Case Study:

Achieve Higher Uptime of Mainline Traps


Beverage

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Customer Details
A Beverage Manufacturer in Indonesia.
Problems
Improper trapping practices and frequent trap failure, leading to waterlogging in the lines and high steam losses.
Objective
To achieve higher uptime of mainline traps through corrections in the steam system design and trapping methods.
Case Details
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 waterlogged or leaking.
The process area as well was not equipped with the right type of traps, and 40NB bypass valves were kept in an 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 are 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 recommendation and implemented suggestions for mainline improvement in stage 1.  With the installation of the CMTD42M-F, the customer was happy to note that there was no more steam leak from the mainline, thereby reducing steam loss significantly.

Benefits
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.