Copyright 2017
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 100 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
STEAMGENERATION 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
Swivel Connector Traps 37
STEAM TRAP TESTING METHODS 37
Visual Testing 37
Ultrasonic Trap Testing 37
Temperature Testing 38
Conductivity Testing 38
Wireless Steam Trap Monitoring 39
BY-PASSES AROUND STEAM TRAPS 40
PREVENTIVE MAINTENANCE PROGRAMS 40
Steam Trap Fault Finding 40
Steam Trap Discharge Characteristics 42
STEAM TRAP SELECTION 42
Waterlogging 42
Lifting of Condensate 43
REQUIREMENTS FOR STEAM TRAP/APPLICATIONS 43
Application Requirements 43
Steam Trap Selection Chart 44
Steam Trap Sizing 45
STEAM TRACING 46
CRITICAL TRACING 46
NON-CRITICAL TRACING 46
Attaching Tracer Lines 47
JACKETED PIPE TRACERS 48
STEAM TRACING MANIFOLDS 49
CONDENSATE MANIFOLDS 49
CONDENSATE MANAGEMENT 51
FLASH STEAM RECOVERY 52
CONDENSATE RECOVERY SYSTEMS 56
Electrically Driven Pumps 58
Non Electric Pressure Powered Pumps 59
WATERHAMMER IN CONDENSATE RETURN LINES 61
5
Basic Steam Engineering Principals
6
Basic Steam Engineering Principals
it condenses and the water is the per pound). This is because the make the steam flow.
same temperature of the steam. non-compressible liquid (water) The need for optimum
The sum of the two heat con- is now a compressible gas. The efficiency increases with every
tents, sensible and latent, are higher the pressure, the higher rise in fuel costs. Steam and
known as the Total Heat. the temperature. The lower the condensate systems must be
A very interesting thing hap- latent heat content of the steam, carefully designed and main-
pens when we go through this the smaller the volume the steam tained to ensure that unnecessary
exercise and that is the change occupies (Fig. 3). This allows the energy waste is kept at a mini-
in volume that the gas (steam) plant to generate steam at high mum. For this reason, this course
occupies versus the volume that pressures and distribute that will deal with the practical aspects
the water occupied. One pound steam in smaller piping to the of energy conservation in steam
of water at atmospheric pressure point of usage in the plant. This systems, as we go through the
occupies only .016 cubic feet, but higher pressure in the boiler pro- system.
when we convert this water into vides for more driving force to
steam at the same pressure, the
Figure 1
steam occupies 26.8 cubic feet Total Heat of Steam
for the same one pound.
1200Total Heat of Steam Total Heat of Steam (L&S)
The steam that we have just
created on our stove at home 1100
1200 Total Heat of Steam (L&S)
will provide humidification to the
1000
of steam
600
500
will be utilized, there has to be a
BTUs
500
difference in pressure. 400
400 Sensible heat (S) available
Therefore, our pan type steam 300
at various pressures
Sensible heat (S) available
generator will not create any sig- 300
200 at various pressures
nificant force to move the steam. Sensible heat at atmospheric
200 pressure
Sensible heat at atmospheric
A boiler, for all practical pur- 100
pressure
100
poses, is a pan with a lid. There 0
0 10 20 30 40 50 60 70 80 90 100
are many types of boilers that are 10 20 30 40 50 60 70 80 90 100
subjects of other courses. We will Pressure, psig
Pressure, psig
simply refer to them as boilers
in this course. If we contain the
Figure 2
steam within a boiler, pressure
will begin to rise with the change
of volume from liquid to gas. As SteamSaturation
Steam Saturation Curve
Curve
this pressure rises, the boiling 500
500
point of the water inside also Areaofofsuperheated
Area superheated
rises. If the pressure of saturated steam
steam
Boiling
Boiling pointpoint of water
of water
steam is known, the temperature 400
400 (temperature of saturated
(temperature of saturated
F
Temperature F
7
Basic Steam Engineering Principals
8
Basic Steam Engineering Principals
9
Steam Generation
Boilers & Boiler Efficiency The sizing of a boiler for It requires about one to two
Boilers and the associat- a particular application is not minutes to place the boiler back
ed firing equipment should be a simple task. Steam usages on line. And, if theres a sud-
designed and sized for maximum vary based upon the percent- den load demand, the start-up
efficiency. Boiler manufacturers age of boiler load that is used sequence cannot be acceler-
have improved their equipment for heating versus process and ated. Keeping the boiler on line
designs to provide this maximum then combining those loads. assures the quickest response to
efficiency, when the equipment is These potentially wide load vari- load changes. Frequent cycling
new, sized correctly for the load ations are generally overcome also accelerates wear of boil-
conditions, and the firing equip- by installing not just one large er components. Maintenance
ment is properly tuned. There are boiler but possibly two smaller increases and, more importantly,
many different efficiencies that units or a large and a small the chance of component failure
are claimed when discussing boil- boiler to accommodate the load increases.
ers but the only true measure of a variations. Boiler manufacturers Once the boiler or boilers
boilers efficiency is the Fuel-to- usually will recommend that the have been sized for their steam
Steam Efficiency. Fuel-To-Steam turndown ratio from maximum output, BTUs or lb./hr, then the
efficiency is calculated using load to low load not exceed 4:1. operating pressures have to be
either of two methods, as pre- Turndown ratios exceeding 4:1 determined. Boiler operating
scribed by the ASME Power Test will increase the firing cycles and pressures are generally deter-
Code, PTC4.1. The first method decrease efficiency. mined by the system needs as to
is input-output. This is the ratio of A boiler operating at low product/process temperatures
BTUs output divided by BTUs load conditions can cycle as needed and/or the pressure
input, multiplied by 100. The frequently as 12 times per hour, losses in transmission of the
second method is heat balance. or 288 times a day. With each steam in distribution throughout
This method considers stack cycle, pre- and post-purge air the facility. (Fig. 4)
temperature and losses, excess flow removes heat from the boil-
air levels, and radiation and con- er and sends it out the stack.
vection losses. Therefore, the This energy loss can be elimi-
heat balance calculation for fuel- nated by keeping the boiler on
to-steam efficiency is 100 minus at low firing rates. Every time
the total percent stack loss and the boiler cycles off, it must
minus the percent radiation and go through a specific start-up
convection losses. sequence for safety assurance.
10
Steam Generation
11
Steam Generation
Velocity ft/min
3"
F G
commonplace as design criteria. Heating Systems 4"
6000
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
1 "
reduced waterhammer potential 14 2"
16 "
and piping erosion. "
1000
25 0
6000
Capacity lb/h
20 0
0
15 25
tical. Steam is generated and 5000
1 00
4000 1 5
7
3000
25
2000
ferences in the surroundings and
5
0
25 00
as the steam, the condensate 500
2 0
0
15 25
400
1 00
(water) is still going to erode the 1 5
7
300
bottom of the pipe. This erosion
50
25
100
steam velocity, the less erosion
Steam Pressure psig
will take place.
(Saturated Steam)
The chart (Fig. 5) will be very
helpful in sizing steam carrying
pipes for proper velocities. that can be insulated. A sin- a single foot of pipe. The net effect
gle foot of 3 pipe with 100 is the consumption of more fuel to
EXAMPLE: PSI steam in it exposed to an produce this lost energy. (Fig. 6)
Steam flow is 1,000 lb/hr. ambient temperature of 60F will
Find pipe size for 100 psig and radiate 778 BTUs per hour of
25 psig. operation. The latent heat energy
The steam system piping and content of 100 PSI steam is 880
associated equipment, contain- BTUs per pound.
ing this high heat energy source Nearly a pound of steam per
(steam), will constantly be a hour per foot of pipe is con-
source of radiation losses. A sim- densed just in distributing this
ple but often overlooked energy valuable energy supply to the
savings is to insulate all the pip- point of usage. Flanges, valves,
ing, steam and condensate, and strainers and equipment will
all heat exchange equipment waste much more energy than
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
450 369 230 431 262 497 296 615 358 742 422 859 482 933 519
Air and Non-Condensable end of the main line. The last example would be 100 PSIG sat-
Gases In The Steam System kettle, therefore, would be fed urated steam has a temperature
We know that when steam with a mixture of steam and non- of 338F, if in this steam there
comes into contact with a cooler condensable 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 condensa- ture or latent heat of steam. It of this mixture would be 331F,
tion takes place, the condensate will, therefore, cause a reduction or 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
heat transfer. A film of water accepted that a thin layer of air it will be absorbed into the con-
only 1/100 inch thick offers the only 0.04 inches thick can offer densate. This reduces the pH
same resistance to heat trans- the same resistance to the flow of the condensate and creates
fer as a 1/2 inch thick layer of of heat as a layer of water 1 inch a substance known as carbonic
iron or a 5 inch thick layer of thick, a layer of iron 4.3 feet thick acid. The acidity of the conden-
copper. The air and other non- or a layer of copper 43 feet thick. sate will then attack the piping,
condensable gases in the steam Even a small amount of air in a heat exchange equipment or any
cause a variety of problems to steam system will cause fairly other part of the steam system
steam systems. Foremost is the drastic temperature losses, an that it comes into contact with.
reduction of area to deliver the
steam. Air is a simple bi-product Figure 7
of 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. 250F Surface
Air and other non-condens-
able gases are released when 210F
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
collect at high points and at the
end of the steam piping. If a
steam line feeds a series of heat
exchangers, such as cooking Steam Air Condensate Water Water
kettles, the air collects at the at 15 Film Film Film Being
psi Heated
13
Steam System Basics
14
Steam System Basics
Steam Piping Design heat the piping. This transfer of steam distribution main piping
Considerations heat energy creates condensate, network, condensate drip sta-
Since we have already estab- (Fig. 11 and 12) or if the piping tions need to be installed to
lished that steams principle job is is already at the same tempera- remove this condensate from the
to give up its latent heat energy ture as the steam, there are still system. These pockets should
and re-condense to water, by loses to the ambient air condi- be designed with as much care
doing so, we can assume that it tions, even when insulated. This as possible. This allows the con-
will do so anywhere and every- liquid condensate would con- densate a low point in which to
where (Fig. 10) because all heat tinue to build up to the point of drop out of the steam flow and
flow is from hot to cold. When blocking all of the steam piping be removed by steam traps.
the steam is admitted into the if it is not properly removed,
distribution piping network, the and create waterhammer in the
steam immediately begins to steam system. Periodically in a
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 70F. Based on Sch. 40 pipe to 250 psi
Sch. 80 above 250 except Sch. 120 5 and larger above 800 psi
Steam Main Size 0F
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 0F, 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 70F. Insulation 80% efficient.
Load due to radiation and convection for saturated steam.
Steam Main Size 0F
Pressure Correction
psi 2 2-1/2 3 4 5 6 8 10 12 14 16 18 20 24 F
actor *
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 0F, multiply load value in table for each main size by correction factor shown.
16
Steam and Condensate Metering
The proper design of these densate during the low pressure specific volume and temperature.
drip stations is fairly simple. The times of shut down and start-up Performance of different types of
most common rules to follow are: of the steam main. Remember, meters when used on steam will
1. Drip Stations on steam the intent of the distribution line vary and the measurement may
mains must be located at is to deliver steam at as high a not always be accurate. Most
all low points in the system, quality as possible to the heat meters depend on a measure-
elevation changes, direction- process equipment. The equip- ment of volume. Since volume
al changes, expansion loops ment downstream will suffer depends on pressure, measure-
and at all dead ends. severe damage if we dont do ments need to be taken at a
2. In the horizontal run of the this step correctly. constant pressure to the meter or
steam main piping drip sta- else specific corrections have to
Steam and Condensate be applied. Readings taken under
tions must be located at
regular intervals of 100 to
Metering fluctuating pressure conditions
200 feet. Difficulties in energy manage- are inaccurate unless the meter
3. The drip station itself is a ment of steam arise from the fact can automatically compensate.
section of piping connected that it is often a totally unmeasured Steam metering should be
to the bottom of the main service. Metering (Fig. 13) starting done downstream of a good qual-
piping. The diameter of the in the boiler house, is essential ity reducing valve which maintains
drip station pipe should be if savings are to be validated. a constant pressure. Readings
the same size as the steam Although fuel consumption is fairly should be interpreted using the
main piping up to 6 piping. easy to monitor, measurement of meter factor and the meter cali-
For steam main piping larger steam is a bit more difficult. A bration should be checked from
than 6 the drip station pip- steam meter must compensate time to time.
ing shall be 1/2 the nominal for quality as well as pressure,
pipe size but no less than
Figure 13
6.
4. The vertical drop of the drip A Typical Steam Metering Station
Eccentric
station shall be 1-1/2 times Pipeline Reducers
the diameter of the steam Strainer Steam
Meter
main but not less than 18
inches.
5. Horizontal run of the steam
piping must fall 1/2 in 10 Steam
Separator 6 Pipe 3 Pipe
feet towards drip stations. Separator Diameters Diameters
&Trap Set
The reasoning behind these
rules is simple. First, the diam-
eter of the hole in the bottom of
Although steam metering is most often carried out in the boiler
the steam main should be such
house, it is also important in order to determine:
that it can allow the water ample
area to fall into. Gravity is our 1. Custody transfer. To measure steam usage and thus determine
only force to allow this to hap- steam cost:
pen. If the diameter of the drip a) Centrally at the boiler house
station was too small, the veloc- b) At all major steam using areas
ity of the water would simply
2. Equipment efficiency. Identifying major steam users, when loaded
allow it to pass either on the side
to capacity or idle; also peak load times, plant deterioration and
or over the top of the hole. The
cleaning requirements.
length of the drip station allows
the water to fall far enough out of 3. Process control. Meters indicate that the correct steam require-
the steam flow as to not be pulled ment and quantity is supplied to a process, when bypass lines are
back out and forced on down the opened; and when valves and steam traps need attention.
piping, and to provide the steam 4. Energy efficiency. Compare the efficiency of one process area with
trap with some hydraulic head another; monitor the results of plant improvements and steam sav-
pressure for drainage of con- ing programs.
17
Steam and Condensate Metering
Why Measure Steam? checks to be kept on individual Costing and Custody Transfer
Steam is still the most widely plant performance. Costs can Steam meters can measure
used heat carrying medium in the be analyzed for each part of the steam usage and thus steam
world. It is used in the processes process and pay-back records cost.
that make many of the foodstuffs can be established following the
(a) Centrally
we eat, the clothes we wear, implementation of energy saving
measures. (b) At major steam using
components of the cars we ride
centers.
in and the furniture we use. It The steam meter is the
is used in hospitals for steriliza- first basic tool in good steam Steam can be costed as a
tion of instruments and surgical housekeeping - it provides the raw material at various stages
packs, in the refining process knowledge of steam usage and of the production process thus
for crude oil based products, in cost which is vital to an efficiently allowing the true cost of individu-
chemical production, and in the operated plant or building. The al 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 indi-
attempt to monitor its usage and to steam pressure for equipment
cate process efficiency. For
costs, as they would for other or for the flow of this valuable
example, whether idle machin-
raw materials in the process. heat energy source to heat trans-
ery is switched off; whether
But a steam meter wont plant is loaded to capacity and fer equipment is mandatory for
save energy. This statement whether working practices are todays industrial and HVAC
is sometimes used as a reason satisfactory. It will also show the steam users for efficient usage of
for not installing steam meters. deterioration of plant overtime, this energy source. The control
It cannot be argued against if allowing optimal plant cleaning of heat flow to product tempera-
steam meters are evaluated in or even replacement, to be cal- tures in process equipment is
the same way as other pieces culated. Further, it can establish mandatory, otherwise production
of energy saving equipment or peak steam usage times or iden- wastage becomes intolerable,
schemes. tify sections or items of plant which means lost profits.
A statement such as the which are major steam users. The control of steam pres-
one quoted earlier does little to This may lead to a change in sures and the regulation of
ease the frustration of the Energy production methods to even out steam flow to heat exchangers is
Manager or Factory Manager try- steam usage and ease the peak accomplished by several differ-
ing to establish where steam is load problems on boiler plant. ent types of valves. This section
being used, how much is being is intended to describe the differ-
used and whether it is being Energy Efficiency ent types of valves used for these
used wisely and effectively. Steam meters can be used operations and the differences
All too often, when the need to monitor the results of energy that will help the user in deciding
for a steam meter is accepted, saving schemes and to compare which type of valve is necessary
only central monitoring i.e. in the the efficiency of one piece of for his specific application. This
Boiler House or a major Plant plant with another. section will not go into complete
Room is carried out. Monitoring Process Control descriptions of these valves but
at branch mains or at each plant just an overview of their oper-
Steam meters can indicate
room, a section of the process ational characteristics and the
that the correct quantity of steam
or 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 perature and pressure.
will establish overall steam flow
figures (and thus, costs), depart-
mental monitoring will give data
which is much more useful.
Such steam meters will enable
18
Control and Regulation of Steam
Pressure Reducing Valves Direct Acting Control Valves the underside of the diaphragm
Most steam boilers are The direct acting valve is tends to close the valve as does
designed to work at relatively the simplest design of reducing the inlet pressure acting on the
high pressures, generally above valve (Fig. 14a). Reduced pres- underside of the main valve itself.
the steam pressure required in sure from downstream of the The control spring must be capa-
equipment, and should not be valve acts on the underside of ble of overcoming the effects
operated at lower pressures. the diaphragm A, opposing the of both the reduced and inlet
Operation at lowered pressures pressure applied by the control pressures when the downstream
causes reduced efficiencies and spring B. This determines the pressure is set. Any variation in
increased potential for boiler opening of the main valve C the inlet pressure will alter the
carryover. For this reason, the and the flow through the reduc- force it produces on the main
highest efficiency is maintained ing 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
from open to the closed position,
boiler is capable of producing. To in that it allows greater fluctua-
there must be a build up of pres-
produce lower pressure steam at tion of the downstream pressure,
sure under the diaphragm A.
the point of use, a building pres- under unstable load demands,
This overcomes the pressure
sure reducing valve should be and these valves have relatively
exerted by the control spring
used. This system design allows low capacity for their size. It is
B. This action results in an
for much smaller distribution pip- nevertheless perfectly adequate
inevitable variation of the down-
ing, reducing costs and reducing for a whole range of simple appli-
stream pressure. It will be the
heat losses from these pipes. cations where accurate control
highest when the valve is closed,
Also every piece of steam using is not essential and where the
or nearly closed, and will droop
equipment has a maximum safe steam flow is fairly small and
as the load demand increases.
working pressure which can- reasonably constant.
The outlet pressure acting on
not 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 great-
er in lower pressure steam. More
heat content per pound means
less pounds of steam to do the
work. These are not the only
reasons for reducing steam pres-
B
sure. Since the temperature of
saturated steam is determined by
its pressure, control of pressure
is a simple but effective method
of accurate temperature control.
This fact is used in applications A
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 vented con- Inlet Outlet
densate return receivers.
Most pressure reducing
valves currently available can be
divided into three groups and C
their operation is as follows:
19
Control and Regulation of Steam
by controllers will provide pres- Selection & Application the type of control valve select-
sure reduction with even more The first essential is to select ed. A valve that is too large in
accurate control. Controllers the best type of valve for a given capacity capabilities will have
sense downstream pressure fluc- application and this follows to work with minimum open-
tuations interpolate the signals logically from the descriptions ing between the valve head and
and regulate an air supply signal already given. Small loads seat on less than maximum
to a pneumatic positioner which where accurate control is not loads which can and does cause
in turn supplies air to a dia- vital should be met by using the wire-drawing, valve cutting, and
phragm opening a valve. Springs simple direct acting valves. In erosion. In addition, any small
are utilized as an opposing force all other cases, the pilot oper- movement of the oversized
causing the valves to close upon ated valves will be the best head will produce a relatively
loss of or a reduction of air pres- choice, particularly if there are large change in the flow through
sure applied on the diaphragm. periods of no demand when the the valve orifice in an effort to
Industry sophistication and downstream pressure must not accommodate load changes,
control needs are demanding be allowed to rise. almost always allowing more
closer and more accurate con- or less flow through the valve
Oversizing, a common
trol of steam pressures, making than was actually needed caus-
industry practice, should be
Pneumatic control valves much ing larger pressure fluctuations
avoided at all costs regardless of
more popular today. downstream.
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 must be sized to handle Manual Control Valves
reducing valve will be less prone the maximum steam flow of the Manual valves can be applied
to wear and will give more reducing valve at the desired set to a piece of equipment to con-
accurate control. Where it is nec- relief pressure. ASME standards trol the energy supplied to the
essary to make bigger reductions state that those set relief pres- process as simply as they are
in pressure or to cope with wide sures are to be 5 PSI above the used to regulate the flow of other
fluctuations in loads, it is rec- equipment maximum operating fluids. The major drawback of
ommended to use two or more pressure for equipment operat- manual valves to control tem-
valves in series or parallel to ing up to 70 PSI, and not to peratures is that these valves
improve controllability and life exceed 10% greater than maxi- will undoubtedly need frequent
expectancy of the valves. mum operating pressures for adjustments and monitoring to
Although reliability and accu- equipment operating above 70 maintain just the correct temper-
racy depend on correct selection PSI but below 1000 PSI. atures under constantly changing
and sizing, they also depend on Temperature Control Valves load conditions, which is the
correct installation. case of most pieces of process
Most types of steam equip-
Since the majority of reduc- equipment.
ment need to utilize some form
ing valve problems are caused by of temperature control system. Self Acting Control Valves
the presence of wet steam and/ In process equipment, product Self-Acting Control Valves
or dirt, a steam separator and quality is often dependent upon (Fig. 17) are operated by a sen-
strainer with a fine mesh screen accurate temperature control, sor system that senses the
(100 mesh) are fitted before the while heating systems need to product temperatures, causing
valve. The strainer is installed be thermostatically controlled in a heat sensitive fluid to expand
with the Y portion of its body order to maintain optimum com- or contract based on the prod-
just below horizontal in a hori- fort conditions. From an energy uct temperature transferring heat
zontal steam line to prevent the saving point of view, control- energy to the sensors fluid. This
body from filling up with conden- ling the steam energy supply to expansion and contraction of the
sate during periods of shut down a process piece of equipment heat sensitive fluid is transmit-
and to ensure that the full area of to maintain the desired product ted up through a capillary tubing
the screen is effective in prevent- temperature, whether air or any arrangement and the respective
ing dirt from passing through. product, is mandatory. If process expansion and contraction of the
As a part of a Preventative systems are not controlled to the fluid applies or relieves pres-
Maintenance Program all strain- desired temperatures then the sure to a valve head, causing
ers should be installed with system will run wild either not the valve head to move. This
blowdown valves for regular dirt providing the required heat ener- movement allows the control
removal. All upstream and down- gy or over heating the product valve to throttle the steam flow
stream piping and fittings should to unacceptable levels. A very to the equipment. These control
be sized to handle the maximum important item to remember in the systems are calibrated by the
steam flows at a reasonable use of temperature control valves amount of heat sensitive fluid to
velocity of not more than 6,000 on systems is that in order to reg- control within a given tempera-
feet per minute. Eccentric pipe ulate the heat energy transferred ture range and can be set to any
reducers, with the flat side on the to the process the control valve temperature between the upper
bottom, should be used to pre- effectively regulates not only the and lower limits by means of an
vent any build up of condensate flow rate of energy in pounds adjustment knob.
in the piping during shutdown. per hour, but, also accomplishes
If the downstream equipment temperature control by regulating
is not capable of withstanding the saturated steam pressure/
the full upstream steam pressure, temperature levels admitted
then a safety relief valve must be to the process heat exchange
fitted either on the downstream equipment. Temperature control
piping or the specific piece of can be accomplished by several
equipment to be protected from methods and valves:
over pressurization in case of
a valve failure. This safety relief
22
Control and Regulation of Steam
23
Control and Regulation of Steam
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
of the many types of control cur- Traps which give a heavy with proper installation, and will
rently available for use on steam blast discharge, such as a large not air lock or attempt to control
heat exchange equipment. inverted bucket trap, may upset the discharge temperature of the
When a modulating control the accurate temperature control condensate.
is used, the steam trap should of certain units because of the If waterhammer is likely to
be capable of giving continuous sudden change in pressure in the occur, the float and thermostatic
condensate discharge over the steam space which occurs when trap is liable to become dam-
full range of pressures. If maxi- they open. This effect is most aged, for this reason and for the
mum output is required from the likely to be noticeable in equip- longevity of the heat exchange
unit, the trap used must be able ment where the steam space has equipment waterhammer situa-
to discharge condensate and air a high output in relation to its tions should be corrected at all
freely and must not be of a type volume. costs. In most cases waterham-
which is prone to steam lock- The most suitable type of mer in heat exchange equipment
ing. A thermostatic trap is not trap for temperature controlled is caused by water logging of the
suitable because it has a fixed applications is the continuous equipment. Note: Condensate
discharge temperature that may discharge float and thermostat- must be allowed to drain freely
cause condensate to be held ic trap. This trap will discharge by gravity at all times. If conden-
back just when the control valve condensate immediately as it is sate has to be lifted up into a
is wide open and the equip- formed without upsetting pres- return system, then this lifting
ment is calling for maximum heat sure conditions in the steam has to be done by a pumping
transfer. space. It will not steam lock, device.
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 selected to meet all the obvious
should be utilized, these are: a feed tank which requires pre- criteria may be less reliable in a
heating, the efficient trap has system where water treatment
Air Venting done little for the overall effi- compound carried over from the
At start up the trap must ciency of the steam system. boiler, or pipe dirt, is allowed to
be capable of discharging air. interfere with trap operation.
Care must also be taken
Unless air is displaced, steam
in evaluating any application The prime requirement how-
cannot enter the steam space
involving a cooling leg. Draining ever is the adequate removal of
and warming up becomes a
through a bimetallic steam trap air and condensate. This requires
lengthy business. Standing loss-
may look attractive in terms of a clear understanding of how
es increase and plant efficiency
lower temperature discharge and traps operate.
falls. Separate air vents may be
reduced loss of flash steam. On NOTE: WATERHAMMER
required on larger or more awk-
the other hand, if heat is being CONDITIONS IN A STEAM
ward steam spaces, but in most
lost to atmosphere through an SYSTEM DAMAGE MORE THAN
cases air in a system is dis-
unlagged cooling leg, then the JUST STEAM TRAPS AND IS
charged through the steam traps.
net gain in thermal efficiency is A VERY SERIOUS CONDITION
Here thermostatic traps have a
probably negligible. WHICH 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 reservation First, a definition of a steam
Float traps with inbuilt ther- trap may be in order to fully
must be whether the plant itself
mostatic air vents are especially understand the function of this
will accept this waterlogging. It
useful, while many thermodynam- piece of equipment. A steam trap
is permissible with non-critical
ic traps are quite capable of is an automatic valve designed
tracer lines or oversized coils,
handling moderate amounts of to stop the flow of steam so that
but as already indicated, it can
air. The small bleed hole in the heat energy can be transferred,
be disastrous in the case of heat
inverted bucket trap or the orifice and the condensate and air can
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 avoid- matic valve.
Once the requirements of air
ance of trouble. Undoubtedly, This infers that there is some
and condensate removal have
reliability is a major consider- form of automatic motion that
been considered we can turn our
ation. Reliability means the ability must take place. It is designed
attention to thermal efficiency.
to perform under the prevailing to stop the flow of steam so that
This is often simplified into a con-
conditions with the minimum of heat energy can be transferred.
sideration of how much heat is
attention. This portion of the description
profitably used in a given weight
of steam. Given thought, the prevailing is such that it would imply the
conditions can usually be pre- transmission of energy whether
On this basis the thermostat-
dicted. by flowing down a distribution
ic trap may appear to be the best
Corrosion due to the condi- pipe or giving up energy to a
choice. These traps hold back
tion of the condensate or of the product in a heat exchanger. The
condensate until it has cooled
surrounding atmosphere may be definition also continues to say
to something below saturation
known, and can be countered discharge condensate and air
temperature. Provided that the
by using particular materials of as required. This portion of the
heat is given up in the plant itself,
construction. definition implies that some types
to the space being heated or to
may handle differing amounts of
the process, then there is a real Waterhammer, often due to a
either condensate or air, or even
saving in steam consumption. lift after the trap, may be over-
a combination of the two.
Indeed, there is every induce- looked at the design stage and
ment to discharge condensate at can mean unnecessary damage In the beginning, steam traps
the lowest possible temperature. to otherwise reliable steam traps. were manually operated valves.
27
Steam Traps and the Removal of Condensate
The major problem with this type process fluids, foods etc.). These attached to a valve head and
of condensate drainage system differing applications will be dis- pivot point. When condensate
is the variation to changing con- cussed later. Our purpose now is enters the trap, the float rises
densate flows. Condensate, you to explore the operating charac- with the liquid level and mechani-
will recall, is steam that has given teristics of traps and where they cally pulls the valve off the seat
up its enthalpy and reformed into fall within each category. to 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 There are two basic designs but located inside the body on
of a block valve or fixed hole in of steam traps in this cate- most modern day designs of F&T
a drilled plug cock valve can- gory. They are the Float and traps.
not adjust automatically to the Thermostatic and the Inverted Some manufacturers locate
varying 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 auto-
removal would warrant an opera- design. mating the air venting procedure.
tor be present much of the time The first float type trap con- It is also noteworthy to note here
to correct the setting of the valve. sisted of a free floating ball in that this type of trap has one
If condensate was allowed to an expanded area of pipe. It basic application point, and that
back up, less heat transfer would was a top in, bottom out type of is for process purposes. This
take place, causing production to system that required water to fill is due to the fact that this trap
fall off. If, on the other hand, the the expanded area and float the type immediately removes air
condensing load was less, the ball upwards, exposing the outlet and non-condensables as they
operator would have to close the piping and outlet orifice. As long enter the trap and discharges
valve to the point that steam was as condensate was flowing to condensate in the same manner,
not continuously being released. the trap, condensate would flow at saturation temperatures. There
Because of the changing nature from the trap at the same rate. may be some limited uses other
of condensing loads, this would The floats were weighted slightly than process for this type of trap,
be a full-time job. to require water to always be but primarily it is used in this type
True steam trap operation present in the trap and there- of application.
will fall under one of the following by stop steam from leaking into The main advantages to this
three categories: the condensate 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 accu- start up or during the process
2. Thermostatic or Temperature
mulate in the expanded area of procedure. It also has a con-
Controlled
pipe and form a bubble which tinuous discharge characteristic
3. Thermodynamic or Velocity kept condensate from flowing that follows exactly the forming
These categories of traps downward. A piece of pipe was of condensate. In other words,
have distinctive operating added to the inlet piping to the what comes in goes out at the
characteristics and work most trap and a manual valve attached same rate. This type of steam
efficiently when used for their to be periodically blown down trap adjusts automatically to
designed purpose. It would to keep water flowing to the trap either heavy or light loads of
stand to reason that steam and air removed. When the ther- condensing and is not adversely
traps evolved with industry and mostatic bellows steam trap was affected by changes in pressure.
demand. There are really only invented, it soon took the place Condensate removal is also
three applications for steam of the manual valve and auto- done at steam temperature, so
traps: drip stations (located on mated the procedure. heat exchange takes place at
steam delivery lines), tracing constant temperatures, insuring
(steam lines designed to maintain Float And Thermostatic Trap maximum efficiency use of the
a product temperature or keep a Modern Float and Thermo- energy supply.
liquid system from freezing) and static traps (Fig. 21) still have
process (steam used specifically a ball type float, but it is now
for heating products such as air, attached to a lever. The lever is
28
Steam Traps and the Removal of Condensate
29
Steam Traps and the Removal of Condensate
and sinks in the surrounding liq- This type of trap is most internal pressure of the capsule,
uid. In doing so, it pulls the appropriately suited for stable, which is greater than that within
valve head off of the valve seat steady load and pressure condi- the trap body so forcing the valve
and allows the collected air to tions such as one would find on down onto its seat, and prevent-
discharge. Flow from under the a steam distribution system. ing the trap from blowing steam.
bucket starts again. This allows As the steam condenses back to
either more air or steam to begin
Thermostatically or condensate, 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 reliev-
bellows type of steam trap was ing the internal pressure of the
If it is steam, however, the
first manufactured with a bellows capsule and thus lifting the valve
sequence is different. Steam
of copper design. This bellows back off its seat, allowing con-
passes through the bucket vent
(Fig. 23) had a liquid fill which, densate to flow through the trap.
hole to the top of the trap and is
in the beginning, was distilled
condensed by heat losses from The mixture of distilled
water. Modern thermostatic type
the trap body, in particular the water and alcohol in the bel-
traps still have a liquid fill but it
cap or top. This loss is necessary lows is the key to the operating
is made up of a distilled water
to keep steam and condensate temperatures of the balanced
and alcohol mixture and they
coming to the trap. As conden- pressure trap. Most manufactur-
are contained within an enclosed
sate enters under the bucket, ers provide thermostatic traps to
capsule rather than a bellows.
it fills the space and again the operate within 20 to 40 degrees
Alcohol was added to the fill to
bucket loses buoyancy and sinks. of saturated steam temperatures.
lower its boiling point.
Discharge flow is first downward An important point to remem-
from under the bucket, and then The capsules work by ber is that all thermostatically
upward to the discharge orifice. exploiting the difference in the operated steam traps will cause
boiling point between the alco- condensate to back up in the
The biggest advantage to
hol mixture and the surrounding system. The amount of backup
this type of trap is its ability to
condensate. As the temperature in the system is dependent upon
withstand high pressures. It has
of the condensate gets closer the temperature that the trap is
a reasonable degree of toler-
to steam temperature, the mix- designed to operate at, along
ance to waterhammer damage
ture contained within the capsule with the condensate loads com-
but suffers from freeze damage.
gets closer to its boiling point ing to the trap.
In the case of freezing, however,
at a set temperature below that
most of the damage is done to The advantage to this type
of steam (before steam reaches
the body of the trap rather than of trap is its ability to freely and
the trap), the mixture evaporates.
to the mechanism or float. immediately discharge air and
This results in an increase in
The disadvantage to this
trap type is its limited ability
to discharge air and other non-
condensable gases. This is due
to the small vent hole and low
differential pressure driving the
air through it. It is suspect at
times to rapid pressure chang-
es in the system due to the
requirement of a prime being
maintained internally 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 Figure 23
prime has a tendency to boil Stainless Steel Bellows for Thermostatic Trap
off (flash). Without the required
prime, this type of trap fails
open.
30
Steam Traps and the Removal of Condensate
non-condensables as soon as
they enter the traps body, as
in the F & T. These traps have
the ability to operate up to 600
PSIG and provide constant and
consistent levels of subcooling
of the condensate in relation to
the saturated steam pressure/
temperature curve. The most
modern designs have overcome
the earlier models sensitivities
of waterhammer and superheat Valve Open
damage by encapsulating the Figure 24
filling in a much more robust Bimetallic Trap
enclosure.
The disadvantages of ther-
mostatically operated traps is
that there is always a backup
of condensate in the system,
A characteristic of this differing and condensate cannot coex-
which could reduce heat trans-
expansion rate is that the element ist. Another application in which
fer in some applications. These
has to bend or arch. This bending these are used is for non-critical
traps also will require a time
motion can then be used to open tracing (freeze protection) where
period to adjust to load changes
or close a valve accordingly. energy efficiency is maximized.
in the system. Balanced pressure
steam traps are used very com- This type of trap has a very A disadvantage to this type
monly in air venting, distribution, deep subcooling range. This of trap is the lag time required
main drip drainage and in tracing range may be as much as 100F when condensate loads change
applications. below the saturation tempera- to open the trap. Response to
tures, thus causing excessive changes are very slow. Another
back up of condensate into the disadvantage to this type of trap
Bimetallic Thermostatic Traps system. Extreme caution must is that they are highly susceptible
Bimetallic type traps have be taken when applying a bimetal to dirt being caught between the
shown a lot of variation since thermostatic trap to equipment valve head and seat. Also, dirt
their original design. The mod- so as not to cause equipment attaches to the bimetal strips or
ern types of bimetal traps all damage from this backup of con- disks and acts as and insulator,
are common in that the valve densate. changing the discharge charac-
is located on the outlet side of The advantages to this type teristics.
the trap and the bimetal strips, of trap are its ability to with-
or disks, are located inside the stand waterhammer and handle
body. This means that the action fairly large condensate loads for
of the trap is to pull the valve its small physical size. They do
head into the valve seat oppos- discharge air and non-condens-
ing the steam pressure of the able gases well, but because of
system, trying to drive the valve their low temperature sensitiv-
head off of the valve seat. ity (subcooling), they may fully
The bimetal strips or disks (Fig. close before all of these gases
24) are made of two dissimilar are removed. The trap drains
metals, usually of 304 and 316 freely upon drop in temperature
stainless steel. Because they are or system shutdown, so freeze
dissimilar metals, one expands damage should not be a fac-
more than the other at a given tor. Its primary use is for drip
temperature. It is said to have dif- stations on superheated steam
ferent coefficients of expansion. mains, where superheated steam
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 categories 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 varia-
tions 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
and sealed. the valve to allow discharge. There have been many design
The problem with having a This popping action meant that changes over the evolution of
liquid fill on the inside of a bellows it would insure the trapping of the bimetal type of steam trap.
still exists. That problem being the some condensate around the They started off by the strip of
fill over expanding and rupturing capsule at all times and prevent metal expanding and pushing the
the bellows when a small amount over expansion. Superheat has valve into the seat. The obvious
of superheat may be allowed to no condensate, as you know, and problem with that was aligning
reach the trap internals. There also has a tendency of vaporizing the valve head to the seat. Then
have been two attempts to try any condensate in a system once it evolved to pull the valve into
to correct for this. As mentioned it is up to full temperature. This the seat (Fig. 31). In either case
earlier, thermostatic type traps still created over expansion, but though, a single strip of very
usually (but not always) reach a the trap now had a more distinct heavy metal could only create
point where the inside pressure on and off type of operation when a linear tracking of the steam
balances to the outside pres- used on saturated steam lines. curve. Close inspection of this
sure of the bellows. This causes The problem with this type of shows that the deepest subcool-
them to basically average the trap was the design and location ing range occurred at about the
pressure temperature and con- of the liquid fill that causes the highest point in the steam curve.
stantly dribble. One attempt to trap to operate. Later design of This meant that there was a lot of
solve the over expansion problem the capsule put the liquid fill on condensate backed up into the
and dribble discharge was to cre- the outside of the moving part lines. A point to remember is that
ate a single wafer type of capsule of the wafer. The result of the fill these traps can be adjusted by
where the center portion contain- vaporizing and forcing the valve adjustment nuts on the stem. This
ing the valve was forced in during to the seat in part then doubles controls the valve stem stroke
the filling procedure of manu- the thickness of the wafer at its and discharge temperature.
facturing. This created a bowing weakest point. It is also appar- The next step in evolution
type of appearance and caused ent that the fill then be encased was to stack strips that were
the capsule to operate more like in a thicker shell to prevent water of different thickness to both add
the bottom of an oil can. As hammer damage to the element. power to draw on the valve stem
the fill vaporized it popped the As you can see, the operation and also operate at differing levels
portion of the capsule outward of this type of design improve- of the steam curve. This change,
and forced the valve head on to ment for the thermostatic trap is as can be seen in the curve, cre-
the seat. As the fill cooled and much more resistant to damage ates the effect of bending the
contracted it popped again to by either superheat or water ham- straight line discharge of single
the original position and opened mer.
35
Steam Traps and the Removal of Condensate
36
Steam Traps and the Removal of Condensate
37
Steam Traps and the Removal of Condensate
vide continuous modulating and thermocouples all have open steam trap in the system
discharge, the tester again has to their advocates. Unfortunately, that is causing this pressure or it
open the strainer blowdown valve these methods are of limited use could be purely the fact that the
and divert condensate away from since the temperatures of con- condensate return line was sized
the trap inlet so that the trap sees densate and flash steam on the for water only and is not able to
only steam. Again, if it is a prop- downstream side of a correctly accommodate the flash steam
erly operating trap, it will shut off working steam trap are controlled volume without becoming pres-
completely. The ultrasonic test- by the pressure in the conden- surized. Temperature testing will
ing device must be calibrated to sate return system. A very large identify a failed closed steam
eliminate external piping noises percentage of steam traps in the trap due to very low temperatures
or other steam traps discharge. USA are thought to discharge at the inlet of the steam trap.
When testing traps that are in into 0 PSIG, atmospheric grav- Temperature testing of traps to
close proximity, all traps except ity returns, which means that the find failed open traps is by far the
the one being tested must be iso- maximum temperature that could least accurate of all the testing
lated to remove any false signals be expected is 212F, regardless methods available to users.
from the other traps. of the traps operating condition.
It does not necessarily mean that Conductivity Testing
The ultrasonic testing method
a trap has failed when an elevat- A more recent development
can provide very positive answers
ed temperature above 212F is in trap testing uses the electri-
to a traps operating condition as
recorded downstream of a steam cal conductivity of condensate.
long as the operator doing the
trap. More likely it means that the This involves the installation of
test has been trained, has devel-
condensate return line is under a a chamber (Fig. 33) containing
oped some experience with the
positive pressure, which means an inverted weir upstream of the
testing instrument and is able to
that the pressure/temperature steam trap shown as follows.
identify the type of trap operation
by visual inspection. relationship of steam must exist. With the trap working nor-
Thus if we were to record mally, condensate flows under
Temperature Testing a temperature of 227F on the this weir and out through the
Temperature testing of traps outlet side of a trap, this tells trap. There is a small hole at the
involves measuring the tempera- the tester that the return system top of the weir that equalizes the
ture at, or close to, the inlet is at 5 PSIG saturated steam pressure on each side. A sensor
and outlet of the steam trap. conditions, even though it was is inserted in the chamber on
Pyrometers, temperature sensi- thought to be a 0 PSIG return the upstream side which detects
tive crayons, paint, band-aids system. There could be a failed the presence of condensate by
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
Building 2 Building 1
PC
Head Unit
Assembly
Head Unit
Assembly acting
as a repeater
Steam Trap
Receiver Unit
LAN
39
Steam Traps and the Removal of Condensate
central PC. The PC determines the a program of planned preventive If historical records show
trap condition and calculates any maintenance. In general, this will that thermodynamic traps on
steam loss. mean regular cleaning of strain- one particular application suf-
er screens and replacement of fer repeatedly from rapid wear,
Each head unit assembly is pow- any internals which are begin- suspect either an oversized trap,
ered by a long life Lithium battery. ning to show signs of wear. It is undersized associated pipe work
It can communicate directly to a always advisable to hold a stock or excessive back pressure.
receiver that is connected to the of spares recommended by the Symptom-Trap will not pass
PC software via a LAN connection relevant manufacturer and a num- condensate
or via another intelligent head or a ber of standby valves and traps
head unit acting as a repeater. The While the traps discharge
which are on hand for use in an orifices may be plugged shut
PC software can be installed onto emergency.
the site internal network, or onto a with dirt, this symptom is most
Most steam system mainte- likely due to air binding, particu-
stand-alone local PC. The head, nance will have to be carried out larly if it occurs regularly during
repeater and receiver create a net- during an annual shutdown, but start up. Look at the air venting
work and can communicate with it is usually easier to spread the requirements of the steam using
each other, passing on the steam work evenly over the course of an equipment in general.
trap data to the coordinating PC. entire year. Most items will only
The illustrations below and oppo- Balanced Pressure
need attention once every twelve
site show typical networks. Thermostatic Trap
months, although strainer screens
Symptom-Trap blows steam
By-Passes Around Steam may need more frequent cleaning,
especially in the case of newly Isolate the trap and allow it
Traps to cool before inspecting for dirt.
installed systems. In conclusion,
The habitual use of by-pass If the seat is wire-drawn, replace
it may be useful to list some of
valves around steam traps can all the internals including the
the causes of problems common-
result in significant waste and thermostatic element. The origi-
ly experienced with the various
loss of steam energy. Although nal has probably been strained
designs of steam traps which are
a by-pass can be a very use- by the continuous steam blow.
available.
ful emergency device, it should If the valve and seat seem to be
never be regarded as a normal Steam Trap Fault Finding in good order, then check the
means of discharging conden- Thermodynamic Disc Trap element. To check the element
sate or air. Some trapping points remove the complete element
Symptom-Trap Blows Steam
still incorporate by-passes due and holder assembly from the
to the misguided belief that they The trap will probably give
a series of abrupt discharges trap. Place the complete assem-
are essential to cope with start-up bly in a pan of boiling water below
conditions. The operator may also (machine gunning). Check for dirt,
including the strainer, and wipe the the water level in the pan with
be tempted to leave the by-passes the discharge end pointing up.
disc and seat. If no improvement,
cracked open during normal run- Leave the assembly submerged
it is probable that the seating
ning. A valve used in this way will in the boiling water for 5 minutes
face and disc have become worn.
rapidly become wire-drawn and then carefully lift the assembly
The extent of this wear is evident
incapable of giving a tight shut-off. out of the water, as the element
by the normal crosshatching of
Once this has occurred, greater machining. This can be dealt with is removed from the water there
steam losses are inevitable. Steam by: should be a water accumulation
traps are fully automatic devices in the discharge of the element.
which should be properly sized so 1. Re-lapping the seating face
Set the element assembly on a
that by-passes are unnecessary. and disc in accordance with
table, still with the discharge end
the manufacturers instruc-
Preventive Maintenance up and observe the water in the
tions.
discharge side of the element.
Programs 2. Installing a new disc if the trap If the element is working cor-
In order to ensure that pres- seat is in good condition. rectly, the water will remain in
sure reducing valves, temperature the discharge until the element
3. If both seating face and disc are
controls, steam traps, etc. give cools then the water will drain out
not repairable, then the com-
long life and trouble-free ser- onto the table. If the element has
plete trap must be replaced.
vice, it is essential to carry out
40
Steam Traps and the Removal of Condensate
failed, the water will leak out of If this seems suspect, see if the should be corrected.
the immediately. trap will respond to adjustment. If Inverted Bucket Trap
Symptom-Trap will not pass cleaning has no effect, a complete Symptom-Trap blows steam
condensate new set of internals should be
installed. Check for loss of the water
The element may be over- seal prime. Isolate the trap, wait
extended due to excessive Symptom-Trap will not pass for condensate to accumulate and
internal pressure making it impos- condensate start up the trap again. If this
sible for the valve to lift off its Bimetallic traps have the valve cures the trouble, try to discover
seat. An over-expanded element on the downstream side of the the cause of the loss of the water
could be caused by super heat, valve orifice which means that they seal prime. This could be due to
or perhaps by someone opening tend to fail in the open position. superheat, sudden pressure fluc-
the trap while the element was Failure to pass cold condensate tuations or the trap being installed
still very hot, so that the liquid fill indicates either gross mis-adjust- in such a way that the water seal
boiled as the pressure in the body ment or complete blockage of the can drain out by gravity. Try fitting
was released. valve orifice or built in strainer. a check valve before the trap to
Liquid Expansion Thermostatic Float & Thermostatic Trap prevent this loss.
Trap Symptom-Trap blows steam If steam blow persists, check
Symptom-Trap blows steam for dirt or wear on the valve head
Check the trap for dirt foul-
and seat or failed mechanism.
Check for dirt or wear on ing either the main valve and seat
Replace the complete valve
the valve and seat. If wear has or the thermostatic air vent valve
mechanism and linkage as a com-
occurred, change the complete and seat. If a steam lock release
plete set.
set of internals. It must be remem- is installed in the trap, check to
Check the bucket to determine
bered that this type of trap is insure that it is not open caus-
if it is distorted from waterhammer.
adjustable in the temperature of ing a leak. Make sure that the
discharge, check to see if inadver- float and valve mechanism has not Symptom-Trap will not pass
tently the traps adjustment has been knocked out of line either by condensate
been turned out too far for it to rough handling or waterhammer, Check that the maximum oper-
close. Try adjusting the trap to preventing the valve from seating. ating pressure of the mechanism
a cooler setting. If it does not Check that the float ball has not has not been exceeded causing
appear to react to temperature, been damaged by waterhammer the trap to lock shut. While check-
a complete new set of internals and developed a leak which would ing the internals, insure that the
should be fitted. not allow the float ball to float or air vent hole in the bucket is not
bind in its operation. The air vent obstructed, as this could cause
Symptom-Trap will not pass
assembly should be tested in the the trap to fail closed. Air venting
condensate
same manner as the Balanced could also be a cause of a failed
Check that the traps adjust- Pressure Thermostatic trap ele- closed trap, especially in systems
ment has not been turned in too ment. When replacing the main that start up and shut down fre-
far to a setting thats too cold. float mechanism and valve assem- quently. Look at the air venting
Bimetallic Thermostatic Trap bly, these should be replaced as a arrangements of the steam using
Symptom-Trap blows steam complete set. equipment in general.
Check as usual for dirt and Symptom-Trap will not pass Conclusion
wear on the valve and seat. A condensate It is important to know the
bimetallic trap has only limited Check that the maximum type of trap discharge (see
power to close by virtue of its operating pressure rating of the Fig. 34 on page 42) which should
method of operation and the trap mechanism has not been be expected when making main-
valve may be held off its seat exceeded. If this has happened, tenance checks or trap testing.
by an accumulation of quite soft the mechanism will not have the The table on the following page
deposits. This type of trap is usu- power to open the valve against sets out the usual discharge
ally supplied pre-set to a specific the higher steam pressure. A leak- characteristics of the most com-
amount of subcooling. Check to ing or damaged float is almost monly used traps.
see that the locking device on the certainly the result of waterham-
manual adjustment is still secure. mer damage and the problem
41
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 con-
It can be claimed that the position? sider the difference in trapping
majority of steam trap types 7. Is the steam supply super requirements of a steam radia-
will work on any application heated? tor and a unit heater. While the
(provided that the operating con- steam space of the radiator is
8. Is air likely to be present in
ditions fall within the pressure great compared with its heating
any quantity?
range and condensate discharge surface, the steam capacity of
9. Is steam locking a possibility? the unit heater is small compared
capacity of the trap) (Fig. 35).
However, we do not just want 10. Is the installation made up with its heat output. The radia-
steam traps to work moderate- of several steam heated tor can make good use of the
ly well. We must aim to achieve units? sensible heat in the condensate
maximum output and efficiency before it is discharged, but the
from all steam using equipment. unit heater cannot. For this rea-
Waterlogging
This means selecting the best son, the radiator should be fitted
With most steam heated with a thermostatic trap that will
trap to suit each particular appli- equipment it is desirable, and
cation (Fig. 36). hold back condensate until its
very frequently essential, to dis- temperature has dropped a pre-
The following list contains a charge condensate as soon as determined number of degrees
number of important questions it forms in the steam space. below that of the steam.
which should be considered Although sensible heat in the
when choosing a steam trap for condensate is usable heat, a On the other hand, the unit
a 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 trans- immediately as it forms. The
charged immediately as it
fer surface. slightest waterlogging in this
forms?
case would reduce heat output
2. Is there condensate back Steam traps of the mechani- and cause the heater to blow cool
pressure or a return line high- cal type should always be chosen air. Condensate held back in the
er than the steam heated for applications which require unit heater will also promote cor-
equipment? rapid condensate removal. rosion and unnecessarily reduce
3. Are there waterhammer con- Thermostatic type traps cannot the life of the heater tubes.
ditions in the steam supply release condensate until it has
cooled a set number of degrees The extent to which water-
line? logging 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.
42
Steam Traps and the Removal of Condensate
Lifting Of Condensate particularly concerned with the up period. The condensate will
The rate at which a steam problems which may arise from also prevent any air from escap-
trap can discharge condensate lifting condensate by the steam ing through the steam trap which
depends on the size of the valve pressure 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, conden- ture controlled, the very action
between the inlet and the outlet sate can be lifted to a height of of the control may reduce the
of the trap. approximately 2.31 feet. In order steam pressure below the point
If a steam trap discharges to lift condensate, the trap must at which it can successfully
to atmosphere, the differential have positive steam pressure at lift condensate to an overhead
pressure across the trap will be all times. There are disadvan- return line. Once again the
the same as the upstream steam tages to lifting condensate in steam space will waterlog until
pressure. The same will be true this manner. In the first place, the control valve opens, result-
if the trap discharges into a the necessary steam pressure ing in poor temperature control
return line at a lower level which may not always be available at and the possibility of waterham-
allows the condensate to gravi- the trap inlet. If, for example, the mer as the steam rushes into
tate back to the boiler feed tank. normal operating pressure is 25 the waterlogged steam space.
Unfortunately, such an arrange- psi, it is theoretically possible Additionally, if the steam space is
ment is often ruled out because to lift the condensate 57.5 feet. a coil, considerable erosion and
either the boiler feed tank is high- However, on a cold start up, the corrosion may take 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 drop to, or even below, zero. certain types of steam traps are
to clear obstructions. In these Until this pressure builds up, limited as to the amount of back
cases, the condensate must be condensate cannot be removed pressure against which they will
lifted either directly by steam from the equipment and will col- satisfactorily operate.
pressure in the apparatus or by lect in the steam space. This will
a pump. In this section we are result in a greatly extended heat
Figure 35
Requirements for Steam Trap/Applications
43
Steam Traps and the Removal of Condensate
44
Steam Traps and the Removal of Condensate
Steam Trap Sizing 3. The temperature of the con- have the valve on the pressure
The benefits of selecting the densate. side (the inlet side) of the valve
best type of steam trap for a We must now examine these seat. The only notable exception
given application (Fig. 35 & 36) factors in more detail. to this arrangement occurs in the
will be wasted if the trap is not bimetallic type of traps where the
1. Differential Pressure
correctly sized. It is bad practice valve is on the outlet side of the
The maximum amount of con- valve seat. In the case of traps
to choose a 3/4 trap simply
densate the trap will discharge with the valve on the pressure
because it has to go on a 3/4
will increase as the differential side of the valve seat, the valve,
drain line. In order to size a
pressure (the difference in pres- when closed, will be held on
steam trap, we obviously need to
sure between the inlet and outlet its seat by the steam pressure.
know the quantity of condensate
of the trap) increases. In other According to the type of trap in
to be handled in a given time.
words, the capacity of a trap question, the thermostatic ele-
The makers of most standard
discharging to atmosphere with ment, ball float or bucket must
kinds of steam equipment usu-
steam at 75 psi will be greater have enough force to pull the
ally supply reliable figures on
than that of the same trap with valve away from its seat against
the condensation rates of their
steam at 30 psi. The capacity this pressure.
equipment. If such information
does not, however, increase in
is not available, it has to be In any given trap, the force is
proportion to the pressure.
acquired either by calculation a fixed amount. Force Required =
or practical measurement of the It is not wise to assume that pressure x area.
condensate produced. A test the pressure at which steam is
The maximum pressure at
procedure which will give rea- supplied to a piece of equip-
which the valve of the trap can
sonably accurate results is set ment will be the pressure on the
open is the pressure at which
out at the end of this section. inlet to its steam trap. Pressure
this operating force is just greater
losses often mean that the steam
Reference has already been than the valve seat area multi-
pressure at the trap will be con-
made to start-up loads and plied by the pressure in the trap
siderably less than the steam
running loads in this course. body.
supply pressure.
We know that steam will con- In the case of traps with the
dense most rapidly on start up If a steam trap is discharging
valve at the outlet side of the
when the system is cold. It is condensate to atmosphere, the
valve seat, the situation is dif-
for this reason that it is common outlet pressure will be atmospher-
ferent. In this type, the steam
practice to size traps using a ic and, therefore, the differential
pressure tends to open the valve,
safety factor. The trap selected pressure will be the same as the
so the maximum pressure at
should be able to handle twice gauge pressure at the trap inlet.
which the trap can close is when
the normal running load, or as However, if the trap discharges
the operating force is just greater
much as 3 times the running load into a main which is under pres-
than the steam pressure multi-
following an automatic tempera- sure, the differential pressure will
plied by the valve seat area.
ture control. An undersized trap be reduced by an amount which
can be determined by subtract- 3. The Temperature Of The
will cause waterlogging of the
ing the outlet pressure from the Condensate.
steam space when it can be least
afforded. trap inlet pressure. The quantity The capacity of a trap should
of condensate which the trap is never be based on the amount
Steam Pressure and Trap capable of passing in a given of cold water the trap will pass
Capacity time will be reduced accordingly. at any given differential pres-
We know that for a steam 2. Size of Discharge Orifice sure. Condensate in a steam
trap to operate, there must be a trap is usually at a temperature
The size of the discharge
higher pressure at its inlet than above atmospheric boiling point.
orifice not only helps to deter-
there is at its outlet. The actual When the condensate is pass-
mine the capacity of the trap but
amount of condensate which the ing through the valve seat of
also often fixes the maximum
trap can discharge is governed the trap, its pressure is quickly
pres-sure at which the trap will
by the following three factors: reduced and a certain amount
operate. Reference to the steam
1. The differential pressure of flash steam is generated.
trap section reveals that the vast
This flash steam tends to choke
2. The size of the trap discharge majority of the traps described
orifice.
45
Steam Tracing
the discharge orifice, reducing product at the specific tempera- that will not necessarily freeze
its effective area. As the con- ture it already has. It is, therefore, become very thick if not heated
densate temperature rises, the a heat maintainer, and not a heat and kept heated throughout their
amount of flash steam generated exchanger. Because of this, the processing. An example usually
will increase and the discharge consumption of the steam is usu- used is thick as molasses.
capacity of the trap will decrease. ally very low. In fact, it is one of There are many different
The extent of which condensate the smallest steam consumers ways of attaching tracing and
temperature affects the traps in a given plant. The fact is how- there are many different types
discharge capacity is relative to ever, that in some plants (such as or methods of using the tracing
its temperature below saturation Hydrocarbon Processing facili- concept. The following discusses
temperature -- lower tempera- ties), they account for as much these.
tures, lower flashing rates. as 70% of the steam using loca-
Typically, tracing is copper
tions. The fact that they consume
tubing attached to a pipe filled
very little steam is then over-
with some type of liquid (Fig. 37).
shadowed by the sheer numbers
of lines. The method of attaching
also varies from plant to plant
Freeze Protection and spec to spec. The lines
(Non-Critical) themselves can be banded or
Steam Tracing In areas of the country where strapped, (when temperature dif-
There are two typical appli- freezing conditions prevail during ferences between the steam and
cations of tracing. They are winter months, many different product fluid are low and steel
typically referred to as either types of systems require protec- pipe is used), attached using
process fluid (critical) or freeze tion from freeze-up. Obviously, Heat Conducting Paste (Fig.
protection (non-critical) tracing. these lines are water lines or 38) and Channels and straight
There are different requirements perhaps metering equipment wiring them in place. The place-
for each as far as heat is con- that use water in sensor tubes ment of the tracer tubing is more
cerned, so we will separate their to detect flow of gases, etc. important in most cases than the
requirements prior to discuss- Tracing lines keep the water from method used for attachment. In
ing how to attach tracing to the freezing which will in turn pos- whichever method of attaching is
application. sibly rupture piping, tubing or selected, it is most important to
Tracing is as its name implies, equipment. Sometimes, liquids avoid crimping the tubing.
a pipe or tube following either
process fluid lines or lines where
it is desirable to prevent freez-
ing during the winter months. Figure 37
Steam tracing is the distribu- Tracer Line Attachments
tion of steam through small bore 18 Max.
tubing or pipes which basically
transfer heat to a larger pipe to Process Fluid
keep fluids from becoming vis- Tracer Tubing
cous, solidifying or freezing. Stainless Wire (Wrapped)
46
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 informa-
tracing is the use of jacketed transfer of the heat of the steam tion such as traced and maybe
pipe (Fig. 40). This method of into the flowing fluids as it is lost even the number of tracer lines
tracing is used particularly when to the atmosphere. attached along with the pres-
there is need to keep a fluid (such The tracer line then should sures being used. This may help
as Sulfur) from solidifying in the also be installed running in a in future maintenance of the sys-
pipes. We will look at each of the straight line as far toward the tem itself. It may also help in
methods mentioned above and bottom of the piping as is possi- using the numbers of tracers as
discuss some dos and donts. ble (Fig. 42). The tracer is housed they are needed.
inside the insulation wrapping There may be times when the
Attaching Tracers
on the pipe, and we gain much number of tracer lines being used
The easiest method of trac-
benefit from attaching it in this can be reduced. For example,
ing is by attaching copper tubing
manner. Heat, which you may a process pipe during the win-
to the pipe. It is used mostly
recall, rises naturally and sur- ter months may require multiple
because of the abundance of
rounds the piping allowing for tracer lines to insure that the
copper tubing and the cost which
as much natural conduction of fluids remain at the proper tem-
is relatively low. The tubing is
BTUs as possible. This heat bar- perature. However, during the
attached in the lower quadrant
rier also reduces the heat losses summer months, the numbers
of the pipe being traced (Fig.
from the process fluids. of tracer lines may be reduced
41). Another important consider-
On some occasions, the because of less heat loss through
ation in tracing is to oppose the
amount of heat available and the insulation. Some plants list
two flows, fluids in the process
temperature of the steam is such the steam manifold header num-
piping and steam in the tracer
that spacers are used to prevent ber where the on/off valves may
tubes. This may not always be
burning the liquids on the inside be found to help with reducing
practiced, however, but there
of the process lines. This could the amount of steam being con-
are some solid reasons why one
cause coking (burning) of the sumed unnecessarily.
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 used,
by the process fluid. As it trans- it is important that the insulation
fers from point A to point B be sized to allow for the extra
in the plant, heat will naturally be space required. It may also be
lost through the insulation. The advisable to label the outside
47
Steam Tracing
48
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 con-
tinue over the top of the flanges.
Condensate to grade
49
Steam Tracing
Air
tagged with a number that iden-
Steam Out tifies the trap, size, pressure,
Vent
etc. so that a maintenance pro-
gram can help determine the
correctness of either the traps
being selected or size of trap
being used. These manifolds
can be either horizontally or
Vertical Manifold
Figure 46
NUMBER OF 1/2 TRACERS USED WITH DIFFERENT SIZES OF PRODUCT LINES
50
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
densate sides of the system, but
When steam condenses, a figure of 10-15% by mass is
Figure 49
energy is transferred to the cool- typical (Fig. 48). Approximate amount of energy in
er material to be heated. This Condensate
accounts for only around 75% About half of the energy Flash
of the energy supplied in the mentioned above (i.e. 12.5% of Steam
50%
boiler to produce the steam. The the total energy supplied) could
remainder, about 25%, is still be lost through flash steam (Fig.
held by the condensed water. 49).
As well as having heat con- Flash Steam Recovery is,
tent, the condensate is distilled therefore, an essential part of
water: ideal for use as boiler feed achieving an energy efficient Water
water. An efficient installation will system. 50%
collect every drop of condensate This section will bring
it economically can, and either together Condensate Recovery,
return it to the deaerator or boiler Condensate Removal and Flash
feed tank, or use it in the pro- Steam Recovery under the head- lines requires much planning to
cess. ing of Condensate Management. control velocities of liquids and
The objective is to examine the gases. It should be remembered
Condensate is discharged
technical aspects for the benefit that condensate lines are, in fact,
through steam traps from a high-
of the expert and then to use bi-phase systems that require
er to a lower pressure. As a result
this as a basis to provide simple proper planning. Review the
of this drop in pressure, some
guide lines for the occasional Condensate Line Sizing Chart for
of the condensate will then re-
user. assistance in this area (Fig. 50).
evaporate, and is referred to as
flash steam. The proportion that Condensate line sizing plays You will note that it is rec-
will flash off differs according to an important role in success- ommended to increase the line
the level of pressure reduction fully controlling and collecting size on the discharge of all
between the steam and con- condensate. Sizing condensate steam traps. This is intended
51
Condensate Management
to allow for the flashing that substantial increasing velocities shown in the steam tables. The
will be expected when steam that may damage existing con- surplus heat is utilized by the
traps discharge condensate into densate recovery systems. condensate as latent heat caus-
lower pressure systems. A chart ing some of it to re-evaporate
is provided to assist in quickly Flash Steam Recovery into steam.
estimating the amount of flash When hot condensate under
The quantity of flash steam
that can be produced. The vol- pressure is released to a lower
available from each pound of
umetric change of condensate pressure, its temperature must
condensate can be calculated
flashing into steam may cause very quickly drop to the boiling
using this formula:
point for the lower pressure as
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
60 0
4 0
Pipe Size
3 0
20,000 Factor
2
1/2" 1.30
10
5000
10 0
3000
0
8
60 0
4 0
3 0
2000
2
0
10
5
0
1000
800
500
A B
300
200
10 0
0
8
100
60 0
4 0
3 0
80
2
60
10
5
50
40
30
P
c re
20
nk te
(p lin
si e
g) or
52
Condensate Management
Percentage Quantity of Flash upstream and downstream of Before discussing the ways
Steam the trap and the corresponding of recovering flash steam and
= Sensible Heat at temperatures of those pressures why we want to recover it, there
the Higher Pressure in saturated steam. The higher are two important practical points
- Sensible Heat at the initial pressure and the lower which should be noted:
the Lower Pressure the flash recovery pressure, First, one pound of steam has
Latent Heat of the greater the quantity of flash a specific volume of 26.8 cubic
the Lower Pressure steam produced. feet at atmospheric pressure. It
To simplify this procedure It must be noted here that also contains 970 BTUs of latent
we can use the chart (Fig. 51) to the chart is based upon saturat- heat energy. This means that if
read off the percentage of flash ed steam pressure/temperature a trap discharges 100 pounds
steam produced by this pressure conditions at the trap inlet, and per hour of condensate from 100
drop. An example would be if we that the condensate is discharged PSIG to atmosphere, the weight
had 100 PSIG saturated steam/ as rapidly as it appears at the of flash steam released will be
condensate being discharged trap. Steam traps that subcool 13.3 pounds per hour, having a
from a steam trap to an atmo- the condensate, such as bal- specific volume of 356.4 cubic
spheric, gravity flow condensate anced pressure thermostatic and feet. It will also have 12,901
return system (0 PSIG), the flash bimetallic traps, hold condensate BTUs of latent heat energy. This
percentage of the condensate back in the system allowing it to will appear to be a very large
would be 13.3% of the volume give up sensible heat energy and quantity of steam and may well
discharged. causing it to cool below the satu- lead to the erroneous conclusion
rated steam temperature for that that the trap is passing live steam
Conversely, if we had 15
pressure. Under those circum- (failed open).
PSIG saturated steam dis-
stances, we must calculate from Another factor to be consid-
charging to the same (0 PSIG)
the formula above the percent- ered is that we have just released
atmospheric gravity flow return
age of flash steam produced, but 13.3 pounds of water to the atmo-
system, the percentage of flash
the amount of subcooling (the sphere that should have gone
steam would be only 4% by
condensate temperature) must back to the boiler house for recy-
volume. These examples clearly
be known before calculating. cling as boiler feed water. Since
show that the amount of flash
released depends upon the dif- we just wasted it, we now have
ference between the pressures to supply 13.3 pounds of fresh
city water that has been softened,
Figure 51: Percent Flash chemically treated and preheated
Steam to the feedwater systems tem-
Pressure Atmosphere Flash Tank Pressure (psig)
(psig) 0 2 5 10 15 20 30 40 60 80 100 perature before putting this new
5 1.7 1.0 0 water back into the boiler.
10 2.9 2.2 1.4 0 Secondly, the actual forma-
15 4.0 3.2 2.4 1.1 0 tion of flash steam takes place
20 4.9 4.2 3.4 2.1 1.1 0
within and downstream of the
30 6.5 5.8 5.0 3.8 2.6 1.7 0
steam trap orifice where pres-
40 7.8 7.1 6.4 5.1 4.0 3.1 1.3 0
60 10.0 9.3 8.6 7.3 6.3 5.4 3.6 2.2 0
sure drop occurs. From this point
80 11.7 11.1 10.3 9.0 8.1 7.1 5.5 4.0 1.9 0 onward, the condensate return
100 13.3 12.6 11.8 10.6 9.7 8.8 7.0 5.7 3.5 1.7 0 system must be capable of car-
125 14.8 14.2 13.4 12.2 11.3 10.3 8.6 7.4 5.2 3.4 1.8 rying this flash steam, as well
160 16.8 16.2 15.4 14.1 13.2 12.4 10.6 9.5 7.4 5.6 4.0 as condensate. Unfortunately,
200 18.6 18.0 17.3 16.1 15.2 14.3 12.8 11.5 9.3 7.5 5.9 during the past 80 years, con-
250 20.6 20.0 19.3 18.1 17.2 16.3 14.7 13.6 11.2 9.8 8.2 densate return lines have been
300 22.7 21.8 21.1 19.9 19.0 18.2 16.7 15.4 13.4 11.8 10.1 sized using water volume only
350 24.0 23.3 22.6 21.6 20.5 19.8 18.3 17.2 15.1 13.5 11.9 and did not include the flash
400 25.3 24.7 24.0 22.9 22.0 21.1 19.7 18.5 16.5 15.0 13.4
steam volume that is present.
Percent flash for various initial steam pressures and flash tank pressures.
53
Condensate Management
54
Condensate Management
which either equals or When all else fails, in many to water converter or a large
exceeds the available flash facilities there is always a need air handling coil bank, but we
steam supply. The deficit can for hot water, especially in the cannot forget that flash steam
then be made up through a boiler house. This can be sup- recovery systems by design will
pressure reducing valve set. plied via a heat exchanger and apply a backpressure to the
If the supply of flash steam the use of flash steam. equipment that is being drained
exceeds the demand for it, 3. It is also preferable to select or to the flash steam source.
the surplus may have to be an application for the flash Another very common area from
vented to waste through a steam which is reasonably which flash steam is recovered
backpressure relief valve. close in proximity to the high is boiler blowdown. Dissolved
Thus it is possible to utilize pressure condensate source. solids that create the need for
the flash steam from process Piping for low pressure steam boiler blowdown drop out and
condensate on a space heating is inevitably of larger diam- will produce usable flash steam
installation, but the savings will eter. This makes it somewhat and condensate.
only be achieved during the heat- costly to install. Furthermore, Boiler blowdown flash steam
ing season. When heating is not the heat loss from large recovery (Fig. 53) is a very effi-
required, the recovery system diameter pipes reduces the cient method for recovery. It not
becomes ineffective. benefits obtained from flash only is a continuous supply of
Wherever possible, the bet- steam recovery and in the valuable heat energy to be uti-
ter arrangement is to use flash worst cases could outweigh lized, but it is in close proximity to
steam from process condensate them. an area of definite need as in the
to supply process loads, and Flash steam recovery is sim- boiler feed or deaerator system
that from heating condensate to plest when being recovered from that demands a constant source
supply heating loads. Supply and a single piece of equipment that of low pressure heat energy for
demand are then more likely to condenses a large amount of preheating the boiler make up
remain in step. steam, such as a large steam water supply. This simple instal-
lation is shown below.
Safety Valve
Cold Water
Figure 53
Boiler Blowdown Heat
Recovery System
Hot Water
55
Condensate Management
Control Valve
Steam
Air
Flow
Steam Trap
Flash Vessel
Figure 54
Control of Flash
Steam Pressure
Condensate
Another area that works very on 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 effec-
section air heating coils (Fig. 54). condenser on a receiver (Fig. 55 tive condensate removal from
Many times flash steam can be on following page). Flash steam steam spaces has been stressed
supplied to a coil added to the is allowed to flow up through throughout this course. If maxi-
system to maximize use of the the condenser (heat exchanger), mum steam system efficiency
flash steam supplied by the pri- that has a supply of fluid flowing is to be achieved, the best type
mary coils in the system. An through it, to capture the heat of steam trap must be fitted in
example is shown in the follow- energy contained in the flash the most suitable position for the
ing sketch. This example clearly steam. This type of system is an application in question. Having
fulfills the basic requirements of atmospheric pressure system, considered how to best utilize
having a flash steam recovery which allows condensate from any flash steam which may be
system which is in step with the flash steam to flow by gravity available, we must now decide
demand. back into the original condensate what to do with the condensate
Only when air coils are called receiver. This provides the user which 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
become available, and it can then densate from that system, and not be allowed to discharge to
be condensed in the first air coil enables the user to accomplish drain. The most important con-
which is essentially a pre-heater. this without presenting all of the sideration is the valuable heat
This simple arrangement ensures equipment in that system with which it contains even after flash
that higher pressure traps are not any backpressure. steam has been recovered. It is
subjected to any backpressure possible to use condensate as
56
Condensate Management
Heat Exchanger
Condensate
Return System
Figure 55
Flash Steam Condenser or Heater
hot process water but the best of the plants steam generating of condensate in different hold-
arrangement is to return it to costs. One justifiable reason for ing areas of a plant to determine
the boiler house, where it can not returning condensate is the condensate quality and providing
be re-used as boiler feed water risk of contamination. Perforated a means to re-route the conden-
without further treatment, saving coils in process vessels and sate if contaminated.
preheating fuel, raw water and heat exchangers do exist and Vented open return sys-
the chemicals needed for boiler the cross contamination of con- tems have been utilized for
feed treatment. These savings densate and process fluids is 90 plus years where the con-
will be even greater in cases always a danger. If there is any densate is allowed to flow by
where effluent charges have to possibility that the condensate gravity to a central collection
be paid for the discharge of valu- is contaminated, it must not be receiver and then the use of
able hot condensate down the returned to the boiler. These electrically driven pumps
drain. problems have been lessened return it to the boiler house
Condensate recovery sav- by the application of sensing when these receivers are full.
ings can add up to 25 to 30% systems monitoring the quality
57
Condensate Management
58
Condensate Management
59
Condensate Management
Vent to Atmosphere
Figure 59
OPEN Atmospheric Pump Exhaust
System
Receiver
Pressure
Inlet Strainer Powered
Pump
Pressure
Powered
Pump
60
Condensate Management
61
Condensate Management
Figure 61
Controller
Closed System
Moisture
Separator
Strainer
Steam Trap Station Temperature
Control Valve
Temperature
Control Sensor
Motive
Condensate Steam
Return Supply
Reservoir
Thermo-
Dynamic
Steam Trap
Pressure
Powered
Float & Thermostatic Pump
Steam Trap
Figure 62
Discharging Into Condensate Return Line Sparge Pipe to made of
Stainless Steel
Sparge Pipe
62
Steam Utilization Course Review
63
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 three groups can pressure reducing valves be divided?
1. ___________________________________________________________________
2. ___________________________________________________________________
3. ___________________________________________________________________
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 H.P. - sh L.P.) / Lh L.P.
64
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Bandar Sunway 6th Floor
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(Above Gilamis) Waryaki Way Santa Caterina, NL 9th Floor, Benjaporn Building
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Sorvaajankatu 9 Northpoint Park
00810 Helsinki, Finland Nigeria 1150 Northpoint Blvd.
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Cedex, France Norway Venezuela
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P.O. Box 47 Apartado 81088
1483 Skytta, Norway Caracas 1080A, Venezuela
65
Spirax Sarco, Inc
1150 Northpoint Blvd
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Phone: (800) 883-4411
www.spiraxsarco.com/global/us
66