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SC-GCM-79 CM Issue 2 © Copyright 2006 Spirax-Sarco Limited
Module 11.1
Introduction - 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?
o Is the system trouble free, or does inadequate steam trapping permit waterhammer,
corrosion and leakage, and high maintenance costs?
o 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.
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
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.
o Operating steam and condensate pressures.
o Temperatures and flowrates.
o 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.
o 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.
o 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 170.5°C. If this condensate is discharged to atmosphere, it can only exist as
water at 100°C, 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.
Questions
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 ¨
Answers
1:c, 2: a, 3: d, 4: b, 5: c, 6: b