Avoiding steam leaks--How to take care of it in Design phase itself?
Avoiding steam leaks--How to take care of it in Design phase itself?
(OP)
Dear All,
I have been recently visited a plant site for some revamp project information & saw steam leaking everywhere like at utility stations, steam traps etc. Most of the cases it was passing valves....
Steam leaks have multiple negative effects on steam-based plant operations, including energy losses, increased emissions, loss of reliability, production issues, and safety. Steam leakage is a major energy loss and we accept it as normal, but is it really normal?
You can also save tons of CO2 by changing steam systems to reduce leaks. Steam will erode and the leak will increase, which means you need to be very proactive in stopping it.
What can we do at design stage to avoid steam leaks to the extent possible?
I have been recently visited a plant site for some revamp project information & saw steam leaking everywhere like at utility stations, steam traps etc. Most of the cases it was passing valves....
Steam leaks have multiple negative effects on steam-based plant operations, including energy losses, increased emissions, loss of reliability, production issues, and safety. Steam leakage is a major energy loss and we accept it as normal, but is it really normal?
You can also save tons of CO2 by changing steam systems to reduce leaks. Steam will erode and the leak will increase, which means you need to be very proactive in stopping it.
What can we do at design stage to avoid steam leaks to the extent possible?
Thanks & Regards,
Abhijit





RE: Avoiding steam leaks--How to take care of it in Design phase itself?
RE: Avoiding steam leaks--How to take care of it in Design phase itself?
To minimize "steam leaks" in the piping design phase:
- Minimize flanged joints
- Seal weld all threaded piping joints
Have a responsible maintenance department with money and personnel assigned to:
- Stop and repair valves with steam stem or through leakage.
- Monitor repair and/or replace defective steam traps (this is a very simple thing to accomplish)
- Periodically blow down dirt legs
MJCronin
Sr. Process Engineer
RE: Avoiding steam leaks--How to take care of it in Design phase itself?
Weld as much as you can instead of screw joints
Make repair and isolation easy for the maintenance crews.
Remember - More details = better answers
Also: If you get a response it's polite to respond to it.
RE: Avoiding steam leaks--How to take care of it in Design phase itself?
RE: Avoiding steam leaks--How to take care of it in Design phase itself?
Considering that Valves are a prime source of steam leaks, & the primary reason valves leak is because they are purchased based on price rather than the leak rate.
Even a brand new valve will leak if it is not suited for the application.
What kind of valves are making the difference here? Is there a choice? In which ways?
Also, I think we should completely avoid threaded connections in steam service as these are prone to leakages.
Thanks & Regards,
Abhijit
RE: Avoiding steam leaks--How to take care of it in Design phase itself?
MJCronin
Sr. Process Engineer
RE: Avoiding steam leaks--How to take care of it in Design phase itself?
It's a frustrated reality.
RE: Avoiding steam leaks--How to take care of it in Design phase itself?
- Use single body/piece valves
I think there's a bit of a trade-off between leak possibility and maintainability
RE: Avoiding steam leaks--How to take care of it in Design phase itself?
MJCronin, basically it is all started with my recent field trip the article you are referring to below...
http://www.plantservices.com/articles/2014/steam-l...
However, as I am mostly working on the Engineering part of it, I am really keen on the what kind of valves are making the difference here? Is there a choice? In which ways this can overcome?
If the Valve class & the cost is the issue how Client can insist on the correct class & not the obvious one due reduced cost by a contractor?
As per the same article, "A Class 1 valve leaks like a river. Class 6 valves have the tightest shutoff,”. Then what holds us to go with Class 1 or is it overdoing / overspending for the steam service?
Thanks & Regards,
Abhijit
RE: Avoiding steam leaks--How to take care of it in Design phase itself?
https://europeansealing.com/en/publications
I am with you a great deal of easy savings can be done on plants by sealing better and more efficiently. I fail to understand why plant designers spend millions on equipment and then try to locate the cheapest possible connections they can find. Seals are by the very definition the weakest links in the pressure chain.. much safer places to be saving money IMHO.