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Case Study:

Achieve a Sustainable Zero Leak Steam System


Oil & Gas

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Customer Details
A major refinery in Western India.
Problems
Major Steam Loss

Frequent failure of steam traps

Water hammering

Frequent shutdown

Noise pollution
Objective
To achieve a sustainable zero leak steam system by implementing a steam trap management system.
Solution
Steam Trap System Management - audit, rectification and sustenance by Forbes Marshall.

Phase 1 :
Total steam traps population : 12,000
Steam trap performance rate: 29.72%
Steam loss identified: 23 Ton/hr

Phase 2 :
Supervision of the steam trap system rectification by Forbes Marshall and replacement with Forbes Marshall products.
Improved steam trap performance rate : 97.6%
Steam savings achieved: 21Ton/hr

Phase 3 :
Sustain the achieved performance for next 30 Months.
Steam trap performance rate : 98%
Steam savings achieved further: 4.39 Ton/hr
Benefits
Reduction in Steam losses.

Increased steam system reliability.

No water hammering.

Increased steam trap life.

Savings in fuel consumption.

Reduced noise pollution.

Improved steam leak factor from 0.96 Kg/MT (2017) to 0.37Kg/MT (2019) - CHT audit.