4

(Steam Trap Management)

29 20-30%
26% 14%
300,000 /
(TM5)
(TM5)

1)
2)
3)
4)

4-1

2
1)
() 4.1
2) ()
4.1
0 bar(G) (ATMOSPHERIC PRESSURE :)
SATURATED
STEAM

100 C

WATER

hf

=419.06 KJ/kg

WET
STEAM

hfg

=2257.01 KJ/kg

SUPERHEATED
STEAM

hg =2676.07 KJ/kg

4.1

4-2

() 4.2

WATER

WET STEAM

DRY STEAM

SUPERHEATED

4.2


4.3

CLEAN

STERILE

CLEAN
NOT TOXIC

4.3

4-3

STEAM SYSTEM OVERVIEW

HEAT TRANSFER

DISTRIBUTION SYSTEM
MAIN LINE

WATER

EQUIPMENT

30 C
Header

80oC

PRESSURE
REDUCING
STATION

BOILER

WATER
TANK

FLASH

STEAM TRAP

STEAM

CONDENSATE
RECOVERY
90 C

PUMP

FLASH
VESSEL

10 3

4.4
4.4

(**)

2
1) (Initial load)
4.5
2) (Running load)

**

4-4

STEAM DISTRIBUTION
Water Hammer

HEAT LOSS

WET STEAM
FROM BOILER

4.5

Energy Transfer
Jacketed Tank

Condensate forms
and is discharged

4.6
4.6

Steam trap
4-5

4.1 (Purpose)
(Steam trap)

(Steam trap)
1)
2)
3)
(Steam trap)
(Steam
Trap)

4.2 (Type and Function of Steam Trap)

(Steam Trap)

1.

Thermostatic steam trap

2.

Mechanical steam trap

1. Bimetallic
2.
Balance pressure
Bellow type
Capsule type
X- Element type
1.
()
1 .1
()
1.2
-
2.
2.1
2.2

4-6

3.
1. Disc

Air vent
Thermodynamic steam trap
Air vent

-

4.2.1 (Thermostatic Steam Trap)

2
(1) (Bimetallic) 4.7
(2) (Balance pressure) 3
(2.1) Bellow type
(2.2) Capsule type
(2.3) X- Element type

4-7

4.7

4.2.1.1 (Bimetallic)
-
4.8

4.8
4-8

(Bimetallic)
4.9

4.9 ( Bimetallic)

4.10

4.10

4-9

4.11

4.11

4-10

4.2.1.2 (Balance Pressure)

(Balance pressure) - +
4.12

4.12
4.12

6 10 20

4.13 : Bellow Type

4-11

4.14

4.15

4-12

( 7 8 4.15)

4.16 : Capsule Type

Diaphragm

4-13

4.17

Diaphragm
Diaphragm


Diaphragm
4 6 4.17

4-14

4.18 : X-Element Type

X-Element
X-Element

4.19
4-15

X-Element X-Element

X-Element X-Element
X-Element
4.19

4.20
X-Element
X-Element
- X-Element 7
8 4.20

4.2.2 (Mechanical Steam Trap)

()
() - 2

4-16

1)
1.1)
1.2)

2)
2.1)
2.2)

4.21
4.21

4.2.2.1 (Inverted Bucket Steam Trap)

Inverted bucket trap

()

(Steam trap) (Fulcrum)
Air vent 4.22
4-17

4.22 Inverted bucket

4.23 Buoyancy of the inverted bucket

( Relationship between the size of orifice and
working pressure) 4.23
FW
x L > PxA
Orifice Orifice

Orifice (Steam Trap)

4-18

4.24


( )
3
4

5
(Slow air vent) -

4-19

4.24

4.25

4.25

4-20

4.26

4.27
4-21

10
12 4.26

11 15

(Steam lock) 4.27

(1) ( Inverted Bucket Trap Form of Construction)

Bimetal

Pin (Air Hole)

Ball Bucket

4.28 : Inverted bucket (UFO Series)

4.28


Stainless steel Hard tungsten carbide Ball bucket
(Air vent) Pin Dumbell
Bimetal strip Ball bucket Air Vent

4-22

4.2.2.2 (Float-thermo Static Steam Trap)

( Float-thermostatic steam trap)
2
(1) (Lever float)
(2) (Free float)

(1)
Thermostatic
air vent

Float
()

4.29
4.29 (Steam trap)
(Steam trap)
Standing condensate level
Thermostatic air vent
(Steam trap) (Steam trap)
Thermostatic air vent
(Steam trap)


(Steam trap) Air vent

(Steam trap)

4-23

(Relationship between the Size of Orifice and Working Pressure)

(Orifice & pressure)
(Buoyancy)
(Fulcrum) 4.30

4.30
(Orifice) A
(Buoyancy) (P) (A),
FB x L > P x A

(L = Advantage of lever)

Buoyancy
Buoyancy 100 Orifice 1 Square unit
100
10 x 10 > 99 x 1
Orifice 0.5 Square units 200
10 x 10 > 199 x 0.5

Orifice Different pressure
4-24

Thermostatic
Air Vent
Float ()

Orifice

4.31 Free float steam trap

4.31

Stainless steel grade 316L Stainless steel grade 420L
Orifice P x A
Buoyant P x A

4-25

4.32 (Free float)

4.32
X-Element
Orifice

4.33
4-26

4.33
X-Element
Orifice

4.34
4.34
7
(Water seal) X-element

4-27

4.35
4.35

Orifice 10 11
Orifice

(Use on Superheated Steam)

3 Point seating Air vent
Superheated steam

(Effect of Back Pressure)

Back pressure

Back pressure

(Insulation)
(Steam trap)

4-28

4.2.3 (Thermodynamic Steam Trap)

2

4.2.3.1 (Thermodynamic Disc Steam Trap)

4.36 Body
Body 2

4.36 : Thermodynamic (Disc

4.37 Disc trap

( Air vent)
4-29

4.37

4.38

( )



4-30

6 15 4.39

4.39

(Superheated
steam) No load leak

4-31

(Effect of Back Pressure)

20 %
(Steam trap) (Chattering) 50%
(Steam trap) (Blowing) 4.40

4.40

(Insulation)
(Steam trap) (Natural cooling
Chamber) (Steam trap)

4-32

(Free float)

(Steam locking)
(Air
binding)

4-33

(Siphon)


(Steam
locking)
UFO

4-34

(Regulating valves)

(Back pressure)

4-35

4.3





(Steam trap)
(Steam trap) (Steam trap)

4.3.1

(Steam trap)


(Steam trap)
(Steam trap)

4.3.2 (Steam trap) 12

1)
(Steam trap)
(Steam
Trap)
2)
(Steam trap)



4-36

3)

4) (Steam trap)
(Steam trap)

(Steam trap)
5)

(TM5) TM5
6)

7)
(Steam trap)

8)


9)

10)

11)

12)

4-37

4.4 (Steam Trap)

(Steam trap) (Steam trap)
() 2
1)
2)

4.4.1 (Steam Trap)

1) (Steam trap)
2) (Steam trap)
3) (Steam trap)
4) (Steam trap)
5) (TM5) TLV

Testing Reliability
LISTENING

ULTRASONICS

47.2%

53.8%
TrapMan
SKILLED USERS

TrapMan
ALL USERS

97.8%

90.3%

4.41

4-38

4.4.2 (TM5)
(TM5) 2
1) ( TM5)
2) () ( TM5 -EX)

() ( )
15

4.4.3 (TM5)
TLV Japan
TLV ultrasonic
(TM5) 4.42
(TM5) Windows 95

(TM5) (Probe)
(Ultrasonic) (Data logging
function)

Test a Trap
Displays Trap
Number

Place Probe
On Trap Inlet.

Probe
measures:
TEMP
Ultrasonic
Sound

4.42 (TM5)
4-39

(TM5)
(TM5)
(TM5)
(TM5)
(TM5)

TrapMan Ultrasonics
Ultrasonic Sound level

$$$$$
$$$$
$$$
$$
$

Trap
A

Trap
B

Trap
C

STEAM
LOSS DATA

TRAPMAN MEMORY

4.43

4.4.4 (TM5)

TLV co.,ltd
(TM5)

(Steam Trap)

()

()

4-40

4
()

()

(Steam trap)

(Steam trap)
(TM5)

(TM5)

(TM5)
(Steam trap)

(Thermostatic trap)

(TM5)

(Steam trap)
(TM5)

(Steam trap)

4-41

4.5 (TM5)
4.5.1
4.5.2

3
5
5

4.5.3
TM5

4.5.4
(TM5)

Probe Test Positions

For mechanical, thermodynamic and thermostatic traps
Standard horizontal installation

Standard vertical installation

A - Standard measurement point.
(Highest accuracy).
B,C,D - Suitable measurement
Points (accuracy may be adversely
affected).
E&F - Incorrect measurement points.

4.44

4-42

4.5.5 (TM5)
1.
2.
3.
4.
5.
6.
7.
8.

9.
10.
11.

15 1
Transfer Computer
FUNC + 5
Steam trap 30 Steam trap
AREA NO. TRAP NO. ENTER
Probe Steam trap 15
( (TM5)
)
Condensate load factor
Condensate

10 90 %
Load status
10 %
90 %

2: MIN
3: MAX
1:? Or ENT
Enter
(Steam trap)
Transfer Computer

4.5.6 (TM5)

TrapMan

/ Open/New File
Add Area
Add Trap Number
Edit Data of
Trap Number
Unit Changing
[Report (Master Log, Fail
Trap)]
Graph
4.45
Export (Excel)
1

4-43

/ Open / New File

1. Shift + Double Click/Enter

2. Copy and Paste MasterE to Copy of MasterE

3. Change name Copy of MasterE to name of Job

2
3
2

Add Area / Add Trap Number

1. Right Click at My Steam Plant

2. Select New Area
3. Fill Name of Area
4. Right Click and Select New Trap
1

3
4

2
3

4-44

Add
Add Area / Add Trap Number
5. Select New
Trap and fill Data for each trap
6. For copy
data for new trapclick bottom near
trap number
7. Change
trap number and data
6

Edit Data of Trap Number

1. Right Click and Select Modify Trap

2 OR Double Click Trap to change
2. Edit your Data
2

4-45

Unit Changing
$ , baht
1. Setup Menu Bar
2. Select Units
3. Other baht , Save
1
2
3
6

Edit Data of Trap Number

1. Right Click 2 Double
Clicks Trap Number for Edit
2. Modify Trap
3. Edit Data
1

3
2

4-46

1. Menu Bar
2. New
3. Analysis
4.

3
4

Report (Master Log)

1. Reports Menu bar

2. Master Log
3. Area Filter
4. trap
5.

3
4

4-47

Report((Fail

Report
Fail traps)
Traps)

1. Menu bar
2. Fail Traps
3. Areas

10

Open Graph
1

1. Analysis Menu Bar

2. Open
3. file of graph
2
3

11

4-48

Export (to excel)

1. envelop icon
2. Format : Select Excel 5.0 (XLS)
3. OK
1

12

Change Information

You can change Information at master log for your Company

1. Select View from Menu Bar

2. Select Customer Info
3. Change for your Company
1

3
2

13

4-49

Download Data
: Transmit Data to Hardware (TM5)
1
2
3
4

1. Utilities & Communications

2. Select Upload Bar.
3. Press Start buttom.
TM5
Press DATA TRANS
4. Download.
5. Data Trans.
14

Upload Data
1

: Receive Data from Hardware (TM5)

1. Utilities & Communications
2. Upload Bar.
3. Start buttom.
2
TM5 DATA TRANS
3
4. Data Trans.
4

15

4-50

TrapManager

1) TM5
2) TM5 Computer
3) Com Port
16

Com Port
1
2

1. Utilities & Communications

2. select Setup
Com Port
TM5

TrapManager
17

HASP
HASP ?
4-51

4.6 (Maintenance)
(Steam trap)

(Steam trap)
(Steam trap)

(Steam trap)

(Steam trap) (Steam trap)

(Steam trap) 3
1) (Condensate)
2)
3)
(Steam trap)
(Steam trap)

4.6.1 4
1) (Blockage) (Steam trap)
Condensate 4.46

2) (Steam blowing)

4-52

3) (Steam leakage)
(Steam trap) 4.46
4) (Insufficient discharge) Condensate (
) Condensate

4.46
4.46
(Steam trap)
(Steam trap)
TM5

4.6.1.1 (Blockage)
(Steam trap)

4-53

4.47
4.47 (Steam trap)
(Steam trap)

Steam locking Air binding

(Steam trap)
Steam locking Air inding
Steam locking (Steam trap)
Blockage
Steam locking Air binding
Disease

(Blockage) Steam locking Air binding 2

(1)
(Steam trap)

(2) (Steam trap)

(Steam trap)
(Steam trap) Blockage
(Steam trap)
(2.1) (Blockage of screen)
4-54

(2.2) (Blockage of pipes, valve)

(Steam trap)
(2.3) Mechanical trap Blockage

(2.4) Balance pressure Blockage

(Superheated steam)

4.6.1.2 (Steam Blowing)

(Steam trap)


(Steam blowing) (Steam trap)

(Steam trap)
Valve Valve seat
4.48
Mechanical trap (Steam trap)
Condensate
Disc trap Disc 50% Steam blowing
Condensate Back pressure 20% Inlet
Thermostatic Condensate Bimetal

4.48

4-55

4.6.1.3 (Steam Leakage)

Blowing
(Steam leakage) 3
1) (Steam trap) Condensate
2) (Steam trap) Condensate
3) (Steam trap)


)
(Steam trap)

) (Steam trap) Condensate (Steam trap)

(Steam trap) (Steam trap)
) (Steam trap)

4.6.1.4 Insufficient Discharge

Insufficient Discharge (Steam trap) Condensate
Load
(1) (Steam trap) (Steam locking)
(2) (Abnormal decrease in pressure differential)
(3) Strainer (Partial blockage of strainer screen)
(4) (Partial blockage of orifice)
(5) (Dirt accumulation in the inlet or outlet
pipe)

4.6.2
4


(Steam trap)

(Steam trap)

4-56

4.6.3
1.
2.
3.
4.

4
(Steam trap)
(Steam trap)

4.1 (Steam trap)
4.2 (Steam trap) Load
4.3 Inlet (Steam trap)
4.4 (Steam trap)
4.5 (Steam trap)
4.6 By pass
4.7 Blow down (Steam trap)
4.8

4.9 Back pressure Return line

4.10 Condensate


1)
2) (Steam trap) Start up
3)
4) Water hammer

4.6.4
(Steam trap)
Mechanical
(Steam trap) Steam Locking 4.49

(1) Steam locking

(2) Inlet pipe
(3) By pass Inlet (Steam trap)
Steam locked

4-57

4.49 Steam leaking

(Steam trap) Condensate
(Steam trap) Condensate
Inlet Blocked Condensate Drain plug Condensate
Drain plug Screen (Steam trap)

Condensate Drain plug Valve
(1)
(2) Orifice
(3) (Steam trap)

4.6.5 Steam Blowing

Blowing
1. (Steam trap)
Blow steam
2. Disc trap Back pressure 20%
Water hammer
3.
Blowing Valve

4-58

4.6.6 Steam Leaking

Condensate 2

1) (Steam trap) Leaking

1.1 (Steam trap type)

1.2 (Condensate loads)
Leak Load Disc trap Leak Load
(Steam trap) Mechanical Load Leak

2) (Steam trap) ()
2.1 Valve Valve seat
2.2 Valve Valve seat
2.3 Valve Valve seat

4.6.7 Insufficient Discharge

1)
1.1) (Steam trap)
1.2) (Steam trap)

2)
2.1) Steam locking
2.2) Back pressure

3)
3.1) Screen Orifice Inlet pipe & Outlet pipe

4-59

4.6.8 (Steam Trap)

2
1.
2.

4.7 (Activities)
4.7.1 (Exercise)
1 (Steam trap)
2 3
2.1 (Mechanical steam trap)
2.2 (Thermostatic steam trap)
2.3 (Thermodynamic steam trap)

3 (Back pressure)
4 (Water hammer)
5
5.1 (Free Floatthermostatic steam trap)
5.2 (Inverted Ball - bucket steam trap)
5.3 (Thermostatic steam trap)

4-60

4.7.2 (Solution of Exercise)

1

Condensate

2.1 (Mechanical steam trap)

Condensate
Condensate

2.2 (Thermostatic steam trap)

Condensate Condensate
Condensate
Condensate

2.3 (Thermodynamic steam trap)

Condensate Condensate

(Back pressure) Condensate

Condensate
Condensate
Condensate

4-61

Condensate
Condensate
Condensate

Condensate

5.1 (Free float Thermostatic steam trap)

(Stream
lock)
5.2 (Inverted ball - Bucket steam trap)
(Stream lock) (Cylinder dryers)

5.3 (Thermostatic steam trap)

4-62

4.7.3 TRAPMAN
(TM5)

TrapMan

/ Open/New File
Add Area
Add Trap Number
Edit Data of
Trap Number
Unit Changing
[Report (Master Log, Fail
Trap)]
Graph
Export (Excel)

4.45

1

/ Open / New File

1. Shift + Double Click/Enter

2. Copy and Paste MasterE to Copy of MasterE

3. Change name Copy of MasterE to name of Job

2
3
2

4-63

Add Area / Add Trap Number

1. Right Click at My Steam Plant

2. Select New Area
3. Fill Name of Area
4. Right Click and Select New Trap
1

3
4

2
3

Add
Add Area / Add Trap Number
5. Select New
Trap and fill Data for each trap
6. For copy
data for new trapclick bottom near
trap number
7. Change
trap number and data
6

4-64

Edit Data of Trap Number

1. Right Click and Select Modify Trap

2 OR Double Click Trap to change
2. Edit your Data
2

Unit Changing
$ , baht
1. Setup Menu Bar
2. Select Units
3. Other baht , Save
1
2
3
6

4-65

Edit Data of Trap Number

1. Right Click 2 Double
Clicks Trap Number for Edit
2. Modify Trap
3. Edit Data
1

3
2

1. Menu Bar
2. New
3. Analysis
4.

3
4

4-66

Report (Master Log)

1. Reports Menu bar

2. Master Log
3. Area Filter
4. trap
5.

3
4

Report

Report
(Fail(Fail
Trapstraps)
)

1. Menu bar
2. Fail Traps
3. Areas

10

4-67

Open Graph
1

1. Analysis Menu Bar

2. Open
3. file of graph
2
3

11

Export (to excel)

1. envelop icon
2. Format : Select Excel 5.0 (XLS)
3. OK
1

12

4-68

Change Information

You can change Information at master log for your Company

1. Select View from Menu Bar

2. Select Customer Info
3. Change for your Company
1

3
2

13

4-69

Upload Data
1

: Receive Data from Hardware (TM5)

1. Utilities & Communications
2. Upload Bar.
3. Start buttom.
2
TM5 DATA TRANS
3
4. Data Trans.
4

15

TrapManager

1) TM5
2) TM5 Computer
3) Com Port
16

4-70

Com Port
1
2

1. Utilities & Communications

2. select Setup
Com Port
TM5

17

TrapManager

HASP
HASP ?

18

4-71

4.7.4 Trapman

Insufficient discharge

1)
1.1) (Steam trap)
1.2) (Steam trap)
2)
2.1) Steam locking
2.2) Back pressure
3)
3.1) Screen Orifice Inlet pipe & Outlet pipe

Spec (Steam trap) 2

1)
2)

4-72