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Steam Traps
Steam traps are valves that release condensed water and air from the steam system. They play an important role in maintaining a steam plant’s efficiency by removing condensate, which can lead to corrosion and erosion and condensate is an insulating media and very poor for heat transfer. There are many different types of steam traps available on the market, each with its own set of characteristics to suit a range of situations . We will discuss the different types of steam traps available and how they work. We will also provide tips for choosing the right steam trap for your needs.
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Steam Traps Explained
What is a Steam Trap?
A steam trap is a valve that removes condensate from a steam system. Steam traps are an important part of any steam system, as they help to maintain the system’s efficiency by removing these contaminants.
Why are Steam Traps Installed?
As we have seen, steam traps are installed in order to remove condensate from the system. This is important for two reasons. Firstly, it helps to maintain the efficiency of the system by preventing corrosion, erosion and thermal efficiencies. Secondly, it helps eliminate water hammer issues which can reduce the efficiency of the system. There are a variety of different types of steam traps available, each with its own advantages and disadvantages. The type of trap that you choose will depend on your specific needs and requirements.
How do Steam Traps Work?
The most common type of steam trap is the thermostatic steam trap . It uses a temperature-sensitive element to open and close the valve. The advantage of this type of trap is that it can be used in a wide range of applications and is very reliable.
Mechanical traps work using a float. As the name suggests, the float is attached to the trap’s valve. When condensate starts to build up in the trap, the float rises and opens the valve. This allows the condensate to be released into a drain or other suitable location.
Inverted bucket steam traps use a bucket that is inverted when there is no condensate present. When condensate starts to build up, the weight of the water causes the bucket to flip over and open the valve. This allows the condensate to be released into a drain or other suitable location.
Steam Trap Services
Specification & Design
Valveforce is proud to offer comprehensive specification and design services tailored to your steam trapping and trap set requirements. Traps are an essential component in steam systems for efficient energy management and process control. Understanding that the right steam trap can significantly impact system performance, Valveforce provides expert guidance to help clients select the most suitable types for their unique applications.
Our team at Valveforce specialises in various steam trap technologies, including:
Thermostatic Steam Traps: These traps use temperature-sensitive elements to control the discharge of condensate, ensuring that steam remains in the system while efficiently venting condensate and air during start-up. The operating pressure range is typically wider, as the thermostatic elements allow continued opening with increase in pressure, expanding the limits when compared with fixed orifices.
Ball Float Steam Traps: Utilising a buoyant ball that rises and falls with the water level, these traps offer reliable discharge of condensate and are ideal for applications requiring a continuous flow. They can also handle varying loads well, maintain efficiency under fluctuating pressures, and are resistant to water hammer, enhancing their durability in demanding environments. When used with automatic air venting, they improve start-up times by expelling air and non-condensable gases quickly. Their robust design makes them suitable for high-capacity applications and reduces the risk of steam locking, ensuring reliable and uninterrupted operation.
Inverted Bucket Steam Traps: These traps utilise a floating bucket mechanism. They are particularly useful in high-capacity steam systems and can withstand high pressures and water hammer. They are very robust and can be closely matched to specific conditions meaning they can be a good choice for consistant industrial applications.
Thermodynamic Steam Traps: These traps operate based on the dynamic pressure differential created by steam and condensate, providing a robust solution for applications with high pressure and temperature variations. These are simple, cost effective traps, most commonly used on steam distribution lines, they work over their full design range. They are vulnerable to blocking and do not work well where there are low differential pressures.
At Valveforce, we source our steam traps from leading manufacturers, including TLV, Gestra, Rifox, Sart, Spirax Sarco and Armstrong. This extensive supplier network allows us to offer a diverse range of products, ensuring that we can meet the specific needs of our clients, whether they require standard or customized solutions.
Our specification and design services begin with a thorough assessment of your steam system's requirements, including pressure, temperature, flow rates, and specific application needs. Our experienced engineers collaborate closely with clients to identify the optimal steam trap type and model, providing tailored recommendations that enhance system efficiency and reliability.
Installation & Commissioning
Expert Sizing and Selection
Valveforce recognises the critical importance of selecting the right steam trap for your application. Our experts help you choose the perfect type of steam trap—be it thermostatic, mechanical, or thermodynamic—tailored to your system's specific needs and operating conditions. We ensure your steam trap is precisely sized to manage the expected condensate load efficiently, ensuring water hammer is avoided and the system maintains its thermal efficiency.
Maintenance and Monitoring for Peak Performance
Valveforce emphasises the accessibility of steam traps for easy inspection and maintenance. We recommend and offer steam trap surveys, to ensure your steam traps are always functioning at their best, allowing for prompt issue identification and resolution, ensuring your steam system is as efficient as possible.
Orientation and Location
Valveforce installs steam traps in their correct orientation and at strategic locations to ensure optimal performance, effective condensate removal, and ease of maintenance.
Pressure Considerations
Understanding the nuances of differential and back pressure, Valveforce ensures your steam trap operates within its effective range, accommodating the specific pressure dynamics of your steam system for seamless operation.
Piping Configuration
We follow best practices in piping configuration, including the installation of strainers to protect against debris, the correct use of check valves, and the inclusion of bypass lines for maintenance, ensuring your system operates smoothly and reliably.
Adaptation to Environmental Conditions
Selecting materials that withstand the temperature and potential corrosive effects of steam and condensate, Valveforce steam traps are built for durability and compliance with relevant safety and operational standards.
Condensate Discharge Optimisation
Valveforce solutions account for variations in condensate loads during startup and normal operations, ensuring your steam trap can handle these changes efficiently. Some of our steam traps are designed to vent air and non-condensable gases effectively. We ensure your system is designed to prevent air locking and maximising heat transfer, and ensure condensate is effectively removed from steam pipework.
System Design Considerations
Our engineering approach accounts for thermal expansion and contraction in the piping system, ensuring the longevity and reliability of your steam traps and associated piping. We design your system with optimal drain points to effectively manage condensate and prevent water hammer, safeguarding your operations.
Overhaul & Repair
Blockages
Dirt, debris, and scale can render steam traps ineffective, leading to steam leakage or system back up and waterlogging. Valveforce's cleaning and repair services eliminate these blockages, restoring proper function and preventing costly energy losses.
Improper Installation and Location
A steam trap's efficiency is heavily reliant on its correct installation. Valveforce's team provides expert installation services, ensuring optimal orientation and sizing for your steam traps, thus avoiding inadequate drainage or excessive wear.
Wear and Tear
The conditions within steam systems can wear down even the most robust components. Valveforce's experts can rejuvenate your steam traps, replacing worn valves and seats to prevent failures and leaks, ensuring longevity and reliability.
Air Locking
Valveforce addresses air locking by ensuring steam traps are equipped or installed with proper air venting capabilities if appropriate, thus eliminating condensate discharge issues and improving system efficiency.
Thermostatic Failure
The thermostatic elements in steam traps require precise operation. Valveforce's skilled technicians can repair or replace these elements, ensuring responsive and efficient temperature regulation.
Corrosion
Acidic condensate and chemical presence in steam can lead to corrosion, weakening steam trap components. Valveforce's solution involves not only repairing the damage but also offering guidance on corrosion prevention to enhance the durability of your steam traps.
Maintenance & Service
Maximise Efficiency and Reduce Energy Costs with Expert Steam Trap Maintenance
Steam traps are vital components in your steam system, ensuring the efficient removal of condensate and preventing steam loss. Proper maintenance and servicing of your steam traps are essential to optimising system performance, minimising energy waste, and preventing costly downtime.
The Importance of Regular Steam Trap Maintenance:
Energy Efficiency: A malfunctioning steam trap can lead to significant energy loss, as live steam escapes instead of being used in your process. Regular maintenance ensures your steam traps function optimally, reducing energy consumption and lowering operational costs.
System Reliability: A well-maintained steam trap prevents the buildup of condensate, which can cause water hammer, corrosion, and other damage to your steam system. This leads to more reliable operations and fewer unexpected shutdowns.
Cost Savings: By identifying and repairing faulty steam traps, you avoid unnecessary steam loss and reduce the costs associated with energy waste, repairs, and downtime.
Extended Equipment Lifespan: Regular servicing of your steam traps helps to extend their lifespan, reducing the frequency of replacements and saving on capital expenses over time.
Our Comprehensive Steam Trap Maintenance Services Include:
Steam Trap Surveys
We perform detailed steam trap surveys to assess the performance of each trap in your system. Our technicians identify traps that are leaking, blocked, or stuck open or closed.
Trap Testing and Dignostics
Using advanced diagnostic tools, we test each steam trap to ensure it is operating correctly. This includes checking for proper discharge, ensuring there is no steam leakage, and verifying trap performance under different conditions.
Cleaning and Repair
We clean steam traps to remove any debris or buildup that may impede their function. If a trap is malfunctioning, we repair or replace it with high-quality parts to restore optimal performance.
System Optimisation
Beyond individual trap maintenance, we analyze your entire steam system to ensure it is balanced and functioning efficiently, making recommendations to improve overall system performance.
Scheduled Maintenance Programs
We offer custom maintenance plans designed to keep your steam traps in peak condition, ensuring long-term efficiency and reliability. These programs are tailored to your operational needs and budget.
Detailed Reporting
After each service, we provide a comprehensive report detailing the condition of your steam traps, the work performed, and any recommendations for future maintenance.
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