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STEAM TRAPS

STEAM TRAPS ARE DEVICES THAT


ARE USED TO REMOVE CONDENSATE
FROM STEAM LINES.
TRAPS THE STEAM INSIDE THE LINE,
BUT DRAINS THE CONDENSATE.
THEREFORE KNOWN AS STEAM
TRAPS
SCOPE OF THIS PRESENTATION
WHY TRAPS
TYPES OF TRAPS
WORKING PRINCIPLES
INSTALLATION
TRAP SELECTION
TRAP MONITORING
ADVANTAGES OF MONITORING
IMPORTANCE OF TRAPS
STEAM COSTS Rs.300 PER TON
A LEAKING TRAP CAN DISCHARGE
AS MUCH AS 120 TONS OF STEAM IN
A YEAR WHICH WORKS OUT TO
Rs.36000 PER YEAR
THERE ARE APPROXIMATELY 15000
TRAPS INSTALLED IN MRPL
IMPORTANCE OF TRAPS
IF 10% OF ALL TRAPS LEAK THE LOSS
PER YEAR IS 1500 X 25000 = Rs. 3.75 cr
TRAPS BECAUSE OF THEIR LARGE
NUMBERS AND SMALL SIZE MAY NOT
GET THE ATTENTION THAT IS
REQUIRED.
WHY TRAPS?
STEAM IS USED EXTENSIVELY IN THE
REFINERY AND POWER PLANT
STEAM CONDENSES
CONDENSATE IF LEFT IN THE LINE CAN
CAUSE WATER HAMMER CAUSING
DAMAGES TO LINES AND EQUIPMENT
WHY TRAPS
CONDENSATE EXPANDS 16 TIMES TO
FORM STEAM - CAN CAUSE A
PRESSURE SURGE IN COLUMNS ETC
CAUSING DAMAGE TO THE
INTERNALS
WHY TRAPS.
CONDENSATE OVER
TIME ACCUMULATES
MORE CONDENSATE.
THEREFORE HAS TO
BE REMOVED
IMMEDIATELY.
TO REMOVE
CONDENSATE STEAM
TRAPS ARE USED.
TYPES OF TRAPS
DENSITY OPERATED TRAPS
BALL FLOATS
INVERTED BUCKETS
TEMPERATURE OPERATED TRAPS
BAL. PRESSURE
LIQUID EXPANSION THERMOSTATIC
BIMETALLIC

TYPES .
KINETIC ENERGY OPERATED
DISC TRAPS
IMPULSE TRAPS
WORKING PRINCIPLES
DENSITY OPERATED TRAPS
BALL FLOAT
TEMPERATURE OPERATED
BALANCED PRESSURE (BPT)
KINETIC ENERGY OPERATED
THERMODYNAMIC DISC (TD)
DENSITY OPERATED TRAPS
BALL FLOAT TRAPS
WORK ON PRINCIPLE
THAT DENSITY OF
CONDENSATE IS
MORE THAN THAT OF
STEAM.
CONDENSATE LIFTS
A WEIGHTED BALL,
WHICH OPENS A
VALVE WHICH
DRAINS
CONDENSATE

TEMPERATURE OPERATED
BPT - BALANCED PRESSURE
THERMOSTATIC
WORKS ON THE PRINCIPLE OF TEMPERATURE
DIFFERENCE BETWEEN STEAM AND
CONDENSATE
A BELLOW EXPANDS WHEN SUBJECT TO
HIGHER TEMPERATURE
BPT USES A BELLOW ATTACHED TO A BALL TO
OPEN AND CLOSE A DRAIN VALVE.
TEMPERATURE OPERATED
INSTALLATIONS
INSTALLATION
INSTALLATION
KINETIC ENERGY OPERATED
THERMODYNAMIC TRAP - TD
WORKS ON THE PRINCIPLE OF FLASH
STEAM
HOT STEAM/ CONDENSATE FORMS
FLASH STEAM ABOVE THE DISC WHICH
CAUSES THE DISC TO MOVE DOWN.
AS CONDENSATE GETS COLLECTED THE
STEAM TRAPPED ABOVE COOLS,
ALLOWING DISC TO OPEN AGAIN.
THERMODYNAMIC TRAP
INSTALLATION
INSTALLATION
TRACING STATIONS-Discharging to common header
INSTALLATION
APPLICATION
APPLICATION 1
st
Choice 2
nd
Choice
HEATING SYSTEMS FLOAT BUCKET
STEAM LINES TD BUCKET/ TS
STEAM TRACERS BPT TD
TANK COILS FLOAT TD / BUCKET
SHP LINES TD BIMETALLIC
MONITORING OF TRAPS
TRAP MONITORING
DONE BY DEVICE
CALLED
TRAPMAN
MONITORING...
PLANTS ARE DOWN LOADED TO
TRAPMAN AND SURVEY IS
CARRIED OUT.
SURVEYED TRAPS ARE UPLOADED
BACK TO THE SOFTWARE AND THE
ANALYSIS IS DONE.
RECTIFICATION OF FAILED TRAPS IS
DONE IMMEDIATELY
MONITORING
TRAPMAN USES TEMPERATURE OF
INLET PIPE TO MEASURE
EFFECTIVENESS OF TRAP
A HIGHER THAN NORMAL
TEMPERATURE (/ RISE) INDICATES A
PASSING TRAP
A LOWER THAN NORMAL TEMP IS
INDICATED AS BLOCKED
MONITORING
TO QUANTIFY LEAK LEVELS,
TRAPMAN USES ULTRASONIC
EMISSIONS FROM TRAPS
EMPIRICAL RELATION BETWEEN
LEVEL OF ULTRASONIC EMISSION
AND QUANTITY OF LEAK FOR
DIFFERENT PR AND TYPE IS
AVAILABLE IN HARDWARE
MONITORING
MONITORING STATISTICS - FROM APR 00

TRAPS MONITORED - 5600
FAILED TRAPS - 635
LOSS CONTROL - 20.41(IN Rs. Lacs)
THANK YOU

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