Why is it so important for facilities to have a dedicated steam trap survey and repair program?

There are many benefits for a facility with the foresight and wisdom to initiate a steam trap survey and repair program. The most obvious benefits are:

Savings through reduction of steam loss through failed open traps and through leaks associated with the steam trap station.

Increased equipment reliability due to reduction in damaging condensate in steam lines.

Improved product processing through improved quality of steam (hot and dry).

Reduce equipment repairs, down-time, and replacement costs.

Typical failure rates for failed open steam traps is 15-30% of a facility's steam trap population. A facility with 1000 steam traps may have 150 to 300 failed open traps. This translates into a loss of $120,000.00 to $300,000.00 per year in steam loss alone!!

The Steam Loss Chart can be used as a reference for estimating steam loss from failed open traps.

There is more to improving a steam system than the usual trap changing program. While a simple steam trap survey and repair program is a good start, it will not correct many costly problem areas such as waterlogged exchangers, blowing through exchangers (exchangers which will not get hot enough), waterlogged coils, wet steam damaged turbines, and incorrect trap applications. It is possible for every steam trap in a system to test "OK" and the steam system still be in poor shape.

An aggressive steam system management program designed for troubleshooting the entire steam system can make improvements in the system and in the reliability and efficiency of process equipment, save millions of dollars in lost steam, and reduce equipment repairs, downtime, and replacement costs.

To be successful in implementing a program, the facility must make a commitment to improve the total steam system.

The following elements are necessary for a successful steam system maintenance program:

Highly skilled and experienced survey and maintenance personnel who have real world experience or receive specialized training. (The idea that a machine using self-diagnostics can replace a skilled technician is a myth purported by manufacturers wishing to sell their products) Proper equipment including both ultrasonics and temperature. Computer database designed to assist in tracking steam system management and report on savings.

Steam Loss Chart / Steam Solutions

This information was furnished by Field Data Specialists, Inc. For more information you may visit their website at: www.trapbase.com

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