PREFERED ARRANGEMENT FOR COMPARATIVE BUCKET TEST Sketch A Application discharging to atmosphere

Heat Output

Steam IV Application IV Steam trap

Flexible Hose

IV GEM steam trap Bucket

Flexible Hose

Bucket

Sketch B Applications with condensate return

Heat output

Steam IV

Application IV Original steam trap IV Condensate return IV To condensate return

S
IV IV

Pressure Gauge (fitted if pressurised return)

Branch IV GEM steam trap (on by pass) Flexible Hose

Bucket

File REF: Comparative Bucket Test a .doc

Date: Aug 03

Instructions for Comparative Bucket Tests

Aim To determine relative trapping efficiency of types of steam traps by measuring the total flow of condensate and live steam through the traps by means of bucket tests (with the application under the same operating load) Limitations Bucket tests may only be conducted on relatively small applications like drip legs, trace heating or boiling pans. As a general rule, traps over 20mm NB have flow rates too large for bucket testing. Arrangements 1. Traps discharging to atmosphere - SEE SKETCH A - it may be possible to insert the bucket directly beneath the trap discharge to perform the test, otherwise simply isolate the trap and connect a hose. 2. Traps discharging to condensate return - SKETCH B - a branch tee should be installed with an isolating valve (IV) to allow for the test and ensure there is an IV on the condensate return to stop any backflow. 3. Trap discharging to pressurised condensate return - as 2 above but with a pressure gauge upstream of the IV. The branch IV would then be throttled back to give the correct back pressure condition. Apparatus * A branch/tee for GEM Trap from inlet of the existing trap, or alternatively fit GEM on trap bypass - SEE SKETCHES A&B * A valve condensate outlet as detailed above (the HSE require isolation by two valves) * A bucket, flexible steam hose, fittings/jubilee clip, scales, protective gloves, clothing and safety glasses. Method a) Using the attached Standard Form, record trap location / reference No., size, make & type. b) Describe application e.g. Drip leg: 200mm dia, 50mm thick Rock Wool, 30m long. c) Record temperatures on the traps' inlet and outlet with infrared temperature guns d) Ensure the hose is of a suitable length and secure the hose to the valve outlet while isolated. e) With the hose outlet held near to a drain / ground, SLOWLY open the branch isolation valve (IV) - if the trap is failed open / flow is too great, the hose will try to 'snake' around and the test should be stopped. f) Half fill the bucket with cold water and weigh the bucket - record 'initial weight' in form below. g) Ensure that the application is at full running load and that there is no flooding of the application. h) Ensure there is no water sitting in the hose by fully draining it and running it at a gradient down to next to the bucket. I) Put the hose into the bucket so that its outlet is held well below the water level in the bucket and j) Simultaneously: * open the IV on the line to the test trap so condensate flows into the bucket * close the IV on the other trap & the return (if fitted) stopping any potential back flow * start stop watch / record time in minutes and seconds k) When bucket gets 3/4 full and / the water in the bucket starts to boil, simultaneously: * pull hose out of the bucket or close the IV on the tee ^ open the IV on the other trap branch & the condensate return (if fitted) ^ stop the stop watch / record time

l) Calculate the weight and time difference. Hence fill in the total flow rate of condensate and live steam through the trap m) Repeat the test until results are consistent and then switch over valves to repeat the tests for the GEM Trap n) The trap with the least flow is working more efficiently and the % reduction can express increase in efficiency. Please Note GEM recommends that all bucket tests are carried out to this procedure with a GEM Engineer in attendance Hot fluids are hazardous, especially if not handled properly. GEM Ltd. does not accept liability for others not abiding to health & safety guidelines & rules. File Ref: Comparative Bucket Test, Aug'02