Steam traps are essential components in steam and thermal fluid systems, responsible for removing condensate and non-condensable gases while preventing the loss of live steam. When functioning correctly, they maintain energy efficiency, protect equipment from damage, and ensure consistent system performance. However, like any mechanical component, steam traps can fail — and when they do, the consequences can include increased energy consumption, water hammer, corrosion, and even total system failure.
At ISIS Fluid, we supply and support reliable steam system solutions across industrial sectors. In this article, we highlight five of the most common steam trap failures and explain how to prevent them before they escalate into costly issues.
1. Dirt and Blockages
One of the most common causes of steam trap failure is the accumulation of dirt, rust, scale, or debris within the trap or upstream piping. Over time, these particles can obstruct the trap’s internal mechanisms or clog the built-in strainer, leading to performance issues. A blocked trap may prevent condensate from draining properly, resulting in waterlogging and poor heat transfer. In some cases, particles may damage internal sealing surfaces, causing the trap to leak steam continuously.
Prevention Tips: To prevent this failure, it’s essential to install strainers upstream of each trap to capture contaminants before they reach sensitive components. Regular cleaning of the strainer and inspection of drain lines should be integrated into routine maintenance schedules. Using high-quality piping and ensuring the steam system is flushed and treated before commissioning can also minimise debris build-up from the outset.
2. Incorrect Sizing or Installation
Steam traps must be correctly sized for the system’s pressure, condensate load, and flow rate. An oversized trap may cycle too frequently, increasing mechanical wear, while an undersized one might struggle to discharge condensate, leading to pooling or water hammer. Incorrect installation — such as poor orientation, back-pressure issues, or inadequate drainage slope — can also compromise the trap’s function, causing inefficiency and early failure.
Prevention Tips: Choose traps based on specific application parameters, including maximum and minimum load conditions. It’s also important to adhere strictly to manufacturer installation guidelines, ensuring proper positioning, pitch, and orientation relative to the condensate line. Pipework layout should support effective drainage and avoid the creation of pockets where condensate can accumulate.
3. Mechanical Wear and Tear
Over time, continuous exposure to high pressures, temperatures, and cycling causes internal parts of steam traps — such as valves, floats, seats, and thermostatic elements — to wear down. This wear can result in the trap becoming stuck in an open or closed position. If stuck open, it wastes steam and energy; if closed, it traps condensate, reducing heat transfer and potentially damaging downstream equipment.
Prevention Tips: Invest in high-quality steam traps suited to the specific demands of the system. Establishing a preventive maintenance programme — with scheduled inspections and part replacements — will help catch signs of wear early. Using diagnostic tools such as ultrasonic detectors or thermal imaging can assist in identifying malfunctioning traps without shutting down the system.
4. Water Hammer
Water hammer is a severe form of hydraulic shock that occurs when condensate accumulates and is suddenly pushed by steam, creating a high-velocity surge. This can damage trap internals, pipework, and valves. Steam traps exposed to water hammer can fail abruptly due to cracked housings or misaligned components.
Prevention Tips: To avoid water hammer, ensure that condensate is removed promptly and that the steam system is designed to avoid rapid pressure changes. Use appropriate pipe gradients and avoid sudden directional changes in the layout. Installing pressure-reducing valves and silencers, or employing traps designed to withstand hydraulic shock, can also protect the system.
5. Condensate Contamination
In some systems, poor water treatment or leaks in heat exchangers can cause the condensate to become acidic or chemically aggressive. This contaminated condensate corrodes the internal components of steam traps, leading to early failure, leaks, or even structural damage to the valve body. Corrosion may also create particles that contribute to further blockages downstream.
Prevention Tips: Proper water treatment, including deaeration and pH balancing, is essential for long-term steam trap performance. Regular testing of condensate samples will help identify contamination early. Where contamination risk is high, using steam traps made from corrosion-resistant materials such as stainless steel can significantly extend service life.
Building a Reliable Steam System
Avoiding steam trap failure isn’t just about fixing what breaks — it’s about building systems designed for resilience and reliability. At ISIS Fluid, we encourage clients to adopt a comprehensive approach to steam trap management. This includes maintaining a full inventory of installed traps, scheduling periodic audits, and using modern diagnostic tools to assess performance in real-time.
Training staff in steam system operation and steam trap maintenance is also vital. When on-site teams understand how steam traps work and what failure signs to look for, issues can be identified and resolved more quickly — preventing larger problems from developing.
Conclusion
Steam trap failures — whether caused by dirt, incorrect sizing, wear, water hammer, or contamination — can have significant consequences if left unresolved. But with the right knowledge, maintenance practices, and equipment choices, these problems are entirely preventable. By working with experts like ISIS Fluid, you can implement a proactive strategy that maximises efficiency, reduces downtime, and extends the life of your steam and thermal fluid system.
What is the most common reason steam traps fail?
The most common cause of steam trap failure is dirt and debris blocking the internal components or strainer. This can lead to blocked condensate discharge or continuous steam leakage. Installing strainers and carrying out regular maintenance helps prevent this issue.
How can I tell if a steam trap is not working properly?
Signs of a malfunctioning steam trap include reduced heat transfer, unusual noises (such as banging or knocking), visible steam loss, or condensate build-up. Diagnostic tools like ultrasonic testers or thermal cameras can be used for accurate detection without dismantling the system.
What happens if a steam trap is incorrectly sized?
An oversized trap can cycle too frequently, causing wear and energy waste, while an undersized trap may not discharge condensate effectively, leading to water hammer or flooding. Proper sizing based on system conditions is essential for reliable performance.
Can steam trap failures cause damage to other equipment?
Yes. Failed traps can lead to condensate accumulation, resulting in water hammer, corrosion, or inefficient heat transfer — all of which can damage valves, heat exchangers, and pipework over time.
How often should steam traps be inspected or tested?
Steam traps should be inspected at least biannually, or quarterly in high-demand systems. Regular testing using acoustic or thermal methods allows early identification of problems, helping reduce downtime and repair costs.
What is the best way to prevent steam trap failures?
Prevention starts with correct sizing, proper installation, and regular maintenance. Implementing a steam trap management programme and using high-quality, corrosion-resistant traps can significantly reduce failure risk and improve system efficiency.
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The ADCATrol V16/2 is a series of single seated, two-way globe control valves designed for simple…
VALSTEAM ADCA | PS100 ELECTRO-PNEUMATIC POSITIONERS & CONVERTORS
The ADCATrol PS100 is a digital electronically configurable positioner designed for mounting to pneumatic linear or…
VALSTEAM ADCA | PPV15 ASME FLANGED TWO-WAY CONTROL VALVES
The ADCATrol PPV15 is a series of single seated, two-way pneumatic on/off globe valves with piston…
VALSTEAM ADCA | PP981 PNEUMATIC POSITIONER POSITIONERS & CONVERTORS
The ADCATROL PP 981 positioner requires an input signal of 0,2÷1bar (3÷15psi) for the proportional control…
VALSTEAM ADCA | TR25R SELF-ACTING TEMPERATURE CONTROL VALVES
The TR25/R valves series are designed for temperature control in cooling systems where the valve opens…
VALSTEAM ADCA | TR25SS DN08-DN10 SELF-ACTING TEMPERATURE CONTROL VALVES
The TR25 series of temperature regulators were designed for direct acting temperature control systems where the…
VALSTEAM ADCA | VPA26/2 INTERMEDIATE BOILER BLOWDOWN VALVE VALVES FOR SPECIAL APPLICATIONS
The VPA26/2 bottom blowdown valve series was specially designed for application on steam boilers, to remove…
VALSTEAM ADCA | PS31SS PRESSURE SUSTAINING VALVES
The ADCA PS31 series direct-acting, spring-loaded piston sensing, pressure sustaining valves are designed for use on…
VALSTEAM ADCA | PS30SS PRESSURE SUSTAINING VALVES
The ADCA PS30 series direct-acting, spring-loaded diaphragm sensing, pressure sustaining valves are designed for use on…
VALSTEAM ADCA | TSW22 THERMOSTATIC
The TSW22 all stainless steel thermostatic steam traps and air eliminators are specifically designed for use…
VALSTEAM ADCA UCX41 | PIPELINE CONNECTOR UNIVERSAL STEAM TRAPS & CONNECTORS
The UCX series pipeline connectors are used in steam systems where a simple and economic maintenance…
VALSTEAM ADCA UDT46 | THERMODYNAMIC STEAM TRAP UNIVERSAL STEAM TRAPS & CONNECTORS
The UDT46 series thermodynamic steam traps are excellent for high-pressure systems, including steam tracing applications. The…
VALSTEAM ADCA UFS32 | FLOAT & THERMOSTATIC STEAM TRAP UNIVERSAL STEAM TRAPS & CONNECTORS
The UFS32 series float and thermostatic (integral air vent) steam traps are maintenance-free and sealed. They…
VALSTEAM ADCA | UTS22 THERMOSTATIC STEAM TRAP UNIVERSAL STEAM TRAPS & CONNECTORS
The UTS22 series thermostatic steam traps and air eliminators, completely in stainless steel, are maintenance-free and…
VALSTEAM ADCA UBS20 | BIMETALLIC STEAM TRAP UNIVERSAL STEAM TRAPS & CONNECTORS
The UBS20 series bimetallic steam traps and air eliminators, completely in stainless steel, are maintenance-free and…
VALSTEAM ADCA | UIB36 UNIVERSAL STEAM TRAPS & CONNECTORS
The UIB36 series inverted bucket steam traps, completely in stainless steel, are maintenance free and sealed….
VALSTEAM ADCA UCX90 | 4 BOLT PIPELINE CONNECTOR UNIVERSAL STEAM TRAPS & CONNECTORS
The UCX series pipeline connectors are used in steam systems where a simple and economic maintenance…
VALSTEAM ADCA UBS90 | 4 BOLT BIMETALLIC STEAM TRAP UNIVERSAL STEAM TRAPS & CONNECTORS
The UBS90 series bimetallic steam traps and air eliminators, completely in stainless steel, are maintenance free…
VALSTEAM ADCA | VB21M COMPLIMENTARY EQUIPMENT
The VB21 vacuum breakers are simple and reliable devices that automatically relieve or “break” an unwanted…
VALSTEAM ADCA | UTT100 COMPLIMENTARY EQUIPMENT
The UTT – Ultrasonic Trap Tester is a battery-powered instrument that gives a visible and audible…
VALSTEAM ADCA | TH13A THERMOSTATIC
The TH13A series thermostatic steam traps and air eliminators are specifically designed for use on process…
VALSTEAM ADCA | TSS22 THERMOSTATIC
The TSS22 all stainless steel thermostatic steam traps and air eliminators are specifically designed for use…
VALSTEAM ADCA | TH21 THERMOSTATIC
The TH21 series thermostatic steam traps and air eliminators are specifically designed for use on process…
VALSTEAM ADCA | TH32Y THERMOSTATIC
The TH32Y series thermostatic steam traps and air eliminators are specifically designed for use on process…
VALSTEAM ADCA | TH32I THERMOSTATIC
The TH32i series thermostatic steam traps and air vents are specifically designed for use on process…
VALSTEAM ADCA | TH35 & TH35 THERMOSTATIC
The TH35 series thermostatic steam traps and air eliminators are specifically designed for use on process…
VALSTEAM ADCA | TH36 THERMOSTATIC
The TH36 series thermostatic steam traps and air eliminators are specifically designed for use on process…
VALSTEAM ADCA | RP45 THREADED PRESSURE REDUCING VALVES
The ADCA RP45 series pressure reducing valves are single seated, bellows sealed controllers that operate without…
VALSTEAM ADCA | RP45 EN PRESSURE REDUCING VALVES
The ADCA RP45 series pressure reducing valves are single seated, bellows sealed controllers that operate without…
VALSTEAM ADCA | RP45 ASME PRESSURE REDUCING VALVES
The ADCA RP45 series pressure reducing valves are single seated, bellows sealed controllers that operate without…
VALSTEAM ADCA | RPW45B PRESSURE REDUCING VALVES
The ADCA RPW45B series pressure reducing valves are single seated, diaphragm sensing proportional controllers that operate…
VALSTEAM ADCA | PRV57 PRESSURE REDUCING VALVES
The ADCA PRV57 pilot operated pressure reducing valves are designed for use with steam, compressed air,…
VALSTEAM ADCA | PRV47 PRESSURE REDUCING VALVES
The ADCA PRV47 pilot operated pressure reducing valves are designed for use with steam, compressed air,…
VALSTEAM ADCA | PRV41SS PRESSURE REDUCING VALVES
The ADCA PRV41 series direct-acting, spring-loaded piston sensing, balanced plug pressure reducing valves, are designed for…
VALSTEAM ADCA | PS46 PRESSURE SUSTAINING VALVES
The ADCA PS46 series pressure sustaining valves are single seated, diaphragm or piston sensing bellows sealed…
VALSTEAM ADCA | PSW46B PRESSURE SUSTAINING VALVES
The ADCA PSW46B series pressure sustaining valves are single seated, diaphragm or piston sensing proportional controllers…
VALSTEAM ADCA | PS47 PRESSURE SUSTAINING VALVES
The ADCA PS47 pilot operated pressure sustaining valves are designed for use with steam, compressed air,…
VALSTEAM ADCA | PRV25 PRESSURE REDUCING VALVES
The ADCA PRV25 series of direct acting pressure reducing valves, are designed for use on steam,…
VALSTEAM ADCA | POT PRESSURE REDUCING VALVES
The ADCA POT is specially designed to protect the actuator’s diaphragms of RP45 pressure regulators when…
VALSTEAM ADCA | P7 PRESSURE REDUCING VALVES
The ADCA P7 series direct-acting, spring-loaded diaphragm sensing pressure reducing valves, are designed for use with…
VALSTEAM ADCA | P20D PRESSURE REDUCING VALVES
The ADCA P20D series direct-acting, spring-loaded diaphragm sensing, balanced plug pressure reducing valves are designed for…
VALSTEAM ADCA | P20DS PRESSURE REDUCING VALVES
The ADCA P20DS series direct-acting, spring-loaded diaphragm sensing pressure reducing valves, are designed for use on…
VALSTEAM ADCA | P20P PRESSURE REDUCING VALVES
The ADCA P20P series pressure reducing valves are direct acting, spring loaded, piston sensing balanced plug…
VALSTEAM ADCA | PRV30SS DN15 – DN25 PRESSURE REDUCING VALVES
The ADCA PRV30SS is a series of direct acting, spring-loaded, diaphragm sensing and balanced plug pressure…
VALSTEAM ADCA | PRV30SS DN25 – DN50 PRESSURE REDUCING VALVES
The ADCA PRV30SS is a series of direct acting, spring-loaded, diaphragm sensing and balanced plug pressure…
VALSTEAM ADCA | PRV31SS DN15 – DN25 PRESSURE REDUCING VALVES
The ADCA PRV31SS is a series of direct acting, spring-loaded, piston sensing and balanced plug pressure…
VALSTEAM ADCA | PRV31SS DN25 – DN50 PRESSURE REDUCING VALVES
The ADCA PRV31SS is a series of direct acting, spring-loaded, piston sensing and balanced plug pressure…
VALSTEAM ADCA | FLT47 FLOAT AND THERMOSTATIC
The FLT47 is a range of float and thermostatic steam traps with integral air vent designed…
VALSTEAM ADCA | FLT49 FLOAT AND THERMOSTATIC
The FLT49 is a range of float and thermostatic steam traps with integral air vent designed…
VALSTEAM ADCA | FLT49TW FLOAT AND THERMOSTATIC
The FLT49TW is a range of high capacity float and thermostatic steam traps with integral air…
VALSTEAM ADCA | FLT50S & FLT65S FLOAT AND THERMOSTATIC
The FLT50 and FLT65 are a series of high capacity float and thermostatic steam traps with…
VALSTEAM ADCA | FLT80 FLOAT AND THERMOSTATIC
The FLT80 is a series of high capacity float and thermostatic steam traps with integral air…
VALSTEAM ADCA | IB12 INVERTED BUCKET
The IB12 is a series of general purpose robust and versatile inverted bucket steam traps manufactured…
VALSTEAM ADCA | IBB12 INVERTED BUCKET
The IBB12 is a series of general purpose robust and versatile inverted bucket steam traps manufactured…
VALSTEAM ADCA | IB30S INVERTED BUCKET
The IB30S is a series of general purpose robust and versatile inverted bucket steam traps manufactured…
VALSTEAM ADCA | IB30SS INVERTED BUCKET
The IB30SS is a series of general purpose robust and versatile inverted bucket steam traps manufactured…
VALSTEAM ADCA | IB36S INVERTED BUCKET
The IB36S is a series of robust and versatile inverted bucket steam traps manufactured in carbon…
VALSTEAM ADCA | IB36I INVERTED BUCKET
The IB36i is a series of robust and versatile inverted bucket steam traps manufactured in stainless…
VALSTEAM ADCA | IB30S DN40 – DN50 INVERTED BUCKET
The IB30 series inverted bucket steam traps are recommended for applications where the most important requirements…
VALSTEAM ADCA | FLT16 FLOAT AND THERMOSTATIC
The FLT16 is a series of float and thermostatic steam traps with integral air vent designed…
VALSTEAM ADCA | FLT20 FLOAT AND THERMOSTATIC
The FLT20 is a series of float and thermostatic steam traps with integral air vent designed…
VALSTEAM ADCA | FLT21 FLOAT AND THERMOSTATIC
The FLT21 is a series of float and thermostatic steam traps with integral air vent designed…
VALSTEAM ADCA | FLT25 FLOAT AND THERMOSTATIC
The FLT25 is a series of float and thermostatic steam traps with integral air vent designed…
VALSTEAM ADCA | FLT27 FLOAT AND THERMOSTATIC
The FLT27 is a range of float and thermostatic steam traps with integral air vent designed…
VALSTEAM ADCA | FLT29 FLOAT AND THERMOSTATIC
The FLT29 is a range of float and thermostatic steam traps with integral air vent designed…
VALSTEAM ADCA | FLT29TW FLOAT AND THERMOSTATIC
The FLT29TW is a range of high capacity float and thermostatic steam traps with integral air…
VALSTEAM ADCA | FLT30 FLOAT AND THERMOSTATIC
The FLT30 is a series of float and thermostatic steam traps with integral air vent designed…
VALSTEAM ADCA | FLT31 FLOAT AND THERMOSTATIC
The FLT31 is a series of float and thermostatic steam traps with integral air vent designed…
VALSTEAM ADCA | FLT35 FLOAT AND THERMOSTATIC
The FLT35 is a series of float and thermostatic steam traps with integral air vent designed…
VALSTEAM ADCA | FLT37 FLOAT AND THERMOSTATIC
The FLT37 is a range of float and thermostatic steam traps with integral air vent designed…
VALSTEAM ADCA | FLT39 FLOAT AND THERMOSTATIC
The FLT39 is a range of float and thermostatic steam traps with integral air vent designed…
VALSTEAM ADCA | FLT39TW FLOAT AND THERMOSTATIC
The FLT39TW is a range of high capacity float and thermostatic steam traps with integral air…
VALSTEAM ADCA | FLT40 FLOAT AND THERMOSTATIC
The FLT40 is a series of float and thermostatic steam traps with integral air vent designed…
VALSTEAM ADCA | FLT41 FLOAT AND THERMOSTATIC
The FLT41 is a series of float and thermostatic steam traps with integral air vent designed…
VALSTEAM ADCA | FLT45 FLOAT AND THERMOSTATIC
The FLT45 is a series of float and thermostatic steam traps with integral air vent designed…
VALSTEAM ADCA | FLT22 FLOAT AND THERMOSTATIC
The FLT22 is a series of high capacity float and thermostatic steam traps with integral air…
VALSTEAM ADCA | FLT312 & FLT314 FLOAT AND THERMOSTATIC
The FLT312 and FLT314 are a series of high capacity float and thermostatic steam traps with…
VALSTEAM ADCA | FLT314TW FLOAT AND THERMOSTATIC
The FLT314TW is a series of high capacity float and thermostatic steam traps with integral air…
VALSTEAM ADCA | FLT151 FLOAT AND THERMOSTATIC
The FLT151 is a series of high capacity float and thermostatic steam traps with integral air…
VALSTEAM ADCA | DT40/2 THERMODYNAMIC
The thermodynamic DT40/2 disc steam traps are compact and lightweight-easy to install traps, excellent for high-pressure…
VALSTEAM ADCA | DT42/2 THERMODYNAMIC
The thermodynamic DT42/2 disc steam traps are compact and lightweight-easy to install traps, excellent for high-pressure…
VALSTEAM ADCA | DT46 THERMODYNAMIC
Thermodynamic DT46 disc steam traps are compact and lightweight-easy to install traps, excellent for high-pressure systems,…
VALSTEAM ADCA | BM20 BIMETALLIC
The BM20 series bimetallic steam traps and air eliminators are simple and robust traps, recommended for…
VALSTEAM ADCA | BM20I BIMETALLIC
The BM20i is a series of robust and efficient bimetallic steam traps and air vents. These…
VALSTEAM ADCA | BM20R BIMETALLIC
The BM20R series bimetallic steam traps and air vents are simple and robust traps, recommended for…
VALSTEAM ADCA BM24 | DN15 – DN25 BIMETALLIC
The BM24 series bimetallic steam traps and air eliminators are simple and robust traps, recommended for…
VALSTEAM ADCA BM24 | DN40 – DN50 BIMETALLIC
The BM24 series bimetallic steam traps and air eliminators are simple and robust traps, recommended for…
VALSTEAM ADCA BM32 | DN15 – DN25 BIMETALLIC
The BM32 series bimetallic steam traps and air eliminators are simple and robust traps, recommended for…
VALSTEAM ADCA BM32 | DN40 – DN50 BIMETALLIC
The BM32 series bimetallic steam traps and air eliminators are simple and robust traps, recommended for…
VALSTEAM ADCA | BM87 BIMETALLIC
The BM87 is a series of robust and efficient bimetallic steam traps and air vents. These…
VALSTEAM ADCA | BM88 BIMETALLIC
The BM88 is a series of robust and efficient bimetallic steam traps and air vents. These…
VALSTEAM ADCA | BM89 BIMETALLIC
The BM89 is a series of robust and efficient bimetallic steam traps and air vents. These…
VALSTEAM ADCA | BM90 BIMETALLIC
The BM90 is a series of robust and efficient bimetallic steam traps and air vents. These…
VALSTEAM ADCA | BSS20 BIMETALLIC
The BSS20 all stainless steel bimetallic steam traps and air vents are simple and robust traps,…
VALSTEAM ADCA | CTS4U COMPACT TRAPPING STATION UNIVERSAL STEAM TRAPS & CONNECTORS
The CTS4U is designed as a complete and compact steam trap station, to be used in…
VALSTEAM ADCA | CDV32 COMPLIMENTARY EQUIPMENT
The CDV32 condensate drain valve automatically discharges air and condensate from steam systems during start-up. A…
VALSTEAM ADCA | DF COMPLIMENTARY EQUIPMENT
The ADCA DF series are compact noise diffusers designed to disperse the high-speed discharge from steam…
VALSTEAM ADCA | BM-HC BIMETALLIC
The BM–HC series of bimetallic steam traps and air vents are simple and robust traps, recommended…
VALSTEAM ADCA | BDV, AFZ, HVV BLOWDOWN & VENT VALVES
The BDV, AFZ and HVV vent valves are designed to drain (blowdown) or vent (depressurize) pipework,…
VALSTEAM ADCA | SV32 CONTROL ACCESSORIES & LEVEL PROBES
3/2 way solenoid valves are available as single station units and they are designed for use…