Steam Trap Selection: Understanding Specifications

Operating Conditions Effect on Trap Specifications

System conditions determine the minimum trap specifications for pressure, temperature,
discharge capacity, material, and connection type.

Installed Piping and Piping Connections

Installed piping influences connection type and sometimes the trap body material, so it important to make
sure that the selected trap meets the piping requirements. For example, a trap may have a standard
connection in NPT (national pipe thread), but the piping pressure requires socket weld.

Additionally, other requirements include that the discharge capacity must be suitable for the maximum load
at minimum differential pressure under all environmental conditions.

Body Material
Trap body material is one of the first items to look at when selecting a trap. The material is
selected based on the maximum operating temperature and pressure at the condensate
discharge location (CDL), the surrounding environment, and requirements for longevity/
minimal maintenance. The material must also meet the pressure test and maximum
pressure and temperature piping design specifications.
The materials used for the steam trap body, cover, and other pressure-resistant parts are no
different from those used in other types of valves. Some examples are:
 Gray Cast Iron/ Ductile Cast Iron
 Carbon Steel
 Stainless Steel
The maximum applicable pressure and temperature of the body material are not necessarily
equivalent to the maximum operating pressure and temperature of the trap. This is because
the maximum operating pressure and temperature can be limited by the
pressure/temperature resistance of other parts such as gaskets and other internal
components.
In addition, different standards such as ASME or DIN can affect the maximum operating
pressure / temperature of the trap material. For example, A126 cast iron has a maximum
allowable pressure of 13 barg (190 psig) according to DIN standards, but 16 barg (250 psig)
according to ASME standards. Also, stainless steel traps have recently become more and
more popular because they are typically easier to maintain and offer a longer service life.

Sizing
A large number of steam users improperly select trap size based on the size of existing
piping. However, trap size should closely match the size of the piping on the outlet side of
the equipment that supplies condensate to the trap.
It is generally recommended to size condensate piping on the discharge side of equipment
that supplies condensate to the steam trap according to the following table:

Maximum Condensate Load Equipment Outlet Piping Size

Less than 200 kg/h [440 lb/h] 15 mm [1/2 in.]

200 - 500 kg/h [440 - 1100 lb/h] 20 mm [3/4 in.]

0.5 - 1 t/h 25 mm [1 in.]

1 - 2 t/h 32 mm [1 1/4 in.]

2 - 3 t/h 40 mm [1 1/2 in.]

3 - 5 t/h 50 mm [2 in.]

Over 5 t/h 65 - 100 mm [2 1/2 - 4 in.]

*Provided as a general reference. Please consult a steam specialist such as TLV if you are
unsure about trap selection or piping design.

Generally, the trap should never be sized smaller than the equipment outlet piping because
this can lead to waterlogging and ensuing damage and / or heating problems.
In addition, pipe sizing at the trap outlet should not be based on trap size, but instead
should be designed to deliver the required flow rate and limit pressure loss for two-phase
flow. For more information on this topic, please read: Condensate Recovery Piping

Connection Type
Most steam users typically require threaded (screwed), socket-welded, or flanged steam
trap connections depending on the standard national, industry, or company codes and
specifications.
Threaded connections cost much less than flanged connections to install, but need to be
screwed-in during installation, meaning that either the trap outlet piping needs to remain
disconnected or a union needs to be used to allow for easy trap replacement. On threaded
connection steam traps, it is important that the trap threads follow official standards to help
minimize poor connection sealing to the connected piping.
Traps with socket weld connections are generally preferred in some plants to limit the
amount of steam leaks, but socket weld connections can be more difficult to remove during
replacement, and may also have higher installation or maintenance costs. Additionally, some
areas may have shortages of qualified welders, which can reduce the overall installation or
repair efficiency.
Traps with flanged connections can be easily removed and replaced only if the new trap has
the exact same size and face-to-face dimension. It is best to require a strict face-to-face
dimension according to a trap manufacturer’s standard production item when specifying
flanged traps on new construction projects.
Example of Trap with Flanged Connections

After selecting the trap specifications according to operating conditions and environment,
the next step is evaluating the necessary discharge capacity that includes the safety factory,
and selecting the most economical trap. For more info on these topics, please read part 3.

What is the Safety Factor?

The safety factor is a coefficient used when selecting the trap’s required discharge capacity.
It helps provide a buffer zone for instances when condensate volume exceeds
calculated/predicted values. The estimated condensate load should always be multiplied by
the recommended safety factor for trap selection.
The following is a table that summarizes how trap type affects the safety factor:

TLV Trap Type Minimum Recommended Safety Factor

Float 1.5

Bucket 2

Disc 2

Thermostatic (X-element) 2

Bimetal 3 to 5
The safety factor is influenced by at least two elements: peak condensate load and the trap
type relative to response time.

Peak Condensate Load

The peak (or maximum) condensate load on equipment may be higher than the average
load for several reasons. Cold equipment at start-up, for example, typically causes much
greater condensate loads than during regular operation. The condensate load can also
severely increase during the period when the product is the coldest in batch processes.
For steam traps on steam distribution mains, whenever a single trap blocks, the next trap in
line may be required to drain condensate for two condensate drainage locations (CDL).

The Safety Factor Numerical Value

Manufacturer safety factor recommendations can vary between 1.5 to 5.0, or more. These
depend on factors such as trap design, conservative capacity rating, orifice wear
characteristics, how critical an application is, etc.
Since condensate discharge capacity on specification sheets is calculated assuming
continuous discharge, some steam trap types that operate intermittently (on/off), such as
disc and bucket type traps, may require the use of a larger safety factor to minimize back-up
issues in between cycles.
Moreover, some manufacturers’ traps have higher safety factor recommendations simply to
provide larger orifice sizes to lessen blockage. In comparison, traps that discharge
condensate continuously, such as conservatively rated float type traps, typically only require
a safety factor of 1.5.
The safety factor may also help compensate for when an insufficient pressure differential
across the trap impedes condensate discharge, such as when backpressure increases.
During steam trap selection, it is therefore extremely important to apply the trap
manufacturer’s recommended safety factor after calculating the application load, making
sure that the trap size also offers a sufficient capacity for the application.

Trap Life Cycle Cost (LCC)

Steam traps are an essential and permanent part of steam systems, and should be selected
according to their Life Cycle Cost (LCC) to offer the lowest system cost over the long-term.
This means that initial purchasing cost should only be one of the decision factors when
selecting a trap. Other costs related to maintenance, installation, replacement, as well as
operational monetary losses from functional and failure steam leakage, etc. should also be
taken into account.
Rapid wear of internal components such as the valve seat causes steam leakage to increase
over time, eventually leading to premature steam trap replacement. The timing for
replacement is usually determined by evaluating replacement costs and comparing these to
increased losses from steam leakage and other losses such as those caused by trap failure.
Alternatively, some trap designs leak more steam than others even while in perfect
accordance with the design specifications. These traps can be eliminated in the design
phase.
The following is an example of the influence of Life Cycle Cost (LCC) on steam trap
selection. Model A and model B are two different types of traps. Model A has a higher initial
purchasing cost, but a longer service life than model B.
 Item Model A Model B

Purchasing Cost $300 $100

Replacement Costs* $80 $80

Initial Functional Steam Loss 0.05 kg/h 1.0 kg/h

Yearly Increase in Steam Loss from Wear 0.06 kg/h (per year) 0.4 kg/h (per year)

Typical Service Life 8 years 3 years

* Costs related to man-hours and replacement of parts such as gaskets, etc.

The Life Cycle Cost of both these traps over a 9-year span can be calculated. Assuming both
traps are operated 24 hours a day, 365 days a year at an average steam cost of $20 per
ton, the estimated cost of model A is $1180, including purchasing and replacement costs in
year 9. The estimated cost of model B, on the other hand, is $3060 including purchasing
and replacement costs in year 4 and 7. Despite it's lower initial cost, model B is therefore
2.4 times more expensive than model A when Life Cycle Cost is taken into account, showing
the importance of calculating long-term costs when selecting a trap.
Life Cycle Cost of Model A vs. Model B

Trap reliability / service life, maintenance costs, and functional / failure steam losses are all
important economic factors when determining the best model for steam trap selection.