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The cost of CO2 emissions cannot be ignored neither, ranging from $10 to $100 per metric ton.Today, manufacturing plants either have their own boiler to generate steam or buy steam from a third party to control building temperatures and support process requirements. Steam traps are more than a century old but play a vital role in any steam system today—with a primary function of removing condensate from the system as quickly as it collects, helping to prevent equipment damage and enhance the overall efficiency of the system. Therefore, implementing a comprehensive steam trap management program can ensure the efficient operation of a building’s heating system and process equipment. Regular inspections, repairs, and ongoing monitoring of system performance can identify and prevent issues before they become significant problems. Consequently, it will lead to lower costs, increased efficiency and enhanced safety. But what does a program like this look like? Here are the three marks of a safe and efficient steam trap management program:
SMART STEAM TRAP MANAGEMENT SYSTEM
Managing your steam trap population can be a headache. From 50 steam traps in a hotel, to 20,000 in a refinery, managing them is a manual and cumbersome process that typically includes annual binders, endless Excel sheets that can be corrupted or lost over time, and thousands of documents—making it nearly impossible to track history over time. But thanks to advancements in technology, there are better ways to manage a trap population efficiently, which is critical to a successful steam trap management program. Armstrong’s SAGE® smart thermal utility system management software, for example, offers 24/7 monitoring with regular updates, precise documentation, custom[1]filtered reports, and real-time alerts that allow managers to take control of their savings. Also, tools like steam-loss calculators can offer real-time emission- and energy-loss data, historical reporting, trend analysis, performance KPIs, benchmarking and more.
TEST OFTEN
As much as 5 to 15 percent of steam traps fail in a given year, according to industry wide data, so having the knowledge and wherewithal to react quickly and appropriately is key to a successful steam trap management program. There are two ways a steam trap can fail:
Failing closed, also known as “going cold,” means it is plugged and something could be broken inside the trap that is not allowing anything to pass. It could also be an undersized steam trap or there is not enough differential pressure, causing condensate to back up in front of the steam trap. This results in wet steam, which can cause water hammering or a damaged turbine, piping corrosion or the erosion of valves. A cold trap can also flood the heat exchanger and damage it, turning a $300 steam trap problem into a multi-thousand dollar heat exchanger replacement.
Failing open means the trap is leaking or blowing through. This can cause increased back pressure in the condensate return line, therefore reducing the flow of condensate for the surrounding steam traps. This not only results in steam and monetary losses, but also creates major environmental and safety issues.
In addition to substantial energy waste and environmental harm, perhaps the worst thing that can happen when a failing steam trap goes undetected is water hammer, which can cause damage to the piping system over time. The repeated shock waves can weaken the pipe and cause it to fail prematurely, leading to leaks or catastrophic failure. In many cases, water hammer is a dangerous situation and can be fatal. For example, on July 18, 2007, a giant explosion occurred in New York City, bursting manholes sky high and debris as far up as 40 stories, killing at least one person and burning 80% of another person’s body, all because water hammer caused a pipe to burst.Engineers can avoid many problems by ensuring they’re using the right steam trap for the right application and installing them correctly. Using a specific steam trap technology for the wrong application can lead to shorter lifespans, causing premature trap failures. In fact, one failed trap can result in tens of thousands of dollars per year and release tons of pollutants into the atmosphere.
There are three types of steam traps, including mechanical, thermodynamic, and thermostatic. While all share the common goal of efficiently and reliably removing condensate and non-condensable gases from the steam system, each has a unique function for a specific situation. For example, a thermostatic trap will open and close based on temperature while the thermodynamic technology is based on velocity and the mechanical on density. Knowing when to use each technology is of utmost importance. Doing so, will extend the life of your traps, avoid a dangerous situation and ensure you’re not wasting energy or resources.
"Steam traps are more than a century old but play a vital role in any steam system today—with a primary function of removing condensate from the system as quickly as it collects, helping to prevent equipment damage and enhance the overall efficiency of the system"
A comprehensive steam trap management program should include regular inspections of steam traps, repairs or replacement of faulty traps, and ongoing monitoring of system performance. There’s no excuse for waiting long periods between inspections, especially with the technology that’s available today. Just as heart problems can lead to decreased physical activity, increased healthcare costs, and even life-threatening situations, failing to detect and replace faulty steam traps lead to poor efficiencies, higher costs and even safety hazards, including death.
It is true that monitoring technology can have up[1]front costs, but the savings can be exponentially greater. Manufacturing plants, for example, can have thousands of steam traps, and just one failed trap can cost upwards of $60,000 per year in energy losses. Nearly all of those losses could be mitigated by installing 24/7 steam trap monitoring technology. This helps maintenance managers identify issues before they become significant problems.
Those who use the latest technology available today can cut their trap failure rates from 5-15 percent down to 3-5 percent at any given time, sometimes saving millions of dollars in energy costs. Depending on the budget of the organization, the manager will have to determine whether it makes more sense to invest in a wireless monitoring system as previously mentioned or stick to manual testing with handheld devices.
At the very least, steam traps should be tested every year (see table). Based on budget and resources, it’s best to prioritize the testing of the high-risk steam traps or use a combination of wireless testing and manual hand-held devices. There are many options available for all types of steam systems, which is why it’s important to partner with an energy management provider who can help you determine your best path toward success.
REPLACE QUICKLY
The reality is steam traps are going to fail. But the difference an organization can make is how they respond. No matter how advanced your steam trap management system is, or how far-reaching your decarbonization efforts span, failing to quickly replace even one faulty steam trap among thousands can undo all the potential savings, and even worse, create harmful, life-threatening situations.
The key to swift replacement is planning, and that is only possible if the engineers have the data and knowledge to react to an issue before it becomes a problem. With our current supply chain issues, it’s even more important to know ahead of time whether you’re going to need a replacement of an entire steam trap or a single part. That last thing a company wants is to lose tens of thousands of dollars while waiting on a $50-part or $300 steam trap. Teams should know when a trap is nearing the end of its life, so they can order the necessary parts to be on hand when the time comes to replace.
Many companies wait months or years to replace failed traps, until they shut their entire steam system down for scheduled maintenance, losing energy and money along the way. Instead, companies should have a find-and-fix mentality and look at ways to safely repair the problems without having to shut down the entire system.
One solution to promote the swift and safe replacement of failed traps is a “double block and bleed” piping configuration, which is a critical safety measure in steam production that is used to prevent the release of hazardous materials and it involves the use of two inlet valves and two outlet valves each with a bleed valve to isolate the steam trap safely during maintenance or repair—allowing you to quickly replace the failed trap via the trap valve station (TVS), like the TVS-6000, which is the most high[1]tech TVS solution on the market today. However, it’s important to remember that replacing steam traps can be dangerous, especially if the person is inexperienced or the steam system is experiencing back pressure or water hammer. But it’s even more dangerous to allow a failing steam trap to go unnoticed or stay in use.
A comprehensive steam trap management program is a crucial part of a well-functioning steam system. By implementing a program that includes smart management, frequent testing and rapid replacement, organizations can improve their energy efficiency, reduce costs, and minimize their impact on the environment, while ensuring the safety of employees and the community at large. Failing to do so is not an option in today’s world
Failing closed, also known as “going cold,” means it is plugged and something could be broken inside the trap that is not allowing anything to pass. It could also be an undersized steam trap or there is not enough differential pressure, causing condensate to back up in front of the steam trap. This results in wet steam, which can cause water hammering or a damaged turbine, piping corrosion or the erosion of valves. A cold trap can also flood the heat exchanger and damage it, turning a $300 steam trap problem into a multi-thousand dollar heat exchanger replacement.
Failing open means the trap is leaking or blowing through. This can cause increased back pressure in the condensate return line, therefore reducing the flow of condensate for the surrounding steam traps. This not only results in steam and monetary losses, but also creates major environmental and safety issues.
In addition to substantial energy waste and environmental harm, perhaps the worst thing that can happen when a failing steam trap goes undetected is water hammer, which can cause damage to the piping system over time. The repeated shock waves can weaken the pipe and cause it to fail prematurely, leading to leaks or catastrophic failure. In many cases, water hammer is a dangerous situation and can be fatal. For example, on July 18, 2007, a giant explosion occurred in New York City, bursting manholes sky high and debris as far up as 40 stories, killing at least one person and burning 80% of another person’s body, all because water hammer caused a pipe to burst.Engineers can avoid many problems by ensuring they’re using the right steam trap for the right application and installing them correctly. Using a specific steam trap technology for the wrong application can lead to shorter lifespans, causing premature trap failures. In fact, one failed trap can result in tens of thousands of dollars per year and release tons of pollutants into the atmosphere.
There are three types of steam traps, including mechanical, thermodynamic, and thermostatic. While all share the common goal of efficiently and reliably removing condensate and non-condensable gases from the steam system, each has a unique function for a specific situation. For example, a thermostatic trap will open and close based on temperature while the thermodynamic technology is based on velocity and the mechanical on density. Knowing when to use each technology is of utmost importance. Doing so, will extend the life of your traps, avoid a dangerous situation and ensure you’re not wasting energy or resources.
"Steam traps are more than a century old but play a vital role in any steam system today—with a primary function of removing condensate from the system as quickly as it collects, helping to prevent equipment damage and enhance the overall efficiency of the system"
A comprehensive steam trap management program should include regular inspections of steam traps, repairs or replacement of faulty traps, and ongoing monitoring of system performance. There’s no excuse for waiting long periods between inspections, especially with the technology that’s available today. Just as heart problems can lead to decreased physical activity, increased healthcare costs, and even life-threatening situations, failing to detect and replace faulty steam traps lead to poor efficiencies, higher costs and even safety hazards, including death.
It is true that monitoring technology can have up[1]front costs, but the savings can be exponentially greater. Manufacturing plants, for example, can have thousands of steam traps, and just one failed trap can cost upwards of $60,000 per year in energy losses. Nearly all of those losses could be mitigated by installing 24/7 steam trap monitoring technology. This helps maintenance managers identify issues before they become significant problems.
Those who use the latest technology available today can cut their trap failure rates from 5-15 percent down to 3-5 percent at any given time, sometimes saving millions of dollars in energy costs. Depending on the budget of the organization, the manager will have to determine whether it makes more sense to invest in a wireless monitoring system as previously mentioned or stick to manual testing with handheld devices.
At the very least, steam traps should be tested every year (see table). Based on budget and resources, it’s best to prioritize the testing of the high-risk steam traps or use a combination of wireless testing and manual hand-held devices. There are many options available for all types of steam systems, which is why it’s important to partner with an energy management provider who can help you determine your best path toward success.
REPLACE QUICKLY
The reality is steam traps are going to fail. But the difference an organization can make is how they respond. No matter how advanced your steam trap management system is, or how far-reaching your decarbonization efforts span, failing to quickly replace even one faulty steam trap among thousands can undo all the potential savings, and even worse, create harmful, life-threatening situations.
The key to swift replacement is planning, and that is only possible if the engineers have the data and knowledge to react to an issue before it becomes a problem. With our current supply chain issues, it’s even more important to know ahead of time whether you’re going to need a replacement of an entire steam trap or a single part. That last thing a company wants is to lose tens of thousands of dollars while waiting on a $50-part or $300 steam trap. Teams should know when a trap is nearing the end of its life, so they can order the necessary parts to be on hand when the time comes to replace.
Many companies wait months or years to replace failed traps, until they shut their entire steam system down for scheduled maintenance, losing energy and money along the way. Instead, companies should have a find-and-fix mentality and look at ways to safely repair the problems without having to shut down the entire system.
One solution to promote the swift and safe replacement of failed traps is a “double block and bleed” piping configuration, which is a critical safety measure in steam production that is used to prevent the release of hazardous materials and it involves the use of two inlet valves and two outlet valves each with a bleed valve to isolate the steam trap safely during maintenance or repair—allowing you to quickly replace the failed trap via the trap valve station (TVS), like the TVS-6000, which is the most high[1]tech TVS solution on the market today. However, it’s important to remember that replacing steam traps can be dangerous, especially if the person is inexperienced or the steam system is experiencing back pressure or water hammer. But it’s even more dangerous to allow a failing steam trap to go unnoticed or stay in use.
A comprehensive steam trap management program is a crucial part of a well-functioning steam system. By implementing a program that includes smart management, frequent testing and rapid replacement, organizations can improve their energy efficiency, reduce costs, and minimize their impact on the environment, while ensuring the safety of employees and the community at large. Failing to do so is not an option in today’s world 