Steam System Analysis
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Optimize Your Steam Distribution
Steam System Analysis identifies energy losses across your boiler, distribution network, and condensate return system. Our comprehensive audits use ultrasonic leak detection, thermal imaging, and steam trap testing to quantify losses and recommend corrective actions.
Typical findings include faulty steam traps (20-30% failure rate), uninsulated valves and flanges, condensate losses, and oversized safety valves. By addressing these issues, industries can achieve 15-30% fuel savings and improve process steam quality.
Steam Audit Services
Steam Trap Survey
Ultrasonic testing of all steam traps, categorization (pass/fail/blow-through), replacement recommendations.
MethodThermal Imaging
Infrared thermography to identify uninsulated surfaces, leaks, and heat loss zones.
ResultsCondensate Recovery Analysis
Flash steam recovery, condensate return temperature, flash vessel sizing, heat exchanger opportunities.
SavingsSteam Balance Study
Generation vs. consumption mapping, pressure drop analysis, header sizing verification.
ProcessAudit Focus Areas
Key areas we evaluate during a comprehensive steam system analysis.
| Component | Issues Detected | Improvement Potential |
|---|---|---|
| Boiler Efficiency | Excess air, flue gas temperature, blowdown rate, scale formation | 2-8% fuel savings |
| Distribution Network | Steam leaks, uninsulated pipes, pressure drops, improper trap placement | 5-15% fuel savings |
| Steam Traps | Failed open (blow-through), failed closed (waterlogging), undersized traps | 5-10% fuel savings |
| Condensate System | Flash steam venting, low recovery %, cold condensate discharge | 3-7% fuel savings |