STEAM SYSTEMS BEST PRACTICES

Swagelok Energy Advisors, Inc. Document No. 18

Steam System Best Practices

Ultrasound Testing Steam Traps

Ultrasonic testing equipment provides the most versatile and accurate steam system diag-
nostics tool available today. The ultrasonic unit allows the operator to hear sounds undec-
tible by the human ear. This type of equipment receives a high frequency signal (typically
between 20 – 100 KHz) and heterodynes the signal providing an audible sound for
the operator to hear with the aid of headphones.

Ultrasonic steam trap testing is the final test method to be used in the steam trap
testing program for detecting faulty steam traps. The operator utilizes the stetho-
scope module to contact the discharge side of the steam trap, and has the ability to
sense and detect even subtle changes in operational characteristics or malfunctions.

The sensitivity of most high frequency monitoring equipment allows the testing
person to hear not only completely failed steam traps (blowing steam), but even
leaking steam from a steam trap in operation. This test method provides the earli-
est signal of steam trap wear and is used as a predictive tool for steam trap monitor-
ing. Ultrasonic testing permits the testing person to hear the internal operation of
the steam trap; so the effectiveness of the steam trap operation can be determined.
When listening to the ultrasound testing unit, remember condensate will crackle
and steam will whistle during testing with the ultrasound equipment

What are the correct settings?

Ultrasound Testing Sensitivity Settings for Ultrasound
(Scale = 0 – 100%)

0 – 20 psi = 92% or higher

20 – 150 psi = 80% to 85%
150 – 300 psi = 74% to 78%
300 – 600 psi = 60% to 65%
600 psi or higher = comparison method

Selecting Testing Procedure

Testing steam traps is simplified on all manufacturers’ steam traps by classifying them
as follows:
• On/Off operation
• Continuous flow

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Comparison Method
When testing a steam trap the testing person should use the comparison method.
The comparison method is accomplished by taking a minimum of three or
more individual ultrasonic readings upstream and downstream of the steam
trap. When doing the comparison method, the sensitivity should be adjusted to
achieve an accurate test of the steam trap performance.

Dicharge Orifice of the Steam Trap

To test using ultrasound, the measurement must be downstream of the discharge
orifice of the steam trap. The downstream location is the location of the highest
and clearest ultrasound generation.

Orific eELLocation
OR I FI C
Orifice Loc ation
OC A T I ON

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Inverted Bucket Operation

1.) Points about the steam trap
a. Mechanical steam trap
b. (On/Off Operation)
c. Test point – downstream of the discharge orifice
2.) Visual inspection
a. Steam trap should be level to the eye
b. Check flow arrow to insure steam trap is installed correctly
3.) Temperature measurement
a. Take temperatures before and after steam trap
b. Temperatures below 212°F or 100°C, steam trap is not in operation
c. Take temperature at the process inlet. Temperatures at the process
inlet and the steam trap inlet will be relatively close.
4.) Off position during operation
a. Ultrasound level should be low or zero on the ultrasound meter
b. Long off periods can cause “loss of prime”

Steam
Condensate

5.) Discharge Operation (discharging condensate)

a. When the inverted bucket drops due to the loss of buoyancy, this
will bring the valve away from the discharge orifice. This action
will allow the steam trap to discharge the condensate.
b. The ultrasound indicator will rise due to the increase in ultrasound
from the discharge cycle. The ultrasound will stay high or full
scale until condensate is discharged from the steam trap. The
ultrasound level (meter) should deflect more than 30% of scale.
c. When condensate is completely discharged, the inverted bucket will rise,
due to buoyancy, and bring the valve in contact with the discharge orifice.
The steam trap is now in the off position. The ultrasound level should be at
zero or minimum.
d. Ultrasound level should proceed to full or high ultrasound level during the
discharge cycle and return to minimum scale reading or zero after the discharge
is complete.
e. Condensate will crackle and steam will whistle during testing with the ultrasound equip-
ment, therefore during the cycling there will be a crackling + whistling sound during the
discharge cycle (steam and condensate passing through the orifice of the steam trap).
f. The steam trap should stay in the off position for a least 15 seconds before cycling (less
than 15 seconds if the steam trap is undersized)

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STEAM SYSTEMS BEST PRACTICES
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g. Discharge – ultrasound meter should increase the ultrasound level.

h. The steam trap has a fast on/off operation.

Steam
Condensate
Flash Steam

6.) Light Condensate Load Operation

a. Ultrasound levels will cycle on and off at low ultrasound levels. This is an
indication of low condensate flows.

7.) Failure Modes

a. Leaking steam

Steam trap valve wear or linkage will cause the steam trap to leak steam.

The following are indicators of leaking steam:

• Ultrasound meter does not return to zero or baseline after condensate
discharge cycle.
• Ultrasound levels are continuous off base line and there is not distinct cycle/no
cycle operation.

Steam
Condensate

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b. Blowing steam
Steam trap valve or linkage failure or over sizing (loss of prime) will cause the steam trap to
blow steam directly through the steam trap.
The following are indicators of leaking steam:
• Ultrasound meter is at full scale.
• Hearing a dominant whistling sound and no crackling.

Float and Thermostatic Operation

1.) Points about the steam trap
a. Mechanical steam trap.
b. Continuous condensate flow operation.
c. Test point – When testing the float and thermostatic design steam trap, two points must
be tested. The float and thermostatic design has two discharged orifices, one for the
removal of condensate (main discharge orifice) and an air vent orifice for the removal of
air and non-condensable gases.
2.) Visual inspection
a. Steam trap should be level to the eye.
b. Check to make sure the float is in the correct position
c. Check flow arrow to ensure steam trap is installed correctly.
3.) Temperature measurement
a. Take temperatures before and after steam trap.
b. Temperatures below 212°F or 100°C, steam trap is not in operation.
c. Take temperature at the process inlet. Temperatures at the process inlet and the steam
trap inlet will be relatively close.
4.) Off position during operation
a. This very seldom happens, because the steam trap always allows discharge of
condensate.
b. Ultrasound level should be low or zero on the ultrasound meter.

Steam
Condensate

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STEAM SYSTEMS BEST PRACTICES
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5.) Discharge Operation (discharging condensate)
a. When the condensate levels increase in the steam trap the buoyancy of the
float will bring the valve away from the discharge orifice. This action will
allow the steam trap to discharge the condensate on a continuous bases.
b. The ultrasound indicator will rise due to the increase in ultrasound during
the discharge cycle. The ultrasound level will have some cycling to the
measurement due to the linkage arrangement.
c. The testing person must check the air vent to ensure proper operation
• The air vent ultrasound level should be less than the condensate discharge
orifice ultrasound level.
d. Condensate will crackle and steam will whistle during testing with the ultra
sound equipment, therefore during the cycling there will be a dominant
crackling + whistling (very small amount) sound during the discharge cycle
(steam and condensate passing through the orifice of the steam trap).
e. Discharge – ultrasound meter should detect an increase in the ultrasound level.
f. The steam trap has a slow continuous operation.
g. See below test points.
• A – Condensate discharge
• B – Air Vent
- Air vent ultrasound must be lower in ultrasound levels than the condensate
discharge orifice.

6.) Failure Modes

a. Leaking steam

Steam trap valve wear or linkage will cause the steam trap to leak steam.
The following are indicators of leaking steam:
• Ultrasound meter is steady, there is no cycling action.
• Very little or no crackling sound.

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 STEAM SYSTEMS BEST PRACTICES
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b. Blowing steam
Steam trap valve or linkage failure will cause the steam trap to blow steam directly through
the steam trap.

The following are indicators of leaking steam:

• Ultrasound meter is at full scale.
• Hearing a dominant whistling sound and no crackling.
c. Air Vent Failure
Steam trap air vent device has failed.
The following are indicators of air vent failure:
• Air vent ultrasound is higher than the condensate discharge air vent.

7.) Free Float Steam Traps

a. Use same test methods as the standard float and thermostatic steam trap.

Thermodynamic Operation
1.) Points about the steam trap
a. Thermodynamic steam trap.
b. On/Off Operation.
c. Test point – downstream of the discharge orifice.
2.) Visual inspection
a. Steam trap should be in a horizontal plane.

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STEAM SYSTEMS BEST PRACTICES
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b. Check flow arrow to insure steam trap is installed correctly.

3.) Temperature measurement
a. Take temperatures before and after steam trap.
b. Temperatures below 212°F or 100°C, steam trap is not in operation.
c. Take temperature at the process inlet. Temperatures at the process inlet and
the steam trap inlet will be relatively close.
4.) Off position during operation
a. Ultrasound level should be low or zero on the ultrasound meter
b. Steam trap should be in the off position for more than 15 seconds.

5.) Discharge Operation (discharging condensate)

a. When the steam pressure is above the disc, the steam trap will discharge the
condensate or steam.
b. The ultrasound indicator will rise due to the increase in ultrasound due to
the discharge cycle. The ultrasound will stay high or full scale until conden-
sate or steam is discharged from the steam trap. The ultrasound level (meter)
should deflect more than 30% of scale.
c. When steam (live) or flash steam trap passing under the disc will cause a pres-
sure drop to occur, and the steam trap will shut off. The steam trap is now in
the off position. The ultrasound level should be at zero or minimum.
d. Ultrasound level should proceed to full or high ultrasound level during the
discharge cycle and return to minimum scale reading or zero after the dis-
charge complete.
e. Condensate will crackle and steam will whistle during testing with the ultra-
sound equipment, therefore during the cycling there will be a crackling
+ whistling sound during the discharge cycle (steam and condensate passing
through the orifice of the steam trap).
f. The steam trap should stay in the off position for least 15 seconds before
cycling (less than 15 seconds the steam trap is passing live steam and is an
energy loss).
g. Discharge – ultrasound meter should increase the ultrasound level.
h. The steam trap has a fast on/off operation.

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STEAM SYSTEMS BEST PRACTICES
Swagelok Energy Advisors, Inc. Document No. 18

6.) Failure Modes

a. Leaking steam
Steam trap valve (disc) wear or seat surface wear will cause the steam trap to leak steam.
The following are indicators of leaking steam:
• Ultrasound meter does not return to zero or baseline after condensate discharge cycle.
• Ultrasound levels are continuous off base line and there is not distinct cycle/no cycle
operation.

b. Blowing steam
Steam trap valve (disc) or seat wear will cause the steam trap to blow steam directly through
the steam trap.
The following are indicators of leaking steam:
• Ultrasound meter is at full scale.
• Hearing a dominant whistling sound and no crackling.

Thermostatic Operation
1.) Points about the steam trap
a. Thermostatic operation.
b. On/Off Operation

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STEAM SYSTEMS BEST PRACTICES
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• Slow movement per the cycle.
c. Test point – downstream of the discharge orifice.
2.) Visual inspection
a. A steam trap can be mounted in any position. The steam trap should be
mounted level to the eye.
b. Check flow arrow to insure steam trap is installed correctly
3.) Temperature measurement
a. Take temperatures before and after steam trap
b. Temperatures below 212°F or 100°C, steam trap is not in operation
c. Take temperature at the process inlet. Temperatures at the process inlet and
the steam trap inlet will be relatively close.
4.) Off position during operation
a. Ultrasound level should be low or zero on the ultrasound meter

5.) Discharge Operation (discharging condensate)

a. When the temperature of the condensate is reduce to the sub cool point of
the steam trap, the bellows will contract pulling the valve away from the
discharge orifice. This action will allow the steam trap to discharge the con-
densate.
b. The ultrasound indicator will rise due to the increase in ultrasound due to
the discharge cycle. The ultrasound will stay high or full scale until conden-
sate is discharged from the steam trap. The ultrasound level (meter) should
deflect more than 30% of scale.
c. When condensate is completely discharged, the temperature in steam trap
cavity will increase causing the bellows to expand into the discharge orifice
and shutting the steam trap off. The steam trap is now in the off position.
The ultrasound level should be at zero or minimum.
d. Ultrasound level should proceed to full or high ultrasound level during the
discharge cycle and return to minimum scale reading or zero after the dis-
charge complete.

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 STEAM SYSTEMS BEST PRACTICES
Swagelok Energy Advisors, Inc. Document No. 18

e. Condensate will crackle and steam will whistle during testing with the ultrasound equip-
ment, therefore during the cycling there will be a crackling + whistling sound during the
discharge cycle (steam and condensate passing through the orifice of the steam trap).
f. Discharge – ultrasound meter should increase the ultrasound level.
g. The steam trap has a slow on/off operation.

6.) Light Condensate Load Operation

a. Ultrasound levels will cycle on and off at low ultrasound levels. This is an indication of
low condensate flows.

7.) Failure Modes

a. Leaking steam
Steam trap valve wear or linkage will cause the steam trap to leak steam.
The following are indicators of leaking steam:
• Ultrasound meter does not return to zero or baseline after condensate discharge cycle.
• Ultrasound levels are continuous off base line and there is not distinct cycle/no cycle
operation.

SWAGELOK ENERGY ADVISORS, INC. | WWW.SWAGELOKENERGY.COM | 888-615-3559 | [email protected]

STEAM SYSTEMS BEST PRACTICES
Swagelok Energy Advisors, Inc. Document No. 18

b. Blowing steam
Steam trap valve or linkage failure or over sizing (loss of prime) will cause the
steam trap to blow steam directly through the steam trap.
The following are indicators of leaking steam:
• Ultrasound meter is at full scale.
• Hearing a dominant whistling sound and no crackling.

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