INDUSTRIAL VISIT REPORT

Topic Pressure Gauges, steam trap, steam separator

used in industry/plants, types, installation,
calibration, maintenance and troubleshooting
procedures.

Industry Feroze1888 Mills Limited

Course ME-426 Plant Maintenance

Instructor Sir Abdul Qadir

Group members 1. Hafiz Emmad-ud-din (ME-197)

2. Danyal Arif (ME-202)
3. Bilal Iqbal (ME-217)
4. Ahson Akhlaque (ME-239)

Department of Mechanical Engineering

NED University of Engineering and Technology
Feroze1888 Mills Limited PM Assignment

CERTIFICATION
This is to certify that the students of NED University, Mechanical
Engineering Department, with roll numbers ME-197, ME-202, ME-
217, ME-239 took the industrial visit at Feroze1888 Mills Limited on
10th May, 2018. (Signature of industrial
official)

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Feroze1888 Mills Limited PM Assignment

CONTENTS
1.1 Green Company ...................................................................... 3
1.1.1 Water usage and disposal ................................................ 3
1.1.2 Effluent Treatment Plant ................................................. 3
1.1.3 Solid Waste ..................................................................... 3
1.1.4 Gaseous Emission ............................................................ 3
2. Pressure Gauges ...................................................................... 4
3. Steam trap............................................................................... 5
4. Steam separator ...................................................................... 6
5. References............................................................................... 8

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Feroze1888 Mills Limited PM Assignment

1. Introduction
The foundation stones of Feroze1888 were laid in 1970s. The
company enhanced by and by to become one of the foremost
Producers and exporters of specialized Yarn. The most
distinguishing thing about the company is that it has a vertically
integrated manufacturing facility for terry towels.
Feroze1888 has got the ISO 9001:2008 certification. The goals of the company focus on
manufacture of a controlled quality product along with worker satisfaction.

1.1 Green Company

Today, men have started thinking about their responsibility
towards keeping the environment clean and to overcome any harm
given to it, especially by the industrial sector. The reduction of
natural resources consumption of the industries by reusing or
recycling is what needs to be implemented. Moreover, direct
emission of harmful wastes must be avoided and proper treatment
should be done before releasing them in the environment.
The Feroze1888 has established an Environmental Management
system which is certified by Standard Global Services (SGS) for
fulfilling ISO 14001 requirements.
Following are some of the efforts made by the company:

1.1.1 Water usage and disposal

In any textile industry, dyeing, finishing and raw fiber production requires a great deal of
water. But at Feroze1888 special machinery and water management system is set up to
avoid wastage.

1.1.2 Effluent Treatment Plant

The company avoids direct drainage of liquid waste into the sea. The effluent treatment
plant reduces the harmful effects of sewage.

1.1.3 Solid Waste

The 3R (Reduce, Recycle, Reuse) strategy is practiced in the case of solid waste reduction.
The Solid wastes are properly treated before dumping them into the environment

1.1.4 Gaseous Emission

There are Combined Heat and Power Systems and Variable frequency derives installed to
reduce power loss accompanied with gas emission reduction.

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Feroze1888 Mills Limited PM Assignment

2. Pressure Gauges
When the fluid strikes the Bourden tube, which is present inside the pressure gauge, it applies
pressure and causes it to coil over in its circular shape. As a result, the tube elongates and the
pointer moves across the dial by means of a link and a gear mechanism of high sensitivity.

Description
Types  Piston type
 Bourdon type
 Diaphragm type, etc.
Installation  The point where pressure gauge is to be installed should result in
minimum vibrational effects.
 Adjustable wrench should be used to apply adequate amount of torque.
Too much tight or too much loose gauge ultimately results in improper
readings
 An isolation valve should be installed before pressure gauge to help
repair in case of any problem without shutting down the whole process.
Calibration  To analyses which type of calibration is required upscale and down
scale errors are calculated and plotted.
 A bleed valve is opened in order to separate the gauge form the main
line.
 After that, pressure is taken at maximum and minimum and the pointer
is adjusted accordingly.
 The above procedure is repeated to finally obtain a corrected gauge.

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Feroze1888 Mills Limited PM Assignment

 If the gauge still not works properly then “span” and “nonlinear” errors
are involved which cannot be removed by normal procedures, and
hence the gauge should be replaced.
Maintenance  For critical operations, monthly inspections are to be taken but for non-
critical operations annual inspections are taken place.
 If the readings come out to be wrong then there is a need of re-
calibration or even replacement of pressure gauge.
Troubleshooting  Common issues that occur include damage to Bourden tube leading to
pressure leakage, corrosion of Bourden tube, residual stresses in the
tube or even exposure to high temperatures.
 The solution is removing and replacing damaged parts with new one.
 It is a common industrial practice that if any gauge occurs to be
erroneous it is replaced with a new one immediately.

3. Steam trap
A steam trap is nothing but an automatic valve that functions to filter out non-condensate gases
like air, CO 2 from condensate without the loss of steam. Most of the traps work on the basis of
gravity and density difference between condensate, steam and non-conndensate. Air is
contineously being filtered out through the upper portion while heavier steam left as a residuegoues
to the outlet. When considerable ammount of condensate is collected the float or bucket rises to
open a valve for the condensate to flow. There is no consumption of steam or condensate involved.

Description
Types  Mechanical (free-float, bucket type) trap
 Thermodynamic trap
 Thermostatic trap
 Venture Nozzle trap

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Feroze1888 Mills Limited PM Assignment

Installation  The most important aspect is the consideration of gravity. The flow of
condensate totally depends upon gravity.
 A blow-off valve should be installed on the strainer to help blowdown
the strainer during operation.
 The steam trap must be nearby the plant personnel.
 A rise pipe should not be present after the trap.
 It is a common practice to install check valves along with trap.

Maintenance  Steam trap is a critical device malfunctioning of which can cause great
loss of expensive steam.
 It should be checked on regular basis.
 A steam trap can get damaged by water hammering, poor water
treatment causing corrosion or even metallurgical damages due to
elevated temperatures.
 A faulty trap can be easily detected by having an overheating or
underheating in the conditioned space or by receiving of steam in
condensate returns.
 Most common methods for inspection are:
 Visual inspection
 Temperature inspection
 Acoustic stethoscope inspection
 Ultrasonic testing (most reliable)
 Dirt plugging inside the trap is one of the cause that can prevent valve
from closing leading to other malfunctioning.
 Strainer needs to be cleaned frequently to avoid dirt.
 As a preventive maintenance, the parts of the traps are replaced each
year. But it might prove costly.
Troubleshooting  When a problem occurs it is quite usual in industries to hire a third
party who is specialized in trap troubleshooting. This is far better than
making a mess of this critical equipment by untrained men, causing a
great deal of loss to the company.

4. Steam separator
It is a moisture removing device that helps increasing the dryness fraction of steam. It is quite
necessary that the steam flowing into turbines and engines is moisture free

 to increase thermal efficiency of the plant and

 to increase turbine blade life.
It provides a large surface are for condensation of wet steam which may result in high heat
losses. For that purpose, insulation is an important factor. Condensate is collected inn rgular
intervals by means of an automated valve.

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Feroze1888 Mills Limited PM Assignment

Description
Types  Baffle separator
 Centrifugal separator
 Mechanical coalescence separator
Installation  The maximum pressure inside the separator must be installed in a way
that it is lower than the maximum pressure suggested by the
manufacturer.
 Separator should be installed at a location where there are straight
horizontal runs of steam present.
 Discharge should be vertically downward.
 An isolation or bleed valve should also be installed.
Maintenance  The internal vanes or baffles present inside the separator need periodic
examinations to detect for wear or corrosion which could directly
affect upon the separation efficiency.
 Monthly or even annual inspection is in common practice.
 To remove the contaminants inside the separator, chemicals like CS10-
1 are used to increase the dryness fraction at about 95 %
 Tapping on steam mains should be incorporated to avoid the hazards
of water hammering.
 Insulation inspection should be done to prevent excessive heat loss.
Troubleshooting  Is the separator is not draining moisture then the possible cause will
blocking of drain trap assembly. The remedy will be to remove the
separator and clean draining assembly.
 If the steam is leaking the flange gasket may be damaged. Removing
and replacing gasket will solve the problem

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Feroze1888 Mills Limited PM Assignment

5. References
1. Feroze1888 mills limited official website [www.Feroze1888.com]
2. Ashcroft manual: pressure gauge installation, operation and maintenance.
3. U.S. Department of Energy, Energy tips: steam.
4. Forbes Marshall moisture separator: installation and maintenance manual.

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