STEAM LOST THROUGH LEAKING & OVERSIZED TRAPS

An article in TextileWorld (2-02) says that “even for companies with annual test-and-replace programs, studies show the average steam trap has been leaking for more than six months before it is replaced.”  Even then, failed mechanical traps are typically replaced with the same size and model, although it may not be the right trap.  As a result, it can be oversized as much as 30 times. Trap manufacturer catalogs show that while condensate loads are often less than 10 lbs/hr, the smallest available traps are rated 500-1000 lbs/hr.

DEPARTMENT OF ENERGY’S OFFICE OF INDUSTRIAL TECHNOLOGIES (6-99):  “In steam systems not maintained for 3-5 years, between 15% to 30% of the steam traps may have failed.” They recommend weekly to monthly testing of high-pressure systems (150 psig and over); monthly to quarterly of medium pressure (30 to 150 psig); and annually for low pressure (under 30 psig).

ALLIANCE TO SAVE ENERGY (Tech Profile 7-99)

“In typical facilities, 15-20 percent of steam traps will be inoperative.
An effective trap maintenance and replacement program can reduce the average number of inoperative steam traps to 5-10 percent; thereby saving about 10 percent of the energy in a steam distribution system. Because boilers in steam systems typically are 80 percent efficient, the expected savings from steam trap maintenance and replacement is estimated to be 8 percent. (Savings of up to 30 percent or more can be obtained for the total steam system through a complete steam system maintenance program)”.

• Moving parts degrade over time

• Labor intensive maintenance program for identification and replacing or repairing  

• Ongoing replacement cost – Life expectancy Avg. 3-4 yrs; as little as 3 months

• Steam system inefficiencies in 15% to 30% range are normal

• Leaves condensate in the system that leads to various kinds of water damage