A steam trap survey is a systematic audit of a facility’s steam traps, specialized valves that discharge condensate and non-condensable gases without allowing steam to escape. Hospitals, breweries, food processors, universities, and laundry services all rely on boilers to generate steam for heat, sterilization, and power. Functional steam traps play a crucial role in preserving energy, maintaining safety, and protecting equipment in these systems.
Why Regular Surveys Matter
Faulty steam traps can lead to costly energy losses, equipment damage, and safety hazards if undetected. Up to 30% of the steam traps in facilities lacking regular inspection can fail, causing steam to leak or condensate to accumulate where it shouldn’t. Regular steam trap surveys reduce energy waste, prevent unplanned downtime, and extend boiler life.
Industry guidelines suggest performing steam trap surveys at least annually, or more frequently in high-demand environments. Facilities striving for best-in-class performance target less than 5% trap failure rates through proactive inspection and maintenance.
How Steam Traps Operate
Steam traps work by distinguishing between steam, condensate, and air within the system. Understanding the main types helps inform survey techniques:
- Mechanical Traps (Float & Inverted Bucket): Detect density changes; the float rises or falls as condensate enters the trap.
- Thermostatic Traps: Rely on temperature differences; an internal element expands or contracts, opening or closing the valve based on heat.
- Thermodynamic Traps: Respond to pressure and velocity shifts; a disc or thermodynamic element moves to discharge condensate and trap steam.
Survey Methods and Tools
Modern steam trap surveys combine multiple diagnostic technologies for thorough results:
- Ultrasonic Testing: The preferred industry-standard tool for evaluating trap health, ultrasonic sensors pick up high-frequency sounds from opening, closing, or leaking traps. Technicians use handheld devices like SONOTEC’s SONAPHONE to listen for distinct signals and differentiate between normal operation, leaks, and blockage.
- Temperature Measurement: Infrared thermometers or thermal imaging cameras check inlet and outlet temperatures, revealing whether traps are passing hot steam (leak) or backing up cold condensate (blockage).
- Digital Data Management: Software solutions such as Sonotec’s SteamExpert app and DataSuite PC software streamline survey documentation, mapping, and trend analysis, making results actionable and traceable.
Best Practices for Conducting a Survey
- Prepare and Map Traps: Tag and document each steam trap’s type, location, and maintenance history.
- Perform Combined Testing: Use both ultrasonic and temperature readings for every trap to maximize detection accuracy.
- Record and Analyze Data: Maintain robust records of findings, and prioritize repairs based on risk, criticality, and energy loss estimates.
- Automated Monitoring: For critical applications, install permanent sensors for real-time, automated trap monitoring to catch failures between manual surveys.
- Train Staff: Ensure technicians are versed in recognizing the unique signals of each trap type and system design.
Survey Workflow Example
- Begin at the boiler and follow steam distribution lines.
- Use an ultrasonic detector to listen for trap operation or abnormal sounds.youtube
- Measure temperatures upstream and downstream to verify correct function.
- Note each trap’s condition, type, and any signs of wear, corrosion, or failure.
Spotlight: Sonotec Ultrasound Solutions
Photo courtesy Sonotec Ultrasound Solutions. SONOTEC’s SONAPHONE ultrasonic testing device, paired with the BS20 broadband sensor and SteamExpert app, brings unparalleled accuracy and efficiency to steam trap surveys. Used across industries for preventive maintenance, this technology helps energy scouts and maintenance teams quickly identify defective traps, reduce energy costs, and improve system reliability.
Benefits of Steam Trap Surveys
- Lower energy costs through immediate leak detection and repair
- Improved system reliability and safety
- Data-driven maintenance planning and resource allocation
- Extended boiler and steam system lifespan
Make Steam Trap Surveying Easy
For optimal performance and safety, contact experienced specialists like Sonotec or trusted maintenance contractors for your regular steam trap audits. Investing in proactive, technology-enabled surveys ensures steam systems run efficiently, saving energy, reducing emissions, and keeping operations safe.