Steam contained by a boiler, contains heat energy, which is released either in process heating applications or by radiation losses from pipes and fittings. If condensate is not drained immediately as it forms, it can reduce the operating efficiency of the system by slowing down the heat teansfer to process . presence of condensate in a steam system can also cause physical damage due to water hammer or corrosion. The condensate accumulates in the botom of a horizontal pipe with steam passing over it. As the condensate builds up, it can form a solid slug of incompressible water travelling at high velocities. When the slug of water is suddenly stopped by a pipe bend, fitting or a valve,it can result in mechanical damage to the piping or fitting. The steam plant and piping layout should be designed to drain properly and avoid pockets where condensate can accumulate. A trap is therefore required at all locations where condensate is formed and collects principly.
Steam distribution mains
1. 2. 3. 4. 5.
at all low points in the piping
at elevation changes such as risers and expantion loops at intervals of 20-30 mtrs. on horizontal runs at dead ends of mains upstream of pressure and temperature control valves or meters
Steam tracing service
1. On steam tracers, jacketed piping and valves 2. For instrumental tracers for protecting equipment.
Air venting Air and other non condensible gases such as carbondioxide must also be rapidly purged from the steam system by the trap or by an auxilary air vent for four important reasons.
1. On start up steam enters the system only as fast as air is vented.
2. An air steam mixure has a temperature well below steam temperature lowring the heat transferred. 3. Air is an insulator and clings to the surface of the pipe or vessel causing slow and uneven heat transfer. 4. Dissolved in condensate. The non condensate gases form acid which orrode the system. Automatic air venting of steam mains and heat transfer surfaces is recommended as a standard engineering practice.
BASIC PRINCIPLES OF STEAM TRAP OPERATION
The steam trap is an automatic drain valve which distinguishes between steam and condensate. It must hold back steam and discharge condensate under varying pressures or loads. The trap must also release non condensible gases while holding back steam. The temparature at which the condensate is discharged by the trap is important in maintaining the plant efficiency. Most applications require that the condensate is discharged at steam temperature after utilising the latent heat energy for process since waterlogging of the steam space is generally not desirable. The many different types of steam traps manufactured today ,all operate by sensing the difference between steam and condensate using one of three basic principles when classified according to tyhese operating principles. Each design has advantages and limitations which must be considered when selecting the steam trap. 1. Density operated traps a. Ball float and thermostatic trap b. Inverted bucket trap 2. Temperature operated traps a. Balanced pressure thermostatic trap and air vent b. Liquid expansion thermostatic trap 3. Kinetic energy operated traps a. Thermodynamic disc trap b. Impulse trap Inverted bucket type steam trap This trap is a mechanical trap which operates on the difference in density between steam and water. Steam entering the inverted submerged bucket causes the bucket to float and close the discharge valve. Condensate entering the trap changes the bucket to a weight which sinks and opens the trap valve to discharge the condensate. Unlike other mechanical the inverted bucket also vents air and carbondioxide continuously at steam temperature.
Operation of the inverted bucket steam trap
1. when steam trap is taken in line , bucket is down and valve is wide open, as initial flood of condensate enters the trap and flows under bottom of bucket. Condensate fills trap body and completely submerges bucket. Condensate then discharges through wide open valve to return header. 2. When steam enters from under bottom of the bucket ,it raises and collects at top,imparting buoyancy to the bucket. Bucket then raises and lifts valve toward its seat until valve is snapped tightly shut. Air and carbon dioxide continually pass through bucket vent and collect at top of trap. Any steam passing through vent is condensed by radiation from trap. 3. As the entering condensate starts to fill the bucket , the bucket beginsto exert a pull on the lever. As the condensate continues to rise , more force is exerted until there is enough to open the valve against the differential pressure.. 4. As the valve starts to open , the pressure force across the valve is reduced. The bucket then sinks rapidly and fully opens the valve. Accumulated air is discharged first, followed by condensate. The flow under the bottom of the bucket picks up dirt and sweeps it out of the trap. Dischage continues until more steam floats the bucket, and the cycle repeats. Advantages 1. discharges condensate continuously as rapidly as it forms. 2. High air venting capacity through the air vent valve