CONDENSATE AND STEAM TRAP IN STEAM LINE

INSULATION IN PIPING

FLASH STEAM

Condensate load
Condensate formed during warming

Ci

60W (T t ) S
Lm

Where,
Ci = Initial warm-up condensate load, kg/hr.
W = Total weight of pipe including flanges and fittings
= w x l + Wf
W = Weight per m. of pipe, kg/m.
l = Length of pipe in m., i.e. distance between steam trap( for
steam trap location calculation it can be taken as 50 or
60 m.)
Wf = Weight of flanges, fittings etc
T = Final temperature of pipe, i.e. steam temperature
t = Initial temperature of pipe, i.e. ambient temperature
S = Specific heat of steel , = 0.12 Kcal/kg C
L = Latent heat of evaporation = hfg + (h1-h2), Kcal/kg
hfg= Latent heat of evaporation
h1 = Enthalpy of steam at final temperature
h2= Enthalpy of steam at saturation temperature
m= Warm-up
time (Usually 0.6 C rise per second)
T t
= 0.6 x60

Radiation condensate load

Cr

Ql
L

Kg/hr.

Where,
Q = Heat loss through insulation,
Kcal/hr./m
l & L has been defined earlier.

Total Condensate Load, C = Ci + Cr

A safety factor ( usually 1.2 to 2 for TD type and 2 to 3 for inverted

bucket type ) is multiplied with total condensate load for sizing steam
trap.

GENERAL THUMB RULE

Steam tracing line : Approx. 30 kg/hr. for each 30m. of tracer.
Heating water with steam :
Kg/hr. condensate

Litre/hr. of water x Tempr. Rise, C

500

Litre/hr. of fuel oil x Tempr. Rise, C

1000

Heating fuel oil with steam :

Kg/hr. condensate

Heating air with steam :

Kg/hr. condensate

Nm3/min of air x Tempr. Rise, C

27

Condensate load contd

DISCHARGE CAPACITIES OF STEAM TRAPS
Thermodynamic Steam trap
Inlet Steam
Pressure,Kg/cm2,
g

Discharge in
Kg/hr.
15 NB 20NB

Inverted bucket type Steam trap

Differential
pressure, Kg/cm2
0.35
0.7
1.06
1.41
1.76
2.11
2.82
3.52
4.22
4.92
5.62
7.03
8.79
10.55
11.25

Discharge in
Kg/hr.
15 NB 20NB
195
255
290
315
240
265
295
265
280
300
315
290
310
260
265

378
445
480
400
430
455
350
380
410
430
365
390
430
365
375

0.7
210
455
1.08
235
490
1.41
260
520
1.76
275
580
3.52
355
690
5.27
410
795
7.03
470
860
10.55
580
995
14.06
665
1090
17.58
725
1135
21.09
725
1135
24.61
810
1245
28.12
850
1315
31.64
895
1335
35.15
930 is the
1360
The differential
pressure
difference between the pressure upstream
42.18
985trap.1380
and downstream
of the
Where a trap discharges to atmosphere, the

differential pressure is the same as upstream pressure.

Condensate load contd

TRAP TYPE AND SIZES FOR STEAM SERVICE

Sl.No.

Pipe
Size
DN
(mm)

Trap
Type

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

15
20
25
40
50
65
80
100
125
150
200
250
300
350
400

Thermodynamic
-do-do-do-do-do-do-do-do-do-doInverted Bucket
-do-do-do-

Size
DN
(mm)
15
15
15
15
15
20
20
20
20
20
20
25
25
25
25

Note: The above table is based on maximum trap

spacing of 60 M.

INSULATION THICKNESS CALCULATION

Design Code : IS 14169
OD of insulation, d1

d1

2000 K (t h t c )
mm
d1
h(t c t a ) Ln
D

Where,
K = Kcal/hr-mC at mean temperature tmC
tm = (th + tc)/ ta
th = Temperature of hot fluid, C
tc = Surface temperature of insulation, C
(Usually 55 60 C)
ta = Ambient temperature, C
h = Heat transfer coefficient, Kcal/m2 hr C
= 8.598 [A +0.005 (tc - ta)] for horizontal surface
= 8.598 [B +0.009 (tc - ta)] for vertical surface
D
= OD of pipe, mm

Coefficent for calculating heat transfer

ceofficent (IS - 14169-Annex-c)
Surface
Aluminium bright
rolled
Aluminium, oxidized
Galvanized sheet
metal, blank
Galvanized sheet
metal, dusty

0.25
0.31

0.27
0.33

0.4

0.42

0.53

0.55

INSULATION CONTD
Heat loss from pipe,

th ta )
1
d 1000
ln 1
2K D hd1

Kcal / hr / m

Heat loss From Flat Surface

th ta
Kcal / m2
t 1

h h

INSULATION MATERIAL AND APPLICATION

S Specification
N.
i)
Resin bonded mineral
wool
(rock
wool)
mattress
as
per
IS:8183, with factory
stitched
G.I.
Wire
netting
on
outer
ii) surface.
Rock or Slag wool mats
wire netting on both sides
conforming to IS 3677
Type 3 (for up to 250 C)
Type 2 ( For up to 500 C)
Type 1 ( For up to 900 C)
iii) Glass wool mat with wire
netting on both sides
conforming to
IS 3690
Type 2 Gr. B (for up to
450 C )
Type 3 (for up to 550 C)

Application
For
pipe
sizes
above
DN 350 and
for
flat
surfaces and
equipment

S Specification
N.
iv) Pipe-sections
of
light resin-bonded
mineral
wool
(rock/slag wool) as
per IS:9842

v)

Application

For pipe work upto

DN 350
i)Group1(50-80
Kg/m3) up to 400 C
ii)Group 2 (81-120
Kg/m3) up to 400 C
iii)Group
3
(121160Kg/m3)
up
to
650 C
iv) Group 4 (161-250
Expanded
For
chilled
water
Kg/m3)
up to 750
C
polystyrene blocks pipelines/valves.
and pipe sections/ Board will be used
segments
for flat surfaces
conforming
to
IS:4671 Type 1.
Self-extinguishing
(type 2) material
shall be used where
fire hazard exists.

THERMAL CONDUCTIVITY OF INSULATION MATERIAL

Thermal conductivity of insulating material in Kcal/hr-m-C
Un bonded rock and slag wool - IS 3677
Density
Temperature , C
Kg/m3
50
100
150
200
250
80
0.04299
0.048149 0.048149
0.058466 0.0877
100
0.04299
0.048149 0.058466
0.068784 0.0877
120
0.04127
0.046429 0.056747
0.067064 0.076522
150
0.039551 0.04471
0.053308
0.064485 0.075662
Glass Wool- IS 3690
Density
50
Kg/m3
80
0.036971
100
0.036971
120
0.036971
150
0.0369714

100
0.044709
0.044709
0.044709
0.0447096

Bonded Mineral Wool-IS 8183

Density
50
Kg/m3
80
0.0369714
100
0.0369714
120
0.0369714
150
0.0369714

Temperature
150
0.055027
0.053307
0.053307
0.0533076

100
0.0447096
0.0447096
0.0447096
0.0447096

, C

200
0.067064
0.062765
0.062765
0.0584664

250
NR
NR
NR
NR

300
NR
NR
NR
NR

300
NR
NR
NR
NR

Temperature , C
150
200
0.0550272
0.0670644
0.0533076
0.0627654
0.0533076
0.0627654
0.0533076
0.0584664

250
0.0799614
0.0722232
0.0722232
0.068784

300
0.094578
0.081681
0.081681
0.077382

THERMAL CONDUCTIVITY OF INSULATION MATERIAL

IS 9842 , Thermal conductivity in Kcal/hr-m-C
Group 1
Group 2
Group 3
Mean Tempr.,C
50
100
150
200
250
300

0.0369736
0.0447122
0.0550304
0.0670683
0.0799661
0.0945835

Density
Kg/m3
15
20
25
30
35

0.0369736
0.0447122
0.0533107
0.0627691
0.0730873
0.085985

IS : 4671
Temperature C
0
10
0.029235
0.031814
0.027515
0.030095
0.025796
0.028375
0.024936
0.027515
0.024076
0.026655

0.036974
0.044712
0.053311
0.06019
0.073087
0.085985

Group 4
0.036974
0.044712
0.053311
0.05847
0.068788
0.077387

STANDARD INSULATION THICKNESS FOR PIPES

Hot Service
Pipe Size

a)

DN, mm
15
20
25
40
50
65
80
100
125
150
200
250
300
350
400
450
500
550
600
For hot service

b)

For cold service

Steam

Steam

Cold Service
Condensate

Chilled water
(Supply and
Return)
(7 o C & 14 o C)
25
25
25
40
40
40
40
50
50
50
75
75
75
75
75
75
75
75
75
not exceed 10 0 C

(315 o C)
(190 o C)
(170 o C)
60
40
40
60
45
40
60
45
40
65
50
40
70
50
40
75
55
40
75
55
50
80
55
50
90
60
50
90
60
50
90
60
60
100
65
75
100
65
75
100
65
75
100
65
75
105
65
75
105
70
75
105
70
75
110
70
75
Outside surface temperature shall
maximum ambient temperature
Outside surface temperature shall not fall below 10 0 C

above

FLASH STEAM GENERATION

If the pressure of the condensate - the saturated water at the boiling point at the
actual pressure - is reduced, some portion of the condensate converted in steam
and
is called flash steam.
The energy - or enthalpy - made available when the pressure is reduced, will
evaporate a part of the water, producing the flash steam.

The amount of flash steam produced

during the pressure reduction can be
expressed as:
w = (hil - hfl) / hfe
w = ratio of flash steam generated
(kg flash steam / kg condensate)
hil = initial liquid enthalpy (kJ/kg)
hfl = final liquid enthalpy (kJ/kg)
hfe = enthalpy of evaporation (kJ/kg)
Example : Condensate at a pressure of 5 bar gauge (6 bar absolute) is reduced to atmospheric
pressure - 0 bar gauge (1 bar absolute) through the steam trap. To calculate Flash steam.
hil = initial liquid enthalpy (kJ/kg) of condensate at 6 bara = 670 Kj/kg
hfl = Final liquid enthalpy (kJ/kg) of condensate at atmospheric pr.= 419 Kj/kg
hfe = enthalpy of evaporation at atmospheric pr=2257 Kj/kg
w = ((670.9 kJ/kg)- (419.0 kJ/kg)) / (2,257 kJ/kg) == 0.11 (kg flash steam / kg condensate)

Typical flash vessel