- () ก
BEHN MEYER TECHNO-CHEMICALS ( T ) CO.,LTD
70/1 011,-2345647 8'59&2-$' TELEPHONE 66(0) 2327-9800
%$:ก !2&5 ก 5< 9=> 10520 FACSIMILE 66(0) 2360-6076 / 6194
70/1 LIAP KHLONG MON ROAD., TUBYAO  !"#$%&'()*+,-.$/, 3 10 113897 9
LADKRABANG , BANGKOK 10520
WEB : WWW.BEHNMEYER.CO.TH

STEAM LOSS TEST REPORT

AT
THE BANGCHAK PETROLEUM PUBLIC COMPANY LIMITED

Test to compare the performance of Conventional Steam Trap

and

Orifice SteamPro Condensate Removal Device

Test Date: September 17, 2010

SteamPro Conservation Sdn. Bhd

No 3, Jalan BS 7/15, Bukit Serdang Industrial Park,
43300 Seri Kembangan, Selangor.
Tel: +603-8942 1888 Fax: +603-8943 3057
Email: info@steampro.com.my
Website: www.steampro.com.my

 

  
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BEHN MEYER TECHNO-CHEMICALS ( T ) CO.,LTD
70/1 011,-2345647 8'59&2-$' TELEPHONE 66(0) 2327-9800
%$:ก !2&5 ก 5< 9=> 10520 FACSIMILE 66(0) 2360-6076 / 6194
70/1 LIAP KHLONG MON ROAD., TUBYAO  !"#$%&'()*+,-.$/, 3 10 113897 9
LADKRABANG , BANGKOK 10520
WEB : WWW.BEHNMEYER.CO.TH

Test location :



ก 
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Technical Personnel : Mr. Boon Hong (SteamPro),  ! (Behnmeyer)
Assist by : "# $%
ก (Bangchak)
: # ! &'&(&) (Bangchak)
1.0 Objective

This test is constructed so that two different condensate removal devices (Conventional Steam Traps and Orifice

SteamPro Condensate Removal Device) may be compared to gauge for its energy efficiency.

2.0 Introduction

Condensate is the by-product of heat transfer in a steam system, after the steam given up its valuable latent heat. The

main function of a steam trap is to remove the condensate when it is formed and not allowing the condensate to accumulate

ahead of the steam trap.

Condensate should be removed immediately, completely and continuously in order to maintain the heat transfer at its

maximum efficiency. Accumulated condensate which cooled below the steam temperature in a steam pipe line can produce a

thermal shock (water hammer) when it comes in contact with the steam. This form of shock can damage the pipe line and

equipments.

 

  
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BEHN MEYER TECHNO-CHEMICALS ( T ) CO.,LTD
70/1 011,-2345647 8'59&2-$' TELEPHONE 66(0) 2327-9800
%$:ก !2&5 ก 5< 9=> 10520 FACSIMILE 66(0) 2360-6076 / 6194
70/1 LIAP KHLONG MON ROAD., TUBYAO  !"#$%&'()*+,-.$/, 3 10 113897 9
LADKRABANG , BANGKOK 10520
WEB : WWW.BEHNMEYER.CO.TH

3.0 Test Apparatus

1. A test barrel constructed of thin metal, preferably stainless steel. The size of the barrel should be able to withhold

an amount of condensate equal to that produced by the test process in a period of approximately one hour. The test barrel

should be constructed that the mass of the liquid or condensed liquid may be measured at anytime. The test barrel should be

equipped with a cover to reduce the heat losses due to heat transfer and/or vaporization. The test barrel and its cover should be

well insulated to reduce heat losses.

2. A submersible thermometer.

3. A stop watch.

4. A plastic or wooden stick of a length longer than the total height of the test barrel or stirring.

5. A weighting scale.

 

  
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BEHN MEYER TECHNO-CHEMICALS ( T ) CO.,LTD
70/1 011,-2345647 8'59&2-$' TELEPHONE 66(0) 2327-9800
%$:ก !2&5 ก 5< 9=> 10520 FACSIMILE 66(0) 2360-6076 / 6194
70/1 LIAP KHLONG MON ROAD., TUBYAO  !"#$%&'()*+,-.$/, 3 10 113897 9
LADKRABANG , BANGKOK 10520
WEB : WWW.BEHNMEYER.CO.TH

4.0 Test Procedure

1. The test steam trap is disconnected at the condensate return end. The connection is replaced with a metallic flexible

hose. The condensate is to be removed as quickly as possible. The test device is allowed to run until the entire condensate

backup is clear.

2. The test barrel is filled to a known initial mass of cold water, Mi. Try keeping the initial water as cold as possible to

reduce the heat losses and to increase its ability to condense the discharge from the test device, typically, by adding ice to the

initial mass of water and making sure that all the ice has been melted before beginning the test. The mass of the initial water

should fill the test barrel to about half full.

3. Observe the process which is under the service of the test device to make sure its performance is normal.

4. The temperature of the initial cold water, (Ti ) , is measured.

5. Insert to flexible hose the opening in the barrel cover and make sure the outlet of the flexible hose is totally

submerged.

6. Start the stop watch and open the hose valve simultaneously.

7. Run the test for a period of time. Make sure there is no observable condensate backup with the test device. Observe

the process to make sure that it continues running more or less the same throughout the whole test period. Take note of any

changes. Do not allow the condensed water temperature to exceed 98oC by terminating the test immediately.

8. Terminate the test by closed the valve and stop the stop watch at once and record the final time (t), immediately.

Measure the final water temperature,(Tf ) , and the final water mass, (Mf.)

 

  
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BEHN MEYER TECHNO-CHEMICALS ( T ) CO.,LTD
70/1 011,-2345647 8'59&2-$' TELEPHONE 66(0) 2327-9800
%$:ก !2&5 ก 5< 9=> 10520 FACSIMILE 66(0) 2360-6076 / 6194
70/1 LIAP KHLONG MON ROAD., TUBYAO  !"#$%&'()*+,-.$/, 3 10 113897 9
LADKRABANG , BANGKOK 10520
WEB : WWW.BEHNMEYER.CO.TH

5.0 Result & Calculation

Location : 1. Main Steam Line : Saturated Steam

Steam trap 4Miyawaki SteamPro 4 CRD

Inlet Steam Pressure, Pin (Bar) 11 11
Total time, t (minutes) 10 10
Inlet Steam Temperature (oC) 178 184
Initial Water Temperature, Ti (oC) 33 33

Final Water Temperature, Tf (oC) 40 37

Temperature of the Water (oC) : T = Tf - Ti 7 4

Initial Water Mass, Mi (Kg) 19.2 19.3

Final Water Mass, Mf (Kg) 19.8 19.5

Mass of the Condensate (Kg) : M = Mf - Mi 0.6 0.2

Condensate & Steam loss rate (Kg/hr) : W1 = (M/t) x 60 3.6 1.2
Daily Condensate & Steam loss rate (Kg/day) 86.4 28.8
Monthly Condensate & Steam loss rate (Ton/month) 2.60 0.86
Yearly Condensate & Steam loss rate (Ton/year) 31.2 10.32
Saving (%) : ((W1 of ST- W1 of SP-CRD)/ W1 of ST) x 100 ((3.6 @ 1.2) / 3.6) x 100 = 66.67 %
Saving in Baht per year per trap (Baht 900 / Ton) (( 31.2 @ 10.32 ) x 900 = Baht 18,792

 

  
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BEHN MEYER TECHNO-CHEMICALS ( T ) CO.,LTD
70/1 011,-2345647 8'59&2-$' TELEPHONE 66(0) 2327-9800
%$:ก !2&5 ก 5< 9=> 10520 FACSIMILE 66(0) 2360-6076 / 6194
70/1 LIAP KHLONG MON ROAD., TUBYAO  !"#$%&'()*+,-.$/, 3 10 113897 9
LADKRABANG , BANGKOK 10520
WEB : WWW.BEHNMEYER.CO.TH

Calculation:
1. Main Steam Line : Saturated Steam

Condensate & Steam Loss Rate for Conventional Steam Trap is (W1 of ST) : 3.6 kg/hr
Condensate & Steam Loss Rate for SP-CRD is (W1 of SP-CRD) : 1.2 kg/hr
Savings = W1 of ST @ W1 of SP-CRD kg/hr of condensate & steam
= 3.6 @ 1.2 kg/hr of condensate & steam
= 2.4 kg/hr of condensate & steam
% of Savings = (( W1 of ST @ W1 of SP-CRD ) / W1 of ST) x 100
= ((3.6 @ 1.2) / 3.6) x 100
= 66.67%
From the table above, average yearly steam + condensate savings after installation of 1 unit of SteamPro CRD is
31.2 ton @ 10.32 ton = 20.88 ton and assume cost per ton of steam is Baht 900 ton : Yearly savings of Baht 18,792 per 1 CRD,
Baht 187,920 per 10 CRD, and Baht 1,879,200 per 100 CRD.

6.0 Conclusion

1.) Based on the result obtained from the test (66.67% saving steam loss), the average saving in term of Baht for one

trap per year is Baht 18,792 assuming your whole plant has 100 CRD, the potential saving per year will be :

Baht 18,792 x 100 CRD = Baht 1,879,200 per year* or Baht 156,600 per month*

2.) If we assume 40% saving steam loss only, the average saving in term of Baht for one trap per year will be Baht

11,275 assuming your whole plant has 100 CRD, the potential saving per year will be :

Baht 11,275 x 100 CRD = Baht 1,127,500 per year* or Baht 93,958 per month*

Remark : * This isnGt including cost of maintenance and replacement for the steam traps.

 

  
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BEHN MEYER TECHNO-CHEMICALS ( T ) CO.,LTD
70/1 011,-2345647 8'59&2-$' TELEPHONE 66(0) 2327-9800
%$:ก !2&5 ก 5< 9=> 10520 FACSIMILE 66(0) 2360-6076 / 6194
70/1 LIAP KHLONG MON ROAD., TUBYAO  !"#$%&'()*+,-.$/, 3 10 113897 9
LADKRABANG , BANGKOK 10520
WEB : WWW.BEHNMEYER.CO.TH

7.0 Location Installation

Location 1

Before After

Location 2

Before After

Reported by:

Mr. Jedsada Nuntathanakan (Sales Executive, Behn Meyer Techno - Chemicals (T) Co., Ltd)

17 @ 09 @ 2010