Steam Trap Manuals Explained

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Steam Trap Manuals
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Steam Trap manual
Steam Trap Manual

Table of Content
A. Introduction
1. Why Steam traps
2. Considerations for steam traps selection
3. How steam traps works
4. Steam traps standards
B. Type of Steam traps
1. Thermostatic Steam traps
2. Mechanical Steam Traps
3. Thermodynamics Steam Traps
C. Consideration for Selecting Steam traps
1.
2.
3.
4.
5.
6.
7.
8.
Water hammer
Dirt
Strainers
Steam Locking
Group Trapping
Diffusers
Vacuum Drainage
Draining from temperature controlled processes
D. Methods of Testing Steam Traps

1. Watching trap discharge
2. Using sight glass
3. Checking the vent pipe (for common line return)
4. Spraying water on the traps
5. Temperature sensitive crayon
6. Temperature measurement device (probe or non-contact type)
7. Industrial stethoscope
8. Ultrasonic Leak Detector
9. Conductivity method
E. Maintenance of Steam Traps
F. Installation and Maintenance Instruction Manuals
1. TD42S2 Thermodynamic Steam Traps
2. SMC32 Bimetallic Steam Traps
3. BPC32 Balance Pressure Steam Traps
A. Introductions
Why Steam Traps?
Introduction
Throughout the history of steam utilisation, Spirax Sarco has been at the forefront of improving
the efficiency of steam plant. Since 1935, the Spirax Sarco range of products has widened
considerably and is now specified worldwide on the many types of plant employing steam.
Today, there are few manufacturing processes that do not rely upon steam to provide an end
product.
The steam trap is an essential part of any steam system. It is the important link between good
steam and condensate management, retaining steam within the process for maximum utilisation
of heat, but releasing condensate and incondensable gases at the appropriate time.
Although it is tempting to look at steam traps in isolation, it is their effect on the steam system as
a whole that is often not appreciated. The following questions become important:
o
Does the plant come quickly up to temperature or is it slow to respond,

and its performance less than it should be?
Is the system trouble free, or does inadequate steam trapping permit waterhammer,
corrosion and leakage, and high maintenance costs?
Does the design of the system have a negative effect on the life and efficiency
of the steam traps?
It is often true that if an inappropriate steam trap is selected for a particular application, no ill
effects are noticed. Sometimes, steam traps are even shut-off completely without any apparent
problems, for example on a steam main, where incomplete drainage of condensate from one
drain point often means that the remainder is simply carried on to the next. This could well be a
problem if the next drain point is blocked or has been shut-off too!
The observant engineer may recognise that wear and tear of control valves, leakage and reduced
plant output, can all be remedied by paying proper attention to steam trapping. It is natural for
any mechanism to suffer from wear, and steam traps are no exception. When steam traps fail
open, a certain amount of steam can be passed into the condensate system, although it is often
a smaller quantity than might be expected. Fortunately, rapid means of detecting and rectifying
such failures are now available to the steam user.
Why steam traps?

'The
duty of a steam trap is to discharge condensate

while not permitting the escape of live steam'
No steam system is complete without that crucial component 'the steam trap' (or trap). This is the
most important link in the condensate loop because it connects steam usage with condensate
return.
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.
The quantity of condensate a steam trap has to deal with may vary considerably. It may have to
discharge condensate at steam temperature (i.e. as soon as it forms in the steam space) or it may
be required to discharge below steam temperature, giving up some of its 'sensible heat' in the
process.
The Steam and Condensate Loop
The pressures at which steam traps can operate may be anywhere from vacuum to well over a
hundred bar. To suit these varied conditions there are many different types, each having their
own advantages and disadvantages. Experience shows that steam traps work most efficiently
when their characteristics are matched to that of the application. It is imperative that the correct
trap is selected to carry out a given function under given conditions. At first sight it may not seem
obvious what these conditions are. They may involve variations in operating pressure, heat load
or condensate pressure. Steam traps may be subjected to extremes of temperature or even
waterhammer. They may need to be resistant to corrosion or dirt. Whatever the conditions,
correct steam trap selection is important to system efficiency.
It will become clear that one type of steam trap can not possibly be the correct choice for all
applications
Considerations for steam trap selection

Air venting
At 'start-up', i.e. the beginning of the process, the heater space is filled with air, which unless
displaced, will reduce heat transfer and increase the warm-up time. Start-up times increase and
plant efficiency falls. It is preferable to purge air as quickly as possible before it has a chance to
mix with the incoming steam. Should the air and steam be mixed together they can only be
separated by condensing the steam to leave the air, which must then be vented to a safe place.
Separate air vents may be required on larger or more awkward steam spaces, but in most cases
air in the system is discharged through the steam traps. Here thermostatic traps have a clear
advantage over some types of trap since they are fully open at start-up. Float traps with inbuilt
thermostatic air vents are especially useful, while many thermodynamic traps are also quite
capable of handling moderate amounts of air. However, the small hole in fixed orifice condensate
outlets and the bleed hole in inverted bucket traps both vent air slowly. This could increase
production times, warm-up times, and corrosion.
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. If good heat transfer is critical to the process, then
condensate must be discharged immediately and at steam temperature. Waterlogging is one of
the main causes of inefficient steam plant as a result of incorrect steam trap selection.
Plant performance
When the basic requirements of removing air and condensate have been considered, attention
may be turned to 'plant performance'. Simply put, unless specifically designed to waterlog, for a
heat exchanger to operate at its best performance, the steam space must be filled with clean dry
steam. The type of steam trap will influence this. For instance, thermostatic traps retain condensate
until cooled to below saturation temperature. Should this condensate remain in the steam space,
it would reduce the heat transfer area and the heater performance. The discharge of condensate
at the lowest possible temperature may seem very attractive, but generally most applications
require condensate to be removed from the steam space at steam temperature. This needs a
steam trap with different operating properties to the thermostatic type, and this usually means
either a mechanical or thermodynamic type trap.
Before choosing a particular steam trap it is necessary to consider the needs of the process. This
will usually decide the type of trap required. The way in which the process is connected to the
steam and condensate system may then decide the type of trap preferred to do the best job
under the circumstances. Once chosen, it is necessary to size the steam trap. This will be
determined by the system conditions and such process parameters as:
o
Maximum steam and condensate pressures.
Operating steam and condensate pressures.
Temperatures and flowrates.
Whether the process is temperature controlled.
These parameters will be discussed further in subsequent Modules within this Block.
Reliability
Experience has shown that 'good steam trapping' is synonymous with reliability, i.e. optimum
performance with the minimum of attention.
Causes of unreliability are often associated with the following:
o
Corrosion, due to the condition of the condensate. This can be countered by using particular
materials of construction, and good feedwater conditioning.
Waterhammer, often due to a lift after the steam trap, sometimes overlooked at the design
stage and often the cause of unnecessary damage to otherwise reliable steam traps.
Dirt, accumulating from a system where water treatment compound is carried over from the
boiler, or where pipe debris is allowed to interfere with trap operation.
The primary task of a steam trap is the proper removal of condensate and air and this requires a
clear understanding of how steam traps operate.
Flash steam
An effect caused by passing hot condensate from a high pressure system to a low pressure system
is the naturally occurring phenomenon of flash steam. This can confuse the observer regarding
the condition of the steam trap.
Consider the enthalpy of freshly formed condensate at steam pressure and temperature (obtainable
from steam tables). For example, at a pressure of 7 bar g, condensate will contain 721 kJ /kg at a
temperature of 170.5C. If this condensate is discharged to atmosphere, it can only exist as
water at 100C, containing 419 kJ /kg of enthalpy of saturated water. The surplus enthalpy content
of 721 - 419 i.e. 302 kJ /kg, will boil off a proportion of the water, producing a quantity of steam
at atmospheric pressure.
The low pressure steam produced is usually referred to as 'flash steam'. The amount of flash
steam released can be calculated as follows:
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If the trap were discharging 500 kg /h of condensate at 7 bar g to atmosphere, the amount of
flash steam generated would be 500 x 0.134 = 67 kg /h, equivalent to approximately 38 kW of
energy loss!
This represents quite a substantial quantity of useful energy, which is all too often lost from the
heat balance of the steam and condensate loop, and offers a simple opportunity to increase
system efficiency if it can be captured and used.
How steam traps operate

There are three basic types of steam trap into which all variations fall, all three are classified by
International Standard ISO 6704:1984.
Types of steam trap:

o
Thermostatic (operated by changes in fluid temperature) - 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.
Mechanical (operated by changes in fluid density) - 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.
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.
Also loosely 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.
The following Modules include reference to these steam traps.
International and European Standards

relating to steam traps
ISO 6552 : 1980
(BS 6023 : 1981)
Glossary of technical terms for automatic steam traps
ISO 6553 : 1980

CEN 26553 : 1991 (Replaces BS 6024 : 1981)
Marking of automatic steam traps
ISO 6554 : 1980

CEN 26554 : 1991 (Replaces BS 6026 : 1981)
Face-to-face dimensions for flanged automatic steam traps
ISO 6704 : 1982

CEN 26704 : 1991 (Replaces BS 6022 : 1983)
Classification of automatic steam traps
ISO 6948 :1981

CEN 26948 : 1991 (Replaces BS 6025 : 1982)
Production and performance characteristic tests for automatic steam traps
ISO 7841 : 1988

CEN 27841 : 1991 (Replaces BS 6027 : 1990)
Methods for determination of steam loss of automatic steam traps
ISO 7842 : 1988

CEN 27842 : 1991 (Replaces BS 6028 : 1990)
Methods for determination of discharge capacity of automatic steam traps
Questions
1. Are steam traps required to pass air?
a| Steam traps should not pass air under any circumstances
b| Only when the trap has passed all the condensate
c| Air should be removed as soon as it reaches the trap
d| Only on high pressure steam systems
2. How is flash steam produced?

a| From condensate passing from high to low pressure systems
b| From saturated steam
c| From superheated steam
d| From steam mixed with high temperature air
3. Should steam traps match the application?

a| Any steam trap (if properly sized) can be fitted to any application
b| Only if fitted to a heat exchanger
c| Only on high pressure steam systems
d| Yes
4. Unless they are designed to flood, what is important when removing condensate from
heat exchangers?
a| Condensate is allowed to sub-cool before reaching the trap
b| Condensate is removed at steam temperature
c| Condensate should back-up into the steam space
d| That the trap is fitted level with or above the heater outlet
5. Can temperature controlled applications be trapped?

a| Traps should not be fitted under any circumstances
b| Only if there is no lift after the trap
c| If the pressure on the trap is always higher than the backpressure
d| Pumps should always be fitted to remove condensate
6. What are the main considerations for steam trap selection?

a| Price
b| Air venting, plant performance, flow capacity and reliability
c| Connections
d| The trap must be the same size as the condensate drain line
Answers
1:c, 2: a, 3: d, 4: b, 5: c, 6: b
11.1.7
Thermostatic Steam Traps
Thermostatic Steam Traps

Liquid expansion steam trap
This is one of the simplest thermostatic traps and is shown in Figure 11.2.1. An oil filled element
expands when heated to close the valve against the seat. The adjustment allows the temperature
of the trap discharge to be altered between 60C and 100C, which makes it ideally suited as a
device to get rid of large quantities of air and cold condensate at start-up.
Condensate out
Lock-nut
Oil filled
element
Seat Valve
Adjustment nut
Condensate in
Valve head
Overload spring
Fig. 11.2.1 Liquid expansion steam trap
As discussed in Module 2.2, the temperature of saturated steam varies with pressure.
Figure 11.2.2 shows the saturation curve for steam, together with the fixed temperature response
line (X - X) of the liquid expansion trap, set at 90C.
It can be seen from Figure 11.2.2 that when the pressure is at pressure P1, condensate would
have to cool by only a small amount (DT1), and trapping would be acceptable. However, if
pressure is increased to P2 then condensate has to cool more (DT2) to pass through the steam
trap. This cooling can only occur in the pipe between the process and trap, and if the trap
discharge temperature remains constant, the process will waterlog.
Steam saturation curve
Temperature T
DT2
DT1
90C X
P1
X Fixed temperature
response line
P2
Steam pressure P
Fig. 11.2.2 Response of a liquid expansion steam trap X - X
Typical application
Because of its fixed temperature discharge characteristic, the liquid expansion trap may be usefully
employed as a 'shutdown drain trap'. Here, its outlet must always point upwards, as illustrated
in Figure 11.2.3, to enable continuous immersion of the oil filled element. As the trap can only
discharge between 60C - 100C it will only normally open during start-up. It can be installed
alongside a mains drain trap which would normally be piped to a condensate return line.
Steam main
Condensate
to return line
Liquid expansion
steam trap
Condensate
to drain
Fig. 11.2.3 Installation of a liquid expansion steam trap
Advantages of the liquid expansion steam trap:

o
Liquid expansion traps can be adjusted to discharge at low temperatures, giving an excellent
'cold drain' facility.
Like the balanced pressure trap, the liquid expansion trap is fully open when cold, giving good
air discharge and maximum condensate capacity on 'start-up' loads.
The liquid expansion trap can be used as a start-up drain trap on low pressure superheated
steam mains where a long cooling leg is guaranteed to flood with cooler condensate. It is able
to withstand vibration and waterhammer conditions.
Disadvantages of the liquid expansion steam trap:

o
o
The flexible tubing of the element can be destroyed by corrosive condensate or superheat.
Since the liquid expansion trap discharges condensate at a temperature of 100C or below, it
should never be used on applications which demand immediate removal of condensate from
the steam space.
If the trap is to be subjected to freezing conditions the trap and its associated pipework must
be well insulated.
The liquid expansion trap is not normally a trapping solution on its own, as it usually requires
another steam trap to operate in parallel. However, it can often be used where start-up rate is
not an important consideration, such as when draining small tank heating coils.
11.2.3
Balanced pressure steam trap

A large improvement on the liquid expansion trap is the balanced pressure trap, shown in
Figure 11.2.4. Its operating temperature is affected by the surrounding steam pressure. The
operating element is a capsule containing a special liquid and water mixture with a boiling point
below that of water. In the cold conditions that exist at start-up, the capsule is relaxed. The valve
is off its seat and is wide open, allowing unrestricted removal of air. This is a feature of all
balanced pressure traps and explains why they are well suited to air venting.
Fig. 11.2.4 Balanced pressure steam trap with replaceable capsule
As condensate passes through the balanced pressure steam trap, heat is transferred to the liquid
in the capsule. The liquid vaporises before steam reaches the trap. The vapour pressure within
the capsule causes it to expand and the valve shuts. Heat loss from the trap then cools the water
surrounding the capsule, the vapour condenses and the capsule contracts, opening the valve
and releasing condensate until steam approaches again and the cycle repeats (Figure 11.2.5).
Open
Valve open
Closed
Vaporised fill
Fig. 11.2.5 Operation of balanced pressure steam trap capsule
The differential below steam temperature at which the trap operates is governed by the
concentration of the liquid mixture in the capsule. The 'thin-walled' element gives a rapid
response to changes in pressure and temperature. The result is the response line as illustrated in
Figure 11.2.6.
Temperature T

Y
Response line
Steam pressure P
Fig. 11.2.6 Typical response of a balanced pressure steam trap Y - Y
Early bellows type elements of non-ferrous construction were susceptible to damage by

waterhammer. The introduction of stainless steel elements improved reliability considerably.
Figure 11.2.7 shows an exploded view of a modern balanced pressure steam trap arrangement
that has considerable resistance to damage from waterhammer, superheat and corrosion.
Fig. 11.2.7 Typical balanced pressure capsule arrangement

11.2.5
Advantages of the balanced pressure steam trap:

o
o
Small, light and has a large capacity for its size.
The valve is fully open on start-up, allowing air and other non-condensable gases to be
discharged freely and giving maximum condensate removal when the load is greatest.
This type of trap is unlikely to freeze when working in an exposed position (unless there is a
rise in the condensate pipe after the trap, which would allow water to run back and flood the
trap when the steam is off).
The modern balanced pressure trap automatically adjusts itself to variations of steam pressure
up to its maximum operating pressure. It will also tolerate up to 70C of superheat.
Trap maintenance is simple. The capsule and valve seat are easily removed, and replacements
can be fitted in a few minutes without removing the trap from the line.
Disadvantages of the balanced pressure steam trap:

o
The older style balanced pressure steam traps had bellows which were susceptible to damage
by waterhammer or corrosive condensate. Welded stainless steel capsules introduced more
recently, are better able to tolerate such conditions.
In common with all other thermostatic traps, the balanced pressure type does not open until
the condensate temperature has dropped below steam temperature (the exact temperature
difference being determined by the fluid used to fill the element). This is clearly a disadvantage
if the steam trap is chosen for an application in which waterlogging of the steam space
can not be tolerated, for example; mains drainage, heat exchangers, critical tracing.
Bimetallic steam trap

As the name implies, bimetallic steam traps are constructed using two strips of dissimilar metals
welded together into one element. The element deflects when heated. (Figure 11.2.8):
At normal temperature
Heat
Fig. 11.2.8 Simple bimetallic element
There are two important points to consider regarding this simple element:
o
Operation of the steam trap takes place at a certain fixed temperature, which may not satisfy
the requirements of a steam system possibly operating at varying pressures and temperatures
(see Figure 11.2.9).
Because the power exerted by a single bimetal strip is small, a large mass would have be used
which would be slow to react to temperature changes in the steam system.
The performance of any steam trap can be measured by its response to the steam saturation
curve. The ideal response would closely follow the curve and be just below it. A simple bimetal
element tends to react to temperature changes in a linear fashion.
Figure 11.2.9 shows the straight line characteristic of a simple bimetal element relative to the
steam saturation curve. As steam pressure increases above P1, the difference between steam
saturation temperature and trap operating temperature would increase. Waterlogging increases
with system pressure, highlighting the trap's inability to respond to changing pressure conditions.
Temperature T
Discharging steam
Trap operating temperature
Discharging sub-cooled condensate
P1
Steam pressure P
Fig. 11.2.9 Typical response of a single element bimetal steam trap
It needs to be noted that at pressures below P1, the steam trap operating temperature is actually
above the saturation temperature. This would cause the steam trap to pass steam at these lower
pressures. It may be possible to ensure the steam trap is adjusted during manufacture to ensure
that this portion of the saturation curve is always above the operating line. However, due to the
linear action of the element, the difference between the two would increase even more with
system pressure, increasing the waterlogging effect.
Clearly, this is not a satisfactory operation for any steam trap, and various attempts have been
made by manufacturers to improve upon the situation. Some use combinations of two different
sets of bimetal leaves in a single stack, which operate at different temperatures (Figure 11.2.10).
Open
Closed
Fig. 11.2.10 Operation of a bimetel steam trap with two leaf element
11.2.7
The typical result is the split response line similar to that shown in Figure 11.2.11. This is an
improvement on Figure 11.2.9, but still does not exactly follow the saturation curve. One set of
bimetal leaves deflect to give the response P1 to P2. At a higher temperature a second set of
bimetal leaves contributes to give response P2 to P3. Clearly, although an improvement from the
former design, this is still unsatisfactory in terms of following the saturation curve.
Temperature T
Z Trap operating temperature
P1
P2
P3
Steam pressure P
Fig. 11.2.11 Typical response of a two leaf element Z - Z
A more innovative design is the disc spring thermostatic element shown in Figure 11.2.12. The
thermostatic element is made up of a set of bimetal discs. These discs, if acting directly between
the valve stem and the seat (as with some thermostatic steam traps), cause the discharge
temperature of the condensate to change linearly with changing pressure (curve A, Figure 11.2.13).
By incorporating a spring washer between the discs and a recess in the seat, this absorbs some of
the bimetal expansion at low pressure so that a greater temperature change must occur with
changing pressure. The spring washer shape is preferred over a coil spring because it develops
force in an exponentially increasing rate, rather than in a linear rate. This effect takes place up to
15 bar g until the spring is deflected to the bottom of the recess, and means that the discharge
temperature of the condensate will follow the steam saturation curve more accurately (curve B,
Figure 11.2.13)
Valve stem
Bimetal discs
Recess
Spring washer
Seat
Fig. 11.2.12 Multi-cross elements as used in the Spirax Sarco SM range of bimetallic steam traps
260
240
Temperature (C)
220
200
180
160
140
120
100
80
10
12
14 16 18
Pressure (bar)
20
22
24
26
28
30
32
Fig. 11.2.13 Comparing the operating temperatures of single leaf and multi-leaf bimetallic traps
Advantages of the bimetallic steam trap:

o
o
Bimetallic steam traps are usually compact, yet can have a large condensate capacity.
The valve is wide open when the steam trap is cold, giving good air venting capability and
maximum condensate discharge capacity under 'start-up' conditions.
As condensate tends to drain freely from the outlet, this type of steam trap will not freeze up
when working in an exposed position. The bodies of some bimetallic steam traps are designed
in such a way that they will not receive any damage even if freezing does occur.
Bimetallic steam traps are usually able to withstand waterhammer, corrosive condensate, and
high steam pressures.
The bimetal elements can work over a wide range of steam pressures without any need for a
change in the size of the valve orifice.
If the valve is on the downstream side of the seat, it can act as a check valve and help prevent
any reverse flow through the steam trap.
As condensate is discharged at varying temperatures below saturation temperature and,
provided waterlogging of the steam space can be tolerated, some of the enthalpy of saturated
water can be transferred to the plant. This extracts the maximum energy from the condensate
before it drains to waste, and explains why these traps are used on tracer lines where condensate
is often dumped to waste.
Maintenance of this type of steam trap presents few problems, as the internals can be replaced
without removing the trap body from the line.
Bimetallic steam traps do not respond quickly to changes in load or pressure because the
element is slow to react.
The flash steam produced whenever condensate is discharged from a higher to a lower pressure
will tend to cause an increase in backpressure in the condensate line. The cooling leg allows
the condensate to cool down, producing less flash steam in the condensate line and thus
helping to reduce the backpressure.
11.2.9
Disadvantages of the bimetallic steam trap:

o
As condensate is discharged below steam temperature, waterlogging of the steam space will
occur unless the steam trap is fitted at the end of a long cooling leg, typically 1 - 3 m of
unlagged pipe (see Fig. 11.2.14). Bimetallic steam traps are not suitable for fitting to process
plants where immediate condensate removal is vital for maximum output to be achieved.
This is particularly relevant on temperature controlled plants.
The bimetallic steam trap is vulnerable to blockage from pipe dirt due to low internal flow
velocities.
If the bimetallic steam trap has to discharge against a significant backpressure, the condensate
must cool to a lower temperature than is normally required before the valve will open. A 50%
backpressure may cause up to a 50C drop in discharge temperature. It may be necessary to
increase the length of cooling leg to meet this condition.
Steam main
Drain pocket
Cooling leg
Bimetallic trap set
Condensate return line

Fig. 11.2.14 Bimetallic steam trap with cooling leg
Questions
1. What is a characteristic feature of thermostatic steam traps?
a| They pass condensate at steam temperature
b| They operate by holding back condensate until it has cooled
c| They cannot be fitted outside
d| They can only be fitted on low pressure steam systems
2. Where can a liquid expansion trap be fitted?

a| Where condensate has to be removed just below steam temperature
b| Where it is necessary to discharge condensate above 100C
c| Where it is necessary to remove cool condensate at start-up
d| On a superheated steam main
3. Where would a bimetallic steam trap not be fitted?

a| Outside where freezing can occur
b| Where waterhammer is likely to occur
c| Where condensate is to be discharged below steam temperature
d| Where condensate has to be discharged at steam temperature
4. Balance pressure traps are what type of steam trap?

a| Thermodynamic
b| Mechanical
c| Thermostatic
d| They do not belong to any one specific type of trap family
5. What can a balanced pressure trap do that a bimetallic cannot?

a| It can withstand moderate degrees of superheat
b| It follows the steam saturation curve better than a bimetallic trap
c| It can be fitted where waterlogging can be tolerated
d| It can discharge large quantities of air at start-up
6. What is the effect of increasing backpressure on a bimetallic trap?

a| It reduces the temperature of the condensate released by the trap
b| It allows the trap to be used on a higher steam pressure
c| It increases the differential pressure across the trap
d| The trap must be the same size as the condensate drain line
Answers
1: b, 2: c, 3: d, 4: c, 5: b, 6: a
11.2.11
Mechanical steam traps
Mechanical Steam Traps

Ball float steam trap
The ball float type trap operates by sensing the difference in density between steam and
condensate. In the case of the trap shown in Figure 11.3.1, condensate reaching the trap will
cause the ball float to rise, lifting the valve off its seat and releasing condensate. As can be seen,
the valve is always flooded and neither steam nor air will pass through it, so early traps of this
kind were vented using a manually operated cock at the top of the body. Modern traps use a
thermostatic air vent, as shown in Figure 11.3.2. This allows the initial air to pass whilst the trap
is also handling condensate.
Air cock
Balanced
pressure
capsule
Fig. 11.3.1 Float trap with air cock
Fig. 11.3.2 Float trap with thermostatic air vent
The automatic air vent uses the same balanced pressure capsule element as a thermostatic
steam trap, and is located in the steam space above the condensate level. After releasing the
initial air, it remains closed until air or other non-condensable gases accumulate during normal
running and cause it to open by reducing the temperature of the air /steam mixture. The
thermostatic air vent offers the added benefit of significantly increasing condensate capacity on
cold start-up.
In the past, the thermostatic air vent was a point of weakness if waterhammer was present in the
system. Even the ball could be damaged if the waterhammer was severe. However, in modern
float traps the air vent is a compact, very robust, all stainless steel capsule, and the modern
welding techniques used on the ball makes the complete float-thermostatic steam trap very
robust and reliable in waterhammer situations.
In many ways the float-thermostatic trap is the closest to an ideal steam trap. It will discharge
condensate as soon as it is formed, regardless of changes in steam pressure.
Advantages of the float-thermostatic steam trap

o
The trap continuously discharges condensate at steam temperature. This makes it the first
choice for applications where the rate of heat transfer is high for the area of heating surface
available.
It is able to handle heavy or light condensate loads equally well and is not affected by wide
and sudden fluctuations of pressure or flowrate.
As long as an automatic air vent is fitted, the trap is able to discharge air freely.
It has a large capacity for its size.
The versions which have a steam lock release valve are the only type of trap entirely suitable
for use where steam locking can occur.
It is resistant to waterhammer.
Disadvantages of the float-thermostatic steam trap

o
Although less susceptible than the inverted bucket trap, the float type trap can be damaged
by severe freezing and the body should be well lagged, and / or complemented with a small
supplementary thermostatic drain trap, if it is to be fitted in an exposed position.
As with all mechanical type traps, different internals are required to allow operation over
varying pressure ranges. Traps operating on higher differential pressures have smaller orifices
to balance the bouyancy of the float.
Inverted bucket steam trap

The inverted bucket steam trap is shown in Figure 11.3.3. As its name implies, the mechanism
consists of an inverted bucket which is attached by a lever to a valve. An essential part of the
trap is the small air vent hole in the top of the bucket. Figure 11.3.3 shows the method of
operation. In (i) the bucket hangs down, pulling the valve off its seat. Condensate flows under
the bottom of the bucket filling the body and flowing away through the outlet. In (ii) the arrival
of steam causes the bucket to become buoyant, it then rises and shuts the outlet. In (iii) the trap
remains shut until the steam in the bucket has condensed or bubbled through the vent hole to
the top of the trap body. It will then sink, pulling the main valve off its seat. Accumulated
condensate is released and the cycle is repeated.
In (ii), air reaching the trap at start-up will also give the bucket buoyancy and close the valve.
The bucket vent hole is essential to allow air to escape into the top of the trap for eventual
discharge through the main valve seat. The hole, and the pressure differential, are small so the
trap is relatively slow at venting air. At the same time it must pass (and therefore waste) a certain
amount of steam for the trap to operate once the air has cleared. A parallel air vent fitted
outside the trap will reduce start-up times.
Outlet
Orifice
Bleed hole
Inverted bucket
Inlet
(i)
Orifice
closed
Air and steam

bleeding through
the bleed hole
Orifice
open
(ii)
(iii)
Fig. 11.3.3 Operation of an inverted bucket steam trap

11.3.3
Advantages of the inverted bucket steam trap

o
The inverted bucket steam trap can be made to withstand high pressures.
Like a float-thermostatic steam trap, it has a good tolerance to waterhammer conditions.
Can be used on superheated steam lines with the addition of a check valve on the inlet.
Failure mode is usually open, so its safer on those applications that require this feature, for
example turbine drains.
Disadvantages of the inverted bucket steam trap

o
The small size of the hole in the top of the bucket means that this type of trap can only
discharge air very slowly. The hole cannot be enlarged, as steam would pass through too
quickly during normal operation.
There should always be enough water in the trap body to act as a seal around the lip of the
bucket. If the trap loses this water seal, steam can be wasted through the outlet valve. This can
often happen on applications where there is a sudden drop in steam pressure, causing some
of the condensate in the trap body to 'flash' into steam. The bucket loses its buoyancy and
sinks, allowing live steam to pass through the trap orifice. Only if sufficient condensate reaches
the trap will the water seal form again, and prevent steam wastage.
If an inverted bucket trap is used on an application where pressure fluctuation of the plant can
be expected, a check valve should be fitted on the inlet line in front of the trap. Steam and
water are free to flow in the direction indicated, while reverse flow is impossible as the check
valve would be forced onto its seat.
The higher temperature of superheated steam is likely to cause an inverted bucket trap to lose
its water seal. A check valve in front of the trap should be regarded as essential under such
conditions. Some inverted bucket traps are manufactured with an integral check valve as
standard.
The inverted bucket trap is likely to suffer damage from freezing if installed in an exposed
position with sub-zero ambient conditions. As with other types of mechanical traps, suitable
lagging can overcome this problem if conditions are not too severe. If ambient conditions well
below zero are to be expected, then it may be prudent to consider a more robust type of trap
to do the job. In the case of mains drainage, a thermodynamic trap would be the first choice.
Questions
1. Name one characteristic feature of mechanical steam traps
a| They pass condensate at steam temperature
b| They operate by sensing condensate temperature
c| They can be fitted into any position
d| They are not effected by increasing backpressure
2. Why is a float trap better at venting air than an inverted bucket trap?
a| A float can quickly adjust to the presence of air
b| A float trap is fitted with an automatic air vent
c| A float trap does not vent air better than a bucket trap
d| The air vent orifice is adjustable on a float trap
3. What added benefit does the automatic air vent offer to a float trap?
a| It stops the trap from freezing in cold weather
b| The trap can be used on larger backpressures
c| It significantly increases the cold start-up capacity of the trap
d| The condensate orifice can be the same size for all pressure ranges
4. What advantage does a bucket trap have over a float trap?

a| It is able to withstand waterhammer
b| It can be used on higher pressures
c| It can discharge air freely
d| It cannot lose its water seal
5. A heat exchanger is designed to operate without waterlogging of the steam space.

What is the usual choice of trap for its drainage?
a| Thermostatic trap
b| Inverted bucket trap
c| Thermodynamic trap
d| Float trap with thermostatic air vent
6. Which is the best trap to use when steam locking can occur?
a| An inverted bucket trap with an internal check valve mechanism
b| A balanced pressure steam trap
c| A float trap with automatic air vent
d| A float trap with steam lock release mechanism
Answers
1: a, 2: b, 3: c, 4: b, 5: d, 6: d
11.3.5
Thermodynamic steam traps
Thermodynamic Steam Traps

Traditional thermodynamic steam trap
The thermodynamic trap is an extremely robust steam trap with a simple mode of operation.
The trap operates by means of the dynamic effect of flash steam as it passes through the trap, as
depicted in Figure 11.4.1. The only moving part is the disc above the flat face inside the control
chamber or cap.
On start-up, incoming pressure raises the disc, and cool condensate plus air is immediately
discharged from the inner ring, under the disc, and out through three peripheral outlets (only 2
shown, Figure 11.4.1, i).
Hot condensate flowing through the inlet passage into the chamber under the disc drops in
pressure and releases flash steam moving at high velocity. This high velocity creates a low pressure
area under the disc, drawing it towards its seat (Figure 11.4.1, ii).
At the same time, the flash steam pressure builds up inside the chamber above the disc, forcing
it down against the incoming condensate until it seats on the inner and outer rings. At this point,
the flash steam is trapped in the upper chamber, and the pressure above the disc equals the
pressure being applied to the underside of the disc from the inner ring. However, the top of the
disc is subject to a greater force than the underside, as it has a greater surface area.
Eventually the trapped pressure in the upper chamber falls as the flash steam condenses. The
disc is raised by the now higher condensate pressure and the cycle repeats (Figure 11.4.1, iv).
Peripheral outlets
Disc
Inlet
(i)
(ii)
Control chamber
Flat
sealing
face
(iv)
(iii)
Fig. 11.4.1 Operation of a thermodynamic steam trap
The rate of operation depends on steam temperature and ambient conditions. Most traps will
stay closed for between 20 and 40 seconds. If the trap opens too frequently, perhaps due to a
cold, wet, and windy location, the rate of opening can be slowed by simply fitting an insulating
cover onto the top of the trap.
Advantages of the thermodynamic steam trap

o
Thermodynamic traps can operate across their

entire working range without any adjustment
or change of internals.
They are compact, simple, lightweight and
have a large condensate capacity for their size.
Thermodynamic traps can be used on high
pressure and superheated steam and are not
affected by waterhammer or vibration. The all
stainless steel construction offers a high degree
of resistance to corrosive condensate.
Thermodynamic traps are not damaged by
freezing and are unlikely to freeze if installed
with the disc in a vertical plane and discharging
freely to atmosphere. However, operation in
this position may result in wear of the disc
edge.
As the disc is the only moving part,
maintenance can easily be carried out without
removing the trap from the line.
The audible 'click' which occurs as the trap
opens and closes makes trap testing very
straightforward.
Fig. 11.4.2 Thermodynamic steam trap
Disadvantages of the thermodynamic steam trap

o
Thermodynamic steam traps will not work positively on very low differential pressures, as the
velocity of flow across the underside of the disc is insufficient for lower pressure to occur. They
are subjected to a minimum inlet pressure (typically 0.25 bar g) but can withstand a maximum
backpressure of 80% of the inlet pressure.
Thermodynamic traps can discharge a large amount of air on 'start-up' if the inlet pressure
builds up slowly. However, rapid pressure build-up will cause high velocity air to shut the trap
in the same way as steam, and it will 'air-bind'. In this case a separate thermostatic air vent can
be fitted in parallel with the trap. Modern thermodynamic steam traps can have an inbuilt
anti-air-binding disc which prevents air pressure building up on top of the disc and allows
air to escape, (Figure 11.4.3).
The discharge of the trap can be noisy and this factor may prohibit the use of a thermodynamic
trap in some locations, e.g. outside a hospital ward or operating theatre. If this is a problem, it
can easily be fitted with a diffuser which considerably reduces the discharge noise.
Care should be taken not to oversize a thermodynamic trap as this can increase cycle
times and induce wear. Mains drainage applications often only need to be fitted with low
capacity versions, providing proper consideration is given to siting the drain pockets correctly.
Fig. 11.4.3 Anti-air-binding disc

11.4.3
Block 11 Steam Trapping
Thermodynamic Steam Traps Module 11.4
Questions
1. Name one particular feature of thermodynamic steam traps?
a| They are difficult to maintain
b| They operate by sensing condensate temperature
c| They cannot be fitted upside-down
d| They cannot be damaged by freezing
2. At what typical application does a thermodynamic trap excel?

a| Draining any type of heat exchanger
b| Draining steam mains
c| Draining bulk oil storage tanks
d| Draining any temperature controlled application
3. What effect does air have on a thermodynamic trap?

a| None at all
b| The trap can air bind at start-up unless fitted with a special disc
c| The trap discharges condensate at a lower temperature
d| The trap discharges at a higher temperature
4. On what principle does a thermodynamic trap operate?

a| It senses the difference in density between water and steam
b| It senses the difference in temperature between water and steam
c| It operates on the difference in velocity between water and steam
d| It operates with a fixed orifice position
5. What is a disadvantage of any fixed orifice device

a| They cannot shut off and can therefore waste steam
b| They can waterlog and corrode the application steam space
c| They regularly block up due to the size of the orifice
d| All of the above
6. What effect does a high backpressure have on a thermodynamic trap?

a| It will reduce the trap capacity
b| It will increase the trap capacity
c| It will cause the trap to air bind
d| It will have no effect at all
Answers
1: d, 2: b, 3: b, 4: c, 5: d, 6: a
11.4.7
C. Consideration for selecting

steam traps
Considerations for Selecting Steam Traps

Considerations
By definition, a steam trap must trap or hold back steam whilst at the same time not restricting
the passage of condensate, air, and other incondensable gases. The basic requirements of good
steam trapping have already been outlined but it is worth repeating that the performance of the
plant is paramount. The trap selection follows on the basis that the requirements of pressure,
condensate load and air venting have been met, in the provisional selection. However, system
design and maintenance needs will also influence performance and selection. Please refer to the
following sub-sections in this Module for further advice on this matter
Waterhammer
Waterhammer is a symptom of a problem in the steam system. This could be due to poor design
of the steam and condensate pipework, the use of the wrong type of trap or traps or a leaking
steam trap, or a combination of these factors. It is often futile to install the correct trap for an
application if the system layout will not allow the trap to operate correctly. It is equally pointless
to install the correct layout and not pay proper attention to steam trapping. The Modules 11.6
to 11.11 inclusive 'Selecting steam traps' will deal with the correct matching of steam traps
to applications and layouts. The proper layout of steam pipework is also dealt with in Block 10 'Steam Distribution'. Symptoms of waterhammer are often attributed to malfunction of the steam
trap. A more likely explanation is that a faulty steam trap has been damaged by waterhammer.
Waterhammer can be caused in a number of ways, including:o
o
Failure to remove condensate from the path of high velocity steam in the pipework.
From an application which is temperature controlled and where condensate has to lift to a
return line, or return to a pressurised system.
The inability of condensate to properly enter or travel along an undersized return line, due to
either (a) flooding, or (b) overpressurisation with the throttling effects of flash steam.
Modern design and manufacturing techniques have produced steam traps which are more robust
than those of their predecessors. This allows the steam trap to last longer under normal conditions,
and will also be better able to withstand the effects of poorly designed systems. Basically, however
well a steam trap is made, if it is installed in a poorly designed system it will be less effective and
have a shorter working life.
If a steam trap persistently fails on an established system due to waterhammer, it is probably the
fault of the system layout, rather than the trap. The solution is to investigate and eradicate the
true cause of the problem by correcting the system inadequacies.
Two important applications are the drainage of steam mains, and of temperature controlled heat
exchangers.
As a general rule, steam mains should be drained at regular intervals of 30 to 50 metres with
adequately sized drain pockets. The bottom of any riser must also be drained.
Temperature controlled heat exchangers can only work effectively if condensate is allowed to
drain freely from them. If there is a lift after the trap, there will always be a tendency for
waterhammer, whichever trap is fitted. In this situation, the trap should either be complemented
with a pump, or changed for a punp-trap . This subject will be dealt with in further detail in
Block 13 - 'Condensate Removal'
It is important that the pipework is designed and installed correctly. This will help to maintain
thermal performance of the system throughout its service life.
Dirt
Dirt is another major factor which must be considered when selecting traps. Although steam
condenses to distilled water, it can sometimes contain trace products of boiler feed treatment
compound and natural minerals found in water. Pipe dirt created during installation and the
products of corrosion also need to be considered.
An intermittent blast action trap is the least likely to be affected by dirt. In thermostatic traps this
means that the balanced pressure thermostatic trap is preferable, although the larger flat valve
associated with some diaphragm traps can cause difficulties.
The dribbling action of bimetallic traps, coupled with the arrangement of the valve stem passing
through the seat, means that these are most prone to malfunction (due to added friction) or even
to blockage. It is sometimes claimed that the sensor element can be readily cleaned and is not
subject to fouling. However, fouling of the element is rarely a problem: the relevant parts are the
valve and seat.
Float-thermostatic steam traps are quite resistant to dirt. As an extreme example, when draining
concrete curing autoclaves, the residual sand which precipitates into the condensate can be
carried through large float-thermostatic steam traps quite successfully, due to the low velocity
flow through a relatively large orifice.
The inverted bucket trap has an air vent hole in the bucket. If this blocks, it can cause the trap to
air-bind and be slow to react. If this happens, the scale or dirt blocking the air vent must be
dislodged, which requires the trap to be removed from service.
The impulse trap is intolerant of dirty conditions. The fine clearance between plug and tapered
sleeve is susceptible to high velocity flow and the plug will frequently stick in an intermediate
position. The trap seizes in a fixed position and will either pass steam or condensate depending
on the rate of condensation.
The fixed orifice device is least suited to dirty conditions. The hole is inherently small and frequently
blocks. Enlarging the hole (as is sometimes done in desperation) destroys the concept of sizing
on a fixed orifice. It is wasteful and in some cases merely delays the time until blockage
re-occurs. A strainer is often supplied and fitted but this has to be extremely fine to be effective.
This simply transfers the blockage from the orifice trap to the strainer, which, in turn, requires
regular downtime for cleaning.
Strainers
These devices (Figure 11.5.1) are frequently forgotten about in steam systems, often, it seems, in
an effort to reduce installation costs. Pipe scale and dirt can affect control valves and steam traps,
and reduce heat transfer rates. It is extremely easy and inexpensive to fit a strainer in a pipe, and
the low cost of doing so will pay dividends throughout the life of the installation. Scale and dirt
are arrested, and maintenance is usually reduced as a result.
Selection is simple. The strainer material is selected to match the type of installation and the
system pressure up to which it is expected to operate. Different filter screen sizes may be
considered for differing degrees of protection. The finer the filter, the more often it may need
cleaning. One thing is certain, strainers are far easier and cheaper to buy and maintain than
control valves or steam traps.
Further information on strainers is given in Block 12 - 'Pipeline Ancillaries'
Flow
path
Fig. 11.5.1 Typical Y-type strainer (cut section)

11.5.3
Steam locking
The possibility of steam locking can sometimes be a deciding factor in the selection of steam
traps. It can occur whenever a steam trap is fitted remotely from the plant being drained. It can
become acute when condensate is removed through a syphon or dip pipe. Figure 11.5.2 illustrates
the problem of steam locking in a rotating drying cylinder by using a syphon pipe.
In Figure 11.5.2 (i) the steam pressure is sufficient to lift condensate up the syphon pipe, through
the steam trap and away. Figure 11.5.2 (ii) shows what happens when the level of the condensate
at the bottom of the cylinder falls below the end of the syphon pipe. Steam enters the syphon
pipe and causes the steam trap (in this case a float type) to close.
The trap is temporarily 'steam locked'. Heat loss from the cylinder will result in the formation of
more condensate which, as a result, is unable to reach the trap. Figure 11.5.2 (iii) shows the
cylinder becoming increasingly waterlogged which will result in a reduced drying rate from the
cylinder and an increase in the power required to turn the cylinder. In extreme cases the cylinder
may fill to the centre line and damage may then result from mechanical overload.
Condensate in
the syphon tube
(i)
Steam enters
the syphon tube
(ii)
Steam locked in
the syphon tube
(iii)
Fig. 11.5.2 Steam locking
To relieve this problem a trap is needed with a 'steam lock release' valve. This is an internal
needle valve which allows the steam locked in the syphon pipe to be bled away past the main
valve. The float trap is the only type of trap with this facility and is the correct choice on rotating
machinery such as drying cylinders. Because the needle valve is just open enough to avoid steam
wastage it has a limited capacity to vent air. Traps of this type are often provided with combined
air vents and steam lock release (Figure 11.5.3). The manually operated steam lock release
mechanism works independently of the automatic air vent action. A standard float-thermostatic
steam trap is shown in Figure 11.5.4.
Other types of traps will open and eventually cope with a steam lock, however, the drainage and
plant performance will be erratic. This is clearly unacceptable to users of process plant where
batch times, quality and efficiency are of high importance.
Air vent capsule
Steam lock
release
Fig. 11.5.3 Float-thermostatic trap with

combined steam lock release valve
Air vent capsule
Fig. 11.5.4 Standard float-thermostatic trap
11.5.5
Group trapping
Group trapping describes the use of one trap serving more than one application. Figure 11.5.5
shows two batch processes (jacketed pans) operating at two different steam pressures with the
drain line from each connected to one steam trap. The higher pressure in plant B will allow
condensate from this vessel to drain but will stop condensate being discharged from plant A as
check valve C will be held closed. Plant A will waterlog and will suffer a severe drop in performance.
0.5 bar g steam
3 bar g steam
Air
vent
Air
vent
Ball valve
Ball valve
A
Check valves
C
Strainer
D
IFT14 float type steam trap
Condensate
Fig. 11.5.5 Group trapping with different process pressures
For this reason, group trapping of equipment operating at different pressures is not good practice.
But what if equipment operates at the same pressure? Consider the following installation shown
in Figure 11.5.6.
3 bar g steam
2 bar g steam
Air
vent
Ball
valve
Strainer
Condensate
Ball
valve
Ball
valve
Ball
valve
IFT14 float type

steam trap
Fig. 11.5.6 Group trapping with same process pressures
In Figure 11.5.6, the content of pan A is almost up to temperature and is condensing relatively
little steam. Pans B, C and D have just been filled with cold product and, as the steam is turned
on, their condensation rates are much higher than pan A. Consequently, the steam velocity along
these suply pipes is much higher, resulting in a higher pressure drop along each of the branch
lines. Lower steam pressures will exist at the pan inlets and in the steam jackets, reducing their
heating ability and increasing their production times.
Because of this, the pressures at the drain outlets of pans B, C and D are also lower than that at
pan A. Steam will flow from pan A via the condensate drain line to the other pans to equalise the
pressures, and the condensate from the other pans will have to flow against this steam flow.
When the drainage points of different vessels at different pressures are connected to one trap,
the vessel with the highest pressure (in this instance pan A) will cause condensate to be held back
in the others. Those vessels with the greatest need to discharge condensate (at this instance pans
B, C and D) will waterlog. Hence, the condensate arrangement shown in Figure 11.5.6 is unlikely
to be satisfactory. The situation can be aggravated when group-trapped processes have separate
temperature control.
One possible application suitable for group trapping is an air handling unit with multiple heater
sections in series (Figure 11.5.7).
This 'flow' type application differs from the batch (or non-flow) process in Figure 11.5.6. The
heater sections will always share any load change as they are served by the same control valve. It
is important that the condensate drain connections and common pipework are generously
sized to allow adequate condensate flow in one direction against steam flow in the other. It will
only work where all sections are fed by one control valve and the same secondary fluid is being
heated by all sections.
KE control valve
SX65 controller
VB14
Vacuum breaker
Steam
Float trap
with air vent
EL
temperature
probe
A
Air flow
Float type steam trap
Strainer
Generously sized condensate connections

and pipework
Condensate
Fig. 11.5.7 Three section air handling unit with one control valve
The original reason for group trapping was that there used to be only one kind of steam trap. It
was the forerunner of the present day bucket trap, and was very large and expensive. Steam
traps today are considerably smaller and cost effective, allowing individual heat exchangers to be
properly drained. It is always better for steam using equipment to be trapped on an individual
basis rather than on a group basis.
In many instances it may be necessary to use a pump-trap on temperature controlled equipment,
to remove condensate properly.
11.5.7
Diffusers
With steam traps draining to atmosphere from open ended pipes, it is

possible to see the discharge of hot condensate. A certain amount of flash
steam will also be present relative to the condensate pressure before the
trap. This can present a hazard to passers by, but the risks can be minimised
by reducing the severity of the discharge. This may be achieved by fitting
a simple diffuser (Figure 11.5.8) to the end of the pipe (Figure 11.5.9)
which reduces the ferocity of discharge and sound. Typically, sound levels
can be reduced by up to 80%.
Fig. 11.5.8 Diffuser
Diffuser
Compact trapping station

with an inverted bucket trap
Diffuser
Fig. 11.5.9 Steam tracer line
Special requirements
Vacuum drainage
Condensate removal from a steam space working under vacuum can be a problem. If a steam
trap is used, its outlet must be connected to a source of greater vacuum than that in the steam
space to ensure a constant differential pressure across the orifice to discharge the condensate.
Where this is not possible, a pressure powered pump can be used to drain condensate from the
plant (Figures 11.5.10 and 11.5.11).
High level return line
Vacuum
space
Vacuum
space
Motive
pressure
Pressure
powered pump
Fig. 11.5.10 Pump draining vacuum system

to a high level return line
Atmospheric
pressure
Loop seal when

draining by
atmospheric
pressure
Air break
Drain
Fig. 11.5.11 Pump draining vacuum system
to a low level drain
A soft seated check valve is recommended on the pump outlet where little or no lift is present,
and an air break will act as an anti-syphoning device when draining to a point below the pump.
Atmospheric pressure can be used as the motive force when draining below the pump
(Figure 11.5.11), but the outlet check valve should be positioned in a loop seal below the pump
to induce a minimum opening head (dependant on the type of check valve) and water seal.
Should the pump be draining condensate from a vacuum gas system then compressed air or
inert gas can be used as the motive force to drive the pump.
Steam trap drainage of temperature controlled processes
The steam trap is an automatic valve that relies on the system dynamics to provide flow. It has to
rely on and react to external factors, such as steam pressure or static head pressure on the inlet
side of the trap. The outlet pressure must be lower than the inlet pressure to provide flow in the
correct direction. The rate of flow through any steam trap is therefore related to the differential
pressure across it.
It is also possible to have negative differential pressures across the trap, which would promote
reverse flow through it. When traps are installed to pass condensate into common return lines, it
is advisable to fit non-return valves after each trap to prevent reverse flow under negative pressure
conditions.
The occurrence of zero and negative differential pressure across steam traps is commonplace.
The effects are commonly seen with temperature controlled processes i.e. heater batteries,
calorifiers, jacketed pans, plate heat exchangers, in fact any process that has a control valve on
the steam supply. It can occur irrespective of steam supply pressure, and depends wholly on the
condensate system pressure and the steam pressure in the heat exchanger.
The term 'stall' describes this condition. Whenever it is predicted or diagnosed, another solution,
such as a pump-trap is required to remove the condensate from the heat exchanger.
The phenomenon is discussed in greater detail in Block 13 - 'Condensate removal'.
Controller
Control
valve
Sensor
Vacuum
breaker
Steam at
2.6 bar g
Flow
Shell and tube

heat exchanger
Return
Condensate to
return line
Trap set
Condensate to
vented reciever
Fig. 11.5.12 Typical temperature controlled process
11.5.9
Questions
1. Name the principle cause of waterhammer:
a| Water particles suspended in steam
b| Water allowed to build up in pipes
c| Water droplets carried along the insides of pipes
d| Wet steam passing through steam traps
2. What effect does dirt have on steam systems?

a| It clogs up control valves
b| It clogs up steam traps
c| It reduces heat transfer performance
d| All of the above
3. What effect does steam locking have on rotating machinery?

a| None at all
b| It reduces the drying rate of drying cylinders
c| It increases the drying rate of drying cylinders
d| It causes the steam trap to air bind
4. When can group trapping be used with success?

a| For multiple batch processes fed by the same steam pressure
b| For multiple batch processes fed by different steam pressures
c| For multiple air heater batteries fed by the same control valve
d| For heater batteries generally
5. What is the best method of draining a vacuum main?

a| A thermodynamic steam trap
b| A check valve fitted in reverse
c| A float trap fitted in conjunction with a check valve
d| A pressure powered pump
6. Name one method of reducing the effect of stall in a temperature controlled application:
a| Increase the size of the steam trap
b| Remove the steam trap altogether
c| Install a pump-trap
d| Increase the steam pressure onto the control valve
Answers
1: b, 2: d, 3: b, 4: c, 5: d, 6: c
D. Method of testing steam

traps
METHODS OF TESTING STEAM TRAPS, AND THEIR EFFECTIVENESS

This section will begin with the most basic methods of checking steam trap operation
and move on to the more sophisticated options that are available. Each method will be
explained in turn and the advantages and disadvantages discussed. These can be
employed as useful sales arguments in favour of Spiratec.
There is no substitute for good steam trap maintenance, but maintenance efficiency can
be maximised, if trap leaks can be identified using the most effective and appropriate
methods.
Spraying water on the trap
Least sophisticated method
Watching the trap discharge to atmosphere

Use of sight glasses
Checking the discharge from a vent pipe
Using temperature sensitive crayons
Temperature measurement with instruments
Industrial stethoscope
Ultrasonic leak detector
Conductivity sensor chamber
Most sophisticated method
Most methods use visual, audible or temperature test methods to identify abnormal trap
operation, and are of much more restricted usefulness than is generally appreciated.
The table overleaf gives each method scores in terms of accuracy, time consumption,
cost and operator skill level.
Method
Accuracy level
Time
consumption
level
Cost level
Operator skill
level
Spraying
water on the
trap
6 (visit each
trap in turn)
0 (excluding
labour)
Trap
discharge to
atmosphere
4 (if 3 port
valve installed)
Sight glasses
3
(maintenance)
Checking vent
pipe discharge
Temperature
crayons
Temperature
measurement
(instruments)
9 lengthy
interpretation
5 (instrument
cost)
Industrial
stethoscope
7 (equipment,
labour)
Basic
ultrasonic
detector
8 (equipment,
labour)
Sophisticated
ultrasonic
detector with
software
unknown
7 software
decides trap
'pass' or 'fail'
Conductivity
method
detection
chamber with
temperature
sensor
8 but see
payback
* 1 = Low Level, 10 = High Level

e.g. The conductivity method with temperature sensor monitors steam traps
automatically and so the time consumption level is 1. However it is very accurate and so
the accuracy level is 9.
Some traditional methods of steam trap testing require detailed knowledge of the trap,
such as its discharge characteristics. The table below shows how the discharge
characteristics will vary with trap type and load.
Mode of operation
Trap type
No load
Light load
Normal
load
Full or
overload
Probable
failure
mode
Float and
thermostatic
No action
Usually
continuous but
may cycle at
high pressures
Usually
continuous but
may cycle at
high pressures
Continuous
Main valve
closed or
partially open,
air vent open
Small dribble
Intermittent
Intermittent
Continuous
Open
Balanced
pressure
thermostatic
No action
May dribble
Intermittent
Continuous
Variable
Bimetallic
thermostatic
Small dribble
Usually dribble
action
May blast at
higher
pressures
Continuous
Open
Impulse
Continuous
pass (bleed
facility)
Continuous
bleed with
intermittent
action
Continuous
bleed with
blast at high
loads
Continuous
bleed with
blast at high
loads
Open
Disc Thermo dynamic
Intermittent
Intermittent
Intermittent
Continuous
Rapid cycling
Fixed Orifice
Device
Continuous
steam loss
Continuous
Discharge
some steam
loss
Continuous
Discharge
Continuous
Discharge at
greatly
reduced
temperature
Fully open or
waterlogging,
depending on
sizing criteria,
can also fail
closed due to
dirt
Inverted
bucket
Steam Trap Testing Methods

Visual Methods
Watching The Trap Discharge To Atmosphere
With a blast action trap (such as the thermodynamic, inverted bucket and some types of
thermostatic trap) it may be possible to assess trap operation via observation. When the
trap is closed, little more than wisps of flash steam should be visible. When the trap
opens to discharge condensate, an appreciable amount of flash steam will be visible.
The trap should then positively close as the last of the condensate reaches the trap.
However, some trap variants (including the float trap and some thermostatic traps) will
give a relatively constant discharge. It is harder to tell if they are operating correctly,
simply through observation, because a large amount of flash steam will be produced
even when the trap is operating correctly, at high steam pressures. It is extremely
difficult for the maintenance engineer to distinguish flash steam (normally associated
with the discharge of high pressure condensate to atmosphere) from live steam
leakage.
It is sometimes claimed that the observer can distinguish flash steam and leakage
steam by the colour of the steam at the discharge point. Such a differentiation is, in
fact, impossible:
Imagine trying to differentiate between 99% steam / 1% water and 95% steam with 5%
water!
Familiarity with the normal behaviour of different types of trap is certainly a help, but
experience is required, and detailed knowledge of plant operation (e.g. operating
pressures, expected flow rates etc.)
A trap which is discharging noisily and constantly to atmosphere may be easy to
detect, but it is difficult to identify marginal leaks.
Condensate
Return Main
Watching the Trap Discharge from

Atmosphere: Typical Layout
Plant
Float Trap
Stop Valve
To Atmosphere
The valve required to observe a trap discharging to atmosphere adds to the cost of
the installation and will need maintaining. It is in itself a potential source of leaks, and
can be misleading, because a trap may perform well when tested to an open
discharge, but may not do so when connected to a condensate return system. Such
a system may suffer back pressure, for example if a poorly maintained trap were
leaking in the system, bringing about a reduction in trap capacity. A point might be
reached where condensate could not be adequately cleared from the steam space.
This approach is not widely used.
Opening a three way valve could falsely eliminate back pressure, leading to the
assumption that the trap being tested were operating correctly, when in fact, once the
loop were restored by closing the three way valve, condensate would build up once
more.
Use Of Sight Glasses
The sight glass can be regarded as a window into the condensate system. By
observing the discharge downstream of the trap, the engineer might hope to discover if
a trap were operating correctly. He might hope to be able to distinguish between the
passage of condensate and live steam.
However, in a mixture of condensate and flash steam it is very difficult to determine
whether live steam is also present.
To evaluate trap operation, the engineer needs to be aware of trap type, discharge
characteristics and the type of equipment being drained, to indicate expected load.
Sight glasses can suffer from scale if the steam quality is poor, making observation
difficult, although it would alert the engineer to the scaling problem. The glass may
also be subject to severe wear when fitted downstream of a blast discharge trap (e.g.
thermodynamic trap) Thermal shocking could result in the glass fracturing, therefore
we recommend that sight glasses are fitted at least 1m downstream of the trap.
Sight Glasses
Sight glasses are only suitable for low pressures.

Poor lighting conditions can make accurate observation impossible.
Obviously ease of access to the sight glasses is important.
Float
trap
Check
valve
Sight glass
Sight Glass: Typical Layout

Checking The Discharge From A Vent Pipe
Where condensate is returned to the boiler house, the amount of steam coming from
the vent pipe on the feed tank may indicate live steam leakage from faulty traps.
Abnormal quantities of steam would easily be detected, and may lead the
maintenance engineer into further investigation, but otherwise great familiarity with
the system is required. On a large site where condensate return pumps are used, the
vents on the condensate receivers may be viewed.
On a large system, it is impractical to attempt to locate the faulty trap(s) via a process
of elimination. However, by isolating different parts of the plant it may be possible to
identify the general area of a leak.
Temperature Methods
Measurement of temperature before and after a steam trap is of dubious value.
Consider the following situation:
Steam main pressure
= 7 bar g
(Saturation temperature = 170 C)
Condensate main pressure = 0.7 bar g (Saturation temperature = 115 C)

As the condensate passes through the steam trap orifice, the drop in pressure will
cause some of the condensate to flash to steam. The resulting mix of steam and
condensate will have a temperature appropriate to the pressure in the condensate main
ie. 115 C.
Even if steam were leaking past the steam trap the temperature would still be
C.because the pressure is 0.7 bar g.
115
Only if sufficient steam was leaking to increase the pressure in the condensate main
would the temperature increase.
Simple temperature test methods can only tell us whether the trap is waterlogging,
because the temperature will be lower than expected.
Accurate pressure measurement and interpretation of steam tables is required to
give any meaning to temperature measurements.
However, there are a number of devices available on the market which attempt to use
temperature as a guide to steam trap performance monitoring, these include:
1. Spraying Water On The Trap
Many maintenance engineers once insisted on this method of spraying water (or even
spitting!) on the pipework adjacent to the trap, and watching the reaction of the water
and its rate of evaporation. However, this method will only tell the engineer whether or
not the pipework is cold. This technique may reveal whether a trap has failed in the
closed position (as backed up condensate will have begun to cool), but will otherwise
only indicate if the pipework is hot, and not whether the trap is passing hot condensate
or flash steam, or leaking 'live' steam. This 'traditional' method is therefore thoroughly
unreliable. Those who can interpret the results with any degree of accuracy will have
had many years experience with steam traps. Such individuals are now rare.
Spraying Water on the Trap
2. Temperature Crayons
By using a series of temperature sensitive crayons to make marks upon the
downstream pipework, the upstream temperature at which a trap is operating can be
determined.
Wax Based Temperature

Sensitive Crayon
Two types of crayon are employed: one is wax based and melts at a variety of known
temperatures, the other is known as a chromatic crayon, and changes colour at a
specific temperature. Series of crayons are produced, where each crayon has a
different temperature threshold.
However, these crayons are only accurate within margins of 5C and the actual
surface temperature of the pipe itself may be dramatically lower than the actual
temperatures within the pipework. Thus when testing a trap which is designed to
operate within 5C of the saturated steam temperature (such as a balanced pressure
or bimetallic trap), the temperature differential across the trap is not wide enough to
overcome the limits of the crayon. Temperatures can only be measured within 5C
and results may be misleading.
In any case, we know that it is wrong to assume that measuring the temperature
downstream of a trap will help to determine whether or not it is leaking steam.
3. Temperature Methods Using Instruments
We now know that crayon methods upstream of the trap are unreliable, and that any
method downstream of the trap is also unreliable.
Temperature readings can be affected by the temperature gradient through the pipe
wall, scale etc. Only comparative readings are possible.
However, accurate thermometry (using a thermocouple with accuracy of 0.1 C) can
be used to check the operation of thermostatic traps.
Thermostatic traps discharge condensate below steam saturation temperature. A
contact probe from a thermometer or surface pyrometer can be placed on the inlet
pipework close to the trap, and if the trap is below saturation temperature it is working
satisfactorily. If possible, a second temperature reading upstream of the trap would help
to establish whether there is a temperature gradient along the pipework. If there is, the
trap is working, if not, the trap is failing in some way. If the temperature is very low ,
waterlogging may be taking place.
However, many incidental errors are possible with this method, giving lower
temperature readings than the actual in-pipe temperature.
This means that a great deal of experience and skill are needed to assess trap
operation.
Listening Devices
Correct trap operation can often be determined with the use of listening devices. For
example, the correct operation of traps with a positive open/shut action (such as the TD)
can be heard as a definite click. Listening devices are designed to allow the operator to
hear characteristic noises emitted by the trap as it operates. He can use his findings to
assess whether or not the trap is operation correctly.
Industrial Stethoscope
The stethoscope, comprising a metal rod and diaphragm construction, is held against
the equipment. Vibrations and noise within the audible frequency range (up to 20 MHz)
are transmitted through rubber tubes to be heard by the operator.
Practice using test rigs is necessary in order to enable the operator to identify the
correct and faulty operation of other types of trap.
However, vibration travels a long way, and pipework or
control valve noise from adjacent plant or even the boiler
house may swamp the operating noise of the trap in
question, creating confusion.
The stethoscope is difficult to interpret and any diagnosis
is merely comparative. Small leaks may go undetected.
The operator would require a thorough knowledge of trap
operating principles.
Usually, an
screwdriver!
'Industrial
Stethoscope'
is
actually
Ultrasonic Leak Detector

All fluid flow and mechanical friction emits noise and vibration which is higher in
frequency than the normal hearing range and is known as ultrasound. It is rapidly
absorbed by the surrounding pipework and can therefore be used to detect the flow of
steam or condensate through a steam trap without becoming confused by other nearby
plant.
The ultrasonic leak detector has a probe or mechanical / electrical transducer, which
converts the mechanical vibration into a small electrical signal.
The signal is then amplified and filtered, and translated into a signal in the audible
range, which can be monitored through a pair of headphones and/or on a meter
(analogue or LED display).
Ultrasonic leak detectors are very sensitive, and some would claim that they leave no
room for doubt.
However, ultrasonic leak detectors can only give a reliable indication as to whether a
steam trap is passing condensate or leaking steam (or a mixture of steam and
condensate) when conditions are fixed. (In terms of differential pressure, operating
temperature and so on).
When conditions are fixed, practice and training will allow the operator to identify a
number of simple conditions, by comparing trap discharge to the ultrasound signal.
When they are not fixed, or are not accurately known, it may be difficult to judge
whether live steam, condensate or flash steam are flowing through the trap,
particularly when it is discharging into a closed return system.
A moderately loaded trap under certain conditions may then appear to give an
identical reading to a trap which is leaking steam under no load conditions.
Practice and training are required. The operator needs to have gained experience on
a test rig, be familiar with each type and model of trap, and be aware of the
application and installation of each trap. As with the industrial stethoscope, each trap
must be visited in turn. Ultrasound results can be difficult to interpret, and
interpretations cannot necessarily be relied upon. Slightly better are the newer, 'high
tech' versions which use sophisticated software to decide whether or not a trap is
operating correctly. However, the results of these can be (and are) manipulated to
bias the output i.e. good/bad.
All the methods we have examined so far are:
Limited
Time consuming and inconvenient (such as when each trap must be visited in turn,
and where traps are located in awkward places).
Require operator training.
Require skilful interpretation.
Do not give the option of continuous monitoring to detect a trap problem as soon as it
occurs. Periodic checking of steam traps can have serious consequences. A trap
may give a good reading, but may fail shortly after the test has been carried out. In a
large plant, testing may only be carried out once every six months to a year. A faulty
trap can leak, unnoticed, for a potential period of five months and twenty-nine days! It
may never be detected if the steam trap testing method is faulty.
Conductivity Method
The conductivity method was purposely developed to check steam trap operation. It can
detect whether a steam trap has failed open (live steam leakage) or failed closed
(waterlogging).
The conductivity method contrasts with all the steam trap performance monitoring
methods we have described so far because it is rapid, reliable, does not require
experienced interpretation and may be used for checking all types and makes of trap.
Steam traps are rapidly checked whilst they are in operation. This can be done as part
of a planned maintenance system or as an automatic, continuous process.
All types and makes of steam trap can be checked.
This eliminates:
System shut down.
Trap stripping to identify which traps are responsible for a leak or to decide at random
if maintenance is required.
Wasted labour
Unnecessary spare parts consumption.
Regular monitoring can be carried out using a handheld indicator. Continuous
monitoring is possible if the detection device (sensor chamber) is hardwired to a
controller.
How It Works
The conductivity system consists of a sensor chamber, fitted immediately upstream of
the steam trap. This is connected to an automatic steam trap monitor for (multiple traps)
or a single trap monitor (for individual traps).
Alternatively a portable hand held indicator can be plugged directly into the sensor.
The chamber is fitted with a sensor which is capable of distinguishing between steam
and condensate, due to their different conductivities. This is because condensate will
conduct electricity, but steam cannot do so to the same degree.
Balance
Hole
Flow
Sensor
Shroud to
eliminate
spurious
signals due to
splashing
Condensate
flows under
the weir
Sensor Chamber Cut Section
In certain cases the sensor is combined with a temperature sensor which detects
waterlogging and can therefore detect traps which have become blocked, failed shut or
isolated.
Trap Operating Correctly
If a trap is working, condensate flows from the plant to the steam trap under the weir in
the sensor chamber.
A small hole in the top of the weir balances the pressure on either side of the chamber,
ensuring that the sensor on the upstream side of the weir remains submerged by
condensate (the water seal). It also allows a small amount of steam (variable) to pass
through and compensate for heat losses from the trap. Otherwise the seal would be
blown away, particularly as the plant cooled after shutdown. Steam would condense in
the trap and 'suck' the water seal into the vacuum created.
When the trap is working normally, the sensor remains submerged. This means that an
electrical circuit is completed when either the Hand Held Indicator or the continuous
Automatic Steam Trap Monitor is connected. In all cases, a completed circuit will
illuminate a green LED and a
which signals that the trap(s) are working properly.
Sensor chamber
Steam trap
Sensor
submerged
Automatic
trap
monitor
Green light
Trap Operating Correctly

Trap Leaking Steam.
If the trap is leaking an appreciable amount of live steam, the steam volume in the
sensor chamber and trap increases. This raises the pressure difference across the weir
hole, depressing the water seal on the upstream side of the weir plate, exposing the
sensor and giving an open circuit.
on the handheld indicator or the automatic trap
This illuminates a red LED and a
monitor, which indicates that a trap has failed and is leaking steam.
Sensor
exposed
Red light
Trap Leaking Steam

Trap Failed Closed
If the trap has failed closed and is waterlogging, (due to blockage, failure or isolation),
condensate will back up upstream of the trap and sensor chamber. After a period, the
condensate will cool below a pre-set temperature. The temperature sensor will then
illuminate an orange light on the automatic trap monitor, signifying that a trap has failed
shut and is waterlogging.
Sensor
detects
lowered
temperature
Obstruction
Orange Light
Trap Failed Closed
Sensor immersed
in hot condensate
Sensor surrounded
by steam
Sensor immersed
in cool condensate
Fig. 11.14.1 How traps with integral sensors work
Thermodynamic
Automatic
Balanced pressure
or bimetallic
Local
manual
Float
thermostatic
Remote manual
Fig. 11.14.2 Manual, remote, or automatic monitoring with integral traps
11.14.3
E. maintenance of steam traps
Maintenance of steam traps

Routine maintenance
Routine maintenance depends on the type of trap and its application. The balanced pressure
steam trap for example, has an element which is designed for easy replacement. Changing these
on a regular basis, maybe once every three years or so, might seem wasteful in time and materials.
However, this practice reduces the need for trap checking and should ensure a trouble free
system with minimal losses through defective traps.
Routine maintenance which involves cleaning and re-using existing internals uses just as much
labour but leaves an untrustworthy steam trap. It will have to be checked from time to time
and will be prone to fatigue. Any routine maintenance should include the renewal of any
suspect parts, if it is to be cost effective.
Replacement of internals
The renewal of internal parts of a steam trap makes good sense. The body will generally have as
long a life as the plant to which it is fitted and it is only the internal parts which wear, depending
on system conditions. There are obvious advantages in replacing these internals from time to
time. It depends on the ease with which the new parts can be fitted and the reliability and
availability of the refurbished trap. The elements of thermostatic traps can generally be changed
by removing a screwed in seat. Replacement is simple and the remade trap will be reliable
assuming the maintenance instructions are correctly carried out.
If the seat or disc faces of a thermodynamic trap become damaged, the disc can simply be
replaced (Figure 11.14.3). Damage to seating faces can be rectified by lapping gently. Replacing
the seats of some higher pressure thermodynamic traps is more complicated. Two separate
gasketed joints may have to be made or a single gasket may have to cope with two or more
steam/condensate passages. The weakest point is often the joint between trap body and seat,
particularly if this has been allowed to blow steam.
Always check with the manufacturer regarding the correct technique for any maintenance work
required on steam traps. A reputable manufacturer will always be able to supply appropriate
literature, advice, and spare parts.
Fig. 11.14.3 Sectional view of a thermodynamic trap with the disc as one moving part
A lot will depend on site conditions. The small float trap, shown in Figure 11.14.4, is designed so
that the cover with the internals attached can be taken to the workshop, leaving the main body
attached to the pipe. This is often preferable to renewing the seats of inaccessible traps, which
have been welded into the pipework under dirty site conditions.
Fig. 11.14.4 Internals of float-thermostatic trap with steam lock release and air vent
Replacement of traps
On occasions, it will be easier and cheaper to replace traps rather than repair them. In these
cases it is essential that the traps themselves can be changed easily. Flanged connections provide
one solution, although the flanged trap is more expensive than the equivalent screwed trap.
Mating flanges are an additional expense.
A swivel connector allows rapid easy removal and replacement of the sealed trap. The trap
shown in Figure 11.14.5 is specifically designed for easy replacement for such a system. It comprises
a pipeline unit or connector which remains in the pipeline during the maintenance procedure.
The trap can be replaced simply by attending to two bolts. This type of trap can be matched to
the same connector providing flexibility of choice and rationalisation of spares. Connectors are
also available with integral piston isolation valves ensuring downtime is kept to a minimum.
Fig. 11.14.5 Swivel connector trap for quick replacement
11.14.5
Questions
1. What effect does a steam trap have when failed in the open position?
a| It will stop the plant from operating
b| It will loose steam and cost money
c| Plant efficiency is maintained
d| Plant efficiency is increased
2. Which of the following is the most reliable steam trap tester?

a| A sight glass
b| An ultrasonic listening device
c| A temperature monitoring device
d| An integrated steam trap sensor
3. What are the operating principles of an integrated trap sensing system?

a| Ultrasound detection
b| Conductivity and temperature for leaks and blockages respectively
c| Temperature sensing only
d| Pressure sensing
4. Why is it not feasible to rely on temperature sensing for testing steam leaks?
a| Because it is too difficult
b| Temperature sensing devices cost too much
c| Because steam and condensate can co-exist at the same temperature
d| Because saturation temperature varies with steam pressure
5. What are the most convenient steam trap connections to consider for maintenance
purposes?
a| Screwed connections
b| Flanged connections
c| Socket weld connections
d| Universal swivel connections
6. Which of the following statements is true?

a| Ultrasonic trap testers cannot differentiate live steam and flash steam
b| A Spiratec hand held unit cannot indicate a failed closed steam trap
c| Sight glasses cannot differentiate between live steam and flash steam
d| All of the above
Answers
1: b, 2: d, 3: b, 4: c, 5: d, 6: d
Swivel Connector Trap

Gasket mating
faces in same
material to
eliminate
galvanic
corrosion
Welded
construction
with no
gasketed joint
to ASM IX
2 bolts for
minimum
downtime
Flange
rotation to
suit pipeline
connector
Screwed, socket weld,

butt weld or flanged
connections
High integrity, spirally

wound gasket
Typical Applications
Steam mains drainage

For both saturated and superheat applications. Suitable traps
include the UTD30L and UTD52L.
Thermodynamic Trap
UTD30, UTD30A
UTD30H, UTD30HA
UTD52L

Steam Trap Manuals Explained

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Steam Trap Manuals Explained

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MALAYSIA

Steam Trap Manuals

BP CHEMICALS SDN BHD - KUANTAN

Steam Trap Manual

D. Methods of Testing Steam Traps

Why Steam Traps?

Does the plant come quickly up to temperature or is it slow to respond,

Why steam traps?

duty of a steam trap is to discharge condensate

The Steam and Condensate Loop

Considerations for steam trap selection

The Steam and Condensate Loop

Maximum steam and condensate pressures.

Operating steam and condensate pressures.

Temperatures and flowrates.

Whether the process is temperature controlled.

The Steam and Condensate Loop

How steam traps operate

Types of steam trap:

Thermostatic (operated by changes in fluid temperature) - The temperature of saturated

The Steam and Condensate Loop

International and European Standards

Glossary of technical terms for automatic steam traps

ISO 6553 : 1980

ISO 6554 : 1980

Face-to-face dimensions for flanged automatic steam traps

ISO 6704 : 1982

ISO 6948 :1981

Production and performance characteristic tests for automatic steam traps

ISO 7841 : 1988

Methods for determination of steam loss of automatic steam traps

ISO 7842 : 1988

Methods for determination of discharge capacity of automatic steam traps

The Steam and Condensate Loop

b| Only when the trap has passed all the condensate

c| Air should be removed as soon as it reaches the trap

d| Only on high pressure steam systems

2. How is flash steam produced?

b| From saturated steam

c| From superheated steam

d| From steam mixed with high temperature air

3. Should steam traps match the application?

b| Only if fitted to a heat exchanger

c| Only on high pressure steam systems

b| Condensate is removed at steam temperature

c| Condensate should back-up into the steam space

5. Can temperature controlled applications be trapped?

b| Only if there is no lift after the trap

c| If the pressure on the trap is always higher than the backpressure

d| Pumps should always be fitted to remove condensate

6. What are the main considerations for steam trap selection?

b| Air venting, plant performance, flow capacity and reliability

Thermostatic Steam Traps

Thermostatic Steam Traps

Fig. 11.2.2 Response of a liquid expansion steam trap X - X

The Steam and Condensate Loop

Advantages of the liquid expansion steam trap:

Disadvantages of the liquid expansion steam trap:

The Steam and Condensate Loop

Balanced pressure steam trap

Fig. 11.2.4 Balanced pressure steam trap with replaceable capsule

Fig. 11.2.5 Operation of balanced pressure steam trap capsule