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1. SDT North America 2003
All Rights Reserved Steam Traps Testing steam traps using airborne ultrasound inspection Welcome To:
Testing Steam Traps Using Airborne Ultrasound Inspection.
I am Allan Rienstra, general manager of SDT North America.
This Free training presentation will help guide you toward better steam trap inspection utilizing airborne ultrasound technology.
Learn and enjoy!Welcome To:
Testing Steam Traps Using Airborne Ultrasound Inspection.
I am Allan Rienstra, general manager of SDT North America.
This Free training presentation will help guide you toward better steam trap inspection utilizing airborne ultrasound technology.
Learn and enjoy!
2. April 5, 2012 SDT North America What is Steam? Add heat energy to water (BTUs)
British Thermal Units
Produces gas from water Steam is an invisible gas produced by adding heat energy to water to raise its temperature to the boiling point. Heat energy is commonly expressed in British Thermal Units.
It takes one BTU to change the temperature of one pound of water, by one degree Fahrenheit.
This works in reverse too. When one pound of steam condenses back to one pound of water, one BTU of heat energy is lost back to the atmosphere.Steam is an invisible gas produced by adding heat energy to water to raise its temperature to the boiling point. Heat energy is commonly expressed in British Thermal Units.
It takes one BTU to change the temperature of one pound of water, by one degree Fahrenheit.
This works in reverse too. When one pound of steam condenses back to one pound of water, one BTU of heat energy is lost back to the atmosphere.
3. April 5, 2012 SDT North America What is a Steam System? Deliver steam from boiler to point of use
Collection of pipes, valves, and steam traps
Steam traps keep steam pure
Steam traps protect the system from damage A steam system is a collection of components that deliver steam from the boiler room to the point of use. The design and installation of the system impact how efficiently steam is transferred from Point A to Point B. The goals are:
Minimum steam loss
Maximum transfer of heat
Timely removal of condensable and non-condensable gases.
Poor designs and failed components mean more steam is condensed back to water, wasting expensive heat energy.A steam system is a collection of components that deliver steam from the boiler room to the point of use. The design and installation of the system impact how efficiently steam is transferred from Point A to Point B. The goals are:
Minimum steam loss
Maximum transfer of heat
Timely removal of condensable and non-condensable gases.
Poor designs and failed components mean more steam is condensed back to water, wasting expensive heat energy.
4. April 5, 2012 SDT North America What is a Steam Trap? Automatic valve
Open for condensate, air, and CO2
Closed for steam
Purpose
Maintain efficient heat transfer
Eliminate corrosive gases
Eliminate water hammer A steam trap is an automatic valve that opens for condensate and non-condensable gases and closes for steam.
It is designed to trap and remove water, air, and CO2. These undesirables hinder the efficient transfer of heat through the system, can corrode system components, and cause system damaging water hammer.A steam trap is an automatic valve that opens for condensate and non-condensable gases and closes for steam.
It is designed to trap and remove water, air, and CO2. These undesirables hinder the efficient transfer of heat through the system, can corrode system components, and cause system damaging water hammer.
5. April 5, 2012 SDT North America Types of Steam Traps Operative modes
Density
Temperature
Velocity
Four common types
Inverted bucket (A)
Float and thermostatic (B)
Thermostatic (C)
Thermodynamic or disk (D) There are four common types of steam traps, and all work to remove impurities from the steam system.
The four types are known as:
Inverted Bucket
Float and Thermostatic
Thermostatic
Thermodynamic or Disk
Traps work on one of three operative modes.
Change in Density
Change in Temperature
Change in Velocity
There are four common types of steam traps, and all work to remove impurities from the steam system.
The four types are known as:
Inverted Bucket
Float and Thermostatic
Thermostatic
Thermodynamic or Disk
Traps work on one of three operative modes.
Change in Density
Change in Temperature
Change in Velocity
6. April 5, 2012 SDT North America Testing Methods Visual Testing Evaluating the condition of traps should be a part of every plants regular PM. Traps can be tested using one of three methods, but for the best results, combine all three.
Visual Testing
Thermal Testing
Ultrasonic Testing
When testing traps using these methods it is equally important to
Know your surroundings and pay attention to safety. Serious burns can result from carelessness or unfamiliarity.
Know the system and understand how the traps function. Traps are tested online with live steam inside them. They are going to cycle at different stages, and those stages are reliant on ongoing processes in motion
Choose the test methods that will give the best result, and
Document your findings for trendingEvaluating the condition of traps should be a part of every plants regular PM. Traps can be tested using one of three methods, but for the best results, combine all three.
Visual Testing
Thermal Testing
Ultrasonic Testing
When testing traps using these methods it is equally important to
Know your surroundings and pay attention to safety. Serious burns can result from carelessness or unfamiliarity.
Know the system and understand how the traps function. Traps are tested online with live steam inside them. They are going to cycle at different stages, and those stages are reliant on ongoing processes in motion
Choose the test methods that will give the best result, and
Document your findings for trending
7. April 5, 2012 SDT North America Ultrasonic Data Collectors Sense high frequency (HF) sounds
Convert HF to representative audible sounds
Eliminate audible parasite noise
Measure and collect data for trend analysis The best, and most commonly used technology for evaluating steam trap condition is an Ultrasonic Data Collector. Some ultrasonic devices also collect infrared temperature readings which conveniently combines all three test methods
Visual
Thermal
Ultrasonic
Ultrasonic data collectors sense high frequency noise created by the turbulence of steam and condensate, and the mechanical movements of the traps inner components. Ambient plant noise is ignored while sounds inside the trap are translated to an audible level.
The ultrasonic data is listened to for quality interpretation, measured for quantitative interpretation, and logged for trending.
The best, and most commonly used technology for evaluating steam trap condition is an Ultrasonic Data Collector. Some ultrasonic devices also collect infrared temperature readings which conveniently combines all three test methods
Visual
Thermal
Ultrasonic
Ultrasonic data collectors sense high frequency noise created by the turbulence of steam and condensate, and the mechanical movements of the traps inner components. Ambient plant noise is ignored while sounds inside the trap are translated to an audible level.
The ultrasonic data is listened to for quality interpretation, measured for quantitative interpretation, and logged for trending.
8. April 5, 2012 SDT North America Ultrasound Testing - Basics Connect headphones to detector
Connect contact sensor to detector
Touch sensor to housing of trap
Adjust sensitivity for measuring and listening according to instruments instructions
There is a basic setup procedure to follow when testing steam traps with ultrasonic data collectors. In all cases, these 4 basic steps come first:
Connect headphones to the detector
Connect the contact sensor to the detector
Turn the detector on and ensure equipment is functioning
Touch the contact sensor to the housing of the trapThere is a basic setup procedure to follow when testing steam traps with ultrasonic data collectors. In all cases, these 4 basic steps come first:
Connect headphones to the detector
Connect the contact sensor to the detector
Turn the detector on and ensure equipment is functioning
Touch the contact sensor to the housing of the trap
9. April 5, 2012 SDT North America Setting Sensitivity of Detector For Low-Pressure Steam:
Set Amplitude Level to Middle to High Range between A=50 or A=80
For High-Pressure Steam:
Set Amplitude Level from A=10 to A=50
Note* Setting proper amplitude is done by having enough sound in the headphone to be able to diagnose a failure. The sensitivity of the detector needs to be set such that an ideal level of sound is heard in the headphones.
For low pressure steam, the sensitivity is best set between the range of A=50 to A=80
For high pressure steam, set the detector between A=10 and A=50.
Evaluating steam trap condition is a combined science of listening and measuring ultrasound levels. So its important to clearly hear the sounds in the headphones. The sensitivity of the detector needs to be set such that an ideal level of sound is heard in the headphones.
For low pressure steam, the sensitivity is best set between the range of A=50 to A=80
For high pressure steam, set the detector between A=10 and A=50.
Evaluating steam trap condition is a combined science of listening and measuring ultrasound levels. So its important to clearly hear the sounds in the headphones.
10. April 5, 2012 SDT North America Ultrasound Testing Data Collection Listen to internal ultrasounds
Take dBV readings and store to data collector to trend:
dBV during collection phase
dBV during dumping phase
Make an audio recording of trap cycle to compare, share, and train future inspectors Listen to the quality of sound produced in the headset. Hear the trap collect and purge as it cycles out impurities and maintains a clean and efficient steam system.
Record and store the dBV reading during both collection and purging phase.
Measure the temperature upstream and downstream of the trap and log it to the detectors data collector
Keep audio recordings of the different traps used in your facility. This is useful for comparing, predicting failures, and for training future inspectors.
Listen to the quality of sound produced in the headset. Hear the trap collect and purge as it cycles out impurities and maintains a clean and efficient steam system.
Record and store the dBV reading during both collection and purging phase.
Measure the temperature upstream and downstream of the trap and log it to the detectors data collector
Keep audio recordings of the different traps used in your facility. This is useful for comparing, predicting failures, and for training future inspectors.
11. April 5, 2012 SDT North America Inverted Bucket Inverted Bucket traps work on the principle of density
Steam keeps the purge valve closed
Condensate opens the purge valve
Collection and purge phases are continuous Inverted Bucket traps work on the principle that condensate is more dense than steam.
Steam causes an upside down bucket to float, which keeps the discharge valve closed
As the denser condensed gases collect the bucket sinks, opening the discharge valve and purging the steam system
A proper functioning trap will continuously cycle through collection and discharge phases.
Inverted Bucket traps work on the principle that condensate is more dense than steam.
Steam causes an upside down bucket to float, which keeps the discharge valve closed
As the denser condensed gases collect the bucket sinks, opening the discharge valve and purging the steam system
A proper functioning trap will continuously cycle through collection and discharge phases.
12. April 5, 2012 SDT North America Ultrasonic Testing Inverted Bucket Traps Follow procedures for Basic Ultrasound Testing
Log US dBV readings on upstream and downstream sides of trap
Log Temp readings on upstream and downstream sides of trap
Distinct and clear cycling sound indicates proper:
Collection phase (gurgling sounds as condensate collects)
Purge phase (Sudden gushing sound as air and condensate is purged)
If clear cycling sounds are not evident:
Trap is stuck closed or open
Louder downstream, trap is open and condensate is passing
Low sound level, trap is closed
Listen for faulty mechanical sounds to identify traps in early stages of failure
Record sounds for future comparisons and operator training Testing Inverted Bucket Traps
Following procedures for basic ultrasound testing discussed earlier, measure and log ultrasound levels upstream and downstream.
Also log temperature readings at the same points.
Listen for a clear cycling sound characterized by
Slow gurgling sounds as condensate collects
Rapid gushing sound as air and condensate are purged
If the cycling sounds are not evident it is possible the trap is either stuck open, plugged, or stuck shut.
Look at the upstream/downstream dBV values. If its louder downstream, trap is open and condensate is passing
If the sound level is low, trap is closed or pluggedTesting Inverted Bucket Traps
Following procedures for basic ultrasound testing discussed earlier, measure and log ultrasound levels upstream and downstream.
Also log temperature readings at the same points.
Listen for a clear cycling sound characterized by
Slow gurgling sounds as condensate collects
Rapid gushing sound as air and condensate are purged
If the cycling sounds are not evident it is possible the trap is either stuck open, plugged, or stuck shut.
Look at the upstream/downstream dBV values. If its louder downstream, trap is open and condensate is passing
If the sound level is low, trap is closed or plugged
13. April 5, 2012 SDT North America Float and Thermostatic Works on combined principle of density and temperature
Density:
No condensate, ball sinks and valve is closed
Condensate collects and lifts ball, opening discharge valve
Temperature
A separate thermostat reacts to temperature changes from the presence of non-condensable gases (air, co2, and carbonic acids)
As it cools it opens a secondary discharge valve at the top of trap Float and Thermostatic traps combine a floating ball purge action with a separate temperature controlled device that opens when the presence of air and condensate cool the trap to a preset temperature.
When no condensate is present the ball sinks and closes the purge valve.
As condensate collects the ball lifts and opens the discharge valve.
Non-condensable gases such as air, CO2, and carbonic acid cool the temperature. When this change of temperature is significant a thermostatic vent opens and discharges the gases.Float and Thermostatic traps combine a floating ball purge action with a separate temperature controlled device that opens when the presence of air and condensate cool the trap to a preset temperature.
When no condensate is present the ball sinks and closes the purge valve.
As condensate collects the ball lifts and opens the discharge valve.
Non-condensable gases such as air, CO2, and carbonic acid cool the temperature. When this change of temperature is significant a thermostatic vent opens and discharges the gases.
14. April 5, 2012 SDT North America Ultrasonic Testing Float and Thermostatic Traps Follow procedures for Basic Ultrasound Testing
Log US dBV readings on upstream and downstream sides of trap
Log Temp readings on upstream and downstream sides of trap
Inspection of ball float follows same procedure for inverted bucket identify cycle of collection and purge phases
Damaged secondary vent valve characterized by chattering, or constant venting
Scan outside of trap in airborne mode Test Float and Thermostatic Traps first following the basic procedures discussed earlier for ultrasonic inspection.
Since F&T traps work on the principle of density the same cycling sound in inverted bucket style traps, characterized by gurgling and gushing, should be evident. If not, follow the procedure to determine if trap is open or closed.
Listen for the secondary thermostatic valve to open and close characterized by a sharp click sound. Remember that this valve only opens in the presence of non-condensable gases. If none are present then the valve is not called upon to open.
These valves can fail open, shut, or chattering. Also scan in airborne mode around the valve for continuous external leakage.Test Float and Thermostatic Traps first following the basic procedures discussed earlier for ultrasonic inspection.
Since F&T traps work on the principle of density the same cycling sound in inverted bucket style traps, characterized by gurgling and gushing, should be evident. If not, follow the procedure to determine if trap is open or closed.
Listen for the secondary thermostatic valve to open and close characterized by a sharp click sound. Remember that this valve only opens in the presence of non-condensable gases. If none are present then the valve is not called upon to open.
These valves can fail open, shut, or chattering. Also scan in airborne mode around the valve for continuous external leakage.
15. April 5, 2012 SDT North America Thermostatic or Bimetallic
Thermostatic or Bimetallic traps work solely on the principle of temperature. The presence of steam closes the disk. Condensate cools the disk element causing it to contract and open. The system is purged, the temperature rises, and the disk closes the trap.Thermostatic or Bimetallic traps work solely on the principle of temperature. The presence of steam closes the disk. Condensate cools the disk element causing it to contract and open. The system is purged, the temperature rises, and the disk closes the trap.
16. April 5, 2012 SDT North America Ultrasonic Testing Thermostatic/Bimetallic Traps Follow procedures for Basic Ultrasound Testing
Log US dBV readings on upstream and downstream sides of trap
Log Temp readings on upstream and downstream sides of trap
Failure signs
Trap is closed low ultrasound levels
Trap is open higher levels downstream
Mechanical Failure chattering element Following the same basic procedures for ultrasonic testing, thermostatic type traps are tested by logging upstream and downstream levels both ultrasonically and thermally.
This style of trap has a shorter cycling phase.
Listen for the sharp click as the valve opens, and then closes.
Failed bimetallic traps produce either
Constant staccato chattering sound
Low ultrasound levels if trap is closed
Higher ultrasound levels downstream is trap is open
Following the same basic procedures for ultrasonic testing, thermostatic type traps are tested by logging upstream and downstream levels both ultrasonically and thermally.
This style of trap has a shorter cycling phase.
Listen for the sharp click as the valve opens, and then closes.
Failed bimetallic traps produce either
Constant staccato chattering sound
Low ultrasound levels if trap is closed
Higher ultrasound levels downstream is trap is open
17. April 5, 2012 SDT North America Thermodynamic or Disk Operates on the principle of velocity
Condensate and air enter the trap
Flow velocity increases as steam reaches inlet
Disk is force toward the inlet seat and bleeds off condensate
Increase in pressure snaps the disk closed
Cycle starts again Thermodynamic or disk traps operate on the principle of changing velocity of the medium. The internal disk serves the dual function of sealing itself in the open, or purge phase, and closed, or collection phase.
The trap purges condensate when steam reaches the inlet orifice. The faster flow rate of steam causes the disk to kinetically pull away from the vent seat allowing condensate to escape and keep the system pure.
When the disk pulls away a control chamber is sealed. This chamber builds in pressure causing the disk to snap back to the closed position.Thermodynamic or disk traps operate on the principle of changing velocity of the medium. The internal disk serves the dual function of sealing itself in the open, or purge phase, and closed, or collection phase.
The trap purges condensate when steam reaches the inlet orifice. The faster flow rate of steam causes the disk to kinetically pull away from the vent seat allowing condensate to escape and keep the system pure.
When the disk pulls away a control chamber is sealed. This chamber builds in pressure causing the disk to snap back to the closed position.
18. April 5, 2012 SDT North America Ultrasonic Testing Thermodynamic or Disk Traps Follow procedures for Basic Ultrasound Testing
Log US dBV readings on upstream and downstream sides of trap
Log Temp readings on upstream and downstream sides of trap
Characteristics to listen for:
Disk is forced open rushing sound as condensate discharges
Disk snaps shut sharp snapping sound as disk is pushed closed
Failed mechanism continual snapping sound as disk flutters
Record sound files for comparison, trending, and training Testing disk traps with ultrasound requires following basic testing procedures described earlier.
After logging temperature and decibel readings upstream and downstream, listen for these characteristics:
Disk forces open with a click, followed by rushing sound as condensate discharges.
Disk snaps shut and rushing sound stops.
If you hear continual snapping sound the mechanism has failed and the disk is simply fluttering.
Record the sounds for comparison, trending, and training.Testing disk traps with ultrasound requires following basic testing procedures described earlier.
After logging temperature and decibel readings upstream and downstream, listen for these characteristics:
Disk forces open with a click, followed by rushing sound as condensate discharges.
Disk snaps shut and rushing sound stops.
If you hear continual snapping sound the mechanism has failed and the disk is simply fluttering.
Record the sounds for comparison, trending, and training.
19. April 5, 2012 SDT North America Cause and Effect of Failed Traps Efficient transfer of heat energy
Trap is stuck open?
Waste of $$$
Excess steam in system create back pressure
Back pressure can cause other traps to malfunction
Trap is stuck shut?
Water Hammer
Line Freezing and possible rupture Steam traps are necessary for the overall efficiency of heat energy transfer. When traps fail they waste money, they create back pressure in the steam system, and they cause process failures or quality issues with the end product
Traps that are closed can create damaging water hammer, line freezing, and possible rupture.
When one part of a system does not function properly other parts of the system are forced to pick up the slack. Added strain to the rest of the system will expedite future failures, and an eventual breakdown of the system.
Make frequent ultrasound inspection of your steam traps a part of your regularly planned maintenance.
Steam traps are necessary for the overall efficiency of heat energy transfer. When traps fail they waste money, they create back pressure in the steam system, and they cause process failures or quality issues with the end product
Traps that are closed can create damaging water hammer, line freezing, and possible rupture.
When one part of a system does not function properly other parts of the system are forced to pick up the slack. Added strain to the rest of the system will expedite future failures, and an eventual breakdown of the system.
Make frequent ultrasound inspection of your steam traps a part of your regularly planned maintenance.
20. April 5, 2012 SDT North America End Thank you, we appreciate your attention and interest!
Click below to download a copy of our Basics of Ultrasonic Steam Trap Testing
Request additional information about ultrasonic testing
Contact:
SDT North America
1-800-667-5325
www.sdtnorthamerica.com
freecd@sdtnorthamerica.com
Some Steam Trap graphics provided by: Plant Support and Evaluations, Inc www.plantsupport.com
Thank you for your time.
A copy of this presentation is available upon request from SDT North America.
Additional resources for steam systems can be found at www.plantsupport.com and www.reliabilityweb.com
Thank you for your time.
A copy of this presentation is available upon request from SDT North America.
Additional resources for steam systems can be found at www.plantsupport.com and www.reliabilityweb.com
