- Steam Theory
- 1. Basics of Steam
- 2. Steam Heating
- 3. Basics of Steam Traps
- 4. Steam Trap Selection
- Steam Trap Selection: How Application Affects Selection
- Steam Trap Selection: Understanding Specifications
- Steam Trap Selection: Safety Factor and Life Cycle Cost
- Traps and Orifices Part 1
- Traps and Orifices Part 2
- Casting vs. Forging
- Applications of Different Types of Steam Traps
- Don't Get Steamed : Selecting Steam Trap Design
- Understanding Steam Traps
- Compare Two Fixed Orifice Venturi Products to a Variable Orifice Free Float Steam Trap
- 5. Steam Trap Problems
- 6. Steam Trap Management
- 7. Water Hammer
- Water Hammer: What is it?
- Water Hammer: The Mechanism
- Water Hammer: Cause and Location
- Water Hammer: In Steam Distribution Lines
- Water Hammer: In Equipment
- Water Hammer: In Condensate Transport Piping
- Identifying Water Hammer Using a Thermal Camera
- Mitigation of Water Hammer in Vertical Flashing Condensate Transport Piping
- Stop Knocking Your Condensate Return
- Steam Trap Management: Do Something; Anything. Please!
- 8. Risk Mitigation
- 9. Steam Quality
- 10. Steam Distribution
- 11. Condensate Recovery
- Introduction to Condensate Recovery
- Returning Condensate and When to Use Condensate Pumps
- Condensate Recovery: Vented vs. Pressurized Systems
- Condensate Recovery Piping
- What is Stall?
- Methods of Preventing Stall
- Cavitation in Condensate Pumps
- Steam Heat Exchangers are Underworked and Over-Surfaced
- Allocate New Plant Focus to Steam System Design—Part 2
- 12. Energy Efficiency
- Tips to improve steam plant efficiency
- Advice on Winter Preparation for Steam Systems
- Insulating Traps
- Steam Compressors
- Why Save Energy?
- Management Strategies for Conserving Energy
- Recovering Steam Clouds and Waste Heat
- Waste Heat Recovery
- Boiler Energy Saving Tips
- Steam Line Energy Saving Tips
- Steam-Using Equipment Energy Saving Tips
- Preventing Steam Leaks
- Handle Steam More Intelligently
- Optimize the Entire Steam System
- Use Available Data to Lower System Cost
- 13. Compressed Air / Gas
- 14. Other Valves
Steam Trap Losses - what it costs you
Contents:
Have you had times when you can see the white cloud of your breath in the winter and the interior of the plant is white with thick clouds of vapor?
This is a time when the outside temperature is low and more vapor than usual is generated - a cause for concern for the persons doing trap maintenance. It is recommended that a failed trap be replaced as soon as it is found.
Even one failed trap can have steam leakage resulting in losses of hundreds of dollars/pounds/euros per year. Though it depends somewhat on the other conditions, traps on applications of 10 barg or less will typically have a service life of many years, making it possible to recover investment costs in approximately 1 year in most regions. Vapor is not only unsightly - let’s calculate the monetary losses that shouldn’t be overlooked if the vapor results from steam leakage.
Calculating the cost of losses from one trap
Please note, values are approximate.
- Amount of steam leakage (kg/h)
-
- Necessary field
- Please enter standard-width Arabic numerals
- Hours in operation (h/yr)
-
- Necessary field
- Please enter standard-width Arabic numerals
- Unit cost of steam (GBP/1000kg)
-
- Necessary field
- Please enter standard-width Arabic numerals
- Cost of losses from 1 trap
Use the samples below and enter the numbers, then click “Calculate” to find the cost of losses.
Steam Leakage | Hours in Operation | Unit Cost of Steam |
---|---|---|
Small leak - 4 kg/h Leak - 7 kg/h Blowing - 15 kg/h |
Day shift only - 2000 h/yr Multiple shifts - 4000 h/yr Operating continuously - 8000 h/yr |
GBP20 / 1000 kg |
The following formula is used:
Cost of losses (GBP/yr) = |
A x B x C 1000 |
A = Steam leakage (kg/h)
B = Operation hrs (h/yr)
C = Steam unit cost (GBP/1000 kg)
Calculating steam leakage amounts from holes in piping
Enter the numbers, then click “Calculate” to find the amount of steam leakage from the hole in the piping.
Please note, values are approximate.
- Size of hole (mm)
-
- Necessary field
- Please enter standard-width Arabic numerals
- Gauge steam pressure (barg)
-
- Necessary field
- Please enter standard-width Arabic numerals
- Amount of steam leakage from hole in piping
Enter this steam leakage amount into the cost of losses calculation above to find the monetary cost of the steam being lost through the hole.
The following formula is used:
Steam leakage (kg/h) = A² x B x C
A = Size of hole (mm)
B = 0.4 (Constant)
C = Absolute steam pressure (bar) [Gauge pressure + 1]
Introduction to Steam Trap Management | A Guide to Steam Trap Testing |