The SteamPro is a fixed orifice device. Each SteamPro is custom-fitted to your production equipment. First, we do the survey of your equipment. Select the proper SteamPro for you. Open the SteamPro. Test it real-time. Make sure the SteamPro is working properly for you. Otherwise replace the orifice of a different size or model. Repeat the whole process again until everyone is satisfied.
The end result is a perfectly fitted SteamPro for your equipment. The SteamPro is of the latest design. All its internal components maybe repair or replace online, without disturbing any of your existing piping, within five (5) minutes. The condensate/steam discharge maybe observed by opening the return cap. This testing is real-time and with little or no effects on the current production. The SteamPro will last and work almost exactly like new for 20 plus years. The live steam losses will be less than one (1) pound per hour for each SteamPro. If the steam losses are larger, you will be informed and you can make an informed decision.
Conventional steam traps are also orifice devices. They have mechanisms which allow them to close when the accumulated condensate is insufficient. Condensate backup is a real problem. The SteamPro drains the condensate immediately and completely – 100% of the time. Your equipment is being supplied with the full energy which it is designed for. The process temperature is optimal and constant - improving your product quality.
Conventional steam traps are thought of as automatic device. As long as the steam trap is big enough, it will be okay. Armstrong Machine Works suggested a factor of safety of 3.0. That is, calculate or estimate your maximum condensate load. The designed condensate rate equals to the calculated condensate load multiplied by three (3.0.) Use a steam trap with a condensate capacity equal to or greater than the designed condensate rate. For an Inverted Bucket (IV) trap, the actual condensate capacity of the steam trap is almost double that of the listed capacity. Let assume that your calculated maximum condensate load is 100 pounds/hour. Your design condensate rate is 300 pounds/hour. The smallest IV trap you can find has a listed capacity of 550 and an actual capacity of approximately 1,000 pounds/hour. That is the only selection you may have.
When was the last time your engineers calculated the condensate loads. How do you do the calculations? Ask the steam trap manufacturer. They do not think the calculations are necessary.
Table below is an Armstrong steam leaks for various orifice size at a steam pressure differential of 100 psig. The figures are gross exaggerations. These are single-phase steam leaks with the presence of any condensate. That is, they are the maximum possible steam leaks. The leakages are sizeable because the orifices are large. The steam cost of $10.00 per l, 000 lbs is a very old cost.
| Cost of Various Sized Steam Leaks at 100 psi (Assuming steam cost $10.00 per 1000 lbs) |
Size of
Orifice
inches |
Lb. Steam
Wasted
Per Month |
Total
Cost
Per Month |
Total
Cost
Per Year |
1/2 |
835,000 |
$ 8,350.00 |
$ 100,200.00 |
7/16 |
637,000 |
$ 6,370.00 |
$ 76,440.00 |
3/8 |
470,000 |
$ 4,700.00 |
$ 56,400.00 |
5/16 |
325,000 |
$ 3,250.00 |
$ 39,000.00 |
1/4 |
210,000 |
$ 2,100.00 |
$ 25,200.00 |
3/16 |
117,000 |
$ 1,170.00 |
$ 14,040.00 |
1/8 |
52,000 |
$ 525.00 |
$ 6,300.00 |
$10.00 is in U.S. currency. This table is taken directly from the
Armstrong’s “Steam Conservation Guidelines for Condensate Drainage.” |
There is no simple ways that maybe used to test your steam traps for live steam losses. Therefore, the steam traps must be reliable. The SteamPros have a 20 plus years of useful life expectancy. They are guaranteed for five (5) years. They will be fixed or repair at our expenses.
It would be common to find 5 to 10 percent of your steam traps has failed open (blown through.) Therefore, a saving of 5 to 10 percent of your energy or steam is not unusual. At Safe Skin there are many production lines. This makes it simple for us to pick any one of the production line and test it for the effectiveness of the SteamPros. A saving of a few percent is common for a well run and well maintained facility. If the maintenance is under par, I have seen savings up to 50 percent.
It is my suggestion that you consider replacing your conventional steam trap with the SteamPros for ultimate reliability, smooth and increase productivity, and, an improvement of your product quality plus a handsome saving in energy and money.
Written By:
Dr Michael Troy
(On November 2005 at Kuala Lumpur, Malaysia)
Note:
This write-up shall be used with the permission of SteamPro Conservation Sdn Bhd and is not meant for public usage or circulation.
