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Case Study:

Achieve Higher Uptime of Mainline Traps


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Customer Details
A Beverage Manufacturer in Indonesia.
Improper trapping practices and frequent trap failure, leading to waterlogging in the lines and high steam losses.
To achieve higher uptime of mainline traps through corrections in the steam system design and trapping methods.
Case Details and Solutions
When the Forbes Marshall engineer visited the customer plant for the first time, he was taken aback to note the loss of live steam and extreme water hammer in the 15 m3 through the condensate line. On checking, it was noticed that 4 of the 5 installed traps were either water logged or leaking. The process area as well was not equipped with the right type of traps, and 40NB bypass valves were kept in open position. After doing a detailed root cause analysis, a proposal was made to the customer for improvements in the steam system improvement. It was suggested that the drain modules be implements in the distribution network and conventional TD traps be replaced by the Forbes Marshall Compact Module Thermodynamic Trap for the mainline. Installation of a Steam Operated Pump Trap in the pasteuriser area was also suggested to completely eliminate the need of opening the bypass valve. The customer accepted the recommendations, and implemented suggestions for mainline improvement in stage 1. With installation of the CMTD, customer was happy to note that there was no more steam leak from the mainline, thereby reducing steam loss significantly.
Forbes Marshall conducted a detailed to identify problem areas, and corrective action taken accordingly :

Proper drain modules implemented in the steam distribution network.

Conventional thermodynamic traps replaced with 11 nos. compact module thermodynamic trap, model CMTD42M-F.
Increase in uptime of mainline traps from 20% to 100%.

Steam loss of approximately 1.5 TPD due to leakages averted.

Outlet temperature at Mainline 1 reduced by > 34 degC and > 50 degC at Mainline 2.