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IPCL NC
TRAINING MODULE

Module No.
IPCLDSMEC107

INDIAN PETROCHEMICALS CORPORATION LTD.

MAHARASHTRA GAS CRACKER COMPLEX, NAGOTHANE

TRAINING MODULE
ON
STEAM TRAP

LEARNING CENTRE
IPCL- MGCC

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CATEGORY:

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IPCL NC
TRAINING MODULE

Module No.
IPCLDSMEC107

MODULE IMPLEMENTATION PLAN

TOPIC: Steam Traps
FOR:
REV: 0

CODE:
DATE:
SITE:
Availa Learning
ble
(Y/N)

Sr.
No

Contents

Autho
r

Resources

Introduction

KGG

Experience

Purpose of steam traps

KGG

Internet

3
4
5

Types of traps
Importance of Traps
Failed Traps -- Cause and
Effect

KGG
KGG
KGG

Internet
Internet
Internet

Y
Y
Y

6
7

Trap failure
Testing Methods for
Steam Traps
Application
Finding malfunctioning
traps
Trap inspection methods

KGG
KGG

Internet
Internet

Y
Y

KGG
KGG

Internet
Internet

Y
Y

KGG

Internet

8
9
10

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Validation

Self
study

8 hrs

Quiz

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hrs

CATEGORY:

Mechanical

IPCL NC
TRAINING MODULE

Module No.
IPCLDSMEC107

LIST OF CONTENTS
Sr.No.

Descriptions

Page No.

01.

Introduction

02.

Purpose of steam traps

03.

Types of traps

04.

Importance of Traps

05.

Failed Traps -- Cause and Effect

10

06.

Trap failure

10

07.

Testing Methods for Steam Traps

11

08.

Application

12

09.

Finding malfunctioning traps

13

10.

Trap inspection methods

14

11.

Questionnaire

15

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IPCL NC
TRAINING MODULE

Module No.
IPCLDSMEC107

01. Introduction:
Steam traps are automatic valves that release condensed steam (condensate) from a
steam space while preventing the loss of live steam. They also remove non-condensable
gases from the steam space. Steam traps are designed to maintain steam energy
efficiency for performing specific tasks such as heating a building or maintaining heat for
process use. Once steam has transferred heat through a process and becomes hot
water, it is removed by the trap from the steam side as condensate and either returned to
the boiler via condensate return lines or discharged to the atmosphere, which is a
wasteful practice
There are many different styles of steam traps but they all serve the same basic purpose:
to automatically allow condensate and non-condensable gases like air to escape while
maintaining an efficient thermal transfer process. Most traps function while remaining
closed to live steam but some use simple control valves to pass steam at a regulated
rate.

02. Purpose of steam traps

Steam traps serve two main purposes. First, they ensure efficient transfer of heat and
maximize the cost of creating the steam. Second, they reduce the possibility of damage
to the system from water hammer.
Processes using steam to produce high quality products depend on the good heat
transfer rates. Condensate and the presence of non-condensable gases adversely affect
the transfer of heat. To ensure maximum efficiency condensate must be removed from a
system as soon as it forms. Non-condensable gases such as air must be vented to
atmosphere at start up and on an on-going basis. When steam condenses in pipe work it
is crucial to purge it to prevent the potential catastrophe of water hammer.

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IPCL NC
TRAINING MODULE

Module No.
IPCLDSMEC107

03. Types of traps

There are five types of traps.

a. Inverted Bucket Steam Trap

b. Float & thermostatic steam trap
c. Disc steam trap
d. Thermostatic steam traps
e. Fixed orifice steam trap
The description of each trap is given below.

a. Inverted Bucket Steam Trap:

These types of steam traps have a bucket

that rises or falls as steam and/or

condensate enters the trap body. When steam is in the body, the bucket rises closing a
valve. As condensate enters, the bucket sinks down, opening a valve and allowing the
condensate to drain. Inverted bucket traps are ideally suited for water-hammer conditions
but may be subject to freezing in low temperature climates if not insulated. Usually, when
this trap fails, it fails open. Either the bucket loses its prime and sinks or impurities in the
system may prevent the valve from closing.

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IPCL NC
TRAINING MODULE

Module No.
IPCLDSMEC107

Fig: Inverted Bucket Steam Trap

b. Float & thermostatic steam trap: In contrast to the inverted bucket trap, both
types of thermostatic traps allow rapid purging of air at startup. The inverted bucket trap
relies on fluid density differences to actuate its valve. Therefore, it cannot distinguish
between air and steam and must purge air (and some steam) through a small hole.

A thermostatic trap, on the other hand, relies on temperature differences to actuate its
valve. Until warmed by steam, its valve will remain wide open, allowing the air to easily
leave. After the trap warms up, its valve will close, and no continuous loss of steam
through a purge hole occurs. Recognition of this deficiency with inverted bucket traps or
other simple mechanical traps led to the development of float and thermostatic traps.

The level of condensate inside the trap drives the condensate release valve, while the
temperature of the trap drives an air release valve. A float and thermostatic trap, shown
here (at left), has a float that controls the condensate valve and a thermostatic element.
When condensate enters the trap, the float raises allowing condensate to exit. The

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IPCL NC
TRAINING MODULE

Module No.
IPCLDSMEC107

thermostatic element opens only if there is a temperature drop around the element
caused by air or other non-condensable gases.

c. Disc steam trap:

Thermodynamic trap valves are driven by differences in the pressure applied by steam
and condensate, with the presence of steam or condensate within the trap being affected
by the design of the trap and its impact on local flow velocity and pressure. Disc, piston,
and lever designs are three types of thermodynamic traps with similar operating principles
disc trap is used.

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IPCL NC
TRAINING MODULE

Module No.
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When sub-cooled condensate enters the trap, the increase in pressure lifts the disc off its
valve seat and allows the condensate to flow into the chamber and out of the trap. The
narrow inlet port results in a localized increase in velocity and decrease in pressure as
the condensate flows through the trap, following the first law of thermodynamics and the
Bernoulli equation. As the condensate entering the trap increases in temperature, it will
eventually flash to steam because of the localized pressure drop just described. This
increases the velocity and decreases the pressure even further, causing the disc to snap
close against the seating surface. The moderate pressure of the flash steam on top of the
disc acts on the entire disc surface, creating a greater force than the higher-pressure
steam and condensate at the inlet, which acts on a much smaller portion on the opposite
side of the disc. Eventually, the disc chamber will cool, the flash steam will condense, and
inlet condensate will again have adequate pressure to lift the disc and repeat the cycle.

d. Thermostatic steam traps:

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Mechanical

Module No.
IPCLDSMEC107

As the name implies, the operation of a thermostatic steam trap is driven by the
difference in temperature between steam and sub-cooled condensate. Valve actuation is
achieved via expansion and contraction of a bimetallic element or a liquid-filled bellows.
Bimetallic and bellows thermostatic traps are shown here. Although both types of
thermostatic traps close when exposure to steam expands the bimetallic element or
bellows, there are important differences in design and operating characteristics.
Upstream pressure works to open the valve in a bimetallic trap, while expansion of the
bimetallic element works in the opposite direction. Note that changes in the downstream
pressure

will

affect

the

temperature

at

which

the

valve

opens

or

closes.

In addition, the nonlinear relationship between steam pressure and temperature requires
careful design of the bimetallic element for proper response at different operating
pressures. Upstream and downstream pressures have the opposite affect in a bellows
trap; an increase in upstream pressure tends to close the valve and vice versa. While
higher temperatures still work to close the valve, the relationship between temperature
and bellows expansion can be made to vary significantly by changing the fluid inside the
bellows. Using water within the bellows results in nearly identical expansion as steam
temperature and pressure increase, because pressure inside and outside the bellows is
nearly balanced.

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IPCL NC
TRAINING MODULE

Module No.
IPCLDSMEC107

e. Fixed orifice steam trap:

Another type of steam trap is the fixed orifice steam trap. Fixed orifice traps contain a set
orifice in the trap body and continually discharge condensate. They are said to be selfregulating. As the rate of condensation decreases, the condensate temperature will
increase, causing a throttling in the orifice and reducing capacity due to steam flashing on
the downstream side. An increased load will decrease flashing and the orifice capacity
will become greater.

Orifice steam traps function best in situations with relatively constant steam loads. In

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IPCL NC
TRAINING MODULE

Module No.
IPCLDSMEC107

situations where steam loads vary, the orifice trap is either allowing steam to escape or
condensate to back up into the system. Varying loads, such as those found in most steam
heating systems, are usually not good candidates for orifice steam traps. Before an orifice
trap is specified, a careful analysis of appropriateness is recommended.

04. Importance of Traps:

Steam is used both for process applications and to build heating spaces. Rising energy
costs make steam an expensive utility...too expensive to waste. Even if steam is a byproduct of what you make, conserving it can add dramatically to the bottom line.
A steam system can be a complex collection of pipes, valves and steam traps carrying
and regulating steam to countless areas within your facility. Traps are like stop signs at

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CATEGORY:

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IPCL NC
TRAINING MODULE

Module No.
IPCLDSMEC107

the end of the route. They keep the steam from blowing off to atmosphere, and purge it of
impurities that can make your system inefficient or cause damage.
Steam is hotter and lighter than water so it travels through the steam much faster. Water
or condensate forms in the pipe work and settles to the bottom. It tends to be pulled along
by the high velocity steam. If too much condensate collects in the pipe it can actually form
little waves. If the waves become large enough to touch the top of the pipe they cause a
momentary blockage. The force of steam behind the wave is still being forced through the
pipe. It will push the water forward with the force and velocity of a bullet. This
phenomenon is commonly referred to as water hammer. Its effects can be catastrophic to
pipe elbows, valves and even steam traps.
Removing condensate and air as soon as they form creates a more efficient transfer of
thermal energy throughout the steam system. More efficient is a synonym for more
profitable.

05. Failed Traps -- Cause and Effect:

Steam traps can fall open, fail shut, or in the case of mechanical thermodynamic and disk
styles they can continuously flutter between open and shut. When a trap fails open it is
often referred to as "blow-by". When a trap is blowing-by, it means that, in addition to
condensate and non-condensate gases, some steam is also being vented. If steam is a
commodity and it's being wasted by a faulty trap, then your facility is not running as
efficiently as it could. A typical failure rate for failed open steam traps is 15-30% of a
facility's steam trap population. A facility with 1000 steam traps may have 150 to 300
failed open traps. This translates into a loss of steam.
A trap that is failed open can also create downstream problems for other traps within the
system. Steam traps, aside from purging unwanted condensate, also act as flow
regulators for the entire system. Like the locks in a canal, if one trap is failed open, the

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CATEGORY:

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IPCL NC
TRAINING MODULE

Module No.
IPCLDSMEC107

other traps in the system are subject to increased pressures. Certain traps may not
perform well with the added pressure and will have a shorter lifespan.
Traps that fail shut, due to corrosion from lime or other minerals, will allow condensate to
build-up in the system. The accumulation will follow the piping to low spots where enough
water will cause damaging water hammer. In colder climates there is also the threat of the
water freezing and bursting the pipe.

06. Trap failure:

Excluding design problems, two of the most common causes of trap failure are over
sizing and dirt.

Over sizing causes traps to work too hard. In some cases, this can result in
blowing of live steam. As an example, an inverted bucket trap can lose its prime
due to an abrupt change in pressure. This will cause the bucket to sink, forcing the
valve open.

Dirt is always being created in a steam system. Excessive build-up can cause
plugging or prevent a valve from closing. Dirt is generally produced from pipe scale
or from over-treating of chemicals in a boiler.

07. Testing Methods for Steam Traps:

With a fuller understanding of steam traps basics maintenance personnel are better
equipped to inspect traps throughout the facility using common methods.

1. VISUAL INSPECTION:
In a visual inspection the operator will check that the discharge valve is functioning.
This requires venting live steam to atmosphere and can pose safety issues. Because
it opens the closed portion of the system it is not a 100% reliable test. Visual

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CATEGORY:

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IPCL NC
TRAINING MODULE

Module No.
IPCLDSMEC107

inspection is important because a trained operator can look for potential problems in
engineering and design that can lead to trap failures.

2. THERMAL INSPECTION :
Another method for routine testing of traps is with contact or non-contact temperature
checks. Upstream and downstream temperature checks can reveal failed open traps.
But variables such as back pressure in the system can make temperature checks less
accurate. Thermal inspections are useful for identifying heat loss, overloads and
pressure build-ups.

3. ULTRASONIC INSPECTION :
Using both visual and thermal methods it is easy to spot traps that have completely
failed. But an ongoing predictive maintenance program involves looking for problems
before they become catastrophic so as to minimize system damage (water hammer),
minimize inefficiency (loss of heat transfer), and reduce the residual decline in product
quality.
Ultrasonic testing gives the inspector an "inside view" of the trap. A quality detector
translates high frequency ultrasonic noise to audible frequencies. These frequencies
are localized to the source of contact so the inspector will not be disturbed by ambient
parasite noise downstream. More sophisticated ultrasonic detectors are equipped with
digital measuring capabilities, internal data loggers that track all your steam system's
assets on board, and a direct PC interface for downloading collected data to an
organized filing system. Multi functional inspection tools combine both ultrasonic and
temperature measuring capabilities in one versatile device.
Inspectors using ultrasonic inspection methods as part of a regular predictive
maintenance schedule can accurately locate steam traps with full or partial fault
conditions.

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Mechanical

Module No.
IPCLDSMEC107

08. APPLICATION:
There are three primary categories of steam traps:

Mechanical

Thermostatic

Thermodynamic

Popular traps in these categories include the inverted bucket, the float, the
thermostatic and the thermodynamic disc types.
Which one to use depends on the application. The steam traps prime missions is to
remove condensate and air preventing the escape of live steam from the distribution
system.
The steam trap must adapt to the application. A disc thermodynamic steam trap
should never be used together with a modulating heat exchanger. Nor is it necessary
to overkill using floating ball steam traps for draining steam pipes.
The table below can be used as a short guide for the selection of steam traps:

Type of Steam
Trap

No or
little load

Float &
Thermostatic

No
Action

Inverted Bucket

Small
Dribble

Bimetal
Thermostatic

No
Action

Impulse

Small
Dribble

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Operation
Normal
Light Load
Load
Usually
Usually
continuous. continuous.
May cycle. May cycle.
May
Intermittent
dribble
Usually
May blast
Dribble
at high
Action
pressures
Usually
Usually
continuous continuous
with blast with blast

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Heavy
Load
Continuous

Normal
Failure
Mode
Closed
A.V.
open

Continuous Variable
Continuous Open

Continuous Open

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at high
loads

Module No.
IPCLDSMEC107

at high
loads

Disc
No
Intermittent Intermittent Continuous Open
Thermodynamic Action

09. Finding malfunctioning traps:

As with any mechanical device, a steam trap can malfunction. "If the steam trap fails
closed," the device that should be draining will flood and the heat transfer process will
stop, and whatever product is being produced ... will no longer be up to the required
quality standards. If the trap fails open, there will be a waste of energy, steam will not be
completely consumed or condensed in the exchanger and steam will blow through."
Banyacski notes that a plume of steam escaping from the condensate receiver or from
some part of the condensate return system signals such a condition.
He adds that it is difficult to determine whether a steam trap has failed just partially open,
indicating a slow leak and a developing failure. "Such a ... failure could persist for quite
some time without any outward sign. Therefore, a maintenance person should make
periodic surveys of the installed base of steam traps. Banyacski emphasizes that steam
blowing through a trap indicates that the trap needs to be repaired or replaced.

10. Trap inspection methods:

Oftentimes, a misapplied steam trap (too small, the wrong design) will malfunction.
Ultrasonic, infrared temperature measurements and visual inspection have proven useful
to maintenance personnel in checking for malfunctioning steam traps. Of the three,
ultrasound is the most reliable. Visual inspection requires an inspector to let a steam trap

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TRAINING MODULE

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Module No.
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discharge to atmosphere. However, doing that changes the parameters of the closed
system and, therefore, can be unreliable.
There are enough variables in the system - backpressure, for example - so that
temperature is not the most reliable indicator either. Portable infrared thermometers
provide close estimations of pressures on valves, traps, and coil heaters. These devices
are also useful for spotting conditions such as heat loss, the need for insulation,
overheating, overloads, and cooling failures. Thus, an infrared thermometer be used
along with ultrasound.
Traps that have failed completely open are easy to detect, but the object is to find failing
traps before they fail completely. Ultrasonic testing can do that. In essence, using an
ultrasonic instrument is like putting the inspector inside the steam trap and piping system
allowing him to detect a leaking steam trap.

Ultrasonic detectors translate ultrasonic

emissions ... into sounds the human ear can hear.

Technicians who use ultrasonic detectors on a daily basis can achieve accuracy that
exceeds 98%.

And regarding frequency of inspections, process components of

equipment, as well as drip mainstream traps should be checked twice a year.

Heating steam traps (in facilities that use steam for space heating) should be tested
annually and instituting a reporting system to keep tabs on the location, type, size,
capacity and condition of all traps in a steam system is imperative.

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