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ST-01-00

INTERNAL TRAINING
FOR
STEAM PIPING WORK
TAIKISHA VIETNAM ENGINEERING
TERUMO BCT PROJECT
VERSION 1
OCTOBER 2013
PURPOSE
Give critical knowledge to staffs
A Saturated Steam Property
A 1. Absolute Pressure and Gauge Pressure
A 2. Saturated Steam Property
B Steam pipe expansion
B 1. Expansion amount
B 2. Long Pipe/Main Pipe Expansion absorbtion (Expansion Joint, Expansion Loop, Fixing and Guiding)
* Expansion Joint
* Expansion Loop
* Fixing
* Guiding
B 3. Branch ( 2 elbow, 3 elbow ..), it depends on lengh from fixed point
B 4. Steam Piping arround Equipment
C Steam condensate
C 1. Steam condensate
C 2. Steam trap selection, location; Steam drain pipe inside of hot well tank; Reducer, valve direction
C 3. Insulation of Steam trap
C 4. Flash Steam
C 5. Flash tank
D Pressure reducing valve
Steam Pressure reducing valve
E Steam Pressure Gauge
Steam Pressure Gauge
ST-01-01 TERUMO BCT
STEAM PIPING
TRAINING CONTENTS
ST-01-02 A-1
STEAM PIPING
ABSOLUTE PRESSURE and GAUGE PRESSURE
Absolute pressure and gauge pressure
Gauge pressure. ..Gauge pressure is the pressure as indicated by a gauge. It is important to understand that
gauges are calibrated to read zero at atmospheric pressure. Gauges measure only the difference in
pressure between the total pressure of the fluid in the vessel and the atmospheric pressure.
Gauge pressures are expressed as "kgf/cm2G", "psig" or"kPa(G)".
Absolute pressure.. .Absolute pressure is the "total" or "true" pressure of a fluid. When the fluid pressure
is greater than the atmospheric pressure, the absolute pressure of the fluid is determined by adding the
atmospheric pressure to the gauge pressure, and when the fluid pressure is less than the atmospheric
pressure, the absolute pressure of the fluid is found by subtracting the gauge pressure from the
atmospheric pressure.
Absolute pressures are expressed as "kgf/cm2abs", "psia" or "KPa (A)"
However, it is normal to omit "G", "g", "abs" or "a" except when it is necessary to discriminate gauge
pressure from absolute
Example 1:
A pressure gauge reads 1.8MPa (18kgf/cm2). What is the absolute pressure in this case?
Solution : Absolute pressure=[1.8+0.1] MPa; (18+1.03) kgf/cm2 =1.9MPa; (19.03kgf/cm2)
Example 2 : A compound gauge on the suction pipe reads 200mmHg. What is the absolute pressure?
Solution : Absolute pressure=760-200=560mmHg
(bar) (C) (m3/kg) (kg/m3) (kJ/kg) (kcal/kg) (kJ/kg) (kcal/kg) (kJ/kg) (kcal/kg) (kJ/kg)
1 99.63 1.694 0.59 417.51 99.72 2675.4 639.02 2257.9 539.3 2.0267
1.1 102.32 1.549 0.645 428.84 102.43 2679.6 640.01 2250.8 537.59 2.0373
1.2 104.81 1.428 0.7 439.36 104.94 2683.4 640.93 2244.1 535.99 2.0476
1.3 107.13 1.325 0.755 449.19 107.29 2687 641.77 2237.8 534.49 2.0576
1.4 109.32 1.236 0.809 458.42 109.49 2690.3 642.56 2231.9 533.07 2.0673
1.5 111.37 1.159 0.863 467.13 111.57 2693.4 643.3 2226.2 531.73 2.0768
1.5 111.37 1.159 0.863 467.13 111.57 2693.4 643.3 2226.2 531.73 2.0768
1.6 113.32 1.091 0.916 475.38 113.54 2696.3 643.99 2220.9 530.45 2.086
1.7 115.17 1.031 0.97 483.22 115.42 2699 644.64 2215.8 529.22 2.095
1.8 116.93 0.977 1.023 490.7 117.2 2701.5 645.25 2210.8 528.05 2.1037
1.9 118.62 0.929 1.076 497.85 118.91 2704 645.83 2206.1 526.92 2.1124
2 120.23 0.885 1.129 504.71 120.55 2706.3 646.39 2201.6 525.84 2.1208
2.2 123.27 0.81 1.235 517.63 123.63 2710.6 647.42 2193 523.78 2.1372
2.4 126.09 0.746 1.34 529.64 126.5 2714.6 648.36 2184.9 521.86 2.1531
2.6 128.73 0.693 1.444 540.88 129.19 2718.2 649.22 2177.3 520.04 2.1685
2.8 131.2 0.646 1.548 551.45 131.71 2721.5 650.03 2170.1 518.32 2.1835
3 133.54 0.606 1.651 561.44 134.1 2724.7 650.77 2163.2 516.68 2.1981
3.5 138.87 0.524 1.908 584.28 139.55 2731.6 652.44 2147.4 512.89 2.2331
4 143.63 0.462 2.163 604.68 144.43 2737.6 653.87 2133 509.45 2.2664
4.5 147.92 0.414 2.417 623.17 148.84 2742.9 655.13 2119.7 506.29 2.2983
5 151.85 0.375 2.669 640.12 152.89 2747.5 656.24 2107.4 503.35 2.3289
5.5 155.47 0.342 2.92 655.81 156.64 2751.7 657.23 2095.9 500.6 2.3585
6 158.84 0.315 3.17 670.43 160.13 2755.5 658.13 2085 498 2.3873
6.5 161.99 0.292 3.419 684.14 163.4 2758.9 658.94 2074.7 495.54 2.4152
7 164.96 0.273 3.667 697.07 166.49 2762 659.69 2064.9 493.2 2.4424
7.5 167.76 0.255 3.915 709.3 169.41 2764.8 660.37 2055.5 490.96 2.469
8 170.42 0.24 4.162 720.94 172.19 2767.5 661 2046.5 488.8 2.4951
8.5 172.94 0.227 4.409 732.03 174.84 2769.9 661.58 2037.9 486.73 2.5206
9 175.36 0.215 4.655 742.64 177.38 2772.1 662.11 2029.5 484.74 2.5456
9.5 177.67 0.204 4.901 752.82 179.81 2774.2 662.61 2021.4 482.8 2.5702
10 179.88 0.194 5.147 762.6 182.14 2776.2 663.07 2013.6 480.93 2.5944
11 184.06 0.177 5.638 781.11 186.57 2779.7 663.91 1998.6 477.35 2.6418
12 187.96 0.163 6.127 798.42 190.7 2782.7 664.64 1984.3 473.94 2.6878
13 191.6 0.151 6.617 814.68 194.58 2785.4 665.29 1970.7 470.7 2.7327
14 195.04 0.141 7.106 830.05 198.26 2787.8 665.85 1957.7 467.6 2.7767
15 198.28 0.132 7.596 844.64 201.74 2789.9 666.35 1945.2 464.61 2.8197
16 201.37 0.124 8.085 858.54 205.06 2791.7 666.79 1933.2 461.74 2.862
17 204.3 0.117 8.575 871.82 208.23 2793.4 667.18 1921.6 458.95 2.9036
18 207.11 0.11 9.065 884.55 211.27 2794.8 667.53 1910.3 456.26 2.9445
19 209.79 0.105 9.556 896.78 214.19 2796.1 667.83 1899.3 453.64 2.9849
20 212.37 0.1 10.047 908.56 217.01 2797.2 668.1 1888.7 451.1 3.0248
21 214.85 0.095 10.539 919.93 219.72 2798.2 668.33 1878.3 448.61 3.0643
22 217.24 0.091 11.032 930.92 222.35 2799 668.54 1868.1 446.19 3.1034
23 219.55 0.087 11.525 941.57 224.89 2799.8 668.71 1858.2 443.82 3.1421
24 221.78 0.083 12.02 951.9 227.36 2800.4 668.86 1848.5 441.5 3.1805
25 223.94 0.08 12.515 961.93 229.75 2800.9 668.99 1839 439.23 3.2187
26 226.03 0.077 13.012 971.69 232.08 2801.4 669.09 1829.7 437.01 3.2567
27 228.06 0.074 13.509 981.19 234.35 2801.7 669.17 1820.5 434.82 3.2944
28 230.04 0.071 14.008 990.46 236.57 2802 669.24 1811.5 432.67 3.332
29 231.96 0.069 14.508 999.5 238.73 2802.2 669.28 1802.7 430.56 3.3695
30 233.84 0.067 15.009 1008.33 240.84 2802.3 669.31 1793.9 428.48 3.4069
(total heat)
The Saturated Steam Table with properties as boiling point, specific volume, density,
specific enthalpy, specific heat and latent heat of vaporization
ST-01-03 A-2
STEAM PIPING
SATURATED STEAM PROPERTY
Abs. pres.
Boiling
point
Specific
volume
(steam)
Density
(steam)
Specific enthalpy
of liquid water (sensible
heat)
Specific enthalpy of
steam
Latent heat of
vaporization
Specific
heat
Example:
A pressure gauge at Steam header indicates 7.0kgf/cm2. What is the steam temperature in this case?
Solution : Absolute pressure= (7.0+1.03) kgf/cm2 = 8.03kgf/cm2
=> Steam temperature is ~ 170 C
Linear coefficient of expansion of various material pipes ; Unit m/m
(source) Mechanical engineering handbook
For PVC pipe, reference value of manufacturer
Carbon Steel Pipe
SUS Pipe
Copper Pipe
Polyvinyl chloride pipe
608010
-6
Copper pipe
16.510
-6
Stainless pipe
16.710
-6
Steel pipe
12.210
-6
Cast iron pipe
10.510
-6
184
0.2
0.4
0.6
0.8
1
134
152
165
175
Saturated
vapor temp
120
Pipe expansion/contraction per meter
Gauge pressure
MPa
0.1
Saturated vapor temperature
96-2
ST-01-04
H-103-E
B-1
STEAM PIPING
EXPANSION AMOUNT
Steel pipe
Stainless steel , copper
PVC
P
i
p
e

e
x
p
a
n
s
i
o
n
/
c
o
n
t
r
a
c
t
i
o
n

p
e
r

m
e
t
e
r

(
m
m
)
Temperature difference t()
The temperature expansion of pipes depends on the start and final temperature of the pipe and the
expansion coefficient of the piping material at the actual temperature. The general expansion formula
can be expressed as:
L = xL x t
where
L = expansion (m, inch)
L = length of pipe (m, inch)
t= temperature difference (C, F)
= Linear coefficient of expansion (m/mC)
) ( ) (
) / (
3 ) (
10 2 . 12
C
t
m
C m mm
EX
mm
O
o
L L =

) ( ) (
) / (
3 ) (
10 7 . 16
C
t
m
C m mm
EX
mm
O
o
L L =

) ( ) (
) / (
3 ) (
10 5 . 16
C
t
m
C m mm
EX
mm
O
o
L L =

TWO METHODS (for TERUMO BCT SITE)
METHOD 1: EXPANSION LOOP
Advantages:
1. Water leak: very low posiblity [Note] 1. All the fittings of expansion loop should be welded
2. Anchor load: small 2. Should be mounted in between fixed points
3. Installation cost: inexpensive 3. Should not be branched from the loop
4. Access hole: not necessary
5. Installation place: roof space, horizontal * Although many designers frequently use EJ,
expansion loop is more effective for hot/cold water
piping which allows smaller expansion capacity.
Disadvantages
1. Need big space for loop installation
METHOD 2: EXPANSION JOINT
Advantages [Note] 1. Guiding bolt must be removed
1. Need small space after installation
2. Mainly accommodate axial
Disdvantages: movement while slightly absorb
1. Water leak: High Posiblity lateral movement
2. Anchor load: Big 3. Should be mounted in the
3. Installation cost: Expensive right direction
4. Access hole: Necessary (must) 4. Pipes should be guided to
5. Installation place: Piping rack accommodate vibration
6. Expansion capacity: max. 50 mm 5. Should not be over-pressurized
7. Guiding: needs multiple guides in water pressure test on site
(standard interval of steel bracing is acceptable)
ST-01-05 B-2
STEAM PIPING
PIPE EXPANSION ABSOBTION
Guide Anchor/Fixing
Guide Anchor/Fixing
Loop
Expansion
METHOD 1: EXPANSION LOOP
Installation of expansion loop
(1) Expansion loop size --- carbon steel piping
Example Pipe diameter 4" with expansion capacity 100mm
W and H of loop should be: W=1.5m and H=3.3m
Test Pipe diameter 50A with expansion capacity 48mm
W and H of loop should be: W=...m and H=..m
ST-01-06 B-2
STEAM PIPING
PIPE EXPANSION ABSOBTION
Expansion capacity e (mm)

P
i
p
e

d
i
a
m
e
t
e
r

(
B
)
METHOD 2: EXPANSION JOINT
EXAMPLE OF VENN JB-14 SERIES
NOTE:
Pipe Expansion <=> Expansion Joint Contraction
ST-01-07 B-2
STEAM PIPING
PIPE EXPANSION ABSOBTION
Expansion
Expansion
Contraction
Contraction
FIXING AND GUIDING METHOD
A. Fixing/guiding interval
(material: SS400)
(1kg=9.8N, 1kg/cm
2
=0.098MPa)
Relation of normal pressure (P kg/cm
2
) and
guiding interval L
2
(carbon steel pipe)
Requirements for 1. able to withstand horizontal load
metallic attachment 2. avoid unnecessary material
3. easy to manufacture (simple structure)
h should be as small as possible
(to reduce bending moment)
102 H-104-A
B-2
STEAM PIPING
PIPE EXPANSION ABSOBTION
Nominal size
3/8
Allowable shear stress
ST-01-08
Allowable stress 58.8MPa (600kg/cm
2
)
26 265
under normal state kN(kg)
1176
1633
1/2
5/8
3/4
7/8
115
160
46
77
2145
2698
1 1/4
1 3/8
1
1 1/8
210
264
339
402
493
558
6789
7691
5033
5697
470
787
2 877 8947
3462
4102
753
1 1/2
1 5/8
Bolt shear stress
1 3/4
1 7/8
665

2
Cantilever shear stress
Normal pressure (kg/cm
2
)
Guiding
interval
(m)
Guided
Guided
(double-bellows)
Anchor
When pipe diameter is D, L
1
should not exceed 4D
(single-bellows)
Anchor Anchor
Fixed Fixed
FIXING AND GUIDING METHOD
B. Fixing/guiding of steam or hot water piping
1. Making use of structural beam
If piping load exceeds 1.96kN (2,000kg), gusset plate
should be installed to reinforce bracket
Bending moment on fixed point includes weight of riser.
should be as short as possible.
ST-01-09
103 H-104-B
B-2
STEAM PIPING
PIPE EXPANSION ABSOBTION

(Material)
Expand
welded
insulation
[Main fixing point]
Angle steel (H800)
20-100A L5x40x40
125-250A L5x50x50
Anchor bolt (p<5kg/cm
2
)
20-100A 12 x 4 pcs
125-250A 15 x 6pcs
(+2pcs for existing building)
Insulation gusset plate
welded
[Main/sub-fixing point]
W=D+200
D --- Pipe nominal size
expand
welded
Reinforcment
beam
metallic
Channel steel
or
[Riser]
l
[Riser]
FIXING AND GUIDING METHOD
2. Making use of slab --- fixing onto slab is not recommended (possibility of fall)
3. Inside tunnel
Piping arrangement is designed along the wall For pipe hanger, flat bar is preferred to round bar,
in order to secure space for maintenance. which should be welded to pipe.
Fixing/guiding method with the help of wall For , strength of anchor bolt should be checked
should be sought. especially for high-temperature steam service.
4. Fixing of bending part
ST-01-10
104 H-104-B
B-2
STEAM PIPING
PIPE EXPANSION ABSOBTION
(Material)
Angle steel (H1,000)
20-100A L5x40x40
125-250A L5x50x50
Anchor bolt (p<5kg/cm
2
)
20-100A 12 x 4 pcs
125-250A 15 x 6pcs
W=D+200
D --- Pipe nominal size
[Main/sub-fixing point]
Insulation
welded
approx 1/5 H
When H>800
welded
welded
welded
welded
water
proof
mortar
Concrete pad
Anchor bolt
hooked up with slab reinforcement
welded welded
welded
C
FIXING AND GUIDING METHOD
5. Inside trench
6. Guiding
[Requirements of metallic guides] a. Friction should be smaller
b. Piping misalignment or movement should be restrained
(Ceiling-mounted piping)
(Riser) (Floor-mounted piping)
* Although pipe itself can be entirely insulated,
installation of pipe shoes is somewhat painstaking.
ST-01-11
105 H-104-B
B-2
STEAM PIPING
PIPE EXPANSION ABSOBTION
Plan view
Plate
Sleeve
Elevation view
Riser clamp
Insulation tube
Pipe hangers and supports
Regular roller support
Hanger
Pipe sleeve
U-bolt or flat bar
pipe strap
Chain Chain
Bracket
Guide
Hanger
Hanger Guide
Fixed
* Guides should be installed every 2-3 hangers
welded
waterproof
(asphalt, pitch,
etc.)
U-bolt to eliminate
vibration
roller support
* prepare drain ditch where necessary
FIXING AND GUIDING METHOD
C. Fixing/guiding of hot/cold water piping
1. Insulated piping
a) insulation may interfere with fixing/guiding
b) condensation may occur through bolt
Although condensation can
be completely prevented,
this requires higher cost.
2. Fastening by welding on site
[Note] Pipe can be tightly attached in the above method, but condensation may
occur with cold water piping. Applicable only for hot water piping.
3. Pipe is insulated at sub-fixing point (where tight fastening is not necessary)
For cooling water piping
1. Expansion loop is preferred if space is available
2. Wood or rigid urethane O-ring should be applied at hanging part of pipe
ST-01-12
106 H-104-C
B-2
STEAM PIPING
PIPE EXPANSION ABSOBTION
Insulation
welded
direction of
Insulation (cypress)
*lauan not acceptable
U-bolt welded
to pipe
Rigid
urethane
O-ring
welded
insulation
welded
welded
W=D+200
(D --- pipe nominal size)
Rigid urethane O-
ring
Insulation (rigid
urethane O-ring)
Insulation (cypress)
Guiding bracket
U-bolt or hanger
(* if fixed, bending moment
works on bracket)
Dew drain pan
(if necessary; EJ should not be
installed in the room which is
susceptible to water leak)
A. Branch piping of horizontal main pipe
B. Use of eccentric reducer
C. Avoiding obstruction
D. Use of globe valve
Globe valve should not be installed in horizontal pipe
which carries large volume of steam condensate.
Condensate is likely to be trapped in the valve.
(Valve may be installed horizontally where volume of
condensate is fewer (e.g.) bypass of pipe end trap)
Steam pipe dia. Drainpipe dia. Return pipe dia. Equalizer dia.
125150 50 125150 50
80100 40 80100 40
5065 32 5065 32
2540A 20A 2540A 20A
ST-01-13
62 F-102-A.B.C.D
B-4
STEAM PIPING
BRANCH PIPING (EXAPMPLES)
Bad
expansion/
contraction
expansion/
contraction
branch (up)
Branch (upward)
Branch (upward)
Branch (downward)
Riser
(down)
Horizontal
main
* Condensate is likely trapped
not exceed 600
* Pipe end trap of
main pipe is omitted.
Steam
Steam
Steam
Steam
Steam condensate
Steam condensate
approx. 400
upward (Not against the
steam flow)
downward
Bushing
Bushing
Steam
Obstruction
Drain plug
or valve (15A)
drainpipe
Steam
Drain plug
or valve (15A)
Obstruction
Return
Steam
condensate and
dirt
Steam
condensate
Steam
condensate
and dirt
Steam
d
Equalizer
POI NT
POI NT
* BRANCH PIPING MOVES DUE TO MAIN PIPING THERMAL EXPANSION/CONTRACTION
Comparison by installation position
a) Single fixed point and no support at the end
1. Friction of guides should be minimized and guides should withstand buckling load of pipe
2. Branch pipe should also accommodate expansion/contraction of pipe
(combined with three elbows, etc.)
3. Force at A-1 is small (friction of guides, etc.)
b) Single-bellows EJ with two fixed points
1. Horizontal load on anchors is larger than c) below
2. Branch pipe should also accommodate expansion/contraction of pipe
(combined with three elbows, etc.)
3. Distance between the two fixed points should be within the allowable expansion capacity of EJ
c) Double-bellows EJ with two fixed points
1. Since thermal expansion/contraction () is smaller than a) and b) above, anchor load is small.
(* where it is necessary to minimize piping stress on construction such as building, etc.)
2. Double-belows EJ is more expensive than other types
3. Expansion capacity is larger than b) above and d) below.
d) Two fixed points and EJ (single-bellows) at the end
1. Horizontal load on anchors is larger than c) above but smaller than b).
2. Branch pipe should also accommodate expansion/contraction of pipe
(combined with three elbows, etc.)
3. EJ is less expensive than b) above, but its expansion capacity may become smaller -should be checked in advance.
ST-01-14
95 H-103-B
B-4
STEAM PIPING
BRANCH PIPING (EXAPMPLES)
expansion/contraction
shrink/stretch
Not fixed
(single-
expansion/contraction expansion/contraction
(double-bellows)
(single-
bellows)
expansion/contraction
expansion/contraction expansion/contraction
expansion/contraction
expansion/contraction
expansion/contractio
expansion/contractio
E. Steam branch piping [Reference]
(the number of elbows combined with)
Low pressure steam Lower than 1.0MPa
Condition Temperature difference 100(100-0=100)
Pipe length 25m
Average expansion coefficient of steel pipe 12x10
-6
mm/mm
ST-01-15
63 F-102-EF
B-4
STEAM PIPING
BRANCH PIPING (EXAPMPLES)
4 elbows
2 elbows 3 elbows
2 elbows
3 elbows
4 elbows
expansion/
contraction
expansion/
contraction
expansion/
contraction
D
i
s
t
a
n
c
e

f
r
o
m

a
n
c
h
o
r

t
o

e
l
b
o
w

Distance from anchor to the point of
branching out
Anchor
Horizontal steam main Expansion joint
Anchor
mm
ST-01-16 B-4
STEAM PIPING
BRANCH PIPING - REMINDER
A. Around boiler

(3) Water-tube boiler


a. Steam drum is protected from boiling water
and branch pipe does not have to rise.
b. Branch pipe should be combined with 4 or
more elbows to prevent thermal expansion
in one direction
(4) Smoke tube boiler-1 (5) Smoke tube boiler-2
Branch pipe should be combined with [for machine room with limited space]
4 or more elbows. In case space is not available to install branch pipe
Horizontal pipe should run over 2m each. combined with 4 or more elbows, ball joint should
Long elbow for welding should be used. be used to absorb thermal expansion.
ST-01-17
57 F-101-A
B-3
STEAM PIPING
STEAM PIPING ARROUND EQUIPMENT
Steam drum
Water drum
Over 2m
Over 2m
Ball joint
Over 2m
According to the law, building a branch pipe from the
boiler to the 1st valve is designated as boiler
engineering work, which requires the license of boilder
welder. (the license is not required for screwed-type
Example :
From Boiler to Header: 5
Elbows
POI NT
B. Around steam (supply) header
a. Size of spare valve --- steam flow (kg/h) of spare valve should
be predefined by multiplying normal steam flow (kg/h) by 0.2.
* or follow specification, if provided
b. Dirt Pocket --- 80A-100A
should be located farthest from supply main
c. Drain valve
Discharge water of each circuit at start-up
(to prevent steam hammer of branch pipe)
Should be mounted on large-sized branch pipe (125A-)
Drainpipe should be connected slightly above the spare valve.
d. Pressure gauge of each circuit --- * if necessary
Socket should be prepared in advance.
Supply of steam in circuit can be checked with gauge.
For year-round type header (hotel, hospital, etc.), pressure
gauge should be mounted on each circuit.
C. Around heat exchanger D. Ventilation of safety valve of high pressure boiler
E. Around hot well tank
Vent pipe --- approx. 32A-50A
(1) If installed in limited space, ventilation should be
adequately done.
(2) To avoid condensation from dripping out of open end
of vent pipe, pipe should be extended by 5m or longer.
Or a condensate drain pipe should be built at open end,
connected to water drainpipe.
Pump boost pressure should be 1m or higher.
(by using tall tank, etc.)
Pump suction pressure should be checked beforehand.
--- J-101 Calculation of pump suction pressure
ST-01-18
58 F-101- BCDE
B-3
STEAM PIPING
STEAM PIPING ARROUND EQUIPMENT
drain
water
Plug
Spare valve
Drain valve
Trap
Dirt pocket
Air vent
Safety valve
Air vent
Relief pipe should extend
to safe area outside
steam
Relief valve 25A
Drain valve
Trap
Vent
Drain valve
Drain valve
(open)
Gas flue
Rise up to
safe area
High-pressure boiler
Condensate return
Vent pipe
Flash steam
Return pipe
should NOT end
here (air will enter
return pipe and
cause pipe to
corrode)
(Atmospheric pressure)
water supply
Boiler water feed pump
Silencer
(if necessary)
* It is acceptable that backflow
will occur due to a vacuum inside
return pipe when turning off the
boiler.
POI NT
POI NT
POI NT
ST-01-19
64 F-103-A
C-1
STEAM PIPING
STEAM CONDENSATE
Steam trap
Steam traps are a type of automatic valve
that filters out condensate (i.e.
condensed steam) and non-condensable
gases such as air without letting steam
escape. In industry, steam is used
regularly for heating or as a driving force
for mechanical power. Steam traps are
used in such applications to ensure that
steam is not wasted.
Vaporization and Condensation
Steam is formed when water vaporizes to form a gas. In order for the vaporization process to occur, the
water molecules must be given enough energy that the bonds between the molecules (hydrogen bonds, etc.)
break. This energy given to convert a liquid into a gas is called 'latent heat'.
Steam-based heating processes use latent heat and transfer it to a given product. When the work is done
(i.e. steam has given up its latent heat), steam condenses and becomes condensate. In other words,
condensate does not have the ability to do the work that steam does. Heating efficiency will therefore
suffer if condensate is not removed as rapidly as possible, whether in steam transport piping or in a heat
exchanger.
Three physical states (phases)
TLV Information
Water
Saturation, super-heating and subcooling
Steam used for HVAC
Steam used for Power (ex thermal power
A. Type
* Need freeze protection of steam/condensate when equipment is turned off.
* Can be installed vertically; however, maintenance-wise, better to be installed horizontally.
3Thermodynamic trap --- operated on the difference in kinetic and thermal characteristics of steam and condensate
1Mechanical trap --- operated by changes in fluid density Installed horizontally
2Thermostatic trap --- operated by changes in fluid temperature (of steam and condensate)
ST-01-20
64 F-103-A
C-2
STEAM PIPING
STEAM TRAP
Open bucket --- single valve
Inverted bucket --- single valve
Ball foat
Bellows
Bimetal (strip) Bimetal (disc)
Labyrinth
2-orifice (impulse)
2-orifice
Labyrinth Disc (lever)
Disc
Control
chamber
Disc
Adjustor
Cylinder
Vent
B. Comparison of steam traps
Same as left Same as left Same as left
Same as left Same as left Same as left
N/A
Moderate
Price
Reasonable Reasonable Reasonable
Maintenance cost
Low
Freezing
Temperature control
N/A
Condensate outside
bucket may damage trap
Simple structure,
comparatively small
compared with open
bucket (single valve)
Small Large
Reasonable
N/A
Same as left Condensate tends to
remain inside trap.
Frozen condensate may
damage trap.
Low Inexpensive
N/A
Same as left
Durable
Same as left Withstand approximate
value to inlet pressure
Valve and pin joint are
easily worn out
Same as left
Discharging capacity is
larger than open bucket
type
Same as inverted bucket Same as inverted bucket
Compared with free
float, less durable
because valve port is
worn out
Installation
Only horizontally
Structure, Size
Application
Valve is easily worn out
resulting in leakage
Applicable for all
pressure ranges but
discharging capability is
extremely small (max. 1-
2t/h)
Durability
Simple structure but
large sized
Change in condition
of use
Automatically respond
Against back
pressure
Withstand approximate
value to inlet pressure
Yes
Capacity
(operation cycle)
Small
(intermittent)
Medium
(intermittent)
Large
(continuous)
Large
(intermittent)
Air venting
N/A Vent small amount of
air along with move of
bucket. This does not
affect operation.
Yes
Cooled condensate is
intermittently
discharged at start-up
Start-up
Steam loss
None 2-3% of loss compared
with open bucket
Yes Yes
Need to vent air
remaining in trap
Remaining condensate
is automatically
discharged
Cooled condensate is
continuously discharged
at start-up
Inverted bucket
Float
(free)
Float
(lever)
Steam entering open
bucket causes it
float/sink and thereby
discharge port
opens/closes
Steam entering inverted
bucket causes it
float/sink and thereby
discharge port
opens/closes
By sensing difference in
density and condensate,
floating ball (no attach-
ment) floats/sinks to
release condensate
continuously
By sensing difference in
density and condensate,
floating ball (attached
with lever of valve)
floats/sinks to open/
close valve
Mechanism
ST-01-21
65-1 F-103-B
C-2
STEAM PIPING
STEAM TRAP
Type
Mechanical
Open bucket
(single valve)
\
B. Comparison of steam traps
Same as left
None
Steam loss
Continuously vent air Same as left Same as left
Same as left
Same as left
Very compact Compact Compact
Anywhere Same as left
N/A OK OK
High
Inexpensive Reasonable Reasonable
Maintenance cost
Price
By installing vertically,
freezing can be
prevented
Same as left
Freezing
Temperature control
Suitable for low-
pressure service (approx
1kg/cm
2
), mostly for
heating
Pressure-wise, widely
applicable next to open
bucket
Application
Durability
Thermo-bellows is not
durable
Highly durable because
of less impact on valve
port
Structure, Size
Installation Direction to which
bellows expand/contract
Condensate does not
remain in trap. No
possibility of freezing
Large
(intermittent)
Change in condition
of use
Need adjustment for
even a slight change
Adjustment not
necessary unless
significantly changed
Extremely weak against
back pressure
Extremely weak against
back pressure but able
to withstand to a certain
extent by adjusting
settings
Withstand higher back
pressure than strip type.
No adjustment needed
up to 50% of inlet
pressure for practical
use
Against back
pressure
Remaining condensate
is automatically
discharged
Discharge of remaining
condensate at start-up is
very smooth
Start-up
If trap is set to allow no
steam loss, it takes
longer until valve is
opened
Air venting
Capacity
(operation cycle)
Small
(intermittent)
Large
(intermittent)
Type
Thermostatic
Thermo-bellows
Bimetal
(strip)
Bimetal
(disk)
Thermo-bellows
operates on temperature
difference
Bimetallic strips made
from metals with
different expansion
coefficients deflect by
condensate temperature,
permitting valve port to
open/close.
Bimetallic discs made
from metals with
different expansion
coefficients deflect by
condensate temperature,
permitting valve port to
open/close.
Mechanism
ST-01-22
65-2 F-103-B
C-2
STEAM PIPING
STEAM TRAP
B. Comparison of steam traps
Application
Durability
Very compact
Anywhere
N/A
Low
Price
Inexpensive Inexpensive
Temperature control
N/A
Maintenance cost
Moderate
No damage from
freezing
By installing vertically,
freezing can be prevented
Freezing
Less durable because of
continuous operation
Operation over the above-
mentioned limit significantly
affects durability
Structure, Size
Compact
Change in condition
of use
Better to be adjusted
Installation
Anywhere
Withstand up to 70% of
inlet pressure with the
help of adjustment
device
Withstand up to 50% of inlet
pressure
Against back
pressure
Despite steam loss,
applicable for high-
pressure systems,
100kg/cm
2
or higher
Max pressure 10kg/cm
2
,
discharge 1-2t/h for practical
use
Automatically respond
Approx 5% of loss compared
with open bucket
Steam loss
Air venting
Vent air along with trap
operation
Same as left
Capacity
(operation cycle)
Large
(intermittent)
Theoretically large but small in
practice
(intermittent)
Flash steam of
condensate creates
pressure over piston
which opens/closes
valve
Disk is pushed up by condensate
pressure and consequently valve is
opened to discharge. When steam
enters instead of condensate,
internal pressure lowers to push
down disk and valve is closed as a
result.
Mechanism
Remaining condensate
is automatically
discharged
Depending on installation,
remaining condensate may
prevent valve from opening
Start-up
Need adjustment,
otherwise considerable
steam loss
ST-01-23
65-3 F-103-B
C-2
STEAM PIPING
STEAM TRAP
Type
Thermodynamics
Impulse Disk
C. Pressure before/after trap
Where P
1
P
2
P --- Initial steam pressure (MPa)
P
1
= P - P(MPa) P --- Total pressure drop of steam pipe (MPa)
P
3
= P' + P' + P' --- Pressure at the opening of steam return (MPa)
No pressure (0) when drained to the atmosphere
P' --- Friction loss of return pipe (MPa)
h --- Rise of return pipe (m)
Pressure differential before/after trap affects volume of discharge
Estimation of trap inlet pressure (P
2
)
If pressure drop of H Ex is large Estimate trap outlet pressure (P
3
- back pressure) to select trap type
If pressure exists at trap outlet (P
3
) and P1 - P3 is small affects draining capacity (Q
T
)
QT P
2
-P
3
* Normally, P
1
P
2 however, P
2
< 1.0-1.5MPa (10-15kg/cm
2
)
D. Calculation of working pressure differential of trap (Exercise)
P --- 0.35MPa (3.5kg/cm
2
)
P
4
--- 0.1MPa (1.0kg/cm
2
)
Steam straight pipe length 60m
Steam return straight pipe length 30m
[Solution]
Trap inlet pressure P
2
= 0.35 - *0.06 - *0.03 = 0.26MPa (2.6kg/cm
2
)
* 0.06MPa (0.6kg/cm
2
) --- Pressure drop of steam pipe
Assuming pipe's equivalent length is double the straight length (60m) = 120m.
Where pressure drop per unit pipe length is 0.05MPa (0.5kg/cm
2
)/100m,
P' = 0.05
* 0.03MPa (0.3kg/cm
2
) --- Pressure drop of automatic valve (assumed approx. 3m)
( In principle, pressure drop of automatic valve should not be included in pipe's equivalent length,
but be separately calculated)
Trap outlet pressure P
3
= 0.1 + *0.014 +
* 0.014MPa (0.14kg/cm2) --- Pressure drop of steam return pipe
Assuming pipe's equivalent length is double the straight length (30m) = 60m.
Where pressure drop per unit pipe length is 0.023MPa (0.23kg/cm
2
)/100m,
P' = 0.023 = 0.014MPa (0.14kg/cm
2
)
Pressure differential P
2
- P
3
= 0.26 - 0.144 = 0.116MPa (1.16kg/cm
2
)
Normally, rise of return pipe is max. 5m per pressure differential of 0.1MPa (1kg/cm
2
).
It is recommended to prepare a list of various traps with working pressure differential in advance.
This should be helpful for test-run.
(Note) When automatic valve is shut, steam condensate will not be drained and therefore
accumulate at the bottom of heat exchanger.
ST-01-24
66 F-103-CD
C-2
STEAM PIPING
STEAM TRAP
h
100
120
100
3
100
60
100
= 0.06MPa (0.6kg/cm
2
)
= 0.144MPa (1.44kg/cm
2
)
Header
Trap
Flash tank
E. Selection of steam trap
(1) By mounting position
(free flow) (Return riser) * exceptional (Horizontal return)
Any type of trap is OK Open bucket type is not suitable Open bucket and Disk types
Bimetal type is most suitable; are suitable
should be kept draining For bimetal type, it should be
For disc type, operating cycle should be kept discharging
set shorter to discharge small amount of steam
Need to intentionally create pressure
differential between trap and the part
where condensate is generated
(2) By piping condition
a. Condensate is charged from steam supply main --- (for drip trap)
Few restriction on trap mounting position
Allows continuous supply of steam over long hours
(disk type may be suitable for the part where steam is intermittently supplied at low pressure)
b. Condensate is discharged from heat exchanger
See above (1) By mounting position
(3) By operating condition
For intermittent operation over a short time,
Need to check whether trap can vent air and its air venting capability
whether valve is opened or not when low-temperature condensate is accumulated
The most suitable type should be Bimetal disc type
(4) Safety factor of trap
(Condensate capacity under normal operation x (2 to 3)) < max capacity of product spec
(Reason) a. Because most traps operate intermittently, condensate capacity should be larger
when valve is opened than when continuously operated.
b. Trap inlet pressure and back pressure on trap outlet under actual operation may vary
depending on operational state.
c. Condensate capacity on start-up should be larger than normal operation.
d. In addition to condensate, trap needs to vent air mixed in steam.
(Note) Trap's discharging capability should not be excessive.
Safety factor varies depending on the type of trap. See manufacturers' catalog for more details.
Steam main pipe (downward slope)
Steam rising pipe
before pressure reducing valve
Equipment
3
3
Trap mounting position Safety factor
3
2
ST-01-25
67 F-103-E
C-2
STEAM PIPING
STEAM TRAP
TLV Information
(5) Selecting trap by condition of use [Reference]
Inlet pressure Highly safe at any Widely applicable next Max. 10kg/cm
2
Normally 2kg/cm
2
1kg/cm
2
or less
pressure to upward bucket Max. 4-5kg/cm
2
Allowable back Inlet pressure should Inlet > outlet Inlet pressure should Inlet > outlet Weak against back
pressure be larger than outlet. Need adjustment if be larger than double pressure
outlet pressure exceeds the outlet
50% of inlet
Condensate capacity Commonly Large Max. 2-3 ton/h 500-600 kg/h Max. 9-11 ton/h Max 2 ton/h
Steam supply pipeWidely applicable Widely applicable Low pressure and OK OK with low pressure
intermittent supply steam
Free flow Widely applicable as OK OK OK OK
long as properly placed
Riser NG OK OK NG OK
Horizontal OK Continuous discharge OK OK OK
is recommended
Continuous OK OK OK OK Steam temperature
and pressure should
be constant
Intermittent Not recommended OK OK but trap may not Not recommended OK
work properly at start-
up depending on pip-
ing condition
F. Considerations in piping and mounting trap
(1) Return pipe and trap mounting position
Condensate of main pipe should be returned with a separate return pipe to HWT. (Note) Where steam pressure is equal
Condensate of heat exchanger should be gathered in a common return pipe. in supply main
The number of traps to be mounted on horizontal main should be minimized. (condensate capacity should be checked)
(2) Trap mounting position
Ball float Bellows Open bucket Bimetal disc Disk
ST-01-26
68 F-103-EF
C-2
STEAM PIPING
STEAM TRAP
P
i
p
i
n
g

c
o
n
d
i
t
i
o
n
F
o
r

e
q
u
i
p
m
e
n
t
O
p
e
r
a
t
i
n
g

c
o
n
d
i
t
i
o
n
A/C
Radiator
Booster
heater (reheater)
A/C
Header
As close as possible
Return
Cooling leg over 1.2m
Cooling leg over 1.2m
Dirt pocket
Steam main
a. Normally, trap should be mounted
nearby equipment
(to prevent pressure drop at inlet and
secure discharging capability)
b. Thermodynamic trap
--- needs cooling leg
(to ensure stable operation)

c. Pipe end trap
-- Intermittent low --- should be set to 3-4.
-- Continuous discharge Back pressure on trap outlet is generally high --- Safety factor can be set to minimum.
(3) Checking of trap operation [Note] Install if necessary
Test valve --- to check the presence of Sight glass --- (example) TLV-T5N
condensate in steam return allows to check trap operation with the move of ball
inside domed sight glass
(4) Protecting from back pressure (reduction of discharge capacity)
Decrease of trap capacity due to back pressure (%)
(To ease static pressure of condensate
in return main)
(5) Mounting position
(6) Use of strainer [Note] Applicable when strainer is mounted before automatic valve
(7) Mounting trap at higher position (8) Lifting trap
H is determined by pressure differential
of steam supply and return pipes.
Max 5m per 0.1MPa (1kg/m
2
) of difference
50 20 12 6
75 38 30 25
Back
pressure (%)
Inlet pressure (MPa)
0.035 0.175 0.70
25 6% 3% 0%
ST-01-27
69 F-103-F
C-2
STEAM PIPING
STEAM TRAP
Sight glass
Test valve (G.V.)
Return main
Connect from the
above of return
Return main
back
pressure
Discharge capacity decreases
due to back pressure
Pressure increase due to re-
vaporization of high temperature
d
Steam main
Condensate
steam
steam
Condensate
open
open
open
Valve
open
open
open
* Useful for test-run. By opening the valve
a couple of times, removing of strainer
mesh for cleaning can be omitted.
* For anti-freezing purposes
(Note) Strainer should not
be placed upward.
Does not act as
heater if
condensate
Steam main
Dirt drain
valve
Return
Discharged to return main if
dirt is not contained in
condensate
POI NT
POI NT
STEAM TRAP INSULATION
ST-01-28 C-3
STEAM PIPING
STEAM TRAP
Steam transport piping is insulated to prevent steam losses due to radiant heat. It is also important to
insulate valves and pressure reducing valves having large radiant heat surface areas that are connected to
this piping. What about steam traps?
Steam is supplied to the inlet of a steam trap, so the inlet piping should also be insulated to prevent
radiant heat losses.
But is it OK to insulate all steam traps without regard to the conditions? Actually, no-there are some
circumstances in which it is not acceptable. There are many different types of traps, and whether or not it
is OK to insulate the trap depends on what type it is.
1. Traps that can be insulated without adverse effects:
Float type
Because the valve opens and closes
based only on the change in water level
inside the trap, insulating the trap has
no adverse effects whatsoever.
Bucket type
The buoyancy of the bucket is used to
open and close the valve, but this
happens in conjunction with the
process of the steam condensing in the
trap, so heavily insulating the trap may
result in impaired operation.
2. Traps that should only have light insulation:
Disc type and thermostatic type
With these types of trap, the trap must cool down for the valve to open (the cooling of the trap is a
necessary condition for the valve opening movement). If the trap is insulated, it is difficult for the trap to
cool down, and the opening of the valve is delayed. This delay in valve opening causes condensate that
should have been discharged to pool, so these types of trap must not be insulated.
3. Traps that should only have light insulation:
As we can see from the breakdown of traps into these categories, only with float type traps is it acceptable
to insulate the trap without regard to conditions. Care must be taken with all other types of traps, as over-
insulating may lead to condensate pooling.
At the same time, care must also be taken that traps in the should not be insulated group do not get too
cold, as this results in the danger of the valve opening even in the absence of condensate, thus leading to
large steam losses.
At the time of the oil crises some 30 years ago, there was talk in Japan of huge energy savings to be gained
by placing an empty can over steam traps, and actually this idea provided a brilliant balance between not
insulating at all and over-insulating. In fact, most modern-day disc traps come equipped with a cap that is
similar to this empty can.
As we have seen, when insulating traps it is critical to do so only with an understanding of the traps
characteristics.
ST-01-29 C-4
STEAM PIPING
FLASH STEAM
Flash Steam
Flash steam is a name given to the steam formed from hot condensate when
the pressure is reduced.
Flash steam is no different from normal steam, it is just a convenient name
used to explain how the steam is formed. Normal or live steam is produced
at a boiler, steam generator, or waste heat recovery generator whereas flash
steam occurs when high pressure / high temperature condensate is exposed to a
large pressure drop such as when exiting a steam trap.
High temperature condensate contains high energy that cannot remain in liquid
form at a lower pressure because there is more energy than that required to
achieve Saturated water at the lower pressure. The result is that some of the
excess energy causes a % of the condensate to Flash.
Condensate discharged out of the orifice of a trap partially evaporates (flash
evaporation) due to the pressure difference (illustration).
ST-01-30 C-4
STEAM PIPING
FLASH STEAM
What causes Flash Steam?
Flash steam occurs because the saturation point of water varies
according to pressure. For example, the saturation point of water is
100 C at atmospheric pressure, but is 184 C at 1.0 MPaG.
So what happens when condensate kept under pressure at 184 C is
released to atmosphere? The condensate contains too much energy
(enthalpy) to remain entirely liquid, and a portion of it evaporates,
causing the temperature of the remaining condensate to drop to the
saturation temperature (i.e., 100 C if discharging to atmosphere).
This phenomenon is known as flash evaporation.
In other words, when hot condensate is discharged into a lower
pressure environment, its enthalpy (total energy) remains the same,
but its saturation point drops (the temperature at which condensate
can exist in both the liquid and gaseous state). To compensate for the
excess amount of energy, part of the water molecules absorb the
excess energy as latent heat and evaporate to form steam.
Additional Note
One of the first things that come to mind when visualizing flash steam
are the steam clouds that can appear outside a non-sub-cooling trap
releasing to atmosphere. These steam clouds can often be
misinterpreted as a live steam leak when in fact they are simply
comprised of flashed condensate with fine water droplets in
suspension, caused by the flashing of hot condensate being released to
atmosphere.
ST-01-31 C-4
STEAM PIPING
FLASH STEAM
Calculating the % Flash Steam Generated
The % of flash steam generated (flash steam ratio) can be calculated from:
where:
h
f1
= Specific Enthalpy of Saturated Water at Inlet*
h
f2
= Specific Enthalpy of Saturated Water at Outlet
h
fg2
= Latent Heat of Saturated Steam at Outlet
* In traps designed to have a significant amount of sub-cooling of the
condensate before discharge, the sensible heat of condensate at the trap inlet
can be significantly lower than when estimated using inlet pressure saturated
steam values.
As seen in the below examples, a higher % of flash steam is generated when
condensate is discharged to atmosphere (example 1) compared to when it is
2
2 1
(%)
fg
f f
h
h h
Flash

=
ST-01-32 C-4
STEAM PIPING
FLASH STEAM
h
f1;
h
f2
h
fg2
ST-01-33 C-4
STEAM PIPING
FLASH STEAM
Volume of Flash Steam generated
Steam is much less dense than water, which means that a small increase in the
percentage of flash steam generated can appear as a large increase in volume
of steam generated. The animation below shows the difference in ratio of
steam to condensate for examples 1 and 2 (see above) when applied to
condensate ret rn piping
To understand with great detail, the specific volume of condensate at 100 C
is 0.00104 m3/kg, and the specific volume of atmospheric steam is 1.67
m3/kg. When high temperature condensate at 1.0 MPaG is discharged to lower
pressure such as atmosphere, 16.1% by mass of that condensate flashes into
steam. The resulting volumetric ratio can be contrasted as follows:
Calculating Flash to Condensate Ratio (Metric)
1.Condensate Volume: (1 - 16.1%) x 0.00104 m3/kg = 0.000873 m3/kg
2.Steam Volume: 16.1% x 1.67 m3/kg = 0.269 m3/kg
3.Flash to Condensate Ratio: 0.269 m3/kg / 0.000873 m3/kg = 308:1
The greater the pressure difference, the larger the amount of flash steam generated at
discharge.
ST-01-34 C-4
STEAM PIPING
FLASH STEAM
What to Do With Flash Steam?
The vapor cloud formed by flash steam is a natural by-product of condensate
discharge. Since flash steam is of the same quality as live steam, modern
facilities often try to reuse significant amounts of flash steam whenever
possible.
Reusing flash steam generated by a higher pressure system for use in a lower
pressure system can enable considerable energy savings in addition to
improving a plant's working environment by reducing vapor clouds. When
trying to implement a waste heat management system, condensate recovery
t d fl h t t ft l t d t th
Flash steam from a high pressure system is recovered into a flash tank and reused as
steam in a low pressure system.
A. Example of use (Functions of flash tank)
1. If higher- and lower-pressure return pipes are
directly connected, condensate in higher-pressure
return will be re-vaporized and increase back
pressure on lower-pressure return.
Flash tank is installed to prevent this.
(to reduce influence on trap capacity of lower-
pressure return)
2. To make efficient use of lower pressure steam
when higher-pressure return has large volume of
condensate.
B. Dimension criteria
Flash tank dimensions MAX. 0.55MPa (5.5kg/cm
2
)
5011/16 509/16
5011/16 80A 80A 16 509/16
50A 50A 16
6000 0.430.55 00.1 1830 220 350
80A
490 150 80A
150 300 370 125 3600 0.430.55 00.1 1830
323/4
1800 0.430.55 00.1 1830 150 5011/16 40A 32A 16 3211/32
32A 25A 100 50A 12 259/32
300 300 125 65A
151/2
1140 0.430.55 00.1 1520 150 250 250
250 150
203/8
680 0.430.55 00.1 1220 150 25A 20A 9 209/32 100 40A
9 203/16 20A 20A 75 32A
205/16
320 0.220.5 00.1 920 150 220 120
220 120
203/16
140 0.220.5 00.1 920 150 20A 20A 9 205/32 75 32A
Port dia.x Orifice
90 0.150.55 00.14 920 150 220 120
(mm) (mm) (mm) (mm)
9 201/8 75 32A 20A 20A
(mm) Port dia.x Orifice
G H
Wall
thickness
Trap
High pressure Low pressure
E F
Condensate
under 0.5MPa
(kg/h)
Pressure range of
trap (MPa)
A B
High pressure Low pressure (mm) (mm) (mm) (mm)
ST-01-35
F-105AB
C-5
STEAM PIPING
FLASH TANK
72
C D
1kg/cm
2
0.1MPa
A
m
o
u
n
t

o
f

l
o
w
-
p
r
e
s
s
u
r
e

s
t
e
a
m

g
e
n
e
r
a
t
e
d

(
k
g
)
H
i
g
h

p
r
e
s
s
u
r
e

c
o
n
d
e
n
s
a
t
e

(
k
g
)
x

1
0
0
(
%
)
Humidifying
Regenerator
Flash tank
High pressure
header
Low
pressure
header
High
Low pressure steam trap
Higher pressure trap
Lower pressure trap
Not to exceed 1,500
Lower pressure steam
Low pressure return water
Relief
valve
Flash tank
Same dia. as trap
i / l Higher pressure
condensate return
Dirt leg
Drain cock
Pressure on higher pressure side
2
Flash steam
Steam pressure on
lower pressure side -
A. Direct-operated (figure on the right shows outer sensor type using pressure detection tube)
Operation:
Valve is directly regulated by expansion/
contraction of control spring (the force of
spring is balanced against downstream
pressure)
Chracteristics:
1. Simple structure, compact, light-weighted
2. Applicable to a limited range of flow
3. As upstream flow or pressure fluctuates
downstream pressure tends to deviate
from preset pressure ("offset")
Application:
Small-sized equipment with less load fluctuations
B. Pilot-controlled
Operation:
Valve is regulated by the force of steam
Characterictics:
1. Complicated structure, large-sized,
expensive. Easily affected by any dirt
which enters valve
2. Applicable for a wide range of flow
3. Offset is less likely to occur
Application:
Steam piping, general equipment (not small-sized, load fluctuations)
In general, pilot-controlled type valve is commonly used for steam piping.
C. Parallel arrangement
* Applicable where downstrem
pressure largely fluctuates.
Or use this arrangement as a spare
unit.
D. 2-step reducing
* Applicable where intended down-
stream pressure cannot be obtained
or downstream pressure cannot be
kept constant with a single pressure
reducing valve.
[Note]
(*) Unit should be pre-assembled
(*) Specification of pressure reducing
valve, other valves, strainer
should be mentioned in the drawing.
(*) Relief pipe of safety valve should
be extended to safe area outside
ST-01-36
E-106-ABCD
D
STEAM PIPING
PRESSURE REDUCING VALVE UNIT
73
Over 3,000
Over 3,000
Over 3,000
not to exceed
200
not to
exceed 200
Equalizer
Downward
safety valve
(* See [Note]
below)
(*)
(*)
Should be pre-assembled
Bypass pipe diameter --- 1/2 of upstream pipe
Bypass pipe diameter --- 1/2 of upstream pipe
Bypass pipe diameter --- 1/2 of upstream pipe
safety valve
safety valve
safety valve
Over 6m away
from each other
(*)
(figure on the right shows internal sensor
A. Mounting position
Measuring device should be mounted around equipment below: B. Specification
O --- Normally installed
--- If necessary Pressure/compound gauge
--- Normally unnecessary Shape --- round
Scale/pointer --- easy to read
(operating pressure should be indicated
with red line)
Size --- dia 100-150
Gage cock --- durable handle, no steam loss
Size --- dia 75-100
* rimless tipe
Max scale --- 150% of operating pressure
Gauges should be connected with siphon pipe
* Measuring device is not necessary for below:
1. Trap unit of supply header
2. In/outlet of radiator body
C. Installation
(1) When automatic valve is installed (2) Around header
Pressure differential before/after
trap can be measured
Operating state of automatic
valve can be observed
Pressure on primary side can be
measured but operating state of
AV or trap cannot be observed
-
Outlet - - O -
Boiler water feed
pump
Inlet - -
Trap on main
drainpipe
Pipe end - - - O
Vertical - - - -
Main pipe end
Vertical O
Horizontal
O -
-
- O
- O
Vacuum pump
Tank - -
Outlet - -
O Humidifier Inlet
(steam spray)
-
- -
-
-
-
Booster heater
Inlet O
Outlet - -
-
Return - - -
- -
Return -
A/C heater
Inlet O
Outlet -
Heat exchanger
Inlet O
- -
High pressure
header
Supply O -
Low pressure
header
Supply O -
-
Boiler
ST-01-37
-
Inlet - - -
Outlet O
Steam Return
Pressure
Gauge
Compound
Gauge
Pressure
Gauge
Compound
Gauge
F-107-ABC
E
STEAM PIPING
STEAM PRESSURE GAUGE
Outlet - -
-

-
-
-
- -
- O
-
74
Heat
source
Load side
Remarks
Hexagonal Square Rounded Round (wrench
(Gauge connectig port)
Rimless Fully rimmed Semi-rimmed Insert
(Gauge shape)
Max.
1,900
Bushing
Socket
(3) Low pressure steam
(4) High pressure steam
(5) Installation
ST-01-38
F-107-C
E
STEAM PIPING
STEAM PRESSURE GAUGE
75
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"
A/C Direct heating
Booster heater
Symbol
Pressure gauge ompound gauge
Pressure reducing
valve
Pressure gauge should be installed in the following cases:
When it is necessary to distinguish circuits in
summer/wintertime.
Pressure is reduced in each circuit
Air
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