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Pick Up Steam With Energy Savings for Steam Trap Repairs and Replacement

Scott Stroup, President, Airometrix Mfg., Inc. January 30, 2014

Practical Items

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Quiz Questions: What do you already know about Steam Traps?

1. True or False: All failed steam traps lose energy.

2. In steam systems that have not been maintained for 3 to 5 years, what % of installed steam traps may have failed?

3. True or False: Thermodynamic Disc Traps are a good choice in almost any application.

Where are the Largest Steam Opportunities?

• Boiler controls

• Insulation

• Stack economizers (Condensing)

• Blowdown heat recovery & control

• Flash heat recovery

• Steam leaks

• Condensate return

• Trap failure

Why Do We Want Condensate Back?

• Energy Recovery

• Chemical Recovery

• Water Recovery

Why Do We Install Traps?

• Water is less efficient heat transfer medium than steam

• Safety - avoid water hammer, erosion, corrosion

• Process reliability

What is Water Hammer?

• Slugs of water form in the pipe and travel at the speed of the steam

Distribution Best Practices

• Steam take offs should be from top of pipe

• Proper pipe insulation thickness

• Proper steam trap selection

• Elimination/reduction of leaks

• Proper strainer placement

Distribution Best Practices

Distribution Best Practices

• Trap every 200-250’ of straight run

• Pocket before trap or water will jump the drain line

Traps Fail!

• Fail Open – Steam blowing by – energy waste

• Fail Closed – No flow – safety/reliability concerns – no energy loss

Why is Condensate Removal Important?

• Product spoilage

• Extended process times

• Water hammer

• Corrosion

• Erosion

• Wasted energy

What are the Types of Traps

• Mechanical

• Float

• Inverted Bucket

• Thermodynamic

• Disc

• Thermostatic

• Bimetallic

• Balanced Pressure (capsule)

• Fixed Orifice

Mechanical - Float Type Traps

• Condensate raises the float - opens valve

• Valve closes when water level drops

• Advantages: • Water hammer resistant

• High capacity for size

• Excellent air venting

Inverted Bucket Type Trap

• Water seal used to prevent steam bypass

• Weight of bucket opens trap

• Steam creates buoyancy to close the valve

• Bleed hole allows steam to vent from bucket

Free Float Type

• Float lifts

• Thermostatic valve allows air to pass

• Capacity limitations

• Roundness of the ball is critical and damage can cause live steam leakage

• Continuous Discharge

ThermoDynamic – Disc Traps

• Pressure pushes disc up

• Flash steam causes disc to close

• Condensing flash steam opens disc

• Most common trap

• One moving part – rugged

• Energy efficient

Thermostatic -Bimetallic

• Starts with the metallic element relaxed with valve open

• When heated valve closes

• Automatically discharges air and incondensables

• Sub-cools condensate to save energy

• Resistant to water hammer and freezing

• Reduces the amount of flash steam

• Used in high pressure applications

Thermostatic - Balanced Pressure Traps

• Capsule with deionized water and alcohol to control discharge

• Easy maintenance

• Resistant to superheat and water hammer

• Automatically discharges air and incondensables

Fixed Orifice

• Sized for each application

• Susceptible to blockage by dirt

• High maintenance costs

• Compromise – Best with constant run steady flow applications

Where to Apply Different Traps

All Float Traps

• All process heat exchange applications

• Process relies on rapid condensate removal for maximum heat output

• Float thermostatic traps unaffected by load variation or pressure

• First choice for steam separators

Where to Apply Different Traps

Inverted bucket traps

• Locations with high potential for water hammer – i.e. large coils in bulk storage

• Infrequent startup

• Does not handle air on startup well

Where to Apply Different Traps

Thermodynamic Traps:

• Mains

• Tracer lines

• Long line runs

• Where temperature control is critical

Where to Apply Different Traps

Bimetallic Trap

• High Pressure superheated applications

• Turbines or main lines

• Handles high temperatures

Where to Apply Different Traps

Balanced Pressure Thermostatic Traps

• Where temperature variation is acceptable

• Some sub-cooling will occur, saving energy

Trap Maintenance and Performance

• Ultrasonics

• Infrared

• Trap monitoring systems

• Universal connectors – quick changes

Trap Failure Rates

• Vary by facility and application

• Typical failure rate is 3-8% per year

• Energy savings depend on failure mode (open or closed)

• Typical payback on trap replacement 1-3 years

• Reliability may be worth more than lost energy

Presented by:

Scott Stroup, President

Airometrix

(303) 333-7037

The Ameren Illinois ActOnEnergy® Business Program

Over $40 million in

energy-efficient cash incentives

ActOnEnergy® Incentives Available

STANDARD

• Lighting

• HVAC/Water Heaters

• VFDs

• Steam Traps

• Leak Survey & Repair

• Specialty Equipment

CUSTOM

• Custom

• New Construction

• Feasibility Study

RETRO COMMISSIONING

(RCx)

• Compressed Air

• Healthcare

• Commercial Buildings

Cash incentives are available for a variety of process steam projects, including: •Steam trap surveys •Steam trap repair or replacement

Process Steam & Steam Trap Incentives

For steam traps that are greater than or equal to 250 psig the unit incentive is $500/trap

The benefits to PMP Fermentation include:

• More than $60,000 in annual savings

• $4,800 in incentives from ActOnEnergy

• More than 7,000 therms saved every year

Ameren Illinois ActOnEnergy

Energy

Advisors

Find a Contractor Click here to find a

Contractor who is an ActOnEnergy Program Ally.

• Website: ActOnEnergy.com/Business

• Phone: 1.866.800.0747

• Fax: 1.309.677.7950

• Email: ActOnEnergyBusiness@Ameren.com

Resources

Quiz Questions:

What did you learn about Steam Traps?

1. True or False: All failed steam traps lose energy.

2. In steam systems that have not been maintained for 3 to 5 years, what % of installed steam traps may have failed?

3. True or False: Thermodynamic Disc Traps are a good choice in almost any application.

v

Questions?