To access the audio conference, call the toll free number ... · Where to Apply Different Traps All...
Transcript of To access the audio conference, call the toll free number ... · Where to Apply Different Traps All...
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To access the audio conference, call the toll free number 1.877.668.4490 And enter the access code: 575 723 854
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Pick Up Steam With Energy Savings for Steam Trap Repairs and Replacement
Scott Stroup, President, Airometrix Mfg., Inc. January 30, 2014
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Practical Items
Please type any questions you have during the presentation into the Chat window located on the right-side of your computer screen.
If you can't hear me, please type a message in the Chat window located on the right-hand side of your screen.
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Quiz Questions: What do you already know about Steam Traps?
1. True or False: All failed steam traps lose energy.
2. In steam systems that have not been maintained for 3 to 5 years, what % of installed steam traps may have failed?
3. True or False: Thermodynamic Disc Traps are a good choice in almost any application.
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Where are the Largest Steam Opportunities?
• Boiler controls
• Insulation
• Stack economizers (Condensing)
• Blowdown heat recovery & control
• Flash heat recovery
• Steam leaks
• Condensate return
• Trap failure
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Why Do We Want Condensate Back?
• Energy Recovery
• Chemical Recovery
• Water Recovery
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Why Do We Install Traps?
• Water is less efficient heat transfer medium than steam
• Safety - avoid water hammer, erosion, corrosion
• Process reliability
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What is Water Hammer?
• Slugs of water form in the pipe and travel at the speed of the steam
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Distribution Best Practices
• Steam take offs should be from top of pipe
• Proper pipe insulation thickness
• Proper steam trap selection
• Elimination/reduction of leaks
• Proper strainer placement
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Distribution Best Practices
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Distribution Best Practices
• Trap every 200-250’ of straight run
• Pocket before trap or water will jump the drain line
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Traps Fail!
• Fail Open – Steam blowing by – energy waste
• Fail Closed – No flow – safety/reliability concerns – no energy loss
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Why is Condensate Removal Important?
• Product spoilage
• Extended process times
• Water hammer
• Corrosion
• Erosion
• Wasted energy
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What are the Types of Traps
• Mechanical
• Float
• Inverted Bucket
• Thermodynamic
• Disc
• Thermostatic
• Bimetallic
• Balanced Pressure (capsule)
• Fixed Orifice
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Mechanical - Float Type Traps
• Condensate raises the float - opens valve
• Valve closes when water level drops
• Advantages: • Water hammer resistant
• High capacity for size
• Excellent air venting
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Inverted Bucket Type Trap
• Water seal used to prevent steam bypass
• Weight of bucket opens trap
• Steam creates buoyancy to close the valve
• Bleed hole allows steam to vent from bucket
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Free Float Type
• Float lifts
• Thermostatic valve allows air to pass
• Capacity limitations
• Roundness of the ball is critical and damage can cause live steam leakage
• Continuous Discharge
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ThermoDynamic – Disc Traps
• Pressure pushes disc up
• Flash steam causes disc to close
• Condensing flash steam opens disc
• Most common trap
• One moving part – rugged
• Energy efficient
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Thermostatic -Bimetallic
• Starts with the metallic element relaxed with valve open
• When heated valve closes
• Automatically discharges air and incondensables
• Sub-cools condensate to save energy
• Resistant to water hammer and freezing
• Reduces the amount of flash steam
• Used in high pressure applications
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Thermostatic - Balanced Pressure Traps
• Capsule with deionized water and alcohol to control discharge
• Easy maintenance
• Resistant to superheat and water hammer
• Automatically discharges air and incondensables
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Fixed Orifice
• Sized for each application
• Susceptible to blockage by dirt
• High maintenance costs
• Compromise – Best with constant run steady flow applications
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Where to Apply Different Traps
All Float Traps
• All process heat exchange applications
• Process relies on rapid condensate removal for maximum heat output
• Float thermostatic traps unaffected by load variation or pressure
• First choice for steam separators
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Where to Apply Different Traps
Inverted bucket traps
• Locations with high potential for water hammer – i.e. large coils in bulk storage
• Infrequent startup
• Does not handle air on startup well
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Where to Apply Different Traps
Thermodynamic Traps:
• Mains
• Tracer lines
• Long line runs
• Where temperature control is critical
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Where to Apply Different Traps
Bimetallic Trap
• High Pressure superheated applications
• Turbines or main lines
• Handles high temperatures
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Where to Apply Different Traps
Balanced Pressure Thermostatic Traps
• Where temperature variation is acceptable
• Some sub-cooling will occur, saving energy
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Trap Maintenance and Performance
• Ultrasonics
• Infrared
• Trap monitoring systems
• Universal connectors – quick changes
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Trap Failure Rates
• Vary by facility and application
• Typical failure rate is 3-8% per year
• Energy savings depend on failure mode (open or closed)
• Typical payback on trap replacement 1-3 years
• Reliability may be worth more than lost energy
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Presented by:
Scott Stroup, President
Airometrix
(303) 333-7037
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The Ameren Illinois ActOnEnergy® Business Program
Over $40 million in
energy-efficient cash incentives
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ActOnEnergy® Incentives Available
STANDARD
• Lighting
• HVAC/Water Heaters
• VFDs
• Steam Traps
• Leak Survey & Repair
• Specialty Equipment
CUSTOM
• Custom
• New Construction
• Feasibility Study
RETRO COMMISSIONING
(RCx)
• Compressed Air
• Healthcare
• Commercial Buildings
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Cash incentives are available for a variety of process steam projects, including: •Steam trap surveys •Steam trap repair or replacement
Process Steam & Steam Trap Incentives
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For steam traps that are greater than or equal to 250 psig the unit incentive is $500/trap
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The benefits to PMP Fermentation include:
• More than $60,000 in annual savings
• $4,800 in incentives from ActOnEnergy
• More than 7,000 therms saved every year
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Ameren Illinois ActOnEnergy
Energy
Advisors
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Find a Contractor Click here to find a
Contractor who is an ActOnEnergy Program Ally.
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• Website: ActOnEnergy.com/Business
• Phone: 1.866.800.0747
• Fax: 1.309.677.7950
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Resources
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Quiz Questions:
What did you learn about Steam Traps?
1. True or False: All failed steam traps lose energy.
2. In steam systems that have not been maintained for 3 to 5 years, what % of installed steam traps may have failed?
3. True or False: Thermodynamic Disc Traps are a good choice in almost any application.
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v
Questions?