Steam trap surveys typically give return on investment within four months at PQ Silicas

Survey revealed 50% failure rate for fixed orifice traps

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It’s hard to quantify the savings, but the payback on a survey is typically 3 to 4 months”

Mr Hitchin (Energy Manager)

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Key benefits
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  • Typical payback from each steam trap survey is under 4 months.
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  • Standardising on two-bolt quick fit connector steam traps allows failed traps to be replaced in a matter of minutes, not hours, with no need to wait for plant shut downs.
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Overview
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PQ Silicas is a world leader in silica and alumina technology, with over 900 employees and 8 manufacturing sites on five continents, producing a range of silica products.

An initial two-day steam trap survey was ordered after it became clear that a significant number of steam traps had failed. The results of the initial survey led to a programme of trap surveys being rolled out across the entire Warrington site.

The failed steam traps “were obviously wasting energy,” says Mr Andy Hitchin, Energy Manager. “..the failures also created a maintenance issue, as condensate was accumulating in the pipes”.

Spirax Sarco were asked to focus on the traps around the boiler plant and the pipework leading to the process plant. A particular problem was discovered with the fixed orifice traps, where 50% of the installed population had failed. Unfortunately PQ Silicas had to wait several months for the plant to shut down before the traps could be replaced, as it was impossible to isolate and remove the affected traps safely while the plant was running.

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The Spirax Sarco Solution
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  • Resulting from the initial survey, PQ Silicas have standardised on Spirax Sarco quick fit connector traps, offering double block and bleed. This enables faulty traps to be replaced without waiting for a scheduled plant shutdown, and means the company can immediately benefit from energy savings. “Now if we spot a problem, we can do something about it straight away,” says Mr Hitchin. Following this success, PQ Silicas embarked upon a programme of surveys around the entire site, covering several hundred steam traps.
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  • Spirax Sarco has implemented annual surveys to keep the plant running as efficiently as possible. “It’s hard to quantify the savings, but the payback on a survey is typically 3 to 4 months -- -- No one can afford to waste energy these days, especially with the way gas prices are rising,” adds Mr Hitchin.
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Call +44 (0)1242 521361 for more information

Key facts
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  • A planned programme of steam trap surveys has resulted in significant energy savings with a typical return on investment of 3 to 4 months.
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  • Using two-bolt quick fit connector traps allows rapid replacement of failed steam traps significantly reducing maintenance costs.
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