Steam trapping - an overview - Spirax Sarcopointing.spiraxsarco.com/pdfs/SB/gst_33.pdf · Steam...

an overviewSteam trapping

1

Steam trapping solutionsWith nearly 100 years of steam engineering experience Spirax Sarco has attained the coveted position as the market leader for supplying steam traps of the highest quality.

When you buy from Spirax Sarco you are investing in more than just a steam trap - We supply high quality, reliable products ensuring that your steam system operates at its’ optimum level at all times.

Our aim is to provide the right solutions and appropriate products to meet all of your application needs by offering unparalleled technical & commercial support, before, during and after purchase.

KnowledgeService

Products

The team you want on your sideOur exceptional team of specialists are

well trained, extremely knowledgeable,

and accessible through our worldwide

network. They’ll take time to understand

your needs and work with you to find

the most effective ways to improve your

business performance by optimizing your

steam or industrial process plant.

Services matched to your needsWe’re renowned for our high quality products and expert

knowledge – however our offering goes way beyond this.

You can benefit from a complete and flexible range of services

that cover all your needs – we’ll carry out a steam trap survey or

project manage a complete new plant, and everything in between.

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All the products, services and

expertise you need to make the best

investments in building and optimizing

your steam or industrial process plant.

We endeavour to supply quality products

that will create: energy saving, carbon

saving, production output improvement,

less wastage, simplified servicing and

peace of mind.

A global network ofoutstanding local peopleSpirax Sarco is an international organization represented in over 100 countries

with over 1100 specialist field engineers. We have local support only a phone

call away.

All the supportyou needWe have extensive teams of dedicated

personnel strategically placed globally

who are ready to take ownership of your

projects and day-to-day requests, seeing

them through to a satisfactory conclusion.

Forward thinkingto keep youone step aheadSpirax Sarco is a clear market leader in

steam systems. We have the market

presence and resources to keep abreast

of the latest legislative and technological

developments in the steam industry. It is

part of our commitment to share our

insight and knowledge to provide you with

the best advise and solutions.

High performance, high quality productsOur comprehensive product range covers the entire steam and condensate

loop. Forget the hassle and time to source from multiple suppliers – with

everything supplied direct from Spirax Sarco you can be assured that products

will integrate seamlessly, spares are readily available and servicing will be

straightforward.

3

Types

of s

team trap

There is no such thing as a universal steam trap!Steam traps are a critical part of the steam and condensate loop. Selecting an incorrect steam trap for an application,

or not taking into account the load on start-up and during running conditions may have a major impact on your process

efficiency, energy costs, and have safety implications.

Each steam application has its own requirements - it is impossible to meet all needs with just one type of steam trap.

For example: condensate must be removed promptly from a plant where maximum heat transfer is sought at all times. The

presence of excess condensate in an item of heat transfer equipment will reduce its efficiency, preventing it from achieving

its maximum rated output and may also reduce its service life.

However; In other applications, it may be required to hold back the condensate to extract some of its heat and thus save

on steam. Furthermore, by discharging condensate well below steam temperature, flash steam losses can be reduced or

avoided altogether.

Mechanical traps are operated by changes

in fluid density

Mechanical steam traps discharge

condensate at steam temperature. This makes

them the first choice for applications where

the rate of heat transfer is high for

a given heat transfer area, such as

heat exchanger application.

Thermostatic traps are operated by variations

in fluid temperature

Thermostatic steam traps do not

open until the condensate temperature has

dropped below steam saturation temperature.

These traps are widely used in applications

where it is acceptable to utilise some of

the sensible heat in the condensate

and reduce flash steam losses,

such as non-critical tracing.

Thermodynamic traps are operated by changes

in fluid dynamics

Thermodynamic steam traps are compact,

simple, lightweight and not affected by

waterhammer or vibration. Thermodynamic

traps discharge condensate close to steam

saturation temperature. This makes them

the first choice for steam mains

drainage and critical tracing.

The duty of a steam trap is to discharge condensate while retaining live steam in the system

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Steam trap operation Mechanical Thermodynamic Thermostatic

Steamtrap types

Ball float Inverted bucket Thermodynamic Balanced pressure

Bimetallic

Main features

• High capacity.

• Excellent air venting

capabilities.

• Continuous

discharge of

condensate for

maximum heat

transfer.

• Will not back-up with

condensate.

• High capacity.

• Robust design.

• Near continuous

discharge of

condensate.

• Minimal back-up of

condensate.

• Robust design giving

excellent resistance to

waterhammer and

vibration.

• Inexpensive.

• Positive discharge with

tight shut-off.

• Discharge condensate

close to steam saturation

temperature.

• Utilises sensible heat

in the condensate,

reducing flash steam

losses, which saves

energy.


properties for quick

start-up.

• Utilises sensible heat

in the condensate,

reducing flash steam

losses, which saves

energy.


properties for quick

start-up.

Typical applications

Temperature / pressure

controlled applications

with fluctuating loads.

Temperature / pressure

controlled applications

with fluctuating loads.

Mains drainage and all

tracing applications.

Some process applications

with light loads such as

small presses and cylinders.

Where condensate

back-up can be tolerated

or is required to remove

excess enthalpy,

e.g. sterilisers and

non-critical tracing.

Where condensate

back-up can be tolerated

or is required in order to

remove excess enthalpy,

e.g. non-critical tracing.

SizeDN15 – DN100

(½" – 4")

DN15 – DN50

(½" – 2")

DN8 – DN25

(¼"– 1")

DN8 – DN25

(¼"– 1")

DN8 – DN100

(¼"– 4")

Maximum body rating

PN100 and

ASME Class 600PN63 PN250

PN40 and

ASME Class 300

PN420 and

ASME Class 2500

Maximum operating pressure

80 bar g 62 bar g 250 bar g 32 bar g 210 bar g

Spirax Sarco’s steam trap range

The duty of a steam trap is to discharge condensate while retaining live steam in the system

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Ball float mechanical steam traps

Ball float (FT) mechanical steam traps have an integral air

vent as standard and the options of a manually adjustable

needle valve (SLR - steam lock release mechanism)

and drain cock tapping, the FT range is adaptable to all

applications where ball float traps are recommended and

instantaneous removal of condensate is required.

How a ball float steam trap works

On start-up a thermostatic air vent allows air to bypass the

main valve (1) which would otherwise be unable to escape

(a condition known as 'air-binding').

As soon as condensate reaches the trap, the float is raised and

the lever mechanism opens the main valve (2). Hot condensate

closes the air vent but continues to flow through the main valve.

When steam arrives the float drops and closes off the main

valve, which remains at all times below the water level,

ensuring that live steam cannot be passed.

In syphon dip pipes draining rotating cylinders or long drain

lines, a steam pocket may form which can prevent condensate

from reaching the trap (a condition known as 'steam locking').

A manually adjustable needle valve (SLR - steam lock release

mechanism) should be specified to bleed away the steam (3).

Key features:

• Immediatecondensatedischargewithclean,tightshut-off.Noback-upofcondensateensuresmaximumplantefficiency.

• Worksefficientlyonbothheavyandlightloadswithnopassageoflivesteam.

• Notaffectedbywideandsuddenfluctuationsofpressureorflowrate.

• Stainlesssteelinternalsthatcantoleratecorrosivecondensate.

• Integralairventtoensurerapidwarm-upofplant.

• Robustconstructiontoguaranteelonglifeagainstwaterhammerandvibration.

Mechanical steam traps

1 2 3

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MaterialMaximumoperatingpressure

Connection

Sizes

InstallationDN15½"

DN20¾"

DN251"

DN321¼"

DN401½"

DN502"

DN803"

DN1004"

Cast iron

13 bar g Flanged

FT43FT43 FT53

FT43 Horizontal

FT43VFT43V FT53V

Vertical down

14 bar g Screwed FT14 Horizontal

SG iron

14 bar g

Screwed

FT14 Horizontal

FT14V Vertical down

Flanged FT14 Horizontal

21 bar g Screwed FT14HC FT14 Horizontal

32 bar g

FlangedFT47 FT57

FT47 FT57

Horizontal

FlangedFT47V FT57V

FT47V FT57V

Vertical down

ENP coatedSG iron coverandstainless steelbody

14.6 bar g

Screwed FTGS14 Horizontal

Flanged FTGS14 Horizontal

17 bar g Screwed FTGS14HC Horizontal

Carbon steel

32 bar g

Screwed Socket weld

FTC32 FT450 Horizontal

FTC32V Vertical down

Flanged

FTC32 FT44 FT54

FT44 FT54

FT44 FT54

FT44 FT450

Horizontal

FTC32V FT44V FT54V

FT44V FT54V

FT44V FT54V

Vertical down

80 bar gSocket weld

FlangedFTC80 Horizontal

Stainless steel

19 bar gScrewed

Socket weld Flanged

FTS14 Horizontal

FTS14V Vertical down

25.5 bar g Flanged FT46 FT46 Horizontal

32 bar g Swivel UFT32 Universal

Stainless steel (Clean steam)

4.5 bar ΔP Clamp

FTS14-4.5 Horizontal

FTS14V-4.5 Vertical down

Ball float steam traps - Product range

7

Inverted bucket mechanical steam traps

Spirax Sarco inverted bucket steam traps employ a

simple and well-proven principle, which relies on the

difference in density between steam (a vapour) and

condensate (a liquid). They have a robust design and

incorporate a simple density sensitive bucket and

lever mechanism.

How a inverted bucket steam trap works

Key features:

• Nearcontinuouscondensatedischargewithtightshut-off.Minimalback-upofcondensateensuresmaximumplantefficiency.

• Deepwater-sealtoprotectagainstthepossibilityofsteamloss.

• Suitableforsuperheatconditionswhenfittedwithinternalinletcheckvalve.

• Simpleandrobustconstructiontoguaranteelonglifeagainstwaterhammerandvibration.

• Stainlesssteelinternalsareattachedtothecoverforeaseofmaintenance.

• Integralstrainer(HM,HM34andSCAmodelsonly).

• Optionalblowdownvalve(onlyforHMandHM34).

Mechanical steam traps

1. As condensate reaches the trap it forms

a waterseal inside the body. The weight

of the bucket keeps the valve off its seat.

Condensate can then flow around the

bottom of the bucket and out of the trap.

2. When steam enters the underside of the

bucket it gives it buoyancy and the bucket

rises. This positions the lever mechanism

such that the main valve 'snaps' shut due

to flow forces.

3. The bucket will lose its buoyancy as the

enclosed steam condenses due to

radiation losses and steam escapes

through the vent hole. Once this happens

the weight of the bucket will pull the valve

off its seat and the cycle is then repeated.

4. Any air reaching the trap will also give

the bucket buoyancy and close the valve

preventing condensate flow. The small vent

hole positioned at the top of the bucket will

bleed air into the top of the trap. Because

the vent hole at the top of the bucket is

small in diameter it will vent air very slowly.

Consequently a separate external air vent

may therefore be required to ensure speedy

and efficient start-up of steam plant.

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MaterialMaximumoperatingpressure

Connection

Sizes

InstallationDN15½"

DN20¾"

DN251"

DN401½"

DN502"

Cast iron

13 bar gScrewed Flanged

S SF

Horizontal


HM Horizontal


200 Vertical up

Carbon steel

32 bar gScrewed

Socket weld Flanged

HM34 Horizontal

41 bar gScrewed

Socket weld Flanged

SCA Horizontal

Stainless steel

30 bar g

Screwed Socket weld

Flanged

SIB30 SIB30H

Horizontal

SwivelUIB30

UIB30HUniversal


SIB45 Horizontal

Alloy steel

41 bar g Flanged 600 Vertical up

62 bar g Flanged 900 Vertical up

Inverted bucket steam traps - Product range

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Thermodynamic steam traps

The Spirax Sarco TD was first launched in 1950 and has

become the most advanced thermodynamic steam trap

available. Constant design improvements have made

today’s TD an extremely robust steam trap, ideally suited

to the rigorous demands of any steam system.

How a thermodynamic steam trap works

On start-up, incoming pressure raises the disc and cooled

condensate, plus air, is immediately discharged (1).

Hot condensate flowing through the trap releases flash steam.

High velocity creates a low pressure area under the disc and

draws it towards the seat (2).

At the same time there is a pressure build-up of flash steam

in the chamber above the disc which forces it down against the

pressure of the incoming condensate until it seats on the inner

ring and closes the inlet. The disc also seats on the outer ring

and traps pressure in the chamber (3).

Pressure in the chamber is decreased by condensation of

the flash steam and the disc is raised. The cycle is then

repeated (4).

Thermodynamic steam traps

Key features:

• Positivecondensatedischargewithcleantightshut-off.Dischargecondensateatveryclosetosteamtemperaturethatensuresmaximumplantefficiency.

• Justonemovingpart,adisc,ensuresreliableoperationandminimalmaintenance.

• Compactandlightweight,reducinginstallationcosts.

• Hardeneddiscandseatforlonglife.

• Onetrapcoversawiderangeofoperatingpressuresmakingselectionandreplacementsimple.

• Optionalinsulatingcoverforlowambienttemperatureorwetenvironments.

• Optionalblowdownvalveforsomemodels.

1 2

3 4

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MaterialMaximum operating pressure

Connection

SizesRecommended

installationDN8¼"

DN10"

DN15½"

DN20¾"

DN251"

Low temperature steel

42 bar g Socket weldTD42S3

TD42S3LCHorizontal

Carbon steel 42 bar g Socket weldTD42S2

TD42S2LCHorizontal

Stainless steel

10 bar g Screwed TD10 Horizontal

30 bar g SwivelUTD30L UTD30H

Universal

32 bar g FlangedTD32F

TD32FLCHorizontal

42 bar g

Butt weld TD3-3TD3-3

TD3-3LCTD3-3 Horizontal

ScrewedTD259 TD52M

TD42LC TD42L TD52M

TD42 TD42LC TD42H TD42L TD52M

TD52MLC

TD42 TD42H TD42L TD52M

TD42H TD42L TD52M

Horizontal

Swivel UTDM42L Universal

45 bar g

Screwed Socket weld

Butt weldTD1464 Horizontal

FlangedTD1464 TD45

Horizontal

Alloy steel

62 bar gScrewed

Socket weld Flanged

TD62M TD62LM

Horizontal

250 bar gSocket weld

Butt weld Flanged

TD120M Horizontal


10 bar g

Screwed BTD52L Horizontal

Clamp Tube end

BTD52L Horizontal

Thermodynamic steam traps - Product range

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Thermostatic steam traps

Balanced pressure thermostatic steam traps

Spirax Sarco has been manufacturing balanced pressure

thermostatic steam traps for over 70 years. Continuous

investment in product development has resulted in a

design evolution, which leads the world.

How a balanced pressure thermostatic steam trap works

On start-up, cold air and condensate enter the trap. As the capsule is also cold, the valve is open and the air and condensate are discharged (1).

The capsule warms up as the condensate approaches steam temperature. Its liquid filling boils, and the resultant vapour pressure acting on the diaphragms pushes the valve head towards the seat (2), fully closing at the selected discharge temperature before any steam is lost.

As the condensate within the trap cools, the vapour filling condenses and the internal capsule pressure falls. The valve reopens, discharges condensate and the cycle repeats (3).

Key features:

• Condensateisdischargedatbelowsteamsaturationtemperature,utilisingsensibleheatinthecondensateandreducingflashsteamlosses.

• Automaticallydischargesairandotherincondensablegasestoaidrapidwarm-upofplant.

• Itautomaticallyadjustsitselftovariationsofsteampressureuptoitsmaximumoperatingpressureandcantoleratesuperheatupto70°C.

• Dischargetemperaturesetbycapsuleselection–norequirementtoadjustonsite.

• Patenteddesignofcapsulemanufacturedusingadvancedtechnologytoexactingqualitystandards.

• Allstainlesssteelinternalsextendworkinglifeandreducesplantmaintenance.

• TheBPC32andBPS32serieshasatwoboltcoverdesignforeaseofmaintenance.

1 2 3

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MaterialMaximum operating pressure

Connection

SizesRecommended

installationDN8¼"

DN10"

DN15½"

DN20¾"

DN251"

DN401½"

Brass 13 bar g Screwed

BPT13SBPT13US

Horizontal

BPT13ABPT13UA

Angle

Carbon steel

21 bar g

Screwed BPM21L Horizontal

Socket weld BPM21L Horizontal

32 bar g

Screwed Socket weld

BPC32 BPC32Y

Horizontal

Flanged

BPC32 BPC32F BPC32Y

BPC32YF

Horizontal

Stainless steel

21 bar g

Screwed MST21MST21

MST21H TSS21

MST21H Vertical down

Sandwich between flanges

BPW32 Vertical down

30 bar gScrewed

Socket weld Flanged

SBP30 Horizontal

32 bar g

Screwed Socket weld

Flanged

BPS32 BPS32Y

Horizontal

Swivel UBP32 Universal


7 bar g

ScrewedBTM7 BTS7

BTM7 BTS7

Vertical down

ClampBTM7 BTS7

Vertical down

Tube endBTM7 BTS7

Vertical down

6 bar gClamp

Tube endBT6-BH BT6-BL

Vertical down

Balanced pressure thermostatic steam traps - Product range

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Bimetallic thermostatic steam traps

Spirax Sarco has been manufacturing bimetallic

thermostatic steam traps for over 40 years. Bimetallic

thermostatic steam traps are primarily used to control

the release of condensate so that its sensible heat can

be utilised and energy losses caused by flash steam on

discharge reduced. These factors are all important in

today’s energy conscious world.

How a bimetallic thermostatic steam trap works

On start-up, the bimetallic element is relaxed and the valve

is open. Cooled condensate, plus air, is immediately

discharged (1).

Hot condensate flowing through the trap heats the bimetallic

element causing it to pull the valve towards the seat (2).

As the hot condensate is discharged and approaches steam

saturation temperature the bimetallic element closes the valve

(3). When there is no flow through the trap the condensate

surrounding the element cools causing it to relax and the

upstream pressure opens the valve. Condensate is discharged

and the cycle repeats.

Thermostatic steam traps

Key features:

• Condensateisdischargedatbelowsteamsaturationtemperature,utilisingsensibleheatinthecondensateandreducingflashsteamlosses.

• Automaticallydischargesairandotherincondensablegasestoaidrapidwarm-upofplant.

• Thebimetalelementscanworkoverawiderangeofsteampressureswithoutanyneedforon-siteadjustment.

• Patenteddesignofbimetallicelement.

• Resistanttowaterhammerandfreezing.

• TheSMC32serieshasatwoboltcoverdesignforeaseofmaintenance.

1 2 3

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MaterialMaximum Operating Pressure

Connection

SizesRecommended

installationDN8¼"

DN10"

DN15½"

DN20¾"

DN251"

DN401½"

DN502"

DN803"

DN1004"

Carbon steel

21 bar gSocket weld

Butt weld Flanged

SP80 SP100 Horizontal

32 bar g

Screwed Socket weld

Butt weld

SMC32 SMC32Y

Horizontal

Flanged

SMC32 SMC32F SMC32Y

SMC32YF

Horizontal

40 bar gScrewed

Socket weld Flanged

ABL Horizontal

45 bar g

Screwed Socket weld

Butt weld Flanged

HP45 Horizontal

Stainless steel

17 bar g Screwed T3 Vertical down

21 bar g Swivel USM21 Universal

32 bar g

Swivel USM32 Universal

Screwed Socket weld

FlangedPBX Horizontal

Alloy steel

45 bar g

Screwed Socket weld

Butt weld Flanged

SM45 Horizontal

80 bar gSocket weld

Butt weld Flanged

HP80 Horizontal

100 bar g HP100 Horizontal



Bimetallic thermostatic steam traps - Product range

15

Pipeline connectors

Steam traps

The pipeline connectors require 2 bolts for connection with a steam trap.

Key features:

• Asimpletwo-boltconnectordesignallows

quickandsimplemaintenanceofasteamtrap

-Reducingsystemdowntimeandmaintenance

costscomparedtotraditionaltrappingstations.

• Singlepermanentin-linecomponentforease

ofspecificationandinstallation.

• Prefabricatedconstructionminimiseson-site

fabricationandtheweldedjointseliminate

potentialleakpaths.

• Allstainlesssteelconstructionformaximum

systemlife.

PC10 up to 32 bar g

PC10HP up to 42 bar g

PC20up to 32 bar g

PC30 seriesup to 42 bar g

IPC20 and IPC21up to 32 bar g

Pipeline connector with integral

Spiratec sensor

Reducing production running costs

Spirax Sarco can supply fabricated steam trap stations and a range of ‘quick-fit’ solutions that will allow rapid steam trap replacement and significantly reduce labour costs.

UTD30L and UTD30Hup to 30 bar g

Thermodynamic steam trap

UTDM42L up to 42 bar g


16

Pipeline connectors

Steam traps

The pipeline connectors require 2 bolts for connection with a steam trap.

Downstream isolation valve

Upstream isolation valve

Check valve

Pipeline connector with an integral strainer screen

STS17up to 17.5 bar g

Steam trapping station

PC40 seriesup to 42 bar g

Reducing production running costs

Spirax Sarco can supply fabricated steam trap stations and a range of ‘quick-fit’ solutions that will allow rapid steam trap replacement and significantly reduce labour costs.

UFT32up to 32 bar g

Ball float steam trap

UIB30 and UIB30Hup to 30 bar g

Inverted bucket steam trap

UBP32up to 32 bar g

Balanced pressure steam trap

USM21 up to 21 bar g

USM32up to 32 bar g

Bimetallic steam trap

UTDM42L up to 42 bar g


17

Steam tracing using the Spirax Sarco compact dual duty manifoldSteam tracing is used principally to maintain a

reasonable product temperature and viscosity in

order to simplify pumping, avoid freezing,

solidifi cation and stagnation. Although the rates of

condensate are relatively small, trap populations

will be large since all tracer lines should be

individually trapped. For ease of design and layout,

the condensate from the traps is collected in a

manifold. The steam to the tracers can be distributed

utilizing a similar manifold arrangement.

The Spirax Sarco forged MSC series manifold

minimises on-site fabrication and testing.

Key features:• Minimiseson-sitefabricationandtesting.

• Lowercostthanconventionalweldeddesign.

• Shortensprojectleadtimes.

• Spacesavingwithstandardiseddesign.

• Lightweighttosupportandeasytoinstallwithoptionalmountingkit.

• Easytomaintain.

• Optionalinsulationjacketforenergyconservation.

Steam main

Condensate main

To tracer lines From tracer lines

Product line

MSC steam distribution manifold

MSC condensate collection manifoldConsult Spirax Sarco

regarding steam trap type

18

Spirax Sarco can help you manage your steam trap population through Steam System Services Working in partnership to deliver a cleaner more efficient future – ‘Our aim is to reduce your total cost of ownership

through improved efficiency of your steam system.’

It has been evident in recent years that our customers’ requirements have changed due to the significant increase in

fuel cost and environmental issues. In addition, many of our customers have been forced to make cost cutting exercises

resulting in the reduction of maintenance teams and loss of steam engineering experience. This is where our Steam

System Services have evolved to support you, by helping you to maintain performance and reduce costs, by working

alongside your maintenance teams to improve and sustain your plant’s efficiency.

Steam System

Services

ServiceMaintaining plant performance

Installation and commissioning

Solution implementation

AuditsProblem and potential solution identification

Benefits to your business

Steam System Services can help to maintain your steam system at it’s optimum level, ensuring that steam reaches the

point of use at the correct quantity, quality and pressure.

Increased turnover

• Reduced downtime through preventative maintenance.

• Reduced product rejects by ensuring steam reaches point of use at correct

conditions.

• Faster warm-up times through good engineering practices.

Health and safety• Helping you comply

with regulations / legislation.

Increased profit

• Reducing energy wastage and emissions.

• Reducing stock holding through rationalisation of steam equipment

and using a single supplier.

• Lower fuel bills through improved energy efficiency.

• Reduced administration costs.

• Accessing steam expertise through Spirax Sarco without the

extra overhead.

19

Spirax-Sarco LimitedCheltenham UK

GL53 8ERt: +44 (0)1242 521361f: +44 (0)1242 573342

e: [email protected]

© Copyright 2010 Spirax Sarco is a registered trademark of Spirax-Sarco LimitedSB-GST-33 ST Issue 1

Some products, services or solutions may not be available in certain markets

20

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