Steam Theory 1. Basics of Steam What is Steam? Principal Applications for Steam Types of Steam Flash Steam How to Read a Steam Table 2. Steam Heating Heating with Steam Steam Heating Mechanism Overall Heat Transfer Coefficient What is Vacuum Steam? Tracing the Causes of Heat Maintenance Issues 3. Basics of Steam Traps What is a Steam Trap? The History of Steam Traps #1 The History of Steam Traps #2 How Mechanical Traps Work: A Look at their Mechanism and Merits How Disc Traps Work: A Look at their Mechanism and Merits How Bimetal-Type Thermostatic Steam Traps Work: A Look at their Mechanisms and Merits 4. Steam Trap Selection Steam Trap Selection: How Application Affects Selection Steam Trap Selection: Understanding Specifications Steam Trap Selection: Safety Factor and Life Cycle Cost Traps and Orifices Part 1 Traps and Orifices Part 2 Casting vs. Forging Applications of Different Types of Steam Traps Don't Get Steamed : Selecting Steam Trap Design Understanding Steam Traps Compare Two Fixed Orifice Venturi Products to a Variable Orifice Free Float Steam Trap 5. Steam Trap Problems Is My Trap Leaking Live Steam? Temperature Control Trap Precautions Trap Installation Orientation Trap Back Pressure Double Trapping Group Trapping Steam Locking Air Binding My Steam Trap Is Good - Why Doesn't It Work? 6. Steam Trap Management Introduction to Steam Trap Management Steam Trap Losses - what it costs you A Guide to Steam Trap Testing Implement a Sustainable Steam Trap Management Program Impact Plant Performance by Improving the Steam System 7. Water Hammer Water Hammer: What is it? Water Hammer: The Mechanism Water Hammer: Cause and Location Water Hammer: In Steam Distribution Lines Water Hammer: In Equipment Water Hammer: In Condensate Transport Piping Identifying Water Hammer Using a Thermal Camera Mitigation of Water Hammer in Vertical Flashing Condensate Transport Piping Stop Knocking Your Condensate Return Steam Trap Management: Do Something; Anything. Please! 8. Risk Mitigation Steam System Optimization and Risk Mitigation Risk Based Methodology for Industrial Steam Systems Why Bad Things Happen to Good Steam Equipment Beware of the Dangers of Cold Traps Steam System Winterization: How to Protect Your Plant 9. Steam Quality Wet Steam vs. Dry Steam: The Importance of the Steam Dryness Fraction Separators and their Role in the Steam System Clean & Pure Steam Temperature Problems Caused by Air Removing Air from Steam Equipment Air Vents for Steam Steam Quality Considerations 10. Steam Distribution Best Practices for Condensate Removal on Steam Lines Installation Tips for Steam Traps on Steam Mains Erosion in Steam and Condensate Piping Corrosion in Steam and Condensate Piping Allocate New Plant Focus to Steam System Design—Part 1 11. Condensate Recovery Introduction to Condensate Recovery Returning Condensate and When to Use Condensate Pumps Condensate Recovery: Vented vs. Pressurized Systems Condensate Recovery Piping What is Stall? Methods of Preventing Stall Cavitation in Condensate Pumps Steam Heat Exchangers are Underworked and Over-Surfaced Allocate New Plant Focus to Steam System Design—Part 2 Optimize Reboiler Performance via Effective Condensate Drainage Vent Away Condensate Pump Frustrations in a Flash 12. Energy Efficiency Tips to improve steam plant efficiency Advice on Winter Preparation for Steam Systems Insulating Traps Steam Compressors Why Save Energy? Management Strategies for Conserving Energy Recovering Steam Clouds and Waste Heat Waste Heat Recovery Boiler Energy Saving Tips Steam Line Energy Saving Tips Steam-Using Equipment Energy Saving Tips Preventing Steam Leaks Handle Steam More Intelligently Optimize the Entire Steam System Use Available Data to Lower System Cost 13. Compressed Air / Gas Removing Condensate from Compressed Air Preventing Clogging of Air Traps Air Compressor Energy Saving Tips Improving Compressed Air Quality and Countermeasures Against Leaks 14. Other Valves Types of Manual Valves Bypass Valves Check Valve Installation and Benefits Pressure Reducing Valves for Steam Methods of Preventing Stall Contents: The following article will discuss Methods of Preventing Stall in heat exchangers. For a detailed discussion on the causes of Stall and its consequences, please visit the article: What is Stall? How to Prevent Stall Stall occurs if the inlet (primary) pressure is smaller than the outlet (secondary) pressure across a drainage device such as a steam trap, which prevents condensate from being discharged and can cause condensate to pool inside the equipment. To prevent this condition and allow condensate to discharge, the primary (inlet) pressure must be made larger than the secondary (outlet) pressure. Theoretically, there are two ways to resolve Stall: A. Raising the primary (inlet) pressure, or B. Lowering the secondary (outlet) pressure Effect of Trap Operating Differential Pressure Stall can be resolved by either raising the trap primary pressure or lowering the trap secondary pressure. Raising the Inlet Pressure Raising the inlet pressure can be achieved by changing system configuration to include one of the following: Mechanical pump/trap (e.g., PowerTrap® GT) Trap discharging in flash receiver with mechanical pump (e.g., PowerTrap® GP) Trap discharging in flash receiver with motorized pump When using a mechanical pump or combined mechanical pump/trap, steam or air pressure is applied to the pooled condensate to raise the trap primary (inlet) pressure so that it is higher than the trap secondary (outlet) pressure. This forces the discharge of condensate before it pools into the equipment. Examples: Mechanical Pump/Trap By installing a mechanical pump equipped with an internal steam trap (such as a PowerTrap® GT), and utilizing the steam pressure introduced from another pressure line, condensate can be discharged intermittently without accumulating inside the equipment (at the heat transfer surface). This type of pump/trap also eliminates any fear of cavitation. Mechanical Pump By installing a mechanical pump (such as a PowerTrap® GP), and utilizing a trap discharging into a flash receiver, condensate can be discharged from the trap because the trap secondary pressure (backpressure) is reduced. As shown in the animation, the pump is used when the condensate is returned to an elevated location. This type of pump also eliminates any fear of cavitation. Motorized Pump By installing a motorized pump, condensate is able to be discharged from the trap because the trap secondary pressure (backpressure) is reduced. As shown in the animation, a pump is used when the condensate is returned to an elevated location. When using a motorized centrifugal pump, a pump system for the prevention of cavitation, such as the TLV CP-S or CP-N, is required. Lowering the Outlet Pressure Lowering the outlet pressure requires the use of a vacuum pump. When using a vacuum pump, the pressure in the trap outlet piping (condensate return line) is reduced to below atmospheric pressure, thereby maintaining the differential pressure required for the trap to operate. Example: Vacuum Pump By using a vacuum pump, outlet pressure of the steam trap becomes less than the inlet pressure and condensate can be discharged through the trap. Depending on the capacity of the vacuum pump, one pump may be able to handle several pieces of equipment. Selecting the most appropriate solution for preventing Stall requires careful investigation of various factors such as operating conditions, the configuration of the equipment, and the number of pieces of equipment installed. It is strongly recommended that a qualified technician evaluate the site before any decisions are made on which method to use. What is Stall? Cavitation in Condensate Pumps Also on TLV.com Condensate Recovery Pump for Closed Systems Steam and Condensate Training Seminars Engineering Calculator Steam Bulletin: Archive - Email Magazine