Ignoring Steam Traps Causes Significant Losses
The U.S. Department of Energy in Steam Tip Sheet #1, warns that “In steam systems that have not been maintained for 3 to 5 years, between 15% to 30% of the installed steam traps may have failed—thus allowing live steam to escape into the condensate return system.” They go on to say “In systems with a regularly scheduled maintenance program, leaking traps should account for less than 5% of the trap population. If your steam distribution system includes more than 500 traps, a steam trap survey will probably reveal significant steam losses.” We also find, in addition to steam losses, our Stream Trap Survey clients experience increased equipment failures and rising maintenance costs.
Impressive ROI on Routine Steam Trap Maintenance
The DOE provides this example. In a plant where the value of steam is $10.00 per thousand pounds ($10.00/1,000 lb), an inspection program indicates that a trap on a 150-pound-per-square-inchgauge (psig) steam line is stuck open. The trap orifice is 1/8th inch in diameter. The table shows the estimated steam loss as 75.8 pounds per hour (lb/hr). After the failed trap is repaired, annual savings are: Annual Savings = 75.8 lb/hr x 8,760 hr/yr x $10.00/1,000 lb = $6,640
Recommended Steam Trap Testing Intervals (U.S. Department of Energy)
• High-Pressure (150 psig and above): Weekly to Monthly
• Medium-Pressure (30 to 150 psig): Monthly to Quarterly
• Low-Pressure (below 30 psig): Annually
Our Steam Trap Survey Process
1. Locate, Identify and Smart Tag all the steam traps located within your facility
It’s important that our technician understands current operating conditions of the steam plant before a survey starts, including any safety issues that need to be addressed. Once we are cleared to start the survey, our technicians locate and identify every steam trap in the steam system. We attach a smart tag to each steam trap upon verification. The smart tags have a QR code that can be scanned to acquire information about that steam trap, helping people to make more effective decisions.
2. Assess, Analyze, and Test Steam Traps
Our technician tests all steam traps wherever possible and identify those traps that are not operating properly. The surveyor utilizes a combination of testing methods including but not limited to: test valve method, ultrasonic listening device test, infrared thermography camera, and visual observation. Our technician analyzes the steam trap operations using advanced ultrasonic detection equipment and an infrared camera. Together, these components are very effective in determining the condition of a steam trap. Our technician also be assesses steam trap piping arrangements, scanning for steam leaks, and observing poor steam insulation.
3. Reporting Steam Trap Conditions
We discuss preliminary results of the survey with steam trap owners after our technician is satisfied that all steam traps have been assessed, giving them an idea of their current situation. We generate a detailed report, clearly identifying the condition of the steam traps. Our report includes necessary repair recommendations to return the steam system back to optimum operating conditions and provides energy loss calculations describing how the steam losses are affecting the plant and the business.
4. Follow-up Energy Rebate Applications
Trap Energy Solutions is familiar with current rebate programs being offered by some utility companies and we help customers complete necessary rebate applications to ensure all available resources are acquired to help offset energy and maintenance costs.
5. Unbiased Survey Results
We feel that our surveys must be 100% independent stand-alone reports - with no sales strings attached - in our best effort to give customers a thorough and honest consultation. As a result, Trap Energy Solutions is completely independent and NOT affiliated with any steam trap manufacturing or service repair companies. Although we frequently consult with steam trap manufacturing and service repair firms, we do not sell steam trap equipment or provide steam trap repair services.
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