The CERTUSS Universal TC industrial steam generator produces 500 to 2,000 kg/h of steam, with full output available roughly five minutes from a cold start. That start-up time is the reason plants choose this type over a conventional shell boiler: a process that runs one shift, or in campaigns, does not have to hold a large water volume hot overnight waiting for the next batch. Techmatic Controls is the CERTUSS distributor in Singapore and supplies the range as a turnkey project.

Output and pressure

Four sizes cover the range, with heat output from 328 to 1,320 kW. Operating pressure is 6/8 to 29 bar, with maximum permissible overpressure from 10 to 32 bar depending on the configuration specified. Where a plant needs more than 2,000 kg/h, multiple units can be run together.

Sizes and dimensions

The construction is vertical, so the footprint is small for the output. Units are suitable for mezzanine installation, which is often what makes a retrofit possible in an existing building where floor space at ground level is already committed.

Burner and fuels

A two-stage burner with full modulation between 50 and 100 per cent matches firing rate to steam demand instead of cycling on and off against it. Fuels supported:

• Natural gas
• LPG
• Light fuel oil
• Bio-fuel
• Dual fuel, combi-fired

Dual fuel is worth considering where the plant needs to keep producing through a gas supply interruption, or where fuel pricing makes switching worthwhile over the life of the asset.

Efficiency

Standard thermal efficiency is above 93 per cent. Two things drive the in-service figure beyond the nameplate: the modulation range, which keeps the burner firing rather than cycling at part load, and the short heat-up time, which removes the standing losses that come from holding a boiler hot between production runs. On an intermittent load, those two together usually matter more than the headline efficiency number.

Control and integration

Operation is through a touch screen interface with automatic start, stop and blowdown. The controller connects over Profibus, CAN bus, Modbus and BACnet, so the boiler reports into an existing BMS or plant control system rather than sitting as an island that someone has to walk to.

Applications

• Food and beverage processing, where steam demand follows production batches
• Pharmaceutical and biotechnology plants
• Chemical process plant
• Laundries, sterilisation and general process heating
• Standby or supplementary capacity alongside an existing boiler house
• Retrofits replacing an oversized shell boiler running at low load

Compliance and registration in Singapore

The Universal TC is built to PED 2014/68/EU. In Singapore, a steam boiler is a pressure vessel under the Workplace Safety and Health framework: it must be registered with the Ministry of Manpower and examined by an Authorised Examiner, with a Certificate of Fitness in place before it is operated, and re-examined at the required intervals thereafter. The manufacturer’s design, material and test documentation required for that submission is supplied with the boiler.

Sizing and site survey

Steam generators are not sold from a catalogue. The right size depends on your actual steam load and how it varies through the day — not on the rating of the boiler being replaced, which is why so many existing installations are oversized. An oversized boiler cycles, wastes fuel and wears its burner. So before we quote, we size the unit against your load and survey the site.

To size the unit we need:

• Steam demand — peak, average, and how it varies across the shift or batch
• Required steam pressure at the point of use
• Fuel available on site: natural gas, LPG, light oil, or a preference for dual fuel
• Operating pattern — continuous, single shift, or campaign production
• Feedwater supply and whether condensate is returned

The site survey covers:

• Space, access route and floor or mezzanine loading for the unit
• Flue route and termination
• Fuel supply and gas train, and the electrical supply
• Water treatment, feedwater and blowdown arrangements
• Steam distribution from the boiler to the point of use

How we supply it

Boilers are supplied as turnkey projects — sizing, supply, installation, commissioning, in-service optimisation & MOM Approvals — with servicing, upgrades and maintenance afterwards.

Techmatic has an in-house Singapore Certified Energy Manager and carries out boiler efficiency monitoring, so the performance of the installed plant can be measured rather than assumed. Our processes are aligned to ISO 50001.

Related equipment

Techmatic also supplies the CERTUSS UMX range for 1,500 to 2,000 kg/h, the Junior TC for 80 to 400 kg/h, and electric steam generators from 6 to 320 kg/h where no combustion is wanted. We also supply the steam system around the boiler — Miyawaki steam traps, pressure reducing valves, separators, strainers and flow instrumentation — and carry out steam trap surveys.

Arrange a sizing review and site survey

Contact our sales team for a free consultation today!