Steam energy, whether produced on-site or purchased for a power utility, typically accounts for one of the main expenditures of any commercial or industrial facility. The incorrect functioning of even a small percentage of steam traps can result in significantly higher energy costs. Malfunctioning steam traps can also cause severe operational problems as well as dangerous corrosion damage to nearby pipping and related valves. Annual steam trap testing is the best way to ensure limited operational costs and maximize the efficiency and longevity of any steam system.

A steam system that has not been maintained for a period of time will have many failed traps. Experts estimate that facility with no active steam trap testing program in place will have 50% of its traps blowing steam. These failed steam traps not only spike wasted energy costs, but also minimize the efficiency of your heating system. Implementing a regular testing program will solved these problems.

With energy prices on the rise, now it's more important than ever to have cost saving steam trap program in place. To understand the cost of steam trap failure consider this: An unchecked blowing steam trap at 150 pounds per square inch with an orifice diameter if 3/16 inches will waste 120 pounds of steam. Using an average cost of steam at $12.00 per 1000 pounds produced, one blowing trap will expend approximately #38.50 per day, or an amazing $14,050 a year. The first step in determining how much your facility might be wasting is to conduct a steam trap survey. Most of our clients see a full return on testing and repair costs in only 2 months!

An annual testing program is recommended to ensure a maximum return on your investment. This included a full diagnostic report on all steam traps surveyed from year to year.

• All surveyed traps are tagged with permanent brass tags for the purpose of easy identification as well as tracking and trending
• Inspection for faulty check valves and steam leaks in addition to trap testing
• All failed traps tagged and photographed to be put in an itemized report

• Complete master trap listing of all steam traps testing including trap typer, manufacturer, model, application, pipe size, orifice size, and location of trap
• A dollar loss cost analysis based on-line pressure, degree of failure, and specific client cost to product 1000 pounds of steam
• An individual trap performance section to associate dollar loss to failed traps

Due to the ever-increasing cost of energy, conservation and efficiency have become priorities:

AJP Testing solutions offers building envelope testing. Inspecting your building's envelope using infrared thermography will identify porous areas in the facility where you can see your money, in the form of heat, seeping out of faulty windows, doors, facades, etc.

A building envelope test will pinpoint areas where gross heat loss is occurring, identify the probable cause, and work with your facility's personnel to best determine how repairs should be made.

By sealing your building, your heating and cooling equipment will not have to work as hard to maintain a constant temperature, saving your building on future equipment replacement and repairs.

Testing your building's envelope will not only reduce energy costs and drafty conditions in your facility but it will also increase the operation lifetime of your heating and cooling equipment.

Heat loss scanning of building envelopes is an invaluable tool for locating areas of heat/energy loss. Building envelope scanning must be performed late at night after the solar radiation has been released from the building surface. A minimum of a 20 degree temperature differential between the interior an exterior of building is needed to ensure the proper results.

Our experienced technicians are able to determine if the thermal profiles found are of normal profile or problems that need correction. With rising energy costs, building envelope scanning is a must have in any company's energy conservation program.

Cold air infiltration can also be evaluated by scanning the exterior walls from the interior of the building with access permitting.

Motors:
motors are scanned to determine if the surface temperature exceeds the nameplate rating. If a motor is dirty, overloaded, and undersized or near end of life thermal imaging will detect uneven heating patterns indicating problems

Shafts:
shafts that show abnormal heating patterns will indicate misalignment

Bearings:
elevated temperature on bearings will indicate improper greasing or worn components

Thermal imaging is extremely effective in identifying the location of pipes for mapping purposes and for locating broken or leaking hot water and steam pipes. Boiler systems with leaks in return piping that are constantly requiring fresh water to make up volume are operating extremely inefficiently. Underground testing of exterior piping is also performed late in the evening after solar radiation has been released from the ground.