Select and size steam traps for process, tracing and drip-leg applications based on condensate load and pressure.
Engineering & Maintenance
Steam Trap Surveys and Condensate Recovery System Maintenance
Trains utilities and maintenance engineers to survey steam traps with ultrasonic and thermal tools, quantify energy loss and design reliable condensate recovery systems.
🗓️Duration5 training days
📚Content4 modules · 8 sessions
🎓On completionAccredited attendance certificate
About the programme
Course Overview
An open steam trap can waste more energy in a week than a plant's entire lighting upgrade saves in a year, yet many trap populations go unsurveyed for seasons at a time because failures are silent and hidden behind insulation. This course covers steam trap operating principles, failure modes and the ultrasonic and thermal survey techniques used to find failed traps before they inflate the steam bill. Participants learn to quantify energy loss from a failed-open trap, prioritise replacement across hundreds of trap locations, and design condensate return systems, flash tanks and pump stations that recover heat and water without waterhammer or backpressure. Sessions link condensate quality to boiler feedwater performance and show how to build the preventive maintenance schedules and spares strategy that keep a trap population reliable. The course finishes with the reporting and business-case skills needed to turn survey data into funded improvement programmes, leaving participants able to run a structured steam trap and condensate management function from first survey to measurable savings.
Expected Learning Outcomes
Diagnose failed-open, failed-closed and cycling trap faults using ultrasonic and thermal survey techniques.
Plan and run a plant-wide steam trap survey programme with prioritised replacement lists and savings reports.
Design condensate return piping, flash tanks and pump systems that avoid waterhammer and backpressure.
Evaluate condensate quality risks and their effect on boiler feedwater and deaerator performance.
Build preventive maintenance schedules and spares strategies for traps and condensate recovery equipment.
Present steam trap and condensate performance data to justify energy-saving investment decisions.
Who Should Attend
Utilities and energy engineers responsible for steam system efficiency.
Maintenance technicians and supervisors who inspect and replace steam traps.
Reliability engineers building condition-based maintenance programmes for steam plant.
Boiler house operators managing condensate return and feedwater quality.
Facilities engineers in process plants with extensive steam distribution networks.
Energy managers tracking steam loss and carbon reduction targets.
Course Modules
Select any module to see its sessions and points.
01Steam Trap Types and Failure Modes
2 sessions · 8 points
Session 1Steam Trap Operating Principles and Selection
- Distinguish thermodynamic, thermostatic and mechanical float-and-thermostatic trap operating principles and typical applications.
- Select trap type and capacity based on condensate load, pressure differential and application such as process, tracing or drip leg.
- Explain the role of air venting and cold-start behaviour in trap selection for process heating equipment.
- Interpret manufacturer capacity charts to size traps against maximum and minimum condensate flow conditions.
Session 2Common Failure Modes and Their Energy Impact
- Identify failed-open, failed-closed and cycling failure modes and their distinct symptoms on ultrasonic and thermal surveys.
- Quantify steam loss and cost impact of a failed-open trap using orifice discharge calculations and site steam tariffs.
- Recognise waterlogging and backpressure effects caused by undersized condensate return piping.
- Assess the impact of trap failure on process temperature control and product quality in heat exchangers.
02Steam Trap Survey Methods and Technology
2 sessions · 8 points
Session 1Ultrasonic and Thermal Survey Techniques
- Conduct ultrasonic leak surveys to detect internal trap blow-through masked by insulation or ambient noise.
- Use infrared thermography to compare inlet and outlet trap temperatures and confirm cycling behaviour.
- Apply acoustic and vibration sensors for continuous online trap monitoring on critical process lines.
- Combine visual sight-glass inspection with instrument readings to confirm survey findings before trap replacement.
Session 2Building and Reporting a Steam Trap Survey Programme
- Plan a plant-wide trap survey route, sampling frequency and tagging system linked to the asset register.
- Prioritise trap replacement using a ranked list of energy loss, safety risk and process criticality.
- Prepare a steam loss summary report translating survey findings into annual energy and cost savings.
- Track survey history over successive rounds to demonstrate improvement trends and justify continued investment.
03Condensate Recovery System Design and Operation
2 sessions · 8 points
Session 1Condensate Return Piping and Flash Steam Recovery
- Size condensate return lines and pumped condensate systems to avoid waterhammer and backpressure on traps.
- Design flash tanks to recover low-pressure flash steam for reuse in deaerators or low-pressure heating loads.
- Select condensate pump types, including electric and pressure-powered pumps, for lift and capacity requirements.
- Evaluate insulation and pipe routing choices that minimise heat loss in condensate return networks.
Session 2Water Quality and Boiler Feed Integration
- Assess condensate contamination risks from process leaks and their impact on boiler feedwater quality.
- Specify condensate polishing or monitoring points to protect boiler and deaerator performance.
- Calculate the economic and water-treatment savings from increasing condensate return rate to the boiler house.
- Coordinate condensate recovery upgrades with boiler house operations to avoid feedwater temperature swings.
04Maintenance Planning and Continuous Improvement
2 sessions · 8 points
Session 1Maintenance Strategy for Traps and Condensate Equipment
- Develop a preventive maintenance schedule for trap testing, strainer cleaning and flash tank inspection.
- Define a spare parts strategy for trap internals, pressure-powered pump components and condensate pump seals.
- Integrate steam trap survey data into the computerised maintenance management system for work order generation.
- Establish acceptance criteria for newly installed or repaired traps before returning them to service.
Session 2Energy Management and Continuous Improvement
- Link steam trap and condensate performance metrics to plant energy management and carbon reporting systems.
- Benchmark trap failure rate and condensate return percentage against industry good-practice targets.
- Build a business case for trap management programmes using payback period and steam cost avoidance figures.
- Present survey outcomes and improvement plans to plant management to secure ongoing programme funding.
What the participant receives
4 course modules
A structured syllabus
8 training sessions
across 5 days
32 detailed points
Applied, detailed content
Accredited attendance certificate
On completing the programme
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