A steam trap is a device used in an industrial steam system to remove condensate, air, and other non-condensable gases from the system while preventing the loss of live steam that’s used for heating, power generation, and sterilization.
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When steam traps malfunction, the efficiency and safety of the entire steam system can be compromised, leading to costly issues and significant energy loss. This article explores why steam traps fail, how failures affect the larger steam system, and what you can do to address and prevent these issues.
5 Reasons Steam Traps Fail
Anything mechanical can malfunction; steam traps are no exception. Below are the top five reasons steam traps fail, how those failures affect the larger steam system, and steps you can take to address and prevent these issues.
1. Worn-out or Damaged Components
According to industry studies, roughly 10-15% of steam traps in a typical industrial facility may fail each year due to worn components. In high-temperature, high-pressure environments, steam trap valves, seats, and mechanisms can degrade over time. This degradation can cause traps to either fail open or fail closed.
- Failing open allows steam to escape, leading to energy inefficiency, increased fuel costs, and potentially damaging downstream equipment.
- Failing closed prevents the proper discharge of condensate, resulting in water hammer (hydraulic shock), corrosion, and impaired heat transfer in the system.
2. Blocked or Clogged Traps
Another common cause of steam trap failure is blockages from dirt, scale, and debris in the system. When condensate and impurities are not removed efficiently, the trap may become obstructed, preventing it from functioning as designed.
Clogging can cause back pressure, reducing the flow of steam and affecting the efficiency of the entire steam system. And, in severe cases, blockages can lead to water hammer, which occurs when slugs of condensate move at high speed through pipes, potentially causing extensive damage to valves, piping, and other equipment.
3. Incorrect Sizing or Installation
Steam traps must be properly sized and installed for the specific operating conditions of the steam system. Incorrect sizing can lead to inefficient operation and premature failure. For example, an oversized steam trap might cycle too quickly, causing wear and tear, while an undersized trap may not be able to handle the volume of condensate, leading to flooding or water hammer.
Improper installation can also affect the trap’s functionality. If a trap is installed without proper drainage or if it’s not level, it may not operate as intended, leading to issues such as condensate buildup or steam leaks.
4. Failure Due to Pressure and Temperature Fluctuations
Industrial steam systems experience fluctuations in pressure and temperature, which can place extra stress on steam traps. Abrupt changes in these conditions can cause traps to fail. For instance, rapid pressure changes may cause mechanical parts to seize or malfunction.
Thermostatic traps are particularly susceptible to temperature fluctuations because they rely on temperature differences between steam and condensate to function properly. Frequent cycling or thermal shock can cause premature wear, reducing their lifespan.
5. Lack of Regular Maintenance
Like all mechanical equipment, steam traps require regular inspection and maintenance to ensure proper operation. Unfortunately, many facilities neglect regular steam trap audits, leading to undetected failures that affect the entire steam system’s efficiency. Facilities that regularly inspect and maintain their steam traps can reduce energy loss by as much as 20%.
How Steam Trap Failure Affects the Entire Steam System
The failure of even a single steam trap can cause a chain reaction of costly issues throughout the entire steam system.
When steam is lost through a failed-open trap, the system has to work harder to maintain pressure and temperature, leading to increased fuel consumption and higher operational costs. According to the U.S. Department of Energy, a single failed steam trap can waste approximately $6,600 annually in lost steam. This also results in reduced efficiency in processes relying on steam, such as heating or sterilization.
When traps fail closed, condensate builds up in the system, causing water hammer, corrosion, and uneven heat distribution. Over time, this can lead to costly equipment damage, safety hazards, and unplanned downtime.
What to Do About Steam Trap Failure: Create a Proactive Action Plan
Preventing steam trap failure requires a combination of regular maintenance, expert oversight, and the use of the right technology. Here’s a proactive action plan to ensure your steam traps stay in optimal working condition.
Implement a Steam Trap Station Management Plan
A well-designed steam trap station management program helps ensure that steam traps are regularly inspected, maintained, and replaced as needed. This program should include:
- Routine visual and ultrasonic inspections to detect leaks, blockages, or malfunctioning traps.
- Documenting trap performance and scheduling replacement or repairs for aging traps.
Use Expert Contractors for Installation and Maintenance
The expertise of trained professionals is essential for ensuring that steam traps are properly installed and maintained. Working with expert contractors who specialize in industrial steam systems can help prevent common installation errors and ensure that the right type of trap is used for each application.
Embrace Technologies for Better Monitoring
Modern technologies, such as remote monitoring systems and wireless steam trap sensors, allow for real-time monitoring of steam traps. These tools provide data on trap performance, alert operators to potential failures, and reduce the need for manual inspections. This can lead to significant energy savings and prevent downtime.
Perform Regular Steam System Audits
In addition to inspecting individual steam traps, conducting regular audits of the entire steam system is essential. These audits should assess the system’s pressure, temperature, and flow rates to identify any issues that could affect trap performance.
Replace Aging or Inefficient Traps
Don’t wait for a failure to occur. Replace steam traps that are nearing the end of their lifecycle or those that have become inefficient. Investing in high-quality, properly sized traps will help maintain system efficiency and prevent costly failures.
Contact PALA to Ensure a Problem-free Steam System
As a licensed industrial and mechanical contractor with the credentials to work in the most demanding facilities, our team can perform a wide variety of services to repair and maintain your entire steam system. From component replacement to completely reworking your system’s piping and fittings, we can get your system back up to optimal performance. Give us a call or contact us online to get the process started.