INTELLIGENT STEAM TRAPS
Intelligent steam traps to detects steam leaks and other incidents in real time to correct them with diligence, and thus reduce energy consumption, increase reliability and reduce production costs, inspection and maintenance.
MONITORING OR ALARM SYSTEMS
Unlike the alarm systems that do not allow to analyze evolution or trend, the monitoring systems send not only alarms, but also measurements of the monitored parameters with the scheduled frequency, so that the user can perform a historical analysis of evolution of the these parameters and predict their trend.
TOTAL OR PARTIAL MONITORING
The total monitoring of steam traps implies that the system includes all the necessary sensors to diagnose any failure or incidence in the monitored equipment. In this case the required sensors are the following:
♦ Ultrasound: To detect internal and / or external steam leaks.
♦ Temperature: To determine the steam trap energy efficiency and / or low temperature due to excessive accumulation of condensate.
♦ Back pressure: To detect excessive pressurization in condensate return pipelines.
Highlight the importance of the back pressure sensor because the most serious operational problems in steam traps occur as a consequence of excessive pressurization in condensate return pipes, caused by excessive expansion steam formation in steam trap discharges, added to the leakage of live steam through it.
PROFITABILITY OF MONITORING
Refining processes consume huge amounts of steam. The rate of steam leakage on steam traps is usually between 15% and 20%, which produces huge economic losses in Refineries and Petrochemical Plants.
Monitoring projects carried out by BITHERM manage to reduce the rate of steam leakage in traps below 0.5% permanently, generating steam savings between 15% and 30%.
On the other hand, apart from many other benefits, these projects significantly increase the reliability of steam networks, a benefit that is difficult to quantify but of enormous value in avoiding unscheduled shutdowns of Process Plants.
The following diagram shows the powerful topology of the SmartWatchWeb™ system:
Its great advantages lie in its extraordinary flexibility, which makes it possible to extend the monitoring system to tens of thousands of steam traps managed under a platform common to all of them. This greatly reduces installation and maintenance costs.
INTELLIGENT STEAM TRAPS
The following images show two typical BITHERM monitored steam traps:
LIMITATIONS OF ULTRASOUNDS
The detection of ultrasound has become a tool of great predictive maintenance value for the detection of gas or steam leaks in valves. However, it is necessary to know its limitations when applied to vapor leak detection in steam traps, where condensate discharge generates flash steam that can be misinterpreted as a live steam leak.