Rethinking the Routine:
Steam trap management made simple
There is one component in a steam system whose importance cannot be overstated. From the most straightforward, small-scale steam and condensate loop to the most intricate, complex industrial-sized operation, its role is both simple and vital. It has one job: to discharge condensate and incondensable gases while not permitting live steam to escape.
It is, of course, the steam trap. It is a device with more than 200 years of history and an impact on any steam system that belies its size. Today, its significance is arguably more important than ever, as it is crucial in maintaining efficient, safe, and sustainable thermal processes.
The usual approach to steam trap maintenance
Anyone focused on the process productivity of their steam system will be acutely aware of their steam traps' performance. Potentially, sleepless nights can be caused when you know the effects of failed steam traps on your plant, reducing efficiency, causing downtime to remedy the situation, or even introducing the risk of water hammer.
Steam traps that are not functioning correctly will cause concern for others, too. Those with an eye on a business's sustainability, or profitability, will have reason to worry about the resulting increase in fuel consumption and reduced ability to meet stringent environmental targets.
Knowing that your steam traps will, at some point, fail, at least acknowledges the fact. It also led to the usual approach to mitigate the effects of steam trap failures: introducing regular steam trap surveys or audits. Exactly how often these are conducted varies tremendously, depending on the steam system. For example, the U.S. Dept. of Energy has suggested these intervals, determined by the operating pressures of the traps:
- High-Pressure (150 psig and above): Weekly to Monthly
- Medium-Pressure (30 to 150 psig): Monthly to Quarterly
- Low-Pressure (below 30 psig): Annually
These are "recommended" intervals; not obligatory standards. The same body has said 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.. .¹U.S. Department of Energy
If you search online archives for statistics on steam trap failures, the costs in terms of lost energy, reduced operational performance, and the expected life span of traps, you will find many wildly varying examples. But one thing is for certain: at some point, as with all mechanisms, failure (either by being permanently open or closed) will happen. Estimates are that an average-quality trap might only have a four-year operational life versus eight years for the higher-quality steam traps produced at GESTRA.
Why unexpected steam trap failures may be a thing of the past
The ability to remotely monitor steam traps, almost in "real-time", has been available for over a decade. Early versions relied upon a simple "traffic light" means of letting plant operators know whether a trap was functioning correctly (green) or had failed (red).
Even with the use of hand-held instrumentation for manual monitoring of steam traps, there has always been a potential for error. A brief snapshot of the trap is taken, sometimes as short as 15 seconds, and can be influenced by other equipment's "noise", leading to a false conclusion. This underscores the need for more reliable and accurate monitoring methods.
GESTRA's ecoBolt marks a leap forward in gaining reliable, trustworthy information about the state of a steam trap's performance. It is the cornerstone of our wireless steam trap monitoring solution (WSTM), offering continuous monitoring and avoiding the losses that would be incurred by more periodic forms of testing.
ecoBolt does far more than monitor your steam trap status-it will quantify steam and financial losses, plus any CO2 emissions.
There is a connection with the traditional, manual form of steam trap testing here. You may have the most astute, dedicated engineers looking at your steam trap population's health, but outside "noise" may still lead to the wrong result. Similarly, the quality of the ultrasonic and temperature data given by a WSTM device is of utmost importance. And how that data is interpreted is also vital.
GESTRA's WSTM solution is linked to its IoT (internet of things) platform, building a repository of valuable data on past performance. This is may be accessed remotely, via a customised portal. These insights will be critical to preventing failures before they happen and help prepare your business as the demands to meet operational efficiencies and emissions-related regulations grow.
Proving its worth, one steam trap at a time
Aside from the manufactured quality of your steam traps, they are not all alike. Napier's formula is widely used to determine steam loss through an orifice. This depends upon both the steam pressure and the size of the steam trap. This means there are a number of "high-value" steam traps in any system. This might not just be a financial consideration (i.e. in terms of lost energy/increased fuel costs); it could be that they are traps that protect valuable equipment, or, should they fail, have major consequences for plant processes.
We have convinced even the most sceptical of the solution's value by identifying these essential steam traps, connecting them to the WSTM service, and delivering the most accurate, reliable data.
Restore confidence in your steam traps today
Operational efficiency and cost control have long been watchwords for businesses looking for long-term growth. Today, sustainability and process optimisation join those as forward-thinking businesses navigate the net zero journey. If steam is part of your process, continuing with past practices is no longer enough. Embracing every opportunity to improve steam generation, distribution, and utilisation is crucial for securing its future.
It is unlikely that steam traps will ever be replaced. The need for them remains constant in any system. But, we can evolve to ensure that their work is completed as efficiently and not just assume that the way things used to be is how they always must be.
Note:
¹: U.S. Department of Energy: Inspect and Repair Steam Traps