My Steam Trap Is Good Why Doesnt It Work
My Steam Trap Is Good Why Doesnt It Work
Heat Transfer
cation or installation of a trap. It can be particularly frustrating to maintenance or operations personnel who replace a
failed trap only to have the new trap fail in the same way as
the trap it replaced. This raises the question: Why doesnt
my good steam trap work?
There can be several reasons why a new, correctly manufactured steam trap might not be functioning properly, most
of which are due to misapplication. This article explores
some of these reasons and explains how to recognize
potential problems, and provides guidance on avoiding such
problems.
COLD FAILURES
Cold failures should be considered the highest priority.
A cold trap does not adequately drain condensate from the
system. This has the potential to cause the most disastrous
results (1). Possible causes for cold failures of good steam
traps include:
negative pressure differential
undersizing
modulating into a stall condition
steam locking due to lift or to distance
group trapping
double trapping
pressure blockage
incorrect low temperature setpoint
high backpressure
backwards installation
debris or deposits
inability to discharge air
isolation or valving-out.
Article continues on next page
CEP April 2015 www.aiche.org/cep
27
Heat Transfer
P1
P1>P2
P2
Flow
P1
P1P2
No Flow
Steam locking
The essential function of a steam trap is to automatically
open to discharge condensate and shut off to prevent steam
loss. Steam locking occurs when steam collects in the line
between the condensing source and the trap, filling the trap
and preventing it from opening. Steam locking can occur if
there is a vertical rise in the piping or if the trap is located a
long distance from the condensate source.
Steam locking due to lift. Figure 4a depicts a steam trap
with a vertical lift from the condensing source into the trap.
After condensate is initially discharged through the trap, the
vertical riser pipe and trap immediately fill with steam, causing the trap to close. Condensate can continue to form in the
equipment, but it cannot displace the steam in the trap body,
so the trap remains closed. In essence, the trap is steam-locked
shut and the equipment becomes cold or thermally stratified,
even though the trap itself may be hot to the touch. It is the
heat exchange system that is cold due to a steam lock.
Pressure
Vary
Pre ing Ste
ssu
re L am
ine
Trap
Time
Site of
Water Hammer
P2
Pump
Stall Point
Process Fluid
28
Constant
Backpressure Line
Condensate
Steam
Vertical Rise
in Piping
Before Trap
Process
Fluid
Condensate
Move Trap
Closer to
Heat Exchanger
p Figure 4b. Locating a trap a long horizontal distance from the condensing source can allow
steam to flow across the top of the condensate, leading to severe steam locking.
Steam locking due to lift can occur with any riser pipe
into the trap, particularly when the riser is made of largebore piping. The lift condition needs to be analyzed and a
solution such as a small-bore lift fitting, drilled vent, or
steam lock release provided to prevent the steam lock.
Otherwise, the CDL will fail cold and not drain the equipment adequately, even though the steam causing the lock
may make the trap itself hot to the touch.
Steam locking due to distance. A similar phenomenon
occurs when a trap is located too far away (horizontally)
from the condensing source (Figure 4b). A trap may be
located relatively far from the process equipment if there
is not enough space available near the equipment to install
a trap in close proximity. A trap might also be installed at a
distance so it is more readily accessible or outside of a zone
where special garments or permits are required.
In a distance-related steam-lock situation, the trap itself
may be hot to the touch from the steam causing the lock, but
condensate can pool on the inlet side and back up into the
equipment, causing a cold condition. Condensate has a low
specific volume (approximately 0.017 ft3/lb) and occupies
very little space in the pipe between the equipment and the
steam trap. Steam can pass over the top of the condensate in
the line and lock the trap, even though more condensate is
being produced in the equipment.
To obtain the best performance from a steam trap, locate
the trap as close to the vertical drop as possible. If it is not
possible to move it closer, a simple solution to prevent steam
locking is to install a vertical drop immediately before the
trap, even if the trap is located a distance away from the
equipment. The vertical drop usually helps to prevent a
steam lock due to distance by allowing for a leg of condensate at the traps entrance, as long as the condensate piping is
pitched downward toward the trap.
A third alternative is to install a balance line directly on
or immediately before the locked trap at its inlet. This allows
the steam that would normally be compressed to return to
the steam line instead.
Group trapping
Collecting condensate from several sections of steamheated equipment into one condensate line that discharges
into a single steam trap is a practice known as group
trapping. Reasons cited for group trapping include space
limitations (real or perceived) and the desire to reduce
installation costs. However, group trapping provides a false
sense of economy. In most instances, it limits the performance of the heating system due to pressure differentials and
short-circuiting.
It can be difficult to identify problems with group trapping at the trap itself. The trap condition might appear to be
good the trap is hot to the touch and is not leaking steam.
However, the equipment being drained by the trap often
suffers from significant thermal stratification. A trap in this
condition is categorized as a cold failure.
Consider the four-coil air heater shown in Figure 5.
The cool air encountering the first coil absorbs the largest
14.5 psi
14.7 psi
14.9 psi
15.0 psi
29
Heat Transfer
amount of heat and therefore creates the most condensation. When the steam condenses, the steam pressure in
the coil drops simultaneously. The heated air reaching
the last coil is much hotter and absorbs less heat, creating
less condensation and a smaller pressure drop across that
coil. Even though the inlet pressure to the four-coil system
remains constant, the effective pressure drop from the inlet
to the outlet of the first coil is larger than the pressure drop
across the fourth coil. This pressure imbalance creates
a short circuit. The second and third coils can also have
outlet pressures lower than the fourth coils outlet. The
result is significant thermal stratification and reduced heattransfer capacity of the coils.
Installing a single trap, instead of low-cost, individual
traps for each coil, is a costly design decision, because it can
significantly reduce the heating capability of the equipment
and prevent it from performing at its maximum.
Double trapping
Double trapping is the practice of installing a second
trap in series immediately after another trap (Figure 6). It
is sometimes intended to be a temporary measure, where a
so-called master trap is installed on a condensate line downstream of a failed trap (or traps), or as a second trap to act as
a backup in case the first trap fails. While installing two traps
in series might seem to be a good safety measure, it can lead
to trap blockage and waterlogging of all of the equipment
the trap is supposed to drain.
Double trapping can cause a cold failure in two ways:
live or flash steam exiting the first trap enters the second trap, causing the second trap to close
the available pressure differential is split over two
traps, and the driving force across the second is insufficient
for the required load.
When a trap fails, it leaks live steam; when it functions
properly, a portion of the discharged condensate flashes
into steam because of the pressure differential. In either
case, when two traps are set in series, live or flash steam
Pressure blockage
When the steam traps valve head is located on the inlet
side of the valve seat (Figure 7), thermodynamic action
easily closes the traps automatic-opening mechanism. This
type of trap needs a mechanical advantage to overcome the
closing force created by steam pressure on the valve head.
For example, traps that operate based on the density principle (i.e., the difference between the densities of the steam
and the condensate), such as float and inverted-bucket
mechanical traps, open to discharge condensate when the
buoyancy of the float or bucket overcomes the closure
force. The mechanical advantage needed to allow this is
Closing
Force
Valve Head
(Float)
Opening Force
p Figure 6. The full pressure differential between the inlet and outlet is
split between traps that are double-trapped. This reduces the capacity of
the second trap. Additionally, flash/live steam can close the second trap.
30
Valve Seat
ve
Cur
ion
t
a
r
u
Sat
Subcooling
am
Ste
Before Opening
Temperature
Trap Starts
to Open
Trap is
Fully Open
Pressure
High backpressure
Many bimetallic and some balanced-pressure thermostatic steam traps have a downstream valve head design,
where the valve head is downstream of the valve seat
(Figure 9). High backpressure pushes the valve head toward
the seat. Thus, dynamic system conditions that significantly
increase the backpressure can increase the closure force
from the downstream side, closing the steam trap early and
causing a cold condition.
Depending on the condensate load and the application,
these traps can require a significant backup length to allow
the condensate to subcool sometimes as much as 40 ft or
more. The risk of water hammer damage or personnel injury
in the event of such backup is high in systems that may not be
able to provide the necessary volume to hold the subcooled
condensate without incident. Because of the large volume of
condensate in the line, it is unwise to use these traps on steam
main drips or process heating applications. They may be
suitable, or in some cases recommended, for low-temperature
trace heating or instrument enclosure warming. If the backup
is too far from the trap and extends into the application being
drained, then it becomes a cold failure.
Valve Seat
Hot
Condensate
Valve Head
(Closed)
Backpressure
31
Heat Transfer
Backwards installation
Installing a steam trap with the flow arrow pointing in the
downstream direction seems like a simple task. Nevertheless,
it is not uncommon to find a trap that has been installed
backwards.
When a trap with a downstream valve head or integral
check valve (such as a bimetallic trap) is installed backwards,
the inlet steam pressure can hold the valve shut, causing a
blocked, cold condition. Density-based and thermodynamic
traps do not have a valve that can be held closed by reverse
flow, so if installed backwards they typically experience hot
failures rather than cold failures.
Debris or deposits
Mud legs should be blown down regularly for
example, at system startup or shutdown and before and after
installing a new trap. If maintenance, operations, or contractor personnel do not do this, debris can accumulate quickly
and be deposited in the new trap, creating a blockage.
A longer-term condition can occur when the condensate
contains particulates, such as iron oxide or leached copper.
Debris can accumulate at the entrance of the valve seat and
prevent the trap from closing, thereby causing a hot failure (Figure 10). But, some condensate flashes as it passes
through the steam traps orifice. The incondensable particles
that were in solution can simultaneously precipitate out of
the flashed fluid. This precipitate forms deposits that can
metallically bond to the orifice, build up, cause a blockage,
and create a cold condition.
Inability to discharge air
Some steam traps that operate on the density or thermodynamic principle are not able to vent significant amounts
of air. This can cause them to close when they encounter
air upon startup or ingressed air (for instance, from vacuum
breakers). Noncondensable air inside the trap body can lock
p Figure 10. Minerals in the condensate can build up at the orifice outlet
and prevent the trap from closing.
32
Isolation or valving-out
This type of cold failure can involve one of two
scenarios.
Scenario 1: After a new steam trap is installed, it needs
to be put into service. If the installer leaves this task for
the operations staff, but the operators do not realize they
are expected to do it, the CDL will not be able to drain
condensate.
Scenario 2: A leaking trap represents a hot failure, and
although the trap is leaking steam, it is at least discharging
condensate as intended. If a worker valves-out the CDL to
stop the leak, what was an inefficient operation leaking
steam becomes a dangerous cold failure.
HOT FAILURES
Many facilities assign the highest maintenance-response
priority to hot failure i.e., leaking steam traps. However, hot failures typically do not present the same safety
issues as cold failures. Even though the drainage of leaking
traps is inefficient, they nevertheless discharge condensate
from a steam system. The main benefits to fixing hot failures
are economics-related. Possible causes for hot failures of
good steam traps include:
backwards installation
incorrect orientation
oversizing
high backpressure
inability to handle superheat
incorrect high temperature setpoint.
Backwards installation
Depending on the type of trap, backwards installation
can cause either a cold failure as discussed earlier or a hot
failure.
When density-based or thermodynamic traps are
installed backwards, it is usually not possible for the valve
mechanism to close. Steam loss occurs until the installation
is corrected.
Incorrect orientation
A steam trap installed in the wrong orientation may
experience a hot failure in two ways.
If a density-principle trap is installed in an incorrect orientation, the valve mechanism may be unable to close, and
steam will leak. For example, the horizontal trap installed
vertically in Figure 11 may experience steam blow-through
Oversizing
Except for float-type designs, an oversized steam trap
also typically has a shorter life than one that is properly
sized. Inverted-bucket, thermostatic, and thermodynamic
traps can be more prone to early failure than float traps
when oversized. The result of shortened life is premature
hot failure.
Technically speaking, if an oversized trap experiences
a hot failure, its condition would not be considered good.
However, the user may consider the trap to be relatively
new and wonder why it failed
sooner than expected.
High backpressure
High backpressure can
cause a cold failure in some
trap designs, but it can also
cause a hot failure in others.
Thermodynamic steam traps,
in particular, are susceptible to hot failure due to high
backpressure. Many thermo
t Figure 11. Many traps require (or
operate better in) a specific orientation.
This horizontal density trap installed
vertically is likely to experience
blow-through.
p Figure 12. This disc trap may work in any orientation, but cycling in the vertical position shortens the
traps life.
Hot
Condensate
33
Heat Transfer
Acknowledgments
The author acknowledges his colleagues Philip Woodward, Drew Mohr,
Jon Walter, and Norm White for their help in preparing this article.
34
Steam
Condensate
Inverted Bucket
Prime
Literature Cited
1. Risko, J. R., Beware of the Dangers of Cold Traps, Chemical
Engineering Progress, 109 (2), pp. 5053 (Feb. 2013).
Additional Resources
Risko, J. R., Steam Heat Exchangers are Underworked and OverSurfaced, Chem Eng., 104 (11), pp. 5862 (Nov. 2004).
Risko, J. R., Handle Steam More Intelligently, Chem. Eng.,
124 (11) pp. 4449 (Nov. 2006).
Risko, J. R., Steam Traps Operating Principles and Types,
Fluid Controls Institute Technical Sheet #ST 107, www.fluid
controlsinstitute.org/pdf/resource/steam/ST107OperatingPrinciplesandTypes.pdf, FCI, Cleveland, OH (Apr. 2008).
Walter, J. P., Implement a Sustainable Steam-Trap Management
Program, Chemical Engineering Progress, 110 (1), pp. 4349
(Jan. 2014).
TLV, What Causes Stall to Occur, www.tlv.com/global/US/
steam-theory/stall-phenomenon-pt1.html, TLV Co., Kakogawa,
Japan (2010).
TLV, What is Water Hammer, www.tlv.com/global/TI/steam-theory/
what-is-waterhammer.html, TLV Co., Kakogawa, Japan (2011).
TLV, Group Trapping, www.tlv.com/global/US/steam-theory/
group-trapping.html, TLV Co., Kakogawa, Japan (2013).
TLV, Double Trapping, www.tlv.com/global/US/steam-theory/
double-trapping.html, TLV Co., Kakogawa, Japan (2013).
TLV, Steam Locking, www.tlv.com/global/US/steam-theory/
steam-locking.html, TLV Co., Kakogawa, Japan (2014).