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STEAM TRAPS, EXPANSION JOINT

Steam Traps:
Steam tarps are automatic relief valves that release condensate from a
steam header. Special Traps also removes air and non-condensate from
the steam space particularly in surface condensers of very big turbines.
Steam traps are mainly divided into three groups:

Thermostatic,

Mechanical and Kinematic. Each of these types contains groups of various

specific styles according to service condition and application.
Thermostatic:- Steam traps open and close with the expansion of a
temperature sensitive element in the trap called disc. These traps
operates on the principal of temperature difference between steam,
steam condensate and air. Thermodynamic traps may be balance type
traps, bimetallic traps or pinch type traps. Balance pressure traps open
and close through the expansion and contraction of a temperature
sensitive element that responds to the lower temperature created by the
condensate and non-condensing gases in the trap.Bimetallic traps have a
metal element with the proper thermal co-efficient of expansion for the
application.
Pinch-traps uses self regulating action due to modulator fixed inside. The
pinch modulator begins to automatically close off flow as the wax around
the modulator expands with the passage of hot condensate. As the
condensate builds up and cools the wax around the modulator contracts
allowing the orifice to open and create flow.
Mechanical steam traps:-These are buoyancy operated i.e. based on
the difference in density between steam and condensate. These are float
thermostatic traps and bucket traps. Bucket type traps are widely used.
Bucket traps are build around floating buckets that have their open side

facing downwards(Inverted bucket). Steam entering these traps is fed into

the bucket causing it to flow to the top of the surrounding pool of
condensate and close the discharge valve. When only condensate enters
the traps(when more condensate collected the bucket tends to rise due to
buoyancy caused by difference in density) the bucket sinks, opening the
discharge valve.
In case of float traps the trap consists of a floating chamber with a
discharge orifice at the bottom. The float responds to the amount of
condensate and moves up and down. When it rises up it opens the orifice
and allow the condensate to drain out.

Kinematic steam traps:-It is based on the different flow characteristic of

steam and condensate. These are disc steam traps, piston steam traps,
impulse steam traps and orifice traps. Thermodynamic disc steam traps

are very robust with a simple mode of operation by the dynamic effect. It
is widely used in steam tracings. Disc traps consists of a float disc resting
on a smaller circular seat. The disc is enclosed in a chamber above the
seat. On start up incoming pressure raises the disc and cool condensate
and air is discharged from the inner ring under the disc located under the
perimeter of the disc. When hot condensate flow through the inlet
passage into the chamber under the disc drops in pressure and releases
flash steam moving at high velocity a low pressure(injector) area under
the disc drawing it towards disc. Again at the same time flash steam
pressure builds up inside the chamber above the disc forcing it down
against the incoming condensate until it seats on the inner ring. At this
point the flash steam is trapped inside the upper chamber and the
pressure above the disc equals the pressure under the disc. But the force
on the trap is greater as the surface area is more.
When the trapped pressure in the upper chamber falls (as the flash steam
condenses) the disc is raised by the bottom higher pressure and
condensate is allowed to go out. These cycle repeats.
Traps are very essential in a steam line as the increase of condensate
amount in a steam header decreases the thermal efficiency and also
condensate is very corrosive. So traps are used to drain the condensate
from point to point in the line. Some times condensate causes hammering
in the steam lines which is very dangerous as it may cause mechanical
failure of the lines.
Selection of steam traps:- A good steam traps must trap the condensate
and hold back steam while at the same time not restricting the passage
of condensate, air and other condensable gases to drain out from the
system. The selection of traps depends on system pressure, system
temperature,

condensate

load,

air

venting,

system

design

and

maintenance needs.
Dirt and debris content is another major factor when selecting traps. Pipe
dirt created during installation and the products of corrosion also need to

be considered and so a strainer must be provided in the traps in the

upstream of steam line.
Diffuser:- When steam trap drains to atmosphere it is possible to
discharge hot condensate with certain amount of flashing steam which is
at higher pressure relative to the condensate pressure. If diffuser is
installed at the open end pipe of the drain of traps then it will reduce the
velocity of discharge and also sound levels up to 80%.

THERMODYNAMIC STEAM TRAPS

FLOAT THERMOSTATIC TRAP

DIFFUSER

EXPANSION JOINT AND FLOW THROUGH PIPES:

Expansion joint are incorporated in pipe and duct system to take up or
withstand the thermal expansion, pressure variations, vibration and
misalignment to prevent damage to the pipe work system. They are
installed in air, steam and flue gas duct system of all power plant,
chemical industries, gas turbine system, petrochemical industries, Primary
reformer ducts and burners, steel plants etc. In case of steam lines or any
pipes that carry hot fluids at higher temperature a loop is provided to
compensate expansion of pipe lines. With the increase of temperature
from ambient to working conditions, stress is created in the line due to
thermal expansion. If this expansion is not taken care, it will stress certain
areas within the distribution system e.g. piping joints, which could results
in fracture at certain extremes. The piping work system must be sufficient
flexible to accommodate the movement of the components due to
expansion and contraction. Piping supports are designed keeping in mind
the flexibility of the piping system. Roller supports may be the ideal
method for supporting big pipe lines for allowing the pipe to move in
either direction. The expansion loop are another alternatives to avoid the
movement of the pipe lines with service fluids in. These loops may be full
loop or horse shoe loop or expansion loop depending upon the
requirement.
Full loop:- This is simply one complete turn of the pipe. The full loop does
not produce a force in opposition to the expanding pipe work and there is
a tendency to unwind which produces stress on the end joints.

Full Loop

Horseshoe loop: In this case pressure does not tends to blow the ends of
the loop apart (loop and the main are on the same plane)but, there is a
slight straightening our effect. if this loop arrangements are vertically
above the pipe then a drain must be provided on the upstream side.

Horseshoe loop
Expansion loop: This is a simple loop fabricated from straight pipes and
elbows and widely used.

Expansion Loop
Expansion Bellows:
In low pressure high flow piping, thermal expansion is taken care by
Expansion joints, which may be of bellow type or flexible fiber material.
Expansion joints needs to have tie-rod to limit the sliding and expansion.
The material of construction of bellow are generally stainless steel but it
can be of special grades of SS or Teflon coated fabrics as per need. Some
expansion joints may have a sleeve inside the bellow of fiber which
basically works as a deflector inside to prevent direct contact between

flue gas and the below. In such case the expansion joints are marked with
direction of flow. These are called uni directional bellows.
Allowance for expansion:
Expansion(mm)= L x t x
where
L=length of pipe between anchor in metere(M)
t=temperature difference between ambient and working temp in
C
= Co-efficient of thermal expansion inmm/m degree C x 1/1000
Co-efficient of thermal expansion of materials can be had from the table
for different temperature range and for different material.
In various system there can be different types of expansion joints which
are used for specific services. Expansion joints can be of single bellow
type, universal expansion joint, Internal sleeve expansion joint, Hinged
expansion joint etc. Genarally all expansion joints are designed and
manufactured under EJMA (Expansion Joints Manufacturing association).
All OEMs supplies special instructions for the erection / maintenance of
expansion joints. These instructions shall be followed strictly.
The bellow is the main flexible component of the expansion joint. It must
be strong enough circumferentially to withstand the pressure and
deflection of the joint. Bellows may be of one or more convolutions. The
total movement capacity of a bellow is proportional to the number of
convolutions it contains. Bellows are subjected to withstand cyclic
deflection and pressure.
Most bellows fail by circumferential cracking resulting from cyclic bending
stresses or fatigue. The best design is a compromise or balance between
pressure strength and flexibility and so good factor of safety shall be
taken to avoid fatigue failure.
There are other components in a expansion bellow joints besides bellow.
e.g. control rods, cover, sleeve, anchor, flanges, limits rod, guide etc. Each

component need care while designing the expansion joint for a particular
service.
EJMA

standards

fifth

edition

define

each

of

the

components of expansion joint and various type of expansion joint

according to various service and application.