SMI Impact

Created safe workspaces with full coverage of uninsulated piping and equipment

Generated asset allocation database for ongoing maintenance and repair

Improved system functionality for steam trap maintenance with installation of new steam trap strainers and isolation valves

Steam Management Inc. was contracted by an ESCO to design and install steam trap upgrades, condensate pumps replacements, and insulation upgrades as part of a Utility Energy Services Contract (UESC) to improve energy efficiency across the Marine Corps Air Station Cherry Point which is comprised of 139 buildings.

Customer

The goal was to address aging components, heat loss, and operational inefficiencies across the high-pressure steam and condensate systems.

The existing steam and condensate systems across MCAS Cherry Point exhibited significant energy losses and maintenance issues. Many steam traps were in a state of failure or disrepair, leading to excess steam discharge and inefficient heat transfer. Several condensate pumps were operating with worn or faulty equipment, reducing system reliability and condensate recovery. Additionally, large sections of piping and equipment lacked insulation or had degraded insulation, creating safety concerns and unnecessary thermal losses. The absence of removable insulation on fittings, valves, and other components further limited the ability to perform ongoing maintenance efficiently without sacrificing heat retention.

Conditions

Scope Overview:

Steam Traps
Insulation
RICS
Condensate Pumps

To address these issues, Steam Management, Inc. completed a full assessment of the base’s steam system to verify existing conditions and quantify energy-saving opportunities. The team repaired or replaced 387 failed or underperforming steam traps, improving condensate drainage and reducing steam waste. Thirteen condensate pumps were upgraded by replacing the actuation mechanisms and check valves, restoring reliable system functionality. A total of 529 custom-fabricated removable insulation covers (RICs) were installed on valves, fittings, and equipment to retain heat while allowing easy access for future maintenance. In addition, 1,853 linear feet of piping was insulated to eliminate thermal losses and enhance safety across the site.

SMI managed the turnkey installation across multiple secure buildings, coordinated with base personnel for site access and utility shutdowns, and conducted on-site project management and safety briefings. Pre- and post-installation measurement and verification were performed, including infrared thermal imaging to document performance improvements. The project concluded with comprehensive training for facility personnel and the delivery of detailed O&M documentation and warranty information.

Solutions

Repaired/replaced 387 steam traps
13 condensate pumps – replaced actuation mechanism and check valves
529 RICs
1,853 feet of pipe insulation
Survey and develop IGA scope of work
Prepare final application schedules for project approval
Prepare product submittal packages for project approval
Prepare work and safety plans with JHA for project approval
Manage material purchasing and handling on site across a large high- medium security military base
Manage all subcontracted labor for turnkey installation
Work with facility and building managers for site access and utility shutdowns
On-site project management by SMI personnel
Conduct start-up and weekly safety meetings
Pre & post M&V data with IR photos for all installed components
Complete project commissioning, punch list and sign-off walk throughs
Provide site training with videographer
Provide O&M Manual with material and workmanship warranty

Key Actions

Before

After

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(800) 731-0131 ext. 701 | info@steammgt.com