KTDA Tea Factories

Thermal Manual®

2019
 Presentation Outline

1. Introduction
2. Firewood Management
3. Boilers and Steam Systems
4. Production Floor Machinery Operations &
Maintenance
5. Health and Safety
 Target Group
o Plant Technicians
o Mechanics and
o Boiler Operators
 MOD 1: INTRODUCTION
Why Energy Efficiency
1. High cost of energy and production: 25% cost of
producing black CTC teas.
2. Shortage of wood fuel: Logging ban by Govt of Kenya
3. Environmental protection: Reduce greenhouse gases
and mitigate global warming
4. Legal requirement: Energy Management Regulations
2012
Key Figures for KTDA managed factories
• Entire KTDA (69 factories) annual firewood
consumption is 900,000 m3 (1,575,000,000.00 kWh)
while electricity is 150,000,000 kWh.
• Cost of electricity -KSh18 /kWh while cost of
firewood is Kshs 2000/m3
• Annual energy bill about KSh. 4.5 billion, firewood is
KSh1.8 billion whereas electricity is KSh 2.7 billion
• 600,000 farmers (families)
• 10,000 direct jobs
 Energy End Use and Cost

• 1 kWh of energy = 3.6MJ ( whether thermal or electrical)

• Electricity costlier than firewood
• 1 kWh of electricity=KSh 18 while 1 kWh of firewood= KSh 1.14
 Role of Plant Technicians
▪Maintenance of machinery to sustain
efficiency
▪Support operations to improve energy
efficiency
▪Training and awareness creation: As
members of the energy committee.
▪Ensure safe working environment
 Sources of Thermal Energy

Wood logs
Furnace Oil
Tree stamps

Macadamia Solar Water heaters

nut shells Briquettes
 Sources of Electricity
1. Kenya Power- Grid electricity

2. KTDA Power – 50% of factories to be connected

3. Diesel Generators: backup electricity

 Where is energy used in factories
1. Steam : 60-70% drying, 30-40% withering

2. Electricity
 MOD 2: Wood fuel Management
• A 3 line factory [15 million Kg.GL/year; 23% OT;
300kgMT/m3] uses 11,500m3/year of firewood
Made Tea = (23×15,000000)/100
= 3,450,000 Kg.MT/year
FUI= 300 Kg.MT/m3 therefore
Firewood Consumed= 3,450,000
Kg.MT/(300Kg.MT/m3)
=11,500 m3/year
Similar case FUI of 250 Kg.MT/m3,
firewood consumption will be ??
=13,800 m3/year
Firewood Cost difference= (13800- One mature tree produces 1.0 m3 of
11500)m3×2000 Kshs/m3 quality firewood. Therefore one
= Kshs 460,000 factory consumes 11,500 trees/year.
 Wood fuel management
❖Factories have established wood fuel plantations but will not meet
the entire demand – 20,000 acres
❖The best age for harvesting wood is from 8 years and above : Why 8
years? Discuss with Trainees
❖An acre has about 700 trees. For a factory consuming 70m3 per day it
will require 3 acres/month and 36 acres/year.
 Moisture Content vs. Calorific Value
MC(%) CV
0 18
10 16
20 14
30 12
40 10
50 8

The higher the MC the lower the CV; more firewood

consumption
 Firewood Seasoning-Sheds
➢ Reduce M.C. through seasoning and keeping out rain
1. Heavy gauge anti-
UV polythene
❖More heat penetration
❖Easy and faster to
replace if damaged
❖Good air circulation
❖Cheaper than iron sheet

Consider heavy gauge polythene

shed when expanding capacity.
Firewood Sheds
2. Iron sheets +
translucent sheets
Common shades in many
factories
❖Less heat penetration
(reflective property of iron
sheets)
❖Time involving to repair if
damaged
❖Instances of air condensation
due to poor air circulation
❖Costlier than polythene sheet
Firewood Sheds
3.Translucent
sheets
Less common in KTDA
factories
❖More heat penetration as
compared to Iron sheets
❖Needs regular cleaning to
remove dirt and improve
transparency
❖Costly to set up;
compared to polythene.
Firewood Stacking
Best Practices In Firewood Management
 Bad Practices In Firewood Management
• Not draining firewood sheds
• Leaving dry wood in the rain
• Feeding wet wood to boiler
• Billeting thin logs – unnecessary saw dust, waste of labour and power
 Wood Measurement
You
can’t manage
what isn’t
measured.
If you don’t
measure, you
can't improve it

Correct (More •Dense) Wrong (Less dense)

Density: 493kg/m3 Density: 394kg/m3
Calorific: 14MJ/Kg Calorific: 14MJ/Kg
At 20% MC At 20% MC
Energy: 6902MJ Energy: 5516MJ

Use firewood with the highest density for more C.V (Energy)
 Environmental Impact

❖The combustion efficiency while

burning wood for the production
of heat energy is crucial to avoid
emission of Carbon Monoxide and
un-burnt particulates to the
atmosphere.
C + O=CO ❖ The air pollution caused by
discharging this kind of flue gases
𝐶𝑎𝑟𝑏𝑜𝑛 𝑚𝑜𝑛𝑜𝑥𝑖𝑑𝑒 causes asthma & related diseases.
❖Trees harvesting leads to soil
erosion
❖Deforestation by tree harvesting
impacts on climate
 Green House Gas (GHG) Emissions

➢ GHG emission contributes to

global warming
➢ CO2eq considers total emission
from all green house gases
➢ Green house gases include CO2,
CH4, NOX, CFC.
➢ Coal emits more GHG than oil.
➢ Biomass (firewood) GHG emission
lower than oil.
➢ Hydroelectric & wind emit the
least (clean energy)
➢ KTDA commits to reduction of
carbon footprint – environmental
protection by:
1. Reducing electricity use &
2. Reducing diesel, FO and biomass
(thermal energy) in the production
process
3. Generating energy from clean energy
sources e.g. hydro, solar
 MOD 3 : Boilers and Steam System
Classification of Steam Boilers

• Stationary boilers (power plant, industrial, centralized heating,

combined heat and power (CHP) or portable boilers (marine,
Locomotive)
• Vertical or horizontal boilers: depending on orientation
• Solid, liquid or gas fired boilers
• Fire (Smoke) tube boiler: water is outside tubes while the hot
gases are inside tubes or
• Water tube boiler: contains large number of small tubes through
which water circulates, the fire and hot gases being outside of the
tubes e.g. High Pressure in CHP plants
 Boiler and Steam System

Boilers in KTDA factories

can be classified as:
1. Horizontal
2. Stationary
3. Solid fired (previously
liquid fired)
4. Fire (smoke) tube

❖ Maximum heat transfer in 3 pass fire (smoke) tube boiler .

❖ Boiler generates steam at 8-10 bars.
 Boilers and Steam System

Driers and
Withering
Troughs

o Thermal energy in steam critical in tea processing

o Steam consumed in Drying and Withering processes
o Required steam pressure at dryers radiators is 8 bar while at the withering trough radiators is 4 bar.
 Energy Conversion Factors

› Electricity 1KWH=3.6MJ

› Fuel Oil = 40.28 MJ/Litre

› Firewood 1 m3 = 5170 MJ => 1800 Kgs of steam/m3

› Bagasse 50% mc 1 Kg=7.5 MJ

› Bagasse 30% mc 1 Kg=12.6 MJ

› Coffee Husks 1 Kg=15.1 MJ

2626
Key Thermal Energy Performance Indicators
KTDA Target for thermal Energy Efficiency
➢ 300 Kg.MT/m3
➢ 3.5 – 4 Kg.Steam / Kg.MT (drying alone)
➢ Boiler Efficiency: 1800 Kg. steam/m3- Firewood boiler
➢ Boiler Efficiency : 14 Kg. Steam/ ltr.- F.O boiler
➢ 18.79 MJ/Kg.MT – Steam energy
➢ 1.98 MJ/Kg MT – Electrical energy
➢ 95% condensate recovery percentage
 The combustion theory
◊Solid fuels (coal, wood & agro-waste briquettes) have
a mixture of carbon, hydrogen, Sulphur and non-
combustible substances like nitrogen, water and
minerals
◊The best quality of solid fuel contains 90% C,H2 and a
small amount of nitrogen, Sulphur and moisture
◊Air contains 21% O2 + 79%N2 (neglecting other minor
constituents)
◊With complete combustion the C, S & H2 are oxidized
to CO2, SO2, H2O & CO
Combustion Theory
❖CO production in a boiler
should be avoided at all times
since increased CO gives a sharp
rise in heat-loss besides air
pollution
❖Correct fuel to air ratio is
essential to provide an
efficient combustion. Less
air mean insufficient oxygen
available to burn all the fuel.
❖With excess air, fuel is used
up to heat the excess air from
boiler-room temperature to the
funnel temperature.
 Boiler Combustion
❖Depending on the amount of fuel fed into the furnace and the
moisture content of the said fuel, the air required in the furnace
to achieve a complete combustion is vital
❖The optimum excess air level varies with furnace design, type of
burner, fuel and process variables. For FO– 5-10% excess air and
Firewood – 20-25% excess air
❖Most Boilers have both ID and FD fans. The ID fan will induce a
negative draft in the furnace thus draws out the burnt gases (Flue
gas) whereas the FD fan will force in oxygen rich atmospheric air
into the furnace to enhance combustion.
 Boiler combustion
Air Fuel Ratio
Induced Draught
(ID) Fan ❖Forced draught (FD) fan:
provides combustion air (O2).
❖Induced draught (ID) fan: -ve
draft to draw out products of
combustion.
❖Air damper setting: Correct
position for optimal combustion
efficiency.
Effect of back pressure on combustion

Backpressure
 Boiler combustion efficiency
❖ Combustion efficiency is an indication of the burners ability to burn fuel
❖ Measured directly by a combustion analyzer

Same Boiler

10am morning 3pm afternoon

 Boiler Efficiency
❖ Boiler efficiency relates to overall efficiency
of boiler plant.
❖ Compares total energy input (fuel) against
usable energy output (steam) Measured by a steam meter

Measured 1m3 box

Direct
method
 Boiler Efficiency
Boiler efficiency
by indirect
method: Heat
loss method

Flue gas measurements by

combustion analyzer
 Feed and makeup water metering
❖ Feed water meter used to estimate steam
generation i.e. if the FW reading is 4m3/hr. then steam
generation is 4000 Kgs per Hour
❖Boiler efficiency can be calculated as steam generated / m3.
firewood
❖Target efficiency-1800 Kg. Steam/m3
❖Make up water metering allow for system losses analysis
𝑭𝑾−𝑴𝑾
❖ Condensate Recovery (%) = × 𝟏𝟎𝟎
𝑭𝑾
❖Target condensate recovery-95% by minimizing steam and
condensate leaks.
Boiler water treatment-make up water
❖It is critical that Boiler make up
water goes through all the steps
of water treatment:
Coagulation; Sedimentation;
Filtration (up to 50ppm) then
softening.
❖Maintain water hardness at
less than 1.0 ppm
❖Only softened water should be
used as makeup to the
condensate in the feed tank
Boiler water treatment- boiler blow down
Reasons for Boiler Blow down
➢Blow down keeps the boiler water TDS
level under permissible limits.
➢ Blow down prevents corrosion and
scale formation in boiler tubes.
➢ It prevents the carryover of contaminants
in steam
➢ Manual boiler blow down currently
practiced in KTDA factories.
➢Too much blow down can lead to energy
wastage.
Steam
For the smoke tube boilers at 10.5 bars, the
maximum allowable TDS in boiler water is
between 3000-3500 ppm.
 Soot and scales on boiler tubes
❖Scales and Soot insulates the tubes and inhibit heat
transfer leading to energy loss through the flue gas.
❖ Thermal conductivity of scale is about 1/100 of that of
steel.
❖Scales forms on the water side of a fire-tube boiler –
Control Method: Boiler water treatment and De-scale
❖Soot forms inside the tubes of a fire-tube boiler –
Control method: Weekly cleaning.
 Effects of Soot and scales on boiler tubes
› More firewood consumption
› Tubes become distorted or
deformed due overheating
› Life of equipment reduced
› Tube replacement cost
› Production loss: Drying and
withering process
 Soot and scales on boiler tubes
A poorly cleaned boiler with
a soot layer of 2mm
thickness consuming 2000m3
per month loses 5% on
energy i.e. about 100m3
(appr. KSh 220,000) of the
firewood as a result of boiler
tubes fouling. When
combined with scaling losses
due to poor water treatment,
the loss is even higher.
 Boiler tubes cleaning
o Done weekly as part of
boiler maintenance.
o All tubes should be
cleaned to remove soot
o Clean from one end to
the other.
oUse correct brush size
 Air pre-heater (APH)

Heat
Exchanger

FD fan

Spark
Arrestor

Raising the combustion air temperature by 20ºC improves the boiler thermal efficiency by 1%.
 Air pre-heater
Flue Gases ❖Flue gases from the Boiler furnace
(waste heat)
at a temperature of about 1800C
Waste heat passes through flue tubes and air
recovery-improve
boiler efficiency at ambient temperature of 250C is
Stack
140 0C forced over the tubes by the FD
Fan. Heat from the flue gases is
Stac
k
Proposed
intake air
transferred through the tubes
Air Preheater
walls to the fresh air
180 0C
25 0C ❖The temperature of the fresh air
rises upto 1200C which is highly
suitable for combustion thus
100-120 0C Boiler improving the boiler efficiency.
Current
intake ❖Air pre-heaters should be
air
designed to allow for external
cleaning of tubes and ash removal.
 Air pre-heater…case study

Average efficiency without APH: 77.9% Average efficiency with APH: 81.6%

Average boiler efficiency improvement with APH: 3.7%

 Boiler Instrumentation & Safety
1. Safety valves
• The safety valves are located at the highest part of the steam
side of the boiler and connected directly to the shell.
• They are designed to pop open at some set pressures and
when both are open no steam pressure accumulation should
be there.
• The safety valves can be tested by hand ( by lifting the test
lever) or by pressure (by bringing the boiler pressure up to
the point it will pop. when testing by hand, make sure there
is at least 75% of the popping pressure in the boiler.
 2 . Water column gauge glass
• A water column gauge glass shows the water level
in the boiler and should be set at the normal
operating water level so that the lowest visible part
of the gauge glass is 2-3 inches the highest heating
surface. This is important because no matter how
low the level goes, the boiler operator knows it is
safe to add water to the boiler.
• It is very dangerous to add water to a boiler if there
is no water visible in the gauge glass for it might
cause a boiler collapse. At the bottom of the gauge
glass there is a gauge glass blow down valve to be
used to blow down any sludge or sediments.
3. Two- switch control Mobrey switches
 4. Single- switch control Mobrey switch
o The switch is float-operated and its
function is to switch the burner off when
water level in the boiler falls to a
dangerously low level ( extra low water).
o The burner can only be manually restarted,
at the control panel, when the water has
risen to a safe level.
 5. Bottom blow down valves
The bottom blow down is used so as to;
• Control high water level
• remove sludge and sediments in the boiler
• Control chemical concentrations in the boiler water.
• Dump a boiler for cleaning or inspection.
6. Air cock
• Air cock is used to vent the air from the boiler when being filled with water
• Air cock allows the air to escape during boiler warm-ups.
• Air cock prevents a vacuum from forming in the boiler when taking it out of
service. The vacuum can pull the manholes covers in to the boiler if lose
which can damage to the boiler.
 7. Pressuretrols-pressure switches
o These are pressure switches used to turn the
boiler on and off and controls it pressure
operation range. The pressuretrol has two
adjustment screws and two scales. one scale is
the cut-in and the other is the differential.
oIt is important that pressuretrols are protected
with a siphon to provide the water trap
between the boiler and the pressuretrol.
 8. Fusible plug
• Fusible plug is the last warning a boiler operator has of low water
condition before he starts burning the tubes.
• This is a brass or bronze with a tapered, hollow centre that is filled
with tin metal which melts at about 230oC. It is located about 2’’
above the highest heating surface in the direct path of the gases of
combustion.
• The tin does not melt as long as there is water in contact with the
fusible plug to keep it cool. Fusible plugs must be kept clean both
fireside and waterside. If scale was to build up, water will not cool
the plug and hence would melt even when the water level was
normal. Plugs must be replaced annually, this is because tin has a
tendency to crystallise and this would increase its melting point.
 9. Pressure gauge
• The pressure gauge shows how much steam pressure is
in the boiler. This allows the boiler operator to operate
his boiler in safe operating range.
• The boiler pressure gauges are the Bourdon type and
hence should be protected from steam entering the
Bourdon type otherwise it will be damaged or will give
false readings. To prevent this, siphons are installed
between the boiler and the gauge. The range of the
steam gauge should be 1 ½ to 2 times the MAWP
(maximum allowable working pressure) of the boiler.
 10. Temperature gauges
o Feed water temperature gauge – Measures the temp. of the boiler feed
water; should be around 870C. Higher temps are not good to feed pump and
low are not good for boiler efficiencies.
o Flue gas temperature gauge – Measures the flue gas temp. as it exits the
boiler. High temp readings means low boiler efficiencies and low temp.
readings means incorrect probe location or defective gauge. The flue gas
temp. should be between 185 – 2000C given than the steam saturation temp
at 9 bars is 1800C.
o Combustion air (CA) temperature gauge- measures the temp of preheated air
as it exits the APH. Temperature normally between 100-1200C. Lower temps
indicate reduced heat recovery in APH. If temp of combustion air after APH is
almost equal or equal to ambient air then APH is not working.
Instrumentation & Safety

Flue gas Temp

Gauge

Pressure
Gauge

Boiler
Control
Panel
Instrumentation & Safety

Sight glasses

Mobrey Switch
 Pressure Reducing Station
Bypassing PRS and
Pressure reducing station in feeding steam at 8 bar
Withering Section, pressure to withering trough
reduced from 8 to 4 bars will scorch withered
leaf.
 Why remove air and condensate from
steam
• Improve heat transfer efficiency – Air and water
(condensate) prevent efficient heat transfer across
radiator walls
• Prevent corrosion – air has oxygen which corrodes steel
pipes
• Prevent perforation and equipment wear – Water
droplets in steam moving at high speed impinge on the
inside of steam lines and fittings creating holes/leaks
• Prevent water hammer
 Water Hammer in steam lines
• Common during start up – if main valves are opened rapidly
• Occurs if condensate draining is not effective, failed traps,
upward inclining lines
 Steam Traps
❖Steam traps are automatic valves which close in steam but
open to discharge condensate and air in the system that
would cause barrier to heat transfer
❖Steam radiators receive steam from one point but have the
same steam stopped from going out at the other end by a
steam trap
❖They achieve this either mechanically using float ball traps
and inverted bucket traps or thermostatically or
thermodynamically or venturi principles.
 Steam Traps

Steam fittings arrangement Standard float ball steam trap

 Steam traps failure
❖When a steam trap fails in an open position,
it allows steam to pass through. The
equipment e.g drier will continue to
function normally but its steam consumption
will increase.
❖The overall effect is increased energy cost as
more firewood is consumed in the boilers
for the additional steam generation.
❖When a steam trap fails in a closed position,
the radiator will get flooded since there will
be no discharge of condensate hence
minimal heat transfer across the radiator.
This will negatively affect the equipment
Steam Trap Failed OPEN and passing performance.
Steam in Ogden Pumps
Steam trap checking
An infra-red thermometer can be used to test if
steam trap is functioning normally by taking
upstream and downstream temperatures.
T1 T2
Steam
trap

Upstream Downstream Status

Temp [T1] Temp [T2]
140 0C 110 0C Functioning Well

140 0C 140 0C Failed Open

600C 50 0C Failed Closed
 Strainers

Worn-out strainer

Strainer with particles

• Strainers trap particles in the steam line from reaching the steam trap
and damage or block the condensate discharge ports
• Strainers should be cleared of trapped particles once or twice a year
 Steam and condensate leaks.

Condensate Leak ❖ Steam and condensate leaks through failed

steam trap, valve or through an orifice/hole
on the piping leads to valuable heat loss
❖ Consider a steam leak of 0.5 Kg/min in a
pipe supplying a steam radiator in the dryer .
Assuming daily running time of 16 hrs. and
annual running time of 300 days. Annual
steam loss is 144,000 Kgs.
❖ Efficiency of KTDA biomass boiler 1800
Kg.steam/m3. Therefore, firewood used to
generate 144,000 Kgs of steam is 80m3
❖ Firewood cost is Kshs 160,000 per Annum.
 Ogden pump
Ensure that all condensate is evacuated by the Ogden pump(s) so that the feed water
temperature can be kept as high as practical (870C) to improve plant efficiency
Ogden pump
❖ Ogden pumps are mechanical (steam
powered)

OGDEN PUMP WEEKLY MAINTENANCE

SCHEDULE
1. Checking whether the pump has an overflow
and repair the pump if found.
2. Checking the condition of the exhaust steam
for the Ogden breather, if a lot of steam plume
is found investigate the pump for failure and
main steam traps and repair/replace accordingly.
3. Checking for water and steam leakages and
investigate cause and rectify appropriately.
4. Test the Ogden drain steam trap for faulty
and if faulty repair/replace appropriately.
 Heat Loss Management
❖Why insulate?
Unlagged
steam fittings ❖Un-insulated surfaces means
loss of energy and risk of injury
from burns and heat shock to
workers
❖Insulation is done on boiler
surfaces, steam and condensate
Insulated and lagged line lines, steam fittings, condensate
tanks and APHs
Insulation of Steam and Condensate System
• Insulation must be done in all hot surfaces- If you can't
touch, insulate.
• Choice of insulating material is important: Insulating
properties, thickness, non-contaminating and cost
• Mineral rock wool is commonly used
• Water logged insulation due to steam and condensate
leaks in piping reduces its effectiveness
• Cladding material protect insulation and should be of
low emissivity (reflective)
Lagging of steam lines
 Lagging of steam lines
• Steam fittings can be converted to equivalent pipe lengths (m)
• Consider a 2’’ (50mm) dia. uninsulated 10 m steel pipe carrying
steam at 4 bar in the withering section.
• Surface temp 140˚C, ambient temp 20˚C. Temp difference 120˚C.
• Heat loss on exposed pipework-426 W/m. For 10 m pipe length the
total heat loss is 4.26 kW. Assuming daily withering section is 16 hr.
and annual running time is 300 days, annual energy loss is 20,448
kWh (73,612.8 MJ).
• Enthalpy of steam -2.03 MJ/Kg. Equivalent steam loss -36,262.46 Kgs
• Efficiency of boiler 1800 Kgs. Steam/m3. Therefore, equivalent
firewood consumption 20m3.
• Annual energy cost- firewood is Kshs 40,000
 Bad cases of lagging and cladding

Failed insulation and cladding in feed water

tank Unlagged steam piping in drier
Best practices in lagging and cladding of
steam system

Fixed lagging

Jacket lagging

Removable box with lagging (Kambaa T. Factory

 Steam radiators
❖A heat exchanger in which hot steam is held
in the tubes whereas cold air is forced
externally over the tubes which have fins on
the outer surface to delay the cold air
movement.

❖Steam enters the radiator tubes on one end

and is stopped from getting out by the steam
traps on the other end.
 Steam radiators
❖Flooded radiator is at risk during system start up
when live steam picks condensate in the system
carrying it like a stone. When it gets to a bend or a
valve, it hammers the bend and courses breakages
leading to leakage
❖Trapped air act as an insulator thus heat transfer
is affected.
❖The steam traps installed need to be able to
evacuate condensate and non-condensable gases
 Steam radiators
❖Heat transfer is reduced in a
corroded, leaking and dust covered
steam radiator
❖ Reduced heat transfer results in
increased steam and firewood
consumption
❖End process affected- Longer
drying and withering time

Corroded steam radiator in

withering Leaking steam radiator in
withering trough
Steam radiators

Steam radiator in drier

➢Accumulation of dust in
fins reduces heat transfer
➢As part of maintenance,
dust should be blown off
once per month
 Boiler Records

❖Key boiler performance parameters to be recorded include

firewood consumption (m³), feed water consumption (m³),
boiler pressure (bars), flue gas temp (ºC), combustion air temp
before and after APH (ºC), Feed water temperature (ºC), boiler
running time (hrs).
❖ Boiler operator should maintain accurate and up to date
records.
❖ Analyse key thermal system KPIs; boiler efficiency in Kgs of
steam/m3, firewood utilisation in Kg.MT/m3.
 MOD 4: Production Floor Machinery O & M.
❖ Mechanical systems in the production floor include monorail,
withering fans, dampers and louvres, withering troughs conveyors,
CTC machines, humidifiers, driers, sorters, bulking bins, winnower.
❖ Breakdown and downtime in these systems / machines affect
throughput and as a result production time is increased SAME AS
ENERGY.
❖Plant technicians, mechanics and boiler operators play an important
role in operation and maintenance of these systems.
❖Properly and adequately maintained systems are energy efficient.
❖Maintenance can be: preventive, corrective and reactive
(breakdown).
 Common Machinery Breakdown that affect energy
efficiency

o Unbalanced vibrating fans: Lowers airflow (CFM), increased withering

time results in higher electricity and firewood cost
o Leaking troughs, transition pieces: Lowers airflow, increased withering
time results in higher electricity and firewood cost.
o Leaking steam radiators: Increase in steam and firewood consumption in
the drier and withering section
o Hot air leaks: Increase in steam and firewood consumption in drier and
withering section
o Unsecured (loose) dampers / louvres: Loose dampers can close and
lower airflow to withering troughs.
o Misaligned rollers in CTC: Lowers throughput, increased electricity
consumption
 Common Machinery Breakdown that affect energy
efficiency

o Missing scrappers in CTC: Spillages lowers throughput, increased

electricity consumption and cost
o Over meshed rollers in CTC: High pressures, increased electricity
consumption, affects quality of products.
o Incorrect sharpened rollers in CTC: Affects quality of made teas.
Additional electricity and steam consumed during rework.
o Misaligned discharge conveyors: Spillages lowers throughput,
increased energy consumption and cost
o Worn-out conveyors belts- Spillages lowers throughput,
increased electricity and firewood consumption and cost
 Common Machinery Breakdown that affect energy
efficiency

Spillages due to missing scrappers in Misaligned conveyor divider lowers

CTC rollers affects throughput throughput in CFU
 Common Machinery Breakdown that affect
energy efficiency

Spillages of fermented teas due to

Worn-out conveyors affects throughput misalignment of conveyors
 Going Forward

❖ Reduce machine breakdown and

downtime to realize energy savings.
❖ Maintenance procedures to follow
KTDA maintenance manual.
❖Discuss in details with team on
sectional preventive maintenance
program done on Mondays i.e.
Withering, CTC, CFU, Drying, Sorting
and Packing

Preventive maintenance on CTC

rollers. Done every Monday
MOD 5: Health and safety – Good Practices
o PPE Personal Protective Equipment: Ear muffs, safety
goggles, hard hut, dust mask, safety boots.
o Safe Working Environment: Fixing steam leaks, hot air
leaks , insulation of hot surfaces and ergonomics.
Health and safety – Bad Practices

NO PPE; wearing flip flops while

Bad Housekeeping in Boiler House
splitting firewood
THANK YOU.