OVERVIEW

Why steam traps?

'The duty of a steam trap is to discharge condensate while not permitting the escape of live steam'

As we know, presence of water in steam can have bad effect on the down stream equipment may it be the impingement plates of brine heaters, may it be the nozzles of the ejectors, may it be the Steam turbine blades and vanes or it may the steam turbine bypass station. Not only the water in steam can have a mechanically unacceptable impact on the down steam equipment but it also can have an unacceptable thermal shock on the down stream equipment. A good example is the steam turbine. (A gram of water can reduce the temperature on a steam turbine metal by about seven degrees centigrade at that the point of contact for a short time.) Another serious issue is the possibility of hammering when steam and water are mixed. Therefore steam systems are always provided with that crucial component 'the steam trap' (or trap). A steam trap quite literally 'purges' condensate, (as well as air and other incondensable gases), out of the system, allowing steam to reach its destination in as dry a state/condition as possible to perform its task efficiently and economically. Some of the steam traps are also capable to release air when in the beginning the pipelines and equipment is filled with are and steam is being admitted. Condensate removal Having vented the air, the trap must then pass the condensate but not the steam. Leakage of steam at this point is inefficient and uneconomical. The steam trap has to allow condensate to pass whilst trapping the steam in the process

How steam traps operate There are three basic types of steam Mechanical (operated by changes in fluid density) Thermostatic (operated by changes in fluid temperature) Thermodynamic (operated by changes in fluid dynamics)

Thermodynamic steam traps rely partly on the formation of flash steam from condensate. This group includes 'thermodynamic', 'disc', 'impulse' and 'labyrinth' steam traps. In addition to downstream flash steam assist, this type of trap operates on the difference in velocity or kinetic energy between steam and condensate passing through a fixed or modulating orifice. Also included in this type are 'fixed orifice traps', which cannot be clearly defined as automatic devices as they are simply a fixed diameter hole set to pass a calculated amount of condensate under one set of conditions. All rely on the fact that hot condensate, released under dynamic pressure, will flash-off to give a mixture of steam and water.

MECHANICAL STEAM TRAPS

This range of steam traps operates by sensing the difference in density between steam and condensate. These steam traps include 'ball float traps' and 'inverted bucket traps'. In the 'ball float trap', the ball rises in the presence of condensate, opening a valve which passes the denser condensate. With the 'inverted bucket trap', the inverted bucket floats when steam reaches the trap and rises to shut the valve. Both are essentially 'mechanical' in their method of operation.

A typical trap is described here.

Float & Thermostatic Type Description

The Float & Thermostatic Trap utilizes two individual mechanisms that operate in conjunction with one another. The float operates a valve (Fig. 6) that controls the discharge of condensate. The thermostatic element controls the release of air and CO2. The float itself, which is normally a ball type, is located in the lower portion of the trap body. It is attached to a rod which is, in turn, attached to the body of the trap in such a way that it is free to pivot about that point, allowing the float the freedom to move vertically. Near the end where the rod is attached to the body a valve is attached to the rod. The valve is positioned so that when the float is at rest the valve is seated in the outlet of the trap. The thermostatic element is located in the upper part of the trap body. One end of the element is fixed allowing the opposite end with an attached valve to move in and out of a seated vent discharge opening located in the body of the trap. That vent discharge is connected to the discharge for the condensate. In its relaxed position the valve is pulled away from the seat. With the trap out of service the float rests in its bottomed out position, with the valve closed. The thermostatic vent element is in its contracted position with its valve open. As steam is introduced to the system and begins to move through the piping it will force the volume of air in the piping out ahead of it. This air is forced out of the system through the opened thermostatic vent. Depending upon the length of the piping the steam will initially condense in the piping before it gets to the trap. As the condensate enters the trap and begins filling the trap body the float will rise pulling the valve off of the discharge seat. This allows the condensate to be removed immediately. With the thermostatic vent and the condensate discharge both in their open positions steam begins to enter the trap. As this happens the heat of the steam causes the thermostatic element to expand closing off the vent orifice. However, as long as there is a sufficient condensate level in the trap the condensate outlet orifice will remain open. This trap is self-regulating. If the condensate enters at a constant rate it will discharge at a continuous and constant rate. As the steam condenses the released air and CO2 will accumulate at the top of the trap, around the thermostatic vent. This provides an 3

insulation barrier from the heat of the steam allowing the thermostatic vent to cool down sufficiently to contract, opening the vent discharge orifice. As the air and CO2 are released steam replaces that volume and again comes in contact with the thermostatic element causing it to expand, closing off the discharge orifice.

Fig.

6 - Float & Thermostatic Trap

Float & Thermostatic Type - Application

This trap can be used in Process and utility applications as well as HVAC service. It is a good choice for high capacity requirements. However, it does not stand up well in conditions where the trap may be subjected to water hammer and/or freeze up. The float and thermostatic element can be damaged by water hammer and the float can be damaged by freeze up. If selected, given those considerations, this is an excellent multi-use trap.

THERMOSTATIC STEAM TRAPS

This type of trap operates on the principle of expanding liquids and metals used to drive a valve into or back it away from a seat. The temperature of saturated steam is determined by its pressure. In the steam space, steam gives up its enthalpy of evaporation (heat), producing condensate at steam temperature. As a result of any further heat loss, the temperature of the condensate will fall. A thermostatic trap will pass condensate when this lower temperature is sensed. As steam reaches the trap, the temperature increases and the trap closes. Most of the traps in Power area are of this type.

Adjustment

Stem

Disc

The regulator, item 2 will expand on higher temperature and lifts the stem /disc of the valve thus closing the valve. As can be seen in the drawing the pressure tries to contract the regulator and open the valve and temperature tries to expand the regulator and close the valve. This makes it work in such a way that if the temperature of the medium in the body is less than saturation temperature, the valve opens as the effect of pressure is predominant. If the temperature of the medium is higher than the saturation temperature, the valve closes as the effect of temperature is predominant. By means of the adjustment, we can make the trap operate as saturation temperature or a little bit less or more than the saturation temperature.

THERMODYNAMIC STEAM TRAPS

Most of the traps in Desal area are of this type specifically called disc type thermodynamic traps. The disc trap is made up of three primary components: the body, the cap and the disc. Figure below shows a simple disc trap. As flow, in the form of condensate, moves into the trap and through the inlet orifice it forces the disc to lift, allowing the condensate to pass through and out the outlet. As the temperature of the condensate reaches it's saturation point a percentage of that condensate will flash as it exits the inlet orifice. This formation of steam increases the velocity but creates a low pressure zone between disc and seats pulling the disc down upon the seats. This is made possible due the steam flashed above the disc exerting pressure in the close direction. The disc will remain in place until the flash steam has condensed, thus allowing the disc to open again.

The amount of condensate that accumulates upstream of the trap is dependent upon the amount of time the flash steam remains in that state. This, in essence, is what regulates operation of the trap. 6

Since the flash steam is contained in the cavity under the cap the length of time that the flash steam exists as such depends on the amount of heat transfer through that cap. The cycle of this type of trap depends on the condensing rate of the flash steam that keeps the disc closed and not on the build-up of the condensate itself. The disc trap is lightweight, compact, easy to install, easy to maintain, withstands water hammer and is relatively less expensive than other types of traps. When a slow warm up is part of the start-up procedure it is an excellent trap for automatic start-ups. If, during start-up, steam is introduced suddenly to a system, without benefit of a warm up cycle, the rush of air preceding the condensate and steam to the trap will create enough velocity across the trap seating surface to force the disc to close. Disabling the system in this manner is referred to as air binding. Since there is no flash steam to keep the disc closed the disc will have a tendency to flutter, or chatter. Although it will continue to discharge air it will prevent the trap from discharging it at the necessary rate. In the case where steam is introduced without warm-up it is recommended to either provide additional valving for blow down during start-up or specify a different type trap altogether.

TESTING STEAM TRAP OPERATION

In our plant we monitor the functioning of the traps in the following three ways. One is by measuring the trap body temperature. It has to be around the saturation temperature Second is the trap discharge method. Here the trap is isolated from the condensate return line by one valve, and the bypass valve to atmosphere is opened and if steam and condensate are observed it is Ok. If only cold water gushes out for some time initially, the trap is not working. Third is possible if there is free blow valve or test valve immediately after the trap. Observing the cycling of the trap functioning will indicate the proper functioning of the trap.

QUESTIONS 1. 2. 3. 4. 5. 6. 7. 8. 9. What is the purpose of Steam traps? Mention three basic types of Steam traps? Explain how a mechanical trap works. Explain how a thermo dynamic trap works. Explain how a thermo static trap works. What are the advantages of thermo dynamic trap What are the disadvantages of thermo dynamic trap What the disadvantage if a trap do not drain condensate What is the disadvantage if a trap continuously discharges steam? 10. How to check whether the proper working in case of a trap a. which is discharging to open atmosphere ? b. which has a bypass valve to open atmosphere c. where there is no bypass valve and trap do not discharge to atmosphere?