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INTRODUCTION

1.1. Overview of steam trap audit

PT. Cosmicon Enermatik has conducted surveys at PT. Wilmar Nabati Indonesia
Gersik Plant on 16th November - 31st December 2015.

Survey was carried out using the steam trap leak detection equipment handled by an
experienced personel and the total steam traps surveyed are 4925 units. Upon
completion of physical steam trap checking, all result are compiled on excel table on
our report.

Clearly this is the most important first step taken towards energy conservation
program. Besides identifying working condition of steam trap (s), we will also at the
same time bulid up a database of the entire or particular steam trap population in the
plant . The database will be a platform for all future maintenance and monitoring
activities to achieve a reliable & efficient steam system.

1.2. Scope of work (TDTPR)

- Tag the traps with sequentially numbered taging plate
- Document the traps location, application, working pressure, size, connection, type&
manufacturer comments about existing installation are also documented.
- Test operational status of trap using a combination of ultrasound and temperature
differential.
- Provide complete report noting entire results of trap survey (Traps tested, leaking,
plugged, not in service, etc.)
- Return on investment calculation. This includes the cost of the survey,
replacement steam traps for those traps found to be deficient (except labor &
consumable cost to install the replacement traps). These costs are then compared
to the losses associated with the traps found to be failed closed, leaking or
failed open. Trap application problems and specific recommendations for trap and
trap station improvements are also included.

A detailed formal report includes all of the items above in soft or hardcopy and
outlining findings and recommendations is the final deliverable of the steam trap
survey.

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1.3. The impact of failed steam trap
Properly functioning steam traps open to release condensate and automatically
close when steam is present. Failed traps waste fuel, reduce efficiency, increase
production costs, create Safety Issues and compromise the overall integrity of the
steam and condensate systems. Traps should be tested on a regular basis or
the neglect may be quite costly.

When steam traps fail in the open or blow-by condition, they constantly pass steam.
Steam traps are built with an internal orifice to limit the amount of steam loss, but it can
still be significant.

Failed open Failed close

1. Increased Fuel costs
2. Live steam infiltrate into condensate line.
3. Condensate pressure become higher
4. Water hammering inside condensate line
5. Steam trap back pressure become higher
6. Diff. Press. of steam trap become lower
7. Steam trap capacity dropped
1. Banking up of condensate
2. Product temperature become lower
3. Heat transfer become decreased
4. Longer heating period
5. Corrosion
6. Waterhammer

Why do steam traps fail?

Obviously, anything mechanical will malfunction; steam traps are no exception to
the rule. Proper maintenance improves longevity and helps reduce maintenance
costs.
There are general conditions, which adversely affect traps:
1. Dirt by far the leading cause of failure resulting in either a leaking or plugged
trap.
2. Imporper installation position Over a certain period, they may have suffered
by wire drawing (damage) on the main valve & seat assembly and in the worst
case it would lead to body damage near to outlet stream. And cause un-predictable
opening position this it would allow mixture of live steam and condensate flow
through opening.
3. Over-sizing for example; Mechanical Traps can lose their prime; TD traps
can experience rapid cycling.
4. Pressure surges - (due to sudden steam valve openings, improper piping, or
trap misapplications) resulting in water-hammer and subsequent damage to the
internal steam trap components.

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Fig.1. Sample of two thermodynamic steam traps with different testing result

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1.4. Overview of the steam trap

1.4.1. Ball float steam trap

The Ball float trap works on the principal of sensing the difference in the density of
steam and condensate. This mechanical trap responds almost instantly (modulating
discharge) to any buildup of condensate above its minimum level causing the
condensate to exit out of the discharge port as soon as it is formed.

Fig.2. Working principle of UNA14 Ball Float steam trap

1.4.2. Thermodynamic steam trap

The Thermodynamic Trap works on the principle of difference in the velocities of

Steam and Condensate. Used Mainly on Drip lines of the main steam distribution line,
uses condensate pressure to open the trap and discharge the condensate and then
the Flash steam formed due to the high flash steam velocity & accumulation of flash
steam over disc, Device close and trap the live steam when it appears. Condensate
removed from this trap is intermittent.

Fig.3. Working principle of of Thermodynamic steam trap

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1.4.3 Thermostatic steam trap

Capsule type thermostatic steam trap can discharge the condensate below saturated
steam temperature, because the capsule only open when condensate temperature
dropped (condensate cooler). Due to its design, thermostatic steam trap can function
in any position and it resistent to water hammers.

Fig.4. Working principle of of Thermostatic steam trap

Replacement costs are enourmously reduced due to the independent valve and seat.
This altogether with the external adjustment device result in very low maintenance
costs.

Fig.5. MK45-2 single seat dan MK45-1 double seating (tandem seat)
capsule thermostatic steam trap

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The most innovative of MK45 type is double seat or tandem seat (please see fig. 6).
The self-centring valve cone (i) ensures a steam-tight closure. With increasing
temperature, the downstream single seat (ii) follows, offering a further guarantee of
tightness, even in the case of dirt accumulation. Through the two fold pressure drop,
wear is reduced and the service life extended.

Fig.6. MK45-1 double seating (tandem seat) capsule Thermostatic steam trap

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2. ACKNOWLEDGMENTS

We are very grateful to PT.Wilmar Nabati Indonesia Gresik for good cooperation &
great opportunity to us in order to do survey & checking steam trap job at Gresik
Plant.

On this occassion, we also would like to thank you to Mr. Liew Teik Wie and Mr. Drajat
Priyosaputro upon coordination & your help during this survey job in the field.

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3. WALK THE PLANT
This section provides some information that we found during steam trap checking and it can be used as consideration for
further improvement in the plant. This section complete with snapshots in actual condition and also some
recommendations base on technical information of the equipment, other engineering approach and our technical
experience. A few findings presented in this section are as follows:

Incorrect position of steam trap installation

Unsuitable selection of Maximum Differential Pressure number (PMX)

Banking up of Condensate in Steam Pipe (impact of blocked steam trap)

Over specification (high pressure steam trap fitted in low pressure (3 barg) saturated steam application)

Group trapping

Indication of under-capacity

Flash steam vented to atmosphere (something valuable wasted)

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3.1. Finding : Incorrect position of steam trap installation
Tag. Number : please see the table of steam trap condition (37 pcs found)
Location : please see the table of steam trap condition

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It is clear from all the sample pictures that those traps has been there for a long time. What is not so obvious to the
untrained eye, is that those traps are installed incorrectly and for insulated traps, it would become something neglected.
When steam traps are improperly installed, they cannot function properly and therefore either will not remove the
condensate, let steam blow through, or both.

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If ball float steam trap is fitted in wrong orientation:
Over a certain period, they may have suffered by wire drawing (damage) on the main valve & seat assembly and in the
worst case it would lead to bodydamage near to outlet stream.
Improper opening and closing orientation would cause un-predictable opening position this it would allow mixture of
live steam and condensate flow through opening. Those it would lead to a steam situation.

If thermodynamic steam trap is fitted upside down:

This position will not allow the cleaning of the strainer.
The disc will be difficult to close and it would allow mixture of live steam and condensate flow through opening.

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GESTRA place the nameplate exactly on top of UNA ball float steam trap cover . To help the user during initial
installation or replacement, GESTRA put a sticker with word TOP near to the nameplate.

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Recommendation:
Those traps should be refitted in a correct orientation as soon as possible. Refit (to correct) traps which have a wrong
orientation to follow arrow directions that shown on nameplate (such as picture below) and also on body. Generally the
manufacturers put a arrow marking on the name-plate and it must point to DOWNWARDS perpendicularly to th ground.
The other arrow is located (marked) on the body of the trap which identify the direction of flow (inlet to outlet). The trap is
fitted with the float arm in a horizontal plane so that it rises and falls vertically (please follow the INSTALLATION &
MANUAL INSTRUCTION).

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Hight light..!!:
Please take more attention when refitting the trap to avoid the same or new mistake occurs such as the trap outlet in
opposite direction to the flow of condensate.

Incorrect The position

position corrected but
flow direction
incorrected

BEFORE
AFTER

New position
Incorrect still incorrect
position

BEFORE
AFTER

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3.2. Finding : Unsuitable selection of Maximum Differential Pressure number
Tag. Number : 038-X-11-02 & 039-X-07-02
Location : MES Plant
Body limit is 13 barg
@ 220 degC

But, suitable only for

actual P < 4.5 bar

Working pressure of Reboiler is 10 barg and let say the condensate pressure at the inlet of steam trap about 8 barg. If the
steam trap having total back pressure (cause of pipe lifting & flash steam) of 1 barg, so the actual P must be = 9 - 1 = 8
bar.
If we see the specific Max. Differential Pressure (PMX) on the name plate is only 4.5 bar, which is lower than actual P.

The orifice in the trap is designed to operate up to a maximum differential pressure. If the trap is subjected to a higher
differential pressure than intended, it will tend to close and not pass condensate.

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 Body limit is 13 barg
@ 220 degC

But, suitable only for

actual P < 4.5 bar

The picture above is the Preheater for Methanol Recovery. Working pressure of the equipoment is 7 barg. The exisiting
ball float steam trap spesification installed at the condensate outlet is simillar to REBOILER, and certainly the same
problem will occur.

Recommendation :
Replace it with Float trap higher PMX number or if considered to avoid the risk of stalling then the best choice is to use a
pump trap (as seen on the next page).

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3.3. Banking up of Condensate in Steam Pipe (impact of blocked steam trap)

Tag Code : 087-L-04-03

Condition : Blocked

Pipa steam dengan steam trap yang terpasang pada ujung pipa
dalam kondisi "cold" yang ber-efek pada percabangang pipa yang
lain. Kemungkinan besar pipa steam tersebut penuh dengan
condensate, dimana posisinya lebih rendah dari sumber steam
dan steam trap pada ujung pipa distribusi tersebut dalam kondisi
blocking.
Di sepanjang pipa tersebut terdapat beberapa percabangan untuk
tracing dan jacketing, akan tetapi temperatur pipa dari salah satu
percabangan steam sangatlah rendah yaitu sekitar 75~77 degC
yang sudah bisa dipastikan bukan temperature steam saturasi
dengan tekanan 3 barg.

Untuk lebih jelasnya dapat dilihat pada ilustrasi di halaman-

halaman berikutnya.
 Condensate
return line

Steam line

087-L-04-03

Normall steam piping condition if trap no 087-L04-03 (at the end of pipe) in good condition
(Isometric view)

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 Steam line

087-L-04-03

Normall steam piping condition if trap no 087-L04-03 (at the end of pipe) in good condition
(Side view)

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 Banking up of
Condensate inside
steam line

Banking up of condensate inside of steam piping condition when trap no 087-L04-03 in cold/blocked condition
(Isometric view)

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 Banking up of
Condensate inside
steam line

Banking up of condensate inside of steam piping condition when trap no 087-L04-03 in cold/blocked condition
(side view)

Recommendation: Clean the blockage

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3.4. Over specification (high pressure steam trap fitted in low pressure (3 barg) saturated steam application)
TD120M Spirax sarco is ideally for use as a very high pressure steam applications. It is not practical to use a steam trap
with high pressure & temperature rating for low pressure saturated steam application, or perhaps this is a temporary
decision only.

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3.5. Group trapping
It is tempting to try and save money by connecting several units to a single steam trap. Group trapping describes the use of
one trap serving more than one application.

Group trapping at the outlet of steam coils

Each steam application may generate different condensate rates. If a single trap connects more than one drainage point,
condensate (and air, if exists) from one or more of the coils may fail to reach the trap. Any difference in condensing rates
will result in a difference in the steam pressure drop. A pressure drop difference (which too small to register on a pressure
gauge) is enough to let steam from the higher pressure coil influence the flow of condensate from the lower pressure coil.

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So, typical problems with group steam trapping are reduced heating output, water logging, water hammering, freezing in
cooler climates, and the net result is fuel waste.
This storage tank has 6 heating coils. Each 3 coils has been grouped into one big pocket and an extremely small drain pipe
next to it. But another surprise is we did not see any steam traps fit on the drain pipe outlet.

Group Trapping??
Yesbut where is the trap???

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