The intelligent steam trap IFS-SST

1 The technical starting point: Why classic steam traps become inefficient

A bachelor’s thesis on steam systems and vulcanization systems examined in detail why conventional steam traps often do not work optimally and what systemic efficiency gaps arise as a result.

Typical problems of classic arresters

Float arrester

• Sensitive to water hammer
• Mechanical wear
• Increasing maintenance requirements

Thermal arresters (bimetal)

• Narrow pressure range
• work with subcooling → energy loss
• Unsuitable for variable loads

Thermodynamic arresters

• Valve disk wears out → Leakage increases over time
• No condition monitoring possible

Real effects

The bachelor thesis clearly shows:

• Condensate build-up reduces the heating output by a factor of 4-12, depending on the proportion of steam vs. condensate
• Water hammers can destroy pipes
• A large proportion of the energy is supplied at times when conventional metering systems are already failing

This last point in particular is crucial – and forms the basis for the IFS-SST.

2. the IFS-SST: Intelligent steam trap without measuring gaps

The Smart Steam Trap was developed by Industriefabrik Schneider and tested in industrial environments. The bachelor thesis provides the technical and metrological confirmation.

Innovative functional principle

• Condensate is collected in a defined container
• Subcooling (temperature drop) serves as a precise fill level and switching signal
• Emptying takes place automatically via two valves
• After draining, the temperature rises again immediately – ideal for measuring cycle detection

This principle is wear-free, robust and independent of classic measured variables such as flow velocity, pressure fluctuations or steam quality.

3. scientifically proven: Measuring accuracy < 1 %

The test series documented in the bachelor thesis confirm this:

• Measurement deviation with optimized setup: 0.77 %
• Measurement deviation during final assembly: 0.88 %
• Measurement fully reproducible

This is far more precise than many industrial measurement methods – and without expensive sensors or complex installations.

4 The decisive advantage: The SST continues to measure where other systems give up

A particularly critical finding of the Bachelor’s thesis:

Vortex measuring devices break down completely after around 200 seconds of measuring time – precisely when 78 % of the energy is introduced into the process.
This makes classic methods (vortex, differential pressure, etc.) unreliable for industrial cycle processes.

The IFS-SST, on the other hand, works continuously and precisely, regardless of:

• Flow velocity
• Density and pressure fluctuations
• Steam quality
• Cable length or installation position
• Condensate-steam mixtures

This makes it the only measuring system that measures in real high-temperature steam systems with practical stability.

5. economic benefits: immediately measurable – immediately noticeable

The IFS-SST combines steam trap, consumption measurement and system monitoring in one component:

Energy efficiency

• No unnoticed steam losses
• Visible consumption data for each system

Safety & system availability

• Early warning system for leaks
• Detection of faulty valves
• Prevention of backwater & water hammer

Lowest maintenance effort

• No moving parts
• Long service life
• Minimal operating costs

Industry 4.0-ready

• Precise measured values
• Real-time condition monitoring
• Ideal for ISO 50001, energy audits and optimization projects

6 Conclusion: The IFS-SST sets a new industry standard

The connection from:

• scientifically proven measuring precision
• Integrated monitoring
• robust construction
• High economic efficiency
• outstanding process reliability

makes the IFS-SST a next-level steam trap that eliminates all the weaknesses of classic technologies.
It’s not just a steam trap – it’s an intelligent sensor, an energy monitor and a safety component all in one.