S T E A M

When water is heated Steam is produced

Saturated steam has a “FIXED” table of the relationship of the steam pressure & the steam temperature.

0 barg pressure of steam Temperature = 100°C4 barg pressure of steam Temperature = 151.96°C

10 barg pressure of steam Temperature = 184.13°C

Saturated Steam

Producing steam

When we heat water, the water will receive a heating

energy that is called sensible heat. Then the

water will be boiling.

When the boiling water receive further heat energy that is called latent heat

the water will be transformed into saturated

steam.

Industrial steam

Steam is produced inside an industrial steam boiler

To view how the steam boiler operates, please visit:https://www.youtube.com/watch?v=v0lmCZVrsRw

Usage of industrial steam - HEATING

Shell & tube heat exchanger (water or oil)Steam comes into the u-tube bundle

The secondary fluid to be heated is at the outer side of the u-tube bundle (shell)Condensate is drained out through a steam trap

Usage of industrial steam - HEATING

Plate & frame heat exchanger (Beverage, Food & Medicine)The plate heat exchanger consists of a frame with end plates which squeeze the

corrugated heat transfer plates. The plates form a series of channels for the two media. Steam flows in the odd number channels

The secondary fluid to be heated flows in the evenly numbered channels.Condensate is drained out through a steam trap

Usage of industrial steam - HEATING

Steam jacketed kettle (Food & Syrup)The steam is circulated inside the outer jacket of the stainless steel tank

The food to be heated is inside the stainless steel tankCondensate is drained out through a steam trap

Usage of industrial steam - HEATING

Steam tracing (Heavy oil, Sulphur & Petrochemical products)The steam is going into the tracer pipe

The heavy oil is inside the main pipelineCondensate is drained out through a steam trap

Usage of industrial steam - HEATING

Steam evaporator (Dairy & Syrup thickener)The steam is going into the tubes

The dairy or syrup is going into the outside of the tubesCondensate is drained out through a steam trap

Usage of industrial steam - HEATING

Steam rotary dryer (paper & corrugated paper)The steam is going into the drum dyer

The dried paper is located on the velt at the outside of the drum rotary dyer Condensate is drained out through a steam trap

Usage of industrial steam - HEATINGAIR

Hot Air

Process air heater (food, paper)The steam is going into the fin tubes

The air is blown out and the air is going through the hot fin tubesCondensate is drained out through a steam trap

Latent heat

Condensate (sensible heat)STEAM

Condensate in a steam heating system

1. When steam comes into a steam heating equipment the steam will transfer its latent heat into the secondary fluid to be heated

2. Then some part of the steam will be condensed and become condensate the condensate left only with the sensible heat only

Condensate in a steam heating system

For example: When we send saturated steam into a steam jacketed kettle to heat the soup inside the kettle the saturated steam will give its latent heat to the soup so the saturated steam left only with sensible heat only the steam

become hot water that is called condensate The condensate has to be collected & is drained out through a steam trap

Condensate is a poor heat transfer

Heating with steam

Condensate

Steam trapSteam trap

Steam trap

Steam trapSteam trap

Steam trap

Steam trap

Steam trap

Steam trap

Steam trap

Steam trap

Steam trap Steam trap

Steam trap

Steam trap

Dis-advantage of condensate in steam

• Water hammer in the steam pipe• Corrosion in the steam pipe (at lower temperature than

steam CO2 gas can react with condensate to become carbonic acid)

• HEATING IS NOT EFFICIENT process heating coil full of condensate (FLOODED heating coil with condensate) do not have latent heat anymore steam keeps coming into the heating coil but the heating is not efficient anymore since the steam boiler is still generating steam the steam is wasted in the heating process it will waste the fuel etc. at the steam boiler side !

When air and other non-condensable gases enter the steam system, they consume part of the volume that steam would occupy. The temperature of the air/steam mixture falls below that of pure steam (the air & gases become a heat insulator).

Steam chamber 100 % steamTotal pressure = 1.74 bargSteam pressure = 1.74 bargSteam temperature = 131° C

Steam chamber 90 % steam & 10 % of airTotal pressure = 1.74 barg

Steam pressure = 9/10 x 1.74 = 1.57 bargSteam temperature = 128° C

Dis-advantage of air/gas in steam

Steam trap is used to get rid the condensate

• The purpose of a Steam Trap is to keep steam in the system while removing condensate (water) and air.

• Air can reduce the heat transfer ability of steam and cause corrosion.

• Condensate / Water substantially reduces heat transfer and the ability of a steam device to do work.

• When a steam trap fails, it allows steam to blow-through along with the condensate.

• This loss of steam can represent a substantial energy loss.

or bucket

Type of steam trap

Bellows Balanced Pressure trap

At start-up Cold condensate is drained out

through the steam trap

When the condensate temperature is rising near to the steam temperature the bellow will expand steam trap is closed

To watch how it works, please visit:https://www.youtube.com/watch?v=x_EVtlwPPCs

23

Cold start-up Near steam temperature

Modulating with flow change

Condensate pressure pushed wafer off seat.

Full capacity flow established

Near steam temperatureliquid fill boils raising pressure above wafer which is pushed down on seat

Condensate cools, liquid fill begins to condense, pressure above wafer decreases and wafer leaves seat enough to rebalance pressures. Flow changes adjust valve opening

Outlet Port

Inlet Port

Liquid Fill

Wafer/Diaphragm

Bulkhead

SteamCondensate

Wafer type of trap

Bimetallic type of trap

Bimetal steam trap is using bimetal strips 2 different type

of metal that have different thermal coefficient (different

expansion & contracting properties)

At start-up when the condensate temperature is still

low bimetal strips are contracting trap open

When the condensate temperature increases near to steam temperature bimetal strips are expanding trap

closeTo watch how it works, please visit:https://www.youtube.com/watch?v=5ljv7AiB2q8

Thermodynamic (disc type) trap

Flash steam

Flash steam

Live steam strong flow of steam comes out of a leaking steam trap

Flash steam flying steam comes out of a steam trap together with

condensate

Thermodynamic (disc type) trap

To watch how it works, please visit:https://www.youtube.com/watch?v=pUdt127UXqA

Inverted bucket trap

To watch how it works, please visit:https://www.youtube.com/watch?v=x4c6UN8IqOc

Float & thermostatic trap

To watch how it works, please visit:https://www.youtube.com/watch?v=nQIQzEuGaMw

Steam Trap with Universal Connector

The benefit of steam trap with universal connector:1. If we want to replace the faulty steam trap, we can just disconnect the

steam trap from the universal connector by taking out only two number of tightening bolts and replace it with a new steam trap

2. Universal connector can be swiveled fully 360° during installation of the steam trap at site. So it does not matter is the steam pipe line is not aligned (slanted a bit)

3. If we want to install a steam trap with socket weld connection, we can just weld the steam pipe into the universal connector. So next time w want to replace the steam trap, we just dis-assembly the steam trap only out of the universal connection

4. There is a universal connection with integral strainer & blow-off valve

Steam trap station model TVS-4000

TRADITIONAL INSTALLATION

Shut-off valve

Shut-off valve

TEST valve

Blow-down valve

Y-STRAINER

STEAM TRAP

TVS-4000 trap station

Steam trap station model TVS-4000

To watch how it works, please visit:https://www.youtube.com/watch?v=E5--tej_Ldo

It takes only 3 minutes to replace a new steam trap

In-Expensive solution of steam trap

station model TVS-800