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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: [email protected]
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