Gauges, Sight Glasses and Vacuum Breakers Module 12.

SC-GCM-99 CM Issue 2 Copyright 2005 Spirax-Sarco Limited

Block 12 Pipeline Ancillaries

Module 12.6
Gauges, Sight Glasses and
Vacuum Breakers

The Steam and Condensate Loop

12.6.1

Block 12 Pipeline Ancillaries

Gauges, Sight Glasses and Vacuum Breakers Module 12.6

Gauges, Sight Glasses and

Vacuum Breakers
Gauges
Pressure gauges

Pressure gauges should be installed in at least the following situations:

o
o

Upstream of a pressure reducing valve - To monitor the integrity of the steam supply.
Downstream of a pressure reducing valve - To set and monitor the downstream pressure.
Variations in the downstream pressure can lead to reduced plant productivity and product
quality. Variations in the downstream pressure may also indicate problems with the pressure
reducing valve.
On blowdown vessels - A pressure gauge is used to check the vessel pressure during blowdown.
This improves safety, since a higher pressure than normal would give an early indication of
pipework blockage.
Flash steam vessels - To monitor the flash steam pressure.

The Bourdon tube pressure gauge is the most commonly used type in steam systems. It consists
of a coiled or C shaped tube that is sealed at one end, and open at the other. The open end
of the Bourdon tube is exposed to the process fluid, allowing it to flow into the tube. Any
increase in pressure causes elastic distortion of the tube, causing it to unwind. The resulting
displacement of the closed end of the tube is translated by a series of gears to an angular
displacement of the pointer.The pointer position is therefore proportional to the pressure applied
at the gauges pressure connector. Typically, the maximum deflection of the Bourdon tube
corresponds to a pointer angular displacement of 270.
The tube can be constructed out of a number of different materials, depending on the application;
generally, brass or bronze is used for higher pressures, whereas stainless steel is used for lower
pressures.

(a)

(b)

Fig. 12.6.1 C-shaped (a) and coiled (b) Bourdon tubes

Bourdon tube pressure gauges often have the option of being liquid filled. The area surrounding
the Bourdon tube is filled with a transparent liquid, normally glycerine. This protects the internal
mechanisms against damage from severe vibration and to keep out ambient corrosives and
condensation. This also damps the movement of the pointer making the gauge less susceptible
to small transient pressure fluctuations.
As the Bourdon tube may be damaged by high temperatures, it is common practice on steam systems
to install the gauge at the end of a syphon tube. The syphon tube is filled with water which transmits
the pressure of the working fluid to the Bourdon tube, enabling the gauge to be located some
distance from the actual point where the pressure is being measured. The two most common forms
of syphon tube are the U and ring types. The ring tube is used on horizontal pipelines where there
is sufficient space above the pipe, and the U type is used when mounting the gauge on a vertical
pipeline, or on horizontal pipelines where there is not sufficient space for a ring type siphon.
12.6.2

The Steam and Condensate Loop

Gauges, Sight Glasses and Vacuum Breakers Module 12.6

Block 12 Pipeline Ancillaries

Verticle pipe
Horizontal pipe
(b)

(a)
Fig. 12.6.2 U (a) and ring type (b) syphon tubes

The Bourdon type pressure gauge is not suitable for use on corrosive liquids or fluids containing
suspended solids alone, as these solids may damage the internal elements of the gauge. In such
cases, it is necessary to keep the process fluid separate from the Bourdon tube.
This is done by mounting a flexible diaphragm on the inlet to the gauge. The pressure element
of the gauge and the space behind the diaphragm form a completely sealed system, which is
evacuated and then filled with a suitable filling fluid; in the case of steam this is typically a type
of oil. The system pressure causes the diaphragm to deflect, and the pressure is transmitted
through the filling fluid to the Bourdon tube.
Diaphragm seals should also be used on clean steam applications where no dead space is
allowed.
In addition to the Bourdon tube pressure gauge, several other types of pressure gauge are
available which include; Diaphragm type pressure gauges, Piezoresistive pressure gauges and
Temperature gauges.

Diaphragm type pressure gauges

A metal diaphragm is clamped between two flanges, and is exposed to the pressure medium on
one side. Pressure exerted by the fluid causes elastic deflection of the diaphragm. The amount
of deflection is proportional to the pressure applied on the diaphragm and it causes the linear
displacement of a linkage rod attached to the internal side of the diaphragm. The movement of
the linkage rod is in turn translated to angular movement of the gauges pointer by a series of
gears. Thus, the pointer movement is proportional to the pressure exerted on the diaphragm.
The diaphragm also serves to isolate the fluid from the internals of the gauge; therefore, diaphragm
type pressure gauges are suitable for use on most fluid types.

Dial
Pointer mechanism
Pointer
Diaphragm capsule

Fig. 12.6.3 Schematic diagram of a diaphragm pressure gauge

The Steam and Condensate Loop

12.6.3

Block 12 Pipeline Ancillaries

Gauges, Sight Glasses and Vacuum Breakers Module 12.6

Piezoresistive pressure gauges

These pressure gauges consist of a diaphragm made from a ceramic substrate; piezoresistive
type strain gauges are bonded to the diaphragm and together with the necessary circuitry, they
are integrated on a silicon chip. The diaphragm deflects with changes in pressure, causing a
change in the balance of the strain gauge bridge. This is converted by the integrated circuit
module to an electronic signal that is proportional to the pressure. The output signal can be fed
into a local digital display or further converted into a 4-20 mA signal output for remote transmission.
These gauges are very sensitive and are used where precise measurement of pressure is required.
Since they produce an electrical output signal, it is possible to incorporate them into building
management systems.

Temperature gauges

Although there are a multitude of different temperature gauges available, five major types are
likely to be encountered in steam systems, namely, the bimetallic type, the filled system type,
thermistors, thermocouples and resistance temperature devices (RTDs).
o

The bimetallic type temperature gauge - Consists of a coiled bimetallic element. The gauge
is based on the principle of the bimetallic strip, which consists of two metal strips, made from
different materials, bonded to each other. The two materials are selected so that they have
different thermal coefficients of expansion. The two metals expand by different amounts
when heated, and since they cannot move relative to each other, the bimetallic strip bends.
Higher coefficient of thermal expansion

Fig. 12.6.4 Principle of a bimetallic strip

When the temperature of the coiled element rises, it tends to unwind. The degree to which
this occurs is indicative of the temperature. A pointer is connected to the coil by a series of
linkages, in a similar way to that in the bourdon tube.
Bimetallic gauges tend to be inexpensive, robust and easy to install. They are used where a
simple, quick visual indication of temperature is required.

Fig. 12.6.5 A bimetallic temperature gauge

12.6.4

The Steam and Condensate Loop

Gauges, Sight Glasses and Vacuum Breakers Module 12.6

Block 12 Pipeline Ancillaries

Other methods of temperature measurement - are dealt with in Module 6.7, Controllers
and Sensors. These types of temperature sensors are used when a higher level of accuracy is
required in measuring temperature, or when this function is to be automated or incorporated
into a building management system.
It is common to place a temperature-measuring probe into a pocket when installed into an
item of plant. This enables the sensor to be removed from pipework or equipment without
disturbing the integrity of the system. A heat conducting paste is used in the pocket to provide
good heat transfer qualities.
One area of concern when installing a temperature-measuring device is ensuring that it takes
a representative reading. It is common, particularly in liquid containing vessels, for there to
be some kind of thermal layering of the fluid, and measuring the temperature of the vessels at
different levels may produce different results.
Common applications of temperature-measuring devices include boiler feedtanks, measuring
product temperatures and measuring the steam temperature after de-superheating.

Sight glasses
A sight glass, or sight flow indicator, provides a method of observing fluid flow in a pipeline. It
has two main functions:
o

Indication - Sight glasses are used to indicate if fluid is flowing correctly. They are used
to detect blocked valves, strainers, steam traps and other pipeline equipment, as well as to
detect if a steam trap is leaking steam.
Inspection - Sight glasses can be used to observe the colour of a product at different stages of
the production process.

When sight glasses are used to indicate the correct functioning of blast discharge type steam
traps, they should be positioned at least 1 m downstream from the trap. For other traps, the sight
glass should be positioned immediately after the trap.
Sight glasses do not provide an exact method of monitoring the functioning of steam traps. In
practice, a thorough knowledge of the upstream steam system is required and the diagnosis is
often subjective, depending on the experience of the observer. For example, depending on
the condensate flowrate, pressure and trap discharge pattern, it can be difficult to differentiate
if the steam trap is leaking steam or if flash steam is being generated after the steam trap. Sight
glasses have generally been replaced by electrical devices such as conductivity sensors, which
detect flooding upstream of the steam trap, or leaking traps. These devices do not require steam
trap expertise and produce a consistently accurate result.

Sight glasses

The sight glass has a smooth concentric reduction in the inlet connection, which promotes
turbulence in the sight glass when fluid is flowing through it. The turbulent flow inside the
sight glass permits any fluid to be detected. Sight glasses are available with single, double or
multi-viewing windows.

(b)

(a)

(c)

Fig. 12.6.6 Single (a), double (b) and multiple (c) window sight glasses

Some sight glasses may be fitted with a light source, these are useful when the sight glass is fitted in an
area of low ambient lighting, or where a single window sight glass has to be used, such as in tanks.
The Steam and Condensate Loop

12.6.5

Block 12 Pipeline Ancillaries

Gauges, Sight Glasses and Vacuum Breakers Module 12.6

Sight check

The sight check (see Figure 12.6.7) is a combination of a sight glass and a check valve. A ball in
the top of the flow tube is lifted off its seat by the fluid as it flows through the cylindrical window
to the outlet connection. When there is reverse flow, the ball is forced back onto its seat on the
inlet. The ball movement makes the flow easy to see, as well as providing shut-off on reverse
flow.
As with sight glasses, the sight check is used to observe the discharge of steam traps. In the sight
check, the position of the ball check indicates whether condensate is flowing. Where condensate
rises after the trap, the sight check eliminates the need for a separate check valve, thus simplifying
installation. The sight check is particularly useful for commissioning steam traps fitted with a
steam lock release (SLR).

Ball

Glass

Flow

Fig. 12.6.7 A sight check

Vacuum breakers
Vacuum breakers protect plant and process equipment against vacuum conditions, typically
associated with cooling.

Air allowed in
under vacuum
conditions

Fig. 12.6.8 Vacuum breaker and a cut section of a vacuum breaker

12.6.6

The Steam and Condensate Loop

Gauges, Sight Glasses and Vacuum Breakers Module 12.6

Block 12 Pipeline Ancillaries

The vacuum breaker consists of a spherical stainless steel ball that rests on its seat during normal
operating conditions. At the point of vacuum, the valve is lifted off its seat and air is drawn into
the system.
Normal operation

At point of vacuum

Cooling

Air
inlet

Valve closed

Valve open

Steam connection
Fig.12.6.9 Operation of a vacuum breaker

In some cases, the valve may be spring loaded, which means that the vacuum is only broken
when there is a further pressure decrease. This helps to ensure that the shut-off at near vacuum
conditions remains bubble tight.
One of the most common applications of a vacuum breaker is on process equipment such as
jacketed pans and heat exchangers. When these items are turned off, they still contain a certain
amount of steam. The steam condenses as the vessel cools down, and since condensate occupies
a much smaller volume than the steam, vacuum conditions are generated. The vacuum can
damage the plant and it is therefore necessary to install a vacuum breaker on the steam inlet to
such equipment or onto the plant body. The same situation can occur on steam mains and boilers.
A common application of vacuum breakers is on temperature-controlled heat exchangers that
are likely to suffer from stall (see Block 13). On smaller heat exchangers draining to atmosphere,
the stall condition can be avoided by installing a vacuum breaker on the steam inlet to the heat
exchanger. When the vacuum is reached in the steam space, the vacuum breaker opens to
allow condensate to drain down to the steam trap.
Temperature control system
Steam in

Vacuum
breaker

Secondary flow

Shell and tube

heat exchanger

Static head

Secondary return

Condensate out to return

Fig. 12.6.10 The use of a vacuum breaker to prevent stall

In general, it is not desirable to introduce air into the steam space, since it acts as a barrier to heat
transfer and reduces the effective steam temperature (refer to Module 2.4). This becomes a problem
on larger heat exchangers, where it is not advisable to use a vacuum breaker to overcome stall.
Furthermore, if the condensate is lifted after the steam trap, for example, into a raised condensate
return main, the vacuum breaker cannot assist drainage. In both these cases, it is necessary to use
an active method of condensate removal such as a pump-trap (refer to Module 13.8).
The Steam and Condensate Loop

12.6.7

Block 12 Pipeline Ancillaries

Gauges, Sight Glasses and Vacuum Breakers Module 12.6

Questions
1.

Where is it important to install a pressure gauge?

a| Downstream of a pressure reducing valve station only

b| Upstream of a pressure reducing valve station only

c| Downstream of a steam trap to ensure that live steam is not leaking

d| Both upstream and downstream of a pressure reducing valve station

2.

Why should a Bourdon type pressure gauge be fitted to a syphon tube when used
on a steam system?

a| To protect the Bourdon tube from erosion in the fast moving steam

b| To protect the pressure gauge from the high temperature associated with steam

c| To ensure that the pressure gauge only measures the static pressure

d| A gauge cock can be fitted to the siphon tube so that the pressure gauge can
be isolated when not in use

3.

What is the purpose of liquid filled pressure gauges?

a| Keeps out ambient corrosives and condensation

b| Dampens the movement of the pointer

c| Prevent damage to the internal mechanisms from vibrations

d| All of the above

4.

What is the main application of a sight check?

a| To monitor steam traps that drain into a raised condensate main

b| To monitor blast action steam traps, in which case it must be installed at least 1 m
downstream of the trap

c| To replace check valves on boiler feedlines

d| For inspection of tanks in low light conditions

5.

Where should vacuum breakers be installed?

a| On steam mains

b| On process equipment

c| On small heat exchangers that are prone to stall

d| All of the above

6.

Why is it disadvantageous to use a vacuum breaker in large heat exchangers to

prevent stall?

a| Air acts as a barrier to heat transfer

b| It leads to air locking of the steam trap

c| The amount of air present in a large heat exchanger at start-up is sufficient to

prevent any vacuum forming

d| Vacuum breakers can only assist drainage when small quantities of condensate have
to be raised to an elevated condensate return main

Answers

1: d, 2: b, 3: d, 4: a, 5: d, 6: a

12.6.8

The Steam and Condensate Loop