Lecture 11: Role of Utility Engineers and Utility Systems in Industrial Plants

1 Introduction:

Utility engineers are responsible for ensuring that all utility systems (steam, water, air,
electricity) operate efficiently and reliable to support the core industrial processes. For
example, in a chemical plant, the utility engineer makes sure that the boilers are producing
enough steam, the cooling towers are working properly to remove heat, and the air
compressors are supplying clean, dry air for instruments and machines.

If there is a problem, like low steam pressure or a fault in the cooling system, the utility
engineer quickly finds the issue and fixes it to keep the plant running safely and efficiently.
They also monitor water quality, energy use, and safety systems like the flare network.
Without the utility engineer, the whole plant could face shutdowns or damage due to
failure in these essential services.

Key Responsibilities:

✓ Operation and maintenance of utility systems.

✓ Monitoring energy and water usage.
✓ Troubleshooting system faults.
✓ Ensuring safety and environmental compliance.

2 Boiler Feed Water (BFW)

BFW is a water supplied to a boiler to generate steam. It must be treated to remove

impurities that cause scaling or corrosion.

Source of boiler feed water:

✓ Municipal supply
✓ Groundwater
✓ Recycled water (e.g., from condensate return)

Impurities to Remove:
 ✓ Dissolved solids (e.g., calcium, magnesium)
✓ Dissolved gases (oxygen, carbon dioxide)
✓ Suspended solids
✓ Silica

Treatment Steps:

✓ Pre-treatment:

Filtration and sedimentation are the first steps in treating water before it is used in a boiler.
These processes help remove suspended solids like sand, dirt, and rust particles that can
damage the boiler. In sedimentation, water is allowed to sit in a tank so that heavier
particles settle to the bottom due to gravity. This makes the water clearer. After
sedimentation, the water goes through filtration, where it passes through layers of sand,
gravel, or special filter materials that trap smaller particles still floating in the water. These
steps are important because if solid particles enter the boiler, they can cause scaling and
clogging, reducing the efficiency and lifespan of the boiler. By removing these impurities
early, filtration and sedimentation help protect the boiler and keep the system running
smoothly.

✓ Softening:

Ion exchange is a water treatment process used to remove hardness-causing minerals,

mainly calcium (Ca²⁺) and magnesium (Mg²⁺), from water before it goes into the boiler.
These minerals cause scaling, which is like a hard white layer that sticks to the inside of
the boiler and reduces heat transfer. In the ion exchange process, water passes through
a special tank filled with resin beads. These beads are coated with harmless sodium (Na⁺)
ions. As the hard water flows through, the calcium and magnesium ions stick to the resin,
and in exchange, the resin releases sodium ions into the water. This makes the water
"soft" and safe for use in the boiler.

✓ Deaeration:

Before water is fed into a boiler, it needs to be free from dissolved gases like oxygen and
carbon dioxide because these gases can cause corrosion inside the boiler and piping
system. A deaerator is a special piece of equipment that removes these gases from the
water.

The deaerator works by heating the water and spraying it in a fine mist inside a tank. As
the water is heated, the dissolved gases like O₂ and CO₂ come out of the water and are
vented out of the tank. The process is based on the fact that gases are less soluble in hot
water, so heating helps release them.

✓ Chemical Treatment:

In boiler water treatment, certain chemicals are added to keep the system clean and
running safely. Phosphates are used to prevent scaling inside the boiler. They do this by
reacting with hardness minerals like calcium and turning them into soft sludge, which can
be removed through blowdown. Oxygen scavengers are chemicals like sodium sulfite or
hydrazine that are added to remove dissolved oxygen from the water, which helps prevent
corrosion in the boiler and pipes. Finally, anti-foaming agents are added to stop foam from
forming on the surface of the water inside the boiler. This is important because foam can
lead to carryover, where water droplets are carried into the steam lines, which can
damage equipment. Together, these chemicals help protect the boiler and improve its
efficiency and lifespan.

3 Steam Generation:

n a boiler system, boiler feed water is the clean, treated water that is sent into the boiler.
Inside the boiler, this water is heated using fuel or electricity. As the water gets hotter, it
eventually reaches its boiling point and turns into steam. This steam is then used for
different purposes in the plant, such as heating, running turbines to produce electricity, or
powering equipment. So, the basic process is: boiler feed water goes into the boiler →
heat is applied → steam is produced, which is then used wherever it's needed in the plant.

✓ Types of Boilers:

Fire-tube boilers: Fire-tube boilers are a type of boiler commonly used to produce low-
pressure steam. In this design, hot gases from the fire pass through tubes that are
surrounded by water. As the hot gases move through the tubes, they heat the water
around them and turn it into steam. These boilers are simple in construction, easy to
operate, and good for small to medium-sized steam needs—like in small factories,
laundries, or heating systems. Because they work at lower pressures, fire-tube boilers
are safer and more cost-effective for basic steam applications

✓ Water-tube boilers:

Water-tube boilers are used to produce high-pressure steam, especially in power plants
and large industrial setups. In this type of boiler, water flows inside the tubes, and hot
gases from the fire surround the outside of the tubes. As the hot gases heat the tubes,
the water inside turns into steam. Because the water is inside small tubes, it can handle
high pressure and heats up quickly. This makes water-tube boilers ideal for producing
large amounts of steam needed to run steam turbines for generating electricity (used for
high-pressure steam in power plants)

✓ Steam Uses:

Steam is used in many industries because it carries heat and energy. One major use is
for driving turbines in power generation, where high-pressure steam spins a turbine
connected to a generator to produce electricity—like in power plants. Steam is also used
for heating, such as in chemical reactors and distillation columns, where it helps maintain
the right temperature for chemical reactions or separating mixtures. In the food and
pharmaceutical industries, steam is used for sterilization because its high temperature
kills bacteria and keeps equipment clean and safe. Another use is for mechanical work,
like in old steam engines that powered trains and machinery, where steam pressure
pushed pistons to create movement. These examples show how useful steam is across
many different areas.

✓ Steam Quality:

try to cool it even a little, it will start turning back into water. Superheated steam, on the
other hand, is steam that has been heated above the boiling point and contains extra
energy. It is completely dry and doesn’t turn into water easily. For example, in a kitchen
pressure cooker, the steam that forms when the water boils is saturated steam. But in a
power plant, steam is heated even more after boiling to make it superheated, so it can
spin turbines more efficiently without turning back into water. So, saturated steam is great
for heating, while superheated steam is better for power generation.

After water boils and turns into saturated steam, it still contains some moisture and is at
the boiling temperature. To turn this into superheated steam, we continue to add heat—
but without adding more water or pressure. This extra heat raises the steam’s temperature
above the boiling point, and all the remaining moisture evaporates. This process is usually
done in a part of the boiler called a superheater. The superheater is a set of special tubes
placed in the path of hot flue gases, where the saturated steam flows through and picks
up more heat. The result is dry, high-temperature steam that can be used in turbines for
power generation because it doesn't condense easily and carries more energy.

Dry steam is important because it contains no water droplets, only pure steam. If steam
is wet (meaning it has water mixed in), it can cause serious problems in pipes and
equipment. One of the main issues is water hammer—this happens when water droplets
in the steam suddenly hit the inside of a pipe or valve with great force, creating a loud
banging sound and possibly damaging the system. Wet steam can also cause erosion,
where the fast-moving water droplets wear down the inside of pipes, valves, and turbines
over time. This leads to leaks, reduced efficiency, and costly repairs. Using dry steam
helps avoid these problems, keeps the system running smoothly, and extends the life of
equipment

4 Cooling Water Supply:

To absorb and remove excess heat from industrial processes and equipment.

4.1 Types of Cooling Systems:

✓ Once-through System:

In some industrial plants and power stations, cooling water is used once and then
discharged back into the environment. This is called a once-through cooling system. In
this method, large amounts of water are taken from a nearby source like a river, lake, or
sea, passed through heat exchangers or condensers to absorb heat from the plant, and
then released back into the source at a slightly higher temperature. This method is
common where a high flow rate of water is available and where environmental rules allow
the return of warmer water. For example, a power plant near a river might pump in river
water to cool steam in the condenser and then discharge the warmed water back into the
river. It’s a simple and low-cost method, but it can affect aquatic life if not properly
controlled

✓ Closed-loop Recirculating System

In a closed-loop water cooling system, the same water is reused again and again instead
of being discharged. The water flows through equipment or machines to absorb heat, and
then it is sent to a cooling tower or heat exchanger, where the heat is removed. After
cooling, the water goes back into the system to be used again. This loop continues without
wasting water. Cooling towers help by allowing some water to evaporate, which removes
heat, while heat exchangers transfer the heat from the hot water to another cooler fluid
or air. This system saves water and is better for the environment, especially in places
where water is limited

✓ Cooling Water Treatment:

Scale inhibitors, corrosion inhibitors, and biocides are chemicals added to cooling water
systems to protect equipment and improve efficiency. Scale inhibitors prevent minerals
like calcium from building up on the inside of pipes and heat exchangers, which can block
flow and reduce heat transfer. Corrosion inhibitors protect metal parts from rusting by
forming a protective layer on the surface. Biocides are used to kill or control algae,
bacteria, and fungi, which can grow in the water and cause blockages, foul smells, or
even damage equipment. These chemicals are essential to keep the cooling system clean
and working properly.

To keep the system running safely and efficiently, it is important to monitor key water
quality parameters such as temperature, flow rate, pH, TDS (total dissolved solids), and
conductivity. These values help operators know if the water is suitable for use or if
treatment is needed. For example, high TDS or conductivity might mean there's too much
dissolved salt or mineral in the water, which could cause scaling or corrosion.

The role of instrumentation and control is very important in modern cooling systems.
Temperature and pressure sensors help monitor system performance and detect
problems early. Flow meters measure how much water is moving through the pipes.
Water quality analyzers check for pH, TDS, and other important chemical levels.
Advanced systems also include automated blowdown (to remove dirty or mineral-rich
water) and chemical dosing systems (to add the right amount of treatment chemicals).
Together, these tools help maintain water quality, reduce manual work, and prevent
system failures

5 Common Problems and Solutions:

Problem Cause Solution

Scaling in boiler Hard water Softening & chemical

dosing

Corrosion in pipes Oxygen in feed water Deaeration, scavengers

Algae in cooling tower Warm stagnant water Biocide addition

Poor steam quality Wet steam Better separator & control

6 Flare Network – What It Is and Why It's Important:

In any chemical or petroleum processing plant, safety is a top priority. The flare network
is a critical safety system designed to safely burn off excess or unwanted gases during
emergency situations, startup, shutdown, or equipment venting.

✓ What Is a Flare Network?

A flare network is a system of pipes and equipment that collects flammable gases from
different parts of the plant and sends them to a flare stack or flare tower—a tall vertical
pipe where the gases are safely burned at the top. This combustion converts dangerous
hydrocarbons into less harmful gases like carbon dioxide and water vapor.

✓ Why Use It?

In industrial plants, especially those that handle chemicals or gases, unwanted or leftover
gases sometimes need to be safely removed. These gases can come from different
sources. For example, during a reactor shutdown, there may be leftover gases that need
to be released from the system. Sometimes, relief valves automatically release gases
when the pressure inside a tank or pipe gets too high, to protect the equipment. In other
cases, operators may manually remove gas to reduce pressure in a vessel for
maintenance or safety reasons. These gases cannot be released directly into the air, so
they are usually sent to a flare system where they are burned safely. This prevents air
pollution and reduces the risk of fire or explosion.

Imagine a pressure vessel in a refinery starts building up more pressure than it can
handle. A pressure relief valve opens and sends the gas to the flare system. Instead of
causing an explosion, the gas travels to the flare tip and burns as a visible flame,
protecting equipment and people.

7 Plant Air Utility – What It Is and How It's Used

Compressed air is one of the most commonly used utility services in any industrial plant.
The plant air utility system supplies compressed air to operate various tools, equipment,
and control systems.

✓ What Is Plant Air?

Plant air refers to compressed atmospheric air that is cleaned (filtered), dried (moisture
removed), and stored under pressure in tanks. It is distributed throughout the plant via a
network of pipelines. There are usually two types:
 • Instrument Air: Very clean and dry air used to operate control valves, instruments,
and automation systems.
• Utility Air (General Plant Air) : Used for general services like cleaning, air tools,
pneumatic cylinders, etc.
✓ Why Use It?

Compressed air is widely used in industries because it is very safe to handle. Unlike many
fuels or gases, compressed air is non-flammable, which means it does not catch fire or
explode easily. This makes it ideal for use in environments where safety is a top priority.

Another important reason for using compressed air is that it is reliable. Compressed air
systems can provide air whenever it is needed, day or night, without interruption. This
reliability ensures that machines and control systems can keep running smoothly without
delays

In a bottling plant, a pneumatic arm uses compressed air to move bottles on a conveyor.
Meanwhile, instrument air is being used to open and close control valves in the process
line with high precision. All of this air is supplied by the plant air utility system, usually
powered by large air compressors and air dryers.

Utility Purpose Example Use

Flare Network Safely burn excess or Flare burns gases from a

emergency gases pressurized reactor

Plant Air Power tools, instruments, Compressed air opens

and controls valves and moves
actuators

Utility Purpose Example Use