Steam traps are critical components in every petrochemical plant’s steam system, responsible for removing condensate and non-condensable gases while preventing live steam loss. Global Heritage Systems LTD has conducted over 20,000 steam trap surveys across different SABIC companies and replaced 7,000+ steam traps for facilities in Jubail — making us the most experienced steam trap service provider in Saudi Arabia’s Eastern Province.
Why Steam Trap Management Matters
Failed steam traps are one of the largest sources of energy waste in petrochemical plants. A single failed-open steam trap can waste SAR 50,000-150,000 annually in lost steam. Industry studies show that plants without active steam trap management programs have failure rates of 15-30%, meaning hundreds of traps could be wasting energy at any given time.
| Trap Failure Type | Energy Impact | Annual Cost Per Trap (SAR) | Detection Method |
|---|---|---|---|
| Failed Open (Blowing) | Maximum steam loss | 50,000 – 150,000 | Ultrasonic / Temperature |
| Failed Closed (Blocked) | Condensate backup, water hammer | Equipment damage risk | Temperature differential |
| Leaking / Passing | Partial steam loss | 15,000 – 50,000 | Ultrasonic testing |
| Oversized Trap | Cycling inefficiency | 5,000 – 20,000 | Engineering review |
GHSL’s Steam Trap Survey Methodology
Phase 1 — Asset Inventory
Complete mapping of all steam traps including type, size, manufacturer, location, and P&ID reference — typically 500-3,000 traps per plant
Phase 2 — Diagnostic Testing
Non-invasive ultrasonic and temperature testing of every trap to determine operational status: working, failed open, failed closed, or leaking
Phase 3 — Analysis & Reporting
Detailed report with failure statistics, energy loss calculations, cost-of-waste analysis, and prioritized replacement recommendations
Phase 4 — Replacement Execution
Procurement and installation of replacement traps, prioritized by energy loss severity — typically completed during routine operations or shutdowns
Phase 5 — Ongoing Monitoring
Annual or semi-annual re-survey program to maintain trap health and prevent regression to high failure rates
Steam Trap Failure Rates by Plant Age
* Based on GHSL field data from 20,000+ steam trap surveys across SABIC affiliates