Steam Trap Maintenance

Steam Trap Maintenance Made Easier With Pipeline Connector

Steam is a common source of heat or power throughout industrial and commercial installations. Most steam systems operate as a closed system, with the return of condensate to maximize energy efficiency and gain other operational benefits. Steam traps are the workhorse of many condensate return systems, routing condensate back to the boiler and non-condensible gases out of the system, all without a major loss of steam.

What is a Steam Trap?

A steam trap is a mechanism that filters out condensate (i.e., condensed steam) and non-condensable gases. It does this without removing the live steam from the system.

Depending on the steam system, the quantity of condensate steam the trap can carry varies. The trap may discharge condensate as soon as the condensed steam forms, or it may hinder below the steam temperature.

When picking the right trap for your system, you want to ensure it can carry out its given functions, no matter the condition. If you aren’t sure what the requirements are, try contrasting operating pressures, heat load, or condensate pressure. Also, steam traps contain different extremes of temperature or water hammers. No matter the condition(s), correct the steam trap selection to improve your system’s efficiency.

Steam traps are points of high maintenance in the steam system. They are also an integral part of the system, meaning they are under pressure. Steam trap maintenance requires isolating the trap from the system, venting the pressure within the isolated section, and removing liquid that may be contained in the trap.

Two of the Most Common Causes of Steam Trap Failure

Two of the most common causes of steam trap failure are oversizing and dirt within the system. Oversizing can cause traps to overwork while dirt buildup can cause plugging or prevent a valve from closing. To help you better assess steam trap failure, here are some general indications to look out for:

An abnormally warm boiler roomJourneyman Inspecting A Boiler
Condensate receiving venting steam
The condensate pump water seal is failing prematurely
Over-heating or under-heating in a conditioned space
The boiler operating pressure is challenging to maintain
Vacuum in the return lines is difficult to keep up
There’s a water hammer in steam and condensate lines
Steam buildup in condensate return lines
The energy bill is higher than normal
Inlet and outlet lines are the same temperatures

Maintenance of Steam Traps

Routine maintenance

Routine maintenance depends on the type of trap and its application. The balanced pressure steam trap, for example, has an element that is designed for easy replacement. Changing these on a regular basis, maybe once every three years or so might seem wasteful in time and materials. However, this practice reduces the need for trap checking and should ensure a trouble-free system with minimal losses through defective traps.

Routine maintenance which involves cleaning and re-using existing internals uses just as much labor but leaves an untrustworthy steam trap. It will have to be checked from time to time and will be prone to fatigue. Any routine maintenance should include the renewal of any suspect parts if it is to be cost-effective.

Replacement of Parts

Renewing the internal parts of a steam trap can save both time and money. As the body of the trap will most likely last as long as the plant to which it is fitted, it makes more sense to replace internal parts rather than taking out the whole trap and fitting a new one. An example of this is in thermodynamic steam traps. If the seat or disc faces of a thermodynamic trap are damaged, the disc can simply be replaced. The elements of thermostatic traps can usually be changed by simply removing a screwed-in seat. Replacement is easy and the remade trap will be reliable assuming the maintenance is carried out correctly.

Preventive Maintenance Schedules

The general rule for steam trap preventive maintenance is the higher the pressure, the more frequent the test. For example, high-pressure traps with rates greater than 250 PSIG should be tested daily. However, low-pressure traps with rates below 30 PSIG can be checked monthly or even annually. On average, steam traps are replaced every three to four years.

Preventive Maintenance Checklist

When maintenance technicians are inspecting steam traps, they should be paying attention to temperature, pressure, condensation, and proper equipment operation. For example, a warm boiler room, the incorrect temperature of conditioned space, or a high energy bill can indicate steam trap failure. The pump water seal, boiler operating pressure, and vacuum in return lines should be checked as well.

Benefits of Steam Trap Maintenance

The benefits of preventive maintenance keep steam traps working properly, create a safer working environment, and saving energy in your facility.

If a steam trap creates a backup of condensate within the system, it can affect the steam velocity. An improperly operating steam trap can increase the force of the water hammer and blow out a strainer or valve. This is a potential safety hazard as well as a risk for further equipment damage.

Steam traps that are stuck open allow steam to escape continuously, wasting energy as long as this condition goes unrecognized. According to Industrial Controls, a steam trap that has not been maintained can cost thousands of dollars in lost energy per year.

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