Steam trap maintenance and maintenance

Steam trap maintenance and maintenance

Steam traps differ from other types of steam valves. As an automatic valve, steam traps operate and switch frequently. After using for a certain period of time, it is often faced with problems such as increased leakage, decreased sealing, and delayed response.

The service life of the steam trap is first determined and the correct type is selected. Watt's energy-saving experience shows that unsuitable types and calibers can affect the actual performance and life of the trap. Secondly, the material of the trap, especially the choice of the valve seat material and the heat treatment process are also very important.

During the use, the changes and conditions of the working conditions and the timely maintenance and maintenance of the trap have a great influence on the service life of the trap. Even with the same quality of steam traps, the performance of life in different processes and applications is often not consistent.

Failure of the trap is often unpredictable. Early failures often start with an increase in leakage, which is almost impossible to detect in time. Therefore, the preventive maintenance test of the trap is the main one. Some factories in Europe and America implement on-line detection of traps, but the actual effects are not satisfactory due to the instability of the detection objects (flow, pressure, flow rate), flashing and back pressure.

Watt Energy believes that the planned management of the trap is very important. Program management of trap valves includes data statistics and archives of traps, periodic and irregular inspections, periodic maintenance, replacement planning and replacement of important components, removal and removal of trap filters, and scaling of spools , the evaluation of the wear of key traps, etc.

The planned management of steam traps is an important part of enterprise energy management and must be established and implemented in a timely manner.

The life of a steam trap varies depending on the characteristics of the steam equipment, operating conditions, steam pressure, amount of condensate, the number of steam traps used, the proficiency of the repairman, and the seriousness of the repair work. However, the biggest factor in shortening the life of a trap is the handling of impurities and impurities during the initial period after the new piping is installed.

If improper handling of impurities such as weld slag and impurities after piping and trap installation, it will have a significant adverse effect on the steam trap. It is very important to thoroughly clean the pipelines installed and install the filters regularly to remove scale and impurities from the initial operation.

Based on past practical experience, we believe that it should be cleared once a week in the month after it is put into operation; one month to three months after being put into operation, it should be cleared once a month, and then cleaned every 6 months thereafter. .

In normal use, in order to prolong the service life of the steam trap, it is necessary to perform early detection (foreseeing) and early settlement (overhaul) when abnormal work occurs. This is the regular maintenance during operation.

Regular maintenance times and steam loss increase are positively related to your relationship. For example, the inspection and maintenance of the trap is changed from once a year to twice, and the energy saving effect is very obvious. The effect of changing to three times a year three times a year has not changed much. Therefore, the periodicity of regular steam traps can be determined twice a year, that is, every six months or so.

In order to carry out maintenance work, it is desirable to know in advance the time required to replace a new steam trap or the time to repair (replace parts) of the main parts. The cycle of replacing parts, from the point of view of preventive maintenance, it is best to replace the new valve or replace the main parts during the wear of the steam trap before its service life. However, the service life of the trap is affected by various factors, making it difficult to predict the life of the trap.

For this method of predicting the life arrival period, Hangzhou Watt hopes to use the “statistical management method”, which is to calculate the failure rate of steam traps that have been used for a period of time. Based on these data, calculations are performed. The law should be carried out according to the guidance of professional books or production plants.

For the initial failure, the failure caused by the structural defects of the trap itself is quickly exposed. The problems that occurred during the initial failure were almost always due to the operational use of impurities and incomplete cleaning of impurities during the initial operation.

For accidental failures, the failure is entirely due to accidental reasons. During this period, the failure rate is very low and it is generally considered that this period is the effective life period. From a common sense point of view, we can think of the length of this period and the size of the failure rate. It is closely related to the quality of steam traps and the quality of operation and management.

The experience of Hangzhou Watt Energy Saving Engineering Co., Ltd. shows that after a certain period of accidental failure, the trap will wear, corrosion, crack and other faults, and the failure rate begins to increase sharply. This period is called the wear period. If the wear period fails, it is best to replace the new trap. When the maintenance cost (the price of the parts and the manpower, material resources, construction costs, etc. required for repair) exceeds 30% of the unit price of the steam trap, it is better to replace the new trap. This can be performed as a standard.

In order to predict when the steam trap enters the wear period that needs to replace the main components, the preventive maintenance is satisfactorily completed, and the organization and management are carried out, and the working conditions of each steam trap (the inspection time and the operation state during the maintenance period, the maintenance situation) are recorded in detail. On the maintenance record sheet, the life cycle, fault condition and maintenance cost are statistically calculated to predict and master the replacement cycle.

In order to properly carry out the planned maintenance management of the steam trap, Hangzhou Watt Energy Co., Ltd. assists the customer to establish a management organization within the enterprise, and needs to establish statistics such as steam trap category management account, steam trap single machine management account, steam trap maintenance record table, etc. Form, form a complete management system.

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