STEAM

&
STEAM TRAPS
 STEAM

 Vapor form or
simply gaseous
phase of water
 USES OF STEAM

 Process-air heaters
 Heat exchangers
 Evaporators
 Jacketed kettles
 Rotating dryers
 Process
 Kitchen
 Laundry
 Tires factory
 USES OF STEAM

 Steam
Common in industrial process (like power plant)
Primary medium for distributing heat in factories,
hospitals and hotels
 Means of sterilizing, cooking (Chinese restaurants)
 Space heating
 Hot water supply
Heat transfer
 Latent heat of evaporation = 2257 kJ/kg at atm pressure
 Sensible heat of water = 419 kJ/kg (0 to 100 oC)
 USES OF STEAM

 Steam (cont’d)

Flow at high velocity (30-50 m/s) and high temperature

(100-198 oC)

Advantages over hot water systems

Smaller heat emitters, no pumps required

Disadvantage:
More complicated, more maintenance & supervision
 WHY STEAM
High latent heat allows given amount of heat to be
conveyed in relatively small pipes.
Weight of steam within a distribution system is
relatively low compared with the weight of hot water
No need to install expensive circulating pumps.

Odorless and non-toxic.

Doesn’t pose safety hazard when leaked.

 BASIC DEFINiTIONS

Enthalpy of Saturated Steam: Total heat content of steam

(sensible heat + latent heat)

Dryness Fraction: Steam quality is described by its 'dryness

fraction' ('dryness fraction' = proportion of completely dry steam
present in the steam-moisture mixture).

Saturation Curve: A graphical presentation of pressure &

temp. at which saturated steam and water exist. As pressure
increases, boiling point also increases.
BASIC BOILER OPERATION
FLUE GASES

STEAM
WATER

FUEL BOILER
AIR
ASH

BLOW DOWN
BASIC BOILER OPERATION
 TYPES OF STEAM
DRY SATURATED STEAM:
Dry saturated steam is one which has been completely evaporated
(contains no droplets of liquid water).
In practice, steam often carries tiny droplets of water.

WET STEAM
The steam becomes 'wet' if water droplets in suspension are present
Wet steam has a heat content substantially lower than that of dry
saturated steam at the same pressure.

SUPERHEATED STEAM
If saturated steam is remove from contact with water and further heated
at constant pressure, its temp. and volume both increase. The steam is
called superheated steam.
 SUPER HEATER

Super Heater is a Contrivance for producing

Super Heated steam so vital for power plant
for adding extra heat to saturated steam
produced in a steam boiler with out
increasing its pressure
 DESUPER HEATER

A desuperheater is an a appliance to convert

superheated steam to saturate state by addition of
moisture to reduce the temperature of steam for
auxiliary unit and also for very close temperature
regulation
Treated water is sprayed in the path of following
superheated steam
PURIFICATION IN THE STEAM
DRUM
 ADVANTAGES / SUPERHEATED
STEAM

The steam quality depends on moisture in it. The moisture in

saturated steam can corrode and erode turbine blades.

The superheated steam contains no moisture and does not

start to condense into water droplets until it is much farther
along in the turbine
 FLASH STEAM

steam that results when saturated water or condensate is

discharged to a lower pressure. When saturated water or
condensate is released to a lower pressure, its boiling
point is instantaneously reduced. Some of the condensate
will boil or flash into steam. This steam could not exist at
the higher pressure.
 STEAM PRESSURE

 Different pressure of steam are being used at plant,

Low pressure: up to 4 Kg/Cm2

Medium pressure: 8 to 13 Kg/Cm2

High pressure: 40 Kg/Cm2

STEAM GENERATION AT FFBL

 Auxiliary Boiler: Capacity: 95 tons/hr, 40 Kg/cm2,380oC

 HRSG: Capacity: 85 tons/hr, 40 Kg/cm2, 380 oC

 HSU: C-105 : 260 tons/hr, 40 Kg/cm2, 380 oC

V-405 : 110 tons/hr, 40 Kg/cm2, 380 OC

MS: Back-end:60 tons/hr,12.5Kg/cm2,250 oC

LS:Generated through let down of MS 3.5 Kg/cm2, 150oC

Generated from HPCC: 70 tons/hr,3.5 Kg/cm2, 150oC
STEAM LOSSES
 INSULATION
Surveyors indicates that energy demand can be reduced by
10% through improved insulation.

An uncovered 100m length , 50mm dia pipe carrying steam will

lose ~ 180kg/hr of steam

Heat loss from a single pair of flanges is equivalent to 0.3m

length of pipe.

Insulation efficiency should be greater than 80% is essential.

 STEAM LEAKS

3mm diameter hole can discharge as much as 40Kg/hr of

steam at 10 barg which represents a waste of approximately
31 tones of coal, 18 tones of oil over a period of 8400 hrs
operation.

STEAM LOSS THROUGH ORIFICES (Pound per hr)

Orifice,
2 psi 5 psi 10 psi 15 psi 25 psi 50 psi
inch

1/4 20.0 31.6 44.6 54.7 73.1 119.0

CONDENSATION
 CONDENSATION
As soon as the steam leaves boiler, it begins to give
up some of its heat energy.

Formation of Condensate Depends on:

Rate of Heat Transfer

Insulation of Pipes
Ambient Temperature / Air velocity
 PROBLEMS DUE TO CONDENSATION

STEAM HAMMERING

STEAM STARVATION

LOW HEAT TRANSFER

IRREGULAR EXPANSION
STEAM HAMMERING
STEAM STARVATION
RESISTANCE TO HEAT FLOW
RESISTANCE TO HEAT FLOW
 COLD SPOTS

Cold spots cause uneven temp. at heat transfer surface,

which can let to unequal expansion may cause joint
failures.
 AIR REMOVAL

Complete air removal is

essential at the time of
start-up.
ALIGNMENT & DRAINAGE
OF STEAM LINES
 ALIGNMENT & DRAINAGE OF
STEAM LINES
Steam lines arranged with a fall in the direction of
flow. Steam line should be drained at regular
intervals.

A fall of 40 mm in 10m is adequate.

The distance between drain points is 30 ~ 50 m.

(depends upon line size and frequency of start-up

intervals)
ALIGNMENT & DRAINAGE OF
STEAM LINES
INSTALLATION PRINCIPLE
 DRIP LEGS

Drip leg dia 2 ~ 3 size smaller than the line dia.

Drip leg dia is same as header dia upto 4”, above 4”,
½ header size but never less than 4”
DRIP LEGS
BRANCH CONNECTION
 STEAM CIRCUIT

heat radiation from the distribution system causes condensate to form and,
therefore, requires steam traps at natural low points or ahead of control valves.
In the heat exchangers, traps perform the vital function of removing the
condensate before it becomes a barrier to heat transfer. Hot condensate is
returned through the traps to the boiler for reuse.
INSTALLATION PRINCIPLE
STEAM TRAPS
WHY STEAM TRAPS..??
 STEAM TRAPS

Steam traps are automatic drain

valves, that are installed all
along the steam header so that
condensate can be drained
properly.

Steam traps are the key to

optimum steam / condensate
system operation.
FUNCTION OF STEAM TRAPS

 Remove Condensate

 Remove Air And Other Gases

 Prevent Steam Loss

 TYPES OF STEAM TRAPS

● Thermostatic (Temperature Difference)

● Mechanical (Density Difference)

● Thermodynamic (Change Of State)

 THERMOSTATIC TRAPS

Operates on temperature difference between steam and

condensate.
They have a expansion / contraction elements that
drives the valve to On / Off condition caused by
temperature change.

examples: Bellows traps

Bimetallic traps
 BELLOWS TRAPS
The closed bellows contains
a volatile spirit which has a
boiling point suiting the
temperature.
When steam enters the traps
the volatile spirit expands
open the bellows  close
the valve.
Water enters the traps at a
temperature lower than
steam, the spirit contracts
and closes the bellows 
opening the valve + allowing
water to flow back to boiler.
BELLOWS TRAPS
Steam
Condensate

Bellows

Liquid fill

Valve

Seat
 ADVANTAGES
(BELLOW TRAPS)

Can be mounted in several position.

Small size and weight.

Excellent air handling capacity

 DISANDVATGES
(BELLOW TRAPS)

Water hammer may damage bellow.

Not suited for high pressure.

 BIMETALLIC TRAPS

Water enters the traps at a

temperature lower than
steam, the metal leaf
contracts  opening the
valve + allowing water to
flow back to boiler.

When steam enters the traps

the metal leaf expands
close the valve  stop the
steam to flow
 Simple Bi-Metal Operation
Valve inside trap
 Back pressure can
blow trap open
 Opening and closing
temperatures wide
apart
 Must sub-cool deeply
to prevent steam loss
 ADVANTAGES
(BIMETTALIC)

Can be mounted in several position.

Capable of discharge temperature

adjustment.
 DISADVANTAGES
(BIMETALLIC)

Dirt particles may prevent tight closure.

Slow response to condensate changing

load

Bimetallic elements are susceptible to

corrosion
 MECHANICAL TRAPS

Operates on difference of density between steam and

condensate
they have a float mechanism that rises and falls in
relation to condensate level and have a mechanical
linkage that opens / close the valve.

examples: Inverted bucket

Float type
Float & thermostatic
INVERTED BUCKET TRAPS
 Inverted Bucket

A. Bucket

B. Valve on linkage

C. Air Vent
D

D. Body

E. Inlet
 IB At Start-Up
 Condensate fills body
 Condensate surrounds all internals; Condensate
pressure same on all surfaces of all
Valve wide open
internals.
 Valve wide open for maximum flow
rate; quick drain
 Air pushed out ahead of condensate
through wide open valve; quick vent
 Small dirt particles suspended in flow
and flushed through valve
 Large dirt particles are too heavy to
be carried to valve by low velocity
flow around bucket lip, so they stay at Low
bottom velocity
flow
 IB Closed
 Start-up condensate
accumulation gone Valve tightly closed
 Steam enters depressing water
level in bucket
 When bucket approximately 2/3
full of steam, bucket becomes
buoyant
 Bucket floats valve to seat
 Pressure difference pushes valve
softly into seat
 Valve seats tightly
 Air passes through vent to collect
at top of trap
Condensate
level
 IB Filling
Valve tightly closed
 Valve closed; condensate continues
to enter trap; no condensate back-up
 Intermittent discharge but continuous
drain
 Water condenses and displaces
steam; water level rises
 Air continually rises through vent to
top of trap
 If air accumulation becomes Steam
excessive, air will depress water level
and open valve
Condensate
 IB Opening
 Water level continues to rise
Valve wide open
 Bucket 2/3 full of water loses
buoyancy; bucket falls pulling valve
wide open
 Air flushed out
 Full capacity flow carries small dirt
particles to wide open valve to flush
each cycle
 Pressure changes affect capacity only
 Cycle rate adjusts immediately with
flow changes Small dirt
flushed
IB VALVE SEAT
 ADVANTAGES
(INVERTED BUCKET)

Immediate response to condensate.

Dirt handling ability/low dirt problem.

Continuous air/non condensable venting.

Simple construction.
 DISADVANTAGES
(INVERTED BUCKET)

Can me only mounted in single position.

Marginal air handling during startup.

FLOAT TRAPS
 Float and Thermostatic

Start-Up Modulating Air Venting

Condensate flow decreases Air increases;

temperature drops; vent
Condensate enters Ball moves downward; opens
valve open less
Ball rises opening valve Steam lost with air
to full capacity Valve modulates to balance removal
outlet flow
Bellows cold; vent open Dirt falls to bottom; may
to air and/or condensate Steam enters; steam closes stop ball from dropping
flow vent. holding valve open; may
plug valve
 ADVANTAGES
(FLOAT TRAPS)
Wide pressure range

Respond quickly to condensate laod change.

Simple construction.

Suitable for large flow rate handling.

Combination of F&T is a plus point

 DISADVANTAGES
(INVERTED BUCKET)

Relatively large and heavy.

Float easily damaged by water

hammering.
THERMODYNAMIC TRAPS

These traps operate on the principal that hot

condensate flash off to give a steam and water
mixture.

In simple words they work on pressure difference

examples: Disc trap

Lever trap
DISC TRAPS
DISC TRAPS
 ADVANTAGES
(DISC TRAP)
Simple construction.

Small size and light weight

Can be mounted in any position

Withstands water hammer

 DISADVANTAGES
(DISC TRAP)

Marginal air handling capacity

High discharge noise level.

Excessive back pressure can prevent

closing
BOOSTER PUMPS
SELECTION OF STEAM TRAPS
● Sensitivity to back pressure.
● Sensitivity to dirt.
● Air venting capability.
● Responsiveness to changing loads.
● Resistance to shock, vibration, hammer.
● Predominant failure modes.
● Installation versatility.
● Resistance to corrosion.
● Energy consumption.
● Ease of maintenance.
 INSTALLATION PRINCIPLE
 Condensate should drain freely to and from
the steam trap.
 Line restrictions should be avoided.
 Easy access for checks and maintenance
activities.
 Strainers must be installed at upstream of
steam traps.
INSTALLATION PRINCIPLE
INSTALLATION PRINCIPLE
STEAM STEAM

COIL COIL COIL COIL

TRAP TRAP
TRAP
 CHECKING PERFORMANCE

● Traps Discharging To Atmosphere.

● Temperature.

● Sound.
 TEMPERATURE

The inlet temperature can be measured by

contact pyrometer, A tarp operating properly
should be close in temperature to that of
steam, Hot is defined as within 30F of the
steam, Cold is more than 30F.
Some critical services may require that
condensate be within 5F of steam
temperature.
CHECKING
TROUBLESHOOTING
 COLD TRAP--------NO DISCHARGE

Reasons for cold trap,

● Pressure may be too high

● No condensate coming to steam trap
broken valve in the line to trap
chocked strainer
● Trap body filled with dirt
● For IB, bucket vent filled with dirt
● For F&T , air vent is not functioning properly / ball
damaged.
● For thermostatic traps the bellows elements may
rupture from hydraulic shock causing the trap to fail
closed
 HOT TRAP---------STEAM LOSS

If the trap blows live steam, the reason may be

● Valve may fail to seat.( piece of scale lodged in

orifice)
● For F&T thermostatic element may fail to
close.
 CONTINOUS FLOW

If an IB or disc trap discharges continuously,

or an F&T or thermostatic tarp discharge at
full capacity then the reason may be

 Trap too small ( larger trap or additional tarps

should be installed in parallel)
 High pressure traps may have been used for a low
pressure system
 Abnormal water conditions (steam quality)
 SLUGGISH HEATING

When traps operates satisfactorily, but unit

fails to heat properly.

 Traps may be too small for a given job even

handling condensate efficiently ( try larger trap )

 Air may be not reaching trap (use auxiliary air

vent)

 Abnormal water conditions (steam quality)

 TROUBLE
If trap operates satisfactorily when discharging to
atmosphere, but troubles when connected to
network.

 Back pressure may reduce capacity of trap

return line too small ,

Atmospheric vent in condensate receiver may be plugged

 TROUBLE

If it appears that steam escapes every time

thru trap discharge vent

Condensate may form flash steam.

TRAPS TESTING FREQUENCY
Thank You