Steam traps

INTRODUCTION
Mankind first began to use steam in industry following the Industrial Revolution in the 18th
century. Initially, steam was used as a motive source, to drive pumps and locomotives. After a
time, the use of steam as a motive source declined and instead steam began to be more widely
used as a heating source.
Steam is formed when water vaporizes to form a gas. In order for the vaporization process to
occur, the water molecules must be given enough energy that the bonds between the molecules
break. This energy given to convert a liquid into a gas is called 'latent heat'. Steam-based heating
processes use latent heat and transfer it to a given product. When the work is done (steam has
given up its latent heat), steam condenses and becomes condensate. In other words, condensate
does not have the ability to do the work that steam does. Heating efficiency will therefore suffer
if condensate is not removed as rapidly as possible, whether in steam transport piping or in a heat
exchanger.
In the beginning, condensate was removed by manually operating a valve. However, this
practice is not only bothersome, but it also leaks steam. As the number of applications that use
steam grew, a valve to automatically remove condensate was developed and this was the birth of
the steam trap. The first steam trap to make an appearance was a bucket type steam trap,
developed in the first half of the 1800s.
Steam traps are a type of automatic valve that filters out condensate (condensed steam) and noncondensable gases such as air without letting steam escape. In industry, steam is used regularly
for heating or as a driving force for mechanical power. Steam traps are used in such applications
to ensure that steam is not wasted. Applications of steam traps are in refineries, food processing
industries, paper mills, textile plants, steel mills and power plants.

This wide range of users

creates an equally wide range of steam trap applications. In turn this wide variety of applications
is matched by a large array of steam trap types and sizes. Hence, when selecting a steam trap for
a specific process, some factors need to be taken into consideration to most effectively drain
condensate from their steam applications. Thus, in this assignment, factors influencing the
selection of steam traps will be identified.
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Steam traps

TYPES OF STEAM TRAPS

There are three primary categories of steam traps:

Mechanical: Mechanical steam traps are operated based on changes in fluid density.
Mechanical steam traps work by sensing the difference in density between steam and
condensate. Mechanical steam traps include ball float steam traps and inverted bucket
steam traps.

Thermostatic: Thermostatic steam traps are operated using changes in fluid temperature.
The temperature of saturated steam is dependent upon its pressure. In the steam space,
steam provides its enthalpy of evaporation, thus producing condensate at steam
temperature. Any further heat loss will cause the temperature of the condensate to drop.
Thermostatic traps retain condensate until cooled to below saturation temperature. A
thermostatic trap will pass condensate when this lower temperature is reached (sensed).
As steam reaches the trap, the temperature increases and the trap closes. Types of
thermostatic steam traps include liquid expansion, balanced pressure and bimetallic steam
trap.

Thermodynamic: Thermodynamic steam traps are operated based on changes in fluid

dynamics or changes in fluid pressure. Thermodynamic steam traps basically rely on the
principle of formation of flash steam from condensate. Flash steam is the natural
phenomenon occurring when hot condensate flows from a high pressure point to a low
pressure point. As a result, a portion of the liquid boils and a mixture of steam and water
is produced.

Steam traps

FACTORS INFLUENCING SELECTION OF

STEAM TRAPS
Before buying a steam trap for a particular application, a number of factors should be taken into
consideration so that the steam trap is chosen correctly. This is because many types of steam
traps are available today, with different material of construction, sizes, strength and designed for
particular application. Thus knowing which factors to consider during selection of steam traps
plays an essential role in this task.

The criteria to take into consideration for the selection of

steam trap are as shown below.

Dirt
Dirt is a factor which influences the selection of steam trap. Though steam condenses to distilled
water, it can sometimes contain trace products of boiler feed treatment compound and natural
minerals found in water. Moreover, pipe dirt created during installation and the products of
corrosion also need to be considered when selecting a steam trap.
Discharge Capacity
When selecting a steam trap for a particular process, it is foremost essential to identify the
discharge requirements of the steam trap application (e.g. hot or subcooled discharge), and select
the matching trap type.
o Safety Factor
The safety factor is a coefficient used when selecting the traps required discharge capacity. It
helps provide a buffer zone for instances when condensate volume exceeds calculated/predicted
values. The estimated condensate load should always be multiplied by the recommended safety
factor for trap selection.

The table below shows the steam trap type and safety factor

recommended.

Steam traps
Steam trap type

Minimum recommended safety factor

Float

1.5

Bucket

Disc

Thermostatic (X-element)

Bimetal

3 to 5

The safety factor can help compensate for when an insufficient pressure differential across the
trap impedes condensate discharge, such as when backpressure increases. During steam trap
selection, it is extremely important to apply the trap manufacturers recommended safety factor
after calculating the application load, making sure that the trap size also offers a sufficient
capacity for the application.
Resistance to Water Hammer
Water hammer is a common problem in steam system. It arises due to the poor design of the
steam and condensate pipework, the use of the wrong type of trap or a leaking steam trap.
Sometimes, though the correct trap for an application is installed, the system layout does not
allow the trap to operate correctly. When choosing a steam trap, it is important to take into
consideration its resistance to water hammer. Today, modern design and manufacturing
techniques have produced steam traps which are far more robust than those used beforehand.
This allows the steam trap to have a longer lifespan under normal conditions and is also better to
withstand the effects of poorly designed systems. Thermostatic steam traps have good resistant
against water hammer.
Steam Trap Life Cycle Cost
Steam traps are permanent part of steam systems, and should be selected according to their Life
Cycle Cost to offer the lowest system cost over the long-term.

This implies that initial

purchasing cost should only be one of the decision factors when selecting a trap. Other costs
such as maintenance, installation, replacement, operational monetary losses from functional and
failure steam leakage should also be taken into account.
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Steam traps
Rapid wear of internal components such as the valve seat causes steam leakage to increase over
time, eventually leading to premature steam trap replacement. The timing for replacement is
usually determined by evaluating replacement costs and comparing these to increased losses
from steam leakage and other losses such as those caused by trap failure. Alternatively, some
trap designs leak more steam than others even while in perfect accordance with the design
specifications. These traps can be eliminated in the design phase.
Body Material
The body material is one of the first factors that influence steam trap selection. The body
material of a steam trap is selected based on the condensate discharge location, maximum
operating pressure and temperature, the surrounding environment and the requirements for
longer lifespan. Some of the materials used for the steam trap body include gray Cast Iron,
carbon Steel and stainless Steel.
Sizing
The size of the steam trap is one of the factors that should be considered during selection. Often,
steam users select steam trap size based on the size of existing piping. However, this practice is
not good. This is because the proper steam trap size should closely match the size of the piping
on the outlet side of the equipment that supplies condensate to the trap.

Usually, to avoid

waterlogging which can lead to damage and heating problems, the steam trap is never sized
smaller than the equipment outlet piping.
Frost resistance
Sometimes, steam raps are used in applications where they are subjected to freezing
environment. Thus, appropriate steam trap should be chosen as not all steam trap are designed to
withstand such conditions. Some might need insulation such as the ball float steam trap type.
Ease of maintenance and Installation in any position
In addition to the above factors, it is also important to choose a steam trap which can be
maintained easily. Moreover, some users might find it useful to choose a steam trap that can be

Steam traps
installed in any position. The bimetallic steam trap can be installed in any position whereas the
ball float can both installed in any position and maintained easily
Able to handle flash steam
When condensate must be lifted from heat exchangers to the trap (syphon drainage), the pressure
is reduced between the drain point and the trap inlet. A portion of the condensate being drained
will flash back into steam because of this pressure reduction. Most traps are unable to distinguish
flash steam from live steam, so they close, impeding drainage. In order to handle flash steam a
steam trap, such as the differential condensate controller, provides a secondary discharge that can
be manually metered to create sufficient velocity to draw off the flash steam and noncondensable. Energy-conscious designers pipe the secondary discharge to flash tanks and then to
other operations.
Able to vent air at low pressure
Applications where the trap is located above the drip point, called syphon drainage, and some
that use modulating steam pressure may experience a great deal of air trapped in the steam space.
Often, there is little steam pressure to push it through the trap. In these applications, the steam
trap must be very effective at venting air.
Able to perform on very light loads
Many times traps are subjected to condensate load far below the maximum they are designed to
handle. These "light loads" are especially common on main drips and where steam pressure to
the heat exchanger is raised and lowered to meet a specific temperature demand. Where light
loads are present, the trap must be able to sense the small increase in the condensate level and
drain it effectively, yet be able to handle the maximum design load.
Able to operate against back pressure
A trap works best when the maximum differential pressure is applied across it (the maximum
allowable pressure is found at its inlet and a minimum pressure at its outlet). When condensate
lines must be elevated, or if there is a high pressure discharge into the return line, the outlet
pressure applied to the trap (back pressure) rises. While the reduced differential pressure will
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Steam traps
necessarily lower the capacity of any trap, some traps may operate incorrectly because of a
significant increase in back pressure.
Able to handle start-up loads
Some applications require that the supply steam valve be opened and closed regularly. When
systems are shut down, the steam remaining in the piping to the trap condenses, leaving large
amounts of condensate. Sometimes large amounts of non-condensables are present as well.
When the steam condenses, a vacuum is formed. Air can be drawn into the system through leaks
in gaskets or equipment, or through vacuum breakers.

CONCLUSION
It can be concluded that before purchasing a steam trap for a particular application, a number of
factors have to be considered. These factors influence the selection of the steam trap. On the
other hand, by taking these factors into consideration and bearing in mind for which application
the steam trap will be used, a wise choice can be made. These factors also ensure that the chosen
steam trap will be in good working condition during operation and will also have a longer
lifespan. By using the factors identified above during the selection of steam trap, there can be a
save up in terms of cost. This is because there will be no risks of faulty steam trap and change of
steam trap due to incorrect choice.

Steam traps

REFERENCES

Steam Trap Selection Guide. 2014. Steam Trap Selection Guide. [ONLINE] Available at:
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Spirax

Sarco

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Steam

Traps.

[ONLINE]

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http://www.spiraxsarco.com/resources/steam-engineering-tutorials/steam-traps-and-steamtrapping/considerations-for-selecting-steam-traps.asp. [Accessed 30 October 14].

TLV.

2014.

Steam

Trap

selection.

[ONLINE]

http://www.tlv.com/global/TI/steam-theory/cost-of-steam-trap-losses.html.

Available
[Accessed

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31

October 14].

Steam Trap Tables - Armstrong Steam University | Armstrong International, Inc.. 2014..
[ONLINE]

Available

at:

http://www.armstronginternational.com/armstrong-steam-

university-steam-trap-tables. [Accessed 02 November 2014].

Valves and Controls | Actuators, Valves, Controls | Pentair Valves & Controls. 2014.
[ONLINE] Available at: http://valves.pentair.com/. [Accessed 01 November 2014].

GESTRA GmbH. 2014. Steam Traps and Steam Trap Testing. [ONLINE] Available at:
http://www.flowserve.com/vgnfiles/Files/Literature/Products/Flowcontrol/Gestra/GSEBR000
8.pdf. [Accessed 04 November 14].