COURSE OVERVIEW:

Steam traps are essential self-contained valves that automatically drain condensates from a steam-containing enclosure while remaining tight to live steam. This course delves into the mechanical and thermodynamic principles that allow these devices to distinguish between the two phases of water. It covers the critical role steam traps play in maintaining the thermal efficiency of industrial heat exchangers and the structural integrity of steam distribution headers by preventing the accumulation of water.

The scope of this training extends to the comprehensive auditing of steam trap populations across large-scale facilities. Participants will explore the diverse technologies available, including mechanical, thermostatic, and thermodynamic designs, and learn the specific application criteria for each. The Coverage includes the impact of backpressure, the physics of flash steam, and the importance of proper trap sizing to avoid the twin pitfalls of water hammer and steam wastage.

Furthermore, the course emphasizes the implementation of a proactive survey program using advanced diagnostic tools such as ultrasonic detectors and infrared thermography. By understanding the common failure modes—ranging from dirt-related clogging to mechanical wear of internal orifices attendees will be equipped to develop an optimization strategy. This strategy focuses on reducing the carbon footprint of the plant, lowering fuel costs, and enhancing the safety of the steam system through rigorous maintenance and selection practices.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1.  Explain the fundamental purpose of steam traps within a process steam loop.

2.  Differentiate between the operating principles of float, inverted bucket, and thermostatic traps.

3.  Conduct a systematic plant-wide steam trap survey using standardized data sheets.

4.  Utilize ultrasonic diagnostic equipment to identify internal steam leakage.

5.  Apply infrared thermography to detect blocked or failed-closed trap conditions.

6.  Calculate the financial and energy loss associated with various trap failure modes.

7.  Identify the root causes of water hammer and its relationship to poor trap performance.

8.  Select the correct trap type based on process load and pressure requirements.

9.  Analyze the impact of air binding and non-condensable gases on heat transfer.

10.  Determine the optimal location and orientation for trap installation in distribution lines.

11.  Troubleshoot condensate system issues, including excessive backpressure.

12.  Design a preventative maintenance schedule based on trap criticality and service life.

13.  Evaluate the benefits of modern "smart" steam traps with continuous monitoring.

14.  Justify capital expenditure for steam system upgrades using energy savings data.

TARGET AUDIENCE:

This course is intended for Maintenance Technicians, Energy Auditors, Utility Engineers, Boiler House Supervisors, and Process Plant Operators responsible for steam system reliability.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.