Reduce energy consumption by monitoring steam traps and valves with Vigilant

In industry, steam traps and valves are essential for the proper functioning of installations.

Although they are often overlooked in maintenance programs, their performance has a direct impact on energy consumption, safety, and compliance with environmental commitments. The Vigilant remote monitoring solution helps detect failures in these critical components and shift from reactive maintenance to a more sustainable and cost-effective predictive approach.

Effective steam traps to avoid waste

Steam traps drain condensate while preventing live steam from escaping. When operating properly, they help optimize the energy performance of steam systems. However, up to 30% of steam traps in service can be faulty.

A single leaking steam trap, with a 3 mm opening, can cause more than €6,000 in energy losses per year. On the scale of an industrial site, the cumulative losses are considerable, both financially and environmentally: lost steam increases CO₂ emissions, compromises ISO 50001 objectives, and damages the company's image.

And the consequences don't stop there: a blocked steam trap can cause water hammer, corrosion, or mechanical overloads. These phenomena cause unplanned shutdowns and even serious incidents. The famous 2007 accident in New York, linked to a blocked steam trap, is a tragic illustration.

SDT Ultrasound's Vigilant prevents these risks by continuously monitoring the condition of bleeders using ultrasound. It accurately detects leaks, blockages, or other defects, enabling rapid intervention before waste or shutdown occurs.

Valves: A Hidden Source of Inefficiency

Often overlooked, valves play a key role in regulating fluids, gases, and steam. If poorly maintained, they can become blocked, leak, or suffer damage due to cavitation. These failures create imbalances in the network, increase energy consumption, and can jeopardize the safety of installations—particularly in offshore environments, where even the slightest leak can have major environmental and regulatory consequences.

In many industries, valves are still maintained in "run-to-failure" mode—in other words, they are waited until they break down before taking action. Vigilant, on the other hand, enables continuous condition monitoring, identifying early signs of failure (turbulent flow, mechanical friction, cavitation) to maintain their optimal energy performance.

The Real Cost of Negligence

Neglecting steam traps and valves means accepting invisible but very real losses:

• Financial : 10% of defective traps on a site can represent tens of thousands of euros wasted each year.
• Operational : A single failure can be enough to disrupt a process, cause chain failures and extend downtime.
• Safe : uncontrolled steam = risk of burns, explosions, and litigation.
• Environmental : According to the EPA (Environmental Protection Agency in the United States), effective maintenance of steam traps can reduce CO₂ emissions by 10%.

The Vigilant: a consumption-oriented solution

Using ultrasound, the Vigilant analyzes the condition of components in real time, enabling targeted predictive maintenance. Unlike traditional approaches, it provides continuous data, facilitating interventions at the right time—neither too early nor too late.

In particular, it identifies:

For the bleeders:

• Leaks : live steam escaping → immediate energy losses.
• Blowing : steam bypassing the mechanism → waste and risk of overpressure.
• Blockages : retained condensate → water hammer and corrosion.

For the valves:

• Turbulent flow : sign of leak or obstruction.
• Mechanical friction : advanced wear, risk of immobilization.
• Cavitation : pressure differential too high → rapid erosion.

Concrete benefits

Integrating Vigilant into a maintenance program allows:

• Reduce energy consumption by up to 25%.
• Reduce repair costs through early detection.
• Lighten the workload in corrective maintenance.
• Comply with ISO 50001 standards and carbon commitments.
• Secure teams and limit incidents.

Case study: measurable results

A European factory recently installed Vigilant to monitor its bleeders and valves. Results in 6 months:

• 25% steam saved.
• €120,000 in annual savings.
• Fewer interventions, therefore reduced labor costs.

Beyond the financial gains, this plant has strengthened its environmental compliance and improved its competitiveness in an increasingly demanding market.

Conclusion

In a context where energy efficiency is becoming an industrial priority, Vigilant is emerging as an essential solution. It transforms the way steam networks are managed, ensuring continuous monitoring, improved energy efficiency, and reduced environmental impact.

Adopting Vigilant means investing in a more economical, safer, and more responsible future.