A major global steel company, based in India, is saving on energy, replacement steam traps and maintenance after replacing its thermodynamic traps with Thermal Energy International’s GEM venturi orifice design. Following successful bucket tests on drip legs, Thermal Energy International’s Indian agent, Hyderabad based Zenith Marketing & Consultants, has installed 400 GEM traps throughout the plant.
The steel plant, based in India’s eastern region, has a very long steam network measuring approximately 16km. Comprised of a high pressure system with a pressure rate of 63 bar and temperatures of 480°C and a low pressure system with a pressure rate of 15 bar and temperatures of 300°C, the network has approximately 500 steam traps fitted along the length of the pipework.
Despite having tried thermodynamic traps, and in some places inverted bucket traps, from all of India’s five steam trap manufacturers, it was found that none lasted longer than six months. The plant then imported traps from Germany and Japan, and although the life of the mechanical trap increased, they still only lasted between 6 months and a year.
Looking for a steam trap with longevity, the plant contacted Zenith Marketing & Consultants, a company specialising in industrial energy saving products, about the award winning GEM venturi orifice steam trap. Following a number of meetings a bucket test was carried out on the steam line to evaluate the GEM trap’s performance. The evaluation was carried out over a 30-month period and after the protracted trial it was found that the GEM traps were still working well. This provided the plant with conclusive proof that the GEM venturi orifice steam trap offers ultimate reliability.
Fitting GEM steam traps has resulted in the plant achieving energy savings by preventing steam leaks from failed traps and providing added efficiency. In addition the plant has also saved costs on replacement traps and maintenance, eliminated trap inspections, prevented pipe damage that destabilises the steam distribution system and improved the safety characteristics of the steam network.
Commenting on the installation Subhas Naik, Director of Zenith Marketing & Consultants said: “We have installed 15mm and 20mm sized traps, which have helped solve the steam network’s many problems. The plant is delighted with the GEM trap and has made it its steam trap of choice”.
Instead of utilising a valve mechanism to close off steam for maximum energy and water conservation, the highly efficient GEM steam traps use the venturi orifice design to effectively drain condensate from the steam system. GEM steam traps are available in a wide range of sizes for a full cross section of applications. The hardwearing GEM steam traps are manufactured from corrosion resistant stainless steel and are guaranteed for 10 years, eliminating the costs associated with regular repair or replacement of other types of traps.