STEAM SYSTEM

&
STEAM TRAPS

BY: Muhammad Akbar Rao

 Contents
• Introduction
• FFC Steam Network
• Steam traps
• Classification
• Selection
• Monitoring
• Problems associated with traps
• Monitoring system
• Exercises
INTRODUCTION
 Introduction

• Steam is water in vapor phase.

• It is one of the oldest industrial tools
• It allows the energy of fuel burned in a boiler
to be carried to some other point where it
can provide mechanical energy through an
engine or, more commonly, to provide heat.
 Boiling of Water

Steam

Latent heat

Temp

Water

Ice

HEAT
 Steam Terminology
• Sensible heat
– Heat that produces temperature rise
• Latent heat
– The heat that produces phase change
• Saturated steam
– The dry steam at its boiling point
corresponding to pressure.
• Superheated steam
– The steam heated above the saturation
temperature at a particular pressure
Steam Heat Content
 Steam Terminology

• Flash steam
– Steam that results when saturated water or
condensate is discharged to a low pressure
• Enthalpy
– Total energy due to pressure and temperature
of a liquid or vapor.
• Superheat
– Heat added to dry saturated steam
Flash Steam Calculation
Flash Steam Curve
 PV Diagram

V
Pressure Temperature Diagram
 Factors Affecting Steam System
• Water Hammer
– Condensate moving along steam form solid slug
moving at steam velocity result in water hammer
which can cause damage to piping.
• Air
– Before start-up boiler and piping are full of air,
therefore it must be removed during startup. Steam
air mixture has less temperature than steam alone at
a specific pressure.
• Gases
– Oxygen and CO2 are responsible for corrosion.
Water Hammer
Condensate Drainage
Condensate Drainage
Steam Line Branches
Steam Line Reduction
 Steam Tables
• Listing of heat content of steam in KJ/Kg
and its volume in m3/kg at various
pressures and temperatures. The
properties of saturated steam are most
frequently summarized.
 Saturated Steam
Specific enthalpy
Specific
volume
Water Evaporation Steam steam

Pressure Temp (hf) (hfg) (hg)

bar kPa °C kJ/kg kJ/kg kJ/kg m3/kg

absolute

0.30 30.0 69.10 289.23 2336.1 2625.3 5.229

0.50 50.0 81.33 340.49 2305.4 2645.9 3.240
0.75 75.0 91.78 384.39 2278.6 2663 2.217
0.95 95.0 98.20 411.43 2261.8 2673.2 1.777
1.00 100.0 99.63 417.51 2257.9 2675.4 1.694
1.013 101.3 100.00 419.06 2257.0 2676.0 1.673

gauge

0 0 100.00 419.06 2257.0 2676.0 1.673

0.10 10.0 102.66 430.2 2250.2 2680.2 1.533
0.20 20.0 105.10 440.8 2243.4 2684.2 1.414
0.30 30.0 107.39 450.4 2237.2 2687.6 1.312
0.40 40.0 109.55 459.7 2231.3 2691.0 1.225
0.50 50.0 111.61 468.3 2225.6 2693.9 1.149
0.60 60.0 113.56 476.4 2220.4 2696.8 1.088
0.70 70.0 115.40 484.1 2215.4 2699.5 1.024
0.80 80.0 117.14 491.6 2210.5 2702.1 0.971
0.90 90.0 118.80 498.9 2205.6 2704.5 0.923
1.00 100.0 120.42 505.6 2201.1 2706.7 0.881
1.10 110.0 121.96 512.2 2197.0 2709.2 0.841
 Superheated Steam
Pressure
Total Temperature--Degrees Fahrenheit ( t )
lbs. / sq. in. Sat.
Temp
Abs. Gauge t 350° 400° 500° 600° 700° 800° 900° 1000° 1100° 1300° 1500°
P' P

V 31.939 33.963 37.985 41.986 45.978 49.964 53.946 57.926 61.905 69.858 77.807
15.0 0.3 213.03 hg 1216.2 1239.9 1287.3 1335.2 1383.8 1433.2 1483.4 1534.5 1586.5 1693.2 1803.4

V 23.900 25.428 28.457 31.466 34.465 37.458 40.447 43.435 46.420 52.388 58.352
20.0 5.3 227.96 hg 1215.4 1239.2 1286.9 1334.9 1383.5 1432.9 1483.2 1534.3 1586.3 1693.1 1803.3

V 15.859 16.892 18.929 20.945 22.951 24.952 26.949 28.943 30.936 34.918 38.896
30.0 15.3 250.34
hg 1213.6 1237.8 1286.0 1334.2 1383.0 1432.5 1482.8 1534.0 1586.1 1692.9 1803.2

V 11.838 12.624 14.165 15.685 17.195 18.699 20.199 21.697 23.194 26.183 29.168
40.0 25.3 267.25 hg 1211.7 1236.4 1285.0 1333.6 1382.5 1432.1 1482.5 1533.7 1585.8 1692.7 1803.0

V 9.424 10.062 11.306 12.529 13.741 14.947 16.150 17.350 18.549 20.942 23.332
50.0 35.3 281.02 hg 1209.9 1234.9 1284.1 1332.9 1382.0 1431.7 1482.2 1533.4 1585.6 1692.5 1802.9

V 7.815 8.354 9.400 10.425 11.438 12.446 13.450 14.452 15.452 17.448 19.441
60.0 45.3 292.71 hg 1208.0 1233.5 1283.2 1332.3 1381.5 1431.3 1481.8 1533.2 1585.3 1692.4 1802.8

V 6.664 7.133 8.039 8.922 9.793 10.659 11.522 12.382 13.240 14.952 16.661
70.0 55.3 302.93 hg 1206.0 1232.0 1282.2 1331.6 1381.0 1430.9 1481.5 1532.9 1585.1 1692.2 1802.6

V 5.801 6.218 7.018 7.794 8.560 9.319 10.075 10.829 11.581 13.081 14.577
80.0 65.3 312.04 hg 1204.0 1230.5 1281.3 1330.9 1380.5 1430.5 1481.1 1532.6 1584.9 1692.0 1802.5

V 5.128 5.505 6.223 6.917 7.600 8.277 8.950 9.621 10.290 11.625 12.956
90.0 75.3 320.28 hg 1202.0 1228.9 1280.3 1330.2 1380.0 1430.1 1480.8 1532.3 1584.6 1691.8 1802.4

V 4.590 4.935 5.588 6.216 6.833 7.443 8.050 8.655 9.258 10.460 11.659
100.0 85.3 327.82 hg 1199.9 1227.4 1279.3 1329.6 1379.5 1429.7 1480.4 1532.0 1584.4 1691.6 1802.2

V 3.7815 4.0786 4.6341 5.1637 5.6813 6.1928 6.7006 7.2060 7.7096 8.7130 9.7130
120.0 105.3 341.27 hg 1195.6 1224.1 1277.4 1328.2 1378.4 1428.8 1479.8 1531.4 1583.9 1691.3 1802.0

V 3.4661 3.9526 4.4119 4.8588 5.2995 5.7364 6.1709 6.6036 7.4652 8.3233
140.0 125.3 353.04 hg 1220.8 1275.3 1326.8 1377.4 1428.0 1479.1 1530.8 1583.4 1690.9 1801.7

V 3.0060 3.4413 3.8480 4.2420 4.6295 5.0132 5.3945 5.7741 6.5293 7.2811
160.0 145.3 363.55 hg 1217.4 1273.3 1325.4 1376.4 1427.2 1478.4 1530.3 1582.9 1690.5 1801.4

V 2.6474 3.0433 3.4093 3.7621 4.1084 4.4508 4.7907 5.1289 5.8014 6.4704
180.0 165.3 373.08
hg 1213.8 1271.2 1324.0 1375.3 1426.3 1477.7 1529.7 1582.4 1690.2 1801.2
 Advantages of steam
• Requires smaller pipes to transfer specific
amount of heat.
• It is lighter, so steam lines are lighter in weight
• Flows in response to pressure drop and requires
no pumping
• Heat transfer coefficients are high
• Steam fills any space at uniform temperature for
even heating
• Load can be varied easily within defined limits;
no need of variable pumps and valves.
 Steam VS other Heating Mediums
STEAM HTHW HT OIL
Heat Content High Hl=2100Kj/kg Moderate Poor Sp heat 0.4 ~0.7
Cost Cheap but WT cost Cheap Expensive
H.T. Co-eff Good Moderate Relatively poor
Pressure Req’d High press for high temp High press for hi temp No Press for hi temp
Circ. Pump Not required Required Required
Pipe size Small Large Large
Load Control Easy Difficult Difficult
Traps Required Not Required Not Required
Condensate Yes No No
Flashing Yes No No
Blowdown loss Yes No No
Corrosion Yes Moderate No
Fire risk No No Yes
Flexibility Yes Less No
 FFC STEAM NETWORK

Varieties of steam

-LS (Low pressure steam) 3.8 kg/cm2 150 oC.

-MS (Medium pressure steam) 24 kg/cm2 240 oC.

-HS (High pressure steam) 39 kg/cm2 390 oC.

-KS (Very high pressure steam) 104 kg/cm2 510 oC.

 ACCUMULATION
T- 901= 102 PLANT-1 STEAM / CONDENSATE NETWORK VENT

0.5 25.4 LEGEND

LS STEAM 294
444 KS STEAM
V-603 E-206/211
E-501 A/B HS STEAM
E-304
T-901
E-306 LS STEAM
286
TURBINE COND.
F-202 F-202 A E-203 V-201
PROCESS COND.
55.5 0.6
366 BFW
B.D DE-ION,DEMIN
MIXED BED VENT WATER
TO PLANT-2 56.7 317.6
7.0 16
1.4 TONS/HR

B-605

PRC 14A/B
30 396 F-201 ME-206
ME-613/614 ME-450 A/B TK-431
TRAPS
DEIONIZED

B.D
WATER

4.0 NIL 258.5 99.5 NIL 133.6

T-903
51.6 49.6

336 B-601 29 4.0 18.8 9.4

13.1 28.7
26.7 0.0
11
TP-421B
ACCUMULATION B.D
LS VENT TP-441B
T-903 = 26 181 MP B.F.W to Process TK-605
TP-601A ME-612 TP-8O1E
(UTY)
TK-441 TK-421 EJECTORS TP-435A TK-201 UREA
TP-434A
86 49.3 47.9 TP-602C TP-432A PLANT
TP-901C TP-431A
0.0
B-602 UTY. POINT

24.2 1.5
15
BFW 53.2 59.1 1.0
NIL
0
B.D
HS to
B.F.W to Plant-2 Plant-2 1.0 14.1 8.8
5.2 0.0
V-914A-D
1.0 TRAPS
V-601 A/C PLANT C-351 C-301
ME-612
ME-120
ME-452
141

40

TURBINE CONDENSATE

PROCESS CONDENSATE
TURBINE
19.7
CONDENSATE 66
TRAPS
V-604
A/C PLANT

ocument
ANNE
 107.0
131.9
63.3
60.8 LEGEND:
0.0 79.4 KS STEAM
8.7 113.9
CATION EXCHANGER HS STEAM
B 4601 V 4201 E 4501 LS STEAM
DEGASIFIER SAT HS STEAM
MAKEUP FILTERED BFW PREHEATING 1.1 0.7
WATER FROM P 907 ANION EXCHANGER 0.7 SAT LS STEAM
E-4205,E 4502 0.4
1.8 1.9

E-4212 A/B E-4213 A/B BOILER FEED WATER

BOILER PROCESS CONDENSATE
BLOWDOWN 62.6 TURBINE CONDENSATE
105.9 58.9
MIXED 130.1 DEMIN WATER
T 4952 78.7
BED 113.5
SUPER HEATING
SECTION
DESIGN
ACTUAL
PROCESS STREAM, MeT/H
2.5
4.1 E 4209, E 4203 A/B

T 4951
108 Kg/cm2g 516°C
1.0 V 4602
DMW MAKEUP LS
17.9
1.2 V 4604
FROM PLANT-1 58.6
DMW PREHEATING
E-4306, E-4216A/B 1.9 180.1 65.3
E-4206 73.5 14.6
0.2 35.0 194.0 24.3 24.6
2.6 DRAIN
P-4951 A/B 27.1

PV 42026 DKTK
237.9 DSTK 4431
307.3 A/B 4101 25.7
21.8
0.6
3.4 1.5
6.2 2.0 154.7
37.6 172.2
55.3
66.6
MS TO UREA
2
DEAERATOR
HS FROM 38.6 Kg/cm g 378.93°C PLANT
PLNAT-I
0.9 2.8 12.5 1.0 1.4 19.2 3.5 6.1 21.5 16.2 3.3 0.5 61.5 2.8 0.0 0.5 0.0
0.0 4.1 1.0 2.0 3.0 26.2 3.9 8.9 31.6 25.4 4.2 2.0 71.4 4.1 6.0 1.0 15.0
FROM
AREA-45
ME DSTP DSTP DSTP DSTP DSTP DSTU DSTU DSTK DSTK ME R E 4202 VENTS
4201 L 4501 F 4201 TRAPS LEAKS
4202 4951 4801 4421 4432 4601 4601 4201 4421 4441 4102 B UNACCOUNTED
P-4601 A/B
E 4952 E 4951

0.1 HP
C 0.0 4.2 Kg/cm 2 g 197 °C
WATER
4302 0.4
10.7 1.0 0.0 1.0 34.7 4.2
10.9 1.0 9.9 1.0 26.3
0.9
0.7 1.0
VENTS
1.0
56.2 E 4521/C 4521
ME LEAKS VACUUM 58.8
3.4
TRAPS 6.2
4203 UNACCOUNTE EJECTORS
10.8 D
11.9 TO V 4601

E 4435
0.0 0.0 1.8
0.0 0.7 0.5 72.4
83.3

FROM AMMONIA
0.1
BDR PROCESS
0.0 TO A/C 0.0
BDS
UREA LEAKS
PLANT 0.0
VENT 31.9
36.9 V 4322
10.8
MPBFW 11.9
FROM PLANT-1
31.9
V 4321
36.9 C 4321 99.1
105.1
HC 1.5
2.0
46.5 LC
UREA PROCESS 55.0 E 4214
CONDENSATE V 4604 CONDENSATE P 4322 A/B
FROM K-4301 1.5 P 4324 A/B
2.0

UREA STEAM P 4321 A/B

CONDENSATE 124.7
132.2
16.5
15.4
 2.8
4.1 65.3 34.6 LEGEND
73.5 27.1 KS STEAM
HS FROM
AMMONIA PLANT KS DSTK 4101 TO E-4952 HS STEAM
2.8 0.0
4.1 0.0
MS STEAM
SATURATED MS STEAM
55.3 LMS STEAM
66.6
0.0
0.0
LS STEAM
PROCESS PROCESS CONDENSATE
PV
R 4102 CONDENSATE TURBINE CONDENSATE
41048 E 4101
FROM T 4102
DEMIN WATER
DESIGN
9.4 ACTUAL PROCESS STREAM, MeT/H
8.4

V 4109 C 4102

0.0 10.3
0.0 55.3
44.1 22.5
PROCESS CODENSATE TO V 4604 / COOLING TOWER
L 4112

PV E 4102 B
41047
14.0
26.1
E 4102 A

E 4105

0.0 LS IMPORT 13.2 0.0

0.0 65.9 0.0 12.0 20.2
70.5 0.0

5.0 8.0 13.2 3.5 1.2 7.3 0.0

3.8 8.0 12.0 3.5 1.4 8.0 1.6
0.0 0.0
0.0 0.5
TRACING VENT
E 4115 E 4103 E 4114 L 4105 L 4106
FLUSHING LEAKS

DRAIN
VENT
1.0 6.9
28.6 0.0 0.0
27.3

DMW
C 4106
V 4110

16.5
20.0

UREA STEAM
CONDENSATE TO E 4951

P 4110 A/B P 4113 A/B

0.05 0.0 0.0 1.0 1.0 0.4
0.0 0.2 1.0 2.0 0.8 0.2

P 4112 A/B P 4111

KW HW
LT COLD
FLUSHIN FLUSHIN C-4103 C-4104
41011 HW
G G
 Steam Traps

• Basics of steam traps.

• Significance of steam traps
• To remove
- Condensate
- Air
- Non Condensable gases
TECHNIQUES FOR STEAM SYSTEM IMPROVEMENT

Techniques to minimize the load on steam traps

• Improve BFW quality (Avoid Priming)

• Avoid high load on boiler
• Improve insulation of steam lines.
• Reduce length of steam lines
• Audits of steam network
Pre-heating
De-aerator Hydrazine

BFW and STEAM

V-201

distribution system
B-605
B-601/602
KS header

HS header
LS header
 CLASSIFICATION OF STEAM TRAPS
Thermostatic
- Principle of working
- Heat transfer coefficient difference b/w steam &
condensate.

Mechanical
- Principle of working.
- Internal arrangement.

Thermodynamic
- Working on the difference is change of state.
 THERMOSTATIC TRAPS

• Rapid response on change in temp.

• Remove air/ non condensable.
• Their coaching leg should be at least 3 ft long for better response.

Types of Thermostatic Traps:

1- Liquid expansion.
2- Bellows traps.
3- Bimetallic traps.
 LIQUID EXPANSION
This is one of the simplest thermostatic trap. An oil filled element
expands / contracts for opening / closing of valve.

1- Diagram
2- Graph
Response Changes with Change in pressure as temp. varies with pressure
Typical balanced pressure capsule
arrangement
 ADVANTAGES
- Rugged.
- Good air handling capability.
- Withstand water hammer.
- Can be mounted on any position.

ADVANTAGES
- Dirt particles can prevent tight close.
- Requires substantial sub cooling.
- Slow response to changing condensate loads.
- Only works at temperature.
 BELLOWS TRAPS
Their valve actuator is a capsule or bellow filled with
vaporizing liquids which has boiling point somewhat lower
than water.

• Diagram
• Graph
BELLOWS TRAPS
 ADVANTAGES
- Excellent Air handling capacity.
- Energy efficient.
- Condensate discharge temperature follows the saturation

curve.
- Various condensate discharge temperature.
- Can be mounted in several positions.
- Simple construction.
- small size and wt.

DISADVANTAGES
- Delicate bellows.
- Not suited for high pressure.
 BIMETALLIC
These traps utilize the sensible heat in the condensate in
conjunction with line pressure to open and close a valve.

- Diagram
- Graphs
Simple bimetallic traps
MULTI STRIPS BIMETALLIC STRIPS
 ADVANTAGES
- Rugged.
- Energy efficient.
- Withstand water hammer.
- Capable of discharging temp. adjustment.
- Simple construction.
- Can be mounted on several position.

DISADVANTAGES
- Dirt particles can prevent tight valve closing.
- Balance may effected due to back pressure.
- Relatively slow response to changing condensate loads.
- Bimetallic elements corrosion problem.
Disc Spring Thermostatic
 MECHANICAL TRAPS
Main Features:
- Mechanical traps are phase detectors.
- These are independent of temp and pressure.
- These are extremely energy efficient.
BALL FLOAT TRAPS:

These traps are widely used on the plants. The opening and
closing of the valve is caused by changes of the condensate
level with in the traps shell.
SIMPLE FLOAT TRAP
Float Traps
 ADVANTAGES
- Unaffected by sudden or wide pressure changes.
- Responds very quickly to condensate load changes.
- Continuous discharge.
- Condensate discharge temp. Closely follow saturation
curve.
- Simple construction.

DISADVANTAGES
- Relatively large and heavy.
- Float easily damaged by water hammer.
- Can be mounted only in one position.
- Requires auxiliary air vent which is an additional source
of
failure.
 INVERTED BUCKET
As the name implies the working portion consists of an inverted
bucket attached through a lever to a valve. An essential part of
the trap is the small air vent hole in the top of the bucket.

-Step-1
-Step-2
-Step-3
-Step-4
COMPLETE CYCLE OF INVERTED BUCKET TRAP
Inverted Bucket Trap
 ADVANTAGES
- Simple construction.
- Rugged.
- Condensate discharge temp. Closely follow the saturation
curve.
- Fast response the change condensate loads.

DISADVANTAGES
- Marginal air handling during startup.
- Can lose prime and is not self priming.
- Can be mounted only us a single position.

OPEN BUCKET TRAP

This is also member of Mechanical traps but it is being used rarely.
Open Bucket
 THERMODYNAMIC TRAPS
Main Features:
- These traps are phase detectors.
- They can differentiate b/w liquids and gases.
- They can not differentiate b/w stream and air or other
non-condensable gases.
Types of Thermodynamic Traps:
1.Disc traps
2.Piston Traps
3.Lever Traps
4.Impulse
5.Labyrinth
6.Orifice Traps
DISC TRAPS:
This is the commonest type of trap relying on the fact that
hot condensate released in pressure will produce flash
steam. The trap is supremely simple.

Cause i Condensate Removal Phase:

Disc A is raised from the seat “C” by incoming pressure,
allowing air and condensate to pass radially outwards under
the disc before discharging through outlet B.
Cause ii:
Cause iii:
Cause iv:
DISC TRAPS
DISC TRAPS
• Advantages:
- Simple construction.
- Small size and
- Can be mounted in any position.
- Rugged.
- Withstand water hammer

• Disadvantages:
• Marginal air handling capability
• Condensate discharge temp. cannot be adjusted
• Excessive back pressure in return systems can prevent trap from
closing
• High discharge noise level.
 IMPLUSE TRAP
CONSTRUCTION
•It consists of a hollow piston A with a piston disc B working
inside a tapered position C which acts as a guide.
WORKING
At start up the main valve rests on the seat D leaving a
passage of flow through the clearance b/w piston and cylinder
and the hole E at the top of the piston.
Increasing flow of air and condensate will act on the piston
disc B and lift the main valve off its seat to give increased flow.
Some condensate will also flow through the gap b/w piston
and disc through E and away to the trap outlet.
As the condensate approaches steam temperature some of it
flashes to steam as it passes through the gap. Although it is
bled away through hole E it does create an intermediate
pressure over the piston, which effectively positions the main
valve to meet the load.
IMPULSE TRAP DIAGRAM
 ADVANTAGES
- Can handle substantial condensate capacity as compared
to their size.
- Suitable for high pressure applications.
- Good air venturing capabilities.
- Small, compact, easy to install.

DISADVANTAGES
- Cannot give a dead shut off and will blow steam on very
low load.
- Easily affected by dirt and plug small clearance b/w piston
and cylinder and of course the control orifice.
- Trap will not work against a back pressure which exceeds
40 % of the inlet pressure.
 LABYRINTH TRAPS
This is normal types steam trap. It consists of a series of
baffles which can be adjusted by means of a hand wheel.

Hot condensate passes through the baffles and trap

body is subjected to a drop in pressure and some of it
flashes to steam. A series of baffles slows down the
flow of condensate and prevents the escape of live steam.
 ADVANTAGES
- Can handle condensate is large capacity as compared to
its size.
- No mechanical failure since there are no moving parts.

DISADVANTAGES
- Manual adjustment is required with the variation in either
steam pressure or condensate load of the adjustment is
not done, stream wastage or water logging of the steam
space will occur.
 Summary of Traps Characteristics
F&T Bucket Disc Bellows Capsule Bimet- Bimet
thermo T/T
Discharge modul Cyclic Cyclic Cycl/mod Cyclic Cycl/mod Modul

Air Vent Good Poor Fair Excelnt Excelnt Excelnt Excelnt

Dirt Handling Good Good Good Fair Fair Good Good

Superheat Poor Poor Excelnt Good/fair Good Good Good

W/Hammer Poor Poor Excelnt Good/fair G/fair Excelnt Excelnt

Response Exclnt Good Good Good/fair G/fair G/fair G/fair

Fail mode Close Open/ Open Open/ Open/ open open

Close Closed Closed
Freezing Yes Yes No No No No No

Position Yes Yes No No No No No

sensitive
Back Psi No No Yes No No No No
Sensitive
 SELECTION OF STEAM TRAPS

•Sensitivity to back pressure.

•Sensitivity to dirt.

•Air venting capability.

•Venting non condensable at steam temp.

•Responsiveness to changing loads.

•Resistance to shocks, vibrations and water.

SELECTION OF STEAM TRAPS

Predominant failure modes.

Installation versatility.

Resistance to corrosion.
Energy Consumption of steam traps.
Condensate sub cooling.
Ease of maintenance.

Plant standards.
 CHECKING OF STEAM TRAPS
There are following techniques to check the performance.

1- Traps discharging to atmosphere.

2- Test vent.
3- Sight glasses.
4- Temperature difference.
5- Sound.
6- Electronic.