10. 10
10% to 30% average annual
failure rate
Higher on superheated and
high pressure systems
Unpredictable life cycle
Failures undetected without
constant surveys
Typical Mechanical Trap Problems
10
• Can be a maintenance
headache
Replacing traps and installing
service kits
• Low priority…
And therefore OFTEN IGNORED
until process is affected
11. 11
Change To A Permanent Solution
Failure
Mechanical
trap cycle
SurveyReplacement
Current Model
Inefficient short term cycle of
failure and replacement
New Model
Permanent Efficient Engineered
Solution of GEM Traps
12. 12
Reliability
Increase in
energy
consumption
as mechanical
traps fail
EnergyConsumption
SteamLossesIncrease
Mechanical trap
constant fail -replace cycle
GEM Traps maintain efficiency…
New traps
installed
Increased
efficiency of
GEM Traps
1 2
Years
3
PERMANENT SAVINGS
Change To A Permanent Solution
13. 13
Steam Trap: Definition
A steam trap is a device used to discharge condensate and non-
condensable gases with a negligible consumption or loss of live steam.
Most steam traps are nothing more than automatic valves. They open,
close or modulate automatically.
The three important functions of steam traps are:
• Discharge condensate as soon as it is formed.
• Have a negligible steam consumption.(i.e. being energy efficient)
• Have the capability of discharging air and other non-condensable gases.
16. 16
Cost Savings : Research Queen’s University Belfast Feb 2004
Method
According to EN27841
Accepted Practice Among Trap
Manufacturers
New Mechanical Traps
Over Varying Condensate Loads;
0% to 100%
Results
GEM Most Efficient Over Full
Range of Load Conditions
GEM Modulates its Capacity
No Condensate Build Up in Front
of GEM Traps
Fig 5.12 Comparison of the performance of different type of steam traps
IB
Free Float
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2
0 20 40 60 80 100 120 140 160
Condensate flow (expressed as flow level in cm of liquid in evaporative column of test rig (cm))
Steamloss(kghr
-1
)
Float trap
TD
MK
BPT
GEM
Validated $avings: Hundreds of Tests
17. 17
Dripleg Bucket Test Methodology
EXISTING Steam Trap
Record Before & After
• Weight
• Temperature
• Time
•150 PSIG or Less Saturated Steam
•Stable Condensing Load
•Collect Condensate AND Live Steam
GEM Steam Trap
Distribution Header Distribution Header
Record Before & After
• Weight
• Temperature
• Time
Validated $avings: Field Testing
19. 19
Dripleg Bucket Test Results
Date:
16-Dec-13
Purpose of test:
Imperial <---Select
Steam Existing Trap; Application Details; Temps Test Initial Initial Final Final Flow
Trap Size, Make & Type e.g. drip leg/tracer etc. Before & After No Tank Mass Tank Temp Tank Mass Tank Temp lb/hr
Location/Ref. Press in - Back Press = Diff. size, lagging, length.. Trap Min Sec Mi (lb) Ti (°F) Mf (lb) Tf (°F) Btu/hr
Existing Size; 3/4" Make; Armstrong xx - xx 1 10 5 23.4 85.5 26.4 118.5 17.9 6,143
Trap #15 Type; Inverted Bucket 2
Steam Press.; 104 psig 3
Back Press.; 0 psig 4
17.9 6,143
New Size; 3/4" Make; GEM xx - xx 1 10 15 24.0 84.3 26.1 108.5 12.3 4,343
GEM Type; Opal 2
Size S Steam Press.; 104 psig 3
Back Press.; 0 psig 4
12.3 4,343
SAVINGS TO BE REALIZED ASSUMING $50/TON STEAM COST $1,217.64 /YEAR
= 1 - (Q•
2 / Q•
1)
Change in condensate discharge
utilizing the GEM trap -5.56 lb/hr
Dripleg @ PRV
Average condensed in the bucket (condensate, flash and live steam) / hour - Q•
1
Dripleg @ PRV
Average condensed in the bucket (condensate, flash and live steam) / hour - Q•
2
Increased efficiency of the New Trap
over Existing mechanical trap 29.30%
Puerto Rico Customer
Comparative Bucket Test 2
This test is used to compare the efficiency of one model of steam trap against another, to determine which is the most efficient trap. The energy discharged through the trap is collected in a bucket and can be
measured through an increase in bucket mass and temperature. The rate of energy passed through the trap is used to measure the efficiency of trapping.
Time Rate of
Energy
Changet
Validated $avings: Field Testing
22. 22
Large mechanical float trap
which has been removed
Smaller, more compact GEM Ruby
Trap allows SIGNIFICANT space
GEM Ruby Trap
GEM Trap Secondary Benefits
24. 24
A GEM conversion is a fully supported permanent solution
A GEM Trap representative will:
Visit the site and likely survey all the steam traps
Provide training to installation and maintenance teams
Fully understand the system
Take responsibility for establishing the load on each trap
Fully commission all GEM Traps
Supply free of charge replacement traps where
optimization of trap sizing is required
Ensure the end customer is 100% satisfied
These services are offered by TEI and are
included with every GEM Trap conversion
Delivering GEM Trap Benefits
25. 25
Why GEM is Best Applied as a System
Optimized Performance of Customer’s Total System
Most Efficient use of Sales and Engineering Time & Resources
Costs Minimized by Single Mobilization for Customer and TEI
Full Savings Potential Realized by Customer Immediately
125
PSIG
30 PSIG
Atmospheric
PRV
Condensate Steam Vapor
Delivering GEM Trap Benefits
26. 26
What Are The Typical Project Steps?
Survey Steam trap audit with
FLIR Imager
Survey Analysis
and Proposal
Produce a quotation &
trap list that quantifies
the project costs
Energy Loss &
Projected Project
ROI
Quantify the cost savings
potential for the site
Validate Efficiency
(if necessary)
Perform bucket test
and/or process trial
Implement Engineer and install GEM
traps
Commission &
Training
Train staff on use and
care of the GEM traps
30. 30
Installation of Ruby Traps
a
GasketsStrainer
Flow
Direction
GEM Trap Installation
Ruby
Trap
31. 31
Installation of Sapphire Traps
a
Blowdown
Valve
Strainer
Sapphire Trap
Typical Sapphire
Installation
IR Image
Insulation Bag
GEM Trap Installation
32. 32
Installation of Emerald Traps
2- Bolt base typically
already installed
Access to strainer
and trap opening
without removal or
parts needed
GEM Trap Installation
33. 33
Installation of Opal Traps
Access to strainer
and trap opening
without removal or
parts needed
GEM Trap Installation
37. 37
Installation of Emerald & Opal Traps
Patented Magnetic Cap
Magnetic cap
provides another
level of protection.
Can be provided for
Opal (shown) or
Emerald traps
GEM Trap Inspection & Maintenance
38. 38
1st stage
Large surface area reinforced 316 SS strainer baskets
2nd stage
High temperature magnet removes small
corrosion particles, Patent Pending design
3rd stage
Debris deflector to reduce coagulation of small particle
that pass the filter
Unique Patented Three Stage Filter
GEM Trap Inspection & Maintenance
