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According
to major steam trap manufacturers, compiled data has demonstrated
that if there has been no steam trap inspection and maintenance
pro-gram, upwards of 50% of the steam traps at a particular location
may be wasting steam. It is only through a consistent, regularly
scheduled trap maintenance program that effective savings can
be achieved. Below we detail a conservative estimate of those
savings. The data is general and may not necessarily reflect the
exact situation in your plant.
In
a system of 1,000 steam traps, it is assumed that the average
orifice size of a blow-through is estimated at 1/16 inch, the
average pressure is 150 psig, and the cost of steam production
is $4.00/1,000 lbs. It is also as-summed that the plant steam
is in operation 365 days/year, 24 hours/day. Based on these assumptions,
the steam loss per day is 453 lbs. per trap at a cost of $1.81/day/trap
or $662.25/year loss per trap. A conservative assumption that
only 10% of the traps are faulty would result in an annual cost
of $66,225 in lost steam within the system.
The
time to stop neglecting or taking a steam system for granted is
now. The rise in fuel costs over the past fifty years should have
jolted you into the realization that poorly maintained steam systems
makes no financial, engineering or moral sense. For over the past
twenty years, I have pondered why steam systems are treated as
second- class citizens. Some of the reasons I theorized are:
- Lack of
manpower: It is true that cutbacks have depleted many facilities
of the pipe fitters and steam reliability personnel necessary
to maintain their systems.
- Lack of
expertise: Few people at most facilities are well versed in
how the system should be tested or maintained.
- Management
does not consider the system a high priority for resource allocation:
If they only realized the tens of thousands or millions of dollars
they have been wasting over the years.
- Escalating
energy (operating) costs are taken for granted: Many plants
do not meter their steam to individual departments; system add-ons
are used as the excuse for purchasing additional boilers; no
method in the plant exists that can indicate they are using
twice as much fuel as they should be.
Creating
a good predictive maintenance program for steam traps takes vision
and an unrelenting commitment to manage the steam system.
By properly managing the steam system, not only will you improve
the plant bottom-line by reducing fuel consumption, you will impact
the world environmental community by vastly reducing toxic boiler
emissions.
Making the case for purchasing good software:
...one
of numerous examples.
Good steam trap management software permits you to make important
judgment calls based on proper information. As you gather data,
you must have the ability to sort the data and convert it into
useful information. For instance, take the case of a pharmaceutical
or food company that does little or nothing in treating its boiler
with chemicals because contamination issues. By collecting and
entering data into a software package, one can analyze the data
to determine if one of the six manufacturers traps on site provides
nearly trouble-free operations (i.e. an all stainless steel float
and thermostatic trap). As you review the results of current and
past steam trap surveys, the information shows which of the steam
traps have low maintenance costs associated with it.
Information gathering:
...the first step in taking control of your system
The first step in building the software database is to take a
pad with you and record the relevant data for each trap that you
tag and test. The first survey is always the most difficult since
it is necessary to input the most information. The reason for
this is to allow the user to categorize the future data into useful
information for analysis. Subsequent surveys will move at a swift
pace because you need only to record the following data: inlet/outlet
temperatures and the test status.
The next step is to take a photograph of each steam trap and the
application it is draining. Good software should allow you to
include this digital record along with all the associated trap
data. A competent steam engineer may then determine whether proper
attention has been paid to hook-up design. Going one-step further,
the photo can be marked-up (in a paint program) with arrows pointing
to areas that need modification.
Why plant steam trap programs fail:
Serious students learn, if one is to succeed in life's chosen
endeavors, at least two criteria must be met: (1) The willingness
to learn new things and (2) An uncompromising determination to
chart a course to reach your goals. In order to gain confidence
to succeed, we must have the willingness to learn new things.
We also live in world where practical knowledge and experience
should never be given less weight than book learning. Both are
equally relevant. Individuals charged with the responsibility
of the steam conservation program must be well trained so that
they feel comfortable in accomplishing their duties. Secondly,
having an uncompromising determination to chart a course to reach
your goals. Then the discipline, patience, and organization to
forever stay the course will be gained. Perhaps a good steam trap
program for testing and replacement of faulty traps once existed
in your facility. Then, an individual charged with instituting
the program retired or left the plant. The program left with their
departure.
When
you purchase a "kit ready for assembly" you are provided
with the parts and instructions. If I were to break it down into
the two necessary components to begin a steam trap program it
would be (1) equipment and the accompanied training necessary
to attain your confidence level (purchase your equipment and training
from a respected expert in the field) and (2) software that can
be used to manage the steam system.
Control your own system:
...contractors should conform to your standards and specifications.
In a large plant environment expansions and re-piping occurs on
a regular basis. It is surprising how many plants have not created
standard specifications on: (1) which trap manufacturers and models
are required (2) proscribed piping schematics for particular process
applications (3) provisions for strainer blow-downs (4) placement
instructions for check valves, air vents, vacuum breakers, etc.
An outside contractor should never be given free reign over your
system. Especially when you have worked so hard in making it efficient
and well maintained. Remember, after the installation, you are
responsible for the system.
Steam
traps are the most important link between the steam and condensate
system. A malfunctioning steam wastes steam as it blows through
to the condensate side of the system. The days of cheap energy
have ended with a reverberating bang, as has the ability to take
skyrocketing fuel costs for granted. It is imperative that a steam
system be regularly monitored for loss, not only for the sake
of producing quality products swiftly and efficiently, but to
survive in this highly competitive environment. More information
on steam software and system design can be found at the following
websites:
http://www.conserv-it.com
http://www.enerchecksystems.com
http://www.steamonline.com
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