Classification: Confidential
STEAM TRAP INTEGRITY
M. Z. Bin Zulkifli
Plant Inspector
Saudi K-KEM Engineering Service Company
December 4, 2021
Introduction
The heating capability of steam system is depends on the
well-managed steam trap population. Sequentially, steam
system can directly influence the plant’s production and
profit. If a site fails to maintain the steam trap
functionality, it may encounter deterioration of steam
quality, costly steam leakages or water-hammering can
occurred in the steam system and cause significant
damage to any related equipment and piping in the
system.
Steam trap is a valve that discharged condensate from
steam system with a minimal loss of steam. It may looks
simple but many sites do not implement a regular steam
trap maintenance program. However, this investment is
crucial in order to maintain an optimum steam system
quality through a dynamic and effective steam trap
management system.
Optimized Steam System
Steam system is including four main sections that
generate heat; distribute heat; consume heat; recover heat
(condensate return)
An optimum steam system should supply dry steam, drain
condensate fast and return condensate. Supplying less
than optimal steam (e.g., slowing heat transfer and
lowering the steam temperature) can affect the site’s
production capability.
An optimum steam system is achieved when the heat
transferring is only depending on the steam as the heating
medium. Means, condensate accumulation in the system
which occurred due to slow rate of draining of the
condensate will give a significant bad effect to the system.
It is not possible to return 100% of condensate but
recovering a maximum condensate as possible helps to
optimize the steam quality. Recovered condensate returns
heat to the boiler as boiler feed water will reduce the
energy needed to heat up the makeup water.
Blocked traps are often assume as
less critical than leaking traps
Maintaining Steam Trap System
The idea of maintaining the steam trap system is to
identify and replace any malfunction steam traps. The
common failures of steam trap can be divided into two
basic classifications, which are failed close or blocked
failures, and failed open or leaking steam traps.
Often, maintenance programs only focusing on replacing
the leaking steam trap and lowering the priority on
blocked traps. Blocked traps are often assumed as less
critical than leaking traps. However, impact of blocked
steam traps is significantly serious.
Condensate-related Equipment Issues
Water hammering occurred in the system due to
accumulation of condensate in the system. Means, a
blocked steam trap is one of the factor that contribute to
water hammering.
Steam travel at a high velocity along with the condensate
will remove the surface layer of the material. Solid
particles or dirt contains in the condensate will increase
the rate of erosion.
Conclusion
Steam is the main heat source for most of the plants.
Maintaining the condition of steam trap will have a huge
impact to the production and will ensure the integrity of
the piping or equipment in the plant. Failed to implement
an effective maintenance program, reliability issues will
occurred such as water hammer or erosion in the steam
system.
References
1. Jonathan P. Walter, January 2014, TLV Corp.,
Implement a Sustainable Steam-Trap Management
Program
2. James R. Risko, October 2017, TLV Corp., Steam
Trap Management: Do Something; Anything. Please!
3. API 571, Damage Mechanisms Affecting Fixed
Equipment in the Refining Industry, Third Edition,
March 2020