Proper steam trap sizing is a critical factor in obtaining efficient and reliable steam trap operation. Incorrect steam trap sizing can negate proper trap design, installation, and can cause condensate backup, steam loss or both.

 Steam trap sizing is sometimes mistaken for selection of the steam trap connection size. Rather it is the proper sizing of the internal discharge orifice. (For low pressure steam heating systems, manufacturers produce steam traps with connection sizes that relate directly to capacity, orifice size). However, an industrial steam trap must be sized by selecting the proper discharge orifice. A two-inch steam trap can have the same condensate capacity as a steam trap with a half-inch connection. Once the condensate capacity is determined and the proper orifice size is calculated, the steam trap connection size can then be determined to meet the installation requirements.

Read the full Best Practice…..

http://www.plantsupport.com/download/Best%20Practices_No.25R2.pdf

Great software tool from the DOE on pumping applications and it is free……

The Pumping System Assessment Tool (PSAT) is a free online software tool to help industrial users assess the efficiency of pumping system operations. PSAT uses achievable pump performance data from Hydraulic Institute standards and motor performance data from the MotorMaster+ database to calculate potential energy and associated cost savings. The tool also enables users to save and retrieve log files, default values, and system curves for sharing analyses with other users.

http://www1.eere.energy.gov/industry/bestpractices/software_psat.html

Flash Steam is a consistent occurrence in a steam system. Whenever condensate is being released from a higher pressure steam line to a lower pressure it occurs. For example, a steam line operating at 100 psig will have a saturation temperature of 338oF. When the condensate that is formed in this steam line is discharged to the atmosphere, the condensate temperature at atmospheric conditions can not be more than 212oF. This change in energy must be converted and that is accomplished by flashing some of the condensate into steam. Keep in mind that when the condensate is flashed back into steam, the steam takes up a much larger volume and this volume needs to be accounted for when sizing condensate return lines. The amount of flash steam that is going to be produced can be calculated and should be done when designing a condensate return line, however utilizing a Flash Steam Chart can also provide a quick reference tool to help calculate the amount of flash steam that will occur. When designing condensate return lines for condensate/flash steam flow the line velocity should not exceed 4500 feet per minute. Velocities above this rate can cause water hammer issues in your return line.

For additional information of Flash Steam and Condensate Return lines refer to the following Best Practices from Swagelok Energy (www.swagelokenergy.com):

Swagelok Energy Best Practices No.7 – Flash Steam
Swagelok Energy Best Practices No 14 – Condensate Return

Great web site for past and future energy cost.  Pricing is provided on natural gas,  electricity,  coal and even information on emissions.

http://tonto.eia.doe.gov/cfapps/STEO_TableBuilder/index.cfm

Updated Annual Energy Outlook 2009 Reference Case Service Report, April 2009

The Annual Energy Outlook 2009 (AEO2009) reference case was updated to reflect the provisions of the American Recovery and Reinvestment Act (ARRA) that were enacted in mid-February 2009.  The reference case in the recently published AEO2009, which reflected laws and regulations in effect as of November 2008, does not include ARRA. The need to develop an updated reference case following the passage of ARRA also provided the Energy Information Administration (EIA) with an opportunity to update the macroeconomic outlook for the United States and global economies, which has been changing at an unusually rapid rate in recent months. Therefore, the difference between the recently published AEO2009 reference case and the updated reference case incorporating both ARRA and the updated economic forecast reflects more than the energy-related provisions in ARRA alone. Although future analyses will focus on the difference between the updated reference case and cases using that as a baseline and incorporating proposed changes in laws and regulations, users of EIA’s projections may want to understand the relative roles of ARRA and the change in the macroeconomic outlook in driving the difference between the updated reference case and the one presented in AEO2009.

http://www.eia.doe.gov/oiaf/aeo/index.html

It is helpful to remind ourselves the substantial benefits of insulating steam piping.  Huge amounts of energy is put into producing steam and yet as we transport it from point A to point B we often allow large energy losses to radiate freely into the ambient air.  Heat energy as we know moves from a higher temperature to a lower temperature and the rate of this transfer is proportional to the temperature differential and the surface area of the pipe (other factors do impact the losses such as wind speed, surface emittance, and thermal conductivity of the pipe material). 

For example 100 psi steam is 338 F and if the ambient temperature is 60F, that is a  278F incentive for the heat to radiate out of the piping.  Now if we use 3″ piping that is also lots of opportunity for the heat to escape.  So, for every foot of 3″ piping carrying 100 psi steam and exposed to 60F ambient temperature, 778 BTUs per hour are lost.  That is nearly 6.5 million BTUs or the equivalent of 21,000 lbs of steam per year lost for each foot of piping.

In a steam deaerator, steam serves as the scrubbing agent to reduce the partial pressures of the gases being removed.  The phenomenon of gas removal from water through the use of scrubbing in a deaerator can be accomplished in several different ways. 

With the scrubbing action occurring, the deaerator must vent the non-condensable gases into atmosphere.  Therefore, the only acceptable steam venting from a steam system operation is the Deaerator venting of non-condensable gases with a very small percentage of steam.  To accomplish this goal of venting non-condensable gases; the deaerator will vent a small percentage of steam.

With the high cost of steam today, the deaerator vent must be investigated to insure excessive venting of steam is not occurring.  Our Steam Group Members have found steam losses that have exceeded $ 100,000.00 a year cause unnecessary venting from the deaerator.

Read the full best practice @ http://www.plantsupport.com/download/PSE_BP_2.pdf

Too often the real reason for  steam trap failure is missed.  There are a number of things that can cause steam trap failure – one of them being corrosion material or other foreign material getting into the steam trap and affecting it’s operation.  When this occurs it can cause the steam trap to fail closed or fail open.  To help prevent this, a strainer with a 20 mesh or finer screen should be a part of all steam trap stations and blown down at least every six months.

All steam lines need to have adequate condensate removal from the steam line on a continuous bases. No matter how well the steam line is insulated; the heat energy will be transferred from steam into the atmosphere, and the steam in the steam line will change state (latent energy is released); thus condensate will form in the steam line. The condensate volume will depend on the steam line insulation, steam pressure, and steam line length. The condensate will flow with the steam at the bottom of the steam line in a swaying motion (not a straight line); thus the steam line “drip pocket must be large” (drip pocket is the name of the branch line extending down).

Read the Best Practices:  http://www.plantsupport.com/download/PSE_BP_1.pdf

We are looking from our readers recommendations and comments on steam valve insulation covers.  For outside installations.   Sizes 1/2″ to 14″

We have a large number of questions regarding this subject.

Thanks

Kelly Paffel

Technical Manager

What is the best type of steam seperator? And will it improve boiler effeciency?