Despite regular replacement and maintenance efforts, a chemical plant producing sodium cyclamate, a sweetener for food and beverages, and pharmaceuticals in Indonesia was struggling to sustain uptime of its mainline and process traps. Poor steam trap uptime along with venting of flash steam from the condensate recovery tank resulted in higher fuel consumption. Right selection of mainline and process steam traps, with a FlashJet™ Pump were recommended in order to enhance uptime and improve condensate and flash steam recovery.

Objective

PROBLEM

The plant had 0% uptime of mainline and process steam traps and was venting flash steam. This adversely affected the energy efficiency of the facility.

Solution

SOLUTION

Forbes Marshall conducted a detailed walkthrough and implemented a comprehensive solution. This involved improving the steam and condensate network by optimising steam trap selection and installation.

A FlashJet™ Pump, along with mainline and process traps (Compact Module Thermodynamic Trap CMTD42M-F & Compact Module Two-Orifice Float Trap CMTOFT™) were installed, improving steam trap uptime, condensate and flash steam recovery.

Benefit

BENEFITS

Increased mainline trap uptime from 0% to 100%

Increased process trap uptime from 0% to 47%

Enhanced condensate recovery factor from 87% to 100%

Recovered 1,332 tonnes (2.93 million pounds) of flash steam annually

Reduced annual fuel bill by 7%

Annual monetary savings of USD 30,000