In Singapore, where energy costs are high, steam system inefficiency is often hard to see, but it costs money every day [1]. Plant engineers in the pharmaceutical, petrochemical, and laundry industries often focus on how well the boiler works, but they don’t pay enough attention to the distribution and condensate return network [2].
Techmatic Controls doesn’t just sell pressure reducing valves or steam separators; we also help you figure out what’s wrong with the whole system [3]. Here are the four biggest energy thieves and how to stop them, based on 30 years of experience on the job.
1. Leaking steam traps: the quiet budget killer
One steam trap that doesn’t work can waste a lot of steam every year [4]. Unfortunately, staff members often don’t notice a leaking trap because the discharge line isn’t hot enough to alarm them but is too hot to touch safely.
Quick Check:
- Visual: Is the discharge always flowing? (Condensate should not be constant.)
- Thermal: Use a pyrometer. If the temperature downstream is close to the temperature of steam, the trap is blowing live steam [5].
- Auditory: Ultrasonic detectors show that there is a lot of fast flow across a broken seat [6].
Solution: Set up a regular schedule for checking steam traps [7]. Put a tag on every trap and keep track of it. Techmatic suggests grading traps by how important they are and replacing broken ones right away with high-quality thermodynamic or float traps that are right for your application pressure [3].
2. Wet Steam: The Killer of Combustion Efficiency
At least 98% of the steam leaving the boiler should be dry [8]. Wet steam has water droplets in it that lower the heat transfer coefficient, cause water hammer, and wear down control valves [2].
The main cause:
- Carryover because of high Total Dissolved Solids (TDS) or chemical foaming [9].
- There isn’t enough space for the steam in the boiler.
- Headers that aren’t insulated lose heat, which makes condensation happen too soon.
Fix: Put a correctly sized steam separator right after the boiler stop valve and right before the pressure reducing station [8]. A high-efficiency separator removes moisture from the steam mechanically, making sure that only dry vapor gets to your process equipment.
3. Broken Pressure Reducing Valves (PRVs)
When the pressure downstream is not stable, processes have to use more steam than they need to reach the setpoint temperatures [10]. A hunting or wire-drawn PRV wastes energy and hurts equipment that is downstream.
Fast Check:
- Listen: Is the valve making noise? This shows that things aren’t stable [11].
- Monitor: Is the pressure downstream changing a lot while the load stays the same?
- Check: Has the valve ever been put in upside down? A common mistake that stops the actuating chamber from draining properly is putting it in the wrong direction [10].
Fix: Make sure that the drip pockets and strainers are placed above the pressure reducing valve [12]. Correctly sized PRVs with accurate pilot control stabilize pressure right away, lowering steam use by letting processes run at the lowest effective pressure [11].
4. Fittings and flanges that aren’t insulated
Plant managers often insulate straight pipe runs, but they don’t cover valves, flanges, or condensate receiver tanks [13]. One unprotected 150mm flange at 7 bar gives off a lot of BTUs every year.
Quick Check: Use a thermal camera or contact thermometer to walk the line. Any surface that is hotter than 50°C could use insulation or engineering controls [14].
Solution: For valves and flanges, use removable insulation pads that have already been shaped. This keeps the system’s energy and makes sure that operators are safe (by following workplace safety heat stress guidelines) [13].
Action Plan for Plant Engineers with Priorities
You don’t have to fix everything all at once. Try this triage method [7]:
Priority 1 (This Week):
- Check all traps on the main production lines. Fix blow-through traps right away [5].
- To stop carryover, check the chemistry of the boiler water [9].
Priority 2 (This Month):
- Put in steam separators on important process lines that have problems with wet steam [8].
- Put insulation around bare steam valves and flanges in places where people walk a lot [14].
Priority 3 (This Quarter):
- Check how well PRV is doing. Change out regulators that are too small or not stable [11].
- Start a program to monitor digital traps for remote accountability [6].
Conclusion: Going from Parts to Capability
To find steam losses, you need to look outside the boiler house [1]. Fixing leaking traps, making wet steam, broken regulators, and gaps in insulation will lower your fuel bills and carbon footprint at the same time [2].
Techmatic Controls can help you with the right products and the diagnostic knowledge to use them because they are ISO9001:2015 certified and know all the local industry codes [3].
Is your steam system hiding energy waste? Get in touch with our expert team for a system walk-down or to order high-performance steam traps and separators that are made just for your plant.
References
[1] Energy Market Authority (EMA), Singapore. (2025). Singapore Energy Statistics – Industrial Sector Consumption Report.
[2] U.S. Department of Energy. (2023). Steam System Efficiency Handbook – Best Practices for Distribution and Condensate Return.
[3] Techmatic Controls. (2025). Company Profile and Technical Capability Statement.
[4] National Board of Boiler and Pressure Vessel Inspectors. (2024). The Cost of Failed Steam Traps.
[5] Spirax Sarco. (2024). Steam Trap Survey and Management Guide.
[6] Armstrong International. (2023). Ultrasonic Testing for Steam Trap Diagnostics.
[7] Oak Ridge National Laboratory. (2022). Steam System Assessment Tool – Best Practices for Plant Engineers.
[8] Spirax Sarco. (2024). Steam Quality and Separator Selection Handbook.
[9] American Society of Mechanical Engineers (ASME). (2023). ASME Boiler and Pressure Vessel Code, Section VII: Recommended Guidelines for Water Chemistry.
[10] Valve Manufacturers Association of America (VMA). (2023). Pressure Reducing Valve Installation and Troubleshooting Guide.
[11] Leslie Controls. (2024). PRV Performance and Sizing Technical Manual.
[12] Techmatic Controls. (2025). Steam System Ancillaries – Installation Best Practices.
[13] National Insulation Association (NIA). (2024). Energy Savings from Valve and Flange Insulation.
[14] Ministry of Manpower, Singapore. (2025). Workplace Safety and Health (General Provisions) Regulations – Heat Stress Management.
