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The Industrial Boiler_Steamsystems_Handbook

Design, Operation, Maintenance, Energy Management and Optimization For FMCG and Modern Manufacturing Industries

The Industrial Boiler_Steamsystems_Handbook

614 pages. 16 chapters. 27+ years of plant-floor experience. Everything you need to design, operate, maintain, and optimize industrial boilers and steam systems in FMCG and modern manufacturing — in one professional reference. Most boiler books stop at theory. This one follows every concept with its plant-floor consequence — fuel cost, steam quality, maintenance, safety.

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About

About the Book

The Industrial Boiler & Steam Systems Handbook is a comprehensive 614-page professional reference written for engineers working in FMCG and modern manufacturing industries. Drawing on 27+ years of hands-on industrial experience, the author bridges the gap between engineering theory and plant-floor practice across every aspect of industrial boiler and steam utility engineering.

Unlike textbooks that stop at theory, this handbook follows every concept immediately with its practical consequence — what it means for fuel cost, steam quality, maintenance windows, and the people who operate the equipment.

What the book covers:

The handbook spans 16 chapters and 10 appendices, taking the reader from boiler fundamentals through to Industry 4.0 digital transformation:

  • Boiler design, classification, ratings, and selection
  • Thermodynamics, heat transfer, and steam properties
  • Boiler components and auxiliary systems
  • Fuels, combustion systems, and emission control
  • Feedwater treatment, water chemistry, and steam purity
  • Operation, start-up, shutdown, and operational best practices
  • Maintenance, inspection, reliability engineering, and asset management
  • Steam distribution, condensate recovery, and steam utilization
  • Energy efficiency, performance evaluation, and heat recovery
  • Safety, codes, standards, risk assessment, and emergency management
  • Instrumentation, automation, PLC, DCS, and advanced control systems
  • Steam system design and piping engineering (advanced)
  • Boiler house utilities and balance of plant
  • Performance testing, energy audits, and operational optimization
  • Steam utilization in FMCG manufacturing industries
  • Industry 4.0, IIoT, artificial intelligence, and digital transformation

The 10 appendices cover saturated steam tables, unit conversion factors, efficiency formulas, water chemistry reference, fuel properties and combustion data, O&M checklists, troubleshooting guides, codes and standards reference, engineering charts, and a performance improvement register.

Who this book is for:

This handbook is written for utility engineers, boiler engineers, energy managers, maintenance and reliability professionals, instrumentation and controls engineers, plant managers, and engineering graduates entering manufacturing industries. It is equally suited as a day-to-day plant reference and as a structured learning resource.

About the author:

Koti Reddy Vanukuri is an engineering professional with more than 27 years of experience in FMCG manufacturing across confectionery, chocolate, coffee, edible oils, and consumer products. His career spans boiler and steam utility engineering, energy management, reliability engineering, manufacturing excellence, sustainability, and digital transformation.

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Author

About the Author

Koti Reddy Vanukuri

About the Author

Koti Reddy Vanukuri is a seasoned engineering and manufacturing professional with over 27 years of experience in the FMCG industry. During his career, he spent more than 21 years with ITC Limited, leading major capital projects, engineering support, utilities, energy management, and manufacturing excellence across confectionery, chocolate, coffee, and food processing businesses.

He has successfully delivered large-scale greenfield manufacturing facilities, optimized industrial utility systems, and implemented energy-efficient engineering solutions that have improved plant performance and operational reliability. His expertise spans industrial boilers, steam systems, process utilities, maintenance, project engineering, and sustainable manufacturing.

Koti Reddy is a Certified Energy Auditor & Manager, has completed executive education at IIM Bengaluru, and has received specialized international technical training in confectionery manufacturing. Through his writing, he aims to bridge the gap between engineering theory and practical industrial applications, helping engineers, plant managers, and technical professionals solve real-world manufacturing challenges.

BOILERS, STEAM AND ENERGY MANAGEMENT FOR FMCG INDUSTRIES™ is his first book, sharing practical knowledge and industry best practices gained over nearly three decades of hands-on experience.

Contents

Table of Contents

Table of Contents 16 chapters · 10 appendices · 614 pages · Glossary · Abbreviations · Index Chapters Ch 1 Chapter 1. Fundamentals of Industrial Boilers and Steam Generation 13 sections ▸ Ch 2 Chapter 2. Thermodynamics, Heat Transfer and Steam Properties 20 sections ▸ Ch 3 Chapter 3. Industrial Boiler Components and Auxiliary Systems 28 sections ▸ Ch 4 Chapter 4. Boiler Fuels, Combustion Systems, and Emission Control 23 sections ▸ Ch 5 Chapter 5. Boiler Feedwater Treatment, Water Chemistry, and Steam Purity 32 sections ▸ Ch 6 Chapter 6. Boiler Operation, Start-up, Shutdown, and Operational Best Practices 36 sections ▸ Ch 7 Chapter 7. Boiler Maintenance, Inspection, Reliability Engineering, and Asset Management 35 sections ▸ Ch 8 Chapter 8. Steam Distribution Systems, Condensate Recovery, and Steam Utilization 39 sections ▸ Ch 9 Chapter 9. Boiler Energy Efficiency, Performance Evaluation, Heat Recovery, and Fuel Optimization 36 sections ▸ Ch 10 Chapter 10. Boiler Safety, Codes, Standards, Risk Assessment, and Emergency Management 43 sections ▸ Ch 11 Chapter 11. Boiler Instrumentation, Automation, PLC, DCS, and Advanced Control Systems 37 sections ▸ Ch 12 Chapter 12. Steam System Design, Piping Engineering, Pressure Reduction Stations, and Condensate Recovery Systems (Advanced Design) 38 sections ▸ Ch 13 Chapter 13. Boiler House Utilities, Ancillary Systems, and Balance of Plant (BOP) 42 sections ▸ Ch 14 Chapter 14. Boiler Performance Testing, Energy Audits, Efficiency Improvement, and Operational Optimization 43 sections ▸ Ch 15 Chapter 15. Steam Utilization Systems in FMCG Manufacturing Industries 48 sections ▸ Ch 16 Chapter 16. Industry 4.0, Industrial IoT (IIoT), Artificial Intelligence, and Digital Transformation in Boiler & Utility Engineering 48 sections ▸ Appendices App A Appendix A. Saturated Steam Properties 16 sections ▸ App B Appendix B. Unit Conversion Factors 8 sections ▸ App C Appendix C. Boiler Performance and Efficiency Formulas 8 sections ▸ App D Appendix D. Water Chemistry and Steam Purity Reference 5 sections ▸ App E Appendix E. Fuel Properties and Combustion Data 4 sections ▸ App F Appendix F. Operating and Maintenance Checklists 6 sections ▸ App G Appendix G. Troubleshooting Guide 8 sections ▸ App H Appendix H. Codes, Standards and Regulatory Reference 8 sections ▸ App I Appendix I. Engineering Reference Charts 8 sections ▸ App J Appendix J. Performance Indicators and Improvement Register 3 sections ▸ Back Matter Glossary of Terms Abbreviations Index

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