BASF India Saves Energy And Maintenance Following Installation Gem Steam Traps

Prior to the installation of the GEM Venturi orifice steam traps, BASF India had Thermodynamic steam traps fitted on its high and low pressure steam pipeline drip legs. The steam traps not only required extensive and regular maintenance as the traps frequently leaked steam resulting in wasted energy but also caused noise pollution due to their intermittent operation.


A presentation, given by Zenith Marketing & Consultants, explained that by replacing the existing Thermodynamic traps with the GEM venturi orifice design, blocked steam traps could be prevented from impacting on production and by efficiently returning condensate back to the boilers energy saving would be made. A bucket test was carried out over a three-month period and confirmed the trap’s savings potential. An initial order was then given for 22 GEM steam traps, which were fitted on BASF India’s high pressure steam line of 10 Kgs/cm2 drip legs.

Following the successful installation of GEM steam traps on the high-pressure steam line, which showed savings of 7% and a payback of eight months, a survey was carried out on the Thermodynamic steam traps’ performance on the low pressure steam line drip legs. This also confirmed that the traps were passing live steam and wasting energy.


A total of 30 traps were then installed on BASF India’s medium pressure steam line drip legs of 4 kgs/cm2 over January and February 2010. Based on the successful energy savings already achieved, these GEM traps are expected to provide BASF India with a one-year payback.


During a routine inspection it was noted that six of the new trap’s strainers were partially clogged thereby showing less condensate temperature. Zenith promptly informed BASF India how to clean the strainers and the GEM traps are now working at maximum efficiency.


“The GEM steam traps have passed the test for reliability, energy saving, maintenance cost saving and reduction of noise pollution in the factory”, said Mr R K Gulkotwar, Manager-Engineering Services at BASF India. “The revolutionary concept and implementation of the GEM traps at our BASF Thane site was selected in the top five innovations across all division and sites of BASF in India.”


The GEM Trap is a permanent solution to steam trace-trapping problems. Instead of utilising a valve mechanism to close off steam for maximum energy and water conservation, the highly efficient GEM Trap uses the patented venturi orifice design to effectively drain condensate from the steam system. GEM steam traps have no moving parts to wedge open or fail. It therefore provides the ultimate in reliability necessitating only minimal maintenance and requiring no spares, testing or monitoring equipment.


“We have no hesitation in recommending the use of GEM steam traps to other users”, concluded Mr Gulkotwar. “We can proclaim that it is a real revolution in the field of steam distribution.”