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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
Major Steam Loss
Frequent failure of steam traps
Water hammering
Frequent shutdown
Noise pollution

To achieve a sustainable zero leak steam system by
implementing a steam trap management system

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
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
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