We are currently replacing to much steam traps in our refinery. I want to know what is the average replacement per year of traps in other plants or industry. This in percentage related to the total number of traps.
Also any information on ultrasound predictive techniques and surveys on traps is welcome.

I don't know about the ultra sound but you can use an infrared temperature sensor to measure the temperature up stream and downstream of the trap. If the temperature is the same, the trap needs repair or replacing.

A good rule of thumb that I have found useful is that if the temperature difference across the trap is less than 10 degrees F the trap should be replaced due to excessive leakage.  The ROI on trap replacement easily justifies the initial outlay and the bean counters will love you for it.

Steam traps should not be replaced that often, a good trap should have a life expectancy of three years on high pressure thermodynamic traps/Regulators, and longer in mechanical type, I represent a company that manufacture steam traps and we also have the only trap testing equipment along with software to maintain a data base of working condition of the traps. Our traps are specified worldwide by companies such as Exxon/mobil and chevron, and is utilized inmost refineries worldwide.

Educate yourself on the best methods to check your steam traps (I suggest taking an inlet and outlet reading with an inexpensive hand-held infrared- to determine plugging or downstream back-pressure, then ultrasonically listen to the trap to determine status - pass/fail); check your steam traps periodically; input the information into a user friendly software program; begin a steam trap maintenance porgram.

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