MODULE 2

LEARNING OUTCOME:
Upon completion of this module, you will be able:

 Sketch a basic steam distribution system on-board a vessel including the boiler
components and its services supplied by steam

LESSON 1
MARINE BOILER STEAM DISTRIBUTION
Introduction: Improvement in marine boiler both of the scotch type and of the water tube type
such installation do much to retard the introduction of a water tube boilers in the adoption of a
system of force circulation and distribution

EXTERIOR STEAM DISTRIBUTION SYSTEMS

The exterior distribution system is divided into underground and aboveground systems. The
following topics discuss these two systems in detail.
Underground Systems
The major underground systems are the conduit and the utilidor types of systems. These
systems are normally installed only in permanent heating installations because of their high cost
of installation.

 Conduit Type

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 In the conduit type of steam distribution system, the pipe is installed inside a conduit that is
usually buried in the ground below the frost line. The frost line is the lowest depth that the
ground freezes during the coldest part of the winter. The pipe commonly used for steam is
black steel pipe, which is not as strong as that required for condensate return lines. The
conduit and insulation serve to protect and insulate the steam pipe. One type of conduit is
shown in Figure 10-1. The conduit must be strong enough to withstand the pressure of the
earth and the usual additional loads imposed upon it. Several types of materials and various
designs are used in the manufacture of conduit. Common types of conduit are constructed of
masonry cement, galvanized iron, and steel. The conduit is usually sealed with asphaltic tar
or some other type of sealer to prevent water from getting into the insulation and deteriorating
it. Insulation may be attached directly to the pipe, attached to the inner surface of the conduit,
or in loose form and packed between the pipe and the conduit. The bottom of the trench for
the conduit should be filled with coarse gravel or broken rock to provide support and adequate
water drainage. When water is allowed to collect, it seeps into the conduit through porous
openings in the sealer. This wets the insulation and causes it to lose much of its insulating
value. Manholes are required at intervals along the line to give access to the necessary
valves, traps, and expansion joints. A typical manhole is shown in Figure 10-2.

 Utilidor Type

The utilidors, or tunnels, of the utilidor type of system are constructed of brick or concrete.
The size and shape of the utilidor usually depend upon the number of distribution pipes to be
accommodated and the depth the utilidor must go into the ground. Manholes, sometimes doors,
are installed to provide access to the utilidor. A typical utilidor is shown in Figure 10-3. The
utilidor is usually constructed so the steam and condensate return lines can be laid along one
side of the tunnel on pipe hangers or anchors. This is usually done with the type of hanger with
rollers that provides for free movement required by the expansion of the pipe. The other side of
the utilidor should be a walkway that provides easy access to lines when you are inspecting and
doing maintenance.

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 Aboveground Systems
Aboveground steam distribution systems are further divided into overhead and surface
systems:

 Overhead Distribution Systems

Overhead distribution systems are often used in temporary installations and sometimes in
permanent installations. The main
drawback to this type of distribution
system is the high cost of
maintaining it. These overhead
systems are similar in many
respects to underground distribution
systems. They require valves, traps,
provision for pipe expansion, and
insulated pipes. The main difference
is that the steam distribution and
condensate return piping are
supported on pipe hangers from
poles instead of being buried
underground (Figure 10-4).

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 Surface Distribution Systems
In some cases, you will find that steam and condensate lines are laid in a conduit along the
surface of the ground. These systems, however, are not as common as overhead and
underground systems. Surface systems require about the same components as the overhead
and the underground systems—traps, valves, pipe hangers to hold the pipes in place, and
provision for pipe expansion. Sometimes an expansion loop, formed by a loop of pipe, is used
instead of an expansion joint to provide for pipe expansion.
Maintenance
The maintenance required for exterior distribution systems normally consists of inspecting,
repairing, and replacing insulation, traps, valves, pipe hangers, expansion joints, conduit,
utilidors, and aluminum or distribution systems. The maintenance required on conduit and
utilidors consists of keeping the materials of which they are constructed from being damaged
and of ensuring that water is kept out of the tunnels and pipes. The maintenance required on
outside metal coverings is about the same as that for the conduit and utilidors.
INTERIOR STEAM DISTRIBUTION SYSTEMS
Interior steam distribution systems may be classified according to pipe arrangement,
accessories used, method of returning condensate to the boiler, method of expelling air from the
system, or the type of control used. The interior steam systems discussed in this section are
classified by pipe arrangement; they include but are not limited to: Gravity, One-Pipe, and Air-
Vent System. Steam may be fed to interior steam distribution systems from a boiler in the same
building or from the exterior distribution system of a central plant.

 Gravity, One-Pipe, Air-Vent System

The gravity, one-pipe, air-vent system is one of the oldest types of internal distribution systems
(Figure 10-5). Its capacity is usually ample, and its installation cost is low. Because the
condensate is returned to the boiler by gravity, this system is usually confined to one building
and is seldom used as a central plant distribution system. The steam is supplied by the boiler
and is carried by a single system of piping to the radiators. The return of condensate depends
upon the hydrostatic head. Therefore, the end of the steam main, where the main is drained to
the wet return, should be high enough above the waterline to provide the required hydrostatic
head above the entrance to the boiler. The radiators in the system are equipped with an inlet
valve and an air valve. The inlet valve is the radiator shutoff valve, while the air valve permits
the venting of air from the radiators. Condensate is drained from the radiators through the same
pipe that supplies the steam; they flow in opposite directions, however, which is a disadvantage.
Under certain conditions, the condensate is held in the radiators. This causes noisy operation
and a fluctuating water level in the boiler. Water hammer and slow heating are characteristic of
this system when the pipe sizing, pitch, and general design are inadequate.

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 Installation
Although all gravity, one-
pipe, air-vent systems are
alike in design, two
installations are seldom
alike in detail. Since the
details differ with the make
and model of equipment,
the manufacturer’s
installation procedures
should be followed. Also,
you should follow the
mechanical blueprints for a
particular installation.
There is some general
information in this section that applies to most heating systems of this type. To prevent water
hammer and re-evaporation of the water, drain all condensate from the lines. The necessary
internal drainage can be obtained by sloping the lines down in the direction of condensate flow,
at least one-fourth of an inch for every 10 feet of pipe. The radiators must also be tilted so the
condensate flows out of them into the same pipe through which the steam is entering. Air vents
are installed in the steam lines and radiators to eliminate air in the system. Air in the system
tends to block the flow of steam, and it consequently acts as an insulator by preventing the
emission of heat from the heating surface. Therefore, the air must be quickly and effectively
vented from the heating equipment and steam lines to get quick and even heating from the
steam-heating system. Most steam distribution systems are now fitted with automatic vents that
permit the air to pass but which block the passage of steam. Figure 10-5 shows air vents in the
radiator and the distribution system.
Operation
The operating instructions for gravity, one-pipe, air-vent systems vary from one installation to
another. The manufacturer of the equipment usually furnishes the specific operating instructions
for the equipment. Generally speaking, most steam systems have a main steam stop valve
located on the top of the boiler. The purpose of this valve is to hold the steam in the boiler until
you are ready to let it out. When you are ready to turn the steam into the distribution system,
you should only crack (open very little) the valve. The reason for doing this is to allow the
system to warm up slowly and avoid any thermal shock to the lines and fittings. After the system
has warmed up, open the main steam stop valve slowly. While opening the valve, check often to
ensure that the proper water level is maintained in the boiler. You will also note that the radiator
valves in one-pipe steam distribution systems should be either completely open or completely
closed. Partial opening of the valve interferes with the proper drainage of water from the radiator.

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Maintenance
This section covers the problems you are most likely to encounter in the field when maintaining
a gravity, one-pipe distribution system. The most probable causes of these problems and the
remedies for them are also addressed. When a radiator fails to heat or water hammer occurs,
there are several probable causes. One is the failure of the air vents to function, thereby
causing the radiator to become air bound. A second cause is that the radiator valves are not
completely open. Another cause is that the radiators and lines are not correctly pitched. To
remedy these causes of heat failure, inspect the operation of the air vents and the positions of
the radiator valves to make sure they are open. Then check and correct, if necessary, the pitch
of the radiators and lines when the other checks do not correct the trouble. A fluctuating
waterline in the boiler can be caused by an excessive pressure drop in the supply lines, which in
turn is usually caused by partial stoppage in the pipes. This, of course, can be remedied only by
removing the cause of the stoppage. Uneven heat distribution is another trouble that you may
encounter. This can be caused by inoperative radiator vents, improperly vented steam mains, or
incorrectly pitched mains. To eliminate this uneven heat distribution, check and clean the air
vents at the radiator and those in the steam mains. Then check and correct, as required, the
pitch of the steam lines if the other remedies have not corrected the trouble.

 Two-Pipe Vapor System with a Return Trap

The two-pipe vapor system with an alternating return trap is an improvement over the one-pipe
system (Figure 10-6). The return from the radiator has a thermostatic trap that permits the flow
of condensate and air from the radiator. It also prevents steam from leaving the radiator.
Because the return mains are at atmospheric pressure or less, a mechanical return trap is
installed in the system to equalize the condensate return pressure with the boiler pressure. The
mechanical return trap is primarily a double-valve float mechanism which permits equalization of
the boiler pressure and the pressure within the return trap.
Installation
Vapor-steam systems with return traps are similar in design. However, two installations are
seldom alike. Since the details differ with the type of heating equipment, the manufacturer’s
installation instructions should be followed. However, the mechanical return trap should be
installed on a vertical pipe in the return system that is adjacent to the boiler. The top of the trap
should be level with or below the bottom of the dry return main. The bottom of the trap should
be approximately 18 inches above the boiler waterline to provide a sufficient hydrostatic head to
overcome friction in the return piping to the boiler.
Operation
The two-pipe vapor system with a return trap alternately fills and dumps. It returns condensate
to the boiler by a mechanical alternating-return trap instead of by gravity. The alternating-return
trap consists of a vessel with a float that, by linkage, controls two valves simultaneously so that
one is closed when the other is open. One valve opens to the atmosphere; the other is
connected to the steam header. The bottom of the vessel is connected to the wet return. In
operation, when the float is down, the valve connected to the steam header is closed and the
other is open. As the condensate returns, it goes through the first check valve and rises into the

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return trap, which is normally located 18 inches above the boiler waterline. The float starts to
rise when the water reaches a certain level in the trap, the air vent closes, and the steam valve
opens. This action equalizes the trap and boiler pressures and permits the water to flow by
gravity from the trap, move through the boiler check valve, and go into the boiler. The float then
returns the trap to its normal vented condition, ready for the next flow of returning water.
Maintenance
The problems you are likely to encounter in maintaining the two-pipe vapor system with a return
trap will differ with each system. Some of the more common troubles are discussed here. For
specific instructions, you should refer to the manufacturer's manual or pamphlet pertinent to
each piece of equipment. When a radiator fails to heat, the air vent being plugged or the radiator
being waterlogged because of a plugged or defective trap can cause the condition. In case
there is a plugged air vent, all you need to do is clean it. When there is a waterlogged radiator,
check the trap to determine if it is plugged; also check to see if the bellows is serviceable. If the
trap is plugged, then cleaning it should solve your problem. However, if the trap is damaged, the
damaged part, or the whole trap, must be replaced. When the entire steam distribution system
fails, the trouble can be caused by inoperative return traps or inoperative check valves. Clean
and inspect the return traps and the check valves, and replace the defective parts or the whole
unit if necessary.

 Two-Pipe Vapor System With a Condensate Pump The two-pipe vapor system with a
condensate pump is similar to the two-pipe vapor system with the return trap, except that

the condensate is returned to the boiler by a power-driven centrifugal pump instead of by a

return trap (Figure 10-7).
This system includes a separate main, a radiator feed at the top, and a return system with
thermostatically trapped outlets located at the bottom of the radiators opposite to the feed
end. The return main terminates at the receiver of the condensate pump, where all of the

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 air in the system is discharged to a vent on the receiver. With the use of a condensate
pump, all of the returns to the pump are kept dry and the radiators can be located below the
boiler waterline. This is not possible with the steam distribution systems previously
described. The radiators should be installed above the return main to permit gravity flow of
the condensate from the radiator, and the return main should pitch downward to the pump
receiver.
Installation
Two-pipe vapor systems with condensate pumps are basically alike in design. However, since
two installations are seldom alike, it is necessary to install each system according to the
mechanical blueprints furnished by the civil engineer and the instructions of the manufacturer of
the equipment.

Operation
The two-pipe vapor steam distribution system can be operated at the pressure limit of the steam
plant boiler, provided the condensate pump is designed for sufficient discharge head necessary
to overcome discharge pipe friction loss, boiler pressure, and the hydrostatic head between the
pump outlet and the waterline of the boiler. The ends of the steam mains are drained and
vented into the dry return main through a combination float and thermostatic trap. The two-pipe
system with a condensate pump is adapted to relatively large installations and is probably the
most practical and trouble-free system. Most vapor systems differ somewhat with each
installation. For specific instructions for the correct operating procedures, refer to the
manufacturer’s instructions for the specific type of equipment installed.

Maintenance
Most of the two-pipe vapor steam distribution systems differ from one system to another.
Therefore, you will encounter different maintenance problems with each system. It is not
feasible to try and cover all of the problems you might encounter with different systems of this
type. However, the more common ones are discussed. When you find that the individual
radiator fails to heat, either an inoperative steam trap or a radiator that is not installed correctly
can cause the trouble. Repairing or replacing the steam trap or correcting the improper
installation of the radiator can eliminate these troubles. When it is the whole distribution system
that fails to heat, the causes include clogged or closed receiver vents, a flooded return line, the
lack of pump capacity, or air binding the system. These troubles can be remedied by opening
the vents, checking and adjusting the pump cut-in, replacing the pump, or repairing inoperative
rerun traps. One common trouble that occurs in this type of distribution system is the overflow of
water from the receiver vent, usually caused by an inoperative pump. The pump may be
causing the flooding because of its inadequate capacity or because it is unable to handle the
volume of condensate required. This condition can be corrected by either repairing or replacing
the pump. Another cause of overflow of water from the receiver vents is an obstruction in the
line between the condensate receiver and the boiler. The trouble can be remedied by
eliminating the obstruction, regardless of whether it is a closed valve or a clogged line.

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 Two-Pipe Vapor System with a Vacuum Pump and a Condensate Return
The two-pipe vapor distribution system with a vacuum pump and a condensate return is similar
to the two-pipe vapor system with a condensate pump (Figure 10-8). The piping in this system
includes separate steam and return mains.

 STEAM DISTRIBUTION SYSTEM COMPONENTS

In previous sections of this chapter, you read about various components as you studied the
various distribution systems. The components were only mentioned, however, and not
explained in detail. Therefore, in this section, we are going to discuss these components, their
purpose, operation, and maintenance.

 Steam Traps
Steam traps are designed to retain the steam in a radiator or other using device until it changes
into condensate. After the steam has turned into condensate, the trap releases the water so it
can enter the return lines. However, it keeps the steam coming into the radiator from escaping.
The trap performs an important function since the excessive accumulation of water prevents the
proper heating of the radiator or other steam equipment. Also, steam that is permitted to blow
through a defective trap results in heat loss.

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TYPES OF TRAPS
Traps are generally classified according to their operation. The most common types of traps are
float, bucket thermostatic, float thermostatic, impulse, thermodynamic, throttling, and bimetallic
element.

 Float Trap
The float trap normally consists of a body, float, linkage, seat, and valve. A typical
float trap is shown in Figure 10-11. As water enters the trap, the float rises, opens the
valve, and allows the accumulation of water to flow into the return lines that take it to the
boiler. When the water has run out, the float falls, closes the valve, and traps the steam.
The maintenance to be done on a float trap is simple. One of the most common
difficulties is that the float gets water in it and does not rise. In this case, the float must be
replaced. The valve sometimes gets plugged or worn and has to be cleaned or replaced.

 Ball-Float Trap
In a ball-float trap, the valve of the trap is connected to the float so the valve
opens when the float rises. When the trap is in operation, the steam and water that may
be mixed with it flow into the float chamber. As the water level rises, the float is lifted,
thereby lifting the valve plug and opening the valve. The condensate drains out and the
float moves down to a lower position, then closes the valve. The condensate that passes
out of the trap is returned to the feed system.

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 Bucket Trap
There are two types of bucket traps: the upright and the inverted. An example of the
inverted bucket trap is shown in Figure 10-12. During operation of the upright bucket trap,
the steam and water both enter the trap body. As the water enters, it causes the bucket
to float and the valve to close. The water continues to rise; it overflows into the bucket,
which sinks. When the bucket sinks, the trap valve is opened and the steam pressure
forces the water out. When all of the water is expelled from the bucket, the bucket again
floats, the valve closes, and the cycle starts again. During the operation of the inverted
bucket trap, the steam and water both enter under the bucket. The steam makes the
bucket buoyant, causes it to rise, and closes the valve. When the steam condenses, the
bucket drops, opens the valve, and the steam blows the water out of the trap.
Maintenance on bucket traps consists mainly of cleaning and inspecting them periodically.
If the trap begins to leak steam, replace the valve disk and seat. However, if the bucket
fails to open the valve, the trap usually becomes waterlogged. When a valve disk or seat
becomes damaged, the trap allows steam to leak through. The condensate return line
becomes excessively hot when the trap is leaking steam. Bucket traps contain some
water at all times. Therefore, they must be drained when the system is to be off during
freezing weather.

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 Thermostatic Trap
The thermostatic trap is often used on radiators and is commonly known as a
radiator trap. It has a bellows that contains volatile fluid that expands and vaporizes when
heated. Pressure builds up inside the bellows and causes it to lengthen and close the
valve. A typical thermostatic trap is shown in Figure 10-13. When water collects around
and cools the bellows, the bellows contracts. This action opens the valve and permits
water to escape. As the water goes out, the steam that enters contacts the bellows and
causes it to expand, closing the valve and preventing the steam from escaping. The most
common trouble with the thermostatic trap is that the bellows develops holes, fails to
work, and has to be replaced. The bellows and lower valve seat can be removed for
repair without disconnecting any of the piping.

 Float Thermostatic Trap

The float thermostatic trap operates on the principle of the float trap and the
thermostatic trap. Practically the same maintenance is required. A typical example of the
float thermostatic trap is shown in Figure 10-14. The thermostatic bellows acts as an air
eliminate

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 Impulse Trap
The operation of the impulse trap is based on the principle that a portion of hot
water, under pressure, flashes into steam when its pressure is reduced (Figure 10-15).
The trap is operated by a moving valve impelled by changes of pressure in a control
chamber. The valve has tiny orifices drilled through its center that allow the continuous
bypassing of condensate from the inlet of the trap to the control chamber. This bypassing
reduces the chamber pressure below the inlet pressure so the valve opens and allows
free discharge of the condensate. The temperature of the remaining condensate rises
and flashes back to steam. The flow through the valve orifice is choked and pressure
builds up in the control chamber, closing the valve. About 5 percent of the rated capacity
of the trap flows through the valve orifice. The pressure on the discharge side of the trap
should not be over 25 percent of the inlet pressure if the trap is to function properly. Very
little maintenance, except some periodic cleaning, is required for the impulse trap. The
trap may be disassembled for cleaning or repairing without disturbing any of the piping.

 Thermodynamic Trap
A typical thermodynamic trap is shown in Figure 10-16. It contains only one moving
part—a disk. This disk is operated by changes in steam pressure. Pressure under the
disk raises it to allow the condensate to be discharged. Droplets of condensate form on
top of the disk. Then steam enters at high velocity and creates a low pressure under the
disk; the droplets of water above the disk then flash into steam and create a high
pressure above the disk. (Water expands to as much as 1,728 times its volume when it
changes to steam.) The high pressure against the top of the disk overcomes the lower
pressure of the incoming steam, so the trap closes. As more condensate collects in the
trap, the steam above the disk condenses and relieves the high pressure and the cycle is
repeated. The most common trouble is that the trap becomes plugged and has to be

49
 disassembled and cleaned. The thermodynamic trap can be cleaned or repaired without
disturbing any of the piping. Very little other maintenance is required for this trap because
of its simple construction. Also, the trap is usually constructed of stainless steel.

 Throttling Trap
The operation of the throttling trap is based on the principle that the flow of water
through an orifice decreases as its temperature approaches that of the steam used
(Figure 10-17). The rate of flow of the condensate may be adjusted by raising or lowering
a stem (needle valve) that fits into a tapered seat. This throttling trap has no moving parts.
Condensate that is slightly cooler than steam enters the trap, travels up through a baffle
arrangement, and is discharged through an orifice. If the condensate discharge rate is
higher than the inlet rate, the water (condensate) level in the chamber drops. This allows
steam to enter the baffle passage and heat the condensate. The amount of water
flashing into steam increases, so the volume of steam-water mixture handled by the
orifice increases and thereby reduces the capacity of the orifice. The reduced flow
through the orifice permits the level of condensate in the chamber to rise until the heater
water in the baffle passage has been completely discharged and replaced with water that
is slightly cooler. Then the cycle is repeated. Air is vented from this trap through the
same passage as the condensate. The throttling trap can be replaced without disturbing
any of the piping.

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  Bimetallic-Element Trap
The bimetallic-element trap contains bimetallic elements that bend when heated
(Figure 10-18). The metals in the bimetallic strip generally are Emvar and copper. The
copper expands rapidly when heated, but Emvar expands very little. Therefore, the
bimetallic strip bends when it is heated. This trap may be used for higher or lower steam
pressure by increasing or decreasing the number of bimetallic leaves in the trap. This
trap works basically the same as the thermostatic trap. When steam enters the trap, the
element is heated and bends, thus closing the valve. As steam condenses, the elements
cool and straighten out to allow the valve to open and let the condensate escape. The
bimetallic trap can be repaired without disturbing any of the piping.

Pointers on Operating Procedures

To help ensure trouble-free service of steam traps, follow the proper operating procedures
carefully. Some important factors involving operating procedures are furnished below.

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  Steam traps should be operated within the capacity rating and pressure differentials
recommended by the manufacturer. Use traps for the correct pressure and temperature.
If operating pressures change, it may be necessary to change trap sizes, or internal
parts, to fit the new pressure conditions.
 Traps should be insulated where heat must be conserved. Some types of traps which
depend on the cooling effect of the condensate for operation should be left bare. Check
the manufacturer’s instructions regarding insulation.
 Where continuity of service is a requirement, a three-valve bypass is usually provided to
permit drainage while the trap is being overhauled. Bypasses are also used to speed up
the discharge of condensate and air when you are starting a system. In normal
operation, however, the bypass valve should be kept closed to prevent steam from
being wasted.
 Check valves, located in the discharge line, are important in parallel installations to
prevent the discharge of one trap from backing up into that of another. Also, when
condensate from the trap must discharge to a higher elevation, a check valve prevents
backflow of condensate.
 Inverted bucket traps must be primed for operation by providing a condensate seal in
the bottom of the trap. Prime the trap before starting operation by removing the test plug
on top of the trap and filling the trap with water. If no test plug is available, the trap can
be primed by closing the discharge valve and opening the steam supply valve slowly
until the steam is condensed and the trap is filled with condensate.
 Blow down steam traps periodically to rid them of dirt and sediment. Blow down and
clean strainers as required.
 When overhauling traps, do not remove thermostatic elements while hot. This practice
may result in expansion beyond the stroke range of the bellows or diaphragm.
 Periodically, open the air vents of float traps not provided with thermostatic air vents to
vent out accumulated air.

Steam Trap Tests

Methods for testing traps without breaking the installation are stated below.
 Test Valve Method
Close the discharge valve and open the test valve. Observe discharge characteristics.
Intermittent discharge, dribble, or semi-continuous discharge indicates correct operation. A
continuous steam blow indicates loss of prime, defective valve operation, or foreign matter
embedded in the valve seat. A continuous condensate flow may indicate that the trap is too
small, the amount of condensate is abnormally high, or a pressure differential that is too low.
 Glove Test Method
Grab inlet and outlet pipes simultaneously, using a canvas glove on each hand for
protection. A slight temperature difference indicates that no condensate is passing.

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 Pyrometer Test Method
This method is more accurate than the previous one, as it uses a surface contact
pyrometer to check inlet and outlet temperatures. File a clean spot on both pipes before
taking readings.

Water Tanks
It is virtually impossible to operate a boiler plant and heating system in perfect balance. The
demand for water by the boiler may exceed the rate at which water is being returned from the
heating system, or the water may be returning at a rate that is greater than the requirements of
the boiler. One or more tanks can be installed to compensate for uneven flows and for
differences between the demand and supply of water. These vessels are called surge tanks
(Figure 10-19). Sudden reductions in pressure may lead to violent steam formation. Flash tanks
help eliminate disturbances in the piping system caused by this process. These tanks are
usually small and are located near the traps where the pressure release occurs. When the
steam condenses, the steam trap, usually a float thermostatic type, allows the condensate to
drain into the condensate return line. A strainer is installed just ahead of the trap to keep foreign
matter out of the trap.

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Water Heaters
Steam-operated water heaters are used to supply hot water for laundries, dining halls, latrines,
and other facilities. There are two general types of these heaters: storage and instantaneous.

 Storage Type
The storage type of water heater is used to provide potable (drinking) water. The
steam operated storage type of water heater consists of a steel tank that contains a steam
coil like that shown in Figure 10-20. The hot-water tank is connected to the base water
supply system and remains full of water at all times. The steam is circulated through the
heating coil or "bundle," as it is sometimes called. The heat from the steam is transferred
through the walls of the coil to the water in the tank. Because of the difference in weight
between hot and cold water, the hot water rises and the cold water goes to the bottom of
the tank where the steam coil is located. Here the water is heated and begins to circulate.
Eventually, all of the water in the tank becomes heated. When hot water is drawn, more
cold water enters the tank and this heating process repeats itself. This action maintains a
full tank of hot water for use whenever hot water is needed. According to safety regulations,
the hot water should not exceed 180°F. The storage type of water heater may be
constructed to be installed in either the horizontal or the vertical position. Tapping’s are
usually provided in the tank for a thermometer—a thermostatic element for a temperature-
regulating valve (which will be discussed later in this section) and a safety valve. The tube
coil should be inspected annually to make sure steam is not leaking into the water. The
chemicals that are sometimes used in the steam may make the people who use the water
sick if they drink it.

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 Instantaneous Type
Instantaneous heaters are used primarily as boiler feed water heaters; however, they are
sometimes used to provide potable (drinking) water at some installations. The operation of the
instantaneous-type heater is basically the same as the storage-type heater; their construction,
however, is quite different. The diameter of the instantaneous heater is small in comparison to
the storage-type heater. The outer shell of the instantaneous heater is small in comparison to
the storage-type heater. The outer shell of the instantaneous heater barely covers the tube coil,
as you can see in Figure 10- 21. In some makes, the water is circulated through the coil, and
the steam is released in the shell and surrounds the coil. A temperature-regulating valve
controls the water temperature for both types of heaters.

Temperature Regulators
The temperature regulator is used to regulate the quantity of steam necessary to maintain the
hot water at the desired temperature. The unit consists of a temperature bulb, copper line,
diaphragm, spring and temperature adjustment, and steam valve. A typical temperature-
regulating valve is shown in Figure 10-22.

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Condensate Pump Return
Condensate return pumps move the water that has condensed from the steam in radiators,
heating coils, convectors, and unit heaters to circulate back to the boiler. One type of
condensation return pump is shown in Figure 10-23. Units of this type normally consist of a
receiver or condensate tank and pump independently controlled by float switches. A check valve
and a vent on the receiver allow the receiver to fill and empty as the need arises. Condensate
return pumps are maintained as prescribed by the manufacturer of the unit. Usually, the motor
should be oiled, the check valves and vents cleaned, the float switches adjusted, the pump
repacked, and the tank cleaned at least once each year.

Expansion Joints
Expansion joints and expansion loops in long heating lines are convenient devices for handling
the pipe elongation caused by expansion. The five major types of expansion joints are as
follows:
slip joint, bellows joint, swing joint, expansion loop, and ball joint.
The slip joint is shown in Figure 10-24. The female part of the joint is placed over the male part
and the joint is held tight by the packing that permits expansion. The kind of packing used
determines the temperature to which the joint can be subjected.
The bellows joint has a metal bellows that flexes as expansion occurs (Figure 10-25). The joint
consists of a thin-walled corrugated copper stainless steel tube clamped between flanges. Rings
help to keep the corrugations under relatively high pressure.
The steam pipe and joint should be supported and guided to keep misalignment to a minimum.

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The swing, or swivel, joint is most often used to allow expansion to occur naturally in a system
that has threaded joints. When it is used with welded elbows, the swing joint introduces torsional
strains in the elbows and in the swing piece.

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