Steam Trap Replacements

Milliken’s Upstate South Carolina facility requires regular steam trap replacements for their textile operations. Their processes require a lot of heating, and these devices must work properly to capture condensate.

To make sure they work correctly, Milliken calls JDI Industrial Services to get the project done right. Within a one week shutdown our team must changeout 38 steam traps inside the facility. Our mechanical contractors work on lifts and ladders to reach and work on the traps.

Once the team finishes the work on connecting new steam traps to the piping, they replace the piping with the new traps. This keeps Milliken’s operations effective, safe, and efficient.

To see more details about this project, read below.

First things first, our team of mechanical contractors work with the maintenance engineer to understand the entire layout of the piping and steam traps needing work. We then ensure a proper Lockout/Tagout (LOTO) of the steam lines supplying the traps.

There are 38 steam traps, so consequences can be high if safety isn’t taken seriously or the plan of action is not clear. As part of our best practices, our crew also must let the steam system depressurize and cool down before work begins.

Initially, we isolate the traps by closing inlet and outlet valves of the trap line. Then, we drain any remaining condensate using a drain valve or small opening.

Following this, we disconnect the trap and loosen the connections. After removing the old steam traps carefully, we finish this phase by checking for corrosion and pipe misalignment.

Before attaching the new steam traps we confirm that the new trap is suitable for installation. We check the model’s pressure and temperature range, the condensate load rating, and the type of application (drip, process, or tracing).

Our crew confirms that all of the parts are correct for this system to prevent any kind of failure or accident from happening. Following that, JDI’s mechanical contractors apply thread sealant and install the steam traps in the correct orientation.

The JDI team then begins to finalize the project with a system recommission. Following this we perform a leak test, slowly opening the isolation valves, and check for steam leaks at connections using leak detection spray.

Next, we do a performance verification to confirm the trap is cycling properly and discharging condensate. Finally, we update maintenance records and tag the traps for future identification.

• 38 Watson-McDaniel Steam Traps
• 38 New Threaded Screw Pipe Connections
• PTFE Thread Sealant Application
• Loosening & Tightening Connections
• Documentation of Steam Trap Replacements

Without a doubt, the JDI team on this project helps the maintenance team at Milliken. The facility is now back to full operation with the steam traps being more effective than the previous ones.

The team works regularly on capital projects and maintenance needs alike for this facility. Moreover, this project is another example of how we take care of a facility’s steam and process issues.