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1.0 SCOPE

Steam trap, like any mechanical device, will eventually need repair and/or replacement. The
longer a trap is in service, the more opportunity the mechanical internal parts have to wear out. This
wear will eventually lower the trap’s performance and can eventually impede operation or complete
failure.

2.0 Requirements & Guidance

Steam system assessments produce benefits in the near and long term. An optimized system will
produce immediate savings in the form of energy conservation, noise reduction and plant efficiency.
Over time, an optimized steam system will produce a greater number of opportunities for energy saving.

These requirements, definitions and guide should be implemented at Coats plants and the form at the
appendix should be completed by plant Engineering teams. There should be evidence attached (either
documents or pictures for the compiled list and actions should be defined for the maintenance/
repair/replacement of any failed or malfunctioning steam traps.

1. The plant should have the list of steam traps, Information on the number of steam traps and
types of the steam trap.
The list is required to understand how many steam traps, the list can be created using
numbering or tag identifying the steam traps and their location. Types of steam traps
should be also indicated in the list. The list be in excel, or word document, or embedded
into any existing plant maintenance software program.

The types of traps you are likely to find across any Coats plant are -

a. Thermostatic (operate by changes in fluid temperature)

A thermostatic trap responds to changes in temperature. Therefore, they distinguish very well between
steam and cooler non-condensable gases. Its pressure greatly determines the temperature of saturated
steam. The steam in the space gives up its heat and produces condensate at steam temperature. To
prevent further heat loss, the condensate’s temperature will drop. The thermostatic trap will pass
condensate when it’s at a lower temperature. As the steam travels to the trap, the temperature will
increase, and the trap will close.

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b. Mechanical (operated by changes in fluid density).

Mechanical traps tend to work by sensing the difference between steam and condensate. They include
elements such as “ball float traps” and “inverted bucket traps.” In “ball float traps,” the ball will rise in the
occurrence of condensate. Next, the valve will open and transfer the denser condensate. In the “inverted
bucket trap,” the inverted bucket floats once condensate is formed in the bucket . Once the bucket has
no more steam inside the bucket sinks and opens the valve and the condensate is released. The cycle of
condensate removal then start again with steam arriving into the trap , the steam then raises the bucket,
shutting the valve.

c. Thermodynamic (operated by changes in fluid dynamics).

Thermodynamic traps partly rely on the formation of the flash steam from the condensate. These traps
can’t distinguish between steam and or other non-condensable gases. Steam traps associated with the
thermodynamic trap include the following: disc, impulse, and labyrinth steam traps.

Operation of the Disc type Thermodynamic Steam trap – (see graphic on next page)

 The thermodynamic steam trap is simple and robust in design. It operates by means of the
dynamic effect of flash steam as it passes through the trap, as shown in figure (i).
 On start-up, incoming steam raises the disc, & cool condensate & air are immediately discharged
from the inner ring under the disc. & out through peripheral outlets.
 Hot condensate passing through the trap drops in pressure and releases high velocity flash
steam. This high velocity causes a low pressure under the disc drawing it down towards its seat,
figure (ii).
 At the same time, the flash steam pressure builds up above the disc forcing it down against
incoming condensate until it seats on the inner and outer rings. At this point then steam is
trapped in the upper chamber above the disc, figure (iii). The pressures above and below the disc
are now equal however the surface area is greater above the disc.
 Eventually the steam above the disc condenses and the higher condensate pressure raises the
disc and the cycle repeats, figure (iv)

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2. Steam traps should be monitored for any kind of failure, leakage and damage.
Like all mechanical devices, steam traps are subject to wear and tear. To keep them
performing efficiently, they require maintenance to restore it to optimal running conditions.
Monitoring should cover testing, inspecting, periodic checks and breakdown
management. With tracked and recordable information and actions. Monitoring can be
done by checklists, Office documents, pictures or plant maintenance software. There
should be a systematic process for monitoring the steam traps.

3. How often steam traps should be inspected.

Routinely monitoring your steam traps should be part of your steam trap maintenance
plan. Problems within a steam trap can reduce the overall efficiency of the system, lead to
future reliability challenges such as erosion and water hammer, and increase the amount
of unnecessary emissions and energy losses. An optimized steam trap can actually save
the facility money on energy costs, thereby reducing financial and operational risk
simultaneously.
A well maintained steam/condensate system is more efficient at retaining thermal energy.
Over time, this can make a significant difference to a facility’s overall energy use.

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4. What are the methods you can use for testing steam traps

a. Visual inspection
A qualified reliability expert should be able to spot major issues at a glance. Poor installation, extreme
asset degradation and severe failure modes are all examples of challenges that can be identified during
a visual assessment.
Visual assessment is limited to reviewing open systems. When recovering condensate in a closed piping
system, for instance, the piping will prevent performing visual diagnosis. Installing a sight glass at the
trap’s outlet will provide a visual indication in some instances.

Examples of Sight Glasses used in condensate systems

b. Temperature measurement

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When performing a temperature assessment, reliability stakeholders need to understand if the system is
in operation and if the specific steam trap station is operational. They also need to understand the
expected steam and condensate pressure measurements so that they can determine if the system isn’t
functioning properly. An infrared temperature measurement can provide maintenance personnel with a
deep understanding of system performance in a matter of moments.

Cold Traps (Blocked)

Temperature can be extremely useful when trying to determine if:
 A trap is blocked
 Its capacity is insufficient

Using temperature measurement to determine whether a steam trap is leaking or not can lead to
erroneous analysis. This is because higher temperature condensate flashes into steam when introduced
into a lower pressure system. Because the flash steam temperature is the same as that of leaking live
steam, it is not possible to differentiate between a steam leak and regular condensate discharge by the
measured temperature.

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c. Ultrasound comparison
An ultrasonic reading can pick up on minute performance differences that the human ear is not capable
of identifying. This method uses benchmarks to compare current ultrasound output to established
optimal readings. In this way, stakeholders can determine which traps are most likely to fail in the future,
so they can take preventive action. An effective ultrasound assessment compares multiple test points to
ensure an accurate reading. For example, a reliability stakeholder might test the upstream and
downstream piping as well as the trap body.

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Live steam leaking from a trap may also produce a distinct sound which can be explained as the
difference between a “whistle and a wave.” A whistle is a vapor-based, high pitch sound, even if softly
made. It is impossible to duplicate the same sound with a liquid, even one as large as a wave or as small
as a drip from a faucet.

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Recommendations

Testing steam traps is an important part of managing your steam trap population. Once failure is
confirmed, the trap should be either repaired or replaced as soon as possible to capture the maximum
gain on investment.
For an accurate diagnosis of trap condition, obtaining help from an experienced professional that uses
specialized equipment is key. For reasons stated above, it is highly recommended that this equipment be
able to measure both temperature and ultrasonic sounds.

Other than the trap itself, it is also important to inspect peripheral equipment including manual valves,
bypass valves, check valves, and the operational status of the steam-using equipment. Regularly
optimizing your steam system this way can help maximize process efficiency and will often lead to
significant energy savings.

The Opportunity - FAQs

 A failed open steam trap on a 150 psig steam system could cost up to an additional $2,000 per
year. For a processing plant with 100 steam trap units and a 15% failure rate a, additional cost
due to unnecessary steam losses could cost $30,000 annually.
 The use a combination of ultrasonic and thermal imaging to determine the condition of steam
traps in real time is a more efficient way to understand the operating condition of steam traps on
site. The investment in this equipment has very quick paybacks.
 There are now smart steam trap tags these are the latest cost-effective asset tagging &
management solution.
 The ROI for a steam trap survey can be a very short period if recommendations to repair or
adjust affected steam traps are carried out after the survey. If the site has local access to this
service, consider getting a quotation and an ROI calculation in built to the survey.
 An optimized steam system will reduce steam energy losses, enhance system efficiency, and
reduce overall steam plant equipment maintenance.
 Testing steam traps annually is one of the best investments you can make in your steam system
with a typical payback of just a few weeks.
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3.0 Appendix

Appendix File Reference Attachment

Number

Appendix 1 Gap Assessment Link https://forms.office.com/r/1u98v6p5pi

Appendix 2 Steam Trap Testing Procedure

Appendix 3 Measurement Results Table

Appendix 4 Info Pack (technical docs)

Appendix 5 Steam trap List

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