Steam trap failure is a source of concern for many plant operators. Failure of the steam trap diminishes the steam system’s efficiency while also posing a safety issue. Many factors can cause the failure of a steam trap. It might be useful to review a few of them and determine how to avoid them.
The steam that escapes the boiler is mostly dry. As steam passes through the piping, it loses heat and condenses. Condensate develops when steam loses heat to the heated goods. A steam trap survey is crucial when it comes to eliminating condensate as soon as it occurs. The supercooled liquid is inadequately removed due to the steam trap survey failure. The failure rate of steam traps in some steam systems might approach 35% per year. As a result, it’s crucial to figure out why the steam trap survey doesn’t work. The following are the top three factors that cause or accelerate steam trap failure.
Inadequately installed steam traps and a poor maintenance
The active life of steam traps is substantially reduced if they are not installed properly. Therefore, upstream of every steam trap, for example, a filter, should be built. While some steam traps include built-in filters, others require the installation of a separate strainer before usage. In the absence of a filter, other particles or rust may become entrained inside the trap, causing internal damage. In addition, thermodynamic steam traps should be provided with insulating covers when used in excessively cold temperatures to minimize quick cycling, which is frequently referred to as “chattering.”
Each steam trap requires adequate maintenance and a steam trap survey in a brief span of time. However, according to our observations, many plants do steam trap maintenance poorly or not at all. As a result, each steam system should have its own set of maintenance requirements. Early detection of problems and prevention of further aggravation is aided by routine maintenance. Additionally, maintenance and inspection can reveal other issues (visual signs such as corrosion) that may contribute to steam trap failure.
Location
At the lowest natural and inadvertent low points, steam traps should be fitted in the steam system. Like other utilities, steam pipes and traps are installed in regions that are most conducive to serving the structure or process, not necessarily in the most maintenance-friendly position.
Steam traps can be found in drop panel ceilings, maintenance holes, mechanical rooms, pipe chases, beneath false flours, and other hard-to-reach spots. Many items fall into the category of “out of sight.
Buildings rarely have adequate symptoms to seek help when their steam traps fail. The steam boiler will keep running and releasing heat. The procedure is still effective. Most of the time, the failed steam traps aren’t audible. It takes considerable effort to locate, evaluate, and replace malfunctioning steam traps. (steam trap failure)
Staffing
There is a shortage of qualified trade workers capable of repairing or replacing a steam trap and a lack of passion for skilled craftwork. Moreover, half of the qualified labor is about to retire.
The limited potential personnel at large sites is made more difficult by geographic rather than skill-type responsibilities. A building or department, for example, might have a single maintenance group that takes care of all requirements. On the other hand, steam traps are usually not the center of a specialist structure, such as a laboratory or manufacturing facility. (steam trap failure)
The operations group’s line of duty usually terminates at the first heat exchanger or the building wall at most plants.
In these difficult economic times, several facilities seek the simplest way to save money. However, skilled artisans are frequently the first to be laid off because of labor shortages. (steam trap failure)
Steam Trap Survey is one approach for recovering steam trap failure & lost energy. STOPLEAKLOSS Sevey’s professionals inspect each steam trap in your plant, collecting various data points. These numbers are methodically entered into proprietary software that determines annual energy losses. The Steam Trap Monitoring System can also be installed on every steam trap and safety valve. This system, which is linked to the plant’s computer network, will continually monitor each trap and safety valve’s condition. When a problem occurs, it will notify system operators instantly, reducing the period between failure and repair from years to minutes. STOPLEAKLOSS also helps you make sure you get all of the rebates you’re eligible for. (steam trap failure)
To learn more about steam trap and safety valve surveys or see if Steam Trap Monitoring is right for your system, contact the STOPLEAKLOSS team.