Part 5- B

STEAM TRAPS
A steam trap is an automatic valve that allows condensate, air and other non-condensable gases to be
discharged from the steam system while holding or trapping the steam in the system. Air exists in all
steam pipes prior to system start-up when the system is cold. This air must be bled out of the piping
system so that the steam can enter and eventually reach the designated process applications. If the air is
not removed, the steam will effectively be blocked from entering the steam pipes by the residual air. In
addition to blocking the steam, air acts as an insulator to heat transfer. Even after the system is filled with
steam, small amounts of air can re-enter the system throw various paths such as boiler water make-up
systems. Drip applications are by far the most common application for steam traps. This application refers
to removing the condensate that forms in steam lines when steam loses its heat energy due to radiation
losses. Traps used in these applications are referred to as drip traps. Generally speaking, traps used for
these applications require relatively small condensate capacities and don’t normally need to discharge
large amounts of air. (Air removal is the primary function of air vents and process traps located
throughout the system.)
1- TYPES OF STEAM TRAPS
The three types are:
a) Thermodynamic traps
Traps that are actuated by the principles of thermodynamics and fluid dynamics.
b) Mechanical traps
Traps that are actuated by a float, responding to changes in condensate level.
c) Thermostatic traps
Traps that are actuated by temperature sensitive devices, responding to changes in condensate
ternperature.
1.1- THERMODYNAMIC STEAM TRAPS
Thermodynamic steam traps operate in a cyclic on/off process using the thermodynamic properties of
flash steam as it flows through the trap. Thermodynamic traps use only one moving part, the valve disc,
which allows condensate to escape when present and closes tightly upon the arrival of steam. These traps
have an inherently rugged design and are commonly used as drip traps on steam mains and supply lines.
As inlet pressure to the trap increases, the disc lifts off the seat and allows the unwanted condensate to
escape through the peripheral outlet surrounding the inlet. As hot condensate reaches the disc chamber, it
creates flash steam in the chamber. This flash steam travels at high velocity from the inlet to the outlets,
creating a low pressure area under the disc. Some of the flash steam bypasses the disc and enters the top
of the chamber, creating a buildup of pressure above the disc.
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. 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 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

When condensate is present, trap is in the full open position discharging condensate.
Trap will remain closed, trapping steam in the system until the flash steam above the disc condenses, due to ambient
heat loss.

1.2- THERMOSTATIC STEAM TRAPS

The bellows type thermostatic trap uses a fluid-filled thermal element (bellows) that operates under the
principle of thermal expansion and contraction. The fluid vaporizes and expands as the temperature
increases, causing the bellows to close the valve. As the temperature decreases, the fluid condenses and
contracts, causing the bellows to open the valve. These traps provide excellent air handling capability and
are used for drip, tracing and process applications. The main advantage of the thermal element is that on
start-up loads, the trap is in the open position, allowing air and condensate to be rapidly removed from the
system. The most commonly used type of thermostatic trap is the heavy duty BELLOWS TYPE. The
operating element consists of a corrugated bellows (A) mounted within a housing, usually of cast iron.
At the Bottom of the bellows is mounted a valve (B) which closes the orifice (C) when the bellow expands.
Usually the bellows is filled with a liquid, such as alcohol and water, which has a boiling point below that
of water. This means that when condensate approaching the steam temperature comes to the trap, the
liquid inside the bellows vaporizes building up a pressure inside, which causes the bellows to expand and
close the outlet valve. The valve remains closed until radiation of heat from the body of the trap, and
cooling of the condensate within the trap and in the line ahead of the trap, allows the vapour within the
bellows to slowly condensate. The bellows then contract opening the valve wide again. Time required to
condensate the vapour within the bellows depends on a number of factors, such as the size and material of
trap body, length of pipe between trap and apparatus it is draining, and the temperature of air
surrounding the trap. Obviously the cooler the location, the faster the trap will be able to cycle or respond
to temperature changes in the line ahead of it. As the valve is wide open when the trap is cool, this type of
trap provides quick start-up of the equipment and excellent air handling ability. To obtain best
performance from this type of trap the bellows is usually designed so that it will close as near steam
temperature as possible.
1.3- Mechanical Traps

Mechanical traps are density detectors and therefore also have difficulties venting air and non-condensible
gases. Mechanical traps employ either an open or a closed float to actuate a valve. Closed float
mechanical traps usually employ a secondary thermostatic air vent which allows the trap to discharge air
rapidly. The air vent, of course, is an extra component which can fail open, causing the loss of steam, or
fail closed and prevent the trap from discharging condensate. Closed float traps are usually large in
physical size. This, combined with a float that is fragile to external pressure, and the continuous presence
of condensate within the trap, make this device unsuitable for high pressure applications or installations
where water hammer or freeze-ups can be expected.· On the positive side, these devices respond to
changes in condensate level only, independent of temperature or pressure. They respond rapidly to
changing loads.
Ball float trap works in the following method:-
On start up a thermostatic air vent allows air to bypass the main valve.
As soon as the condensate reaches the trap, the lever mechanism opens the main valve. Hot condensate
closes the air vent but continues to flow through the main valve.
When all condensate is removed, the float drops and closes the main valve, which remains at all times
below the water level, ensuring that live steam is not wasted.

2. - STEAM TRAP STATION SIZING

To determine the correct steam trap orifice size, the following data is required:
1. Determine the maximum pressure on the steam line supplying the process. The steam trap design and
materials have to be rated for the maximum steam pressure and temperature.
a) Maximum steam pressure (steam trap body rating)
 b) Maximum steam temperature (steam trap body rating)
2. Select the steam trap orifice, which must be rated for the maximum steam pressure used in the process.
The maximum pressure is especially critical in mechanical steam traps.
• The maximum pressure is determined by the safety valve set pressure that is protecting the steam
system or process.
3. Determine the inlet pressure to the control valve.
• Document the steam pressure at the steam control valve inlet. Do not assume the steam line
operating pressure will equal the steam pressure at the control valve. Pressure drops in the steam line
have to be considered.
4. Determine the outlet pressure from the control valve to the process.
• There is a calculated pressure drop across the control valve. This information can be determined from
the steam control valve performance information.
5. Calculate the pressure drop (heat exchanger).
• All heat transfer components have a pressure drop.
This information can be obtained from the heat transfer performance sheets.
6. Calculate the inlet pressure to the steam trap.
• Subtract the heat transfer pressure drop from the steam control valve outlet pressure to determine
the inlet pressure to the steam trap station.
7. Determine the outlet pressure at the discharge of the steam trap.
8. Calculate the condensate flow rate.
a) Maximum condensate capacity (kg/hour)
b) Minimum condensate capacity (kg/hour)
9. Choose the sizing factor depending on the steam trap design.
10. Determine the steam trap discharge pressure or the condensate return line pressure.
11. Calculate the minimum differential pressure across the steam trap (ΔP) (inlet pressure – outlet
pressure).
12. Evaluate the condensate flow condition in the steam trap operation.
a) On/off condensate flow
b) Continuous flow operation
STEAM TRAP SIZING FACTOR
Steam trap capacity charts provide the condensate capacity of different orifices at various operating
pressures (maximum differential pressure) in pounds/hour. The condensate capacities listed in steam trap
charts indicate the maximum continuous flow of cold water through the steam trap discharge orifice: that
is, with the steam trap discharge orifice never closing (on/off or modulating).
Steam traps are designed to cycle on and off or to provide continuous flow; therefore, to obtain a steam
trap with a condensate capacity sufficient for the application or process requirement, a sizing factor is
required to be added in the condensate capacity. Typical Sizing Factor is 3 to 1

STEAM TRAP STATION SIZING (Heat exchanger application)

EXAMPLE.1
a) Steam line pressure = 2.41317 barg
b) Safety valve setting on the steam line = 10.3421barg
c) Heat exchanger steam flow requirement = 3628.739kg/hour
1- Delivery pressure to the heat exchanger = 2.41317 barg
• P1 = 2.41317 barg
2- Pressure drop across the control valve = 0.344738 barg
• P2 = 2.41317 – 0.344738 =2.06843barg
3- Pressure drop in the heat exchanger = 0.689476barg
• P3 = 2.06843 - 0.689476 = 1.37895barg ( the inlet pressure to the steam trap station)
4- Backpressure in the condensate line = 0.344738 barg
• P5 = 0.344738 barg
5- Steam trap station outlet pressure will be P5 + P4
6- Rise in condensate piping after the steam trap (distance 3.048 m) = 0.344738 barg
• 0.1131 bar / m rise
• Therefore, P4 = 0.344738 barg for the rise in the condensate piping + the pressure at P5 (0.344738 barg)
P4 = 0.689476 barg
7- Steam trap differential pressure = P3 - P4 = 1.37895 - 0.689476=0.689476 barg (differential
pressure)
8- STEAM TRAP SELECTION:
• Mechanical steam trap
• Steam trap orifice rated for a maximum pressure of 10.3421 barg
• Steam trap sizing factor = 2 to 1
Capacity =3628.739x 2 = 7257.4779kg/ hour
• Steam trap sizing differential pressure = 0.689476 barg
• The steam trap station must be able to flow 7257.4779kg/ hour with a 0.689476 barg differential
pressure and a maximum orifice pressure rating of 10.3421 barg

EXAMPLE.2
A factory requires a steam/water heat exchanger operating at a nominal 4 bar g to heat process water
circulating at 1 L/s (1 kg/s) from 10°C to 80°C, giving a design load of 293 kW. The process is such that a
minimum heat load occurs at 60% of the full heat load. This is a permanently running process line with no
future load increase. Two suppliers are asked to provide a heat exchanger. The following information is
important to selection:
- Supplier 'X' can provide a heat exchanger with a heating area of 2 m 2, 'U' = 2500 W/m°C and duty of
350 kW when operating with steam at 4 bar g and with a water flow of 1 L/s.
- Supplier 'Y' is able to provide a heat exchanger with a smaller heating area more suitable for the
design heat load of 293 kW, when operating with steam at 4 bar g and with a water flow of 1 L/s.
'U' = 2500 W/m²
The heat exchanger condensate line will lift 5 meters to a condensate return pipe that falls en route to a
vented receiver, and having a total backpressure of 0.5 bar g. (Note: A one meter column of water under
atmospheric pressure will exert a pressure at the bottom of the column of approximately 10 kP a or 0.1
barg. Any lift in the condensate discharge line will thus exert a static lift due to the column of condensate
held in the line, in addition to any pressure in the condensate system.)
It is necessary to determine the system operating conditions to select and size the trap for proper
condensate removal from both heat exchangers under any operating load condition.

SOLUTION
 The following questions need to be answered for proper condensate removal:
(A) Will stall occur during normal operation?
(B) At what load will stall occur?
Check the application heat load at the design condition.
The heat transfer flow rate, Q= m.Cp.∆T = 1x4.19 (80-10) =293000W
Consider supplier 'X'
A 350 kW heat exchanger with 2 m2 heating area.
A= Q/(U. ∆TLMTD)
∆TLMTD = Q/(U.A)= 293000/(2500x2)= 58.6oC
The steam design temperature can now be calculated, by
∆TLMTD = (∆T1-∆T2)/ln(∆T1/∆T2) =58.6oC
∆T1= Ts -10 and ∆T2= Ts - 80 ,Ts=steam saturation temperature
∆T1 -∆T2 =70
ln (∆T1/∆T2)= 70/58.6 =1.1945
∆T1/∆T2= e1.1945 = 3.3
Ts -10=3.3 (Ts - 80) ,Ts=110.4oC
This saturation temperature is equivalent to a steam pressure of 0.45 barg. This pressure is less than the
0.5 bar g backpressure, and the system will permanently stall.
In this case, if a ball float steam trap were fitted, condensate would permanently flood the heat
exchanger, its level modulating relative to changes in load. Operating performance might be
unsatisfactory as the secondary outlet temperature will tend to fluctuate, and the heat exchanger might
fail prematurely due to corrosion.
A ball float steam trap is the wrong choice for this application, and a pump-trap should be fitted instead.
Consider supplier 'Y'
For the manufacturer to size the heating area that best matches the design condition, it is necessary to
find the minimum heating area that will satisfy the operating full-load. It is first necessary to determine
the rated ∆TLMTD for the heat exchanger with a steam space pressure of 4 bar g (Ts = 152°C).
∆TLMTD = 103°C
A= Q/ (U. ∆TLMTD) =293000/(2500x103)= 1.138m2
Supplier 'Y' can provide a plate heat exchanger that meets the specification with a heating area of 1.198
m2. This is oversized (by about 5%) and steam pressure will therefore be less than 4 bar g at the full-load
operating condition.
The steam saturation temperature, TS, for the heat exchanger with a heating area of 1.198 m²:
∆TLMTD = 293000/ (2500x1.198) =97.8, then Ts= 147oC
This saturation temperature is equivalent to a steam pressure of 3.4 barg at the design condition. As this
pressure is more than the constant 0.5 bar g backpressure, the system will not stall at full-load.
At P=3.4 bar g .hfg=enthalpy of evaporation of 2122 kJ/kg
The steam mass flow rate .Ms= 293x3600/2122=497 kg/h
TDC = Temperature Design Constant= (Ts-T1 )/(Ts-T2)= 2.045
T1 = 10°C ,T2 = 80°C ,Ts = 147°C
The stall condition
At stall, the pressure in the steam space will equal the 0.5 bar g backpressure.
The saturation temperature of steam at 0.5 bar g is 111.6°C
The inlet temperature can be found:T1=111.6-[2.045(111.6 -80)] =47oC at stall
The heat load at stall, Q=m.Cp. ∆T=1.0 x4.19 (80-47) =138kW
The percentage stall load = 138/293= 47%
The selection of the trapping device will depend on whether the minimum heat load is higher or lower
than the stall load.
The minimum load is quoted as being 60% of the full-load of 293 kW, therefore:
Minimum load = 0.6 x 293 kW = 176 kW
Stall load = 138 kW
As the minimum load is greater than the stall load, the system will never stall. It is therefore practical to
fit a ball float steam trap, as there will always be a positive differential pressure across it.
 However, the ball float steam trap has to be sized to carry both the full-load and the minimum load, and
it is therefore necessary to calculate the steam flows and the corresponding steam space pressures at both
conditions.
- It is first necessary to calculate the inlet temperature at the minimum load.
TX = T1+ (1-X) (T2-T1)
T1and T2=Inlet and Outlet temperature at full load
TX = Inlet temperature at load factor,X
The minimum heat load =60% (load factor, X=0.6)
Inlet temperature at the minimum load = 10+0.4(80-10) = 38oC
- The minimum load condition
Steam temperature at minimum load
TS = [T2*TDC – T1]/ (TDC-1) = [80*2.045 - 38]/( 2.045-1)=120oC
This is the steam temperature at the minimum load of 176 kw and is equivalent to a steam pressure of
1.0 barg, The condensate pressure is 0.5 bar g. The differential pressure across the ball float steam trap at
minimum load therefore equals 1.0 - 0.5 = 0.5 bar.
- The steam flow rate at the minimum heat load of 176 kW.
The minimum steam flow rate will depend upon the steam space pressure, which is 1.0 bar g with an
enthalpy of evaporation of 2201.1 kJ/kg.
m∙S =load (kw)*3600/hfg =176*3600/2201.1=288 kg/hr
It is now necessary to size a ball float steam trap for operation up to the maximum system differential
pressure of 3.5 bar
a) The full-load of 498 kg/h with a differential pressure of 3.4 bar g - 0.5 bar g = 2.9 bar g.
b) The minimum load of 288 kg/h with a differential pressure of 1.0 bar g - 0.5 bar g = 0.5 bar g.

From the steam trap sizing chart will satisfy both of these conditions, and could be selected.