Steam Traps

https://processphase.com/steam-traps/

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Condensate creation in steam lines is an inevitable phenomenon. Due to the

pipe’s heat loss, there is always a portion of steam converted into
condensate. This condensate causes many problems to the pipeline such as
corrosion and erosion. It is also the reason of high pressure drop of the line.
Moreover, if there is a pocket (low point) in the pipe’s route, condensate
would trap there. As a result, it harms the fluid hydraulic plus pipe’s
internal surface.
Steam traps are vital components to extract the condensate from steam
lines (for line sizing criteria click here). They can be found in all the steam
generation and handling units. As their name suggests, they are utilized to
remove the liquid condensate by trapping the steam. Without them, steam
is also wasted alongside with the condensate removal. They are almost at
the size of the corresponding valves. Based on their applications, there are
several types of steam traps such as thermostatic, float & thermostatic,
thermodynamic and inverted bucket.

Steam traps have three primary usages:

Removing the condensate from steam lines.

Liquid drainage of process equipment

Trapping the steam at the outlet of heat exchangers while allowing

condensate to pass. Applicable for those exchangers that consume steam
as hot source (reboilers). Therefore, no steam would pass the exchanger
without complete condensation.

In this article, we will study the working principle of various types of steam
traps available in oil and gas industry. In addition, we will provide guidance
on selecting the proper type of steam traps based on their characteristics. At
the end, their design techniques will briefly be discussed.

Typical types of steam traps

Thermodynamic steam traps

Thermodynamic (disk) steam traps are mostly used at main steam headers.
They are small-sized steam tarps with a maximum size of one inch. They
are used for intermittent condensate removal application in a cyclic on/off
operation. They only discharge small amount of air (non-condensable) and
therefore are not used for process applications. Due to their robust design,
they are resistant to water hammer.

Their working principle is based on area difference of the floating disc at

closed condition. At normal condition, where there is only condensate
available, the condensate push up the floating disk and pass to the
discharge. Upon introducing steam, the steam moves across the disk and
enters the flash chamber. Due to the positive pressure, the disk falls down
and blocks the way. The back (upper) surface area of the disk is exposed to
more amount of steam. Therefore, downward force outweighs upward
force and the disk remains closed. As soon as condensate enters the main
chamber again, it makes the trapped steam cool down and condense.
Therefore, the disk would pup up open again and the remaining condensate
will be discharged.

Thermostatic steam traps

Thermostatic steam traps are capable of operating at continuous

applications such as tracing and process. They can handle large amount of
air. The main advantage is that at start-up, the trap is in open status,
allowing air and condensate to be removed from the system easily.

Their working principle is based on thermal expansion and contraction of a

fluid-field thermal element called bellows. When the steam is in contact
with the bellows, the inner fluid vaporizes and expands, causing the valve
to block the discharge by touching the valve seat. On the other hand, when
the bellows are exposed to condensate or air, they contract due to the lower
temperature and open the valve allowing the fluid to be removed.
Float & thermostatic steam trap

Float & thermostatic (F&T) traps are mechanical types of steam traps. They
are the mostly used steam traps in industry. They are usually installed at
the outlet condensate line of those heat exchangers which utilize steam as
their hot source. Float & thermostatic steam traps are the number one
choice for drain line of process equipment. Apart from condensate’s main
discharge orifice, they contain a thermostatic air vent in order to allow the
discharge of the non-condensable components out of the system. Therefore,
they are preferable in start-up situation, where a vast amount of air needs
to be discharged.

Their working principle is based upon the density difference between

floating ball and condensate. There is a floating element that connected to a
valve plug. When the condensate is collected in the chamber, the liquid
level rises the float causing the valve to open and discharge the liquid. In
addition, when air enters the chamber, the thermostatic vent contracts and
open the valve allowing the air to vent out. On the contrary, if the liquid
level drops, the float goes down and close the valve. Meanwhile by
introducing steam the thermostatic valve expands because of higher
temperature and block the discharge of steam.

Inverted bucket steam traps

Similar to thermodynamic traps, inverted bucket steam traps are
mechanical intermittent traps with cyclic on/off characteristic. They are
suitable for removing condensate from steam headers. Due to their poor air
handling capability, they are not used in process applications. The main
limitation is that they have to contain a certain initial amount of water,
known as prime, in order for the bucket to float. Without this prime, the
trap fails to function correctly and would discharge steam accidently.
Inverted bucket steam traps shall not be used in applications with regular
pressure change. Because the prime may flash when the pressure falls
down.

Their working principle is based upon the buoyancy force acting on a

floating bucket. When there is only condensate available, the bucket goes
down causing the valve to open and allow the condensate to discharge.
There is also a small bleed hole on the topside wall of the bucket. This hole
allows the air to pass through and collect at the top section of the chamber.
Finally, this air is discharge alongside with the condensate. However, large
amount of air will lift the bucket and temporarily lock the system. On the
other hand, when the steam enters the trap it collects under the bucket and
rise it due to the buoyance force. Therefore, the valve is closed. As the
trapped steam gradually condenses or is bled through the bleed hole, the
bucket fills with condensate, sink to the bottom of the chamber again, and
opens the discharge valve.

Design techniques

How to size steam traps

In order to size the steam trap’s orifice, two important parameters have to
be reported:

1. Condensate flowrate
2. Pressure drop across the orifice

Condensate flowrate is determined based on the estimated amount of

steam converted to liquid at normal operation. However, since the system
temperature at start-up is not high enough, the condensate flowrate is
expected to be more than normal condition. Thus, it is always
recommended to consider a safety factor for the calculated condensate
flowrate. As a rule of thumb, this safety factor is equal to 2. Therefore, the
reported flowrate shall be 200% of calculated flowrate at normal operation.

For reporting the design pressure drop, it is important to consider the

downstream piping and elevation change. As an example, if the inlet
pressure to the steam trap is 4 barg, and the condensate is planned to
collect in an atmospheric storage tank with a liquid level of 5 m (0.5 bar),
and the pipe’s pressure loss to the tank is 1 bar, the reported pressure drop
is equal to 4 – 1 – 0.5 = 2.5 bar.

Installation tips

Steam traps shall be installed at the drip pockets (lowest elevation of

pipes) in order to function properly.
Steam trap’s installing manifold is like the control valves with a double
block and bleed configuration. There are two block valves at both sides,
one drain at inlet and a bypass line for maintenance.

Conclusion

Steam traps are used to remove condensate from steam lines. There are
various types of steam traps available in industry. Each type has specific
characteristics and applications. Steam traps are design based on maximum
condensate flowrate and pressure drop. In this article we reviewed
different types of steam traps and their design procedures. We also
provided some guidance on selecting the proper type of steam traps.

By S-Pourazimi | January 9th, 2021 | Piping, Process, Selection Guide |