Steam Trap Testing at a Power Plant: TRAPChecker + SDT270

Importance of steam trap testing

Steam traps are a critical component of any steam system. For route-based inspection at a power plant, the TRAPChecker mode on the SDT270 or SDT340 is used — see also the steam and condensate segment of the SDT catalog. Traps that aren't working lead to:

Failed open

• Loss of live steam
• Loss of condensate
• Increased boiler load
• Wasted energy

Failed closed

• Water hammer
• Reduced heat transfer
• Equipment damage
• Production issues

Audit results

Scope

A power plant with 3 boilers and 200+ steam traps

Equipment used

• TRAPChecker — a specialized detector
• SDT270 — for documentation
• Temperature probe for verification

Testing methodology

1. Ultrasound testing

• Contact sensor on the trap
• Listening for characteristic sounds:
  • Working: intermittent clicking
  • Failed open: continuous steam flow
  • Failed closed: silence

2. Temperature verification

• Inlet vs. outlet temperature
• ΔT indicates trap condition
• Confirms the ultrasound findings

3. Documentation

• Each trap tagged and logged
• Before/after measurements
• Photos and notes

Findings

Condition	Count	Percentage	Loss/Year
Working properly	142	71%	—
Failed open	38	19%	$95,000
Failed closed	12	6%	Risk of damage
Unknown	8	4%	—

Total annual loss: $95,000

Cost analysis

Failed open traps (38)

Average steam loss:

• Small traps: 10 kg/hr
• Medium traps: 25 kg/hr
• Large traps: 50 kg/hr

Economic impact:

• Steam cost: $25/1,000 kg
• Average loss per trap: $2,500/year
• Total: $95,000/year

ROI calculation

Item	Cost
TRAPChecker	$3,500
SDT270	$8,000
Training	$2,000
Total investment	$13,500
Annual savings	$95,000
Payback period	<2 months

Recommendations

Immediate actions

1. Replace all 38 failed-open traps
2. Repair the 12 failed-closed traps
3. Investigate the 8 unknown traps

Ongoing program

1. Quarterly testing of all traps
2. Annual training for the maintenance team
3. Database tracking for each trap
4. Replacement schedule based on condition

Best practices

• Test each trap quarterly
• Document findings
• Set alarm levels
• Plan preventive replacements

Additional benefits

Beyond energy savings

1. Improved process — consistent steam quality
2. Extended equipment life — reduced water hammer
3. Safety — fewer emergency repairs
4. Environmental — reduced carbon footprint

Carbon reduction

• Steam production: 0.2 kg CO2/kg steam
• Steam saved: 1,520,000 kg/year
• CO2 reduction: 304 tons/year

Implementation timeline

Phase 1: Immediate (Week 1)

• Test all traps
• Document findings
• Identify failures

Phase 2: Repair (Weeks 2-4)

• Replace failed traps
• Verify operation
• Update the database

Phase 3: Program (Month 2+)

• Quarterly testing schedule
• Training refreshers
• Continuous improvement

Conclusion

Steam trap testing with TRAPChecker and SDT270 provides:

• Quick payback (<2 months)
• Significant energy savings ($95K/year)
• Reduced downtime
• Extended equipment life
• Environmental benefits

Recommended for any facility with steam systems.