122,500 Kilograms fuel saved annually through steam and condensate system improvements for a Thai beverage MNC

A leading beverage plant in Phra Nakhon Si Ayutthaya, Thailand, was facing several issues with its steam and condensate system. Float traps at the Bottle Washer lines 4, 5, 6 and 7 were causing low process temperatures, resulting in condensate stalling. Due to this, the trap bypass valve had to be kept open. Electrical pumps were used for condensate recovery across lines 5 and 7, which had issues causing frequent condensate loss through draining. Forbes Marshall conducted a plant study and recommended solutions to improve bottle washer performance and condensate recovery.

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PROBLEM

The plant was facing stalling in their Bottle Washer lines 4, 5, 6 and 7 due to low process temperature. The existing float traps installed at the Bottle Washer were unable to evacuate condensate. The operator needed to open the bypass valve periodically to evacuate condensate leading to steam and condensate loss. The lines also utilised an electrical pump and tank system to return condensate, however due to frequent issues with the pump, condensate was drained locally.

SOLUTION

Forbes Marshall conducted a plant-wide study. We recommended and implemented solutions at Bottle Washer lines 4, 5, 6 and 7:

Replaced the float trap with a steam-operated pump trap (SOPT) at Bottle Washer lines 4 & 6 to improve process temperatures and eliminate condensate stalling.
Replaced the float trap and condensate recovery system with a combination of a steam-operated pump trap (SOPT) and a steam-operated pressure-powered condensate recovery pump (PPPPU) at Bottle Washer lines 5 & 7. Enabling recovery of condensate at high temperature to the feedwater tank.
Installed a condensate recovery meter (CRM 485R) at Bottle Washer lines 5 & 7.