Diagnostic system for steam traps and pipeline fittings

The system for diagnosing steam traps and pipeline fittings performs the primary task of energy saving - reducing losses. Regular inspection of steam traps and shut-off and control valves for steam leaks can significantly reduce losses in the steam condensate system.

The equipment used in steam condensate systems typically operate at high temperatures and pressures. The working elements are located in cases made of high-strength opaque materials and it is very difficult to visually assess the efficiency of the work or the overall performance of the element. The operability and efficiency of a steam trap is usually determined very roughly by indirect indications, condensate return or temperature. Installation sight glasses facilitates this task, but it is not always convenient to implement in existing schemes, complicates the design and does not allow evaluating the efficiency.

Thermal power engineers of the Japanese company Miyawaki have developed and are actively implementing unique portable computer systems for diagnosing the operation of steam traps and shut-off and control valves directly in operation. To obtain initial data, it is enough to touch certain points of the steam trap or pipeline with two sensors: temperature and ultrasonic vibration. The data directly enters the processor of the device and on the display it is already possible to determine the main parameters of the working environment, operability and approximately efficiency.

Further processing of the data and the issuance of complete detailed survey results are performed by specialized software that can be installed on any modern computer. The program contains data and calculation algorithms for almost all types and models of steam traps and valves produced in the world. Support for an internal database allows you to conveniently take into account and store the state and history of the health of all diagnosed equipment of an enterprise or enterprises. Timely identify problem areas and possible problems without decommissioning the equipment, make decisions on replacement based on accurate reliable information.

In enterprises that use steam, the following questions very often arise:

— Is the condensate trap working?

- Does the valve let steam through?

To date, the system for diagnosing steam traps and pipeline fittings using ultrasound is the most effective. Other methods of verification (visual control of these devices, by ear with the help of phonendoscope devices, with the help of a pyrometer) require a lot of practical experience of the attendants, and at the same time, the analysis results have a high error. And in this case, in principle, it is not possible to draw up a general picture of the state of operation of the condensate removal units for the enterprise.

To answer these questions, Artesia uses Dr. Trap Jr., developed by MIYAWAKI. Dr. Trap Jr., a system for fast, accurate and visual inspection of steam traps, consists of a PM 11 ultrasonic tester and a temperature probe. The survey data is processed by the SurveyPro Light PM150 software.

The PM11 tester measures the level of vibration caused by flying steam. Vibration level readings depend on how the steam trap valve mechanism works. Therefore, even before the start of the survey, the design features of the tested steam traps are taken into account. After entering the data, the operating status of the steam trap is automatically displayed, as well as steam losses and related financial losses. The SurveyPro Light PM150 software contains virtually the entire list of steam traps produced in the world, allowing you to get the most realistic picture of equipment performance.