Steam Management

Spirax Sarco Experience

 Presentation Content

Steam System Survey Steam Trap Survey

Steam System Survey
 Objective of Steam Survey

“To improve steam plants efficiency, identify area for improvement and reduce
energy wastage.”

This can be achieved by :

Identify and proposed area of improvement based on best practice guide

- Selection and sizing of steam traps
- installation and operation
- condensate/flash steam recovery

: also called “Steam System Survey”.

 Steam In Palm Oil Mill

Boiler Area
Engine Room
Steriliser
Threshing/Crude Oil
Oil Room
Tank Farm
 Palm Oil Mill Existing Practise
Boiler : Manual Blowdown
Absence of flowmeter
Overloading

Engine Room : Make up valve not working

BPR Drainage
Leakage & Setting of SV

Steriliser : Terminal end drainage missing

Oil Room /Kernel Station : Branch Line tapping/

Steam Trap Group Trapping

Tank Farm : Coil blockage

Terminal End drainage

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 Best Practise Steam Distribution

From Boiler : Distribution System

Steam Trap Station
Pressure Reduction Station
Selection of steam ancillaries : Steam Trap
To recommend possible steam trap systems improvement
 STEAM DISTRIBUTION
Branch line connections

Steam off-take
BRANCH LINE TAPPING
TERMINAL END CONDENSATE REMOVAL
CONDENSATE REMOVAL

STABBING
 CONDENSATE REMOVAL
Drain points
The amount of condensate formed in a large steam main under start-up conditions is
sufficient to require the provision of drain points at intervals of
30 m to 50 m, as well as natural low points such as at the bottom of rising pipework.
In normal operation, steam may flow along the main at speeds of up to
145 km/h, dragging condensate along with it. Figure 10.3.2 shows a 15 mm drain pipe
connected directly to the bottom of a main.

Fig. 10.3.2 Trap pocket too small

 Piping layout
Drain points
Although the 15 mm pipe has sufficient capacity, it is unlikely to capture much of the
condensate moving along the main at high speed. This arrangement will be ineffective.

A more reliable solution for the removal of condensate is shown in Figure 10.3.3. The
trap line should be at least 25 to 30 mm from the bottom of the pocket for steam mains
up to 100 mm, and at least 50 mm for larger mains. This allows a space below for any
dirt and scale to settle.
The bottom of the pocket may be fitted with a removable flange or blowdown
valve for cleaning purposes.

Fig. 10.3.3 Trap pocket properly sized

 DRAIN POCKET SIZING.
Drain points
Recommended drain pocket dimensions are shown in Table 10.3.1 and in
Figure 10.3.4.
 STEAM DISTRIBUTION

Distribution Line
Waterhammer

Fig. 10.3.6 Potential sources of waterhammer

WATERHAMMER
STEAM LEAKAGES
 Steam leaks
Steam leaking from pipework is often ignored. Leaks can be costly in both
the economic and environmental sense and therefore need prompt
attention to ensure the steam system is working at its optimum efficiency
with a minimum impact on the environment.

Steam leakage rate through holes

 Best Practise Steam Distribution

Pressure Reduction Station

Recommendations
Steam Trap Survey
STEAM TRAP TERMINOLOGY

Passing
Steam trap unit has failed and it is passing live steam, acting as a normally –open
valve. Probably due to wear and tear valve head and seat.

Blocked
Steam trap unit has failed to discharge condensate, acting as a normally – closed
valve. Probably due to blocking flow path.
Ok
The steam trap unit is working fine, intelligently responding to the condensate
from it back steam from escape and remove condensate.
Not in use or Isolated
The trap at the time of survey should be investigated further to determine the
exact reason why the trap is not in operation. These if left unattended will lead to
the accumulation of condensate and eventually could cause reduced efficiency of
plant, pipe erosion and fittings due to wet steam, longer plant warm-up times and
even waterhammer.
Finding & Recommendations
1. Failed Open traps -
Causes – wear & tear, erosion
Recommendation - To be replaced as soon as possible to
avoid greater losses.

2. Failed Closed traps

Causes – accumulated dirt/foreign particles
Recommend - To do physical cleaning & pipe flushing or
replace pipe

3. Not in Use – upstream/ downstream valve has been isolated

- trap has been disconnected
- application in standby mode
Best Practice : Steam Trap
STEAM TRAP INCORRECTLY INSTALLED

BALL FLOAT STEAM TRAP INSTALLED WRONGLY

CAUSING IT TO FAIL.
STEAM TRAP INCORRECTLY INSTALLED

The Ball Float move up and

down according to condensate
Level.

CORRECT INSTALLATION

Upside down Installation will

cause the ball float to rise
when condensate increase thus
closing the valves.

INCORRECT INSTALLATION
GROUP TRAPPING
STEAM TRAP SIZING

OVERSIZED STEAM TRAPS

Amount of steam condensed to warm-up 50 m of schedule 40 pipe (kg)
STEAM TRAP SELECTION

WRONG TYPE STEAM TRAP USED