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Steam trap inspection survey are automated valves designed to drain condensate (and vent air) while retaining steam. And, like other mechanical equipment, they will ultimately require maintenance to return to manufacturer specifications and prevent:

• Steam leakage, or
• Blocked condensate discharge (i.e., cold traps)

Visual observation, measuring temperature, measuring sound/vibrations or ultrasound, and some combination of these methods are used to test the operating condition of a steam trap to determine if it is working correctly.

Why is a Steam trap inspection survey needed? 

Leaks, both to the environment and through valves and steam trap inspection, are a significant source of waste and inefficiency. Insulating steam and condensate return lines, eliminating any steam leaks, and maintaining steam traps are examples of steam system improvements. According to experts, up to 20% of the steam generated at the central boiler is lost due to leaking or malfunctioning steam trap inspection survey.

A good steam trap inspection programme should aim to correct any malfunctioning steam traps and steam leaks that might jeopardise safety, decrease energy waste, and enhance sustainability and product quality.

Using ultrasound technology

Ultrasound technology is employed by maintenance and reliability specialists all over the globe and is often regarded as the most adaptable predictive maintenance technology and steam trap inspection surveys. Ultrasound is commonly used in detecting compressed air and gas leaks, inspecting bearings, motors, gearboxes, and valves, the electrical review of energised electrical equipment, hydraulic applications, and examining steam traps.

Planning for success

Before you begin your inspection, it will be beneficial to consider a few factors that will aid in the effectiveness of the steam trap survey. First, walk around the area, identifying and tagging each steam trap. The tag should include the number and information such as the manufacturer of the steam trap, its kind, the orifice size inside the trap, and the function of the trap.

Steam trap inspection survey with ultrasound

Before testing with ultrasound, it is advised that the inspector first obtain temperature measurements using a basic spot radiometer while doing the Steam trap inspection survey. The temperature not only tells the inspector whether or not steam is entering the trap but it also might be used to determine the steam pressure. If the steam trap is consistently cold, the inspector should examine to see if the valves are open or if the web has been removed from use. If the steam trap is warm or hot, the inspector might take note of the input and exit temperatures before proceeding with the ultrasonic test.

When it comes to steam trap inspection surveys using ultrasound, the inspector will need to know which sort of trap is being inspected. This will define how the steam trap should sound once it has made contact with the ultrasound equipment. Steam traps will have one of two sound characteristics: on/off or continuous flow.

Before beginning the examination, it is advised that you listen to several traps to obtain a “typical” sound characteristic for how the steam trap is performing under the operational parameters of your specific steam system.

Physical contact between the steam trap and the ultrasonic equipment is required to “hear” how well the steam trap is operating. If you have a frequency-tuning ultrasonic device, set the frequency to the suggested setting of 25kHz. Because turbulence is formed on the outlet side of the steam trap when it releases condensate, the contact probe will always be placed near the trap’s discharge orifice, regardless of the kind of trap.

Once contact has been made, adjust the instrument’s sensitivity/volume until the sound of the trap can be heard. It is critical to be patient while evaluating steam traps with ultrasonography. Make contact at the trap’s discharge orifice and wait for it to cycle. If the temperatures have been verified and the trap has not cycled for about one minute, go to the next trap. If the steam trap hasn’t cycled within one minute, it’s difficult to say when it will, but if the temperatures are average and there’s no indication of a plugged condition, move on to the next trap to be tested.

Determine Steam Leaks By Temperature

Once contact has been made, adjust the instrument’s sensitivity/volume until the sound of the trap can be heard during the steam trap inspection survey. It is critical to be patient while evaluating steam traps with ultrasonography. Make contact at the trap’s discharge orifice and wait for it to cycle. If the temperatures have been verified and the trap has not cycled for about one minute, go to the next trap. If the steam trap hasn’t cycled within one minute, it’s difficult to say when it will, but if the temperatures are average and there’s no indication of a plugged condition, move on to the next trap to be tested.