STEAM TRAP

TESTING
TRAPS WILL FAIL AND PASS LIVE STEAM...
DUE TO :-

DIRT (the most common cause)

INCORRECTLY INSTALLED
INCORRECTLY REPAIRED
WATERHAMMER
OVERSIZED
OLD AGE!!
 The Effects of faulty Steam Traps
Trap failed in Closed position:
• Waterlogging
• Decrease in heat output
• Damage to plant equipment
• Waterhammer (carryover in mains)

Trap failed in Open position

• Energy wastage - Steam & Fuel
• High velocity in plant equipment - wear
• Pressurisation of condensate lines
• Failure to maintain constant pressure/temperature
• Steam in condensate line (waterhammer)
• Partial waterlogging effect on system
 THE COST OF NOT CHECKING
TRAPS $$$

From historical data 20% of steam traps will

fail within the first year of installation due to
dirt!!!.
With testing and regular maintenance this rate
can be reduced to approx 6%.
 THE COST OF NOT CHECKING TRAPS
$$$
• 200 Steam traps - 1st year 20% fail……………….....= 40 traps
• Average steam loss per hour 3kg/hr x 40 traps…….= 120kg/hr
• Plant runs 24hr x 350 days……………………………...= 8400 hrs/yr
• 8400 x 120………………………………………………….= 1,008,000 kg steam loss per year
• 1,008,000 / 1000…………………………………………...= 1008 tonnes of steam
• S$14 per tonne of steam

• 1008 x 14………………. = S$14,112 MONEY LOST !!!

With testing the failure rate drops to 6% resulting in a steam loss of
S$4233 per year

Savings to be made by testing traps $14,112 - $4,233

S$9879 SAVING!!!
THE MOST COMMON APPLICATIONS
WHICH WASTE STEAM

STEAM MAINS DRAINAGE

&
STEAM TRACING

With large traps on Heat Exchangers, any steam loss

is absorbed by the high quantity of condensate.
 THE DIFFERENT METHODS OF
CHECKING TRAPS

SOUND
TEMPERATURE
VISUAL
REMOTE TESTING DEVICE

All testing method’s involve some degree of work and

cost to determine the traps operation.
METHODS OF TESTING STEAM TRAPS
BY SOUND... !

ULTRASONIC SOUND DETECTOR

STETHOSCOPE

SCREWDRIVER IN EAR
METHODS OF TESTING STEAM TRAPS
BY TEMPERATURE... !

HEAT SENSITIVE CRAYONS

TOUCHING TRAP OR PIPE
INFRA RED HEAT GUN
DIGITAL PYROMETER
SPIT ON PIPE !!
METHODS OF TESTING STEAM TRAPS
BY VISUAL... !

REMOVE AND DISMANTLE TRAP FOR

INSPECTION
BLOWDOWN VALVE
SIGHTGLASS
 Steam Trap Monitoring System

Steam Trap
Wo rking Correctly

Steam Trap
Leaking Steam

Steam Trap
Failed Cl osed
THINGS TO CONSIDER WHEN SETTING UP A
TRAP MAINTENANCE PROGRAM

IDENTIFY ALL THE TRAPS

THERE LOCATION
ACCESSABILITY
TAGGING THE TRAPS
RECORDING THE RESULTS
FREQUENCY OF TESTING?
WHO WILL BE RESPONSIBLE FOR TESTING AND
REPAIR?
 SUMMARY !

• Any testing program is better than none.

• Before testing, get organized.
• Ultrasonic testing devices give the best results.
• Record your findings and store them, for historical
purposes.
• Measure, Measure, Measure !!! You cannot improve
that which you cannot measure.