DESIGN
OF FLUID
SYSTEMS
Published by
Copyright © 2000
by Spirax Sarco, Inc.
All Rights Reserved
No part of this publication may be reproduced, stored in a
retrieval system or transmitted, in any form or by any means,
electronic, mechanical, photocopying, recording, or otherwise,
without the prior written permission of the publisher.
PREFACE
Recognizing the on-going need for education as it relates to the
fundamentals of steam including the most efficient use of its heat
content, Spirax Sarco has developed the Steam Utilization Course.
This handbook represents over 80 years of steam experience in the
proper selection, sizing and application of steam traps, pressure
and temperature controls, and condensate recovery systems
in major industrial plants throughout the world.
2
Spirax Sarco
3
Contents
STEAM GENERATION 10
BOILERS & BOILER EFFICIENCY 10
SELECTION OF WORKING PRESSURES 11
Steam Velocity 12
Air and Non-Condensable Gases 13
4
Contents
STEAM TRAPS 27
Mechanical Steam Traps 28
Thermostatically or Temperature Controlled Traps 30
Thermodynamic Steam Traps 32
Variations on Steam Traps 33
STEAM TRAP TESTING METHODS 37
Visual Testing 37
Ultrasonic Trap Testing 37
Temperature Testing 37
Conductivity Testing 38
BY-PASSES AROUND STEAM TRAPS 39
PREVENTIVE MAINTENANCE PROGRAMS 39
Steam Trap Fault Finding 39
Steam Trap Discharge Characteristics 41
STEAM TRAP SELECTION 41
Waterlogging 41
Lifting of Condensate 42
REQUIREMENTS FOR STEAM TRAP/APPLICATIONS 42
Application Requirements 42
Steam Trap Selection Chart 43
Steam Trap Sizing 44
STEAM TRACING 45
CRITICAL TRACING 45
NON-CRITICAL TRACING 45
Attaching Tracer Lines 46
JACKETED PIPE TRACERS 47
STEAM TRACING MANIFOLDS 48
CONDENSATE MANIFOLDS 48
CONDENSATE MANAGEMENT 50
FLASH STEAM RECOVERY 51
CONDENSATE RECOVERY SYSTEMS 55
Electrically Driven Pumps 57
Non Electric Pressure Powered Pumps 58
WATERHAMMER IN CONDENSATE RETURN LINES 60
5
Basic Steam Engineering Principals
6
Basic Steam Engineering Principals
A very interesting thing hap- the temperature. The lower the The need for optimum effi-
pens when we go through this latent heat content of the steam, ciency increases with every rise
exercise and that is the change in the smaller the volume the steam in fuel costs. Steam and conden-
volume that the gas (steam) occupies (Fig. 3). This allows the sate systems must be carefully
occupies versus the volume that plant to generate steam at high designed and maintained to
the water occupied. One pound pressures and distribute that ensure that unnecessary energy
of water at atmospheric pressure steam in smaller piping to the waste is kept at a minimum. For
occupies only .016 cubic feet, but point of usage in the plant. This this reason, this course will deal
when we convert this water into higher pressure in the boiler pro- with the practical aspects of
steam at the same pressure, the vides for more driving force to energy conservation in steam
steam occupies 26.8 cubic feet make the steam flow. systems, as we go through the
for the same one pound. system.
The steam that we have just
created on our stove at home will Figure 1
provide humidification to the sur-
Steam Saturation Curve Graph at a Specific Boiler Pressure
rounding air space along with
some temperature rise. Steam is Temperature/Pressure
also meant to be a flexible energy
carrier to other types of process-
es. In order to make steam flow
from the generation point to
another point at which it will be
utilized, there has to be a differ-
ence in pressure.
Latent Heat
Therefore, our pan type
Sensible
steam generator will not create Heat
any significant force to move the
steam. A boiler, for all practical
purposes, is a pan with a lid.
There are many types of boilers
that are subjects of other cours- Total Heat
es. We will simply refer to them
as boilers in this course. If we
contain the steam within a boiler,
pressure will begin to rise with the
Figure 2
25 Steam Vs. Electricity
change of volume from liquid to
gas. As this pressure rises, the
boiling point of the water inside 20
also rises. If the pressure of satu-
rated steam is known, the
Cost ($) per 15
temperature is also known. We 1,000,000
will consider this relationship later BTU’s of
Energy
when we look again at the satu- 10
rated steam tables.
Another thing that happens 5
when steam is created in a boiler
is that the gas (steam) is com-
0
pressed into a smaller volume (ft3
Electricity
(Industrial)
(Industrial)
Steam
(Refinery)
Steam
(Coal)
(No. 6 Fuel Oil)
(0.5% Sulfur)
Steam
Flash
Steam
7
Basic Steam Engineering Principals
8
Basic Steam Engineering Principals
9
Steam Generation
Boilers & Boiler Efficiency The sizing of a boiler for a about one to two minutes to place
Boilers and the associated fir- particular application is not a sim- the boiler back on line. And, if
ing equipment should be designed ple task. Steam usages vary there’s a sudden load demand,
and sized for maximum efficiency. based upon the percentage of the start-up sequence cannot be
Boiler manufacturers have boiler load that is used for heating accelerated. Keeping the boiler
improved their equipment designs versus process and then combin- on line assures the quickest
to provide this maximum efficien- ing those loads. These response to load changes.
cy, when the equipment is new, potentially wide load variations Frequent cycling also accelerates
sized correctly for the load condi- are generally overcome by wear of boiler components.
tions, and the firing equipment is installing not just one large boiler Maintenance increases and,
properly tuned. There are many but possibly two smaller units or a more importantly, the chance of
different efficiencies that are large and a small boiler to accom- component failure increases.
claimed when discussing boilers modate the load variations. Once the boiler or boilers
but the only true measure of a Boiler manufacturers usually will have been sized for their steam
boiler’s efficiency is the Fuel-to- recommend that the turndown output, BTU’s or lb./hr, then the
Steam Efficiency. Fuel-To-Steam ratio from maximum load to low operating pressures have to be
efficiency is calculated using load not exceed 4:1. Turndown determined. Boiler operating
either of two methods, as pre- ratios exceeding 4:1 will increase pressures are generally deter-
scribed by the ASME Power Test the firing cycles and decrease mined by the system needs as to
Code, PTC4.1. The first method efficiency. product/process temperatures
is input-output. This is the ratio of A boiler operating at low load needed and/or the pressure loss-
BTU’s output divided by BTU’s conditions can cycle as frequent- es in transmission of the steam in
input, multiplied by 100. The sec- ly as 12 times per hour, or 288 distribution throughout the facility.
ond method is heat balance. This times a day. With each cycle, (Fig. 4)
method considers stack tempera- pre- and post-purge air flow
ture and losses, excess air levels, removes heat from the boiler and
and radiation and convection sends it out the stack. This ener-
losses. Therefore, the heat bal- gy loss can be eliminated by
ance calculation for fuel-to-steam keeping the boiler on at low firing
efficiency is 100 minus the total rates. Every time the boiler
percent stack loss and minus the cycles off, it must go through a
percent radiation and convection specific start-up sequence for
losses. safety assurance. It requires
10
Steam Generation
11
Steam Generation
Velocity ft/min
/2" 8000
3"
commonplace as design criteria. F G 6000
Heating Systems 4" 5000
4000 to 6000 ft/min
These lower velocities provide for 5" C D 4000
6"
reduced pressure losses, more 3000
8"
efficient condensate drainage, 10 2000
reduced waterhammer potential 1 "
14 2"
16 "
and piping erosion. "
1000
25 0
Capacity lb/h
6000
20 0
0
15 25
cal. Steam is generated and 5000
1 00
1 5
7
4000
distributed throughout the system
50
3000
25
2000
ferences in the surroundings and
0
25 00
as the steam, the condensate
2 0
500
0
15 25
1 00
400
(water) is still going to erode the 1 5
7
300
50
12
Selection of Working Pressures
150 123 77 14 87 166 99 205 120 247 140 286 161 311 173
Product/Ambient
200 164 10 19 117 221 131 274 159 329 187 382 214 415 231
250 205 12 240 146 276 164 342 199 412 235 477 268 519 288
300 246 153 288 175 331 198 411 238 495 281 573 321 622 346
350 288 178 336 205 386 230 478 278 576 328 668 375 726 404
Air and Non-Condensable the main line. The last kettle, example would be 100 PSIG sat-
Gases In The Steam System therefore, would be fed with a urated steam has a temperature
We know that when steam mixture of steam and non-con- of 338°F, if in this steam there
comes into contact with a cooler densable gases. existed a 10% by volume mixture
surface, it gives up its latent heat Air cannot hold the tempera- of air the equivalent temperature
and condenses. As condensation ture or latent heat of steam. It of this mixture would be 331°F, or
takes place, the condensate will, therefore, cause a reduction the steam temperature of 90
begins to form a film of water in temperature first of all. Air, it PSIG not 100 PSIG.
(Fig. 7). It is a fact that water has should be remembered, is an Another major problem with
a surprisingly high resistance to insulator. (Fig. 7) It is generally air in the steam system is that it
heat transfer. A film of water only accepted that a thin layer of air will be absorbed into the conden-
1/100 inch thick offers the same only 0.04 inches thick can offer sate. This reduces the pH of the
resistance to heat transfer as a the same resistance to the flow of condensate and creates a sub-
1/2 inch thick layer of iron or a 5 heat as a layer of water 1 inch stance known as carbonic acid.
inch thick layer of copper. The air thick, a layer of iron 4.3 feet thick The acidity of the condensate will
and other non-condensable or a layer of copper 43 feet thick. then attack the piping, heat
gases in the steam cause a vari- Even a small amount of air in a exchange equipment or any other
ety of problems to steam steam system will cause fairly part of the steam system that it
systems. Foremost is the reduc- drastic temperature losses, an comes into contact with.
tion of area to deliver the steam.
Air is a simple bi-product of Figure 7
steam generation. It is in all The Practical Effect of Air & Water Films
steam systems and should be
dealt with accordingly. Where the
air will collect in the system is the Metal
Heating
problem. Surface
250°F
Air and other non-condens-
able gases are released when 210°F
steam is generated and passes
down the distribution with the
steam. It will collect in areas of
high steam consumption such as
heat exchangers, but will also col-
lect at high points and at the end
of the steam piping. If a steam
line feeds a series of heat
exchangers, such as cooking ket- Steam Air Condensate Water Water
tles, the air collects at the end of at 15 Film Film Film Being
psi Heated
13
Steam System Basics
14
Steam System Basics
Steam Piping Design piping. This transfer of heat ener- distribution main piping network,
Considerations gy creates condensate, (Fig. 11 condensate “drip stations” need
Since we have already estab- and 12) or if the piping is already to be installed to remove this con-
lished that steams principle job is at the same temperature as the densate from the system. These
to give up its latent heat energy steam, there are still loses to the pockets should be designed with
and re-condense to water, by ambient air conditions, even as much care as possible. This
doing so, we can assume that it when insulated. This liquid con- allows the condensate a low point
will do so anywhere and every- densate would continue to build in which to drop out of the steam
where (Fig. 10) because all heat up to the point of blocking all of flow and be removed by steam
flow is from hot to cold. When the the steam piping if it is not prop- traps.
steam is admitted into the distrib- erly removed, and create
ution piping network, the steam waterhammer in the steam sys-
immediately begins to heat the tem. Periodically in a steam
Figure 10
Terms Steam Line Reducer
Steam Header
15
Steam System Basics
Figure 11: Warm-Up Load in Pounds of Steam per 100 Ft. of Steam Main
Ambient Temperature 70°F. Based on Sch. 40 pipe to 250 psi
Sch. 80 above 250 except Sch. 120 5" and larger above 800 psi
Steam Main Size 0˚F
Pressure Correction
psi 2" 2-1/2" 3" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24" Factor *
0 6.2 9.7 12.8 18.2 24.6 31.9 48 68 90 107 140 176 207 308 1.50
5 6.9 11.0 14.4 20.4 27.7 35.9 48 77 101 120 157 198 233 324 1.44
10 7.5 11.8 15.5 22.0 29.9 38.8 58 83 109 130 169 213 251 350 1.41
20 8.4 13.4 17.5 24.9 33.8 44 66 93 124 146 191 241 284 396 1.37
40 9.9 15.8 20.6 90.3 39.7 52 78 110 145 172 225 284 334 465 1.32
60 11.0 17.5 22.9 32.6 44 57 86 122 162 192 250 316 372 518 1.29
80 12.0 19.0 24.9 35.3 48 62 93 132 175 208 271 342 403 561 1.27
100 12.8 20.3 26.6 37.8 51 67 100 142 188 222 290 366 431 600 1.26
125 13.7 21.7 28.4 40 55 71 107 152 200 238 310 391 461 642 1.25
150 14.5 23.0 30 43 58 75 113 160 212 251 328 414 487 679 1.24
175 15.3 24.2 31.7 45 61 79 119 169 224 265 347 437 514 716 1.23
200 16.0 25.3 33.1 47 64 83 125 177 234 277 362 456 537 748 1.22
250 17.2 27.3 35.8 51 69 89 134 191 252 299 390 492 579 807 1.21
300 25.0 38.3 51 75 104 143 217 322 443 531 682 854 1045 1182 1.20
400 27.8 43 57 83 116 159 241 358 493 590 759 971 1163 1650 1.18
500 30.2 46 62 91 126 173 262 389 535 642 825 1033 1263 1793 1.17
600 32.7 50 67 98 136 187 284 421 579 694 893 1118 1367 1939 1.16
800 38.0 58 77 113 203 274 455 670 943 1132 1445 1835 2227 3227 1.156
1000 45 64 86 126 227 305 508 748 1052 1263 1612 2047 2485 3601 1.147
1200 52 72 96 140 253 340 566 833 1172 1407 1796 2280 2767 4010 1.140
1400 62 79 106 155 280 376 626 922 1297 1558 1988 2524 3064 4440 1.135
1600 71 87 117 171 309 415 692 1018 1432 1720 2194 2786 3382 4901 1.130
1750 78 94 126 184 333 448 746 1098 1544 1855 2367 3006 3648 5285 1.128
1800 80 97 129 189 341 459 764 1125 1584 1902 2427 3082 3741 5420 1.127
* For outdoor temperature of 0°F, multiply load value in table for each main size by correction factor shown
Figure 12: Running Load in Pounds per Hour per 100 Ft. of Insulated Steam Main
Ambient Temperature 70°F. Insulation 80% efficient.
Load due to radiation and convection for saturated steam.
Steam Main Size 0°F
Pressure Correction
psi 2" 2-1/2" 3" 4" 5" 6" 8" 10" 12" 14" 16" 18" 20" 24" Factor *
10 6 7 9 11 13 16 20 24 29 32 36 39 44 53 1.58
30 8 9 11 14 17 20 26 32 38 42 48 51 57 68 1.50
60 10 12 14 18 24 27 33 41 49 54 62 67 74 89 1.45
100 12 15 18 22 28 33 41 51 61 67 77 83 93 111 1.41
125 13 16 20 24 30 36 45 56 66 73 84 90 101 121 1.39
175 16 19 23 26 33 38 53 66 78 86 98 107 119 142 1.38
250 18 22 27 34 42 50 62 77 92 101 116 126 140 168 1.36
300 20 25 30 37 46 54 68 85 101 111 126 138 154 184 1.35
400 23 28 34 43 53 63 80 99 118 130 148 162 180 216 1.33
500 27 33 39 49 61 73 91 114 135 148 170 185 206 246 1.32
600 30 37 44 55 68 82 103 128 152 167 191 208 232 277 1.31
800 36 44 53 69 85 101 131 164 194 214 244 274 305 365 1.30
1000 43 52 63 82 101 120 156 195 231 254 290 326 363 435 1.27
1200 51 62 75 97 119 142 185 230 274 301 343 386 430 515 1.26
1400 60 73 89 114 141 168 219 273 324 356 407 457 509 610 1.25
1600 69 85 103 132 163 195 253 315 375 412 470 528 588 704 1.22
1750 76 93 113 145 179 213 278 346 411 452 516 580 645 773 1.22
1800 79 96 117 150 185 221 288 358 425 467 534 600 667 800 1.21
* For outdoor temperature of 0°F, multiply load value in table for each main size by correction factor shown.
16
Steam and Condensate Metering
The proper design of these shut down and start-up of the Performance of different types of
drip stations is fairly simple. The steam main. Remember, the meters when used on steam will
most common rules to follow are: intent of the distribution line is to vary and the measurement may
1. Drip Stations on steam deliver steam at as high a quality not always be accurate. Most
mains must be located at all as possible to the heat process meters depend on a measurement
low points in the system, ele- equipment. The equipment of volume. Since volume depends
vation changes, directional downstream will suffer severe on pressure, measurements need
changes, expansion loops damage if we don’t do this step to be taken at a constant pressure
and at all dead ends. correctly. to the meter or else specific cor-
2. In the horizontal run of the rections have to be applied.
Steam and Condensate Readings taken under fluctuating
steam main piping drip sta-
tions must be located at
Metering pressure conditions are inaccurate
regular intervals of 100 to Difficulties in energy manage- unless the meter can automatically
200 feet. ment of steam arise from the fact compensate.
3. The drip station itself is a that it is often a totally unmeasured Steam metering should be
section of piping connected service. Metering (Fig. 13) starting done downstream of a good quali-
to the bottom of the main in the boiler house, is essential if ty reducing valve which maintains
piping. The diameter of the savings are to be validated. a constant pressure. Readings
drip station pipe should be Although fuel consumption is fairly should be interpreted using the
the same size as the steam easy to monitor, measurement of meter factor and the meter calibra-
main piping up to 6" piping. steam is a bit more difficult. A tion should be checked from time
For steam main piping larger steam meter must compensate for to time.
than 6" the drip station pip- quality as well as pressure, specif-
ing shall be 1/2 the nominal ic volume and temperature.
pipe size but no less than 6". Figure 13
4. The vertical drop of the drip
station shall be 1-1/2 times A Typical Steam Metering Station
Eccentric
the diameter of the steam Pipeline Reducers
main but not less than 18 Strainer Steam
Meter
inches.
5. Horizontal run of the steam
piping must fall 1/2" in 10
feet towards drip stations. Steam
Separator 6 Pipe 3 Pipe
The reasoning behind these Separator Diameters Diameters
&Trap Set
rules is simple. First, the diame-
ter of the hole in the bottom of the
steam main should be such that it
Although steam metering is most often carried out in the boiler
can allow the water ample area to
house, it is also important in order to determine:
fall into. Gravity is our only force
to allow this to happen. If the 1. Custody transfer. To measure steam usage and thus determine
diameter of the drip station was steam cost:
too small, the velocity of the a) Centrally at the boiler house
water would simply allow it to b) At all major steam using areas
pass either on the side or over
2. Equipment efficiency. Identifying major steam users, when loaded
the top of the hole. The length of
to capacity or idle; also peak load times, plant deterioration and
the drip station allows the water
cleaning requirements.
to fall far enough out of the steam
flow as to not be pulled back out 3. Process control. Meters indicate that the correct steam requirement
and forced on down the piping, and quantity is supplied to a process, when bypass lines are
and to provide the steam trap opened; and when valves and steam traps need attention.
with some hydraulic head pres- 4. Energy efficiency. Compare the efficiency of one process area with
sure for drainage of condensate another; monitor the results of plant improvements and steam sav-
during the low pressure times of ing programs.
17
Steam and Condensate Metering
Why Measure Steam? enable checks to be kept on indi- Costing and Custody Transfer
Steam is still the most widely vidual plant performance. Costs Steam meters can measure
used heat carrying medium in the can be analyzed for each part of steam usage and thus steam
world. It is used in the processes the process and ‘pay-back' cost.
that make many of the foodstuffs records can be established fol-
(a) Centrally
we eat, the clothes we wear, lowing the implementation of
energy saving measures. (b) At major steam using
components of the cars we ride in
centers.
and the furniture we use. It is The steam meter is the first
used in hospitals for sterilization basic tool in good steam house- Steam can be costed as a
of instruments and surgical keeping - it provides the 'raw material' at various stages of
packs, in the refining process for knowledge of steam usage and the production process thus
crude oil based products, in cost which is vital to an efficiently allowing the true cost of individual
chemical production, and in the operated plant or building. The product lines to be calculated.
laundry that cleans our clothes. main reasons for using a steam The Control and Regulation of
Despite this, it is commonly meter are, therefore:-
Steam
regarded as an almost free ser-
Plant Efficiency The proper control and regu-
vice - easily available. Very few lation of steam either in regards
A steam meter will indicate
attempt to monitor its usage and to steam pressure for equipment
process efficiency. For example,
costs, as they would for other raw or for the flow of this valuable
whether idle machinery is
materials in the process. heat energy source to heat trans-
switched off; whether plant is
"But a steam meter won't loaded to capacity and whether fer equipment is mandatory for
save energy''. This statement is working practices are satisfacto- today’s industrial and HVAC
sometimes used as a reason for ry. It will also show the steam users for efficient usage of
not installing steam meters. It deterioration of plant overtime, this energy source. The control
cannot be argued against if allowing optimal plant cleaning or of heat flow to product tempera-
steam meters are evaluated in even replacement, to be calculat- tures in process equipment is
the same way as other pieces of ed. Further, it can establish peak mandatory, otherwise production
energy saving equipment or steam usage times or identify wastage becomes intolerable,
schemes. sections or items of plant which which means lost profits.
A statement such as the one are major steam users. This may The control of steam pres-
quoted earlier does little to ease lead to a change in production sures and the regulation of steam
the frustration of the Energy methods to even out steam flow to heat exchangers is
Manager or Factory Manager try- usage and ease the peak load accomplished by several different
ing to establish where steam is problems on boiler plant. types of valves. This section is
being used, how much is being intended to describe the different
used and whether it is being used Energy Efficiency types of valves used for these
wisely and effectively. Steam meters can be used to operations and the differences
All too often, when the need monitor the results of energy sav- that will help the user in deciding
for a steam meter is accepted, ing schemes and to compare the which type of valve is necessary
only central monitoring i.e. in the efficiency of one piece of plant for his specific application. This
Boiler House or a major Plant with another. section will not go into complete
Room is carried out. Monitoring at descriptions of these valves but
Process Control
branch mains or at each plant just an overview of their opera-
Steam meters can indicate
room, a section of the process or tional characteristics and the
that the correct quantity of steam
major pieces of steam using benefits of that operation.
is being supplied to a process
equipment, are not considered.
and that it is at the correct tem-
While central monitoring will perature and pressure.
establish overall steam flow fig-
ures (and thus, costs),
’departmental' monitoring will
give data which is much more
useful. Such steam meters will
18
Control and Regulation of Steam
Pressure Reducing Valves Direct Acting Control Valves underside of the diaphragm tends
Most steam boilers are The direct acting valve is the to close the valve as does the
designed to work at relatively simplest design of reducing valve inlet pressure acting on the
high pressures, generally above (Fig. 14a). Reduced pressure underside of the main valve itself.
the steam pressure required in from downstream of the valve The control spring must be capa-
equipment, and should not be acts on the underside of the ble of overcoming the effects of
operated at lower pressures. diaphragm “A”, opposing the both the reduced and inlet pres-
Operation at lowered pressures pressure applied by the control sures when the downstream
causes reduced efficiencies and spring “B”. This determines the pressure is set. Any variation in
increased potential for boiler car- opening of the main valve “C” and the inlet pressure will alter the
ryover. For this reason, the the flow through the reducing force it produces on the main
highest efficiency is maintained valve. valve and so affect the down-
by generating and distributing the stream pressure. This type of
In order for the valve to move
highest steam pressures that the valve has two main drawbacks in
from open to the closed position,
boiler is capable of producing. To that it allows greater fluctuation of
there must be a build up of pres-
produce lower pressure steam at the downstream pressure, under
sure under the diaphragm “A”.
the point of use, a building pres- unstable load demands, and
This overcomes the pressure
sure reducing valve should be these valves have relatively low
exerted by the control spring “B”.
used. This system design allows capacity for their size. It is never-
This action results in an inevitable
for much smaller distribution pip- theless perfectly adequate for a
variation of the downstream pres-
ing, reducing costs and reducing whole range of simple applica-
sure. It will be the highest when
heat losses from these pipes. tions where accurate control is
the valve is closed, or nearly
Also every piece of steam using not essential and where the
closed, and will “droop” as the
equipment has a maximum safe steam flow is fairly small and
load demand increases. The out-
working pressure which cannot reasonably constant.
let pressure acting on the
be exceeded in operation.
Another energy efficiency reason Figure 14a
for reducing steam pressures is
Direct Acting Pressure Reducing Valve
the “latent” heat content is greater
in lower pressure steam. More
heat content per pound means
less pounds of steam to do the
work. These are not the only rea-
sons for reducing steam
B
pressure. Since the temperature
of saturated steam is determined
by its pressure, control of pres-
sure is a simple but effective
method of accurate temperature
control. This fact is used in appli- A
cations such as sterilizers and
control of surface temperatures
on contact dryers. Reducing
steam pressure will also cut down
on the losses of flash steam from Inlet Outlet
vented condensate return
receivers.
Most pressure reducing
valves currently available can be C
divided into three groups and
their operation is as follows:
19
Control and Regulation of Steam
20
Control and Regulation of Steam
by controllers will provide pres- Selection & Application control valve selected. A valve
sure reduction with even more The first essential is to select that is too large in capacity capa-
accurate control. Controllers the best type of valve for a given bilities will have to work with
sense downstream pressure fluc- application and this follows logi- minimum opening between the
tuations interpolate the signals cally from the descriptions valve head and seat on less than
and regulate an air supply signal already given. Small loads where maximum loads which can and
to a pneumatic positioner which accurate control is not vital does cause wire-drawing, valve
in turn supplies air to a should be met by using the sim- cutting, and erosion. In addition,
diaphragm opening a valve. ple direct acting valves. In all any small movement of the over-
Springs are utilized as an oppos- other cases, the pilot operated sized head will produce a
ing force causing the valves to valves will be the best choice, relatively large change in the flow
close upon loss of or a reduction particularly if there are periods of through the valve orifice in an
of air pressure applied on the no demand when the down- effort to accommodate load
diaphragm. Industry sophistica- stream pressure must not be changes, almost always allowing
tion and control needs are allowed to rise. more or less flow through the
demanding closer and more valve than was actually needed
Oversizing, a common indus-
accurate control of steam pres- causing larger pressure fluctua-
try practice, should be avoided at
sures, making Pneumatic control tions downstream.
all costs regardless of the type of
valves much more popular today.
Steam
Separator
IN OUT
Air Supply
High Pressure
Decrease Piping Size
IN OUT
Strainer Low Pressure
(On Side) Increase Piping Size
Steam
Separator
21
Control and Regulation of Steam
A smaller, correctly sized valve failure. This safety relief Manual Control Valves
reducing valve will be less prone valve must be sized to handle the Manual valves can be
to wear and will give more accu- maximum steam flow of the applied to a piece of equipment to
rate control. Where it is reducing valve at the desired set control the energy supplied to the
necessary to make bigger reduc- relief pressure. ASME standards process as simply as they are
tions in pressure or to cope with state that those set relief pres- used to regulate the flow of other
wide fluctuations in loads, it is sures are to be 5 PSI above the fluids. The major drawback of
recommended to use two or more equipment maximum operating manual valves to control temper-
valves in series or parallel to pressure for equipment operating atures is that these valves will
improve controllability and life up to 70 PSI, and not to exceed undoubtedly need frequent
expectancy of the valves. 10% greater than maximum oper- adjustments and monitoring to
Although reliability and accu- ating pressures for equipment maintain just the correct tempera-
racy depend on correct selection operating above 70 PSI but below tures under constantly changing
and sizing, they also depend on 1000 PSI. load conditions, which is the case
correct installation. of most pieces of process equip-
Temperature Control Valves
Since the majority of reduc- ment.
Most types of steam equip-
ing valve problems are caused by ment need to utilize some form of Self Acting Control Valves
the presence of wet steam and/or temperature control system. In Self-Acting Control Valves
dirt, a steam separator and strain- process equipment, product qual- (Fig. 17) are operated by a sen-
er with a fine mesh screen (100 ity is often dependent upon sor system that senses the
mesh) are fitted before the valve. accurate temperature control, product temperatures, causing a
The strainer is installed with the while heating systems need to be heat sensitive fluid to expand or
“Y” portion of its body just below thermostatically controlled in contract based on the product
horizontal in a horizontal steam order to maintain optimum com- temperature transferring heat
line to prevent the body from fill- fort conditions. From an energy energy to the sensors fluid. This
ing up with condensate during saving point of view, controlling expansion and contraction of the
periods of shut down and to the steam energy supply to a heat sensitive fluid is transmitted
ensure that the full area of the process piece of equipment to up through a capillary tubing
screen is effective in preventing maintain the desired product tem- arrangement and the respective
dirt from passing through. As a perature, whether air or any expansion and contraction of the
part of a Preventative product, is mandatory. If process fluid applies or relieves pressure
Maintenance Program all strain- systems are not controlled to the to a valve head, causing the
ers should be installed with desired temperatures then the valve head to move. This move-
blowdown valves for regular dirt system will run “wild” either not ment allows the control valve to
removal. All upstream and down- providing the required heat ener- throttle the steam flow to the
stream piping and fittings should gy or over heating the product to equipment. These control sys-
be sized to handle the maximum unacceptable levels. A very tems are calibrated by the
steam flows at a reasonable important item to remember in the amount of heat sensitive fluid to
velocity of not more than 6,000 use of temperature control valves control within a given tempera-
feet per minute. Eccentric pipe on systems is that in order to reg- ture range and can be set to any
reducers, with the flat side on the ulate the heat energy transferred temperature between the upper
bottom, should be used to pre- to the process the control valve and lower limits by means of an
vent any build up of condensate effectively regulates not only the adjustment knob.
in the piping during shutdown. flow rate of energy in pounds per
If the downstream equipment hour, but, also accomplishes tem-
is not capable of withstanding the perature control by regulating the
full upstream steam pressure, saturated steam pressure/tem-
then a safety relief valve must be perature levels admitted to the
fitted either on the downstream process heat exchange equip-
piping or the specific piece of ment. Temperature control can be
equipment to be protected from accomplished by several meth-
over pressurization in case of a ods and valves:
22
Control and Regulation of Steam
23
Control and Regulation of Steam
Temperature
Figure 19 Controller
Pneumatic Pilot Operated Temperature Control
Air Regulator
Actuator
Steam
Separator Positioner
IN
24
Control and Regulation of Steam
Temperature
Figure 20a
0% Load Proportional Band Selected Proportional Band
(offset = 0°)
Control Set
Value
Selected
Proportional Band
or Offset at Full
Load
100% Load
for Specific
Application
Load
0% Load
available for use on steam heat inverted bucket trap, may upset charge temperature of the con-
exchange equipment. the accurate temperature control densate.
When a modulating control is of certain units because of the If waterhammer is likely to
used, the steam trap should be sudden change in pressure in the occur, the float and thermostatic
capable of giving continuous con- steam space which occurs when trap is liable to become damaged,
densate discharge over the full they open. This effect is most for this reason and for the
range of pressures. If maximum likely to be noticeable in equip- longevity of the heat exchange
output is required from the unit, ment where the steam space has equipment waterhammer situa-
the trap used must be able to dis- a high output in relation to its tions should be corrected at all
charge condensate and air freely volume. costs. In most cases waterham-
and must not be of a type which is The most suitable type of trap mer in heat exchange equipment
prone to steam locking. A ther- for temperature controlled appli- is caused by water logging of the
mostatic trap is not suitable cations is the continuous equipment. Note: Condensate
because it has a fixed discharge discharge float and thermostatic must be allowed to drain freely by
temperature that may cause con- trap. This trap will discharge con- gravity at all times. If condensate
densate to be held back just densate immediately as it is has to be lifted up into a return
when the control valve is wide formed without upsetting pres- system, then this lifting has to be
open and the equipment is calling sure conditions in the steam done by a pumping device.
for maximum heat transfer. space. It will not steam lock, with
Traps which give a heavy proper installation, and will not air
blast discharge, such as a large lock or attempt to control the dis-
25
Steam Traps and the Removal of Condensate
26
Steam Traps and the Removal of Condensate
there are other reasons equally On the other hand, if cool • Dirt is another factor. A trap
as important to why steam traps condensate is then returned to a selected to meet all the obvious
should be utilized, these are: feed tank which requires preheat- criteria may be less reliable in a
ing, the ‘efficient’ trap has done system where water treatment
Air Venting little for the overall efficiency of compound carried over from the
At start up the trap must be the steam system. boiler, or pipe dirt, is allowed to
capable of discharging air. Unless interfere with trap operation.
Care must also be taken in
air is displaced, steam cannot
evaluating any application involv- The prime requirement how-
enter the steam space and warm-
ing a cooling leg. Draining ever is the adequate removal of
ing up becomes a lengthy
through a bimetallic steam trap air and condensate. This requires
business. Standing losses
may look attractive in terms of a clear understanding of how
increase and plant efficiency falls.
lower temperature discharge and traps operate.
Separate air vents may be
reduced loss of flash steam. On NOTE: WATERHAMMER CON-
required on larger or more awk-
the other hand, if heat is being DITIONS IN A STEAM SYSTEM
ward steam spaces, but in most
lost to atmosphere through an DAMAGE MORE THAN JUST
cases air in a system is dis-
unlagged cooling leg, then the net STEAM TRAPS AND IS A VERY
charged through the steam traps.
gain in thermal efficiency is prob- SERIOUS CONDITION WHICH
Here thermostatic traps have a
ably negligible. SHOULD BE RESOLVED.
clear advantage over other types
since they are fully open at start Without a cooling leg con-
densate will be held back within Steam Traps
up.
the plant and the main reserva- First, a definition of a steam
Float traps with inbuilt ther- trap may be in order to fully
tion must be whether the plant
mostatic air vents are especially understand the function of this
itself will accept this waterlog-
useful, while many thermody- piece of equipment. A steam trap
ging. It is permissible with
namic traps are quite capable of is an automatic valve designed to
non-critical tracer lines or over-
handling moderate amounts of stop the flow of steam so that
sized coils, but as already
air. The small bleed hole in the heat energy can be transferred,
indicated, it can be disastrous in
inverted bucket trap or the orifice and the condensate and air can
the case of heat exchangers.
plate generally leads to poor air be discharged as required. If we
venting capacity. Reliability break this definition down into
It has been said that ‘good sections, it is first of all an “auto-
Thermal Efficiency
steam trapping’, means the matic valve”.
Once the requirements of air
avoidance of ‘trouble’. This infers that there is some
and condensate removal have
Undoubtedly, reliability is a major form of automatic motion that
been considered we can turn our
consideration. Reliability means must take place. It is “designed
attention to thermal efficiency.
the ability to perform under the to stop the flow of steam so that
This is often simplified into a con-
prevailing conditions with the heat energy can be transferred”.
sideration of how much heat is
minimum of attention. This portion of the description is
profitably used in a given weight
of steam. Given thought, the prevailing such that it would imply the trans-
conditions can usually be predict- mission of energy whether by
On this basis the thermostat-
ed. flowing down a distribution pipe
ic trap may appear to be the best
• Corrosion due to the condition or giving up energy to a product
choice. These traps hold back
of the condensate or of the sur- in a heat exchanger. The defini-
condensate until it has cooled to
rounding atmosphere may be tion also continues to say
something below saturation tem-
known, and can be countered by “discharge condensate and air as
perature. Provided that the heat
using particular materials of con- required”. This portion of the defi-
is given up in the plant itself, to
struction. nition implies that some types
the space being heated or to the
may handle differing amounts of
process, then there is a real sav- • Waterhammer, often due to a lift
either condensate or air, or even
ing in steam consumption. after the trap, may be overlooked
a combination of the two.
Indeed, there is every induce- at the design stage and can
ment to discharge condensate at mean unnecessary damage to In the beginning, steam traps
the lowest possible temperature. otherwise reliable steam traps. were manually operated valves.
27
Steam Traps and the Removal of Condensate
The major problem with this type foods etc.). These differing appli- attached to a valve head and
of condensate drainage system is cations will be discussed later. pivot point. When condensate
the variation to changing conden- Our purpose now is to explore the enters the trap, the float rises with
sate flows. Condensate, you will operating characteristics of traps the liquid level and mechanically
recall, is steam that has given up and where they fall within each pulls the valve off the seat to
its enthalpy and reformed into category. allow condensate to be dis-
water. The amount of conden- charged. A thermostatically
sate being created varies in many Mechanical Steam Traps operated air vent is still present
different ways. A fixed position of There are two basic designs but located inside the body on
a block valve or fixed hole in a of steam traps in this category. most modern day designs of F&T
drilled plug cock valve cannot They are the “Float and traps.
adjust automatically to the vary- Thermostatic” and the “Inverted Some manufacturers locate
ing conditions of condensate Bucket” designs. The float and the “air vent” externally, but the
load. thermostatic design evolved pri- purpose is the same. This part of
This method of condensate marily from a free floating ball the trap is strictly there for
removal would warrant an opera- design. automating the air venting proce-
tor be present much of the time to The first float type trap con- dure. It is also noteworthy to note
correct the setting of the valve. If sisted of a free floating ball in an here that this type of trap has one
condensate was allowed to back expanded area of pipe. It was a basic application point, and that is
up, less heat transfer would take top in, bottom out type of system for process purposes. This is due
place, causing production to fall that required water to fill the to the fact that this trap type
off. If, on the other hand, the expanded area and float the ball immediately removes air and
condensing load was less, the upwards, exposing the outlet pip- non-condensables as they enter
operator would have to close the ing and outlet orifice. As long as the trap and discharges conden-
valve to the point that steam was condensate was flowing to the sate in the same manner, at
not continuously being released. trap, condensate would flow from saturation temperatures. There
Because of the changing nature the trap at the same rate. The may be some limited uses other
of condensing loads, this would floats were weighted slightly to than process for this type of trap,
be a full-time job. require water to always be pre- but primarily it is used in this type
True steam trap operation will sent in the trap and thereby stop of application.
fall under one of the following steam from leaking into the con- The main advantages to this
three categories: densate return line or to type of trap is its superior air
1. Mechanical or Density atmosphere. It was soon noted, removal capabilities either on
however, that air would accumu- start up or during the process
2. Thermostatic or Temperature
late in the expanded area of pipe procedure. It also has a continu-
Controlled
and form a bubble which kept ous discharge characteristic that
3. Thermodynamic or Velocity condensate from flowing down- follows exactly the forming of
These categories of traps ward. A piece of pipe was added condensate. In other words, what
have distinctive operating charac- to the inlet piping to the trap and comes in goes out at the same
teristics and work most efficiently a manual valve attached to be rate. This type of steam trap
when used for their designed pur- periodically “blown down” to keep adjusts automatically to either
pose. It would stand to reason water flowing to the trap and air heavy or light loads of condens-
that steam traps evolved with removed. When the thermostatic ing and is not adversely affected
industry and demand. There are bellows steam trap was invented, by changes in pressure.
really only three applications for it soon took the place of the man- Condensate removal is also done
steam traps: drip stations (locat- ual valve and automated the at steam temperature, so heat
ed on steam delivery lines), procedure. exchange takes place at constant
tracing (steam lines designed to temperatures, insuring maximum
maintain a product temperature Float And Thermostatic Trap efficiency use of the energy sup-
or keep a liquid system from Modern Float and Thermo- ply.
freezing) and process (steam static traps (Fig. 21) still have a
used specifically for heating prod- ball type float, but it is now
ucts such as air, process fluids, attached to a lever. The lever is
28
Steam Traps and the Removal of Condensate
A disadvantage is general to
all mechanical type of traps and
that is the power of the float is
constant, so as steam pressure
goes up, the size of the permissi-
ble discharge orifice goes down.
In practice, mechanical traps
must have different sizes of
valves and seats for different
pressure ranges. This is to
ensure that the float and lever
combination has the ability to
generate enough energy to lift the
valve head off of the seat at the
design operating pressures. If it
cannot, the trap mechanism is
overcome by the steam pressure
and the trap fails closed.
29
Steam Traps and the Removal of Condensate
and sinks in the surrounding liq- This type of trap is most pressure of the capsule, which is
uid. In doing so, it pulls the valve appropriately suited for stable, greater than that within the trap
head off of the valve seat and steady load and pressure condi- body so forcing the valve down
allows the collected air to dis- tions such as one would find on a onto its seat, and preventing the
charge. Flow from under the steam distribution system. trap from blowing steam. As the
bucket starts again. This allows steam condenses back to con-
either more air or steam to begin
Thermostatically or densate, and the temperature
to enter the trap body. If it is more Temperature Controlled Traps drops accordingly, the alcohol
air, the sequence is repeated. The balanced pressure or mixture recondenses so relieving
bellows type of steam trap was the internal pressure of the cap-
If it is steam, however, the
first manufactured with a bellows sule and thus lifting the valve
sequence is different. Steam
of copper design. This bellows back off its seat, allowing conden-
passes through the bucket vent
(Fig. 23) had a liquid fill which, in sate to flow through the trap.
hole to the top of the trap and is
the beginning, was distilled water.
condensed by heat losses from The mixture of distilled water
Modern thermostatic type traps
the trap body, in particular the cap and alcohol in the bellows is the
still have a liquid fill but it is made
or top. This loss is necessary to key to the operating temperatures
up of a distilled water and alcohol
keep steam and condensate of the balanced pressure trap.
mixture and they are contained
coming to the trap. As conden- Most manufacturers provide ther-
within an enclosed capsule rather
sate enters under the bucket, it mostatic traps to operate within
than a bellows. Alcohol was
fills the space and again the 20 to 40 degrees of saturated
added to the fill to lower its boiling
bucket loses buoyancy and sinks. steam temperatures. An impor-
point.
Discharge flow is first downward tant point to remember is that all
from under the bucket, and then The capsules work by thermostatically operated steam
upward to the discharge orifice. exploiting the difference in the traps will cause condensate to
boiling point between the alcohol back up in the system. The
The biggest advantage to this
mixture and the surrounding con- amount of backup in the system
type of trap is its ability to with-
densate. As the temperature of is dependent upon the tempera-
stand high pressures. It has a
the condensate gets closer to ture that the trap is designed to
reasonable degree of tolerance to
steam temperature, the mixture operate at, along with the con-
waterhammer damage but suf-
contained within the capsule gets densate loads coming to the trap.
fers from freeze damage. In the
closer to its boiling point at a set
case of freezing, however, most The advantage to this type of
temperature below that of steam
of the damage is done to the trap is its ability to freely and
(before steam reaches the trap),
body of the trap rather than to the
the mixture evaporates. This
mechanism or float.
results in an increase in internal
The disadvantage to this
trap type is its limited ability to
discharge air and other non-con-
densable gases. This is due to
the small vent hole and low differ-
ential pressure driving the air
through it. It is suspect at times
to rapid pressure changes in the
system due to the requirement of
a “prime” being maintained inter-
nally for proper operation. The
“prime” water seal is at saturated
steam pressure/temperatures
and if the steam pressure drops
rapidly due to load changes of
equipment, the “prime” has a ten-
Figure 23
dency to boil off (flash). Without Stainless Steel Bellows for Thermostatic Trap
the required “prime,” this type of
trap fails open.
30
Steam Traps and the Removal of Condensate
31
Steam Traps and the Removal of Condensate
Figure 25
Liquid Expansion Thermostatic Trap
32
Steam Traps and the Removal of Condensate
Conclusion
The three catagories of
steam traps discussed above are
the most commonly used and
widely known trap types. There
are obviously variations to almost
all of the traps described in this
section. Some of those variations
can be seen in the following
descriptions and operating char-
acteristics.
33
Steam Traps and the Removal of Condensate
34
Steam Traps and the Removal of Condensate
Figure 30
Balanced Pressure Capsule Figure 31
for Thermostatic Trap Simple Bimetallic Trap
pressed when filled and sealed. tracted it popped again to the more resistant to damage by
The problem with having a original position and opened the either superheat or water ham-
liquid fill on the inside of a bellows valve to allow discharge. This mer.
still exists. That problem being popping action meant that it There have been many
the fill over expanding and ruptur- would insure the trapping of some design changes over the evolu-
ing the bellows when a small condensate around the capsule tion of the bimetal type of steam
amount of superheat may be at all times and prevent over trap. They started off by the strip
allowed to reach the trap inter- expansion. Superheat has no of metal expanding and pushing
nals. There have been two condensate, as you know, and the valve into the seat. The obvi-
attempts to try to correct for this. also has a tendency of vaporizing ous problem with that was
As mentioned earlier, thermostat- any condensate in a system once aligning the valve head to the
ic type traps usually (but not it is up to full temperature. This seat. Then it evolved to pull the
always) reach a point where the still created over expansion, but valve into the seat (Fig. 31). In
inside pressure balances to the the trap now had a more distinct either case though, a single strip
outside pressure of the bellows. on and off type of operation when of very heavy metal could only
This causes them to basically used on saturated steam lines. create a linear tracking of the
average the pressure tempera- The problem with this type of steam curve. Close inspection of
ture and constantly dribble. One trap was the design and location this shows that the deepest sub-
attempt to solve the over expan- of the liquid fill that causes the cooling range occurred at about
sion problem and dribble trap to operate. Later design of the highest point in the steam
discharge was to create a single the capsule put the liquid fill on curve. This meant that there was
wafer type of capsule where the the outside of the moving part of a lot of condensate backed up
center portion containing the the wafer. The result of the fill into the lines. A point to remem-
valve was forced in during the fill- vaporizing and forcing the valve ber is that these traps can be
ing procedure of manufacturing. to the seat in part then doubles adjusted by adjustment nuts on
This created a bowing type of the thickness of the wafer at its the stem. This controls the valve
appearance and caused the cap- weakest point. It is also apparent stem stroke and discharge tem-
sule to operate more like the that the fill then be encased in a perature.
bottom of an oil can. As the fill thicker shell to prevent water The next step in evolution
vaporized it “popped” the portion hammer damage to the element. was to “stack” strips that were of
of the capsule outward and As you can see, the operation of different thickness to both add
forced the valve head on to the this type of design improvement power to draw on the valve stem
seat. As the fill cooled and con- for the thermostatic trap is much and also operate at differing lev-
35
Steam Traps and the Removal of Condensate
36
Steam Traps and the Removal of Condensate
Steam Trap Testing Methods appropriate amount of flash When testing other traps, like
There is virtually no point in steam and water mixture. Float & Thermostatic and
spending the time and money in Visual testing of steam traps Thermostatic types which provide
creating a highly efficient steam works best on two types of trap continuous modulating dis-
system and then failing to main- operation due to the trap’s inher- charge, the tester again has to
tain it at this same level. ent discharge characteristics. open the strainer blowdown valve
However, all too often leaking Those two traps are the Inverted and divert condensate away from
joints and valve stems are Bucket (Density) and the trap inlet so that the trap sees
accepted as a normal operating Thermodynamic (Kinetic Energy). only steam. Again, if it is a prop-
condition of both steam and con- These two traps operate in a erly operating trap, it will shut off
densate systems. cyclical manner being fully open, completely. The ultrasonic test-
discharging, or fully closed. The ing device must be calibrated to
Even a 1/8" diameter hole
open/closed operation is the key eliminate external piping noises
can discharge as much as 65
to correct visual testing and what or other steam traps’ discharge.
lb/hr of steam at 150 PSIG which
the tester should be looking for to When testing traps that are in
represents a waste of approxi-
indicate a properly operating close proximity, all traps except
mately 30 tons of coal, 4,800
steam trap. the one being tested must be iso-
gallons of fuel oil or 7,500 therms
lated to remove any false signals
of natural gas in a year (8400 If there is installed in the pip-
from the other traps.
hours). ing ahead of the steam trap a wye
(“Y”) strainer with a blowdown The ultrasonic testing method
Elimination of the visible
valve, opening the blowdown can provide very positive
leaks already mentioned is obvi-
valve and diverting all of the con- answers to a trap’s operating
ously reasonably straight
densate away from the steam condition as long as the operator
forward. It is the invisible steam
trap allows only steam into the doing the test has been trained,
leaks through faulty steam traps
trap. has developed some experience
that present a far more taxing
with the testing instrument and is
problem. We know that the basic Any steam trap type should
able to identify the type of trap
function of a steam trap is to dis- close positively when it senses
operation by visual inspection.
charge condensate and only steam. This additional step,
non-condensable gases in our diverting the condensate away Temperature Testing
systems and prevent live steam from the trap’s inlet, allows the Temperature testing of traps
from escaping. Steam trap testing tester to test any type of trap involves measuring the tempera-
has brought about four different operation and receive 100% pos- ture at, or close to, the inlet and
methods of testing. Let’s look at itive answers to the trap’s outlet of the steam trap.
all four methods and see what condition. Pyrometers, temperature sensi-
each will tell us about the condi- tive crayons, paint, band-aids and
tion of the steam trap. Ultrasonic Trap Testing
thermocouples all have their
Ultrasonic trap testing began
Visual Testing advocates. Unfortunately, these
with a screwdriver and has pro-
methods are of limited use since
The first point that has to be gressed to electronic sensing
the temperatures of condensate
understood when visually testing devices which amplify vibrations
and flash steam on the down-
a steam trap is that it will be a of flow. Flow of water and steam
stream side of a correctly working
very rare occasion where the only set up vibrations which are what
steam trap are controlled by the
matter coming out of a steam trap we are looking for with ultrasonic
pressure in the condensate return
will be water!! Almost always, testing. This form of testing
system. A very large percentage
there will be varying mixtures of works very well on traps that
of steam traps in the USA are
flash steam and water and in have cyclical discharge charac-
thought to discharge into “0”
some cases the visual discharge teristics, like the kinetic energy
PSIG, atmospheric gravity
will be all flash steam. So the first Thermodynamic and the density
returns, which means that the
thing to remember is that we do operated Inverted Bucket. The
maximum temperature that could
not want to look for water only, open/closed operation provides a
be expected is 212°F, regardless
nor do we want to attempt to very positive answer to the trap’s
of the trap’s operating condition.
decide if we are seeing the operation.
37
Steam Traps and the Removal of Condensate
It does not necessarily mean that find failed open traps is by far the either side of the weir becomes
a trap has failed when an elevat- least accurate of all the testing disturbed and the steam pressure
ed temperature above 212°F is methods available to users. on the inlet side of the chamber
recorded downstream of a steam displaces the condensate below
trap. More likely it means that the Conductivity Testing the sensor. The sensor is no
condensate return line is under a A more recent development longer surrounded by the conduc-
positive pressure, which means in trap testing uses the electrical tive condensate and the electrical
that the pressure/temperature conductivity of condensate. This circuit is broken, providing a
relationship of steam must exist. involves the installation of a failed signal on the indicator.
chamber (Fig. 33) containing an
Thus if we were to record a A major advantage to this
inverted weir upstream of the
temperature of 227°F on the out- method is the very positive signal
steam trap shown as follows.
let side of a trap, this tells the which can be interpreted without
tester that the return system is at With the trap working normal- resorting to experience or per-
5 PSIG saturated steam condi- ly, condensate flows under this sonal judgment. It is possible to
tions, even though it was thought weir and out through the trap. wire a number of sensor cham-
to be a “0” PSIG return system. There is a small hole at the top of bers to one remote testing point
There could be a failed open the weir that equalizes the pres- for ease of quickly testing larger
steam trap in the system that is sure on each side. A sensor is numbers of traps. The latest
causing this pressure or it could inserted in the chamber on the designs of conductivity testing
be purely the fact that the con- upstream side which detects the equipment have added a temper-
densate return line was sized for presence of condensate by com- ature sensor in the same
water only and is not able to pleting an electrical circuit with chamber that will provide the abil-
accommodate the flash steam the condensate. A portable indi- ity to determine a failed closed
volume without becoming pres- cator is plugged into the sensor trap.
surized. Temperature testing will and the indicator provides the
identify a “failed closed” steam ability to read a completed circuit
trap due to very low temperatures on the sensor. If the trap
at the inlet of the steam trap. becomes defective and begins
Temperature testing of traps to blowing steam, equilibrium on
Steam Trap
Sensor
Hole Chamber
Live Steam
Weir
Condensate
Type 30 Indicator
Figure 33
Conductivity Trap Testing System
38
Steam Traps and the Removal of Condensate
39
Steam Traps and the Removal of Condensate
Liquid Expansion blockage of the valve orifice or sure fluctuations or the trap being
Thermostatic Trap built in strainer. installed in such a way that the
Symptom-Trap blows steam Float & Thermostatic Trap water seal can drain out by gravi-
Check for dirt or wear on the Symptom-Trap blows steam ty. Try fitting a check valve before
valve and seat. If wear has the trap to prevent this loss.
Check the trap for dirt fouling If steam blow persists, check
occurred, change the complete either the main valve and seat or
set of internals. It must be for dirt or wear on the valve head
the thermostatic air vent valve and seat or failed mechanism.
remembered that this type of trap and seat. If a steam lock release
is adjustable in the temperature Replace the complete valve
is installed in the trap, check to mechanism and linkage as a
of discharge, check to see if inad- insure that it is not open causing
vertently the trap’s adjustment complete set.
a leak. Make sure that the float Check the bucket to deter-
has been turned out too far for it and valve mechanism has not
to close. Try adjusting the trap to mine if it is distorted from
been knocked out of line either by waterhammer.
a cooler setting. If it does not rough handling or waterhammer,
appear to react to temperature, a preventing the valve from seat- Symptom-Trap will not pass
complete new set of internals ing. Check that the float ball has condensate
should be fitted. not been damaged by waterham- Check that the maximum
Symptom-Trap will not pass mer and developed a leak which operating pressure of the mecha-
condensate would not allow the float ball to nism has not been exceeded
Check that the trap’s adjust- float or bind in its operation. The causing the trap to lock shut.
ment has not been turned in too air vent assembly should be test- While checking the internals,
far to a setting that’s too cold. ed in the same manner as the insure that the air vent hole in the
Balanced Pressure Thermostatic bucket is not obstructed, as this
Bimetallic Thermostatic Trap could cause the trap to fail
trap element. When replacing the
Symptom-Trap blows steam closed. Air venting could also be
main float mechanism and valve
Check as usual for dirt and assembly, these should be a cause of a failed closed trap,
wear on the valve and seat. A replaced as a complete set. especially in systems that start up
bimetallic trap has only limited and shut down frequently. Look
Symptom-Trap will not pass
power to close by virtue of its at the air venting arrangements of
condensate
method of operation and the the steam using equipment in
valve may be held off its seat by Check that the maximum general.
an accumulation of quite soft operating pressure rating of the
deposits. This type of trap is usu- trap mechanism has not been Conclusion
exceeded. If this has happened, It is important to know the
ally supplied pre-set to a specific
the mechanism will not have the type of trap discharge (Fig. 34)
amount of subcooling. Check to
power to open the valve against which should be expected when
see that the locking device on the
the higher steam pressure. A making maintenance checks or
manual adjustment is still secure.
leaking or damaged float is trap testing. The table on the fol-
If this seems suspect, see if the
almost certainly the result of lowing page sets out the usual
trap will respond to adjustment. If
waterhammer damage and the discharge characteristics of the
cleaning has no effect, a com-
problem should be corrected. most commonly used traps.
plete new set of internals should
be installed. Inverted Bucket Trap
Symptom-Trap will not pass Symptom-Trap blows steam
condensate Check for loss of the water
Bimetallic traps have the seal “prime”. Isolate the trap,
valve on the downstream side of wait for condensate to accumu-
the valve orifice which means that late and start up the trap again. If
they tend to fail in the open posi- this cures the trouble, try to dis-
tion. Failure to pass cold cover the cause of the loss of the
condensate indicates either gross water seal “prime”. This could be
mis-adjustment or complete due to superheat, sudden pres-
40
Steam Traps and the Removal of Condensate
Figure 34
Steam Trap Discharge Characteristics
Steam Trap Selection 6. Will the trap be in an exposed As an example, let us consid-
It can be claimed that the position? er the difference in trapping
majority of steam trap types will 7. Is the steam supply super requirements of a steam radiator
“work” on any application (provid- heated? and a unit heater. While the
ed that the operating conditions steam space of the radiator is
8. Is air likely to be present in
fall within the pressure range and great compared with its heating
any quantity?
condensate discharge capacity of surface, the steam capacity of the
9. Is steam locking a possibili- unit heater is small compared
the trap) (Fig. 35). However, we
ty? with its heat output. The radiator
do not just want steam traps to
“work” moderately well. We must 10. Is the installation made up can make good use of the sensi-
aim to achieve maximum output of several steam heated ble heat in the condensate before
and efficiency from all steam units? it is discharged, but the unit
using equipment. This means Waterlogging heater cannot. For this reason,
selecting the best trap to suit the radiator should be fitted with a
With most steam heated
each particular application (Fig. thermostatic trap that will hold
equipment it is desirable, and
36). back condensate until its temper-
very frequently essential, to dis-
ature has dropped a
The following list contains a charge condensate as soon as it
predetermined number of
number of important questions forms in the steam space.
degrees below that of the steam.
which should be considered Although sensible heat in the
when choosing a steam trap for a condensate is usable heat, a On the other hand, the unit
particular application: much greater rate of heat transfer heater must be fitted with a trap
will be obtained if only the steam that will discharge condensate
1. Will condensate be dis-
is in contact with the heat transfer immediately as it forms. The
charged immediately as it
surface. slightest waterlogging in this case
forms?
would reduce heat output and
2. Is there condensate back Steam traps of the mechani-
cause the heater to blow cool air.
pressure or a return line high- cal type should always be chosen
Condensate held back in the unit
er than the steam heated for applications which require
heater will also promote corrosion
equipment? rapid condensate removal.
and unnecessarily reduce the life
3. Are there waterhammer con- Thermostatic type traps cannot
of the heater tubes.
ditions in the steam supply release condensate until it has
cooled a set number of degrees The extent to which waterlog-
line? ging of a steam space can be
below steam temperature, result-
4. Is there vibration or exces- ing in waterlogging the steam tolerated is clearly a significant
sive movement in the space. There are, however, a factor in steam trap selection.
equipment? number of occasions when such The wrong choice of trap is at the
5. Does the condensate contain waterlogging may be perfectly root of many instances of poor
corrosive substances? acceptable and even desirable. plant performance.
41
Steam Traps and the Removal of Condensate
Lifting Of Condensate ticularly concerned with the prob- period. The condensate will also
The rate at which a steam lems which may arise from lifting prevent any air from escaping
trap can discharge condensate condensate by the steam pres- through the steam trap which
depends on the size of the valve sure at the trap inlet. makes the problem even worse.
orifice and the “differential pres- For every 1 psi of steam If the equipment is tempera-
sure”, the difference in pressure pressure at the trap, condensate ture controlled, the very action of
between the inlet and the outlet of can be lifted to a height of the control may reduce the steam
the trap. approximately 2.3 feet. In order pressure below the point at which
If a steam trap discharges to to lift condensate, the trap must it can successfully lift condensate
atmosphere, the differential pres- have positive steam pressure at to an overhead return line. Once
sure across the trap will be the all times. There are disadvan- again the steam space will water-
same as the upstream steam tages to lifting condensate in this log until the control valve opens,
pressure. The same will be true if manner. In the first place, the resulting in poor temperature
the trap discharges into a return necessary steam pressure may control and the possibility of
line at a lower level which allows not always be available at the waterhammer as the steam rush-
the condensate to gravitate back trap inlet. If, for example, the nor- es into the waterlogged steam
to the boiler feed tank. mal operating pressure is 25 psi, space. Additionally, if the steam
Unfortunately, such an arrange- it is theoretically possible to lift space is a coil, considerable ero-
ment is often ruled out because the condensate 57.5 feet. sion and corrosion may take
either the boiler feed tank is high- However, on a cold start up, the place.
er than the traps or the return steam pressure may for a time It must be remembered that
main has to run at high level to drop to, or even below, zero. certain types of steam traps are
clear obstructions. In these Until this pressure builds up, con- limited as to the amount of “back
cases, the condensate must be densate cannot be removed from pressure” against which they will
lifted either directly by steam the equipment and will collect in satisfactorily operate.
pressure in the apparatus or by a the steam space. This will result
pump. In this section we are par- in a greatly extended heat up
Figure 35
Requirements for Steam Trap/Applications
42
Steam Traps and the Removal of Condensate
43
Steam Traps and the Removal of Condensate
Steam Trap Sizing 3. The temperature of the con- trap section reveals that the vast
The benefits of selecting the densate. majority of the traps described
best type of steam trap for a We must now examine these have the valve on the pressure
given application (Fig. 35 & 36) factors in more detail. side (the inlet side) of the valve
will be wasted if the trap is not seat. The only notable exception
1. Differential Pressure
correctly sized. It is bad practice to this arrangement occurs in the
The maximum amount of bimetallic type of traps where the
to choose a 3/4" trap simply
condensate the trap will dis- valve is on the outlet side of the
because it has to go on a 3/4"
charge will increase as the valve seat. In the case of traps
drain line. In order to size a
differential pressure (the differ- with the valve on the pressure
steam trap, we obviously need to
ence in pressure between the side of the valve seat, the valve,
know the quantity of condensate
inlet and outlet of the trap) when closed, will be held on its
to be handled in a given time.
increases. In other words, the seat by the steam pressure.
The makers of most standard
capacity of a trap discharging to According to the type of trap in
kinds of steam equipment usually
atmosphere with steam at 75 psi question, the thermostatic ele-
supply reliable figures on the con-
will be greater than that of the ment, ball float or bucket must
densation rates of their
same trap with steam at 30 psi. have enough force to pull the
equipment. If such information is
The capacity does not, however, valve away from its seat against
not available, it has to be
increase in proportion to the pres- this pressure.
acquired either by calculation or
sure.
practical measurement of the In any given trap, the force is
condensate produced. A test pro- It is not wise to assume that a fixed amount. Force Required
cedure which will give reasonably the pressure at which steam is = pressure x area.
accurate results is set out at the supplied to a piece of equipment
The maximum pressure at
end of this section. will be the pressure on the inlet to
which the valve of the trap can
its steam trap. Pressure losses
Reference has already been open is the pressure at which this
often mean that the steam pres-
made to “start-up” loads and “run- operating force is just greater
sure at the trap will be
ning” loads in this course. We than the valve seat area multi-
considerably less than the steam
know that steam will condense plied by the pressure in the trap
supply pressure.
most rapidly on start up when the body.
system is cold. It is for this rea- If a steam trap is discharging
In the case of traps with the
son that it is common practice to condensate to atmosphere, the
valve at the outlet side of the
size traps using a safety factor. outlet pressure will be atmos-
valve seat, the situation is differ-
The trap selected should be able pheric and, therefore, the
ent. In this type, the steam
to handle twice the normal run- differential pressure will be the
pressure tends to open the valve,
ning load, or as much as 3 times same as the gauge pressure at
so the maximum pressure at
the running load following an the trap inlet. However, if the trap
which the trap can close is when
automatic temperature control. discharges into a main which is
the operating force is just greater
An undersized trap will cause under pressure, the differential
than the steam pressure multi-
waterlogging of the steam space pressure will be reduced by an
plied by the valve seat area.
when it can be least afforded. amount which can be determined
by subtracting the outlet pressure 3. The Temperature Of The
Steam Pressure and Trap from the trap inlet pressure. The Condensate.
Capacity quantity of condensate which the The capacity of a trap should
We know that for a steam trap is capable of passing in a never be based on the amount of
trap to operate, there must be a given time will be reduced cold water the trap will pass at
higher pressure at its inlet than accordingly. any given differential pressure.
there is at its outlet. The actual 2. Size of Discharge Orifice Condensate in a steam trap is
amount of condensate which the usually at a temperature above
The size of the discharge ori-
trap can discharge is governed by atmospheric boiling point. When
fice not only helps to determine
the following three factors: the condensate is passing
the capacity of the trap but also
1. The differential pressure through the valve seat of the trap,
often fixes the maximum pres-
its pressure is quickly reduced
2. The size of the trap discharge sure at which the trap will
orifice. and a certain amount of flash
operate. Reference to the steam
44
Steam Tracing
steam is generated. This flash product at the specific tempera- thick if not heated and kept heat-
steam tends to choke the dis- ture it already has. It is, ed throughout their processing.
charge orifice, reducing its therefore, a heat maintainer, and An example usually used is “thick
effective area. As the conden- not a heat exchanger. Because as molasses”.
sate temperature rises, the of this, the consumption of the There are many different
amount of flash steam generated steam is usually very low. In fact, ways of attaching tracing and
will increase and the discharge it is one of the smallest steam there are many different types or
capacity of the trap will decrease. consumers in a given plant. The methods of using the tracing con-
The extent of which condensate fact is however, that in some cept. The following discusses
temperature affects the trap’s dis- plants (such as Hydrocarbon these.
charge capacity is relative to its Processing facilities), they
Typically, tracing is copper
temperature below saturation account for as much as 70% of
tubing attached to a pipe filled
temperature -- lower tempera- the steam using locations. The
with some type of liquid (Fig. 37).
tures, lower flashing rates. fact that they consume very little
steam is then overshadowed by The method of attaching also
the sheer numbers of lines. varies from plant to plant and
spec to spec. The lines them-
Freeze Protection (Non- selves can be banded or
Critical) strapped, (when temperature dif-
Steam Tracing In areas of the country where ferences between the steam and
There are two typical applica- freezing conditions prevail during product fluid are low and steel
tions of tracing. They are winter months, many different pipe is used), attached using
typically referred to as either types of systems require protec- Heat Conducting Paste (Fig. 38)
process fluid (critical) or freeze tion from freeze-up. Obviously, and Channels and straight wiring
protection (non-critical) tracing. these lines are water lines or per- them in place. The placement of
There are different requirements haps metering equipment that the tracer tubing is more impor-
for each as far as heat is con- use water in sensor tubes to tant in most cases than the
cerned, so we will separate their detect flow of gases, etc. Tracing method used for attachment. In
requirements prior to discussing lines keep the water from freezing whichever method of attaching is
how to attach tracing to the appli- which will in turn possibly rupture selected, it is most important to
cation. piping, tubing or equipment. avoid crimping the tubing.
Tracing is as its name Sometimes, liquids that will not
implies, a pipe or tube following necessarily freeze become very
either process fluid lines or lines
where it is desirable to prevent
freezing during the winter Figure 37
months. Steam tracing is the dis- Tracer Line Attachments
tribution of steam through small 18" Max.
bore tubing or pipes which basi-
cally transfer heat to a larger pipe Process Fluid
to keep fluids from becoming vis- Tracer Tubing
cous, solidifying or freezing. Stainless Wire (Wrapped)
45
Steam Tracing
Figure 38 Figure 39
Tracer Using Heat Transfer Paste Welded Steam Tracer Pipe
Insulation
Process Fluid
Another popular method of job of the tracer then is to allow of the insulation with information
tracing is the use of jacketed pipe transfer of the heat of the steam such as “traced” and maybe even
(Fig. 40). This method of tracing into the flowing fluids as it is lost the number of tracer lines
is used particularly when there is to the atmosphere. attached along with the pressures
need to keep a fluid (such as The tracer line then should being used. This may help in
Sulfur) from solidifying in the also be installed running in a future maintenance of the system
pipes. We will look at each of the straight line as far toward the bot- itself. It may also help in using
methods mentioned above and tom of the piping as is possible the numbers of tracers as they
discuss some do’s and don’ts. (Fig. 42). The tracer is housed are needed.
inside the insulation wrapping on There may be times when the
Attaching Tracers
the pipe, and we gain much ben- number of tracer lines being used
The easiest method of trac-
efit from attaching it in this can be reduced. For example, a
ing is by attaching copper tubing
manner. Heat, which you may process pipe during the winter
to the pipe. It is used mostly
recall, rises naturally and sur- months may require multiple trac-
because of the abundance of
rounds the piping allowing for as er lines to insure that the fluids
copper tubing and the cost which
much natural conduction of remain at the proper temperature.
is relatively low. The tubing is
BTU’s as possible. This heat bar- However, during the summer
attached in the lower quadrant of
rier also reduces the heat losses months, the numbers of tracer
the pipe being traced (Fig. 41).
from the process fluids. lines may be reduced because of
Another important consideration
On some occasions, the less heat loss through the insula-
in tracing is to oppose the two
amount of heat available and tion. Some plants list the steam
flows, fluids in the process piping
temperature of the steam is such manifold header number where
and steam in the tracer tubes.
that spacers are used to prevent the on/off valves may be found to
This may not always be prac-
burning the liquids on the inside help with reducing the amount of
ticed, however, but there are
of the process lines. This could steam being consumed unneces-
some solid reasons why one
cause coking (burning) of the sarily.
would want to consider this.
Think about what the tracer job is lines and also restrict flow of the
- maintain heat already absorbed process. When spacers are
by the process fluid. As it trans- used, it is important that the insu-
fers from point “A” to point “B” in lation be sized to allow for the
the plant, heat will naturally be extra space required. It may also
lost through the insulation. The be advisable to label the outside
46
Steam Tracing
47
Steam Tracing
Figure 43
Jacketed Tracing System
Stop
Valve
25P Valve
Process Pipe
Jacket
TD 42
NOTE: Each section of jacketed pipe
should be trapped. Steam jumper lines
should continue over the top of the flanges.
Condensate to grade
48
Steam Tracing
Air
should be tagged with a number
Steam Out that identifies the trap, size,
Vent
pressure, etc. so that a mainte-
nance program can help
determine the correctness of
either the traps being selected
or size of trap being used.
These manifolds can be either
Vertical Manifold
Figure 46
49
Condensate Management
Figure 47
Switch Back Tracing Line
End View
Note:
Condensate In some
pipe is cases, using
always switch back
sloped in a tracing adds
downward more surface
direction. contact area.
Steam Trap
Tracing Valves
Steam In Figure 48
Approximate amount of flash
steam in Condensate
Steam In Flash
Steam
15%
Water
85%
Condensate Management
figure of 10-15% by mass is typi-
When steam condenses,
cal (Fig. 48).
Figure 49
energy is transferred to the cool- Approximate amount of energy in
er material to be heated. This About half of the energy men- Condensate
accounts for only around 75% of tioned above (i.e. 12.5% of the Flash
total energy supplied) could be Steam
the energy supplied in the boiler 50%
to produce the steam. The lost through flash steam (Fig. 49).
remainder, about 25%, is still held Flash Steam Recovery is,
by the condensed water. therefore, an essential part of
As well as having heat con- achieving an energy efficient sys-
tent, the condensate is distilled tem.
water: ideal for use as boiler feed This section will bring togeth- Water
water. An efficient installation will er Condensate Recovery, 50%
collect every drop of condensate Condensate Removal and Flash
it economically can, and either Steam Recovery under the head-
return it to the deaerator or boiler ing of Condensate Management.
feed tank, or use it in the process. The objective is to examine the should be remembered that con-
technical aspects for the benefit densate lines are, in fact,
Condensate is discharged
of the expert and then to use this bi-phase systems that require
through steam traps from a high-
as a basis to provide simple proper planning. Review the
er to a lower pressure. As a result
guide lines for the occasional Condensate Line Sizing Chart for
of this drop in pressure, some of
user. assistance in this area (Fig. 50).
the condensate will then re-evap-
orate, and is referred to as flash Condensate line sizing plays You will note that it is recom-
steam. The proportion that will an important role in successfully mended to increase the line size
flash off differs according to the controlling and collecting conden- on the discharge of all steam
level of pressure reduction sate. Sizing condensate lines traps. This is intended to allow
between the ‘steam’ and ‘conden- requires much planning to control for the flashing that will be
sate’ sides of the system, but a velocities of liquids and gases. It expected when steam traps dis-
50
Condensate Management
charge condensate into lower densate recovery systems. surplus heat is utilized by the
pressure systems. A chart is pro- condensate as latent heat caus-
vided to assist in quickly Flash Steam Recovery ing some of it to re-evaporate into
estimating the amount of flash When hot condensate under steam.
that can be produced. The volu- pressure is released to a lower
The quantity of “flash steam”
metric change of condensate pressure, its temperature must
available from each pound of
flashing into steam may cause very quickly drop to the boiling
condensate can be calculated
substantial increasing velocities point for the lower pressure as
using this formula:
that may damage existing con- shown in the steam tables. The
50
E 3000
Vent Pipe Sizing
33 2000
30 28" 26 24 20 18 16 14 12 10 8" 6" 5" 4" 3" 2-1
/2" 2" 1-1 1-1
/2" /4" 1" 3/4 1/2
" " " " " " " " " " "
17 1000
50,000
Multiply chart velocity
by factor below
10 0
in schedule 80 pipe
4 0
3 0
1/2" 1.30
10
1.23
0
5000
10 0
0
8
3000
60 0
4 0
3 0
2
2000
10
5
0
1000
800
500
A B
300
200
10 0
0
8
60 0
100
4 0
3 0
80
2
10
60
5
50
0
40
30
20 P
c re
fla ond ssu
10
sh en re
ta sa in
nk te
(p lin
si e
g) or
51
Condensate Management
Percentage Quantity of Flash ence between the pressures Before discussing the ways
Steam upstream and downstream of the of recovering flash steam and
= Sensible Heat at trap and the corresponding tem- why we want to recover it, there
the Higher Pressure peratures of those pressures in are two important practical points
- Sensible Heat at saturated steam. The higher the which should be noted:
the Lower Pressure initial pressure and the lower the First, one pound of steam
÷ Latent Heat of flash recovery pressure, the has a specific volume of 26.8
the Lower Pressure greater the quantity of flash cubic feet at atmospheric pres-
steam produced. sure. It also contains 970 BTU’s
To simplify this procedure we
can use the chart (Fig. 51) to read It must be noted here that the of latent heat energy. This means
off the percentage of flash steam chart is based upon saturated that if a trap discharges 100
produced by this pressure drop. steam pressure/temperature con- pounds per hour of condensate
An example would be if we had ditions at the trap inlet, and that from 100 PSIG to atmosphere,
100 PSIG saturated steam/con- the condensate is discharged as the weight of flash steam
densate being discharged from a rapidly as it appears at the trap. released will be 13.3 pounds per
steam trap to an atmospheric, Steam traps that subcool the con- hour, having a specific volume of
gravity flow condensate return densate, such as balanced 356.4 cubic feet. It will also have
system (0 PSIG), the flash per- pressure thermostatic and 12,901 BTU’s of latent heat ener-
centage of the condensate would bimetallic traps, hold condensate gy. This will appear to be a very
be 13.3% of the volume dis- back in the system allowing it to large quantity of steam and may
charged. give up sensible heat energy and well lead to the erroneous conclu-
causing it to cool below the satu- sion that the trap is passing live
Conversely, if we had 15
rated steam temperature for that steam (failed open).
PSIG saturated steam discharg-
pressure. Under those circum- Another factor to be consid-
ing to the same (0 PSIG)
stances, we must calculate from ered is that we have just released
atmospheric gravity flow return
the formula above the percentage 13.3 pounds of water to the
system, the percentage of flash
of flash steam produced, but the atmosphere that should have
steam would be only 4% by vol-
amount of subcooling (the con- gone back to the boiler house for
ume. These examples clearly
densate temperature) must be recycling as boiler feed water.
show that the amount of flash
known before calculating. Since we just wasted it, we now
released depends upon the differ-
have to supply 13.3 pounds of
fresh city water that has been
Figure 51: Percent Flash softened, chemically treated and
Steam
Pressure Atmosphere Flash Tank Pressure (psig)
preheated to the feedwater sys-
(psig) 0 2 5 10 15 20 30 40 60 80 100 tem’s temperature before putting
5 1.7 1.0 0 this new water back into the boil-
10 2.9 2.2 1.4 0 er.
15 4.0 3.2 2.4 1.1 0
Secondly, the actual forma-
20 4.9 4.2 3.4 2.1 1.1 0
tion of flash steam takes place
30 6.5 5.8 5.0 3.8 2.6 1.7 0
40 7.8 7.1 6.4 5.1 4.0 3.1 1.3 0
within and downstream of the
60 10.0 9.3 8.6 7.3 6.3 5.4 3.6 2.2 0 steam trap orifice where pressure
80 11.7 11.1 10.3 9.0 8.1 7.1 5.5 4.0 1.9 0 drop occurs. From this point
100 13.3 12.6 11.8 10.6 9.7 8.8 7.0 5.7 3.5 1.7 0 onward, the condensate return
125 14.8 14.2 13.4 12.2 11.3 10.3 8.6 7.4 5.2 3.4 1.8 system must be capable of carry-
160 16.8 16.2 15.4 14.1 13.2 12.4 10.6 9.5 7.4 5.6 4.0 ing this flash steam, as well as
200 18.6 18.0 17.3 16.1 15.2 14.3 12.8 11.5 9.3 7.5 5.9 condensate. Unfortunately, dur-
250 20.6 20.0 19.3 18.1 17.2 16.3 14.7 13.6 11.2 9.8 8.2 ing the past 80 years, condensate
300 22.7 21.8 21.1 19.9 19.0 18.2 16.7 15.4 13.4 11.8 10.1 return lines have been sized
350 24.0 23.3 22.6 21.6 20.5 19.8 18.3 17.2 15.1 13.5 11.9
using water volume only and did
400 25.3 24.7 24.0 22.9 22.0 21.1 19.7 18.5 16.5 15.0 13.4
not include the flash steam vol-
Percent flash for various initial steam pressures and flash tank pressures. ume that is present.
52
Condensate Management
53
a
54
Condensate Management
a
exceeds the available flash
steam supply. The deficit can
Figure 53
Boiler Blowdown Heat
Recovery System
When all else fails, in many
facilities there is always a need
for hot water, especially in the
boiler house. This can be sup-
plied via a heat exchanger and
the use of flash steam.
3. It is also preferable to select
an application for the flash
steam which is reasonably
close in proximity to the high
pressure condensate source.
Piping for low pressure
steam is inevitably of larger
diameter. This makes it
somewhat costly to install.
Furthermore, the heat loss
from large diameter pipes
reduces the benefits obtained
from flash steam recovery
and in the worst cases could
outweigh them.
Flash steam recovery is sim-
plest when being recovered from
a single piece of equipment that
condenses a large amount of
steam, such as a large steam to
Safety Valve
Boiler
Blowdown
Source
Flash Vessel
Cold Water
Hot Water
water converter or a large air
handling coil bank, but we can-
not forget that flash steam
recovery systems by design will
apply a backpressure to the
equipment that is being drained
or to the flash steam source.
Another very common area from
which flash steam is recovered is
boiler blowdown. Dissolved solids
that create the need for boiler
blowdown drop out and will pro-
duce usable flash steam and
condensate.
Boiler blowdown flash steam
recovery (Fig. 53) is a very effi-
cient method for recovery. It not
only is a continuous supply of
valuable heat energy to be uti-
lized, but it is in close proximity to
an area of definite need as in the
boiler feed or deaerator system
that demands a constant source
of low pressure heat energy for
preheating the boiler make up
water supply. This simple instal-
lation is shown below.
Control Valve
Steam
Air
Flow
Steam Trap
Flash
Vessel
Figure 54
Control of Flash
Steam Pressure
Condensate
Another area that works very start up of the system. Condensate Recovery
well in the utilization of flash Another method of flash
Systems
steam recovery is large multi- steam recovery is through a vent The importance of effective
section air heating coils (Fig. 54). condenser on a receiver (Fig. 55 condensate removal from steam
Many times flash steam can be on following page). Flash steam spaces has been stressed
supplied to a coil added to the is allowed to flow up through the throughout this course. If maxi-
system to maximize use of the condenser (heat exchanger), that mum steam system efficiency is
flash steam supplied by the pri- has a supply of fluid flowing to be achieved, the best type of
mary coils in the system. An through it, to capture the heat steam trap must be fitted in the
example is shown in the following energy contained in the flash most suitable position for the
sketch. This example clearly ful- steam. This type of system is an application in question. Having
fills the basic requirements of “atmospheric” pressure system, considered how to best utilize any
having a flash steam recovery which allows condensate from flash steam which may be avail-
system which is in step with the flash steam to flow by gravity able, we must now decide what to
demand. back into the original condensate do with the condensate which
Only when air coils are called receiver. This provides the user remains.
upon to supply heat does the with recovery of heat energy and There are a number of rea-
flash steam recovery system the complete recovery of all con- sons why condensate should not
become available, and it can then densate from that system, and be allowed to discharge to drain.
be condensed in the first air coil enables the user to accomplish The most important consideration
which is essentially a pre-heater. this without presenting all of the is the valuable heat which it con-
This simple arrangement ensures equipment in that system with tains even after flash steam has
that higher pressure traps are not any backpressure. been recovered. It is possible to
subjected to any backpressure on use condensate as hot process
55
Condensate Management
Heat Exchanger
Condensate
Return System
Figure 55
Flash Steam Condensor or Heater
water but the best arrangement is costs. One justifiable reason for areas of a plant to determine con-
to return it to the boiler house, not returning condensate is the densate quality and providing a
where it can be re-used as boiler risk of contamination. Perforated means to re-route the conden-
feed water without further treat- coils in process vessels and heat sate if contaminated.
ment, saving preheating fuel, raw exchangers do exist and the Vented “open” return sys-
water and the chemicals needed cross contamination of conden- tems have been utilized for 80
for boiler feed treatment. These sate and process fluids is always plus years where the conden-
savings will be even greater in a danger. If there is any possibil- sate is allowed to flow by
cases where effluent charges ity that the condensate is gravity to a central collection
have to be paid for the discharge contaminated, it must not be receiver and then the use of
of valuable hot condensate down returned to the boiler. These electrically driven pumps
the drain. problems have been lessened by return it to the boiler house
Condensate recovery sav- the application of sensing sys- when these receivers are full.
ings can add up to 25 to 30% of tems monitoring the quality of
the plant’s steam generating condensate in different holding
56
Condensate Management
57
Condensate Management
58
Figure 59
“OPEN” Atmospheric
System
Condensate to Pump
Filling Head
Vent to Atmosphere
Inlet Strainer
aa
Pump Exhaust
Figure 60
Heat
Exchanger
Operating Steam
or Gas Supply
Pressure
Powered
Pump
“Closed” System
Air Vent
Condensate Management
Steam Trap
When Steam
Supply is
Used
Temperature
Control
Pressure
Powered
Pump
Height (H)
Steam Supply
Float
Type
Steam
Trap
Condensate
Return Line
59
Condensate Management
All temperature controlled When the pump is pumping condensate lines have historically
equipment, as discussed earlier, condensate, the condensate been sized for water volume only
has fluctuating steam pressures being produced in the equipment and not for the volume of flash
inside the equipment based upon is allowed to fall by gravity into steam produced from traps dis-
equipment load demands. the reservoir pipe, again ensuring charging to a lower pressure. If
Historically, we have depended that the equipment is kept dry. there is no other possible area to
upon steam pressure to “lift” con- Upon completion of the pumping discharge a steam trap into
densate out of a piece of cycle, the pressure inside the except a condensate return line,
equipment via the steam trap into pump body is equalized back to the installation shown above
the condensate return system. the reservoir piping and the col- should be followed. This breaks
Because of the operation of the lected condensate in the away from the tradition of dis-
temperature control valves, there reservoir pipe falls by gravity into charging steam traps into
would be times that there would the pump body, starting the cycle condensate return lines at 90° to
be sufficient steam pressure at all over again. the condensate return line by lit-
the trap inlet to overcome the Because this system of con- erally injecting the steam trap
condensate return line pressure densate removal and recovery is discharge into the condensate
or the required lift. designed to be a “closed” system, return line so that the actual out-
At other times during opera- there is no need for vacuum let of the trap discharge is below
tion, there would not be enough breakers as we have used in the the normal water level in the
steam pressure supplied to the past. In fact, the equipment is return line and discharging in the
equipment to lift condensate. At encouraged to work into a vacu- direction of condensate flow.
those times we would begin to um condition if it is required by This prevents sections of
flood the heat exchange equip- the temperature control system. flash steam being trapped by
ment, causing either product Even in vacuum conditions, con- walls of water on both sides
temperature fluctuations or even densate is allowed to fall by which, when steam condenses,
worse, freezing of the air coils, gravity into the pump because the causes a vacuum and violently
because we were unable to effec- pump is equalized in pressure to pulls the two walls of water
tively remove the condensate. the outlet of the equipment together. These shock waves are
Installing a pumping device through the exhaust of the pump. transmitted down the return pip-
between the equipment and the ing causing hammering noises
trap (Fig. 61) allows for conden- Waterhammer In Condensate and pipe movement.
sate to be recovered and Return Lines
In “closed” systems, conden-
removed from the steam equip- Waterhammer in condensate sate return piping must be sized
ment at all times during return lines is an indication of two for two phase flow at low veloci-
operation, whenever the steam possible problems. In “open” sys- ties or the same situation will
pressure is sensed in the equip- tems, atmospheric returns, the occur.
ment. causes of waterhammer are air
When the steam pressure is pockets and/or steam traps dis-
greater than the condensate charging into a flooded section of
return pressure or lift, steam piping. Air pockets in the line are
pressure alone lifts the conden- easily remedied by adding an air
sate out through the steam trap. venting device for water systems,
However, when steam pressure a float actuated device that will
in the equipment is equal to or remain open until it is full of water
lower than that of the condensate and air eliminated. These
return system or lift, condensate devices are mounted on the high
completely fills the pump body, points of the return line and vent
steam pressure is supplied to the to atmosphere. Steam traps dis-
pump and the condensate is charging into a water line should
pumped out through the steam be avoided at all costs.
trap into the condensate return As we mentioned earlier in
system. the flash steam recovery section,
60
Condensate Management
Figure 61 Temperature
Closed System Control Valve Condensate Return
Air Vent
Reservoir Piping
Float &
Thermostatic
Trap
Pressure
Powered
Pump
Figure 62
Discharging Into Condensate Return Line Sparge Puipe to made of
Stainless Steel
Sparge Pipe
61
Steam Utilization Course Review
62
Steam Utilization Course Review
11. Properly sized steam traps are sized to ____________________________ and not to
________________________________ ___________________________________.
12. How many tracer lines are recommended for an 8” product pipe to keep
temperatures at or above 150*F?
_____________________________________________________________________
13. Into what two groups can pressure reducing valves be divided?
1. ___________________________________________________________________
2. ___________________________________________________________________
14. What 3 factors attribute to proper reliability and accuracy of control valves?
1. ___________________________________________________________________
2. ___________________________________________________________________
3. ___________________________________________________________________
15. The term used when condensate is discharged to a lower pressure and partially
vaporizes is __________________________________________________________.
16. Calculate the percent of flash steam created when 100 psig condensate is
discharged to atmosphere (Sh L.P. - SH H.P.) ) Lh L.P.)
63
64
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