UNITS IN THIS COURSE

Unit No. 2 - Pipe fitting - Pipe fitting Unit No. 2

UNIT 1 UNIT 2 UNIT 3 PIPING SYSTEMS PIPE FITTINGS VALVES

TABLE OF CONTENTS
Para 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 COURSE OBJECTIVE PIPE FITTINGS FLANGES GASKETS BLINDS FILTERS STRAINERS STEAM TRAPS TYPES OF STEAM TRAPS Page 3 4 8 10 14 18 25 29 31

No. 2 - Pipe fitting Module No. 7 : Piping systems Module No. 7 : Piping systems No. 2 - Pipe fitting Unit

2.0 COURSE OBJECTIVE This course introduces the students to all major items of static equipment relating to a plant site. Upon completion of the course the trainees will have a general understanding of the following. 2.1 Equipment Terminology. Theory of operation. Equipment construction. Hands on operation. safety features. Equipment interaction with the overall process.

PIPE FITTINGS Pipe fittings are classed according to the way they are joined to section of pipe. The three main types of pipe fittings are:

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* Screwed. Flanged. Welded.

Unit No. 2 - Pipe fitting

Screwed or flanged fittings must be used if the pipe has to be opened up or taken apart for cleaning, inspection or maintenance. The advantages and disadvantages of each are as follows: Screwed Fittings (Advantages) Simple design. Quick to install or remove. Easy to open for cleaning or maintenance. Cheaper to install. Easy to repair / or replace. Screwed Fittings (Disadvantages) More leak problems. More chance of corrosion at the threads. Threads make pipework weaker. Flanged Fittings (Advantages) Strong. Quick to open for cleaning and for repair. Low corrosion possibility. Flanged Fittings (Disadvantages) More possibility of leaks occurring. Prone to leaks if gaskets are not installed correctly. Expensive to buy and install. Heavy. Difficult to insulate.

Module No. 7 : Piping systems

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Unit No. 2 - Pipe fitting

Figure 2-1 Pipe Fittings

Figure 2-1 shows the most commonly used pipe fittings in a plant piping system. Table 1 explains what these fittings are used for.

NAME Coupling Union.

DESCRIPTION AND USE This is a female fitting. Joins piping in a straight line. This is a female fitting which can be taken apart Changes the direction of the piping by 45 or 90 Different size Internal and external thread. Joins a large pipe to a smaller pipe Joins two or more branches together

Module No. 7 : Piping systems

Elbow (45 or 900 angle). Bushing. Tee (T) joint. Y joint .

Joins two or more branches together

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Cross ( +) joint. Plug Cap

Joins three or Four branches together A solid threaded male fitting. It screws into another fitting to plug an opening. An internally threaded female fitting. It screws onto the pipe to seal the end. This is a male fitting. A short section of threaded pipe. It often Joins two fittings Female fitting which reduce the size of the pipe. Most of the above fittings can be used as reducers Table 1 Types of Fittings and Their Uses

Unit No. 2 - Pipe fitting

Nipple Reducers.

Welded Joints

Figure 2-2 Welded Pipe Joints

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Unit No. 2 - Pipe fitting

Figure 2-3 Screw, Flange and Welded Fittings

All fittings can be screwed, flanged or welded (See Figure 2-2 and 2-3). A properly welded joint is as strong as the pipe itself. A welded system does not leak and needs no maintenance. This is important on high pressure systems. The joints are much smoother on a welded system so insulating this type of system is easier. For all permanent installations welding is used to join the sections of pipe and / or the pipe fittings. Welded joints may be Butt-welded, Fillet welded or Sleeve-welded. Butt welding is the most common type of welded joint. Figure 2-2 shows some typical welded pipe joints. Butt-welded joints prevent leaks and give fewer corrosion problems. The advantages of welded joints are: Very Strong. Leakproof. Maintenance free. Smooth / small joints Easy to insulate.

Module No. 7 : Piping systems

The disadvantage of welded joints is that they cannot be taken apart easily. 2.2 FLANGES Page 5/37

Flanges are connecting devices on vessels, tank equipment and piping which give quick and easy connections and leakproof seals. A flange has a contact surface which can be joined to another flange. Flanges have holes around the edge so they can be bolted together. Flanges are attached to piping in different ways. They can be screwed or welded. Welding is the strongest and most permanent. Figure 2-4 Shows different flange surfaces Flat Face (Plain) Raised Faced (Serrated) Ring Joint (Grooved) Tongue and Groove For low pressures and temperatures. For high pressures and temperatures. For high pressures and temperatures. For high pressures and higher temperatures.

Unit No. 2 - Pipe fitting

Flanges can be over 48" in diameter. They are made of different materials for different purposes. They are rated according to the pressure they must hold. They are stamped with this rating.

Module No. 7 : Piping systems

Figure 2-4 Different Types of Flange Faces

Rating 150 Low Pressure 300 Intermediate Pressure 600 High Pressure

to to to

Rating 260 PSIG up to 200 C 300 675 PSIG up to 200 C 700 1350 PSIG up to 200 C 1300 Page 6/37

900 1500 2500

Very High Pressure Very Very High Pressure Maximum Pressure

to to to

2000 PSIG up to 200 C 2000 3375 PSIG up to 200 C 3000 5625 PSIG up to 200 C 5600

As the operating temperature increases, the allowed operating pressure of the flange decreases. For example a 150 flange at 200 C operating temperature is rated for 260 psig.

Unit No. 2 - Pipe fitting

Higher flange ratings use more connecting bolts. The higher the flange rating the more connecting bolts / studs are used. The whole area of a flat face flange is joined to the opposite flange. Only a small inner part of a raised face flange is joined to the opposite flange face. The outer flange edges do not come in contact with each other. A ring joint has a ring on one face that fits into a circular groove machined on the opposite flange face.

Figure 2-5 Blind Flange Blind flanges are used to close off the ends of piping, valves and equipment openings. (See Figure 2-5) The flange bolts pass through the blind flange and the mounted flange. After a gasket has been installed the bolts are tightened to the normal operating specification to make a leakproof seal. 2.3 GASKETS Gaskets are a thin plates which fit between the faces of two flanges. They are especially important when joining two flat metal faces. It is hard to machine two metal faces so that they fit together without leaking. Thermal expansion and pressure causes the metal to lose its shape. The gaskets prevent leaks by filling in the small gaps between the metal surfaces.

Module No. 7 : Piping systems

Many different types of gaskets are used in the plants. Gaskets are made from different materials. The material that is used must resist the temperature and chemical action of the fluid in the pipe. Gasket materials may be metallic or non-metallic.. Some non-metallic gasket material is bought in sheet form and cut to size. Many gaskets for special applications are already cut to size. Table 2 shows some different gasket materials and the different fluids they are used with.

FLUID

GASKET MATERIAL Page 7/37

Water Cold Oil Hot Oil. Gas (Low Temperature). Gas (High Temperature) Acids.

Rubber. Asbestos. Cor, Neoprene Asbestos. Ingot Iron Rubber Asbestos. Sheet Lead / Steel. Table 2 Gasket Materials and Applications

Unit No. 2 - Pipe fitting

Metallic Gaskets Flat metallic gaskets are made of lead, copper, iron, steel, aluminium and monel. Flat metallic gaskets are a simple and cheaper method of sealing . They are strong enough for high temperature and pressure conditions. They can be used for pressures up to approximately 500 psig. Tightening the bolts around the flanges forces the gasket material into the small spaces in the flange faces to form a leakproof seal. Gaskets are made in different shapes and different materials to suit any process. The following are examples of non-metallic gasket materials and applications: Asbestos Rubber / Neoprene Cork Viton Teflon High temperature / pressures. Low temperature / pressures. Low temperature / pressures. High / low temperatures / high pressures High temperatures / pressures

The following are examples of metallic gasket materials and their applications: Stainless steel. colonel Aluminium Lead Tin High temperature / pressures. High temperature / pressures. High temperature / pressures Low temperature / pressures. Low temperature / pressures.

Figure 2-6 shows the most common types of metallic gaskets available for use in the process plant.

ngNo. 2 - Pipe fitting it systems

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Unit No. 2 - Pipe fitting

Figure 2-6 Metallic Gaskets Spiral Wound Gaskets Spiral wound gaskets are made of metallic strips in a special V shape. They are put together with an asbestos material between the Vs. The V's are compressed between the two metal rings. The asbestos filled V's form a good compressible seal for the flange face. They are used where expansion and contraction of the metal parts is common. Most spiral wound gaskets can be used for pressures up to 1200 psig

Module No. 7 : Piping systems

Ring Joint Gaskets Ring joint gaskets are made of stainless steel, iron, nickel, monel and copper. Ring joint gaskets give a seal like a welded joint. However, they are, better than a welded joint because they can be taken apart easily. The ring joint
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gasket fits into a-special groove machined into the flange face.. These gaskets are very good for very high pressures and temperatures. These gaskets can be used for pressures up to approximately 5000 psig. Corrugated Gaskets
Unit No. 2 - Pipe fitting

Corrugated gaskets are made of aluminium, copper, steel and monel. These gaskets require very low bolt tightening force for a leakproof seal. These gaskets are limited to approximately 300 psig. Jacketed Gaskets Jacketed gaskets are made of a soft non-metallic filler material covered by a metallic case. The filler material is usually asbestos or rubber. These gaskets are used where metallic parts expand and contract due to temperature changes. They can be used for pressures up to approximately 1200 psig. Flat Metallic Gaskets Flat metallic gaskets are made of lead, copper, iron, steel aluminium and monel. Flat metallic gaskets are a simple and cheaper method of sealing . They have a good mechanical strength for high temperature and pressure conditions. They can-be used for pressures up to approximately 500 psig. Gaskets are used when joining the following: Flanges. Manways to vessels. inspection ports / hand holes to vessels. Heat exchanger parts. e.g., tube bundles , bell ends and end plates. Pump /turbine cases. Any metal to metal face joint that requires a leakproof seal.
Gaskets must be able to handle the following: Various fluids. High and low temperatures. High and low pressures. Thermal expansion. Vibration / compression forces.

Module No. 7 : Piping systems

Always be sure to use the correct gasket for the process application. The gasket must be the correct: Right Size. Right Shape. Right Material. Right Thickness. Installed correctly. Page 10/37

Metallic gaskets are used for high temperature and high pressure applications. The following table lists some of the metals used in gaskets and their maximum operating temperatures.

Unit No. 2 - Pipe fitting

Material Tin Lead Bronze Aluminium

c 93 100 260 427

Material Stainless Steel Titanium Silver Monel

C 538 538 649 816

Special metallic gaskets are available for temperatures up to 1100C. 2.4 BLINDS A blind is a circular metal plate which is placed between two flanges. It stops the flow of liquids. It is used to isolate a section of piping, usually for maintenance. After the blind and gaskets have been installed, the flange bolts are tightened to make a leakproof seal. The bolts are tightened to the normal operating specification. The blind fits inside the circle of flange bolts as shown in Figure 2-7

Figure 2-8 Blank Blind Installed Between Flanges

Module No. 7 : Piping systems

Sometimes vessels and pipework need to be opened for inspection, cleaning and repair. Before a piece of equipment can be opened it must be totally isolated from the process. Blinds are used to isolate the equipment. Blinds are circular metal plates installed between two flanges or at the end of a pipe to stop any fluid from passing a certain point. They are installed with a gasket on each side to ensure no fluids can leak past and cause a safety hazard for the maintenance workers.

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As an operator you must be able to isolate correctly any piece of equipment or unit in your section of the plant to ensure the safety of all workers. When isolating a piece of equipment or pipework the following must be performed. Depressurise and purge all lines with an inert gas (usually nitrogen) before opening any line or piece of equipment. Blind all lines-to and from the equipment.

Unit No. 2 - Pipe fitting

Make a blind list to ensure that all blinds are installed correctly and removed when the work is complete. Use the correct type and size of blind. Purge all the air from the lines using an inert gas (usually nitrogen) before starting the equipment or process.

Blinds are made in three different types: See Figure 2-9

Figure 2-9 Blinds.

Module No. 7 : Piping systems

Blank Blind two flanges. Spectacle Blind It is easier to open and close. Blind Flange vessel nozzle to stop fluid flow.

Temporary installation only. Installed between Permanent installation between two flanges. Permanently installed at the end of a pipe or

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Unit No. 2 No. 2 - fittingfitting Unit - Pipe Pipe

Figure 2-10 Typical Blinding of a Vessel Process Line Feed Inlet (1) Feed Inlet (2) Reboiler Outlet Reboiler Inlet Blind in Oper. Initials Blind Out Oper Initials

Module No. 7 No. 7 : Piping systems Module : Piping systems

Vapour Inlet Product Inlet Table 3 Blind List for the Vessel in Figure 2-10. Table 3 is a blind list for the vessel in Figure 2-10 Before you sign the blinds in, as an operator you must: Check to make sure the blind is in the correct position. Page 13/37

Check that there is a gasket installed on each side of the b Check to make sure the nuts and bolts on the flange are tight Before you sign the blinds out, as an operator you must:

Unit No. 2 - Pipe fitting

Ensure all the work on the equipment is complete. Check that the inside of the vessel is clean and free from t Check that all the blinds have been removed.
1.

Check that new gaskets have been installed between the . Check that all flanges are aligned. Check that all nuts and bolts have been tightened to the cc specification.

YOU MUST ALWAYS REMEMBER THAT BLINDS ENSURE THE SAFETY OF EVERY PERSON WORKING IN OR ON A PIECE 0F EQUIPMENT. YOU MUST ENSURE THAT THEY ARE INSTALL CORRECTLY AND HAVE BEEN REMOVED WHEN THE WORK COMPLETE. 2.5 FILTERS The most common types of filter are: Edge Type Filter. Sock Type Filter. Cartridge Type Filter. Mixed Bed Filters. A filter is a device used to remove unwanted substances from the process fluids and from a system within the process e.g., amine, glycol, air. To do this the fluid is passed through a material which allows the fluid to pass but catches any solid contaminant. The filter material is usually cloth, paper or wire mesh. The thickness and porosity of the surface of the material is very important. It determines both the amount of fluid which can be handled by the filter and the size of the contaminant which will be filtered out. Filters do the following:

Module No. 7 : Piping systems

They prevent abrasive material entering pumps and turbines. They reduce pipe wear due to erosion. They keep valves clean so they can operate freely. They keep process fluids pure so that treating chemicals operate properly. They keep towers and vessels clean.

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They keep heat exchangers and reboilers free of dirt. They keep contaminants out of the sales products. Filters also maintain good / correct instrumentation operation They keep contaminants from blocking air lines to and from control valves. They keep contaminants from blocking or damaging small instrument orifices. They keep contaminants from blocking gauge glasses or level control column legs. All filters are made up of two main parts: The housing (the outside case) which contains the fluid and the filter internals. The filter element or elements. through which the fluids pass. This is the part that traps the contaminants.

Unit No. 2 - Pipe fitting

Some filters can be removed and cleaned when they become contaminated. Most filters have replaceable elements. These elements are specially designed to fit the particular filter. When the element becomes contaminated it is changed. The used element is thrown away. Most filters cause the fluid flowing through them to make a sharp turn. The larger particles to be removed are too heavy to make the sharp turn. These drop to the bottom of the filter. Other particles are trapped in the filter element.

Module No. 7 : Piping systems

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Figure 2-11 Edge Type Filter A filter in which the element is not changed is shown in Figure 6-24. This is called an edge type filter. It is used to remove impurities from an oil line. This filter is also called a full flow filter. That means all the oil flows through the filter. The filter has a metal case with a large number of thin metal plates inside. The plates are arranged on top of each other. The plates have small bumps on the surface. Every second plate is connected to a shaft which can be rotated. The fluid flows down, across and between the plates.. Any particles or contaminants are trapped between the plates and the small bumps.

Unit No. 2 - Pipe fitting

To clean the filter the shaft is turned manually. This turns 50% of the plates so the contaminants drop to the bottom of the case. These contaminants collect in the bottom of the filter (the sump). These contaminants can be drained off by removing the drain plug when necessary.

Module No. 7 : Piping systems

Figure 2-12 Paper Filter / Cartridge Filter In cartridge type filters either the filter element or the whole filter are replaceable. The housing can be bolted in place or it is threaded so it can be screwed onto the filter body. When the element becomes contaminated it is thrown away and a new element is installed.

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The cartridge type filter has a large metal housing. The cartridge elements are ridged cardboard or metal. They have cloth or paper type material inside. They are strong and will not break under high differential pressure. These filters are used in process fluid systems.

Unit No. 2 - Pipe fitting

Sock Type Filter

Figure 2-13 Sock Type Filter These filters have a large metal housing. They have sock type filter elements. These are long circular tubes of cotton or cloth material through which the fluid passes. The particles / contaminants are trapped in the fibres of the materials. These filters are very good for handling large quantities of particles / contaminants. They are used for low differential pressures. This type of filter will break under high pressure. When the filter elements become blocked they are thrown away and replaced. This type of filter is used in Amine systems.

Module No. 7 : Piping systems

Mixed Bed Filters

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Unit No. 2 - Pipe fitting

Figure 2-14 Example of a Mixed Bed Filter These filters have a large circular metal housing. They are filled with layers of different materials. e.g., gravel, sand and anthracite. The particles / contaminants are trapped between the grains of gravel, sand and anthracite. The filter is cleaned when the fluid flow is reversed, The reversed flow forces the particles / contaminants out to drain. This type of filter is used for water purification. Filters must be cleaned and replaced regularly. A blocked / plugged filter restricts the fluid flow in a line and this must not be allowed to happen. A defective filter system may allow contaminants to remain in the line. You must not forget to maintain filters.

Precoat Filters

Module No. 7 : Piping systems

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Unit No. 2 - Pipe fitting

Figure 2-15 Principle Operation of a Precoat Filter

Precoat filtration is used to remove very small solid particles, oil particles, and even bacteria from water. This method is only used for small quantities of water which contain small quantities of contaminants. Precoat filtration may be used after the normal clarification processes. It produces water which contains very small amounts of suspended solids. It is used for specific purposes. For example, precoat filters are often used to remove oil from contaminated steam condensate.

Module No. 7 : Piping systems

In precoat filtration, the precoat material can be organic, (contains living cells). This acts as a membrane between the two fluids. The base must prevent passage of the precoat material without restricting the flow of filtered water. It must be able to operate under high pressure differentials. Filter cloths, porous stone tubes, and wire wound tubes are used as base materials. Page 19/37

The supporting base material is first precoated with a slurry of precoat material. More slurry (body feed) is usually added during the filter run. When the material removed by the filter has built up there will be a big pressure drop across the filter. Then the filter coating is removed by backwashing. The filter bed is then precoated and returned to service. Chemical coagulants are not usually -needed. However, if an extra pure effluent is needed, they may be used.

Unit No. 2 - Pipe fitting

MICRON RATING There are a number of different types of filters for different fluids and contaminant problems. All filters are marked with a micron rating. The micron rating tells you the size of the holes in the filter or the size of the particles the filter will trap. A low micron rating means the filter element has small holes. A higher rating means larger holes. The holes in ratings below 40 micron cannot be seen with the naked eye. 2.6 STRAINERS A strainer is a wire mesh screen. It is used to remove solid particles from a fluid. The fluid may be water, oil, gas, steam or any other fluid carried by a piping system. Strainers are usually installed in front of valves, pumps or regulators for protection. Particles allowed to flow through a piping system will cause pipe walls and piping system to become worn. They may also cause valves, pumps and regulators to block so they cannot operate properly. The size of the wire mesh used in a strainer will determine the size of the particles which will be removed or blocked by the strainer. The strainers used in piping systems are usually designed to allow free fluid flow through the system with very little pressure loss. Most strainers contain a blow-out or clean-out plug. This allows the strainer to be cleaned. There are various types of strainer:

Module No. 7 : Piping systems

Figure 2-16 Circular Strainer Page 20/37

Circular Strainers are made of two circular screens separated by a small space. The inner screen has larger holes than the outer screen. The fluid flows from the inside out. These are used upstream of steam traps.

Unit No. 2 - Pipe fitting

Figure 2-17 Disc Strainer

A Disc Strainers is a round plate or disc with holes in it. It is installed between two flanges. It will hold small volumes of large particles. It is cheap to make and easy to install and remove. It is installed before pumps.

Module No. 7 : Piping systems

Figure 2-18 Cone Strainers Cone Strainers are made in the shape of a cone. It can handle a large volume of particles / contaminants. This type of strainer is difficult to install and remove. It is mainly' used to protect equipment during the start-up phase of a process.

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Unit No. 2 - Pipe fitting

Figure 2-19 Cone Strainer Installed between a Flange

Module No. 7 : Piping systems

Figure 2-20Y-Type Strainer Page 22/37

Y-Type Strainers are usually used in pipelines of three inches or less. The fluid flows through the screen located in the leg. Any sediment is trapped there. The screen can be removed and cleaned by opening the leg cover. The leg cover is either threaded or flanged for this particular purpose. These Y-type strainers can be installed in the horizontal or vertical position. However, the leg must always point Downwards.

Unit No. 2 - Pipe fitting

Figure 2-21 Simplex Basket Strainer Basket Strainers are generally used in larger piping systems but can sometimes be used in smaller piping systems. This type of filter allows a basket type screen to be inserted or removed through the top of the strainer. It is usually flanged or has a yoke type cover which can be removed quickly. Basket strainers are installed either as a simplex or duplex. The simplex is used where the line can be shut down long enough to allow time for cleaning the basket. The duplex permits continuous operation and does not require the system to be shut down for cleaning.

Module No. 7 : Piping systems

2.7 STEAM TRAPS A steam piping system may contain a small amount of water along with the steam. This water must be removed from the steam line. Steam is used to operate high speed turbines and other equipment. Water in a steam line can damage high speed Turbines. Water may also erode valve faces and seals. Impurities in the water can also cause Page 23/37

erosion and damage. The steam traps main function is to remove condensate (water) from the steam line and to prevent steam from entering the condensate lines.

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Unit No. 2 - Pipe No. 2 - Pipe fitting Unit fitting

A steam trap is an automatic valve. It is installed in a piping system. It allows the release of water (condensate) and air without releasing steam. There is no drop in line pressure when a steam trap operates. Steam traps are installed in lines if the condensate must be drained off as quickly as it collects. They allow the condensate to be recovered for heating, for hot water or for return to the boilers. They are used in steam piping, separators and all steam heated or steam operated equipment. Water Hammer If water is allowed to remain in a steam line it can cause problems such as water hammer, erosion, corrosion and loss of efficiency. Water hammer is a series of shocks produced by a sudden change in the speed of the water flowing in a pipeline. This sudden change in the speed of the water may be caused by a valve opening or closing very quickly. It can also be caused by very fast condensation of a pocket of steam within the pipe. If a pump stops suddenly because of a power failure this can cause water hammer. This happens because the water in the pump discharge line will stop and reverse its direction of flow. The rapid closing of the check valve at the pump will cause water hammer. Water hammer will also happen if steam goes into a pipe that contains some water or condensate. As the steam passes over the water it condenses. This-rapid condensation causes a vacuum to form in the pocket. the water rushing into this vacuum will produce water hammer. This can cause damage to the pipework and fittings. Erosion can occur when water enters high speed turbine blades. This causes erosion damage (rapid wear) to the turbine blades. Corrosion can occur when water lays in low sections of pipework and turbine casings. Loss of efficiency will occur when water enters reboilers and heat exchangers because it lowers the heat energy that is available. Loss of efficiency will also occur when water enters steam ejectors as it reduces their pumping efficiency.
2.8

Module No. 7 : Piping systems Module No. 7 : Piping systems

TYPES OF STEAM TRAPS THERMOSTATIC TRAP

Unit No. 2 - Pipe fitting

Figure 2-22 Thermostatic Trap The thermostatic steam trap responds -to The Temperature difference between the steam and the condensate. Both steam and condensate may enter the trap. When steam enters -.he trap the fluid inside the bellows expands and evaporates. This expands the bellows and closes the valve. (See Figure 2-22) When the fluid in the trap cools and condenses to water the fluid in the bellows condenses This makes the bellows contract. This opens the outlet valve and the condensate escapes into the condensate line. When hot steam re-enters the trap it again expands the bellows and closes the valve.

Module No. 7 : Piping systems

Figure 2-23 Float Thermostatic Trap

FLOAT THERMOSTATIC TRAP When hot steam enters the trap inlet it cannot move the float. So, the trap remains closed. When the steam condenses to water, the water will cause the float to rise. This will open the outlet and allow the condensate to leave the trap and enter the condensate line.

Unit No. 2 - Pipe fitting

INVERTED BUCKET TRAP

Figure 2-24 Inverted Bucket Trap When there is only steam in the trap, the steam pressure will hold the bucket up and keep the outlet valve closed. When the bucket fills with condensate the bucket will sink to the bottom of the trap and open the outlet valve. This allows the condensate to leave the trap.

Module No. 7 : Piping systems

Figure 2-25 Open Bucket Trap THERMODYNAMIC TRAP

Unit No. 2 - Pipe fitting

Figure 2-26 Thermodynamic Trap

Thermodynamic traps use the heat energy in steam or in hot condensate to open and close the trap. When cool condensate or air enter the trap they flow upward through the inlet orifice. They tilt the disc upward to pass through a hole in the seat plate. They then flow through the discharge ports to the trap outlet. If steam enters the trap it flows at high speed under the disc. This causes pressure to build up in the chamber above the disc. The build-up of pressure forces the disc down which closes the trap. If hot condensate enters the trap it will flash into steam as it leaves the inlet orifice. This flash steam will also flow at high speed under the disc. This causes a reduction in pressure and flash steam above the disc will again force the trap to close. The trap stays closed until the steam above the disc condenses.

Module No. 7 : Piping systems

Unit No. 2 - Pipe fitting

Figure 2-27 Trap operation Method of checking steam trap operation Listen to it: A properly working steam trap will be silent except when it opens to allow the condensate to pass out. Check upstream and downstream drains: Upstream should be straight steam. Downstream only hot water.

Check upstream and downstream pressure gauges: Upstream should have steam header pressure (250 psig). Downstream should have condensate pressure only (35 psig). Check temperature before and after the steam trap (Wearing gloves) Upstream side should be hotter Where are steam traps installed: Bottom of large steam headers.

Module No. 7 : Piping systems

End of steam headers. Before steam turbines. Bottom of steam turbine cases. Outlet of steam turbines.

Before reboilers.

On all steam lines.

Module No. 7 : Piping systems

Unit No. 2 - Pipe fitting

Figure 2-28 Typical Steam System

Steam Separators

Unit No. 2 - Pipe fitting

Figure 2-29 Typical Steam Separators Steam separators, (sometimes called steam purifiers) are devices which purify steam. When they are installed in the steam line they will remove moisture droplets and other suspended impurities in the steam. To do this, the separator causes the steam to suddenly change its direction of flow it causes the steam to start circulating quickly. Both of these actions cause the moisture and other particles to be thrown out of the flow of steam. The moisture particles collect at the bottom and pass out through a drain.

Module No. 7 : Piping systems