUESTIONS?

16. THANKYOU