Are You Steam Trap Active?
9/29/2011
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team trap monitoring and testing program is vital to an efficient steam system since generating steam is expensive and can cost anywhere from $12 to $17 per 1,000 pounds.
According to the U.S. Department of Energy a steam system that goes three to five years without proper maintenance, which would include inspecting and repairing and/or replacing malfunctioning steam traps, can result in the failure of between 15 to 30 percent of the installed steam traps. Steam trap failure allows live steam to escape into the condensate return system thereby increasing costs of steam production while also increasing CO2 levels from the fuel sources used to produce steam.
According to Will Grindall, director of institutional markets for Armstrong International in Three Rivers, Mich., an average trap failure rate of 15 percent within a 300 trap population could end up costing more than $100,000 in annual losses, using estimated steam costs of a conservative $10 per 1,000 pounds of steam.
A new concept known as being “trap active” simply means having a program in place that involves locating, identifying, and accurately testing an entire steam trap population. A proper steam trap program can reduce fuel and maintenance costs dramatically, making this concept a must for most institutions.
The testing of steam traps can either be done in house by “trained” personnel or outsourced to a qualified survey contractor. The most accepted method is to use an ultrasonic stethoscope which requires an "experienced ear” to achieve the best accuracy.
Another choice which would eliminate the expense of in house training or outsourcing is the purchase of a popular device known as Dr. Trap. Manufactured by Armstrong International, Dr. Trap is the latest tool for testing steam traps using ultrasonic and infrared technology to analyze and display trap information. Dr. Trap integrates with SteamStar, a web-based platform also developed by Armstrong International that is used for recording, monitoring and managing steam trap information allowing users access to detailed reports that include steam and monetary loss, defective trap insight, trap evaluations, trending, emissions output and manufacturers summaries. These two products working in tandem and with proper implementation can virtually reduce steam trap failure rates to zero.
An example of being “trap active” is The University of Notre Dame Power Plant. After three rounds of steam trap testing using Dr. Trap the university went from a 31.4 percent failure rate reduced to an impressive 10.7 percent failure rate in less than one year. That reduction saved the university $70,000 in annual steam loss!
Steam traps are the low hanging fruit of efficiency and monetary savings since many gas companies, including Nicor Gas of Illinois, now offer rebates of up to $300 per trap to repair or replace steam traps. With available rebates, as well as monetary and efficiency incentives, every institution should look into being more “trap active”.
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