All conventional steam traps leak steam eventually, some sooner than others. The question is, “How long will they leak for, before you pick this up?”. Steam trap surveys help you solve leaks and reduce unnecessary energy loss.
Total steam trap population leak percentages range anywhere between 10% to 55%, depending on factors such as:
- Type of steam trap (thermodynamic, inverted bucket, etc.)
- Quality of water treatment
- How often steam traps are surveyed
- Maintenance schedules
- Steam pressure
WHY SURVEY YOUR STEAM TRAPS?
Steam trap surveys are essential in finding leaking or faulty steam traps and offer significant savings for the customer.
With conventional steam traps, once fitted they could begin leaking anytime from that same day to a month or six later. Without regular testing this would be impossible to determine.
A failed open (leaking) steam trap on a 145 psig steam line, will cost up to US$ 2,000 per year. Thus, for a site with 100 steam traps and a conservative failure rate of 15%, this will cost US$ 30,000 per year in steam losses.
Leaking steam traps are tremendously inefficient: it’s like trying to heat your home with the windows open.
DSS have steam survey engineers ready and equipped to test, analyse and find these leaking steam traps and using proprietary software based Steam Trap Management System (STMS), are able to accurately interpret the ultrasonic readings to provide a detailed report showing:
- Pounds or kilograms of steam lost per trap, per annum
- Cost of steam lost in local currency
- Carbon Dioxide (CO2) emissions
- Steam trap lifespan
- Maintenance costs
The DSS steam trap surveys provides valuable information allowing calculated decisions to be made relating to:
- Emission monitoring
METHODS OF TESTING STEAM TRAPS:
To ensure accurate testing is carried out, DSS uses a combination of ultrasonic and thermal imaging readings to determine the condition of a steam trap.
It is possible to check blocked or undersized steam traps using only temperature readings but it is not sufficient to determine if a steam trap is leaking steam, and certainly not possible to determine how much steam is leaking. This is done by using proprietary ultrasonic steam trap testing equipment combined with the Delta Steam Trap Management System, providing exceptionally accurate and informative results.
Numerous companies offer steam trap surveys and it is essential to ensure that your service provider is using testing equipment which can accurately and reliably calculate losses from steam traps tested.
Without the correct software based Steam Trap Management System, the test engineer is unable to accurately determine the steam loss rate and therefore unable to provide an accurate steam loss report.
WHAT’S IN IT FOR THE CUSTOMER?
Payback is well within a few weeks, if the customer implements the replacement of the steam traps indicated in the STMS report.
The steam trap replacement program required after a steam trap survey is carried out has immediate and large returns. Payback from this replacement program with DSS steam traps is always within one year and sometimes as quick as two to three months. Unlike savings from conventional mechanical steam traps which are only gained for the next year or two, savings achieved from replacing failed conventional steam traps with the DSS venturi steam traps is at least for the next 10 years due to the DSS 10-year steam trap performance guarantee, giving you, the customer, peace of mind of an investment well worth it’s cost.
HOW THE STMS WORKS:
DSS’s Steam Trap Management System (STMS) has a continuously updated database of steam traps from all major trap manufacturers worldwide. This software analysis uses the ultrasonic reading taken from the DSS hand held ultrasonic tester and provides accurate and reliable steam loss data. The information required for the STMS to determine a result from the steam trap reading is:
- The ultrasonic reading taken from the steam trap
- The differential steam pressure for the steam trap
- The trap make, model and size
Final results provide the customer with a clear, unambiguous picture of the condition of every steam trap on site, showing sufficient information to enable an accurate return on investment (ROI) to be calculated for steam trap replacements required to eliminate the existing steam trap leakage.
Along with the above information provided by the standard STMS report, our software can accurately determine the quantity of CO2 that is emitted when additional steam needs to be generated to make up for any steam lost through the leaking steam traps on a site.
This information is essential to map out a path for compliance to the relevant Environmental Emission Legislation which is becoming increasingly more stringent worldwide.
SOME OF OUR CUSTOMERS:
DSS steam trap survey experience stems from over 20 years of steam trap testing having been performed in numerous countries worldwide. Companies where we have tested include:
OTHER STEAM EQUIPMENT:
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.