CORRECT TRAP SIZING FOR STEAM SERVICE | a simple matter when the following information is known: ‘A. Pressure Conditions B. Condensate Load C. Adequate Safety Factor The following Is a bifet description of how each of thase is determined which may be helpful in sizing your requirement, If there are any adaitional ques- tions en slzing or trap selection our local representative or our factory engin- 675 will be pleased to be of assistance if you will write or telephone Clark-Reliance 16633 FOLTZ INDUSTRIAL PARKWAY, STRONGSVILLE, OHIO 44136 (440) 872-1500» FAX: (440) 238-8828 PRESSURE CONDITIONS L DETERMINE THE MINIMUM AND THE MAXIMUM INLET PRESSURES AT THE TRAP. 2. DETERMINE THE TRAP OUTLET PRESSURE 3. (OFTEN CALLED "BACK PRESSURE’). a, Outlet pressure less than zero gage— where a trap drains into a return fine carrying vacu- uum (sub-atmosphere), every 2” of vacuum LOWERS outlet pressure approximately 1 Ib, b, Outlet pressure greater than zero gage— where a trap drains into a return line carrying a definite pressure and/or where the discharge line is elevated above the trap outlet, outlet pressure will be INCREASED by approximately 1 Ib. for every 2 feet of LIFT. DETERMINE BOTH THE MINUMUM AND THE MAXIMUM TRAP DIFFERENTIAL. a. Minimum differential is used to determine the seat orifice that has the required continuous flow capacity (condensate load x safety factor) b. Maximum differential is used to determine the pres- sure rating of trap to be selected, Example: A steam boiler operates at 125 psi during the day and at 30 psi during the night. Main steam line is drained by a trap discharging to atmosphere, Minimum differential=30 - 0 = 30 Ibs. ‘The maximum condensate load x a safety factor= the continuous flow capacity required. ‘Then select a seat orifice large enough to handle this capacity at the 30 Ibs. pressure Maximum differential=125 - 0125 lbs. Select a trap with a pressure rating that will operate at this differential with the seat orifice selected above. CONDENSATE LOAD Condensate loads may be determined by several methods according to the data available Some frequently used methods are: THE B. T. U. METHOD This method is used when the B.TU. rating is given by the equipment manufacturer, or it can be computed, Divide this rating in B..U:/hour by the latent heat of evaporation of steam pressure used (see steam table back page), and we find the condensate load in Ibs /hr. Given a rating of 900,000 B-TU//hr. @ 65 Example: pel sage steam, pressure, from steam table we find latent heat @ 69 Ibs. pressure = 900 B.TU. (approxi: 1000 Ibs./hn condensate load 900 ACCORDING TO RADIATION IN THE AIR Condensate load can be computed in two ways: a, Lineal foot-Table "B" Given steam pressure, size and linear feet of pipe radiation, use values direct from Table B to determine condensate load. APPROXIMATE POUNDS PER HOUR OF WATER CONDENSED IN EACH LINEAR FOOT OF BARE STEEL PIPE WHEN TABLE B CARRYING STEAM AT INDICATED PRESSURES (Based on normal movement of AIR ct 60 room temperature) STANDARD STEEL PIPE SIZES Toeeace [V2 aya ene s 8 1° CONDENSATE IN LBS/HR/LINEAR FOOT OF PIPE 1 ais2 | 189 | 214 | 261 | 309 | 368] 464} 569] 6a] 251 | 1.006 4 165 | 205 | 229 | 282 | 335} ‘398 | 500] 605] 716) 918 | 1.129 6 fz | 213 | 2a1 | 204 | 34a | ais | ‘526 | ‘637 | 753 | 961 | 1.177 10 us7 | 232 | 261 | 318 | 376 | aa9 | ‘567 | ‘c87 | 12 | 104i | 1280 25 231 | 287 | 323 | 398 | 473 | sea | 707 | a59 | 1011 | 1297 | 1.597 50 287 | 356 | aoz | ‘496 | 589 | 702 | 389 | 1.080 | 1277 | 1634 | 2006 75 336 | 417 | 469 | 576 | 687 | ‘820 | 1038 | 1.262 | 1488 | 1912 | 2357 100 377 | ag | 530 | 650 | 772 | 922 | 1.168 | 1.422 | 1oa2 | 2156 | 2658 125 ‘aie | 17 | 583 | 716 | 854 | 1020 | 1289 | 1570 | 1858 | 2390 | 2948 150 as | 558 | 629 | 1775 | 922 | 1105 | 1402 | 1.702 | 2014 | 2585 | 3178 200 ‘sor | 31 | 713 | '881 | 1052 | 1255 | 1592 | 1.984 | 2290 | 2999 | 3.627 250 ‘570 | 707 | 798 | 937 | 1.176 | 1407 | 1781 | 2159 | 2556 | 3203 | 4065Example: Given the equivalent of 500 feet of 3" bare steel pipe carrying steam at 200 psi gage, Table B under’ pipe at 200 Ibe. steam pressure indicates a value of 1.255 IbsJ/hr. for each linear foot; therefore, ‘500 x-1,255-628 Ibs.fhr.-condensate load, b, Square foot of radiation-Table "C" Given steam pressure and the equivalent square feet of radiation heating surface, the condensate load can be determined from values in Table "C" Example: (1) Given 122 sq. ft. of radiation surface heated by steam at 100 psi gage, in Table C for 100 Ibs. steam pressure, we find a value of 0.981 Ibs,/hr. for each square foot; therefore, 122 x 0,981 = 120 Ibs./hr.*condensate load. (approx.) (2) Given 250 foot of 3" bare stee] pipe carrying steam at 125 psi gage, in Table E we find that 3" pipe has 0.916 square feet of external surface per linear foot, In Table C, for 125 Ibs. pressure we find a value of 1.088 Ibs/he. per square foot; therefore, 250 x 0.916 x 1.088=249 Ibs /hr. condensate load. 3. SUBMERGED RADIATION ‘Where heating process is a continuous operation, such as a hot water storage heater, the normal condensate load should be determined. Example: 50 feet of 2" iron pipe coil submerged in water with temperatures of 45°F. inlet and 160° F Sutlet, steam pressure is 125 psi gage. In Table "E* ‘A 2" pipe has 0.622 square feet of external surface face per linear ft, then 60 x0.62*31 Total of aq. Aor'radiation surface, ‘Temperature of steam @ 12 ibe gage-380" F (Steam lable), Average Tem- perature of Watere48'+160-100" ‘Temperature difference between steam and average temperature of water=353" F - 103" F=250" F. Using Table "D" For iron pipe coil, under 250" F. difference, we find a value of BB ibs br. per eq. f, therefore 91.1 x 88*2787 lbs./hour=normal condensate load To determine in this example the peak condensate load, use the maximum temperature differential in place of average differential in your computation. SAFETY FACTOR is used to provide additional capacity to assure adequate intermittent trap operation during periods of unusually heavy condensate conditions, such as startup, surges, lower than normal differential pressures, and’ the fast removal of excessive air. Safety Factors Guggested) Bosfation in A Berdtol ‘Outside Ale Borate! Unt Heater: lnside Alt 2erstol Devin Rooms. Kins 7,8,9.101 Cinder Orven 440 1 upto 1010 1 SE en Rocio boos Serato} StoamuJackoted equipment erste} TABLE D POUNDS OF CONDENSATE FORMED/HR/SQ. FOOT of STEAM RADIATION with COILS SUBMERGED in WATER with Natural Circulation. ‘(A lberdl otowance has been made for pipe incustation, usual drops in pressure, etc. Bright clean pipe wilincrease Ditterence in Degrees ho 1nd Average Temperate eo Water ‘Steam Te hur eo Pont TABLE C merseane STANDARD WEIGHT PIPE DATA Shot Uncovered fet DIAMETER IN INCHES internal | Sqftofétemal | linear AL of pe Sioa & ton Kedoton erwone | (eaing Stace | ead tase ‘ar Indicate in Scr Pesures External Internal sainetos | unatietape | econa sutsce Glemal Movement ot oa we 840 0622 0304 0.220 4547 Pressure | Lbs/Hcof 3a 1.050 0824 0533, 0275 3637 intbsita. | Condensate r 1318 1.049 0864 a3a4 2904 B wave | 1660 1380 1495 0435 2301 vyz | 1900 1610 20% oas7 2010 z 2375 2067 3355, 0622 1.608 212 2875 2.469 4783 0753 1.328 s 3500 3066 7393 avis 1991 9 o7e0 * 4500 4026 12730 1179 0846 ra oes s 5563 5007 20006 1458 0886 8 153 é 6626 6065 28891 1736 0876 1 M82 a 8626 7981 50027 2262 aes x0 1388 1 10750 10020 78858 2817 0355THE AMOUNT OF STEAM CONDENSED IN ANY SYSTEM IS SELDOM CONSTANT. BECAUSE OF VARYING CONDITIONS, IN MOST INSTALLA- TIONS, THERE IS A CONSIDERABLE VARIATION IN THE CONDENSATE LOAD. WITH SO MANY CONTRIBUTING FACTORS, IT IS SOMETIMES DIFFICULT TO DETERMINE THE EXACT CONDENSATE LOAD UNDER ALL CONDITIONS. HOWEVER, IF THE EXACT CONDENSATE LOAD CAN NOT BE DETERMINED, THE SAFETY FACTOR USED CAN BE MADE ADEQUATE ENOUGH TO COVER ANY VARIABLES. CONDENSATE LOAD Other methods for figuring condensate loads: 1. UNIT HEATERS Are usually rated in BTU per hour by the various manufacturers. ‘To determine condensate load, use the BTU method explained on preceding page. 2. STORAGE WATER HEATERS ‘Must be completely drained to prevent "water ham- mer’ damage to heating elements and maintain heat transfer efficiency. Condensate load may be figured in the following manner: Using T = Desired temperature rise of water (in 'F) G = Gallons per hour of water to be heated. W = 8.38 lbs. weight of 1 gallon of water. L = Latent heat of steam at pressure used (Gee steam table.) © = Condensate load in Ibs./hour Formula: Tx G x W-C L Example: 1000 gal-/hr. of water to be heated from 40° F. to 180° F,, using 100 psi gage steam ~ 140_x_1000_x 8.931925 lbs /hr. 880 condensate load 3. STEAM SEPARATORS Under normal conditions, with insulated pipe, trap continuous flow capacity’ should be about 12% the volume of steam thru the separator. 4, STEAM MAINS AND RISERS Drainage of steam mains and risers are important in operating as well as starting up periods even though lines are well insulated. Sudden changes in pressure, flow or water conditions may cause prime carry-over from boiler. Small slugs of water at high velocity can rupture a steam line. Steam main and riser traps should be sized with a capacity for start- ing-up and/or surge loads. LOCATION — INSTALLATION OPERATION - MAINTENANCE LOCATION: Traps should be placed in plain view in an accessible location where they will not be overlooked or forgotten. This promotes closer inspection and care, also reducing both installation and upkeep costs by making the job easier and more agreeable for the maintenance crew. Good gravity drainage from unit being trapped is preferable but when necessary, traps can be installed above the drained unit. When placed above it is good practice to provide a check valve as well as a water seal in the inlet line to trap. INSTALLATION: + Be sure trap is connected properly. Check the inlet and outlet markings on the trap. + See that the pressure rating corresponds to the highest pressure to which the trap will be subjected. ‘+ Blow line out thoroughly to remove all scale, pipe cuttings, joint cement dirt, etc. Install trap in an upright level position, + Provide shut-off valves and unions on both sides of trap for easy removal when necessary. ‘+A test outlet on medium size and large traps will permit easy inspection of trap operation, ‘+ It is recommended that a Clark Strainer be installed on inlet side of trap. If this is not done the next best thing is a dirt leg below trap inlet + Provide a bypass where it is imperative to continue drainage when trap is taken out of line. © When connected for the first time, or when blown out to remove accumulated dirt or scale, BE SURE to fll trap with water ('prime") unless there is a sufficient back up of condensate in inlet line of trap to auto- ‘matically do 80. * Discharge line from trap can run either below, hori- zontal to, or even be elevated above trap if there is sufficient pressure at trap outlet to overcome any back pressure andlor the condensate head in the discharge line. (Every pound of pressure at trap outlet will LA the condensate approximately two feet). OPERATION: A trap under normal conditions wil operate intermittently. The force of the discharge will vary according to the pressure, a forceful discharge being evident at higher pressure, becoming less forceful as the pressure drops. When trap discharges to atmosphere there is considerable flash which should not be confused with a trap blowing steam. Flash occurs only during dis- charge period, while a leaking trap will blow steamcontinuously. Abnormal amounts of air tend to slow up f2up operation, particularly during’ cold starting periods, find jnjauch eates a auciary thermal air by pat Such at Giark ‘Thermostatic ‘Trap will greatly speed up the action. ‘Traps exposed to freeding teliperatares will not as Fong as stoam pressure is maintained at the trap and fhe diécharge line js not. restricted. ‘Keep return’ ines Ehget and covered if possible. A fozen return line will eventually cause trap to freeze. If steam is turned Off Be sure trap is properly drained MAINTENANCE: ‘Traps are installed to remove con- densate and in so doing ellect savings by elimination of ‘condensate and by promoting more efficient heat transfer. “Wraps only’ perform this function when they are operating properly) VTrape, like any other mechaniem of Malls, should be’ periodically checked and int Spected fot correct operation ‘and Wear. ‘Traps should be ifspected at regular intervals and ‘nec ire made, also interior and parts cleaned, so as ¢ Keep them in {op operating condition TRAP CONDITION REASON, REMEDY, T, Condensate does not flow into tra (a) Obstruction in line to trap infet. (a) Remove obstruction () Bypass open or leaking. (8) Close or repair bypass, 2. Tnlet Pressure may be above trap pressure atin DOES NOT fa) Breseuce change has oourved in eve (a) ©), Accurate pressure gauge in- tem without considering trap pres Stalled at trap inlet will give exact con: DISCHARGE sure rating. 6 fap P dition, "Replace with dise and seat of (t) Wrong pressure ratings specified correct pressure rating 8. Accumulation of foreign matter within | Gleam out trap by, means of blow-ol valve of trap. stalled at trap inlet will cure this trouble permanently). 4,_‘Trap held closed by defective mechanism, | Perform needed repairs Trap undersized Detepgine condensate Tod and install conzect ‘Trap held open by defective mechanism, | Poribrm needed repairs QOESNOT ondensate Toad Far tnereased over he SHUT OF &}°May’ be due to excessive boiler foam- (@) Gure conditions causing excessive ing or priming. covidneate, or instal a Clank Sepa- (b) Greater volume of steam used. eal i (© Leaking submerged steam coils allows © Monod ge traps oa On4 instal infiltration of surrounding liquid (0) Repar leaking coils, No prime. () "Trap not orignally primed when in- (a) Prime the trap installed (2) Faire to roprime ator clean out or (©) Prime the trap (© Inverted bucket type trap, very much | (¢) Reducing seat orifice size will fre- oversized, eventually blows out seal. quently sorvest) it not replace with (@ Open or leaking bypass valve (@) Close or repair bypass valve. BLOWS ‘Valve mechanism does not close. STEAM (a) Held open by foreign matter. (a) Remove foreign matter. (If contact e between disc and seat is cut, (b) Mechani: defecti Pe place thelgoing of 7 defective or replace. -(Relapping o ©) Mechanism worn o ise and seat will often restore ori- Sinal tightness). Flash steam IT appears that steam escapes each time trap discharges, c0- member hot condensate forms flash steam when released to atmosphere or lower Breqture, Rowover flaph team aa¥ally Eondenses very quickly in return line, Pressure may be too low to force con-| Increase steam pressure densate through trap. CONDENSATE ‘Abnormal volume of aiz at Tow temper. | Add to present Iqstallation an external ther FAILS TO ‘ature and pressure slows up trap opera- | mal airbypass (Geries 690) oF BRAIN PROM fou: Replace with Series 70-1, ifwithin capacity aN of this series or, replace with a larger trap "Shor creating” where one tap drains | Install separate trap foreach unt several unite T. ‘Trap differential pressure appreciably a a) Reduction in operating pressure. (a) Raise operating pressure to former TRAP . level. impossible, install larger CAPACTY (&) Increase in back pressure. lev SpE 0 ES aon seta ie DECREASES Plagged vent in return Tine ‘Traps blowing steam Inte return Open bypasses,‘Tang pate Roe a mere pore som are nw Tas [imo | 250 | 300 | 300 [ir | to [0 [ [a [Ta ‘CAPACITY not etemtantesemans fr fat eta supe ate eae " pegwcne herent [| on Seer mune bw et. ‘oan smaller, Teese sz | rnolesse4|2sve}esie4|2u6alaa%e4| 14 amen ate tiation | |e ln Latkermeesenicomenmea: HT Sea pe aa ean src 14 ni ah ee wher men st |2seafarisa| oe] ua | 14 | crs2}asiea] sine|ru6e| 92) sexe ‘fetor ofS Sas, ve ™ ise _| 7/16) 5064] 25064 evel er 4] 964] 14 | 144 | Tie] Tie 1aM64| nib chanapuisnien cone ve (eee ale Sete For Capit of Ores Swe lor 2 pa fer Caprty Char Strongsville, Ohio 44136 scant), $99.) $00, g90 spe ae ono PPT PEE 00 pet 822 6 coe 4 eT He ae 5 eee ls ee ete aa = Be 4000 pases 2000] | I seee Se) Boe 000 F eno POUNDS OF CONDENSATE PER HOUR © i x 6 400 sco B00 | B00 200 200 eee aS BES USS os DIFFERENTIAL PRESSURE PSI.