Leaks, both to the atmosphere and through valves and steam traps, become a  major source of waste and inefficiency. Preventing steam leaks and maintaining steam traps are two ways to improve a steam system. The prime objective of a practical steam trap inspection system is to repair any malfunctioning steam traps or steam leaks that can compromise the safety, energy efficiency, and quality.

A successful steam trap maintenance programme should also include properly training employees to effectively execute the steam trap inspection. To increase the overall effectiveness of the steam trap survey, knowing what the potential problems are and how to identify them is essential—having a strong understanding of how the steam system works can also help the inspector spot any faults when performing the steam trap survey.

Ultrasound technology is employed by maintenance and quality professionals worldwide, and it is often regarded as one of the most effective methods of predictive maintenance technology. Various inspection technologies are combined to keep up a world-class standard for the steam trap inspection process. Likewise, visual inspection or temperature measurement can also be used with an ultrasound inspection technique.

Hand-held airborne and structure-borne ultrasonic devices detect and receive high-frequency sound waves generated due to various reasons, including friction (caused by non lubricated bearing), ionisation, and turbulence (caused by a pressurised air leak or a failed steam trap). Since these high-frequency sounds are outside the typical human hearing range, they are not audible to us. The ultrasonic testing instrument can receive these high-frequency sounds and convert them into an audible sound that the inspector can hear through his headset. The sound is then quantified in decibels (dB) on the instrument’s display screen and can also be displayed as a spectrum in the Fast Fourier Transfer (FFT) or Time Wave Form, depending on the device.

Every inspector begins by using a simple spot radiometer to take temperature data. The temperature will tell the inspector whether steam is entering the trap or not, but it can also estimate steam pressure. If the steam trap is cold, the inspector should double-check that the valves are open and that the trap has not been removed from use. If the steam trap temperature is high, the inspector should note the input and exit temperatures before doing an ultrasonic test.