INDUSTRIAL SOLUTION - REDUCE STEAM TRAP LEAKS
The Problem
Steam systems are one of the largest users of energy in a typical industrial plant (compressed air is another). In many plants, these systems waste a tremendous amount of energy due to leaks. The biggest source of leaks are malfunctioning steam traps which experience about 20% failure per year according to the US Department of Energy.
To identify and fix leaks, most facility managers implement annual steam trap audits, which involve using a hand-held Infrared gun to "shoot" trap temperatures. Based on the temperature readings, and depending on whether a trap is in a condensate return or open loop, and whether a trap is of the thermostatic or mechanical type, the audit engineer will declare a trap failed or not. Fixing or replacing a failed trap will then stop the leak.
An average plant may have hundreds of steam traps, many in hard to reach locations, which makes audits very cumbersome and expensive. Unfortunately, since an audit is done only once per year, a leak may not be detected for months. Even for a small steam trap (1/8" orifice), a leak can cost $10,000 per year at current steam cost of about $15 per 1,000 lbs.
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The Cypress Envirosystems Solution
The Wireless Steam Trap Monitor solution provides a cost-effective, easy-to-install retrofit solution for existing steam traps. The wireless clamp-on sensors can be installed without breaking seals or shutting down steam systems, and they monitor trap status multiple times daily. A central receiver/hub collects all the data and allow trending, analysis, alarming, and historization from any Windows PC or Mac using a simple browser. Steam Trap failures can be detected within a hour, and email and/or text message alarms sent to an operator. The data can also be integrated with existing plant automation systems (via OPC or BACnet) and displayed on existing operator control stations.
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Case Studies
The Cypress Wireless Steam Trap Monitor is used by many customers in university campuses, pharmaceutical plants, mining plants, manufacturing sites and hospitals around the world. Because of the low upfront cost and easy installation, the payback on investment has been around 6-12 months. Genentech, one of the earliest users of this solution, has carefully documented the savings and benefits.