Steam Trap Surveys
Did you know that in an average steam-using plant, 23.8% of steam traps are either leaking significant amounts of steam or blocking condensate drainage?*
These failed traps cause considerable amounts of wasted energy and prevent steam processes from running efficiently.
TLV's vast experience with steam trap surveys and in-depth knowledge of steam system equipment empower us to deliver objective, data-driven insights and support our customers in sustaining long-term steam trap management programs to achieve energy savings. Our steam trap surveys are not merely a substitute for in-house inspection work, but a professional service that generates measurable value for your business.
*Based on benchmark data from surveying over 350,000 steam traps.
Quantifying Losses and CO2 Reduction Through Diagnosis
Steam leakage from steam traps and bypass valves can be quantified and converted into monetary values to accurately grasp the financial effect. In particular, steam loss represents a significant amount of money when viewed on a plant-wide basis.
Our surveys are designed to deliver reliable, data-driven insights that support budget planning and return-on-investment analysis. These insights help sites accurately forecast financial savings and implement effective strategies to reduce failures.
Advantages of Using an External Survey Provider
"Eliminating such a large number of defective steam traps will lead to significant energy savings."
We frequently hear this from steam users. However, putting this into practice can be more challenging than expected. When asked what problems and issues they had before requesting a steam trap survey, our users had this to say:
- "We have too many traps to manage effectively"
- "Conventional trap testing methods are unreliable"
- "We have a rough understanding of the site situation, but have not taken measures to rectify problems"
- "Difficult to judge the effect of trap surveys on energy savings"
These are just some of the reasons given for not implementing trap management strategies.
Analyzing the failure rate of a sample of approximately 170,000 traps surveyed in Japan on a site-wide basis, the failure rate was 25.0% at the time of the first trap survey, but fell to 9.4% in the fourth year after implementing TLV's trap management program on a regular basis.
TLV’s steam trap surveys are not just inspections, but part of a consulting service that encompasses the entire steam system, delivering cost-effective solutions for your steam trap management needs.
Surveys by Professionals Using the Latest Technology
Trap diagnostic equipment with excellent judgment accuracy
Our surveys utilize the latest TrapMan® diagnostic equipment specially developed by TLV. The equipment can be used for non-TLV products, and it automatically determines the operation and quantifies the amount of steam leakage. Its reliability has been evaluated by an internationally recognized third-party certification organization.
Assessing the current state with reliable diagnostic technology
Surveys are performed by TLV-trained and accredited professional personnel. The amount of steam leakage is converted into a monetary value and losses are clearly indicated. Recommended models are selected for the parts that need to be replaced. As a general rule, the failure rate, defective parts, and amount of loss are reported on the day the diagnosis is completed.
Continuous management system
Creating a plant map and collecting data
We collect data covering up to 64 items, including steam traps, peripheral valves, piping, operating conditions, etc. We determine the year of installation (= service period) from the serial number, lot number, etc., as well as the manufacturer and model of the trap. We then prepare and submit a trap survey list and layout drawing based on the information collected .
Diagnosis of bypass valves
In addition to the operational status of the trap itself, TLV's surveys also check for leakage of the bypass valves, the open/closed status of the upstream valve, and the operational status of the equipment ahead of the trap to estimate and quantify the total amount of internal leakage.
Follow-up on defective parts
We will follow up on defective areas at a later date with recommended products and installation methods.
Diagnostic Steps
Step 1
Meeting
- Outlining the survey process
- Preliminary coordination
- Discussion of details
Step 2
On-site survey
- Data collection
- Trap and bypass valve survey
- Investigation of trapping problems
- Investigation of surrounding valves, etc.
Failure locations only
- Recommended product selection
- Identifying the ideal replacement method
Step 3
Report on completion date
- Report
- Layout drawing
- Trap list details
Step 4
Proposal
Recommendations for
- Product replacements
- Replacement methods