Sacimem Steam Trap Survey

IMPERIAL TOBACCO STEAM TRAP SURVEY–SACIMEM S.A.
Attn: Petro Anokhin
Sitam S.A. Imperial Tobacco,
Mahajanga, Madagascar
Our Ref: ST/IT/0002 Dated: May 8th, 2023
Dear Petro
Further to the steam system survey carried out on 12th April 2023 to 15th April 2023, I am pleased to
enclose the survey findings and steam trap inventory record.
We at Spirax Sarco East Africa trust that you will find this report resourceful and it assists you in the
equitable use of steam energy at the brewhouse. Should you be in need of further services or clarifications,
please do not hesitate to contact me.
Yours Faithfully
Wycliffe Apindi
Service Engineer, Eastern Africa
M: +254113476132
E: Wycliffe.Apindi@ke.spiraxsarco.com
W: www.spiraxsarco.com/global/en-KE
Contents
 Abstract………………………………………………………………………….1
 Executive Summary………………………………………………………..4
 Observations & Recommendations………………………………..8
 Plant Information…………………………………………………………17
 Steam Loss & CO2 Emission Summary…………………………..19
 Steam Loss & CO2 Emission Details……………………………….20
 Steam Trap Replacement……………………………………………..21
 Detailed Replacement………………………………………………….23
 Steam Trap Inventory………………………………………………….35

Abstract
The steam system survey carried out at Sacimem S.A. factory, Imperial brands was done with the
objectives of benchmarking steam and condensate energy efficiency, reducing ongoing maintenance costs,
optimizing plant performance, and comparing the existing site setup versus that of best practice design.
A total of 17 steam traps were surveyed out of which; 10 steam traps (58.82%) were considered to be in
good condition and working efficiently. 1 steam trap (5.88%) was out of service, meaning that they it was
not in operation during the survey works, and 6 steam traps (35.29%) failed open meaning it is leaking live
steam during its operation, resulting to a loss of 184.13 tons per year which translates to a financial loss
of USD. 14,003.74 yearly. Please refer to page 4 for more on these.
It was also noted that certain good steam practices had not been adhered to resulting to plant problems,
such e.g. stall, incorrect installations and wet steam, these among others have been touched on in the
observation and recommendations section, kindly refer to page 8.
1
Boiler House
Boiler house name/no.

Manned/Unmanned Manned Manned
Annual shutdown Yes Yes
Operational hours/year 3744 3744
Boilers
Boiler No. 2 1
Boiler Ref XF11/47439 4108-07790
Make Babcock-Wanson Babcock-Wanson
Type Fire tube Fire tube
Year of Manufacture 1992 1983
Design Pressure (bar) 50 30
Working Pressure (bar) 8 7
Output F & A (kg/hr) 2800/80 2250/80
Status – Live / Standby
Live Live
/ Maint
Level Controls
On/Off or Modulating On-Off On-Off
Make Sauter Sauter

Blowdown
Bottom – Auto / Manual Manual Manual

Bottom – Line Size (mm) DN40, PN40 DN40, PN40
Bottom – Make Mea-Ino Mea-Ino
Blowdown to Pit / Vessel Pit Pit
TDS – Auto / Manual Manual Manual
TDS – Make Hanna Hanna
Sample Cooler (Y/N) Yes Yes
Heat Recovery from TDS No No
(Y/N)
Feed Tank
Temperature °C 30 30
Capacity (litre) 5000 5000
2
Condition – Good /
Average Average
Average / Poor
Insulated (Y/N) y y
Temperature controlled
No No
(Y/N)
3
Executive Summary
Imperial Brands Tobacco - Sacimem S.A.
Annual Losses
Steam Loss 184.13 tonnes/year
Cost of Steam Loss 14,003.74 $
CO2 Emissions 36,810.45 kg/year
Condition Count Percentage

 OK 10 58.82%
 Failed Open 6 35.29%
 Out Of Service 1 5.88%
Total 17 100%
4
Executive Summary
Suitability Count Percentage

Suitable 13 76.47%
Not Suitable 1 5.88%
Non-Preferred 3 17.65%
Total 17 Tag Number Steam Loss Tag Number Steam Loss
(kg/h) (kg/h)
105 32.93 110 7.68
102 14.55
113 14.00
114 10.45
106 8.91
5
Executive Summary
Bad Actor/Frequent Failures (Please refer to the Failure Frequency Report for further details)
Location Tag Number Failed Total Steam Loss Total Annual Cost ($) Application
(tonnes/year)
105 1 68.49 5,208.69 Drying cylinders
102 1 30.27 2,302.21 Separators
113 1 29.12 2,214.58 Separators
114 1 21.74 1,653.50 Heated rotating cylinder
106 1 18.54 1,409.90 Separators
110 1 15.97 1,214.86 Terminal ends
Application Total % Total Failed % Failed Application Total % Total Failed % Failed
6
Executive Summary

ID Industrial Dryers 1 5.9% 1 16.7% FT Float 16 94.1% 6 100.0%
PE Process 5 29.4% 1 16.7% TD Thermodynamic 1 5.9% 0 0.0%
SM Steam Mains 11 64.7% 4 66.7% Total 17 6 100%
Total 17 6 100%
Site Address Contact

Sacimem S.A.
RTE AMBOSITRA ,
ANTSIRABE
110
VAKINANKARATRA
Madagascar
7
Observations & Recommendations
1. Incorrectly done drain pocket
At the steam supply header, it was noted that, their respective condensate return line was
incorrectly installed in terms of sizing and installation (see photo)
The effect of poor/incorrect condensate return line sizing, is that it results to accumulation of
condensate in the steam main. Here it can be picked up by high velocity steam, leading to erosion
and water-hammer in the pipework. To mitigate such occurrence, the below sizing parameters and
installation method should be adopted:
See below sizing table for the given drain pocket
8
In addition, Air vents should also be installed at the terminal end of the steam line as illustrated
below to remove air present during start up. For this a ¼ “AV13 is recommended.
Still on the supply header, it is recommended that the isolation valve shown below, should be
removed and in its place, a steam trap installed, to ensure only condensate is drained while steam
is trapped
9
2. Poor safety valves installation
Provide venting pipe for the safety valves (highlighted in red) at the supply headers. It poses a
safety hazard presently as it is.
It’s recommended that the outlet pipework must be of longer length and directed to a safe point
for discharge where there is no risk of injury to persons or damage to property in the event of the
valve operating. In addition, it is essential at all times to ensure that the downstream pipework is
well drained so that downstream flooding (which can also encourage corrosion and leakage) cannot
occur, as shown below.
10
3. Mechanical pump maintenance
For the condensate return pump at the boiler house highlighted below, the following are
recommended to ensure its efficient operation
 Replace the mechanism unit complete with the respective cover.

 Add a pressure regulating valve for controlling motive steam supplied.
 Add a pressure gauge; for monitoring the steam pressure supplied.
 Provide an insulation jacket for the pump DN25XDN25.
 Replace the both the pump inlet and outlet non-return valve.
4. Insulation of ancillaries
It was noted at the steam supply header, the steam valves were not insulated hence heat loss
through convection to the environment was being experienced
11
Research has shown that an isolation valve having a size of DN100 and operating at an average
pressure of 10 bars lose about 16GJ of heat energy annually. Insulation jackets are hence
recommended to mitigate these losses i.e. DN80 isolation valve (8pcs), DN80 separator (2pcs),
DN80 strainer (2pc) and DN80 crown valves (2pcs)
5. Automation of the boiler blowdown process

It was noted that, currently a manual blowdown valve (highlighted below) is being used to carry out
the boiler blowdown process for both boilers.
Since boilers are CAPEX investment of high initial capital it is thus always important to always
ensure this important process is carried out to ensure there is no buildup of suspended solids in the
boiler shell, hence to enhance the blowdown process and limit human error, we recommend the
use of a timer controlled automatic blowdown process.
12
The timer should be capable of opening the valve at a specific time, and holding it open for a set
number of seconds. The use of automatic bottom blowdown ensures that this important action is
carried out regularly and releases the boiler attendant for other duties.
To achieve this we recommend the use of a spirax Sarco ABV2i bottom blowdown valve complete
with a blowdown timer and actuated solenoid valve.
6. Boiler TDS regulation

It was noted that the boiler currently does not have a sufficient total dissolve solids (TDS) regulation
system in place
As a boiler generates steam, any impurities which are in the boiler feed water and which do not boil
off with the steam will concentrate in the boiler water resulting to high levels of suspended solids,
high alkalinity or contamination by oils and fats which results to a high Total Dissolved Solids (TDS)
level. Careful control of boiler water TDS level is important to ensure that the risks of foaming and
carryover are minimised.
With regards to this, we recommend the use of a closed loop TDS electronic system, the system is
designed to measure the boiler water conductivity using a conductivity probe. The measured value
is compared to a set point programmed into the controller by the user. If the measured value is
greater than the set point, the blowdown control valve is opened until the set point is achieved.
A typical Installation is illustrated below.
13
7. Metering of steam generated
It was noted that there is no means of metering steam generated from both boilers.
Why meter steam flow rates?
Measuring steam is important as it will helps in providing vital information on usage and associated
costs that can improve efficiency in the following areas:
I. Plant Efficiency
 Is idle machinery switched off?
 Is plant loaded to optimum efficiency?
 Identify cleaning and / or maintenance needs.
 Identify major steam users.
 Highlight peak steam usage periods.
 Indicate whether working practices are satisfactory.
II. Energy Efficiency
 Monitor results of energy saving schemes.
 Compare efficiency of various pieces of plant.
III. Process Efficiency

Confirm if the correct quantity of steam at the right pressure and temperature is being
supplied.
IV. Costing
 Cost steam as raw material
 True cost of individual product lines can be established.
 Relate steam energy costs to total plant efficiency.
 Check individual plant performance.
 Charge steam usage.
Thus from the above discussions, it is recommended that for the boiler steam supply line a Spirax
Sarco VLM-30 should be installed so as to achieve the discussed above.
14
8. Faulty mechanical pump
It was noted that, the mechanical pump conveying condensate to the feed tank from the rotary
dryer 1 was faulty.
This was confirmed by the low return of condensate to the feed tank. Moreover on further
investigation, it was discovered that, the respective pump was not efficiently operating hence there
was condensate accumulation at the receiver which eventually was being drained off through U-
bend overflow pipe to the drainage hence not being recovered.
15
it is recommended that the pump should be serviced to ensure its efficient operation, the following
are recommended:
 Check the motive supply line to ensure steam is being supplied at the right pressure
 Check the motive inlet and exhaust valves and replace as necessary
 Check the mechanism component for any disjoint of the component
 Check for any foreign item at the inlet and outlet non return valve which hinder their
operation obstruction.
16
Site Information

Plant Defaults
Steam Generation Cost -
Customer Specified
Currency $
Steam Source Primary Fuel Unit Cost of FuelCO2 Boiler Feed water Estimated Steam Generation
Pressure bar (g) Fuel Pressure Temp Boiler Cost
($) Efficiency ($)
Mass kg Default Light Oil 1.1400 /L 201.5 9.0 bar (g) 40°C 90 % 76.05
kg/1000kg
Average Hours of
Operation per Item
72 Hours Per
Week
X 52 Weeks Per
Year
3744 Hours Per

Year
17
Notes
Please review the cost of steam and operating hours to ensure this is suitable for your site.
If you feel any of the above figures are inappropriate, please do not hesitate to contact us and we will revise them accordingly.
18
Steam Loss & CO2 Emissions Summary

Location Steam Loss Steam Loss Cost of Steam Average Hours of No. Items Failed Total Annual Emissions CO2
(kg/h) (tonnes/year) Loss per Hour Operation per Open Cost (kg/year)
($) Item ($)
Conditioning Cylinder 24.45 50.86 1.86 2080 2 3868.08 10148.11
Boiler House 23.47 48.81 1.78 2080 2 3712.11 9815.29
Rotary Dryer 1 40.61 84.46 3.09 2080 2 6423.55 16847.05
Totals 88.53 184.14 6.73 6 14003.74 36810.45
19
Steam Loss & CO2 Emissions Details

Tag Connection Size Manufacturer P1/P2 Location Condition Average Steam Loss Cost of Emissions CO2
Number Model Type Orifice Size Leak Severity Hours of (tonnes/year) Steam (kg/year)
Condensate Operation Loss per
Returned per Item Year
($)
105 40.00mm(1 1/2") Spirax Sarco 3.0/0.1 bar(g) Rotary Dryer 1 Failed Open 2080 68.49 5208.69 13639.23
FT43-10 Float 4.50mm(0.18in) Rotating Cylinder Large
Yes
102 25.00mm(1") Spirax Sarco 6.2/0.1 bar(g) Boiler House Failed Open 2080 30.27 2302.21 6078.98
FT14-10 Float 4.50mm(0.18in) Supply Lines Large
Yes
113 25.00mm(1") Spirax Sarco 4.0/0.1 bar(g) Conditioning Cylinder Failed Open 2080 29.12 2214.58 5818.34
FT14-10 Float 4.50mm(0.18in) Steam supply mains Large
Yes
114 25.00mm(1") Spirax Sarco 3.0/2.0 bar(g) Conditioning Cylinder Failed Open 2080 21.74 1653.50 4329.78
FT14-10 Float 4.50mm(0.18in) Drying cylinder Large
Yes
106 15.00mm(1/2") Spirax Sarco 8.0/0.1 bar(g) Boiler House Failed Open 2080 18.54 1409.90 3736.30
FT14-10 Float 4.50mm(0.18in) Supply Lines Large
Yes
110 25.00mm(1") Spirax Sarco 6.2/0.1 bar(g) Rotary Dryer 1 Failed Open 2080 15.97 1214.86 3207.82
FT14-10 Float 4.50mm(0.18in) Steam Supply line Large
Yes
20
Steam Trap Replacement Report

Tag Number Location Connection Size Connection Application Condition Action Notes Pressure
Height Model Type Suitability Leak Severity
Status Manufacturer Standard Flow Direction Condensate
Type Orientation Returned
102 Boiler House DN25 (1") Screwed Separators Failed Open Replace 6.2 bar(g)
Eye Supply Lines FT14-10 BSP Suitable Large
Spirax Sarco Horizontal Right to Left
Float Yes
105 Rotary Dryer DN40 (1 1/2") Flanged Drying Failed Open Replace 3.0 bar(g)
Eye 1 FT43-10 PN16 cylinders Large
Rotating Spirax Sarco Horizontal Suitable
Cylinder Float Right to Left Yes
106 Boiler House DN15 (1/2") Screwed Separators Failed Open Replace 8.0 bar(g)
High Supply Lines FT14-10 BSP Suitable Large
Spirax Sarco Horizontal Right to Left
Float Yes
110 Rotary Dryer DN25 (1") Flanged Terminal ends Failed Open Replace 6.2 bar(g)
Low 1 FT14-10 PN16 Non-Preferred Large
Steam Spirax Sarco Horizontal Right to Left
Supply line Float Yes
21
113 Conditioning DN25 (1") Flanged Separators Failed Open Replace 4.0 bar(g)
Low Cylinder FT14-10 PN16 Suitable Large
Steam Spirax Sarco Horizontal Right to Left
supply Float Yes
mains
114 Conditioning DN25 (1") Flanged Heated Failed Open Replace 3.0 bar(g)
Low Cylinder FT14-10 PN16 rotating Large
Drying Spirax Sarco Horizontal cylinder
cylinder Float Suitable Yes
Left to Right
22
Detailed Replacement Report
Product FT14-10 Height Eye

Tag Number 102 Height Detail
Area Boiler House Access Foot
Sub Area Supply Lines Application Group Steam Mains Photo
Location Detail Application Separators
Condition Failed Open Steam Loss 30.27 tonnes/year

P1/P2 6.2 bar (g)/0.1 bar (g) Cost of Steam Loss 2302.21 $
Condensate Returned Yes Emissions CO2 6078.98 kg/year
Failed Product Detail Replacement Product Detail

Maintenance Details
Present Is Present Maintenance Type Universal Connector Details

Type Float Replace Manufacturer Manufacturer
Manufacturer Spirax Sarco Urgency Model Model
Model FT14-10 Inlet Size Connection Type
Inlet Size DN25 (1") Upstream Isolation Connection Type
Connection Type Screwed No
Flow Direction Right to Left Downstream Isolation Notes
23
Orientation Horizontal No
24
Product FT43-10 Height Eye

Area Rotary Dryer 1 Access Foot
Sub Area Rotating Cylinder Application Group Industrial Dryers Photo
Location Detail Application Drying cylinders


Maintenance Details

Inlet Size DN40 (1 1/2") Upstream Isolation Connection Type
Connection Type Flanged No
25
26
Product FT14-10 Height High

Area Boiler House Access Cherry Picker
Sub Area Supply Lines Application Group Steam Mains Photo


Maintenance Details

Inlet Size DN15 (1/2") Upstream Isolation Connection Type
Connection Type Screwed No
27
28
Product FT14-10 Height Low

Area Rotary Dryer 1 Access Foot
Sub Area Steam Supply line Application Group Steam Mains Photo
Location Detail Application Terminal ends


Maintenance Details

29
30

Area Conditioning Cylinder Access Foot
Sub Area Steam supply mains Application Group Steam Mains Photo


Maintenance Details

31
32

Area Conditioning Cylinder Access Foot
Sub Area Drying cylinder Application Group Process Equipment Photo
Location Detail Application Heated rotating
cylinder


Maintenance Details

Flow Direction Left to Right Downstream Isolation Notes
33
34
Steam Trap Inventory Report

Tag Number Location Connection Size Connection Type Application Condition Replacement Notes Pressure
Height Model Standard Suitability Condensate / Preferred
Manufacturer Orientation Flow Direction Returned Trap
Type
101 Boiler House DN25 (1") Screwed Terminal ends OK None 6.2 bar
Low Steam FT14-10 BSP Non-Preferred (g)
Header Spirax Sarco Horizontal Right to Left Yes
Float
102 Boiler House DN25 (1") Screwed Separators Failed Open Replace 6.2 bar
Eye Supply Lines FT14-10 BSP Suitable (g)
Spirax Sarco Horizontal Right to Left Yes
Float
103 Boiler House DN25 (1") Screwed Separators OK None 6.2 bar
Eye Supply Lines FT14-10 BSP Suitable (g)
Float
104 Boiler House DN15 (1/2") Screwed Steam motive Not in Use None 8.0 bar
Low Mechanical FT14-14 BSP supply (g)
pump Spirax Sarco Horizontal Suitable Yes
Float Right to Left
35
105 Rotary Dryer DN40 (1 1/2") Flanged Drying Failed Open Replace 3.0 bar
Eye 1 FT43-10 PN16 cylinders (g)
Rotating Spirax Sarco Horizontal Suitable Yes
Cylinder Float Right to Left
106 Boiler House DN15 (1/2") Screwed Separators Failed Open Replace 8.0 bar
High Supply Lines FT14-10 BSP Suitable (g)
Float
107 Boiler House DN15 (1/2") Screwed Separators OK None 8.0 bar
High Supply Lines FT14-10 BSP Suitable (g)
Float
108 Rotary Dryer DN25 (1") Flanged Separators OK None 3.0 bar
Low 1 FT14-10 PN16 Suitable (g)
Steam Supply Spirax Sarco Horizontal Right to Left Yes
line Float
109 Rotary Dryer DN15 (1/2") Flanged Steam motive OK None 3.0 bar
Low 1 FT14-4.5 PN16 supply (g)
Mechanical Spirax Sarco Horizontal Suitable Yes
pump Float Right to Left
110 Rotary Dryer DN25 (1") Flanged Terminal ends Failed Open Replace 6.2 bar
Low 1 FT14-10 PN16 Non-Preferred (g)
Steam Supply Spirax Sarco Horizontal Right to Left Yes
line Float
111 Conditioning DN15 (1/2") Flanged Cooker OK None 1.0 bar

Low Cylinder FT14-10 PN16 Suitable (g)
Mixing Horizontal Right to Left Yes
36
Vessels Spirax Sarco
Float
112 Conditioning DN15 (1/2") Flanged Cooker OK None 1.0 bar
Mixing Spirax Sarco Horizontal Right to Left Yes
Vessels Float
113 Conditioning DN25 (1") Flanged Separators Failed Open Replace 4.0 bar
Steam supply Spirax Sarco Horizontal Right to Left Yes
mains Float
114 Conditioning DN25 (1") Flanged Heated Failed Open Replace 3.0 bar
Low Cylinder FT14-10 PN16 rotating (g)
Drying Spirax Sarco Horizontal cylinder Yes
cylinder Float Suitable
Left to Right
115 Conditioning DN15 (1/2") Flanged Heated OK None 3.0 bar
Low Cylinder TD32FLC PN16 rotating (g)
Drying Spirax Sarco Horizontal cylinder Yes
cylinder Thermodynamic Not Suitable
Left to Right
116 Conditioning DN15 (1/2") Flanged Terminal ends OK None 4.0 bar
Low Cylinder FT14-10 PN16 Non-Preferred (g)
Steam supply Spirax Sarco Horizontal Right to Left Yes
mains Float
117 Rotary Dryer DN25 (1") Flanged Heated OK None 3.0 bar
Low 1 FT14-10 PN16 rotating (g)
Rotating Spirax Sarco Horizontal cylinder Yes
Cylinder Float Suitable
Right to Left
37

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IMPERIAL TOBACCO STEAM TRAP SURVEY–SACIMEM S.A.

Attn: Petro Anokhin

Sitam S.A. Imperial Tobacco,

Our Ref: ST/IT/0002 Dated: May 8th, 2023

Service Engineer, Eastern Africa

 Observations & Recommendations………………………………..8

 Steam Loss & CO2 Emission Summary…………………………..19

 Steam Loss & CO2 Emission Details……………………………….20

 Steam Trap Replacement……………………………………………..21

 Steam Trap Inventory………………………………………………….35

Boiler house name/no.

On/Off or Modulating On-Off On-Off

Make Sauter Sauter

Bottom – Auto / Manual Manual Manual

Imperial Brands Tobacco - Sacimem S.A.

Condition Count Percentage

Imperial Brands Tobacco - Sacimem S.A.

Suitability Count Percentage

Imperial Brands Tobacco - Sacimem S.A.

Imperial Brands Tobacco - Sacimem S.A.

Site Address Contact

See below sizing table for the given drain pocket

 Replace the mechanism unit complete with the respective cover.

5. Automation of the boiler blowdown process

6. Boiler TDS regulation

Why meter steam flow rates?

III. Process Efficiency

Imperial Brands Tobacco - Sacimem S.A.

3744 Hours Per

Imperial Brands Tobacco - Sacimem S.A.

Imperial Brands Tobacco - Sacimem S.A.

Imperial Brands Tobacco - Sacimem S.A.

Imperial Brands Tobacco - Sacimem S.A.

Product FT14-10 Height Eye

Condition Failed Open Steam Loss 30.27 tonnes/year

Failed Product Detail Replacement Product Detail

Present Is Present Maintenance Type Universal Connector Details

Imperial Brands Tobacco - Sacimem S.A.

Imperial Brands Tobacco - Sacimem S.A.

Product FT43-10 Height Eye

Condition Failed Open Steam Loss 68.49 tonnes/year

Failed Product Detail Replacement Product Detail

Present Is Present Maintenance Type Universal Connector Details

Imperial Brands Tobacco - Sacimem S.A.

Imperial Brands Tobacco - Sacimem S.A.

Product FT14-10 Height High

Condition Failed Open Steam Loss 18.54 tonnes/year

Failed Product Detail Replacement Product Detail

Present Is Present Maintenance Type Universal Connector Details

Imperial Brands Tobacco - Sacimem S.A.

Imperial Brands Tobacco - Sacimem S.A.

Product FT14-10 Height Low

Condition Failed Open Steam Loss 15.97 tonnes/year

Failed Product Detail Replacement Product Detail

Present Is Present Maintenance Type Universal Connector Details

Imperial Brands Tobacco - Sacimem S.A.

Imperial Brands Tobacco - Sacimem S.A.

Product FT14-10 Height Low

Condition Failed Open Steam Loss 29.12 tonnes/year

Failed Product Detail Replacement Product Detail

Present Is Present Maintenance Type Universal Connector Details

Imperial Brands Tobacco - Sacimem S.A.

Imperial Brands Tobacco - Sacimem S.A.