1

Spirax Sarco Limited

P.O.Box 38919 , 00623

Nairobi, Kenya

Tel: +254 020 4443340, Fax: +254 020 4444232

Mobile +254 0734 333059, +254 0722 509856

Email: james.mburu@ke.spiraxsarco.com

3rd March 2016

Kaptumo Tea Factory P.O. Box: Kenya

FIELD REPORT

Attn: Factory Unit Manager

Reference is made to our visit to your Factory on 26th January 2016 and the subsequent

survey of your steam system.

BOILER HOUSE

Item Description Boiler No. 1 Boiler No. 2

Make Thermax Thermax

1 Capacity 10,000 lb/hr 4,500 kg/hr.

2 Model No

3 Des. Press 157 psi 11.00 Bar g

4 Working

Pressure

150 psi 10.00 Bar g

5 year 2008 2009

6 Feed tank

7 Size: 7000 ltrs Temp 80 Deg. C

2

Boiler House

Thermax Boiler No. 1

The safety valve on the thermax boiler is blowing steam slightly but

continuously. The seat of the safety valve is damaged. Replace the safety

valve with DN40 X 80 SV607DS Safety valve PN16 Set at 11.6 Bar g

The safety valve is blowing steam slightly

but continuously. Replace it with DN40 X 80

SV607 DS Open Bonnet set at 11.6 bar g

3

Steam Header

The main header is missing air vent. Install ½”AV13 air vent on the header to

remove the air from the system.

The header is missing air vent. When the

boiler is put into operation the air is pushed to

the header and later to the heat exchangers

downstream. If it is not removed from the

steam line, its likely causes insulation on the

heat exchangers. Install ½” AV13 on the

header.

4

Drier No. 1

Trap Set

No.

Temp

upstream

(Deg. C)

Temp

downstream

( Deg. C)

Observation Recommendation

1 136 92 The steam trap is

working

Low pressure flash steam from

the flash vessel

2 171 123 The steam trap is

working

3 168 139 The steam trap has

failed in an open

position

Replace the failed steam trap

with 1”FT14-10TV

172 134 The steam trap has

failed in an open

position

Replace the failed steam trap

with 1”FT14-10TV

171 135 The steam trap has

failed in an open

position

Replace the failed steam trap

with 1”FT14-10TV

164 130 The steam trap is

installed upside

down.

Install the steam trap with the

arrow on the body facing

direction of flow and the

arrow on the name plate

facing down.

The steam trap is refurbished The steam trap is installed upside down

5

The steam trap is refurbished. The name plate

is upside down

The steam trap is installed upside down

6

The flash vessel pressure gauge is reading 2.8 Bar g. The high pressure is due

to the failure of some steam traps.

The steam trap on the downstream side of the flash vessel is working. The upstream is

temperaure is 134 Deg. C and the downstream temperature is 115 Deg. C

The flash vessel is pressurized to

2.8 bar g due to the failure of the

steam traps. The best pressure in

the flash vessel is 2.0 bar g

7

Main steam supply Line to Drier

The end of pipe drain point on the main steam supply line to driers has a steam trap that is

working. The upstream temperaure is 167 Deg. C and the downstream temperature is 107

Deg. C

Drier No. 2

The end of pipe drain point on the steam supply line to drier no 2 has a steam trap that

is working. The upstream temperaure is 167 Deg. C and the downstream temperature

is 106 Deg. C

8

Trap Set

No.

Temp

upstream

(Deg. C)

Temp

downstream

( Deg. C)

Observation Recommendation

1 136 106 The steam trap is

working

2 166 106 The steam trap is

working

3 165 130 The steam trap is

1” FT14-4.5. It is not

suitable for the

application

Replace the failed steam

trap with 1”FT14-10TV

4 163 127 The steam trap is

working

5 163 130 The steam trap has

failed in an open

position

Replace the failed steam

trap with 1”FT14-10TV

161 123 The steam trap is

working

9

The steam trap is FT14-4.5. It’s not suitable

for the application

The steam trap is refurbished and the name

plate is coming out

10

The steam trap on the downstream side of the flash vessel is working. The upstream is

temperaure is 135 Deg. C and the downstream temperature is 109 Deg. C

The dial gauge is damaged. Replace the damaged dial pressure gauge with 100mm

dial pressure gauge 0 – 6 bar g

The dial pressure gauge is

damaged.

11

Withering

Pressure reducing station

The pressure reducing station has a dial pressure gauge on the upstream side with the dial

damaged. The gauge is overstrained and it is not going back to zero. Replace the damaged

dial with 100mm Dial pressure gauge 0

The dial pressure gauge is

overstrained and it is damaged.

It’s not going back to zero.

12

PROPOSED SYSTEM IMPROVEMENT

Steam flow meter

Lord Kelvin once said

Point of use metering is often the solution to the above problem which was mentioned by lord

kelvin. If a steam flow meter is installed on each drier , it will be very easy to relate the

amount of steam being used to make a kg of made tea. This will help in detecting when there

is loss of steam probably due to failed steam trap or may be due to leakages of hot air on the

drier. The best steam flow meter for the drier is DN80 TVA Target Variable area flow meter

complete with display unit. See a pictures below

13

The DN80 TVA will be wired to

the M750 below for ease of reach

and reading. The display unit

assist in ensuring that the meter

can be read at a level where

everybody can reach without

climbing a ladder.

14

Kaptumo Tea Factory Ltd

Nandi

Kenya

Quote Ref: 00400/JMB/2016 Rev 0

Date: 03/03/2016

Customer Ref: Field survey Report

PROFORMA INVOICE

Line Item Qty Part Number Description Unit Nett Price Ext Nett Price

Boiler House

1 2384495 1 DN40 SV607DS Safety Valve PN25 8.5-12.0 Bar Set @ 11.6 Bar g

£ 812.98 £ 812.98

Header

2 1232600 1 1/2" AV13 Air Vent BSP 'G' Fill NTS Standard

£ 82.94 £ 82.94

Drier No. 1

3 1475100 3 1" FT14-10 TV Steam Trap BSP R/L £ 255.45 £ 766.35

Drier No. 2

4 1475100 2 1" FT14-10 TV Steam Trap BSP R/L £ 255.45 £ 510.90

5 0273260 1 4" Pressure Gauge 6 Bar U Syphon & Cock 3/8" BSP

£ 108.68 £ 108.68

Withering

6 0273460 1 4" Pressure Gauge 16 Bar U Syphon & Cock 3/8" BSP

£ 108.68 £ 108.68

System Improvement

7 1920100 1 DN80 TVA Flowmeter Assy £ 3,143.13 £ 3,143.13

8 3320260 1 M750 Display Unit £ 880.85 £ 880.85

Others

9 Rev146 1 Pre Shipment Inspection Charges £ 210.00 £ 210.00

Total £ 6,624.51

Export Packing

£ 55.00

Freight Cost £ 0.00

Nett Total £ 6,679.51

If you need any clarification or additional information do not hesitate to talk to us.

Report by James Mburu

For Spirax Sarco Limited